CAL-00-P-0006 Rev A - Vessel Sizing

Contents

1. Summary.................................................................................................................. 3
2. Objective .................................................................................................................. 3
3. Method..................................................................................................................... 3
4. Inputs/Assumptions .................................................................................................. 4
5. References ............................................................................................................... 4
6. Calculations .............................................................................................................. 4
6.1 Design Case...................................................................................................... 4
6.2 Dimensions Based on Vapour Flow..................................................................... 5
6.2.1 Vessel Diameter............................................................................................ 5
6.2.2 Vessel Length ............................................................................................... 6
6.3 Dimensions Based on Liquid Residence Time ...................................................... 6
6.3.1 Liquid Residence Time................................................................................... 6
6.3.2 Vessel Diameter and Length .......................................................................... 6
6.4 Required Vessel Dimensions .............................................................................. 7
6.5 Nozzle Sizings ................................................................................................... 7
6.5.1 Gas Nozzles .................................................................................................. 7
6.5.2 Feed Nozzles ................................................................................................ 7
6.5.3 Liquid Nozzles............................................................................................... 8
7 Results ..................................................................................................................... 8
Appendix A – Flash Calculation .......................................................................................... 9

List of Figures

Figure 1 – Phase 1 – V-5702 Flash Calculation .................................................................. 10

Figure 2 –Phase 2 – V-5702 Flash Calculation ................................................................... 11

List of Tables

Table 1 - Summary ........................................................................................................... 3

Table 2 – Phase 1 and Phase 2 Actual Volume Flows........................................................... 5
Table 3 – Summary of Results ........................................................................................... 8

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1. Summary

This calculation determines the dimensions and nozzle sizes of vessel V-5702.

All calculations are based on the Design Case of greatest combined vapour and liquid flow.
Minimum nozzle sizes have been calculated such that the maximum ρV2 is 3750 kg/ms2 for
the feed and gas, and maximum liquid velocity is 1 m/s. Vessel length and required volume
for 10 minute liquid residence time are based on rules-of-thumb for drum type vessels
(Reference 1). This will be sufficient to allow on/off level control as may be required.

A summary of results is shown below in Table 1. Nominal bore sizes shown correspond to
Schedule 80 pipe dimensions. The calculated minimum gas nozzle size was less than 2”.
However piping smaller than N.B. 2” will not be used.

Table 1 - Summary
Parameter V-5702
Phase 2
Design Case Vapour flow 25.67 Am3/h
Liquid flow 8.66 Am3/h)
Vessel diameter (m) 1.35
Vessel length, tan-to-tan (m) 4.03
Required volume for 10 min
1.443
liquid residence time (m3)
14
Gas nozzle – minimum I.D. (mm)
(Schedule 80, N.B. ¾ increase to 2”)
55
Feed nozzle – minimum I.D. (mm)
(Schedule 80, N.B. 2½”, increase to 3”)
96
Liquid nozzle – minimum I.D. (mm)
(Schedule 80, N.B. 4”)

2. Objective

The objective of this calculation is to determine vessel dimensions of V-5702. Diameter,

length, residence time and nozzle sizes will be considered.

3. Method

• Determine design case for V-5702.

• Flash calculation (refer to Figure 1 and Figure 2).
• Diameter based on GPSA (Reference 2) required for good vapour/liquid separation.
Length based on Rules-of-Thumb length on diameter ratio (Reference 1).
• Liquid residence time calculation. Dimensions (diameter and length) to satisfy Rules-
of-Thumb liquid hold-up criteria and length on diameter ratio (Reference 1).
• Compare vessel dimensions calculated via the 2 methods and choose which is
appropriate.
• Nozzle sizing calculations.

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4. Inputs/Assumptions

• Assume vessel is vertical. This is suitable for high gas to liquid flow rate.
• Data from Hysys Simulation Rev E (refer to Figure 1 and Figure 2).
o Gas exiting V-5702 is at atmospheric pressure. This is the worst case for
vapour production calculation.
o Pressure drop across V-5702 is 34.5 kPa (5 psi).
• K-factor for vertical separators without women wire demisters (for sizing vessel
diameter).
• Required vessel liquid hold-up is 10 times the liquid volume passing per minute.
• Vessel volume required for 10 minute liquid hold-up is 25% of the total vessel
volume.
• Assume maximum allowable ρV2 for feed nozzles is 3750 kg/ms2, the same as
recommended for the gas nozzles by GPSA (Reference 2).

5. References

1. 2002, “Experienced-Based Rules of Chemical Engineering”. Retrieved from The

Chemical Engineers’ Resource Page, www.cheresources.com.
2. GPSA 1994, “Engineering Data Book – Volume I – Sections 1-16”.

6. Calculations

6.1 Design Case

The design case was set up in Hysys as follows:

• Flow through one (50%) train:
o For Phase 1, condensate flow from filter V-1003 and scrubbers V-1000, V-
1001 and V-1002 were combined to create the flow through the condensate
lines of one train.
o For Phase 2, condensate flow from filter V-1003 and scrubbers V-1000, V-
1001, V-1002, V-2000 and V-2001 were combined to create the flow through
the condensate lines of one train.
• Total flow through 3 (50%) trains:
o Flows through single 50% trains for Phases 1 and 2 were multiplied by 3 to
give the total flow through the 3 trains.
o This flow is passed through V-5702 which has been allowed a pressure drop
of 34.5 kPa (5 psi).
o The vapour exits V-5702 at atmospheric pressure (0 kpag).

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Table 2 below shows the total gas and liquid volume flows for the combined condensate
streams. This data is taken from Figure 1 and Figure 2.

Table 2 – Phase 1 and Phase 2 Actual Volume Flows

Phase 1 Phase 2
3
Vapour AGVF (m /h) 8.42 25.67
3
Liquid ALVF (m /h) 3.09 8.66
Total ATVF 11.51 34.33

The design case is that which has the greatest combined gas and liquid flow. Thus Phase 2
will be used as the design case.

6.2 Dimensions Based on Vapour Flow

6.2.1 Vessel Diameter

Calculate the maximum allowable vapour velocity to allow sufficient vapour / liquid separation
(using equations as given in GPSA, Reference 2):
ρl - ρ g
Va = K
ρg
Where
Va = vapour velocity
K = factor for sizing woven wire demisters
ρl = liquid density
ρg = vapour density

Note:
• K factor: Separator with horizontal pad at atmospheric pressure, K = 0.36. K factor is
halved (to K = 0.18) for sizing of vertical separators when they do not have woven
wire demisters, as in this case. Reference 2, Figure 7.9.

The calculation is as follows.

Substitution gives
925.7 - 1.277
Va = 0.18 = 4.84 ft = 1.476 m = 5,314 m
1.277 s s hr

Actual vapour flowrate, Q = 25.67 Am3/h as given in Table 2. This will be multiplied by a
factor of 2 to be conservative. Thus, Q = 2 x 25.67 m3/h = 51.34 m3/h at V-5702 inlet
conditions.

Calculate the diameter required:

Q πD 2
A= and A =
Va 4

Hence
3
4Q 4 x 51.34 m
D= = hr = 0.11m
πVa π x 5,314 m
hr

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6.2.2 Vessel Length

Vessel length is determined by multiplying the calculated diameter by 3 (Reference 1). For
length
drum type vessels, the optimum ratio is usually 3 (range of 2.5 to 5).
diameter

The calculation is as follows:

L = D x 3 = 0.11 x 3 = 0.33m

6.3 Dimensions Based on Liquid Residence Time

6.3.1 Liquid Residence Time

Liquid residence times are determined by dividing the required liquid hold-up volume by the
actual liquid flow. We will design V-5702 as for drum type vessels / knockout drums in front
of compressors. These should be designed for a hold-up of 10 times the liquid volume
passing per minute (Reference 1).

The required vessel volume is:

Required vessel volume =  8.66 m

3  h (10 min ) = 1.44m 3 for 10min hold-up
h 
  60min 

6.3.2 Vessel Diameter and Length

The required vessel volume for 10 minute liquid hold-up is 25% of the total vessel volume.
Thus, the total vessel volume is:
Required vessel volume = 4 x 1.44 m3 = 5.77 m3

length
A vessel internal diameter of 1.35 m was chosen such that the ratio is
diameter
approximately 3.

The vessel height is calculated as follows:

Volume V 5.77m 3
Height = = = = 4.03m
Area π (1.35m)
2 2
πD
4 4

length
The ratio is:
diameter
L 4.03
= = 2.99
D 1.35

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6.4 Required Vessel Dimensions

With reference to Sections 6.2.1, 6.2.2 and 6.3.2, the required vessel dimensions are the
larger set calculated in Section 6.3.2. If the diameter calculated in Section 6.2.1 were used,
the resulting vessel height to accommodate for the liquid hold-up only (noting that liquid
hold-up comprises 25% of vessel volume) would be 149 m. Vapour velocity is not a criteria
for determination of vessel diameter. Thus the internal diameter of the vessel needs to be
1.35 m and the tan-to-tan length of the vessel needs to be 4.03 m.

6.5 Nozzle Sizings

6.5.1 Gas Nozzles

The calculation for V-5702 gas nozzle is shown below:

• Maximum allowable ρV2 = 3750 kg/ms2 (Reference 2).
ρV 2 3750
• Gas velocity, V = = = 62.75 m
ρ 0.952 s

Q πD 2
• A= where Q = 34.42 m3/h at atmospheric pressure and A= so
V 4
m3 h
4 x 34.42 x
4Q h 3600s
D= = = 14mm
πV m
π x 62.75
s
• This minimum I.D. corresponds to a nominal bore of ¾” for Schedule 80 pipe. The
minimum pipe diameter that will be used is 2” for support span reasons.

6.5.2 Feed Nozzles

The calculation for V-5702 feed nozzle is shown below:

• Maximum allowable ρV2 = 3750 kg/ms2 (assume this to be the same as for gas
nozzle).
ρV 2 3750
• Feed velocity, V = = = 4.00 m
ρ 234.4 s

m3 h
4 x 34.33
x
Q πD 2 4Q h 3600s
• A= and A = so D = = = 55mm
V 4 πV m
π x 4.00
s
• This minimum I.D. corresponds to a nominal bore of 2½” for Schedule 80 pipe. This
will be increased to N.B. 3”.

Note:
(Actual vapour volume flow x ρ g ) + (Actual liquid volume flow x ρ L )
• Feed density, ρ f =
Actual vapour volume flow + Actual liquid volume flow

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6.5.3 Liquid Nozzles

The calculation for V-5702 liquid nozzle is shown below:

• Maximum allowable liquid velocity, V = 1 m/s (Reference 2).
• Allow liquid flow rate to be 3 times the actual liquid volume flow, to allow for greater
3
flows for on / off level control. Q L = 3 x 8.66 = 25.97 m .
h
m3 h
4 x 25.97 x
Q πD 2
4Q h 3600s = 96mm
• A= and A = so D = =
V 4 πV m
π x1
s
• This minimum I.D. corresponds to a nominal bore of 4” for Schedule 80 pipe.

7 Results

A summary of the pertinent results is shown below in Table 3.

Table 3 – Summary of Results

Parameter V-5702
Phase 2
Design Case Vapour flow 25.67 Am3/h
Liquid flow 8.66 Am3/h)
Vessel diameter (m) 1.35
Vessel length, tan-to-tan (m) 4.03
Required volume for 10 min
1.443
liquid residence time (m3)
14
Gas nozzle – minimum I.D. (mm)
(Schedule 80, N.B. ¾” increase to 2”)
55
Feed nozzle – minimum I.D. (mm)
(Schedule 80, N.B. 2½” increase to 3”)
96
Liquid nozzle – minimum I.D. (mm)
(Schedule 80, N.B. 4”)

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Appendix A – Flash Calculation

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Figure 1 – Phase 1 – V-5702 Flash Calculation

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Figure 2 –Phase 2 – V-5702 Flash Calculation

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