INTRODUCTION PROCESS SIMULATION DIVISON PT NAWAPANCA ADHI CIPTA

This software is developed by Process Simulation Division, PT Nawapanca Adhi Cipta. The main goal is to participate within industries for an easier and less time consumming of decision making on process conditioning. For more information you can contact us at: nawapanca@indo.net.id

LINE SIZING FOR LIQUID

Basic principles Calculation of pressure drop-flow rate relation in liquid lines is simplified by the near incompressiblity of liquids. For near isothermal conditions, the fluid viscosity does not change drastically from one end of pipe run to the other. Thus, a calculation method that assumes constant properties can be used over lengths of piping. The calculation methods presented in this section: 1. Assume constant fluid properties 2. Applicable to pipe lengths with relatively constant temperature and no flashing Momentum equation General Consideration When the momentum equation is written for a section of pipe carrying a fluid of constant fluid properties, the resulting equation is expressed as:

where:V1 = Upstream fluid velocity, ft/sec V2 = Downstream velocity, ft/sec P1 = Upstream pressure, psi P2 = Downstream pressure, psi Z1 = Upstream elevation, ft Z2 = downstream elevation, ft hL = frictional head loss, ft Y = acceleration of gravity g = 32.17 ft/sec2 Figure below illustrates the condition for which this equation is written. This equation forms the basis for pressure drop predictions using the Darcy Equation.

Bernoulli Equation When the frictional head loss term is omitted, the momentum equation becomes the bernoulli equation. The Bernoulli equation was derived through a momentum balance on a frictionless fluid Units Each term in the momentum equation has the unit s of feet, which is the form presented incivil engineerng textbooks and is used for computations in this section Mechanical and chemical engineering textbooks use and equivalent form in which each term has the dimensions of pressure. Analysis of equation terms Definition of terms V2 terms represent acceleration effects in the fluid P terms represent pressure gradient effects Z terms represent elevation effects hL term represents the frictional pressure drop effect Velocity term Since acceleration effects are generally small for steady state flow in piping pressure drop calculations, the V2 terms are usually ignored. For a constant diameter pipe with an incompressible fluid, terms make no net contribution. Pressure terms y is the weight density and is expressed in units of , r, where : is identical to , and velocity

where: Y = weight density, lbf/ft3

r = mass density, lbm/ft3 g = acceleration gravity, 32.17, ft/sec2 Gc = 32.17 (ft-lbf/lbm sec2) For all practical situations, g = 32.17 ft/sec2 and there is no numerical distinction between y and r The computational convenience of the civil engineering form of the momentum equation arises from the incorporation of the factor Gc into y, weight density Darcy and Fanning Equations The momentum e quation has the frictional effects included in the term, and the methode for calculating frictional effects is unspecified Darcy and Fanning equations provide a means of calculating these friction effects. Coefficient Darcy and Fanning equations can be calculated by Churchil Equation if the flow in laminar condition and Chen equation if the flow in turbulent conditions.

Compressor
Compressor is one of the fluid flow operation equipment. The objective of compressor is to increase the gas stream pressure. Because of many limitation on materials and the shape of compressor, it is usually used in the compression ratio of 3 to 8 for a centrifugal compressor up to 12 to 24 for axial compressor. To select the most satisfactory compression equipment, chemical engineers must consider a wide variety of type, each of which has peculiar advantages for particular applications. Among the major factors to be considered are flow rate, head or pressure, temperature linitations, methode of sealing, method of lubrication, power consumtion serviceability, and cost. Step in Compressor 0.0.2 1. Selecting Component and Thermodynamic Model Before you could use the program, you must determine the component(s) will be processed. Component DataBase for this free software i s limited only for 45 components. Beside the component, user should also select the Thermodynamic model will be used in the calculation. This free software i s limited only for 4 model. This Thermodynamic model i s used in the determination of compressibility factor at suction and discharge condition. If user select Ideal System for it, compressibility factor will be used is one at any condition. The others is used via Equation Of State (EOS) and depend on Temperature, Pressure, mole fraction, and component's critical properties.

2. Determination of Component(s)'s Mole Fraction After component(s) and Thermocynamic model have selected, user must define their fraction on the stream. User could define this at the end of user specification, but still could not calculate before component(s)'s mole fraction is defined. If user do not know their composition, but their molar flow rate (each component), then i t could b e used. Because o f mole fraction only determined if its total is unity, then user must normalize them by click Normalize button.

3. User Specification Input The next step of this program is specification of the condition of its operation. They are stream condition and one of their efficiency (between adiabatic and polytropic). In this step, user could enter a value for relative density or not. The difference of it is that if user enter a value of stream's relative density, then program use that value for the determination of specific heat ratio of stream via Champbell's Generalization(1). If it is not be entered with a valid value or zero value, then program automatically left it as blank and use the specific heat capacity of component(s) in determining that specific heat ratio. the disadvantage of it is that the program use ideal heat capacity. Otherwise in the use of relative density on it, Chambell limitize the use of his generalization for Hydrocarbon Compounds. In the stream condition frame, program show in a taskbar what phase does the stream because a compressor could only be used for a vapor phase stream and so if it's show Liquid with a red color as the background, then user (and the program) could not calculate the operation. There also a big taskbar available to tell user which part of specification that should be entered. If the specification do not completed, its color will still be yellow and if the program could calculate (i.e. all inputs has entered) then its color will be green and it will tell you Ready To Calculate. After calculation has been done, its color will be blue and its word say Solved. User could see his/her compressor's parameters on the Result's Frame.

Calculation: It has been told you about user specification inputs that must be entered and about the calculation of specific heat ratio. other important parameter on the calculation are: Duty, which based on the compressibility factor of suction and discharge stream and not be based on heat content of each streams. Exponent, which is the ratio of k for adiabatic and n for polytropic. Exponent is required as the parameter of compression ratio's significancy in the operation. SCFM (standard cubic feet per minute), which is the standard flow rate of the stream, which on the condition of 288 Kelvin and 100 kPa. In the user specification input, user could select the unit of flow rate of the stream. They are ACFD (actual cubic feet per day), ACFM (actual cubic feet per minute), ACMD (actual cubic meter per day), ACMM (actual cubic meter per minute) and their standard. More: This free software is completed with a curve of only three profiles based on user specifications. This could be loaded from Tools Menu. As like in the basic process calculation, curves also could be generated if only user has entered all of inputs required.

HEATING/COOLING
This software is created only for single phase fluid operation. Its mean you will not able to calculate heating cooling system with phase change. And for information, this software is developed with base of calculation: 1. Heat Duty = Heat content of outlet stream - Heat content of inlet stream 2. Heat content is calculated use specific heat capacity a. For gas, specific heat capacity is calculated using ideal heat capacity b. For liquids, specific heat capacity is taken from data of "Reklaitis"(see refference) Equation (1):

Equation (2):

Heat Duty = HTout - HTin

3. Phase change Temperature is based on mixture's Saturated Temperature. The saturated temperature of component is calculated by Lee-Kesler Correlation, and for mixture Kay's Rule methode is use to calculate pseudocritical. 4.The limitation of software, both of Tout and Tin must greater than 0 K, and Tin must less than 1000 K.

Note:- "Phase is determined based on saturation condition and not based on Vapour-Lquid Equilibrium". - "Step for using heating/cooling software similar with compressor"

Gas-Solid Cyclone
Input Variable Inputs are parameter when we create a unit process. Input variables that you must enetered are: 1. Feed Gas condition and Parameters a. Gas inlet velocity (Vc) b. Diameter of particle that 50% removed (Dpc) c. Gas temperature d. Gas pressure e. Gas density () f. Solid density (s) g. Gas viscosity () Note: - The diameter of particle that 50% removed and gas inlet velocity used to calculate width of rectangular cyclone inlet duct (Bc)

so, if Bc is known another dimension of cyclone will get. - The number gas stream Turn in cyclone (Ne) is optional function. That's mean you can write the value or you can leave it and the software will assume it has value 5. But we recomended for you to give value in this part.

2. Approximation to calculate pressure drop parameter This part is equation to calculate pressure drop parameter and you must select one. We give you 4 optional and there are: a. Lapple b. Stepherd and Lapple

c. Casal and Martinet-Benet d. ter linden

What result will you get it? This part show of calculation of the result. You can get the result in: a. Calculation of result and this show on frame cyclone dimension

b. The cyclone figure with fractional efficiency This form will show after you write the input and then click show figure .

and if you click next then form of fractional efficiency will shows.

System Reporting In nawapanca we give facilities that can make you print the result in Microsoft Excell. How's create this? After you find the result then click Report, without opened the microsoft excell.

Note: 1. If you will print the result you must click Report. 2. You can select and change the dimension on Cyclon dimension with click one dimension you want in Dimension unit (frame of cyclone dimension).

Line Sizing Two Phase

This software is developed with two commonly used correlation.

1. AGA (American Gas Association) Equation Basis: - High gas-liquid ratios - Duckler for frictional component pressure drop - Flanigan for elevation component at pressure drop Overall two phase pressure drop Defined as Pt = Pf + Pe Frictional component of pressure drop is

Elevation component of pressure drop is

Calculation procedure 1. Determine the following liquid volume fraction

2. Determine the mixture viscosity for the Duckler

3. Calculate the superficial liquid velocity

4. Calculate the superficial gas velocity

5. Calculate the mixture velocity

6. Calculate the friction factor ratio

7. Calculate the two-phase mixture density

8. Calculate an estimate for the mixture Reynolds number

9. Determined a better estimate for the Duckler liquid holdup fraction (HLD), using and the Reynolds number 10. Recalculate the mixture density (k) using the improved estimate of HLD. 11. Using this new value of k, recalculate the mixture Reynolds number (Re) 12. Go back to step 9 to determined a new value for HLD. Continue this iterative procedure until convergence. 13. Calculate the single phase friction factor

14. Calculate the frictional pressure drop 15. Determined the Flanigan liquid hold-up fraction

16. Calculate the elevation component 17. Calculate the overall two-phase pressure drop 2. API (American Petroleum Institute) Basis assumptions: - pressure drop is less than 10% P1 - Bubble or mist flow exist - No elevation changes - No irreversiblr energy transfer between phases

Calculation procedure 1. Determine the following liquid volume fraction

2. Determine the mixture viscosity for the Duckler

3. Calculate the superficial liquid velocity

4. Calculate the superficial gas velocity

5. Calculate the mixture velocity

6. Calculate the two-phase mixture density m = W/(Qg+QL) 8. Calculate an estimate for the mixture Reynolds number

9. Calculate Darcy friction factor (fn) 10. Calculate the frictional pressure drop 11. Determined the Flanigan liquid hold-up fraction

12. Calculate the elevation component 13. Calculate the overall two-phase pressure drop Where: Pt Pf Pe fn ftpr k Vm Lm d Hlf Ze

= = = = = = = = = = =

Total two phase pressure drop, psi Frictional component of pressure drop, psi Elevation component of pressure drop, psi single friction factor friction factor ratio two phase mixture density, lb/ft3 mixture of velocity, ft/sec pipeline length, miles pipe inside diameter, inches Flanigan liquid holdup fraction sum of vertical elevation rises of pipe (no elevation drops are considered), ft

 QL Qg n L g VSL A VSg g HLD Re fn

= = = = = = = = = = = = =

flowing liquid volume fraction liquid flow rate at flowing conditions, ft3/sec Gas flow rate at flowing conditions, ft3/sec mixture viscosity, cp liquid viscosity, cp Gas viscosity, cp Superficial liquid velocity, ft/sec Cross sectional area of pipe, ( d2)/4, ft2. Superficial gas velocity, ft/sec -ln () Density of liquid, lb/ft3 Density of gas, lb/ft3 Duckler liquid holdup fraction ( for the first estimate (assumption)) = Mixture Reynolds number = Darcy friction factor

Line Sizing for Gases

Basic Principles Calculation of pressure drop-flow rate relations in single-phase gas lines differs from pressure drop determination in single-phase liquid lines, because of the variation of gas density with pressure and temperature changes. While liquids are nearly incompressible, the density of gases varies strongly with temperature, and more imporantly, with pressure.The momentum wquation assumed that fluid density was constant over the pipe segment under consideration. There are two ways of compensanting for constant fluid density in the momentum equation: 1. Momentum equation may be applied segmentally over sufficiently short pipe segments, so that the gas density is effectively constant over each segment. Differ gas densities are applied in each segment. This approach uses computer where the increased computational effort of multi-segmental evaluation is not problem. 2. For hand calculations, some closed form integration of an essentially differential momentum equation is required. If effect elevations are ignored, and real gas behavior law of the form:

where:
P Z R T M = = = = = = fluid pressure, psia fluid density, lbm/ft3 Gas compressibility factor universal gas constant, 1545 ft-lbf/lb-mole oR Fluid temperature, oT Molecular weight of gas, lbm/lb-mole

Is assumed, the a closed form integration of the momentum equation is possible. The resulting integrated form is the basis for each of the several gas flow equations that are discussed in this section. Even though each of the gas flow equations are different due to the refinement of the basic gas equation to different sets of experimental data, they are similar. Each equation calculates flowline capacity when inlet and outlet pressure are given. Volumetric flow rates calculated by each of the gas equations are at some standard condition of pressure and temperature. Most equations contain an empirical correction factor known as an efficiency factor to permit adjusment of calculated results with field data. General Considerations Assumption: - Isothermal - No work is performed - Steady state conditions - friction factor (f) is constant Determining specific volume at upstream conditions

Rearranging and solving for

,we have:

where: Qg = P1 = P2 = S = Z = T = fD = d =

Gas flow rate, MMSCFD upstream pressure, psia downstream, psia specific gravity of gas compressibility factor for gas gas flowing temperature Darcy friction factor pipe inside diameter

The "Z" factor is assumed to be constant but in reality it will change from point 1 to point 2, thus it is chosen form an average pressure defined as follows:

Approximation of general equation for small pressure drops

This equation yields reasonable results when P1-P2 < 10% of P1 Weymouth Equation Weymouth's data base consisted of pipes having diameters ranging from 0.8 to 11.8 inchies, thus the equation is most accurate for pipes having a diameter less than 12 inches. For larger pipe, Weymouth equation becomes increasingly conservative, that is, predictive flow capacities become increasingly less compared to actual flow capacities. Assumptions: - Turbulent flow, high reynolds number exist and - Friction factor is dependent upon relative roughness (/D) For fixed absolute roughness (), the friction factor was assumed as

Substitution of the above friction value into the general equation for gas yields the Weymouth Equation.The Weymouth equation is of the form

where: Qg = P1 = P2 = S = Z = d = L = T1 =

volumetric flow rate, MMSCFD upstream pressure, psia downstream, psia specific gravity of gas compressibility factor for gas pipe inside diameter pipeline length, feet gas flowing temperature, oR

Assuming a temperature of , a gas compressiblity factor of 1.0 and specific gravity of 0.6 equation reduces to

where:
Qg1 = volumetric flow rate, SCFD Lm = pipeline length, miles Panhandle Eastern Equations General considerations Two gas flow equations were developed by Panhandle Eastern for calculating flow rates in large diameter, 12 inches and above, cross country gas transmission lines. Panhandle equation that have revised is best used for larger diameter pipes. This equation has revised exponents and includes the gas compressiblity factor. It assumes that the friction factor can be represented by a straight line of constant negative slope (fD=C/Ren) in the moderate Reynolds number region of the Darcy Friction Factor diagram.

where: Q = d = P1 = P2 = Lm = S = Z = T = E = = = = =

Volumetric gas flow rate, MMSCFD pipe inside diameter upstream pressure, psia downstream, psia pipeline length, miles specific gravity of gas compressibility factor for gas gas flowing temperature Efficiency factor 1.0 for brand new type 0.95 for good operating conditions 0.92 for average operating conditions 0.85 for unfavourable operating conditions

AGA Equation General considerations Most contemporary and most accurate of the gas equations in use. Contains several features

lacking in the earlier gas equations. Contains explicit inclusion of gas compressibilty factor effects with the "Z" factor being evaluated at effective average pressure in the line segment. Includes an elevation correction factor lacking in the original versions of the other equations. Includes a transmission factor (F) that is related to the fanning Friction Factor (ff). This factor depends on pipe relative roughness, and for sufficiently low Reynolds number, it includes a Reynolds number effect. Its assumes an isothermal flow. The AGA equations is expressed as

where: Q T0 P0 d P1 P2 T Lm S F Ec Zs = = = = = = = = = = = = Volumetric gas flow rate, ft3/D @ T0 and P0 Temperature base, oR Pressure base, psia pipe inside diameter upstream pressure, psia downstream, psia gas temperature, oR pipeline length, miles specific gravity of gas transmission factor elevation correction factor compressibility factor

Elevation correction factor(Ec)

where: h1 = elevation of pipeline inlet, ft h2 = elevation of pipeline outlet, ft Compressiblity factor at average conditions (Za) Its determined from average pressure (Pa), fluid flowing temperature() and by use of a generalized compressibility chart. Average pressure (T) is determined from the following equation:

Transmission factor (F) For high Rynolds number it is determined from the following equation

For a flow Re less than critical Re, the transmission factor is calculated according to the folowing equation:

This equation is implicit in and must be solved iteratively.The flow Re is calculated according to the following equation:

where: = gas viscosity, lbm/ft-sec While the critical Re is calculated using the following equation

Spitzglass Equation Modification of general equation that was developed for piping that would operate near atmospheric pressure. It is derived by making the following assumptions: a. f = (1 + 3.6/d + 0.03 d) (1/100) b. T = 520oR c. P1 = 15 psi d. P < 10% P1 with the above assumptions, and expressing pressure drop in terms of inches of water, the Spitzglass equationcan be converted to oil filds units.

Substituting P = 0.036 hw ; P1=15 psi; and T = 520 oR, we have:

where: Qg hw d S L Note: - specific gravity for air = 1 - For standard conditions P = 14.7 psi and T = = = = = = volumetric flow rate, MMSCFD, at 14.7 psig and 60oF pressure loss, inches of water pipe inside diameter specific gravity of gas pipeline length, feet

520oR