Review Control Sheet

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BLOCK 3/05 TOPSIDE FACILITIES UPGRADE (BUF F1 PAC F2 PAC F4)
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DOCUMENT: SIZING EQUIPMENT (UPDATE) PAC F2
DISCIPLINE: PROCESS
PROJECT N: 015/BLK3/05

DOCUMENT NUMBER
015/BLK3/05 2 FEED11301
DATE:
07

27

10

SIZING EQUIPMENT (UPDATE) PAC F2

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FRANCELI
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ANDRES
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DOCUMENT NUMBER
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DATE: 07/27/10
Page 2 of 52

Rev.: A

INDEX
1

OBJETIVE 5

SCOPE

REFERENCE

5
5

3.1 Documents 5
3.2 Diagrams

3.3 Abbreviations

GENERAL PROCESS DESCRIPTION 6

SIZING DESIGN CRITERIA AND METHODOLOGY 7

5.1 Gas/Liquid Cylindrical Cyclone GLCC (DS 205) 7
5.1.1

Design Criteria............................................................................................8

[Link] GLCC Diameter.....................................................................................8

[Link] Inlet Nozzle Area...................................................................................9
[Link] GLCC Length (Upper and Lower Parts)...............................................9
5.1.2

Methodology...............................................................................................9

5.2 Liquid/Liquid Pipe Separator LLPS (DS 204)

5.2.1

Methodology..............................................................................................11

5.3 Liquid/Liquid Cylindrical Cyclone LLCC (DS 206A/B)

5.3.1

11

Design Criteria..........................................................................................12

[Link] LLCC Inlet...........................................................................................12

[Link] LLCC Diameter...................................................................................12
[Link] LLCC Length.......................................................................................13

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DOCUMENT NUMBER
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PROJECT N: 015/BLK3/05

5.3.2

Page 3 of 52

Rev.: A

Methodology.............................................................................................13

5.4 Liquid/Liquid Hydrocyclone Package LLHC (DS 207A/B)

5.4.1

DATE: 07/27/10

13

Design Criteria..........................................................................................14

[Link] Available Pressure/Pressure Drop......................................................15

[Link] Oil Droplet Size/Distribution................................................................15
[Link] Liquid Viscosity/Temperature..............................................................15
[Link] Hydrocyclone diameter/Performance..................................................15
5.4.2

Methodology.............................................................................................16

5.5 Induced Gas Flotation Unit IGF (DS 208) 16

5.5.1

Methodology.............................................................................................16

5.6 Vessels

16

5.6.1

Design Criteria..........................................................................................16

5.6.2

Methodology.............................................................................................17

5.7 Pumps System

17

5.7.1

Design Criteria..........................................................................................17

5.7.2

Methodology.............................................................................................18

PROCESS DATA
6.1.1

18

Process conditions....................................................................................18

6.2 Forecast and Most Likelihood Estimation (MLE)

7

RESULTS

22

7.1 GLCC DS 205 Sizing

22

7.2 LLPS DS 204 Sizing

23

20

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DATE: 07/27/10
Page 4 of 52

Rev.: A

7.3 LLCC DS 206A/B Sizing 24

7.4 LLHC DS 207A/B Sizing 25
7.5 IGF DS 208A/B Sizing
7.6 Sizing Summary
8

ATTACHMENTS

26

27
30

ATTACHMENT A: Process Flow Diagram 31

ATTACHMENT B: Process Equipment Sizing Results:
LLHC and IGF 33
ATTACHMENT C: Induced Gas Flotation Unit Selection
ATTACHMENT D: Vessels Calculation Notes

38

ATTACHMENT E: Pumps Calculation Notes

42

GLCC, LLPS, LLCC,

36

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DOCUMENT NUMBER
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DATE: 07/27/10
Page 5 of 52

Rev.: A

OBJETIVE

To show calculation notes of major equipments to be installed on PACASSA F2

Platform (PAC F2), as part of the project: ENGINEERING, PROCUREMENT,
INSTALLATION & CONSTRUCTION BLOCK 3/05 TOPSIDE FACILITIES
UPGRADE (BUF F1 PAC F2 PAC F4).
2

SCOPE

This document provides calculations and sizing of the equipments: Gas/Liquid

Cylindrical Cyclone, Liquid/Liquid Pipe Separators (LLPS), Water Treatment Packages
(Liquid/Liquid Cylindrical Cyclone (LLCC), Liquid/Liquid Hydrocyclone (LLHC) and
Induced Gas Flotation (IGF) Unit), pumps and vessels to be installed in the PAC F2
Platform as part of the project: ENGINEERING, PROCUREMENT, INSTALLATION &
CONSTRUCTION BLOCK 3/05 TOPSIDE FACILITIES UPGRADE (BUF F1 PAC
F2 PAC F4).
3

REFERENCE

3.1

Documents

1
2

Description
Basis and Design Criteria
Preliminary Heat &Mass Balance PAC F2

3.2

Diagrams

Description
Process Flow Diagram PAC F2

Document N
015/BLK3/05 0 PFEED001301
015/BLK3/05 2 PFEED111201

Document N
015/BLK3/05 2 PFEED11501

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3.3

DOCUMENT NUMBER
015/BLK3/05 2 FEED11301
DATE: 07/27/10
Page 6 of 52

Rev.: A

Abbreviations

BUF:

Bufalo

PAC:

Pacassa

GLCC:

LLHC:

IGF:

LLPS:

Liquid/Liquid Pipe Separator

LLCC:

Liquid/Liquid Cylindrical Cyclone

Gas/Liquid Cylindrical Cyclone

Liquid/Liquid Hydrocyclone Package
Induced Gas Flotation

APPLICABLE STANDARS AND CODES

API (American Petroleum Institute)
API RP 14E:
Recommended Practice for Design and Installation of Offshore
Production Platform Piping Systems, Fifth Edition, October 1, 1991.
AP Spec 12J:
1, 1989.

Specification for Oil and Gas Separators, Seventh Edition, October

Total General Specification

GS ECP 103:
4

Process Sizing Criteria

GENERAL PROCESS DESCRIPTION

Current production for PAC F2 platform is about 3,900 SCMD of liquid and
140,000 SCMD of gas. New environmental regulation will be complied and current
production losses must be minimized. Therefore, new top facilities are required. Design
of the new facilities is based on MSI IWS Technology (Patent Pending).
New Gas/Liquid Cylindrical Cyclone (GLCC DS 205) receives multiphase flow from
wells to separate gas and liquid phase. The gas from top is sent to COBO P1 via

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DOCUMENT NUMBER
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DATE: 07/27/10
Page 7 of 52

Rev.: A

subsea pipeline, while the liquid from bottom is transferred to Liquid/Liquid Pipe
Separator (LLPS DS 204) for a primary separation, which will reduce the water cut for
crude oil to about 6%.Then crude oil goes to PAC F1 platform via Export Pumps GX
201A/B/C and existing oil pipeline. The water stream from LLPS is rich in oil (6%) and
flows to the Water Treatment Package, which consist of a Liquid/Liquid Cylindrical
Cyclone (LLCC DS 206 A/B) to reduce the oil content at about 2,000 ppm, a
Liquid/Liquid Hydrocyclone Package (LLHC DS 207A/B) which outlet water stream has
a 100 ppm of oil content and an Induced Gas Flotation Unit (IGF DS 208A/B) to obtain
water overboard (with 25 ppm of oil as maximum) to be disposed to the sea or injected
into wells. Process Flow Diagrams for both options are shown in the Attachment A.
5
5.1

SIZING DESIGN CRITERIA AND METHODOLOGY

Gas/Liquid Cylindrical Cyclone GLCC (DS 205)

A schematic representation of the GLCC DS 205 is shown in Figure 1. The separator is

basically a vertical piece of pipe with a downward inclined inlet and two outlets, one at
the bottom and the other at the top. The gas and liquid mixture flows tangentially from
the inlet into the cylindrical cyclone forming a vortex. Due to the centrifugal,
gravitational and buoyancy forces, the liquid moves to the wall, descends and exits
from the lower part, while the gas moves to the centre, ascends and exits from the top.

Figure 1. Gas/Liquid Cylindrical Cyclone (GLCC)

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Rev.: A

The liquid level control and/or pressure control ensure proper operation for different
flow conditions, eliminating or reducing liquid carry over into the gas stream and/or gas
carry under into the liquid stream. Determination of liquid level is important for the
prediction of both liquid carry over and gas carry under. For proper operation of the
GLCC, the liquid level must be maintained below the inlet to avoid gas flowing through
the liquid stream and carrying liquid into the gas. Also, the liquid level should be
sufficiently high above the exit at the bottom to avoid gas carry under into the liquid
stream and prevent gas liberation in the liquid meter.
5.1.1 Design Criteria
For GLCC design criteria following document was taken as reference: Gomez, L. E., R.
Mohan, O. Shoham, J. Marreli, and G. Kouba. Aspect Ratio Modeling and Design
Procedure for GLCC Separators. Journal of Energy Resources Technology (ASME
Transactions) 121, no. 1 (March 1999): 15 23.
GLCC Diameter
The diameter should be such that superficial gas velocity is less than the critical
velocity in order to allow liquids to drop out. In contrast, the diameter should be small
enough to maintain the efficiency of the centrifugal separation and prevent gas carry
under into the liquid stream.
Inlet Nozzle Area

The inlet nozzle area should be small enough to ensure the entrance liquid
tangential velocities in the recommended range of 3 to 6 m/s.

Velocity should be less than the fluid erosional velocity according to API RP 14E.

GLCC Length (Upper and Lower Parts)

The length of the upper part (above the GLCC inlet) should be large enough to prevent
liquid carry over in the form of swirling upward liquid film or as droplets. Also, The
length of the lower part (below the GLCC inlet) should be large enough to maintain a

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DATE: 07/27/10
Page 9 of 52

Rev.: A

finite liquid column below the vortex (for different flow conditions) in order to allow
sufficient time for the separation of bubbles from the liquid phase and prevent the
entrapment of bubbles in the existing liquid stream. Recommended minimum value of
both lengths (upper and lower part) is 1.2 to 1.5 m as minimum.
5.1.2 Methodology

Calculations were developed using calc sheet property of MSI and final results are
presented in the Attachment B.

5.2

Liquid/Liquid Pipe Separator LLPS (DS 204)

Working principles and modeling of this type of separator was presented in: Gassies,
Mathieu, L. Gomez, R. Mohan, and O. Shoham. A Simplified Model for the Design of
the Liquid Liquid Horizontal Pipe Separator. TUSTP Manual, 2008.
Design for LLPS requires determining two key parameters: diameter and length. A flow
condition analysis allows determine the suitable diameter which stratified flow is
promoted using Oil/Water Flow Pattern Maps due to each flow pattern has an unique
hydrodynamic flow characteristics.
Then, an appropriate length can be determined to enable oil water separation
considering two different approaches. The first method considers the trajectories in a
stratified two phase flow for an oil droplet in water and for a water droplet in oil, and
selects the longest one as a design criterion for the length (see Figure 2). The second
method uses the batch separation model describing the evolution of an oil water
mixture in a classic gravity settler in order to determine the length required for full
separation (see Figure 3).

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Rev.: A

Figure 2. Particle Trajectory in Stratified Two Phase Flow.

Figure 3. Classic Gravity Settler Schematic.

5.2.1 Methodology

Calculations were developed using calculation spreadsheet property of MSI and

final results are presented in the Attachment B.

5.3

Liquid/Liquid Cylindrical Cyclone LLCC (DS 206A/B)

Design criteria and physical working principles for this type of equipment were
presented in: Oropeza Vazquez, C., et al. "Oil Water Separation in a Novel Liquid

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Rev.: A

Liquid Cylindrical Cyclone (LLCC) Compact Separator Experiments and Modeling."

Journal of Fluids Engineering (ASME Transactions) 126, no. 4 (July 2004): 553 564.
A schematic of the LLCC DS 206A/B is shown in Figure 4. The LLCC has a
configuration similar to GLCC, i.e. a vertical pipe section, but with a horizontal
tangential inlet. The horizontal inlet promotes oil water segregation and both liquids
phases enter the vertical section through a reducing area nozzle, increasing their
velocities. The swirling motion and the gravity force in LLCC produces a centrifugal
separation, where the oil phase moves to the centre and an oil rich stream exits at top.
While the clear water moves to the pipe wall, flows downward and exits through the
bottom. LLCC has neither moving parts nor internal devices.
The LLCC design criteria are developed based on physical flow mechanisms occurring
in the LLCC and limitations of the application in the field. These design criteria should
be considered as the limiting design parameters appropriate for each element of the
LLCC in order to ensure proper LLCC performance.

Figure 4. Liquid/Liquid Cylindrical Cyclone (LLCC) Compact Separator.

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Rev.: A

5.3.1 Design Criteria

LLCC Inlet
Inlet diameter should be sufficiently large to permit stratification. Also, the inlet length
should be sufficiently long to avoid dispersion of the two layers.
The inlet nozzle should be able to generate an area reduction, providing a water
superficial velocity approximately 2 m/s, in order to keep the slot area reduction
between 20 to 30% of the inlet pipe area.
LLCC Diameter

Water cut should be less than 65%.

Optimal split ratio is 46%.

The diameter should be such that the superficial liquid velocity in the LLCC
permits a tangential velocity /axial velocity ratio (Vt/Vz) of 9, for a tangential
velocity of 1.8 m/s.

LLCC Length
The length of the lower part (below the LLCC inlet) should be large enough to maintain
a finite liquid column below the vortex (for different flow conditions) to allow sufficient
time for the separation of droplets from the oil phase and prevent the entrapment of oil
droplets in the existing water stream.
5.3.2 Methodology

Calculations were developed using calc sheet property of MSI and final results are
presented in the Attachment B.

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5.4

DOCUMENT NUMBER
015/BLK3/05 2 FEED11301
DATE: 07/27/10
Page 13 of 52

Rev.: A

Liquid/Liquid Hydrocyclone Package LLHC (DS 207A/B)

Liquid/Liquid Hydrocyclones (LLHC), also called enhanced gravity separators, use

centrifugal force to remove oil droplets from oily water. As is shown in Figure 5, static
hydrocyclones consist of four sections: a cylindrical swirl chamber, a concentric
reducing section, a fine tapered section, and a cylindrical tail section. The oily water
enters the cylindrical swirl chamber through a tangential inlet, creating a high velocity
vortex with a reverse flowing central core. The fluid accelerates as it flows through the
concentric reducing section and the fine tapered section. The fluid then continues at a
constant rate through the cylindrical tail section. Larger oil droplets are separated out
from the fluid in the fine tapered section, while smaller droplets are removed in the tail
section. Centripetal forces cause the lighter density droplets to move toward the low
pressure central core, where axial reverse flow occurs. The oil is removed through a
small diameter reject port located in the head of the hydrocyclone. Clean water is
removed through the downstream outlet.
They are driven by inlet water pressure and use a pressure drop across the cyclone to
provide the energy to cause oil water separation. Normally, a system pressure is used
to provide the driving pressure, but if too low (<4 bar), a pump can be used to boost the
feed pressure.
The oil stream flow is largely controlled by the orifice size, but can also be regulated by
an outlet control valve and is typically set to allow at 2 to 4% of the inlet flow.

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Rev.: A

Figure 5. Hydrocyclone.

5.4.1 Design Criteria

A comprehensive explanation of operation and design criteria for LLHC is presented in:
Gomez, C., J. Caldentey, S. Wang, L. Gomez, R. Mohan, and O. Shoham. "Oil Water
Separation in Liquid Liquid Hydrocyclones (LLHC): Part 1 Experimental
Investigation." SPE Journal 7, no. 4 (December 2002): 353 361.
Available Pressure/Pressure Drop
It is always preferred to use the full system pressure to drive hydrocyclones. The
preferred site to locate it in a process is on the water outlet line from the separator,
upstream of the level control valves. This provides the highest capacity with minimal
droplet shearing.
The pressure differential ratio (PDR), defined as is shown below, should be maintained
in the range of 1.7 to 2.0.
PDR

Pinlet Preject
Pinlet Poutlet

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Rev.: A

Where, Pinlet is the pressure at unit inlet, Preject is the pressure of reject oil stream and
Poutlet is the pressure of clean water stream.
Oil Droplet Size/Distribution
The oil droplet size range has a major impact on the hydrocyclone performance and it
is important to maintain as little shearing of oil droplets as possible prior to the
equipment, by installing it upstream of control valves.
Liquid Viscosity/Temperature
Temperature has a direct effect on the water viscosity which has a significant effect on
its performance. At higher temperatures the water viscosity reduced, creating less
resistance to the separation of oil droplets and resulting in higher levels of oil/water
separation.
Hydrocyclone diameter/Performance
The effect of the diameter of the liner on oil & water separation is very important:
smaller diameter hydrocyclone provides higher level of oil removal, but they have a
lower capacity. Many liners are packaged inside each vessel to treat large flow, while
still providing high oil removal levels.
5.4.2 Methodology

Calculations were developed using calc sheet property of MSI and final results are
presented in the Attachment B.

5.5

Induced Gas Flotation Unit IGF (DS 208)

Induced Gas Flotation (IGF) has been used to help oil separation from produced water
using microbubbles of gas (approximately 10 to 50 microns) as an improved gas
flotation technology. It is generally accepted that a bubble of gas of a given size will
attach itself to a similar sized oil droplet and promote it to float to the surface where the
oil coalesces, collects and is skimmed off. Using microbubbles, it is easier to get lower
concentrations of oil in the treated water.

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Rev.: A

The IGF is a patented gas/liquid contactor designed to supersaturate liquids with a gas
and does not contain any moving parts. It can be used to entrain a variety of gases into
liquids at or above the saturation point. The Gas Liquid Reactor (GLR TM) is a platform
technology for the creation of microbubble in a moving liquid. The Attachment B shows
factors to select IGF package.
5.5.1 Methodology

5.6

Select IGF Model according to Attachment C and average feed flow rate.
Vessels

5.6.1 Design Criteria

Based on Basis and Design Criteria, Doc. No 015/BLK3/05 0 PFEED001301:

For vertical vessels, L/D ratio should be between 2.5 and 6. It is recommended
L/D equal to 3.

For horizontal vessels, L/D ratio should be between 3 and 4.

For low operational pressure (0 17 barg), it is recommended L/D ratio equal to 3 in

order to provide an economical design.

Retention time 1 to 3 min according to API Spec 12 J due to allow sizing smaller
containers.

5.6.2 Methodology

Get process conditions from Heat & Mass Balance.

Determine liquid volume using API Spec 12J retention time for the liquids phases.

Assume that separator is half full of liquid and L/D ratio is 3.

Calculate minimum diameter and then select next large standard diameter (vessel
diameter is generally expanded in 152.4 mm (6 inch) increments).

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DOCUMENT NUMBER
015/BLK3/05 2 FEED11301
DATE: 07/27/10
Page 17 of 52

Rev.: A

Determinate seam to seam length.

Refer to Attachment D to see calculation notes.

5.7

Pumps System

5.7.1 Design Criteria

Based on Basis and Design Criteria (Doc. No 015/BLK3/05 0 PFEED001301) and Total
General Specification GS ECP 103:

The minimum margin between the normal and rated flow for a pump will be 10%.

Maximum suction velocity is 1.8 m/s.

In general, a minimum margin of 1 m between the Net Positive Suction Head

Available (NPSHA) and the Net Positive Suction Head Required (NPSHR).

Design temperature is increased 15C above nominal pumping temperature.

Pumps should be specified with a maximum head rise to shut in of 1.25 times
design pump differential. The design pressure is the maximum head to shut in
plus the maximum suction pressure. The design pressure shall be no less than
3.5 barg.

The minimum flow for pump protection is 30% of design flow.

5.7.2 Methodology

Get process conditions from Heat & Mass Balance.

Calculate the pump suction conditions, suction pressure, maximum suction

pressure and NPSHA.

Determine the nominal discharge pressure requirements for the pump.

Calculate the pressure differential and pump head.

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DOCUMENT NUMBER
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DATE: 07/27/10
Page 18 of 52

Determine the power requirements: Brake Horse Power (BHP).

Calculate design conditions.

Rev.: A

Refer to Attachment E to see calculation notes.

6

PROCESS DATA

6.1.1 Process conditions

The following tables show the process conditions for the equipments on platform
according to the production forecast supplied by Sonangol P&P:
Table 1. Process conditions for PAC F2 Platform Feed.
Parameter
Total Gas (SCMD)1
Produced Liquid (SCMD)
Pressure (barg)
Temperature (C)

Minimum
204,434
2,220
5.0
88

Maximum
315,849
3,901
7.0
120

Table 2. Well Composition for PAC F2 Platform2.

Component
N2
CO2
C1
C2
C3
i C4
n C4
i C5
n C5
C6
C7
C8
1

Including gas lift injection rate.

Well Fluid Composition supplied by Sonangol P&P.

% Mol
0.2
0.7
37.8
8.3
7.2
1.3
3.5
1.7
1.8
3.6
3.7
3.3

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C9
C10
C11+

2.6
1.8
22.5

Table 3. Oil Characterization for C11+.

Property
Critical Temperature (C)
Critical Pressure (barg)
Acentric Factor
Density @60C (Kg/m3)
Molecular Weight

Value
455
15.5
0.90
910.0
260.00

Rev.: A

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Rev.: A

Table 4. Gas Chromatography for COBO Gas Lift.

6.2

Forecast and Most Likelihood Estimation (MLE)

Production Forecast and Maximum Likelihood Estimation (MLE) envelopes are plotted
to show the operating limits for oil, water and gas. Results of MLE are used to
determine the design conditions (flow rate operating range) for PAC F2 surface facility
equipment. The method takes in account the historical data for the individual well of
each platform which is correlated with the average flow rate of each phase. Figure 6
presents gas and total liquid operating points, production forecast envelope and MLE.

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Rev.: A

Figure 7 shows water and oil operating points, production forecast envelope and the
corresponding MLE.

Figure 6. Liquid and Gas Forecast and MLE.

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Rev.: A

Figure 7. Oil and Water Forecast and MLE.

7
7.1

RESULTS
GLCC DS 205 Sizing

The design of the separator should cover all the expected operating points and the
MLE. In this regard several run were done using maximum gas and total liquid flow
rates, temperature, pressure and fluid properties presented above. Following figure
shows GLCC operating envelope.

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Rev.: A

Figure 8. GLCC Operating Envelope.

7.2

LLPS DS 204 Sizing

This separator was designed to handle the total liquid fluid (oil plus water) under the
most critical conditions. No gas presence is considered for superficial velocities
calculations. Results are presented in Figure 9. This operating envelope is defined by
the superficial velocity given for the MLE; the minimum mixture velocity of 0.015 m/s
which is 10 times less than the stratified flow pattern boundary; the velocity region for
30% of Water Cut and the oil flow rate corresponding to 0.010 m/s to warranty that the
oil flow is under stratified flow pattern.

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Rev.: A

Figure 9. LLPS Operating Envelope.

7.3

LLCC DS 206A/B Sizing

Design considerations for this type of separator include the following:

Maximum allowable pressure drop is 1.38 bar (20 psi)

The equipment is a set of 24 LLCCs of 50.8 mm (2 inches) in diameter inside an

813 mm (32 inches) drum.

Each LLCC will handle 106.52 SCMD (670 BPD) of liquid.

Figure 10 shows the liquid production forecast, the MLE and the performance of the
LLCC. It is notice that two drums could cover the operations from years 2010 to about

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Rev.: A

2015 and one drum is needed during the rest of the operation. However it is
recommended using two drums to assure the expected system reliability.

Figure 10. LLCC Operating Envelope.

7.4

LLHC DS 207A/B Sizing

Design considerations for the Hydrocyclone package are as follows:

Maximum allowable pressure drop is 1.38 bar (20 psi)

The equipment is a set of 75 Hydrocyclones (Liner) of 25.4 mm (1 inch) in

diameter inside a 762 mm (30 inches) drum. Each Liner has an orifice of 2 mm of
diameter.

Each Hydrocyclone will handle 31.80 SCMD (200 BPD) of liquid.

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Rev.: A

Figure 11 shows the liquid production forecast, the MLE and the performance of the
LLHC. Under this operating condition two drums can cover the operations during the
first five years and one drum is needed for the last ten years of operation. However it is
recommended using two drums to assure the expected system reliability.

Figure 11. LLHC Operating Envelope.

7.5

IGF DS 208A/B Sizing

Design considerations for the Induced Gas Floatation Unit are as follows:

The equipment is a set of 2 Micro Bubble Floatation Units of 40 inches diameter.

The system also includes two Gas Clean Drums and two Micro Bubble
Generation Units.

Each Micro Bubble Floatation Unit will handle 1,512 SCMD (9,510 BPD) of liquid.

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Rev.: A

Figure 12 shows the liquid production forecast, the MLE and the performance of the
IGF. Under this operating condition, two units can cover the operations along the
expected production period.

Figure 12. IGF Operating Envelope.

7.6

Sizing Summary

The sizing results for new equipments are shown in the followings tables:

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Rev.: A

Table 5. Separators Sizing Results.

Item Tag
Type
Design
Pressure
(barg)
Working
Temperature Design Max/Min
(C)
Working
Liquid Flow Rate (Sm3/d)
Gas Flow Rate (Sm3/d)
Internal Diameter (mm)
Height or Length TL-TL (mm)

DS 204
Horizontal
8
4.86
135/110
5,700
1,067
5,330

DS 205
Vertical
8
5.0
135/110
7,200
390,000
1,067
5,338

DS 206A/B
Vertical
8
3.47
135/109.9
5,113
813
2,440

DS 207A/B
Vertical
8
6.3
135/109.7
4,770
762
1,220

DS 208A/B
Vertical
8
0.6
135/109.7
3,984
1067
4,073

DS 209
Vertical
8
1.94
135/109.6
XXX
XXX
610
2,286

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Rev.: A

Table 6. Standardization Pumps Results 3.

Item Tag
Design
Pressure (barg)
Working Suction/Discharge
Design Max/Min
Temperature (C)
Working
Normal Capacity (Sm3/d)
Rated Capacity (Sm3/d)
Differential Pressure (bar)
Pump Head (m)
NPSHA (m)
Brake Horse Power (kW)

GX 411A/B
8.3
2.5/7.1
135/110
160
176
4.6
50
>7.6
30.0

GX 412A/B
9.0
0.7/7.3
135/110
160
176
6.6
71.8
2.9
45.0

Refer to Attachment E to see Calculation Notes and Standardization Pumps.

GX 413A/B
153.0
7.3/127.2
135/110
80
88
119.9
1300
>7.6
390

GX 414A/B
6.6
1.6/5.6
135/110
12.7
14.0
4.0
52.6
3.2
2.1

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Rev.: A

ATTACHMENTS

ATTACHMENT A: Process Flow Diagram.

ATTACHMENT B: Process Equipment Sizing Results: GLCC, LLPS, LLCC and LLHC.
ATTACHMENT C: Induced Gas Flotation Unit Selection.
ATTACHMENT D: Vessel Calculation Notes.
ATTACHMENT E: Pumps Calculation Notes.

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ATTACHMENT A: Process Flow Diagram

Rev.: A

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ATTACHMENT B: Process Equipment Sizing Results:

GLCC, LLPS, LLCC, LLHC and IGF

Rev.: A

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Rev.: A

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Rev.: A

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ATTACHMENT C: Induced Gas Flotation Unit Selection

Rev.: A

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ATTACHMENT D: Vessels Calculation Notes

Rev.: A

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DS-209 - Sizing:
1. Estimation of inlet flow rates, densities and viscosities of all phase:
3

Actual gas vol. flow rate:

m
Qg 50.42
hr

Gas density @ P y T:

g 2.89

(from Hysys report)

kg
m

(from Hysys report)

Gas viscosity:

g 0.011cP

Oil mass flow rate:

mo 7875

(from Hysys report)

kg

Oil density:

hr
kg
o 786.44
3
m

Oil vol. flow rate:

mo
Qo
o

Oil viscosity:

o 1.174cP

Water mass flow rate:

mw 481

Water density:

w 940.66

Water vol. flow rate:

(from mass balance)

(from mass balance)
3

m
Qo 10.013
hr
(from Hysys report)

kg

(from mass balance)

hr
kg
m

mw

Qw
w

(from mass balance)

3

m
Qw 0.51
hr
(from Hysys report)

Oil viscosity:

w 0.256cP

Liquid mass flow rate:

mL mo mw

mL 8356

Liquid vol. flow rate:

QL Qo Qw

m
QL 10.52
hr

Liquid density:

kg
hr
3

mL
QL

2. Approximation of Separator Dimensions:

Assumptions:
H/D=3
Separator is half full of liquid (M=0.5)
Liquid retention time (t r) is 1 min.

L 793.9

kg
m

Rev.: A

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(API Spec 12J)

M 0.5

tr 1min

D 150mm

H 600mm

(guess values)

Given
H
D

D = inside diameter of separator

H = height of separator
M = fraction of vertical area filled with liquid

3
2

D M H

QL t r

20.867

Sol Find ( D H)

Re ( Sol)

Outside Diameter,

D 24in

in

62.601

D 610 mm

3. Gas Capacity - Sounder Brown K factor

0.35 ft

Sounder Brown K factor:

Maximum allowance velocity:

V max K

Minimum vapour area:

Amin

Minimum diameter:

Dmin

(API Spec 12J

o g
g

Qg
Vmax
4Amin

K 0.053

m
s

V max 0.878

4Qg

V g

Dmin 5.61 in

V g 0.048

m
s

Actual Vg<Vmax so separator size is controlled by liquid capacity.

5. Liquid Phase Capacity - Retention Time:
Liquid volume:

V L QL t r

Maximum liquid height:

HL

4VL
2

Amin 0.016 m

4. Gas Capacity - Drop Settling

Actual gas velocity:

V L 0.175 m
HL 0.601 m

Rev.: A

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Page 41 of 52

6. Separator Height:
ft

Maximum inlet nozzle velocity:

Ve 30

Minimum inlet nozzle area:

AN

Inlet nozzle diameter:

DN

Height seam to seam:

H HL 1ft 2DN D

Next largest standard size:

H 7.5ft

Ratio L/D:

H
D

(from Design Basis)

sec

Qg QL

A N 1.851 10

Ve
4AN

DN 0.049 m

H 5.29 ft
H 2286 mm

3.75

7. Weight Calculation:
Working pressure:

P 8bar 1atm 1bar

Allowance stress for steel:

S 1200bar 1atm

Joint efficiency:

E 0.85 (initial work)

Shell tickness (including corrosion

allowance equal to 3 mm):

P D

in

Inside Diameter:

ID D 2t

Empty vessel weight (including

heads):

we 3.47

S 1.201 10 bar

3mm

t 5.978 mm

(commercial)

t 6.35 mm

2S E 0.8 P

16

P 10.013 bar

ID 23.5 in
kg
2

cm m

ID H t

we 301 kg

Rev.: A

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ATTACHMENT E: Pumps Calculation Notes

Rev.: A

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GX 210: 2000 ppm Water Pump Calculation:

Oil Mass Flowrate:

kg
mo 247.8
hr

Oil Density:

o 784.41

kg
3

kg
Water Mass Flowrate: m 123643
w
hr

kg
Water Density: 939.72
w
3
m

Total Mass Flowrate:

mt mo mw

kg
mt 123890.8
hr

Total Vol. Flowrate:

Rated Capacity:

QRATED 1.1Q

Fluid Density:

mo
o

mw
w

Q 131.9

hr
3

mt

m
QRATED 145.1
hr
939.3

kg
3

1. Suction Section:
Operating Pressure Vessel:

Po 2.44barg

Hidrostatic Height:

h 1 9in 2ft

h 1 0.8 m

(LLLL=9in minimum according to Design Basis & distance between vessel liquid nozzle and
pump centerline d=2ft).
Suction Pressure:

Ps Po g h 1

Maximum head at suction:

h max 8ft

Maximum Suction Pressure:

Psmax Ps g h max

Ps 2.5 barg

Psmax 2.7 barg

Rev.: A

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GX 211: Water Booster Pump Calculation:

Oil Mass Flowrate:

kg
mo 0
hr

Oil Density:

o 780

kg
3

kg
Water Mass Flowrate: m 123338
w
hr

kg
Water Density: 940.36
w
3
m

Total Mass Flowrate:

mt mo mw

kg
mt 123338
hr

Total Vol. Flowrate:

Rated Capacity:

QRATED 1.1Q

Fluid Density:

mo
o

mw
w

Q 131.2

hr
3

mt

m
QRATED 144.3
hr
940.4

kg
3

1. Suction Section:
Operating Pressure Vessel:

Po 0.6barg

Hidrostatic Height:

h 1 9in 2ft

h 1 0.8 m

(LLLL=9in minimum according to Design Basis & distance between vessel liquid nozzle and
pump centerline d=2ft).
Suction Pressure:

Ps Po g h 1

Maximum head at suction:

h max 160in

Maximum Suction Pressure:

Psmax Ps g h max

Vapor pressure @ 110C:

Pvp 0.4088barg

Ps 0.7 barg

Psmax 1.1 barg

Rev.: A

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NPSHA:

DOCUMENT NUMBER
015/BLK3/05 2 FEED11301
DATE: 07/27/10
Page 45 of 52

NPSHA

Ps Pvp
g

NPSHA 2.9 m

2. Discharge Section:
Discharge pressure:

Pd 7.3barg

3. Pump parameters:
Differential Pressure:

P Pd Ps

Pump Height:

Shut off Pressure:

Pshutoff Psmax 1.2P

Pshutoff 9 barg

Hydraulic Power:

W hyd QRATED g H

W hyd 26.5 kW

Efficiency:

75% ( assumed )

Motor Power:

W BHP

Pd Ps

P 6.6 barg
H 71.8 m

W hyd

W BHP 35.4 kW

Rev.: A

Technical Documents
CONTENT DESCRIPTION

PROJECT: ENGINEERING, PROCUREMENT, INSTALLATION & CONSTRUCTION

BLOCK 3/05 TOPSIDE FACILITIES UPGRADE (BUF F1 PAC F2 PAC F4)
PHASE: D&D / PRE FEED
DOCUMENT: SIZING EQUIPMENT (UPDATE) PAC F2
DISCIPLINE: PROCESS
PROJECT N: 015/BLK3/05

Two operating pumps + 1 spare:

N 2

0 kg
mo
N hr

Water Mass Flowrate: m

w

Oil Density:

123338 kg
N

mt mo mw

Total Vol. Flowrate:

Rated Capacity:

QRATED 1.1Q

Fluid Density:

mo
o

o 780

kg
3

kg
Water Density: 940.60
w
3
m

hr

Total Mass Flowrate:

kg
mt 61669
hr
3

mw

Q 65.6

hr
3

m
QRATED 72.1
hr

mt

940.6

kg
3

1. Suction Section:
Suction Pressure:

Ps 7.3barg

Maximum Suction Pressure:

Psmax 9barg

Vapor pressure @ 110C:

Pvp 0.4088barg

NPSHA:

NPSHA

Ps Pvp
g

2. Discharge Section:
Discharge pressure:

DATE: 07/27/10
Page 46 of 52

GX 212: Water Injection Pump Calculation:

Oil Mass Flowrate:

DOCUMENT NUMBER
015/BLK3/05 2 FEED11301

Pd 127.2barg

NPSHA 74.7 m

Rev.: A

Technical Documents
CONTENT DESCRIPTION

PROJECT: ENGINEERING, PROCUREMENT, INSTALLATION & CONSTRUCTION

BLOCK 3/05 TOPSIDE FACILITIES UPGRADE (BUF F1 PAC F2 PAC F4)
PHASE: D&D / PRE FEED
DOCUMENT: SIZING EQUIPMENT (UPDATE) PAC F2
DISCIPLINE: PROCESS
PROJECT N: 015/BLK3/05

DOCUMENT NUMBER
015/BLK3/05 2 FEED11301
DATE: 07/27/10
Page 47 of 52

3. Pump parameters:
Differential Pressure:

P Pd Ps

Pump Height:

Shut off Pressure:

Pshutoff Psmax 1.2P

Pshutoff 152.9 barg

Hydraulic Power:

W hyd QRATED g H

W hyd 240.2 kW

Efficiency:

75% ( assumed )

Total Motor Power:

W BHP

Pd Ps

P 119.9 barg

H 1299.9 m

W hyd

W BHP 320.3 kW

Rev.: A

Technical Documents
CONTENT DESCRIPTION

DOCUMENT NUMBER
015/BLK3/05 2 FEED11301

PROJECT: ENGINEERING, PROCUREMENT, INSTALLATION & CONSTRUCTION

BLOCK 3/05 TOPSIDE FACILITIES UPGRADE (BUF F1 PAC F2 PAC F4)
PHASE: D&D / PRE FEED
DOCUMENT: SIZING EQUIPMENT (UPDATE) PAC F2
DISCIPLINE: PROCESS

DATE: 07/27/10

PROJECT N: 015/BLK3/05

Page 48 of 52

GX 213: Oil Recirculation Pump Calculation:

Oil Mass Flowrate:

kg
mo 7806
hr

Oil Density:

o 784.42

kg
3

kg
Water Mass Flowrate: m 456.3
w
hr

kg
Water Density: 943.68
w
3
m

Total Mass Flowrate:

mt mo mw

kg
mt 8262.3
hr

Total Vol. Flowrate:

Rated Capacity:

QRATED 1.1Q

Fluid Density:

mo
o

mw
w

Q 10.4

hr
3

mt

m
QRATED 11.5
hr
791.8

kg
3

1. Suction Section:
Operating Pressure Vessel:

Po 1.3barg

Hidrostatic Height:

h 1 9in 3m

h 1 3.2 m

(LLLL=9in minimum according to Design Basis & distance between vessel liquid nozzle and
pump centerline d=2m).

Rev.: A

Technical Documents
CONTENT DESCRIPTION

PROJECT: ENGINEERING, PROCUREMENT, INSTALLATION & CONSTRUCTION

BLOCK 3/05 TOPSIDE FACILITIES UPGRADE (BUF F1 PAC F2 PAC F4)
PHASE: D&D / PRE FEED
DOCUMENT: SIZING EQUIPMENT (UPDATE) PAC F2
DISCIPLINE: PROCESS

DOCUMENT NUMBER
015/BLK3/05 2 FEED11301

PROJECT N: 015/BLK3/05

DATE: 07/27/10
Page 49 of 52

Suction Pressure:

Ps Po g h 1

Maximum head at suction:

h max 7.5ft

Maximum Suction Pressure:

Psmax Ps g h max

Vapor pressure @ 105C:

Pvp 1.3barg

NPSHA:

NPSHA

Ps 1.6 barg

Psmax 1.7 barg

Ps Pvp

NPSHA 3.2 m

2. Discharge Section:
Operating Pressure Vessel:

P1 4.86barg

Hidrostatic Height:

h 2 42in

Valve pressure drop:

Pvalve 0.7barg

Discharge pressure:

Pd P1 Pvalve g h 2

Pd 5.6 barg

Differential Pressure:

P Pd Ps

P 4.1 barg

Pump Height:

Shut off Pressure:

Pshutoff Psmax 1.2P

Pshutoff 6.6 barg

Hydraulic Power:

W hyd QRATED g H

W hyd 1.3 kW

Efficiency:

75% ( assumed )

Motor Power:

W BHP

h 2 1.1 m

3. Pump parameters:

Pd Ps

H 52.7 m

W hyd

W BHP 1.7 kW

Rev.: A

Technical Documents
CONTENT DESCRIPTION

PROJECT: ENGINEERING, PROCUREMENT, INSTALLATION & CONSTRUCTION

BLOCK 3/05 TOPSIDE FACILITIES UPGRADE (BUF F1 PAC F2 PAC F4)
PHASE: D&D / PRE FEED
DOCUMENT: SIZING EQUIPMENT (UPDATE) PAC F2
DISCIPLINE: PROCESS
PROJECT N: 015/BLK3/05

DOCUMENT NUMBER
015/BLK3/05 2 FEED11301
DATE: 07/27/10
Page 50 of 52

Rev.: A

Similar calculations (as shown above) are done for the pumps located in BUF F1 and
PAC F4. The standardization criterion of pumps for same service in the different
platforms is applied. For this, the bigger pump, in relation to capacity and power, is
selected as the standard pump.

Technical Documents
CONTENT DESCRIPTION

PROJECT: ENGINEERING, PROCUREMENT, INSTALLATION & CONSTRUCTION

BLOCK 3/05 TOPSIDE FACILITIES UPGRADE (BUF F1 PAC F2 PAC F4)
PHASE: D&D / PRE FEED
DOCUMENT: SIZING EQUIPMENT (UPDATE) PAC F2
DISCIPLINE: PROCESS
PROJECT N: 015/BLK3/05

DOCUMENT NUMBER
015/BLK3/05 2 FEED11301
DATE: 07/27/10
Page 51 of 51

Rev.: A