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PROJECT TITLE

:DEVELOPMENT OF ENGINEERING PACKAGE FOR INSTALLATION OF GC-27 OLD


NON SMOKELESS FLARE (27-F-0802) AT EPF-18 AS STANDBY HP FLARE
DOCUMENT NAME :LINE SIZING HYDRAULICS AND ADEQUACY CHECK FOR EXISTING INSTRUMENT
AIR AND FUEL GAS LINE
CONTRACT NUMBER : 16051405
REV A
DOCUMENT NUMBER :16051405-A-P-1102

INDEX
1

INTRODUCTION:-....................................................................................................... 3

OBJECTIVE:- .............................................................................................................. 3

DEFINITIONS/ABBREVIATIONS:- ................................................................................. 3

APPLICABLE CODES, STANDARDS & SPECIFICATIONS:- ................................................. 3

REFERENCE DOCUMENTS & DRAWINGS:- .................................................................... 4

DESIGN BASIS:- ......................................................................................................... 4

DESIGN CRITERIA:- .................................................................................................... 7

7.1 Gas line sizing criteria:- ...................................................................................................... 7


7.2 Flare line sizing criteria:- .................................................................................................... 7
8

PURGE RATE CALCULATION:-...................................................................................... 8

HYDRAULIC CALCULATION:- ....................................................................................... 8

10 ADEQUACY CHECK OF EXISTING INSTRUMENT AIR AND FUEL GAS LINE:-..................... 10


11 RESULTS & CONCLUSION:- ....................................................................................... 11

Attachment-1- HYSYS Output for 100m length.


Attachment-2- HYSYS Output for total length.
Attachment-3- Utility summary for existing flare system and burn pit.
Attachment-4- Shell DEP for Equivalent length calculation.

Page 2 of 13

PROJECT TITLE

:DEVELOPMENT OF ENGINEERING PACKAGE FOR INSTALLATION OF GC-27 OLD


NON SMOKELESS FLARE (27-F-0802) AT EPF-18 AS STANDBY HP FLARE
DOCUMENT NAME :LINE SIZING HYDRAULICS AND ADEQUACY CHECK FOR EXISTING INSTRUMENT
AIR AND FUEL GAS LINE
CONTRACT NUMBER : 16051405
REV A
DOCUMENT NUMBER :16051405-A-P-1102

1 INTRODUCTION:Due to current operating scenario continues flaring is being observed from HP flare present at EPF-18,
and this continuous flaring might damage the HP flare and lead to production loss. Hence to avoid the
plant shut down and production loss, KOC has planned to install the GC-27 unused old Non-smokeless
TV flare (27-F-0802) stack at EPF-18 as a redundant to existing HP flare on priority basis.

2 OBJECTIVE:This document describes the calculation of pressure drop & velocity, adequacy check of existing
instrument air & fuel gas line installed as part this project.

3 DEFINITIONS/ABBREVIATIONS:API

American petroleum Institute.

BS

British Standards

CS

Carbon steel

EPF

Early Production facility

FFG

Flame Front Generator

GC

Gathering Center

KOC

Kuwait Oil Company (K.S.C.)

MMSCFD

Million Metric Standard Cubic Feet.

P&ID

Piping and Instrumentation Diagram

PSI

Pounds per Square Inch

SCFH

Standard Cubic Feet per Hour.

4 APPLICABLE CODES, STANDARDS & SPECIFICATIONS:-

The design of flare System shall be in compliance to the KOC Standards/Specifications and relevant
international codes.
KOC Standards

KOC-PR-001 Rev 1

System Isolation

KOC-G-007 Rev 045

KOC Standard for Basic Design Data


Page 3 of 13

PROJECT TITLE

:DEVELOPMENT OF ENGINEERING PACKAGE FOR INSTALLATION OF GC-27 OLD


NON SMOKELESS FLARE (27-F-0802) AT EPF-18 AS STANDBY HP FLARE
DOCUMENT NAME :LINE SIZING HYDRAULICS AND ADEQUACY CHECK FOR EXISTING INSTRUMENT
AIR AND FUEL GAS LINE
CONTRACT NUMBER : 16051405
REV A
DOCUMENT NUMBER :16051405-A-P-1102

015-YH-1003 Rev 02

Loss Prevention Requirements

KOC-Q-014, Rev1

KOC Standard for Project QA/QC Requirements

KOC-Q-015, Rev1

KOC Standard for Positive Material Identification (PMI)

KOC-G-009 Rev 01

KOC Standard for Spare Parts and Maintenance Data

KOC-C-025

Drainage systems- Design, Materials and Construction

KOC-LH-1002

Piping Design

015-FH-1002

Flare Tip and Burner ignition system.

GP-D-001

General Design Criteria

International Standards

API 14 E

API 521 Edition 2014


API 537

Recommended practice for design and installation of offshore


production platform piping system.
Guide for pressure relieving and depressuring system.
Flare details for general refinery and petrochemical service.

5 REFERENCE DOCUMENTS & DRAWINGS:

516-PA-E-31122

MDS for HP Flare package.

B-F-905687-310

GA drawing for 27-F-0802 HP flare stack.

090053-A-P01

Vendor P&ID for EPF-18 HP flare stack.

516-GA-E-08007

Utility summary

6 DESIGN BASIS:Component
H 2O
Hydrogen
H 2S
CO2
Nitrogen
Methane
Ethane
Propane
i-Butane
n-Butane
22-Mpropane
i-Pentane
n-Pentane

Table 1: Composition of waste gas:Scenerio-1 Waste Gas (Mole %)


2.22
0.00
1.81
4.85
0.21
57.00
16.70
9.99
0.98
3.14
0.00
0.72
1.04

Page 4 of 13

PROJECT TITLE

:DEVELOPMENT OF ENGINEERING PACKAGE FOR INSTALLATION OF GC-27 OLD


NON SMOKELESS FLARE (27-F-0802) AT EPF-18 AS STANDBY HP FLARE
DOCUMENT NAME :LINE SIZING HYDRAULICS AND ADEQUACY CHECK FOR EXISTING INSTRUMENT
AIR AND FUEL GAS LINE
CONTRACT NUMBER : 16051405
REV A
DOCUMENT NUMBER :16051405-A-P-1102
Component
n-Pentane
n-Hexane
Mcyclopentane
Benzene
cyclohexane
n-Heptane
Mcyclohexane
Toluene
n-Octane
E-Benzene
m-xylene
p-xylene
o-xylene
n-Nonane
123-M benzene
n-Decane
n-C11
n-C12
n-C13
n-C14
n-C15
n-C16
n-C17
n-C18
n-C19
n-C20
MN 108 cr C36+

Waste Gas
1.04(mole %)
0.68
0.07
0.01
0.05
0.25
0.03
0.03
0.11
0.01
0.01
0.01
0.01
0.04
0.00
0.02
0.01
0.003
0.001
0.003
0.001
0.001
0.000
0.000
0.000
0.000
0.000

Table 2: Composition of fuel gas:Composition


Units
Methane
mol %
Ethane
mol %
Propane
mol %
Iso-Butane
mol %
N-Butane
mol %
Iso-Pentane
mol %
N-Pentane
mol %
Hexane+
mol %
Nitrogen
mol %
Hydrogen Sulphide
mol %
Carbon Dioxide
mol %
Specific Gravity
Moisture Content
Lbs / MMSCFD
Low Heating Value
Btu / SCF (Net)

Value
90.12
7.5
0.2
0.1
0.1
0.1
0.1
0
0.6
0.03
1.15
0.6127
5
955.84
Page 5 of 13

PROJECT TITLE

:DEVELOPMENT OF ENGINEERING PACKAGE FOR INSTALLATION OF GC-27 OLD


NON SMOKELESS FLARE (27-F-0802) AT EPF-18 AS STANDBY HP FLARE
DOCUMENT NAME :LINE SIZING HYDRAULICS AND ADEQUACY CHECK FOR EXISTING INSTRUMENT
AIR AND FUEL GAS LINE
CONTRACT NUMBER : 16051405
REV A
DOCUMENT NUMBER :16051405-A-P-1102
Table 3: Process parameters for Standby HP Flare (27-F-0802)

S.no

Description

Waste gas

Volumetric
flow rate
(MMSCFD)

123.5

Pressure barg (psig)


Refer Doc No :( 516-PAE-311122) & Isometric
DWG.
Operating
pressure
barg(psig)

2(29)

Design
Pressure
barg(psig)

3.5(65.25)

Temperature C(F)
Refer Doc No :( 516-PA-E311122) & Isometric DWG.
Design
Operating
Temperature
Temperature
min C(F)
C(F)
/max C(F)

60.84(141.5)

3(26.6)/
93(200)

Ignition air

0.036096

min: 4(58)
max:
7(102)

10(145)

min: 40(104)
max: 60(140)

3(26.6)/
93(200)

Ignition fuel

0.0036

6(87)

8(116)

min: 15(59)
max: 38(100)

3(26.6)/
93(200)

pilot gas

0.0036

6(87)

8(116)

min: 15(59)
max: 38(100)

3(26.6)/
93(200)

Purge gas

0.047815

6(87)

8(116)

min: 15(59)
max: 38(100)

3(26.6)/
93(200)

Remarks

For flow
rate (Refer
Doc No:516PA-E-31122)
For Flow
Rate (Refer
Vendor
P&ID
090053-AP01)
For Flow
Rate (Refer
Vendor
P&ID
090053-AP01)
For flow
rate Refer
GC-27
Vendor GAD
(B-F905687310)
Flow rate is
Calculated
as per
clause
5.7.6.2 of
API 521.

Page 6 of 13

PROJECT TITLE

:DEVELOPMENT OF ENGINEERING PACKAGE FOR INSTALLATION OF GC-27 OLD


NON SMOKELESS FLARE (27-F-0802) AT EPF-18 AS STANDBY HP FLARE
DOCUMENT NAME :LINE SIZING HYDRAULICS AND ADEQUACY CHECK FOR EXISTING INSTRUMENT
AIR AND FUEL GAS LINE
CONTRACT NUMBER : 16051405
REV A
DOCUMENT NUMBER :16051405-A-P-1102

7 DESIGN CRITERIA:7.1 Gas line sizing criteria:The main criteria to be considered for line sizing is pressure drop and velocity, which must be less than
the available pressure drop indicated by the hydraulic calculation.
Table 4: Table for criteria of Gas line sizing:Services (Process Lines in
Continuous Services)

Friction Loss Range


Bar/100 m (psi/100 ft)

Velocity Range
m/s (ft/s)

Less than 1 bar (vacuum)

0.01 - 0.06 (0.044 - 0.256)

Up to 7 barg (100 psig)

0.02 - 0.1 (0.088 - 0.442)

For Brown field projects, with congested


fields:

0.1 - 0.5 (0.442 -2.21)

Normal Velocity to be considered (ft/s)


= 60 / (density lb/ft3)0.5

From 7 to 67 barg
(100-980 psig)
Over 67.96 barg (980 psig)

0.7% of operating pressure

12 - 18 (40 - 60) for green filed projects.

Maximum Velocity to be considered (ft/s)


= 90 / (density lb/ft3) 0.5

Compressor Anti-surge relief


valve inlet lines and
30 - 45 (100 - 150)
discontinuous service
Notes:
1. Both the upper limit of the friction loss range and the maximum velocity (upper limit velocity range)
shall be the limiting factors in the sizing. When available pressure drop in the system calls for a
lower friction loss/velocity as compared to the above ranges, then such friction loss/velocity shall
apply.
2. Above friction loss ranges can be exceeded for short branch lines when pressure drop is not limited
in intermittent services.
7.2 Flare line sizing criteria:1. The velocity is limited to 0.5 Mach.
2. The HP/LP flare header will be sized according to pressure drop constraints.
3. No pockets and 1:500 slope towards K.O drum.

Page 7 of 13

PROJECT TITLE

:DEVELOPMENT OF ENGINEERING PACKAGE FOR INSTALLATION OF GC-27 OLD


NON SMOKELESS FLARE (27-F-0802) AT EPF-18 AS STANDBY HP FLARE
DOCUMENT NAME :LINE SIZING HYDRAULICS AND ADEQUACY CHECK FOR EXISTING INSTRUMENT
AIR AND FUEL GAS LINE
CONTRACT NUMBER : 16051405
REV A
DOCUMENT NUMBER :16051405-A-P-1102

8 PURGE RATE CALCULATION:To prevent burn back during less amount of waste gas flaring and to avoid air infiltration down the flare
stack continuous purge gas shall be supplied to the flare stack throughout the operation of flaring.
The required purge gas for the actual diameter of the flare stack was calculated by using the formula
provided in API 521 by considering the oxygen volume fraction of 6% at a distance of 7.62 m down the
flare stack.
Q=0.0035283*D3.46*K
Where,
Q= Purge rate required in (SCFH).
D= Flare Stack Diameter in (inch).
K=Constant (Lean Fuel gas based on Methane volume fraction of 90.12% so K value of 2.328 is
considered).
Therefore,
Q=0.0035283*363.46*2.328
=1992.30 SCFH
=0.047815 MMSCFD.
Note: KOC to confirm the purge gas requirement based on the existing calculation available
corresponding to the installed GC-27 flare stack.

9 HYDRAULIC CALCULATION:The hydraulic calculations are performed using "HYSYS 9.0 in build Gas pipe tool and the calculated
velocity, Mach number and pressure drop is checked to the design criteria shown in section 7.
Table 5: Equivalent length calculation:-

S. No

Description

Waste gas
(24-BD-1000C15B)

Size
(in)

24

Schedule

20 S

Straight
length
(m)

Fittings

(Refer Attachment-4)
Equivalent length
(m)

310.33

45
elbow= 1
nos

9.456

Total
length
(m)

Page 8 of 13

PROJECT TITLE

:DEVELOPMENT OF ENGINEERING PACKAGE FOR INSTALLATION OF GC-27 OLD


NON SMOKELESS FLARE (27-F-0802) AT EPF-18 AS STANDBY HP FLARE
DOCUMENT NAME :LINE SIZING HYDRAULICS AND ADEQUACY CHECK FOR EXISTING INSTRUMENT
AIR AND FUEL GAS LINE
CONTRACT NUMBER : 16051405
REV A
DOCUMENT NUMBER :16051405-A-P-1102

Ignition air
(1-AI-1002S10A)

Ignition fuel
(1FG-1001C15B)

90
elbow=
11 nos
Tee=1
no
Gate
valve= 1
no
90
elbow= 2
nos
1

40 S

70

Tee=1
no
Ball
valve= 1
no
90
elbow= 2
nos

XS

70

Tee=1
no
Ball
valve= 1
no
90
elbow=
19 nos
Tee=8
nos

Pilot gas line


(1-FG-1003C15B)

XS

323.163

Ball
valve= 3
nos
Globe
valve=1
no
Strainer =
1 no
NRV= 1

130.02
11.82

469.371

7.683
1.08
0.54

71.836

0.216
0.96
0.48

71.632

0.192
9.12
3.84
0.576

332.475

3.24
6
1.2

Page 9 of 13

PROJECT TITLE

:DEVELOPMENT OF ENGINEERING PACKAGE FOR INSTALLATION OF GC-27 OLD


NON SMOKELESS FLARE (27-F-0802) AT EPF-18 AS STANDBY HP FLARE
DOCUMENT NAME :LINE SIZING HYDRAULICS AND ADEQUACY CHECK FOR EXISTING INSTRUMENT
AIR AND FUEL GAS LINE
CONTRACT NUMBER : 16051405
REV A
DOCUMENT NUMBER :16051405-A-P-1102

Purge gas
(2-FG-1005C15B)

STD

90
elbow= 2
nos

1.96

Tee=1
no

0.98
79.947

70
Ball
valve= 1
no

0.392

Globe
valve= 1
no

6.615

The calculated equivalent length corresponding to the respective line along with composition
mentioned in Table 1 & 2 and process parameter mentioned in Table 3 are inputted in Hysys and the
calculated values like velocity, Mach number and total pressure drop are mentioned in Table-8.

10 ADEQUACY CHECK OF EXISTING INSTRUMENT AIR AND FUEL GAS LINE:Total consumption required for the existing flare packages and burn pit are obtained from the existing
document provided by alkhoreyef (Refer attachment-3).
Table 6: Existing utility consumption details:S. No

Description

Instrument
air

Consumers

Volumetric Flow rate in


( MMSCFD)

Existing flame front generator and burn


pit

=(43 Nm3/hr /0.02679)*(24/1000000)


=0.038522 MMSCFD.

Existing flare and burn pit package

=(2 Nm3/hr /0.02679)*(24/1000000)


=0.001792 MMSCFD.

New Flame front generator


Total instrument air consumption

0.036
0.076314

Page 10 of 13

PROJECT TITLE

:DEVELOPMENT OF ENGINEERING PACKAGE FOR INSTALLATION OF GC-27 OLD


NON SMOKELESS FLARE (27-F-0802) AT EPF-18 AS STANDBY HP FLARE
DOCUMENT NAME :LINE SIZING HYDRAULICS AND ADEQUACY CHECK FOR EXISTING INSTRUMENT
AIR AND FUEL GAS LINE
CONTRACT NUMBER : 16051405
REV A
DOCUMENT NUMBER :16051405-A-P-1102
Existing HP flare purge rates

0.02

Existing LP flare purge rates

0.11

New standby HP flare purge rates

Fuel gas

0.047815

Existing Burn pit Purge rates

0.08

Pilot gas for Existing HP flare

0.007

Pilot gas for New stand by HP flare

0.0036

Pilot gas for Existing LP flare

0.005

Pilot gas for Existing burn pit

0.008

Fuel gas for existing FFG

0.004

Fuel gas for new stand by FFG

0.0036

Total Fuel gas consumption

0.289015

Note: Existing utility summary report (Doc: 516-GA-E-08007) for fuel gas and instrument air shall be
read in conjunction with this additional flow rate required for the new standby HP flare.

11 RESULTS & CONCLUSION:For pressure drop calculation pipe straight length of 100 m is considered for the respective line and the
calculated values like velocity, Mach number and pressure drop are mentioned in table 7 below.
Table 7: Pressure drop for 100 m length:-

S. No

Description

Waste gas
(24-BD-1000C15B)
Ignition air
(1-AI-1002S10A)

Phase

Size
inch

Total
Flow
rate,
MMSCFD

24

123.5

0.036

Allowable
Calc.
velocity limit
Velocity
as
m/s
mentioned
(Refer
in KOC
Attachm
design
ent-1)
criteria, m/s
Mach
Mach no:
no:
0.5
0.48
3.02 m/s

18 m/s

Pressure Allowable pr.


loss
drop limit as
bar/100m mentioned in
KOC design
(Refer
criteria,
Attachme
bar/100m
nt-1)
0.306

0.02 - 0.1

0.038

0.02 - 0.1
Page 11 of 13

PROJECT TITLE

:DEVELOPMENT OF ENGINEERING PACKAGE FOR INSTALLATION OF GC-27 OLD


NON SMOKELESS FLARE (27-F-0802) AT EPF-18 AS STANDBY HP FLARE
DOCUMENT NAME :LINE SIZING HYDRAULICS AND ADEQUACY CHECK FOR EXISTING INSTRUMENT
AIR AND FUEL GAS LINE
CONTRACT NUMBER : 16051405
REV A
DOCUMENT NUMBER :16051405-A-P-1102
3

Ignition fuel
(1FG-1001C15B)

0.0036

0.41 m/s

18 m/s

0.0007

0.02 - 0.1

pilot gas
(1-FG-1003C15B)

0.0036

2.811
m/s

18 m/s

0.0048

0.02 - 0.1

Purge gas
(2-FG-1005C15B)

0.047815

8.95
m/s

18 m/s

0.015

0.02 - 0.1

0.076314

1.65
m/s

18 m/s

0.0054

0.02 - 0.1

0.289015

1.8
m/s

18 m/s

0.002

0.02 - 0.1

Existing
Instrument air
line
(2-AI-10414S10A)
Existing Fuel
gas line
(4-FG-10502AC15B)

For Waste gas line the calculated pressure drop of 0.306 barg is based on the maximum back pressure
considering maximum design flow of 123.5 MMSCFD (Refer attachment-1) and it is exceeding the
allowable pressure drop criteria of 0.1 bar/100m (Maximum). However by taking in to account of purge
gas as a motive fluid available at the immediate gas outlet of Knock out drum and another nearer to the
Tie-in the flare header operating pressure shall be maintained at 2 barg hence back pressure impact is
minimal so taking 24 is not critical since Mach no is within the allowable limit.
Based on the above results, the calculated velocity and pressure drop for selected pipe size shown in
serial no 2-7 of table 7 is within the allowable limit mentioned in the KOC design criteria (Refer section7). Hence the line size mentioned in the above results are adequate.
FFG package line sizes shall be confirmed by FFG Package vendor.
Startup purge gas connection line size of 1 (Refer P&ID 16051405-D-P-1001) for existing flare header
shall be followed based on existing purge gas line size of 1.

Page 12 of 13

PROJECT TITLE

:DEVELOPMENT OF ENGINEERING PACKAGE FOR INSTALLATION OF GC-27 OLD


NON SMOKELESS FLARE (27-F-0802) AT EPF-18 AS STANDBY HP FLARE
DOCUMENT NAME :LINE SIZING HYDRAULICS AND ADEQUACY CHECK FOR EXISTING INSTRUMENT
AIR AND FUEL GAS LINE
CONTRACT NUMBER : 16051405
REV A
DOCUMENT NUMBER :16051405-A-P-1102
Proposed common line size of 4 (Refer P&ID 16051405-D-P-1003) for fuel gas connection required for
the new stand by HP flare is found to be adequate considering the design of existing fuel gas line with
respect to maximum flow mentioned in serial no 7 of table 7.
Existing fuel gas line and instrument line air is found to be adequate considering the velocity and
pressure drop constraints.
Table 8: Pressure drop for total length:Calc.
Velocity m/s
(Refer
Attachment-2)

Pressure loss
barg
(Refer
Attachment-2)

S. No

Description

Phase

Size
inch

Total
Flow
rate,
MMSCFD

Waste gas
(24-BD-1000-C15B)

24

123.5

Mach no:
0.48

1.008

Ignition air
(1-AI-1002-S10A)

0.036

3.02 m/s

0.0275

Ignition fuel
(1FG-1001-C15B)

0.0036

0.41 m/s

0.0005

pilot gas
(1-FG-1003-C15B)

0.0036

2.811 m/s

0.016

Purge gas
(2-FG-1005-C15B)

0.047815

8.95
m/s

0.012

Existing Instrument air


line
(2-AI-10414-S10A)

0.076314

1.65
m/s

0.0054

Existing Fuel gas line


(4-FG-10502A-C15B)

0.289015

1.8
m/s

0.002

Page 13 of 13

ATTACHMENT-1
Blow down line

Instrument air line

Fire ball

Cell Axial Length (Cell Axial Length_12)

100.0

Temperature

57.15

Maximum Velocity

3.021

m/s

Pressure

5.999

bar_g

27.00

mm

Molar Flow

Internal Diameter

Temperature
Pressure

60.00

7.000

bar_g

3.600e-002

Molar Flow

169.1

Maximum Velocity

0.3069

38.00

Pressure

6.000

bar_g

60
Waste
gas

Fire
ball

MMSCFD

Fuel
gas

60
Waste gas
0.3069

Pressure

Pressure

bar_g

Molar Flow

Molar Flow

123.5

MMSCFD

Mass Lower Heating Value

42.43

MJ/kg

Molecular Weight

26.73

57.81

Temperature
60.84

Temperature

bar_g

0.0000

MMSCFD

123.5

Fuel Gas line


100.0

Cell Axial Length (Cell Axial Length_12)

17.75

bar_g

Temperature

m/s

Blow
down
line

Instrument
air

Fuel gas

3.600e-003

MMSCFD

Fuel
Gas
line

Molecular Weight

mm

0.4818

Pressure Drop

MIX-100

Molar Flow

591.0

Instrument
air line

MMSCFD

28.95

Molecular Weight

3.960e-002

100.0

Internal Diameter
Maximum Mach Number

bar_g

3.843e-002

Pressure Drop

Instrument air

Cell Axial Length (Cell Axial Length_12)

Maximum Velocity

0.4062

m/s

Internal Diameter

24.00

mm

7.056e-004

Pressure Drop

bar_g

pilot
gas
line
G

purge line 2"


Purge gas
38.00

Temperature
Pressure
Molar Flow

1.502e-002
4.782e-002

C
bar_g
MMSCFD

Cell Axial Length (Cell Axial Length_12)

100.0

Maximum Velocity

8.958

m/s

Internal Diameter

49.00

mm

1.502e-002

Pressure Drop

bar_g

Pilot
gas

Purge gas out


38.00

Temperature

0.0000

Pressure

4.782e-002

Molar Flow

Pilot
gas
out

pilot gas line


Pilot gas

bar_g
MMSCFD

purge
line
2"

38.00

Temperature

Pressure

4.863e-003

bar_g

Molar Flow

3.600e-003

MMSCFD

Pilot gas out

Maximum Velocity

2.811

m/s

Cell Axial Length (Cell Axial Length_12)

100.0

24.00

mm

Internal Diameter

4.863e-003

Pressure Drop

38.00

Temperature

0.0000

Pressure

3.600e-003

Molar Flow

C
bar_g
MMSCFD

bar_g

Purge
gas

Purge
gas
out

Existing fuel gas line

Existing Instrument air line


Cell Axial Length (Cell Axial Length_12)

Instrument air 1

100.0

Fuel gas 1

Maximum Velocity

6.000

bar_g

Pressure Drop

MMSCFD

Internal Diameter

Maximum Velocity

1.655

m/s

Pressure

7.000

bar_g

Internal Diameter

53.00

mm

Temperature

60.00

Pressure

MMSCFD

Pressure Drop

bar_g

Pressure

6.995

bar_g

Molar Flow

5.410e-003
Existing
Instrument
air line

7.631e-002

Molar Flow

Sat Dec 17 14:46:09 2016

0.2890

1.614e-003
102.0

bar_g
mm

3
Temperature

38.00

Pressure

5.998

bar_g

0.2890

Molar Flow

MMSCFD

Existing
fuel
gas line

MMSCFD

Instrument
air 1

m/s

7.631e-002

1.805

38.00

60.00

Molar Flow

100.0

Temperature

Temperature

Cell Axial Length (Cell Axial Length_12)

Fuel
gas
1

Case: \\193.1.1.175\rfp-2037088\5. PROCESS\DOCUMENTS\Line Sizing Hydraulics\REV-A\Hysys\New Pressure drop total length.hsc

Flowsheet: Case (Main)

ATTACHMENT-2
Blow down line

Instrument air line

60.00

Temperature

7.000

Pressure

3.600e-002

Molar Flow

Temperature

57.15

Maximum Velocity

3.017

m/s

Pressure

5.999

bar_g

Internal Diameter

27.00

mm

Molar Flow 3.960e-002

bar_g

4
G

60

Fuel gas
38.00

6.000

bar_g
MMSCFD

5
Fuel
gas

60
Waste gas
60.84

Pressure

Pressure

1.008

bar_g

Molar Flow

Molar Flow

123.5

MMSCFD

Mass Lower Heating Value 42.43

Temperature 55.27

Temperature

bar_g

0.0000

MMSCFD

123.5

MJ/kg

26.73

Molecular Weight
Fuel Gas line
Cell Axial Length (Cell Axial Length_12)

17.75

Waste
gas

Fire
ball

Pressure

3.600e-003

m/s

1.008
Blow
down
line

Fuel
Gas
line

Molecular Weight

167.9

Pressure Drop

Instrument
air

Temperature

mm

Maximum Velocity

bar_g
MMSCFD

0.4796

Maximum Mach Number

MMSCFD

Instrument
air line

MIX-100

Molar Flow

591.0

Internal Diameter

bar_g

2.759e-002

28.95

Molecular Weight

Cell Axial Length (Cell Axial Length_12) 469.4

71.84

Pressure Drop

Instrument air

Fire ball

Cell Axial Length (Cell Axial Length_12)

71.63

Maximum Velocity

0.4061

m/s

Internal Diameter

24.00

mm

5.054e-004

Pressure Drop

bar_g

pilot
gas
line
G

purge line 2"


Purge gas
Temperature
Pressure

38.00

1.203e-002

Molar Flow 4.782e-002

Cell Axial Length (Cell Axial Length_12)

79.95

Maximum Velocity

8.958

m/s

bar_g

Internal Diameter

49.00

mm

MMSCFD

1.203e-002

Pressure Drop

bar_g

Pilot
gas

Purge gas out


38.00

Temperature
Pressure

0.0000

Molar Flow 4.782e-002

Pilot
gas
out

pilot gas line


Pilot gas

bar_g
MMSCFD

Temperature
Pressure

purge
line
2"

38.00

1.608e-002

Molar Flow 3.600e-003

C
bar_g
MMSCFD

Pilot gas out

Maximum Velocity

2.811

m/s

Cell Axial Length (Cell Axial Length_12)

332.5

Internal Diameter

24.00

mm

1.608e-002

Pressure Drop

38.00

Temperature
Pressure

0.0000

Molar Flow 3.600e-003

C
bar_g
MMSCFD

bar_g

Purge
gas

Purge
gas
out

Existing fuel gas line

Existing Instrument air line


Instrument air 1
Temperature
Pressure

60.00
7.000

Molar Flow 7.631e-002

C
bar_g
MMSCFD

Cell Axial Length (Cell Axial Length_12)

100.0

Maximum Velocity

1.655

m/s

53.00

Internal Diameter

5.410e-003

Pressure Drop

Existing
Instrument
air line

mm
bar_g

Sat Dec 17 15:06:50 2016

Temperature 38.00

7
60.00

Temperature

6.995

Pressure

Molar Flow 7.631e-002

100.0

Maximum Velocity

1.805

6.000

Pressure

m/s

bar_g

Pressure Drop

bar_g

Molar Flow 0.2890

MMSCFD

Internal Diameter

1.614e-003
102.0

bar_g
mm

3
Temperature 38.00
Pressure
Molar Flow

5.998
0.2890

C
bar_g
MMSCFD

Existing
fuel
gas line

MMSCFD

Instrument
air 1

Cell Axial Length (Cell Axial Length_12)

Fuel gas 1

Fuel
gas
1

Case: \\193.1.1.175\rfp-2037088\5. PROCESS\DOCUMENTS\Line Sizing Hydraulics\REV-A\Hysys\New Pressure drop total length.hsc

Flowsheet: Case (Main)

516-GA-E-08007

Sh. 9 of 14
NEW GC-16 IN WEST KUWAIT
Rev C
KOC Contract No. 44930 Document title:

COMPANY DOC No.

SAIPEM PROJECT NO.


032114

UTILITY SUMMARY

Plant & Instrument Air Summary


Sl
No

Consumer

Qty

Consumption
rate (Nm3/h)

Total
Consumption
rate (Nm3/h)

ATTACHMENT-3

Type of
Consumption

Remarks

Plant Air

Utility hose station

Pneumatic driven pumps

Total Plant Air requirement


Instrument Air
1
Control Valves
2
3
4

ON/OFF (ESDVs, SBDVs, XVs)


Valves
Instrument Analysers
Air Coolers

200

Intermittent

Intermittent

200
81

1.3

105

Continuous

69

1.5

21

Continuous

24

Continuous

10

10

Continuous

Balance gas compressor

10

30

Continuous

6
7
8

Wal-Nut Shell filtration package


Fuel Gas Treatment Package
Desalter package

1
1
2

59
60
5

59
60
10

Continuous
Continuous
Continuous

Flame front generator and Burn


pit.

43

43

Intermittent

10

Hot oil Heater Package

110

110

Continuous

30

Intermittent

2
75
87
666
104

Continuous
Continuous

11

Considering
simultaneous
usage of 4 hose
stations. 50 Nm3/h
per hose.
Operated only for
chemical loading

21
Fire water system - Deluge
valves
12 Flare & Burn Pit Package
1
13 Nitrogen Generation Package
1
Margin
Total
Regeneration loss
Total air requirement at the inlet
of Air dryer
Total Air requirement (Approximately)

15%

Total IA

Continuous

Only 20% valves


will be operated
simultaneously
Considering only 4
Analysers out of 7
For fan blade pitch
control
Package
Instruments.
Package
Package
One Flame Igniter
at a time is
considered
Flame scanners
and 20% of on-off
valves are also
included
Maximum 6
valves considered
to operate
simultaneously

As per Vendor

770
1000

Consumption of Nitrogen for Balance Gas Compressor purging in New GC 16 facility has been
estimated and provided in the below table.
Data file: 08007_C.doc
This document is the property of Saipem who will safeguard its rights according to the civil and penal provisions of the law.

516-GA-E-08007

Sh. 10 of 14
NEW GC-16 IN WEST KUWAIT
Rev C
KOC Contract No. 44930 Document title:
SAIPEM PROJECT NO.
032114

COMPANY DOC No.


UTILITY SUMMARY

ATTACHMENT-3

Nitrogen Consumption

S No

User

Flow rate
(Nm3/h)
Normal

Purging gas for each Balance Gas


Compressor

10

12

30

Total Nitrogen Requirement

Flow rate
(Nm3/h)
Maximum

4.5 FUEL GAS


Fuel gas to New GC-16 facility shall be supplied from the existing Company Fuel gas network.
Fuel gas shall be conditioned with in the facility to supply dry clean fuel gas at necessary
pressure to critical consumers and also sweet fuel gas to Hot Oil Package at necessary pressure.
Based on the type of consumers, fuel gas distribution shall be segregated into critical & noncritical headers.
The critical header shall supply fuel gas to the following consumers

Tank blanketing for Wet tank, Produced water tank, Off spec tank, Effluent water tank and
dry tank

Balance gas compressor seals

Pilot gas in HP & LP flares and Burn pit

Purge gas for HP & LP Flares & Burn pit headers

Fuel gas supply to hot oil heater is considered from non-critical header.
Emergency fuel gas supply to critical consumers shall be from HP Gas export header tapped off
prior to metering skid. HP gas after pressure reduction shall be routed to fuel gas distribution
network.
Fuel gas consumption of each consumer has been estimated and provided in the below table.

Data file: 08007_C.doc


This document is the property of Saipem who will safeguard its rights according to the civil and penal provisions of the law.

516-GA-E-08007

Sh. 11 of 14
NEW GC-16 IN WEST KUWAIT
Rev C
KOC Contract No. 44930 Document title:
SAIPEM PROJECT NO.
032114

COMPANY DOC No.


UTILITY SUMMARY

ATTACHMENT-3

Fuel gas Consumption


S No
1
2
3
4
5

7
9
10

Fuel gas
supply

User
Fired Heater for Hot oil (Note 2)
HP Flare Purge rates (Note 1)
LP Flare Purge rates (Note 1)
Burn Pit Purge rates (Note 1)
Pilot gas requirement
a. HP flare
b. LP flare
c. Burn Pit
Blanket gas requirements
a. Wet tank
b. Off Spec tank
c. Dry tank
d. Produced water tank
e. Effluent Water tank
Startup gas requirement for Balance gas
compressor
Walnut Shell Filtration Package Back Wash
Flame Front Generator

Continuou
s

Flow rate
(MMSCFD)
2.44
0.02
0.11
0.08
0.007
0.005
0.008

Intermittent

5.22
5.22
2.98
4.7
3.39
0.2 (Hold)
0.45
0.004

Note 1: Purge rates are calculated as per API 521 and confirmed by Flare vendor.
Note 2: Including Design margin

4.6 DIESEL
Diesel is used in Diesel engines of Fire Water Pump, Emergency Diesel Generator set and the
Source Well Pump Diesel Generator. Diesel oil is received through tankers and unloaded into the
Diesel storage tank. Diesel from the tank is pumped to the consumers by Diesel Transfer Pump.
However the Source well pumps Diesel Generator Day tank shall be filled by the Diesel Supply
trucks directly.
Diesel tank design capacity is fixed to meet one day diesel requirement for Emergency Diesel
Generator and Diesel Engine driven Fire Water Pumps.
The details of the Diesel Users are listed below:
1. Emergency Generators.
2. Fire water pumps driven by Diesel Engine
3. Source Well Pumps (Electrical Driven) by Generators.
Capacity of Emergency diesel Generator is estimated to be 1000 kW based on the critical
consumers power requirement.
Data file: 08007_C.doc
This document is the property of Saipem who will safeguard its rights according to the civil and penal provisions of the law.

ATTACHMENT-4
DEP 31.38.01.11-Gen.
February 2015
Page 18
2.

T he f orm ulae for pres s ure dr op calcula tio ns given in this section are a pplica ble to
fluids whose density and viscosity are constant along the length of the whole pipe,
which is normally the case for liquids.

3.

Pressure drop due to piping components other than straight pipe shall be expressed
for calculation purposes as equivalent lengths (Le) and added to the length of the
straight pipe in the system, thus giving the total length (L) to be used in the pressure
drop calculations.

4.

For valves and fittings, L e is given in Table 5 (in which D = nominal pipe diameter and
for reducing fittings D = large end nominal diameter and d = small end nominal
diameter):

5.

The pressure drop across control valves shall be large enough in order to obtain an
acceptable control valve authority and achieve proper control; refer to Appendix A of
DEP 32.36.01.17-Gen. The pressure drop of in-line instruments, such as vortex or
Coriolis flow meters, shall be determined from the Manufacturer/Supplier's data.

6.

For equipm ent, the pres s ure dr op s hall be tak en f rom the data o btaine d f rom the
equipment Manufacturer/Supplier.
Table 5

Valve and fitting equivalent length

Type of valve/fitting
Valves
(fully
open)

Fittings

Le *

Ball valve

Reduced bore DN 40 (NPS 1 ) and smaller


Reduced bore DN 50 (NPS 2) and larger
Full bore DN 50 (NPS 2) and larger

65 D
50 D
8D

Gate valve

Standard bore
Reduced bore DN 40 (NPS 1 )and smaller

13 D
30 D

Globe valve

Straight pattern
Y pattern
Angle pattern

135 D
80 D
75 D

Check valve

Swing type
Ball or piston type, DN 40 (NPS 1 ) and smaller
Dual Plate type

50 D
135 D
75 D

Plug valve

Regular pattern

60 D

Butterfly valve

Concentric type
Double offset type
Triple offset type

25 D
55 D
60 D

Tee-equal

Flow straight through


Flow through side outlet

20 D
65 D

Elbow

90, R = 1 1 2 D

20 D
16 D

45, R = 1 1 2 D
Bend

90, R = 4 D
90, R = 5 D
180, R = 4 D
180, R = 5 D

14
16
25
28

D
D
D
D

Enlargement

Sudden, d/D = 1/4


Sudden, d/D = 1/2
Sudden, d/D = 3/4
Standard reducer, d/D = 1/2
Standard reducer, d/D = 3/4

73
47
16
35
10

D
D
D
D
D

This document has been supplied under license by Shell to:


Tebodin & Partners LLC slingade@tebodin.co.om 11/10/2015 06:56:39

ATTACHMENT-4
DEP 31.38.01.11-Gen.
February 2015
Page 19
Contraction

Miscellan Strainer
eous
Nozzle

Sudden, d/D = 1/4


Sudden, d/D = 1/2
Sudden, d/D = 3/4
Standard reducer, d/D = 1/2
Standard reducer, d/D = 3/4

40 D
32 D
20 D
16 D
5D

Pump suction Y-type and bucket type

250 D

Product outlet nozzle vessel/tank


Product inlet nozzle vessel/tank

32 D
64 D

* In critical situations, the Manufacturer/Supplier's data shall be obtained.

2.3.4.2

General equation for pressure drop calculation


1.

The pressure drop for a piping system in metric units is given by the equation:
L

AP =

Ax-pv2

or, to convert pressure drop from N/m2 into metres of liquid head loss:

L
v2
A/i = A x
Dt 2g
or, for circular cross-section pipe:

AP=-XA^

pDf

n2 2

where:
1 __ Q J |

I ( A

I f}\3/2

Re =

A = < 2.457 In

VV73027e )(

lm

+-DTI)

/37530\ 1 6
in which:

pressure drop (N/m2)

= friction factor (dimensionless)


L = total design length (m)
Di = inside diameter of pipe (m)
= density (kg/m3)
v = average linear flow velocity (m/s)
h = head loss (m)
g = acceleration due to gravity (9.807 m/s2)
q m = mass flow (kg/s)
= dynamic viscosity (Pas)

This document has been supplied under license by Shell to:


Tebodin & Partners LLC slingade@tebodin.co.om 11/10/2015 06:56:39