SEPARATOR SIZING SPREADSHEET

REV: DATE:

P1 FEBRUARY 1996

MAIN MENU

INSTRUCTIONS

SPREADSHEET INFORMATION

HORIZONTAL SEPARATOR ( 3 PHASE WITH BOOT)

HORIZONTAL SEPARATOR ( 3 PHASE, NO BOOT,

HORIZONTAL SEPARATOR ( 3 PHASE, NO BOOT,

HORIZONTAL SEPARATOR ( 2 PHASE )

VERTICAL SEPARATOR ( 2 PHASE )

FILE SEPARP1.XLS

SEPARATOR SIZING SPREADSHEET

INSTRUCTION NOTES

REV: DATE:

P1 JANUARY 1996

I.PURPOSE The aim of the separator sizing spreadsheet is to assist the designer in saving valuable time resources by providing a user-friendly spreadsheet in Excel to calculate sizing parameters for both horizontal and vertical separators.

II.DESIGN BASES A. Gas residence times are calculated using the normal liquid level as the basis. In the case of the horizontal separator with weirplate partition, the basis used is the height of the weir for the gas volume. Dished end volumes have been neglected for the gas residence time calculations. B. K-values to be used as input data for the spreadsheets are found in the GPSA Handbook, figure 7.9 on page 7-7. The K factors must be converted to m/s to be placed into the spreadsheet. The purpose of the K-factor is for designs which include woven wire demisters. Demisters (mist extractors) can significantly reduce the required diameter of vertical separators. C. Dished-end volume calculations have been included for both vertical and horizontal separators. For the vertical separator, an option is provided for choosing between semi-ellipsoidal and semi-hemispherical ends, however, for all horizontal separators, the ends have been assumed to be semi-ellipsoidal. (Reference: GPSA Handbook sections SI-13.5 to SI-13.10) D. Other standards used in calculations include API RP 521 Section 5.4.2 and calculations for the standpipe were from EXXON Criteria in Design Practice 5B (September 1978).

III.METHOD The following procedure is a step-by step outline for the designer. A. Step One: Choose the type of separator required. The separators available in this spreadsheet include: -Horizontal, 3 Phase, with boot -Horizontal, 3 Phase, no boot, weirplate partition. -Horizontal, 3 Phase, no boot, standpipe for condensate. -Horizontal, 2 Phase -Vertical, 2 Phase

Page 1 of 3

SEPARATOR SIZING SPREADSHEET - INSTRUCTION NOTES

Vertical separators are usually selected when the gasliquid ratio is high or total gas volumes are low. Horizontal separators are most efficient where large volumes of total fluids and large amounts of dissolved gas are present with the liquid. For more information on separators please refer to GPSA Handbook, Section 7. B. Step Two: After the separator type is chosen, begin inputting data into the cells of the spreadsheet which have blue italicised text. Do not write in cells which contain red or black text! Input data is summarised in the top left hand side of the spreadsheet. Feed flowrates, properties and nozzle velocity specifications are entered in this section. Data on vessel length, diameter and liquid levels are entered on the vessel sketch. Unknown values need to be assumed, otherwise errors will occur in the results. C. Step Three: When all blue cells are filled - including the dimensions on the sketch, the spreadsheet will calculate all relevant values. The intermediate calculations can be found below the sketch. Final output results are listed on the sketch and in the top section of the spreadsheet. All formulae are in red text. D. Step Four: Before final outputs can be used, warnings must be considered. Warnings appear in bold green text, and will appear as "OK" when there is no warning present. If a warning does exist, try to change the relevant parameters to remove or reduce the warnings. These generally relate to liquid levels in the separator and gas residence times. E. Step Five: Check your units!!! The units defined on the spreadsheets can be found in the nomenclature section. The notes section may also assist with understanding which units to use. You can change the values in the blue cells as many times as you like. F. Step Six: When you have your final output, SAVE your file by choosing the "SAVE AS" option under the "FILE" menu in Excel 5. Make sure that you use a different file name to the original master copy. (this will safeguard against deletion of the master copy) G. Step Seven: Your work is now ready to PRINT. You may find that Excel 5 does not have enough memory to display the spreadsheet fully. The print range has been setup for A4 landscape paper and will print only the first 2-3 pages of the spreadsheet (the rest of the spreadsheet consists of intermediate calculations). If you find that the spreadsheet will not fit on the paper, choose "PAGE SETUP" from the "FILE" menu in Excel 5 and reduce the size of the sheet.
Page 2 of 3

SEPARATOR SIZING SPREADSHEET - INSTRUCTION NOTES

Another option available is to choose A3 sized paper (page setup menu) to print out your spreadsheet. It is not recommended that the print area be altered as this has been preset. However, if the print area needs to be altered, please use the following procedure. "TOOLS" "OPTIONS" "GENERAL" "MICROSOFT EXCEL 4 MENUS" "OK" (HIGHLIGHT THE AREA THAT YOU WISH TO PRINT) "OPTIONS" "SET PRINT AREA" IV. ADDITIONAL NOTES A. THE CALCULATION TITLE BLOCK

There is a title block at the bottom of each page of the spreadsheet, similar to the title block found on the standard DJB calculation pad. Spaces have been provided for entering the calculation title, project number and calculation number. These spaces are accessed by moving the mouse pointer into the particular box and clicking once with the left hand mouse button. At this point, an object box will appear. Simply click inside the box once using the left hand mouse button and enter the data in the normal way. When you have finished typing the information, move the mouse pointer to another part of the spreadsheet and click once with the left hand mouse button. NOTE: While space has been provided on the title block for entering the originators and checkers initials and relevant dates, these spaces cannot be accessed by the user. This is because signatures are required to be hand written by the originator and checker. B. MAIN MENU The main menu on the separator sizing spreadsheet allows the user to access any of the sheets in the workbook through the use of a macro button. Once the designer is in a particular worksheet, they can return to the menu by clicking the "MENU" macro button in the individual worksheet.

Page 3 of 3

Kvaerner Process Inida

SEPARATOR SIZING SPREADSHEET

SEPARATORS HORIZONTAL SEPARATOR (3 phase with boot) HORIZONTAL SEPARATOR (3 phase, no boot, weirplate partition) HORIZONTAL SEPARATOR (3 phase, no boot, standpipe for condensate.) HORIZONTAL SEPARATOR (2 phase) VERTICAL SEPARATOR (2 phase)

SPREADSHEET APPLICATION Sizing of oil/gas/water separators for the hydrocarbon production industry.

BASIS GPSA Handbook, Volume 1, Section 7. And also Section SI - 13.5 to 13.10 API RP 521, Section 5.4.2 - Sizing a Knockout Drum

REVISION HISTORY Revision P1 issued in February 1996 - file SEPARP1.XLS With help from Don Borchert, Rod Harper, Nerrida Scott and Mark Sloma

INSTRUCTIONS FOR USE Spreadsheet Conventions & Format

Input

Data to be entered by the user is shown on the screen in blue italicised type. When printed the input appears in italics only. Input data is summarised at the top left hand side of the spreadsheet. Feed flowrates, properties and nozzle velocity specifications are entered in this section. Information on vessel length, diameter and liquid levels is entered on the vessel sketch described below.

Output

Cells containing formulae are shown in red text. Cells containing formulae have been protected. Final output data refers specifically to gas, oil and water residence times and oil and water droplet settling times. This data is summarised at the top centre of the spreadsheet. Data on calculated nozzle sizes and other vessel specific dimensions are shown on the vessel sketch.

Warnings

Warning messages will appear to the right of the output data summary to indicate when results fall outside the design criteria described in the DJB procedure. Where results satisfy the design requirements the message 'OK' will appear in the WARNINGS section. Warning messages may also appear on the vessel sketch, however in this case there will be no message if the input/output data meets the design requirements. Messages are shown on the screen in bold green type. When printed, the messages appear in bold type and will be enclosed in double asterisks.

Date and time printed:

22-Jul-13

7:30 AM

Page 1 of 2

SEPARATOR SIZING SPREADSHEET - INFORMATION

Sketch

The vessel sketch appears immediately below the input section. Some input and final output data is shown on this sketch as noted above. Intermediate calculation results such as volumes and flowrates are also shown on the sketch. This section follows the sketch and includes all the equations and intermediate calculations of the spreadsheet. These include specified residence and settling times. Defaults are the minimum design requirements that are required for comparison against calculations. Other recommended values for variables or constants such as K, droplet size, rV2 , maximum nozzle velocities and liquid levels may be found in the DJB procedure. This section includes some important equations and general assumptions used in the spreadsheet. Nomenclature used in the spreadsheets including units used, is detailed below the notes section.

Calculations

Defaults

Notes

Nomenclature

Calculation Title Block There is a title block at the bottom of each page of the spreadsheet, similar to the title block found on the standard DJB Calculation pad. Spaces are provided for entering the calculation title, project number and calculation number. These spaces are accessed by moving the mouse pointer into the particular box and clicking once with the left hand mouse button. At this point an object box will appear. Simply click inside the box once using the left hand mouse button and enter the data in the normal manner. When you have finished typing the information, move the mouse pointer to another part of the spreadsheet and click once with the left hand mouse button. Note: While space has been provided on the title block for entering the originators and checkers initials and relevant dates, these spaces cannot be accessed by the user. This is because signatures are required to be hand written by the originator and checker. Printing The print range is pre-set and covers all of the sections described above. Printing is carried out by selecting the 'Print' command from the normal EXCEL pull down menu and selecting 'OK'.

Date and time printed:

22-Jul-13

7:30 AM

Page 2 of 2

HORIZONTAL SEPARATOR (3 phase with boot)

INPUT OUTPUT

Feed Flow (t/d) Density (kg/m3) Viscosity (cP) Droplet Size (m) Droplet Size (m) Droplet Size (m)
2

GAS 762.8 20.4 0.01 Oil in Gas Oil in Water Water in Oil
2

OIL 6466.0 815.1 4.57 100 1000

WATER 4799.0 1008.1 0.89

500 1500 3750 1.0 1.0 0.06 239.9

r.v max for inlet nozzle (kg/m.s ) r.v2 max for gas outlet nozzle (kg/m.s2) Max vel. in Oil out nozzle (m/s) Max vel. in water out nozzle (m/s) K Value (m/sec) Mixture density (kg/m3)

RESIDENCE TIMES Shell Gas residence time (seconds) HLL-HLSD NLL-HLL NLL-LLL LLL-LLSD LLSD to Outlet Oil Residence Time at NLL RESIDENCE TIMES Boot HIL-HILSD NIL-HIL NIL-LIL LIL-LILSD LILSD to bottom Water residence time at NIL

Specified (mins) 3.0 3.0 3.0 3.0 3.0 3.00 Specified (mins) 3.0 3.0 3.0 3.0 3.0

Actual (mins) 581.7 12.2 17.2 18.6 9.1 11.3 39.0 Actual (mins) 0.2 0.3 0.3 0.3 1.2 1.8

** WARNINGS **
OK OK OK OK OK

** WARNINGS **
** Warning ! Residence time insufficient ** ** Warning ! Residence time insufficient ** ** Warning ! Residence time insufficient ** ** Warning ! Residence time insufficient ** ** Warning ! Residence time insufficient **

SETTLING VELOCITY CRITERION K Factor Gas Velocity (m/s) Gas Velocity (m/s) - calculated Oil Droplet Velocity (m/s) - Gravity Settling Method Oil from Gas Water from Oil Oil from Water Droplet fall time (Oil in gas) 0.37 m/s OK 0.04 m/s Water velocity in Boot 0.137 m/s 0.006 m/s 0.037 m/s OK 21.1 secs OK 0.02 m/sec

NOTE:

Gas Velocity Criteria are based on NLL.

NOTES :

Rev Revised/Issued For OWNER CLIENT PROJECT AREA DATE AND TIME PRINTED: 22-Jul-13

Date

Prepd

Chkd

SEPARATOR SIZING CALCULATIONS

Appd Item No. Description P&ID Ref.

7:30 AM

Page Sheet OF Doc No. Contract No. 9167J \\vboxsrv\conversion_tmp\scratch_3\[159392729.xls.ms_office.xls]Hor-3P-Weir-No Boot Kvaerner Process India

HORIZONTAL SEPARATOR (3 phase with boot)

SKETCH

Min. Gas Out. nozzle ID 202 mm Length T/T= 20400 mm

Gas =

762.76 t/d 1559.71 Am3/h

Inlet Minimum Inlet nozzle ID 544 mm

GAS I. D. = 5300 mm HLSD HLL NLL LLL LLSD Height 3800 mm 3200 mm 2400 mm 1500 mm 1000 mm Vol. (m3) 252.02 67.07 94.71 102.45 49.89 62.28 (Gas) (HLL-HLSD) (NLL-HLL) (NLL-LLL) (LLL-LLSD) (LLSD-Boot)

OIL

Interface Boot Height (mm) 2000 mm HILSD HIL NIL LIL LILSD

Height 2000 ID 1200 mm 1000 mm 700 mm 400 mm 200 mm WATER

Vol.(m3) 0.628 0.942 0.942 1.100 1.204 (HIL-HILSD) (NIL-HIL) (NIL-LIL) (LIL-LILSD) (LILSD-Btm)

Min Oil Outlet nozz ID: 342 mm Oil = 6466.00 t/d 3 330.54 m /h

Min. Water out nozzle ID: 265 mm Water = NOMENCLATURE LLL Low Liquid Level LIL Low Interface Level LLSD Low Level Shut Down LILSD Low Interface Level Shut Down NLL NIL HLL Normal Liquid Level Normal Interface Level High Liquid Level HIL HLSD HILSD Btm X-Area rl rv High Interface Level High Level Shut Down High Interface Level Shut Down Bottom Cross sectional area Liquid density kg/m3 Vapour density kg/m3
NOTES : Dp m Vt VMAX K KCR

4799.00 t/d 198.36 m3/h

Droplet (particle diameter) m Gas viscosity Cp Settling Velocity m/s Maximum vapour velocity m/s Design vapour velocity factor m/s Proportionality constant, dimensionless.

Rev OWNER CLIENT PROJECT AREA

Revised/Issued For

Date

Prepd

Chkd

Appd Item No. Description P&ID Ref. Kvaerner Process India Page Sheet Doc No. Contract No. OF 9167J

SEPARATOR SIZING CALCULATIONS

DATE AND TIME PRINTED:

22-Jul-13

7:30 AM

\\vboxsrv\conversion_tmp\scratch_3\[159392729.xls.ms_office.xls]Hor-3P-Weir-No Boot

HORIZONTAL SEPARATOR (3 phase with boot)

CALCULATIONS
SETTLING VELOCITIES
Dmax is the upper particle size limit for each of the laws.

Oil in Gas (Gravity Settling Laws method)

Oil From Gas ("K" Value method) K Value (m/s) *Max Allowable Velocity,Vmax Gas Horiz. Velocity *note 2 Actual Gas Velocity OK

0.06 0.37 m/s 0.04 m/s

Dmax is the upper particle size limit for each of the laws. Kcr is the critical constant for maximum particle size (from GPSA Handbook). Vt is the settling velocity in m/s. see note 1

Particle size calc for determination of appropriate law Settling Velocity Settling Law Used Law Used: Stoke's Law Intermediate Law Newton's Law Kcr 0.03 0.33 18.13 0.14 m/s Intermediate Law Vt (m/s) 0.37 0.14 0.34 Dp max ( m) 31 412 22356

Oil in Water (Gravity Settling Laws method) Particle size calc for determination of appropriate law Settling Velocity Settling Law Used Law Used: Stoke's Law Intermediate Law Newton's Law 0.037 m/s Intermediate Law Vt Dp max ( m) (m/s) 0.03 0.118 261 0.33 0.037 3491 18.13 0.084 189513

Water in Oil (Gravity Settling Laws method) Particle size calc for determination of appropriate law Settling Velocity Settling Law Used Law Used: Stoke's Law Intermediate Law Newton's Law 0.006 m/s Stoke's Law Vt Dp max ( m) (m/s) 0.006 776 0.008 10373 0.059 563088

Kcr

Kcr 0.03 0.33 18.13

Stoke's Law (Kcr = 0.025) Vt = 1488 g Dp2 (rl - rv)

Intermediate Law (Kcr = 0.334) Vt = 3.54*g

0.71

Newton's Law (Kcr = 18.13) Vt = 1.74 * SQRT(g Dp (rl-rv) / rv )

Dp1.14 (rl *m
0.43

- rv)

0.71

18m

rv

0.29

NOTES 1.
2. 3. 4. 5 Equations for Stokes Law, Intermediate Law and Newtons Law are taken from GPSA Handbook, Volume 1, Section 7. Figure 7.4 Maximum allowable vapour velocity is calculated from the equation in GPSA Handbook, Volume 1, Section 7: = K [ (rl - rv) / rv ] 0.5 VMAX LLSD height calculation is based on the distance between the bottom of the cylinder and the low level shut down for the oil. LILSD height calculation is based on the distance from the base of the boot dished end to the low interface level shut down for the water. Information for partial volumes and dished ends was from GPSA handbook Sections SI - 13.5 to 13.10, and in particular, fig. 13.6. Calculations for gas residence time and area/volume calculations use the normal liquid level, NLL as the height basis. End volumes is ignored for gas volume calculations.

NOTES :

Rev Revised/Issued For OWNER CLIENT PROJECT AREA DATE AND TIME PRINTED: 22-Jul-13

Date

Prepd

Chkd

SEPARATOR SIZING CALCULATIONS

Appd Item No. Description P&ID Ref.

7:30 AM

Page Sheet OF Doc No. Contract No. 9167J \\vboxsrv\conversion_tmp\scratch_3\[159392729.xls.ms_office.xls]Hor-3P-Weir-No Boot Kvaerner Process India

HORIZONTAL SEPARATOR (3 phase with weir, no boot)

INPUT YEAR : 2003-04
GAS 406.8 9.1 0.01 Oil in Gas Oil in Water Water in Oil OIL 3035.3 830.0 6.25 100 150 WATER 675.2 988.5 0.54 Right Side of Weir HLL-HLSD NLL-HLL NLL-LLL LLL-LLSD LLSD to Outlet Oil Residence Time at NLL 0.4 1.0 1.0 1.5 0.3 0.30 0.57 0.28 0.29 1.00 0.24 1.53 OK ** Warning ! Residence time insufficient ** ** Warning ! Residence time insufficient ** ** Warning ! Residence time insufficient ** ** Warning ! Residence time insufficient ** OK

OUTPUT
RESIDENCE TIMES Gas Specified (mins) Actual (mins) 25.34 ** WARNINGS **

Feed Flow (t/d) Density (kg/m3) Viscosity (cP) Droplet Size (m) Droplet Size (m) Droplet Size (m)

seconds

438 10000 3750 1.0 1.0 0.14 83.62

r.v2 max for inlet nozzle (kg/m.s2) r.v2 max for gas outlet nozzle (kg/m.s2) Max vel. in Oil out nozzle (m/s) Max vel. in water out nozzle (m/s) K Value (m/s) Mixture density (kg/m3)

RESIDENCE TIMES Left Side of Weir HIL-Weir NIL-HIL NIL-LIL LIL-LILSD

Specified (mins) 1.0 0.9 1.0 1.0

Actual (mins) 27.0 2.77 2.03 1.91 6.82 5.57 10.76

** WARNINGS ** OK OK OK OK OK mins mins

SETTLING VELOCITY CRITERION K-Factor Gas Velocity (m/s) Gas Velocity (m/s) - calculated Oil Droplet Velocity (m/s) - Gravity Settling Method Oil from Gas Water from Oil Oil from Water DROPLET FALL TIMES (Left Side of Weir) Oil in Gas (Top-Liquid) 6.1 secs Water in Oil (Weir to NIL) 5.35 min Oil in Water (Btm-NIL) 2.41 min

2.19 m/s 0.26 m/s 0.175 m/s 0.003 m/s 0.004 m/s

OK

LILSD to Outlet 0.3 Oil Residence Time (Weir to NIL) Water Residence Time (NIL to Btm)

OK OK OK

D1

ISSUED FOR DESIGN/COST ESTIMATE Rev Revised/Issued For OWNER CEIL CLIENT Owner PROJECT Old CSU De-Bottlenecking Study AREA New CSU 22-Jul-13 DATE AND TIME PRINTED:

NOTES : 1. Maximum allowable vapour velocity is calculated from the equation in GPSA Engineering data book, Vol I, Section 7, 11 th edition. 2. Settling times for water and oil on the left hand side of the separator are based on normal interface level(NIL). 3. Information for partial volumes and dished ends is from GPSA Engineering data book, Vol I, Section 6. 4. Calculation of gas residence time and area/volume calculations use the weir height as the height basis. Date Prepd Chkd Appd End volumes are ignored. Item No. V-101 Page SEPARATOR SIZING CALCULATIONS Description 1st Stage Prod.Sep. Kvaerner Process India Sheet OF P&ID Ref. 9167J Doc No. Case. 7:30 AM O 23000, W 4296 G 0.04 Contract No. 9167J \\vboxsrv\conversion_tmp\scratch_3\[159392729.xls.ms_office.xls]Hor-3P-Weir-No Boot

HORIZONTAL SEPARATOR (3 phase with weir, no boot)

SKETCH YEAR : 2003-04

Gas Outlet nozzle ID 180 mm Length T/T = Inlet Nozzle ID 258 mm Vol. (m 3) 13.17 12.82 1.31 0.96 0.91 3.23 7720 mm

Gas =

406.78 t/d 3 1870.78 Am /h

Ht.(mm) (Gas) (HIL-Weir) (NIL-HIL) (NIL-LIL) (LIL-LILSD) (LILSD-Out) 610 520 450 380 Interface HIL NIL LIL LILSD Weir Height,Hw = 1371 mm I. D. = 2438 mm OIL

GAS HLSD HLL NLL LLL LLSD Ht(mm) 2057 1574 1371 1168 380 OIL

Vol. (m 3) 1.46 0.72 0.74 2.55 0.60 (HLL-HLSD) (NLL-HLL) (NLL-LLL) (LLL-LLSD) (LLSD-Out)

WATER

T/W =

6700 mm

Oil Outlet nozzle ID 232 mm Oil = 3035.31 152.38 t/d m3/h

Water outlet Nozzle ID 100 mm

Water =

675.21 28.46

t/d m3/h

NOTES :

D1 Rev OWNER CLIENT PROJECT AREA

ISSUED FOR DESIGN/COST ESTIMATE Revised/Issued For CEIL Owner Old CSU De-Bottlenecking Study New CSU 22-Jul-13

Appd Item No. SEPARATOR SIZING CALCULATIONS Description P&ID Ref. Case. 7:30 AM

Date

Prepd

Chkd

V-101 1st Stage Prod.Sep. 9167J O 23000, W 4296 G 0.04

Kvaerner Process India

Page Sheet Doc No. Contract No.

OF 9167J

DATE AND TIME PRINTED:

\\vboxsrv\conversion_tmp\scratch_3\[159392729.xls.ms_office.xls]Hor-3P-Weir-No Boot

HORIZONTAL SEPARATOR (3 phase with weir, no boot)

CALCULATIONS
SETTLING VELOCITIES Oil From Gas ("K" Value method) K Value, m/s Max allowable velocity,Vmax Gas Horiz. Velocity Actual Gas Velocity OK Stoke's Law Intermediate Law Newton's Law Oil in Water (Gravity Settling Laws method) Particle size calc for determination of appropriate law Settling Velocity Settling Law Used Law Used: Stoke's Law Intermediate Law Newton's Law Stoke's Law (Kcr = 0.025) 2 Vt = 1488 g Dp (rl - rv) 18m Water in Oil (Gravity Settling Laws method) Particle size calc for determination of appropriate law m/s Dp max (m) 187 2501 135770 Settling Velocity Settling Law Used Law Used: Stoke's Law Intermediate Law Newton's Law Newton's Law (Kcr = 18.13) Vt = 1.74 * SQRT(g Dp (rl-rv) / rv ) 0.025 0.334 18.13 0.14 2.194 m/s 0.26 m/s

YEAR :

2003-04
Dmax is the upper particle size limit for each of the laws. Kcr is the critical constant for maximum particle size (from GPSA Engineering Databook). Vt is the settling velocity in m/s.
Oil in Gas (Gravity Settling Laws method) Particle size calc for determination of appropriate law Settling Velocity Settling Law Used Law Used: Kcr

0.18 m/s Intermediate Law

Vt (m/s) 0.37 0.18 0.52 Dp max (m) 41 546 29638

0.004
Kcr 0.025 0.334 18.13 Stoke's Law Vt (m/s) 0.004 0.004 0.027

0.003
Kcr Stoke's Law Vt (m/s) 0.025 0.003 0.334 0.005 18.13 0.050

m/s Dp max (m) 1015 13566 736365

Intermediate Law (Kcr = 0.334) 0.71 1.14 0.71 Vt = 3.54*g Dp (rl - rv) rv0.29 * m0.43

NOTE:

Equations for Stokes Law, Intermediate Law and Newtons Law are taken from GPSA Handbook, Volume 1, Section 7, Figure 7.4

NOMENCLATURE
LLL LIL LLSD LILSD NLL NIL HLL HIL HLSD HILSD Low Liquid Level Low Interface Level Low Level Shut Down Low Interface Level Shut Down Normal Liquid Level Normal Interface Level High Liquid Level High Interface Level High Level Shut Down High Interface Level Shut Down X-Area rl rv Dp m Vt VMAX K KCR Hw Cross sectional area 3 Liquid density kg/m 3 Vapour density kg/m Droplet diameter m Gas viscosity Cp Settling Velocity m/s Maximum vapour velocity m/s Design vapour velocity factor m/s Proportionality constant, dimensionless. Height of Weir, mm NOTES : Btm Bottom

D1

ISSUED FOR DESIGN/COST ESTIMATE Rev Revised/Issued For OWNER CEIL CLIENT Owner PROJECT Old CSU De-Bottlenecking Study AREA New CSU DATE AND TIME PRINTED: 22-Jul-13

Appd Item No. SEPARATOR SIZING CALCULATIONS Description P&ID Ref. Case. 7:30 AM

Date

Prepd

Chkd

V-101 Page 1st Stage Prod.Sep. Kvaerner Process India Sheet 9167J Doc No. O 23000, W 4296 G 0.04 Contract No. \\vboxsrv\conversion_tmp\scratch_3\[159392729.xls.ms_office.xls]Hor-3P-Weir-No Boot

OF 9167J

HORIZONTAL SEPARATOR (3 phase with weir, no boot)

YEAR : 2003-04

PARTIAL VOLUME IN HORIZONTAL STORAGE TANKS WITH ELLIPSOIDAL OR HEMISPHERICAL HEADS.

L b

H1

TOTAL VOLUME = Volume in 2 heads + Volume in cylinder = 1 / 6 p K D3 +1 / 4 p D2 L K = 2b / D Ze = H 1 / D Zc = H1 / D PARTIAL VOLUME = (1 / 6 p K D3) * f(Ze) + (1 / 4 p D2 L) * f(Zc) f(Ze) = Ellipsoidal Coefficient f(Zc) = Horizontal cylinder coefficient. For elliptical heads, b = 0.25 * D and K = 0.5

NOTES :

D1

ISSUED FOR DESIGN/COST ESTIMATE Rev Revised/Issued For OWNER CEIL CLIENT Owner PROJECT Old CSU De-Bottlenecking Study AREA New CSU DATE AND TIME PRINTED: 22-Jul-13

Appd Item No. SEPARATOR SIZING CALCULATIONS Description P&ID Ref. Case. 7:30 AM

Date

Prepd

Chkd

V-101 Page 1st Stage Prod.Sep. Kvaerner Process India Sheet 9167J Doc No. O 23000, W 4296 G 0.04 Contract No. \\vboxsrv\conversion_tmp\scratch_3\[159392729.xls.ms_office.xls]Hor-3P-Weir-No Boot

OF 9167J

HORIZONTAL SEPARATOR (3 phase with weir, no boot)

Ze =H1 /D 1.000 f(Ze) 1.000 End Vol (1 end) m3 1.898

TOTAL Cross Sectional Area GAS (Volume to Top) WEIR TO TOP (PART ONE) STORAGE (Volume from Bottom) Left side of weir WEIR HIL NIL LIL LILSD Right side of weir HLSD HLL NLL LLL LLSD

0.44

IGNORE

IGNORE

0.56 0.250 0.213 0.185 0.156 0.844 0.646 0.562 0.479 0.156 Fraction of Dia. =H1 /D

0.593 0.156 0.117 0.090 0.065 0.934 0.712 0.593 0.469 0.065 a (Radians)

1.125 0.297 0.222 0.170 0.124 1.773 1.351 1.125 0.889 0.124 Chord fraction f(Zc)

Area (m2) 4.67

Cylinder Partial Vol. (m3) 36.05

Partial Vol + end vol. (m3) 39.85 IGNORE END VOLUME

Volume Increment (m3)

TOTAL Cross Sectional Area GAS (Volume to Top) WEIR TO TOP (Left side of weir) STORAGE (Volume from Bottom) Left side of weir WEIR HIL NIL LIL LILSD Right side of weir HLSD HLL NLL LLL LLSD

0.4377

1.45

0.42

1.97

13.17

13.17

0.5623 0.2502 0.2133 0.1845 0.1558 0.8436 0.6455 0.5623 0.4790 0.1558 NOTES :

1.70 1.05 0.96 0.89 0.81 2.33 1.87 1.70 1.53 0.81

0.5791 0.1957 0.1560 0.1269 0.0994 0.9001 0.6826 0.5791 0.4733 0.0994

2.70 0.91 0.73 0.59 0.46 4.20 3.19 2.70 2.21 0.46

18.12 6.12 4.88 3.97 3.11 4.29 3.25 2.76 2.25 0.47

19.24 6.42 5.10 4.14 3.23 6.06 4.60 3.88 3.14 0.60

12.82 1.31 0.96 0.91 3.23 1.46 0.72 0.74 2.55 0.60

D1

ISSUED FOR DESIGN/COST ESTIMATE Rev Revised/Issued For OWNER CEIL CLIENT Owner PROJECT Old CSU De-Bottlenecking Study AREA New CSU DATE AND TIME PRINTED: 22-Jul-13

Appd Item No. SEPARATOR SIZING CALCULATIONS Description P&ID Ref. Case. 7:30 AM

Date

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V-101 Page 1st Stage Prod.Sep. Kvaerner Process India Sheet 9167J Doc No. O 23000, W 4296 G 0.04 Contract No. \\vboxsrv\conversion_tmp\scratch_3\[159392729.xls.ms_office.xls]Hor-3P-Weir-No Boot

OF 9167J

HORIZONTAL SEPARATOR (3 phase, no boot, standpipe for condensate)

INPUT
Feed Flow (t/d) Density (kg/m3) Viscosity (cP) Droplet Size (m) Droplet Size (m) Droplet Size (m)

OUTPUT GAS
2288.0 20.4 0.01 Oil in Gas Oil in Water Water in Oil

OIL
19398.0 815.1 4.57 150 1000

WATER
14396.0 1008.1 0.89

RESIDENCE TIMES
Gas HLL-HLSD NLL-HLL NLL-LLL LLL-LLSD LLSD to NIL HIL-HILSD NIL-HIL NIL-LIL LIL-LILSD LILSD to Outlet

Specified (mins) 0.2 0.2 0.2 0.2 0.3 15.0 3.0 3.0 1.0 3.0

500 1500 3750 1.0 1.0 0.06 239.9 360 mm 360 mm

r.v 2 max for inlet nozzle (kg/m.s2) r.v 2 max for gas outlet nozzle (kg/m.s 2) Max vel. in Oil out nozzle (m/s) Max vel. in water out nozzle (m/s) K Value (m/s) Mixture density (kg/m3) Water Level Control Band Oil Level Control Band

Actual (mins) 12.54 0.06 0.02 0.22 0.01 0.33 0.2 0.18 0.16 0.10 0.21 0.6 0.64 0.5

** WARNINGS ** seconds
** Warning ! Residence time insufficient ** ** Warning ! Residence time insufficient ** OK ** Warning ! Residence time insufficient ** OK ** Warning ! Residence time insufficient ** ** Warning ! Residence time insufficient ** ** Warning ! Residence time insufficient ** ** Warning ! Residence time insufficient ** ** Warning ! Residence time insufficient **

NIL-Standpipe Oil residence time (NLL - NIL) Water residence time (NIL-Bottom)

mins mins mins

SETTLING VELOCITY CRITERION

K Factor Gas Velocity (m/s) Gas Velocity (m/s) - calculated Oil Droplet Velocity (m/s) - Gravity Settling Method Oil from Gas Water from Oil Oil from Water 0.37 m/s 0.8 m/s 0.22 m/s 0.006 m/s 0.037 m/s
** Warning ! Gas Vel > Max Allowable **

DROPLET FALL TIMES

Oil in Gas Top-Liquid Water from Oil NLL-NIL Oil from Water Btm-NIL 4.8 1.5 0.2 seconds mins mins
OK ** Warning ! Residence Time Insufficient ** OK

NOTE:

Gas Velocity Criteria are based on NLL Height.

STANDPIPE CALCULATIONS - FROM VESSEL BASE

WATER LEVEL CONTROL BAND WATER INTERFACE LILSD WATER INTERFACE HILSD WATER INTERFACE NIL DIST. BETWEEN WATER HILSD AND OIL OUTLET NOZZLE OIL OUTLET NOZZLE (STANDPIPE) ELEVATION, (Hs) DIST. BETWEEN OIL OUTLET NOZZLE AND OIL LLSD OIL LEVEL CONTROL BAND OIL LEVEL LLSD OIL LEVEL NLL OIL LEVEL HLSD 360 301 661 481 mm mm mm mm

INTERMEDIATE CALCULATIONS

301.16

661.16

321 mm 982 mm 149.4 mm 360 1132 1312 1492 mm mm mm mm

321.23 148.64

1.00 0.99

120.05

0.7

NOTES :

Rev Revised/Issued For OWNER CLIENT PROJECT AREA DATE AND TIME PRINTED: 22-Jul-13

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Page Sheet OF Doc No. Contract No. 9167J \\vboxsrv\conversion_tmp\scratch_3\[159392729.xls.ms_office.xls]Hor-3P-Weir-No Boot Kvaerner Process India

HORIZONTAL SEPARATOR (3 phase, no boot, standpipe for condensate)

SKETCH

Gas = Inlet Minimum Inlet nozzle ID 941 mm Length T/T= 10000 mm

2288.00 t/d 4680.09 Am3/h

Minimum Gas Out Nozzle ID = 349 mm

RECOMMENDED HEIGHTS OIL LEVEL HLSD OIL LEVEL NLL OIL LEVEL LLSD STANDPIPE, Hs HILSD NIL LILSD HEIGHT WARNINGS 1492 mm 1312 mm 1132 mm 982 mm 661 mm 481 mm 301 mm water HILSD water HIL water NIL water LIL water LILSD Interface 590 mm 500 mm 400 mm 300 mm 230 mm oil HLSD oil HLL oil NLL oil LLL oil LLSD Ht. (mm) 1000 mm 950 mm 934 mm 760 mm 755 mm

Incremental Vol. (m3) 16.30 1.05 0.35 3.66 0.10 3.32

GAS
(Gas) (HLL-HLSD) (NLL-HLL) (NLL-LLL) (LLL-LLSD) (LLSD-HILSD)

I. D. = 1972 mm

Height of standpipe, Hs = OIL 1.68 1.76 1.59 1.00 2.06

(HIL-HILSD) (NIL-HIL) (NIL-LIL) (LIL-LILSD) (LILSD-Outlet)

707 mm

WATER

Minimum Water out nozzle ID = 459 mm OK WARNING! LLSD height too low! Minimum Oil Outlet nozzle ID = WARNING! Distance between HILSD and standpipe is insufficient! WARNING! Distance between LLSD and standpipe is insufficient! Oil = OK WARNING! LILSD height too low! 19398.00 t/d 991.63 m3/h 592 mm Water = 14396.00 t/d 3 595.04 m /h

NOMENCLATURE
LLL LIL LLSD LILSD NLL NIL HLL Low Liquid Level Low Interface Level Low Level Shut Down Low Interface Level Shut Down Normal Liquid Level Normal Interface Level High Liquid Level HIL HLSD HILSD KCR Hs rl rv High Interface Level High Level Shut Down High Interface Level Shut Down Proportionality constant, dimensionless. Height of Standpipe, mm Liquid density kg/m3 3 Vapour density kg/m NOTES : Dp m Vt VMAX K Droplet diameter m Gas viscosity Cp Settling Velocity m/s Maximum vapour velocity m/s Design vapour velocity factor m/s

Rev OWNER

Revised/Issued For

Date

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Page Sheet OF Doc No. Contract No. 9167J \\vboxsrv\conversion_tmp\scratch_3\[159392729.xls.ms_office.xls]Hor-3P-Weir-No Boot

CLIENT PROJECT AREA DATE AND TIME PRINTED:

SEPARATOR SIZING CALCULATIONS Description

22-Jul-13

7:30 AM

HORIZONTAL SEPARATOR (3 phase, no boot, standpipe for condensate)

CALCULATIONS Cont'd) Oil in Gas (Gravity Settling Laws method)
Particle size calc for determination of appropriate law 0.06 0.37 m/s

SETTLING VELOCITIES Oil From Gas ("K" Value method)

K Value, m/s Max allowable velocity,Vmax

Dmax is the upper particle size limit for each of the laws. Kcr is the critical constant for maximum particle size (from GPSA Handbook). Vt is the settling velocity in m/s.

Settling Velocity

0.22

m/s

Gas Horiz. Velocity

0.80

m/s

Kcr is the critical constant for maximum particle size (from GPSA Handbook). Vt is the settling velocity in m/s. see note 1

Settling Law Used Law Used: Kcr Stoke's Law Intermediate Law Newton's Law

** Maximum allowable gas velocity exceeded **

Intermediate Law Vt (m/s) 0.03 0.84 0.33 0.22 18.13 0.42

Dp max (m) 31 412 22359

Oil in Water (Gravity Settling Laws method)

Particle size calc for determination of appropriate law Settling Velocity Settling Law Used Law Used: Stoke's Law Intermediate Law Newton's Law

Water in Oil (Gravity Settling Laws method)

Particle size calc for determination of appropriate law m/s Dp max (m) 261 3491 189513 Settling Velocity Settling Law Used Law Used: Kcr Stoke's Law Intermediate Law Newton's Law

0.037
Kcr Intermediate Law Vt (m/s) 0.03 0.118 0.33 0.037 18.13 0.08

0.006
Stoke's Law Vt (m/s) 0.03 0.006 0.33 0.008 18.13 0.059

m/s Dp max (m) 776 10373 563088

NOTES

1.

Stoke's Law (Kcr = 0.025) Vt = 1488 g Dp2 (rl - rv) 18m

Intermediate Law (Kcr = 0.334) Vt = 3.54*g0.71 Dp1.14 (rl - rv)0.71 rv

0.29

Newton's Law (Kcr = 18.13) Vt = 1.74 * SQRT(g Dp (rl-rv) / rv )

*m

0.43

Equations for Stokes Law, Intermediate Law and Newtons Law are taken from GPSA Handbook, Volume 1, Section 7. Figure 7.4 2. 3. 4. 5. Maximum allowable vapour velocity is calculated from the equation in GPSA Handbook, Volume 1, Section 7: VMAX = K [ (rl - rl) / rl ] 0.5 Settling times for water and oil are based on the normal interface level (NIL). Information for partial volumes and dished ends was from GPSA handbook Sections SI - 13.5 to 13.10, and in particular, fig. 13.6. Calculations for gas residence time and area/volume calculations use the NLL height as the height basis. End volumes ignored for gas volume calculations. NOTES :

Rev Revised/Issued For OWNER CLIENT PROJECT AREA DATE AND TIME PRINTED: 22-Jul-13

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Page Sheet OF Doc No. Contract No. 9167J \\vboxsrv\conversion_tmp\scratch_3\[159392729.xls.ms_office.xls]Hor-3P-Weir-No Boot Kvaerner Process India

HORIZONTAL SEPARATOR (2 phase)

INPUT
Feed Flow (t/d) Density (kg/m3) Viscosity (cP) Droplet Size (m) Oil in Gas r.v2 max for inlet nozzle (kg/m.s2) r.v2 max for gas outlet nozzle (kg/m.s2) Max vel. in Oil out nozzle (m/s) K Value (m/s) from mist extractor data GPSA fig 7.9 Mixture density (kg/m3) GAS 520.0 11.10 0.02 OIL 1000.0 829.20 7.00 150 1500 3750 1.00 0.06 31.63

OUTPUT
RESIDENCE TIMES Gas (seconds) HLL-HLSD NLL-HLL NLL-LLL LLL-LLSD LLSD to bottom SETTLING VELOCITY CRITERION K-Factor Gas Velocity (m/s) Gas Horiz. Velocity (m/s) - calculated Oil Droplet Velocity (m/s) (Gravity Settling Method) Droplet fall time (seconds) Specified (mins) 3.0 3.0 3.0 3.0 3.0 Actual (mins) 59.2 3.3 19.2 5.1 3.4 21.5 (m/s) 0.52 0.17 0.23 6.4 ** WARNINGS **
OK OK OK OK OK

OK

NOTE:

Gas velocity critera all based on NLL.

OK

CALCULATIONS
SETTLING VELOCITIES Oil From Gas ("K" Value method) K Value Max Allowable Velocity,Vmax Gas Horiz. Velocity Minimum Vessel Diameter

0.06 0.52 0.17 1158

m/s m/s m/s mm

Dmax is the upper particle size limit for each of the laws. Kcr is the critical constant for maximum particle size (from GPSA Handbook). Vt is the settling velocity in m/s.

Oil from Gas (Gravity Settling Laws method) Particle size calc for determination of appropriate law Settling Velocity Settling Law Used Law Used: Kcr 0.03 0.33 18.13 Vt (m/s) 0.62 0.23 0.57 0.23 m/s Intermediate Law Dp max ( m) 47 621 33733

Stoke's Law (Kcr = 0.025) Vt = 1488 g Dp2 (rl - rv) 18m

Intermediate Law (Kcr = 0.334) Vt = 3.54*g0.71 Dp1.14 (rl - rv)0.71 rv0.29 * m0.43

Newton's Law (Kcr = 18.13) Vt = 1.74 * SQRT(g Dp (rl-rv) / rv )

Stoke's Law Intermediate Law Newton's Law

NOTE:

Equations for Stoke's Law, Intermediate Law and Newton's Law are taken from GPSA Handbook, Volume 1, Section 7. Figure 7.4
NOTES :

Rev Revised/Issued For OWNER CLIENT PROJECT AREA DATE AND TIME PRINTED: 22-Jul-13

Date

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SEPARATOR SIZING CALCULATIONS

Appd Item No. Description P&ID Ref.

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Page Sheet OF Doc No. Contract No. 9167J \\vboxsrv\conversion_tmp\scratch_3\[159392729.xls.ms_office.xls]Hor-3P-Weir-No Boot Kvaerner Process India

HORIZONTAL SEPARATOR (2 phase)

SKETCH

Inlet Minimum Inlet nozzle ID 321 mm Length T/T= 10200 mm

Minimum Gas Outlet Nozzle ID =

Gas = 194 mm

520.0 t/d 3 1951.95 Am /h

GAS
I. D. = 2630 mm HLSD HLL NLL LLL LLSD

Height 1800 mm 1700 mm 1150 mm 1000 mm 900 mm

Vol. (m3) 32.12 2.79 16.06 4.30 2.84 18.04

(Gas) (HLL-HLSD) (NLL-HLL) (NLL-LLL) (LLL-LLSD) (LLSD-Btm)

OIL

Minimum Oil Outlet Nozzle ID =

Oil = 133 mm

1000 50.25

t/d m3/h

NOMENCLATURE LLL LLSD NLL HLL HLSD Btm rl rv Low Liquid Level Low Level Shut Down Normal Liquid Level High Liquid Level High Level Shut Down Bottom Liquid density kg/m 3 Vapour density kg/m 3 Dp m Vt VMAX K KCR g Dmax Droplet diameter m Gas viscosity Cp Settling Velocity m/s Maximum vapour velocity m/s Design vapour velocity factor m/s Proportionality constant, dimensionless. Gas constant Upper Particle Size Limit

NOTES :

Rev Revised/Issued For OWNER CLIENT PROJECT AREA DATE AND TIME PRINTED: 22-Jul-13

Date

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Page Sheet OF Doc No. Contract No. 9167J \\vboxsrv\conversion_tmp\scratch_3\[159392729.xls.ms_office.xls]Hor-3P-Weir-No Boot Kvaerner Process India

VERTICAL SEPARATOR (2 phase)

INPUT HP2 SUCTION SCRUBBER V 7954A (EXISTING -RE-USED)
GAS 3563.3 51.20 0.01 OIL 0.05 600.0 0.16 150 0.11 10000 10000 1.00 51.20

OUTPUT
RESIDENCE TIMES HLL-HLSD NLL-HLL NLL-LLL LLL-LLSD LLSD to bottom SETTLING VELOCITY CRITERION K Factor Gas Velocity (m/s) Gas Velocity (m/s) - calculated Oil Droplet Velocity (m/s) Gravity Settling Method Specified (mins) 3.0 3.0 3.0 3.0 3.0 Actual (mins) 3862.5 5793.7 5793.7 3862.5 5793.7 ** WARNINGS ** OK OK OK OK OK

Feed Flow (t/d) Density (kg/m3) Viscosity (cP) Droplet Size, (m) Oil in Gas K Value (m/s) from mist extractor data GPSA fig.7.9 r.v2 max for inlet nozzle (kg/m.s2) 2 2 r.v max for gas outlet nozzle (kg/m.s ) Max vel. in Oil outlet nozzle (m/s) Mixture density (kg/m3)

Choose Dished end shape by clicking on arrow.

See note 6

0.36 0.36 0.14

** Warning ! Gas Velocity > Max Allowable ** ** Warning ! Gas Velocity > Max Allowable**

Note:

Gas velocity criteria based on NLL.

CALCULATIONS LIQUID / VAPOUR SEPARATION K Value Method (Note 2) K Value Max allow. Velocity (Vmax) Gas Velocity Minimum Vessel Diameter Maximum allowable gas velocity exceeded Stoke's Law (Kcr = 0.025) Vt = 1488 g Dp2 (rl - rv) 18m Intermediate Law (Kcr = 0.334) Vt = 3.54*g0.71 Dp1.14 (rl - rv)0.71 rv
0.29

0.11 0.36 0.36 1687

m/s m/s m/s mm

Dmax is the upper particle size limit for each of the laws. Kcr is the critical constant for maximum particle size (from GPSA Handbook). Vt is the settling velocity in m/s.

Oil from Gas (Gravity Settling Laws method) Particle / droplet size calc for determination of appropriate law Settling Velocity Settling Law Used Law Used: Stoke's Law Intermediate Law Newton's Law Kcr 0.03 0.33 18.13 0.14 m/s Intermediate law Vt (m/s) 0.67 0.14 0.22 Dp max (m) 23 310 16852

Newton's Law (Kcr = 18.13) Vt = 1.74 * SQRT(g Dp (rl-rv) / rv )

*m

0.43

NOTES :

Rev

Revised/Issued For

Date

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Appd Kvaerner Process India Page Sheet OF Doc No. Contract No. 9167J \\vboxsrv\conversion_tmp\scratch_3\[159392729.xls.ms_office.xls]Hor-3P-Weir-No Boot

OWNER CLIENT PROJECT AREA DATE AND TIME PRINTED:

Item No. SEPARATOR SIZING CALCULATIONS Description P&ID Ref. 22-Jul-13 7:30 AM

VERTICAL SEPARATOR (2 phase)

SKETCH

HP2 SUCTION SCRUBBER V 7954A (EXISTING -RE-USED)

Min Gas Outlet Nozz. Size =

Gas = 271 mm

3563.30 2899.82

t/d Am3/h

Calculated Total T/T Height: 3081 mm

300 mm 150 mm

(Note 6) Wire Mesh Demister ID=1687mm

1181 mm Inlet 550 mm Min Inlet Nozzle Size = 271 mm 250 mm

(Note 5)

GAS

(Note 2) 650 mm 550 mm Volume increment 3 0.22 m 0.34 m

3

NOMENCLATURE
LLSD LLL NLL HLL HLSD g Dmax rL rV Dp m Vt VMAX K KCR Low Level Shut Down Low Liquid Level Normal Liquid Level High Liquid Level High Level Shut Down Gas constant Upper Particle Size Limit Liquid density (kg/m3) Vapour density (kg/m3) Droplet diameter (m) Gas viscosity Cp Settling Velocity (m/s) Maximum vapour velocity (m/s) Design vapour velocity factor (m/s) Proportionality constant, dimensionless.

HLSD HLL

NLL

400 mm

OIL
LLL LLSD 250 mm 150 mm (Note 3) Volume to LLSD including dished end =

3 0.34 m

3 0.22 m 3 1.59 m

Min Liquid Outlet Nozz. Size =

Oil = 50 mm

0.05 0.00

t/d m3/h

NOTES :

Rev Revised/Issued For OWNER CLIENT PROJECT AREA DATE AND TIME PRINTED: 22-Jul-13

Appd Item No. SEPARATOR SIZING CALCULATIONS Description P&ID Ref. 7:30 AM

Date

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Kvaerner Process India

Page Sheet OF Doc No. Contract No. 9167J \\vboxsrv\conversion_tmp\scratch_3\[159392729.xls.ms_office.xls]Hor-3P-Weir-No Boot