LINE SIZING CALCULATION REPORT

1.0 INTRODUCTION / PROJECT OVERVIEW

2.0 PURPOSE
The purpose of this document is to provide the results of the calculations carried
out to size lines associated with process equipment, as well as to explain the
process sizing criteria considered in the calculations as to ensure that pressure
drop and velocity calculations are within the acceptable limits as
recommended by API RP 14E.

3.0 SUMMARY
The lines associated with process equipment were sized using stream property
data from HYSYS simulations.
The lines were sized in three categories namely:
 Two phase lines (gas and liquid),
 Liquid lines and
 Gas lines

4.0 ASSUMPTIONS AND NOTES

Design cases were simulated in HYSYS v10 and no design margin was added to
the stream flowrates.
The pipe straight length for the stream lines were all assumed to be 100 m for the
new process lines. The sizes will be validated when the isometrics has been
generated.
The line sizing criteria was based on API RP 14E specifications.

5.0 PIPE SIZING CRITERIA

 1. Two Phase lines were sized so as to ensure that the following criteria were
met;
 Flow velocity is lower than erosional velocity as obtained from the
formula in API RP 14E (See Appendix B) using empirical constant C=100.
 If Possible, flow velocities should be a minimum of 10 ft/s (3.05 m/s) (to
minimize slug flow)
2. The single-phase liquid lines were sized to ensure that the following
conditions were met;
 Flow velocity is within the acceptable range 15 ft/sec (4.5 m/s) – 3
ft/sec (1 m/s) API RP 14E specifications.
 Maximum allowable pressures drop of 0.9 bar/100 m. (Norsok Standard
for line sizing)
3. The single-phase gas line was sized to ensure that the following conditions
were met;
 Pressure drop is within the acceptable range of 0.001 - 0.11 bar/100 m
(Norsok standard).
 Velocity constraint of 18.288 m/s (60 ft/sec) for maximum flow velocity
(API RP 14E noise criteria) to minimize noise.

6.0 Line Sizing Results

Stream Stream Description Line Type Line Pressure Liquid Gas rate Bulk Sizing criteria
No. Classification Size Drop flow rate (mmscfd) Velocity
(in) (bar/100m) (Bpd) (m/s)
101 From inlet manifold Two Phase 8 0.7994 27500 7.5 9.4346 Erosional Velocity = 9.7265
to Test Sep (Selected) m/s (pipe velocity is less than
ER)
101 From inlet manifold Two Phase 6 4.088 27500 7.5 23.0293 Erosional Velocity = 11.481m/s
to Test Sep (Pipe vel. is more than ER)
102 From inlet manifold Two Phase 8 0.7263 27500 7.5 8.608 Erosional Velocity = 9.334 m/s
to HP Sep (Selected) (pipe velocity is less than ER)
102 From inlet manifold Two Phase 6 3.579 27500 7.5 19.89 Erosional Velocity = 10.72m/s
to HP Sep (Pipe vel. is more than ER)
103 From inlet manifold Two Phase 8 `0.5697 27500 7.5 7.818 Erosional Velocity = 9.341m/s
 to LP Sep (Selected) (Pipe vel. is more than ER)
103 From inlet manifold Two Phase 10 0.176 27500 7.5 4.793 Erosional Velocity = 9.183m/s
to LP Sep (Pipe vel. is more than ER)
201 Gas from Test Sep Gas 4 0.6494 7.5 32.421 API Noise velocity = 18.29m/s
to Gas Header
201 Gas from Test Sep Gas 6 0.1434 0.154 7.5 13.65 API Noise velocity = 18.29m/s
to Gas Header (Selected) Erosional Velocity = 43.94m/s
202 Gas from HP Sep Gas 4 0.0257 7.5 28.732 API Noise velocity = 18.29m/s
to Gas Header
202 Gas from HP Sep Gas 6 0.1147 0.154 7.5 12.21 API Noise velocity = 18.29m/s
to Gas Header (Selected) Erosional Velocity = 43.77m/s
203 Gas from LP Sep to Gas 8 0.0883 7.5 17.80 API Noise velocity = 18.29m/s
Gas Header (Selected)
203 Gas from LP Sep to Gas 6 0.1678 7.5 31.73 API Noise velocity = 18.29m/s
Gas Header
204 Gas from KO Pot to Gas 14 0.0155 7.5 15.645 API Noise velocity = 18.29m/s
(Selected)
Flare
204 Gas from KO Pot to Gas 10 0.0564 7.5 27.4195 API Noise velocity = 18.29m/s
Flare
301 Oil from Test Sep to Two Phase 6 0.2789 22000 0.02386 2.44748 Erosional Velocity = 4.374 m/s
HP/LP header (Selected) (pipe velocity is less than ER)
301 Oil from Test Sep to Two Phase 4 2.897 22000 0.2521 6.82 Erosional Velocity = 4.374 m/s
HP/LP header (pipe velocity is higher than
ER)
302 Oil from HP Sep to Two Phase 6 0.2767 22000 0.02399 2.44753 Erosional Velocity = 4.39m/s
LP header (Selected) (Pipe vel. is less than ER)
302 Oil from HP Sep to Two Phase 4 2.874 22000 0.2532 6.81012 Erosional Velocity = 4.86 m/s
LP header (pipe velocity is higher than
ER)
303 Oil from LP Sep to Two Phase 6 0.2194 22000 0.0194 2.249 Erosional Velocity = 4.425m/s
Surge Tank (Selected) (Pipe vel. is less than ER)
303 Oil from LP Sep to Two Phase 4 3.097 22000 0.2885 12.263 Erosional Velocity = 4.86 m/s
Surge Tank (pipe velocity is higher than
ER)
304 Oil from Stabilizer Liquid 5 0.5387 22000 3.136 Flow velocity is within the
tank to Pump (Selected) acceptable range of 1 – 4.5
suction m/s
304 Oil from Stabilizer Liquid 10 0.0183 22000 0.788 Flow velocity is not within the
tank to Pump acceptable range of 1 – 4.5
Suction m/s
306 Oil from Pump Liquid 4 1.694 22000 4.8796 Flow velocity is outside the
discharge to acceptable range of 1 – 4.5
Metering Skid m/s
306 Oil from Pump Liquid 6 0.2146 22000 2.171 Flow velocity is within the
discharge to (Selected) acceptable range of 1 – 4.5
Metering Skid m/s
401 Produced water Liquid 3 0.4626 5500 1.9259 Flow velocity is within the
from Test SEP to (Selected) acceptable range of 1 – 4.5
Water Tank m/s
401 Produced water Liquid 4 0.1177 5500 1.1184 Flow velocity is within the
from Test SEP to acceptable range of 1 – 4.5
Water Tank m/s
402 Produced water Liquid 3 0.4573 5500 1.91399 Flow velocity is within the
from HP SEP to (Selected) acceptable range of 1 – 4.5
Water Tank m/s
402 Produced water Liquid 4 0.1164 5500 1.1115 Flow velocity is within the
from HP SEP to acceptable range of 1 – 4.5
Water Tank m/s
403 Produced water Liquid 4 0.1181 5500 1.1205 Flow velocity is within the
from LP SEP to acceptable range of 1 – 4.5
Water Tank m/s
403 Produced water Liquid 3 0.4643 5500 1.9296 Flow velocity is within the
from LP SEP to (Selected) acceptable range of 1 – 4.5
Water Tank m/s
404 Produced water Liquid 6 0.01854 5500 0.5448 Flow velocity is lower than the
from Water Tank to acceptable range of 1 – 4.5
Liquid transfer m/s
pump
404 Produced water Liquid 4 0.1423 5500 1.2360 Flow velocity is within the
from Water Tank to (Selected) acceptable range of 1 – 4.5
Liquid transfer m/s
pump
405 Prod. Water from Liquid 4 0.1423 5500 1.2360 Flow velocity is within the
pump to Filter (Selected) acceptable range of 1 – 4.5
m/s
405 Prod. Water from Liquid 6 0.01854 5500 0.5445 Flow velocity is lower than the
pump to Filter acceptable range of 1 – 4.5
m/s
RELIEF LINE SIZING

PIPE SIZING CRITERIA

All flare lines shall be designed to meet the following criteria
 Ensure that the line ρV2 <200 000 kg/ms2 (ρ is the fluid density kg/m3)
 Maximum Velocity in the lines downstream of the PSVs should not exceed
0.5 Mach No
 Maximum Velocity for all headers should not exceed 0.3 Mach No.

ASSUMPTIONS
 All line lengths were assumed to be 25m length with a multiplier of 1.2 to
accommodate for fittings loss.
 The relief network line sizes were based on thermal relief at the Manifold
(table 2) and (or) Liquid relief at the manifold (table 3)

Line Sizing Results

Table 1
Line Line Description Line Phase Line Flow rate Mach ρV2 Status
No. Type Size (in) (Kg/hr) No. (kg/ms2)
511 Line from Test Relief Gas 3 1200 0.125 3980 (Selected)
Line
Manifold RV to
Relief Header
512 Line from HP Relief Gas 3 1200 0.126 3995 (Selected)
Manifold RV to Line
Relief Header
513 Line from LP Relief Gas 3 1200 0.130 4119 (Selected)
Manifold RV to Line
Relief Header
502 Line from Test Relief Gas 6 6367 0.209 9700 (Selected)
Line
SEP to Relief
Header
503 Line from HP SEP Relief Gas 6 6367 0.200 8918 (Selected)
Line
to Relief Header
504 Line from LP SEP Relief Gas 6 6367 0.208 9351 (Selected)
Line
to Relief Header
505 Vent from Water Vent Gas 2 NA NA NA (Selected)
Line
Tank to Bund
Wall
506 Line from Surge Relief Gas 3 1000 0.104 2270 (Selected)
Line
vessel 1 to Relief
Header
507 Line from Surge Relief Gas 3 1000 0.101 2147 (Selected)
Line
vessel 2 to Relief
Header
508 Relief Header Relief Gas 12 24701 0.256 11278 (Selected)
Line
509 Flare Header Flare Gas 12 24701 0.291 12811 (Selected)

510 Flare Stack Flare Gas 14 24701 0.286 10413 (Selected)

Table 2
Line Line Description Line Phase Line Flow rate Mach ρV2 Status
No. Type Size (in) (Kg/hr) No. (kg/ms2)
511 Line from Test Relief Two 14 125802.8 0.451 20402 (Selected)
Line Phase
Manifold RV to
Relief Header
512 Line from HP Relief Two 14 125802.8 0.451 20402 (Selected)
Manifold RV to Line Phase
Relief Header
513 Line from LP Relief Two 14 125802.8 0.451 20402 (Selected)
Manifold RV to Line Phase
Relief Header
502 Line from Test Relief Gas 5 6367 0.386 25806 (Selected)
Line
SEP to Relief
Header
503 Line from HP SEP Relief Gas 5 6367 0.368 23499 (Selected)
Line
to Relief Header
504 Line from LP SEP Relief Gas 5 6367 0.377 24278 (Selected)
Line
to Relief Header
505 Vent from Water Vent Gas 2 NA NA NA (Selected)
Line
Tank to Bund
Wall
506 Line from Surge Relief Gas 3 1000 0.290 12401 (Selected)
Line
vessel 1 to Relief
Header
507 Line from Surge Relief Gas 3 1000 0.290 12401 (Selected)
Line
vessel 2 to Relief
Header
508 Relief Header Relief Gas 24 146903.8 0.283 8871 (Selected)
Line
509 Flare Header Flare Gas 24 40325.6 0.146 2474 (Selected)

510 Flare Stack Flare Gas 24 40325.6 0.142 2540 (Selected)