AFM-IMP-OKL-G10-00078-R01 Overpressure Protection of AP Condensate Flash Drum From Fuel Gas System

THE SHELL PETROLEUM
DEVELOPMENT COMPANY OF NIGERIA
PROCESS CALCULATION
CLIENT THE SHELL PETROLEUM

DEVELOPMENT COMPANY OF
NIGERIA
PROJECT OKOLOMA GAS PLANT AND

PIPELINES
PROJECT NO. P1460
TITLE OVERPRESSURE PROTECTION OF

AP CONDENSATE FLASH DRUM
FROM FUEL GAS SYSTEM
IMPAC DOC NO. CLC-1460-PR-087
IMPAC REVISION A
SPDC DOC NO. AFM-IMP-OKL-G10-00078
SPDC REVISION R01
DATE 06.02.2007
Hohe Bleichen 5 No. 2B Evo Road, GRA

D 20354 Hamburg Phase 2
Phone: + 49 (0) 40 355 440 0 Port Harcourt
Fax: + 49 (0) 40 340 500 Nigeria
E-mail: info@impac.de Phone: (+234) 84-23 39 25
URL: www.impac.de Fax: (+234) 84-46 13 25
SPDC DOC NO.: AFM-IMP-OKL-G10-00078 Rev.: R01
IMPAC DOC NO.: CLC-1460-PR-087 Rev. : A
Date: 06.02.2007
Page 2 of 13
SUMMARY PAGE
CLIENT: THE SHELL PETROLEUM DEVELOPMENT COMPANY OF NIGERIA

PROJECT: Okoloma Gas Plant and Pipelines IMPaC Doc NO: CLC-1460-PR-087
PROJ. NO.: P1460 SPDC DOC NO: AFM-IMP-OKL-G10-00078
TITLE: Overpressure Protection of AP Condensate Flash Drum from Fuel Gas
System
IMPaC CLIENT
REV. No. DATE REASON FOR ISSUE PREP'D DIC IDC BY
APP’L APP'L
SPDC IMPaC BY/ ON BY / ON BY / ON BY / ON BY / ON
R01 A 06.02.07 Issued for Review / Comment LB GHO TS
Review Code and Status (to be filled in by Client)
Code 1 Final – Do not resubmit unless modified.
Revise and Resubmit – Incorporate Comments, Up-Rev and

Code 2 Resubmit. Work May Proceed
Code 3 Review Not Required – Do not resubmit
Rejected – Incorporate Comments, Up-Rev and resubmit. Work

Code 4 may NOT Proceed
Date: Position: Sign:
KEY WORDS: Process, P1460, Okoloma Gas Plant and Pipelines, SPDC The Shell Petroleum Development Company of Nigeria
Filepath: \\LIMBA\Projects\P1460 Afam NAG Plant\C - Process\CLC-1460-PR-087 Overpressure Protection of AP Condensate Flash Drum from Fuel Gas
System\Rev A\CLC-1460-PR-087 Rev A.doc Last Printed: 08.02.2007 9:14
Date: 06.02.2007
Page 3 of 13
TABLE OF CONTENT
1 SUMMARY...............................................................................................................................................4
2 GENERAL ................................................................................................................................................5
2.1 INTRODUCTION ......................................................................................................................5
2.2 OBJECTIVE ..............................................................................................................................6
2.3 ABBREVATIONS ......................................................................................................................6
3 BASIS ......................................................................................................................................................7
3.1 METHOD ..................................................................................................................................7
3.2 ASSUMPTIONS........................................................................................................................7
4 CALCULATION .......................................................................................................................................9
5 RESULT .................................................................................................................................................10
6 CONCLUSION .......................................................................................................................................11
7 REFERENCES.......................................................................................................................................12
8 ATTACHMENTS ....................................................................................................................................13
Filename and Path: \\LIMBA\Projects\P1460 Afam NAG Plant\C - Process\CLC-1460-PR-087 Overpressure Protection of AP Condensate Flash Drum from Fuel
Gas System\Rev A\CLC-1460-PR-087 Rev A.doc
Date: 06.02.2007
Page 4 of 13
1 SUMMARY
This calculation has been performed in response to Utility HAZOP action 8.
The aim is to demonstrate that the downstream equipment (AP Condensate Flash Drum) can not be
over pressured by gas breakthrough from the upstream fuel gas system across the liquid outlet control
valve and its bypass.
The maximum gas mass flow rate from the upstream system by fully open control valves on the liquid
outlet is 11,010 kg/h. However the capacity of the relief valve on the AP Condensate Flash Drum is
13,468 kg/h. Hence the downstream equipment is sufficient protected against over pressurisation.
Date: 06.02.2007
Page 5 of 13
2 GENERAL
2.1 INTRODUCTION
In 2001 the Nigerian Government (under the auspices of the Ministry of Power and Steel) and SPDC
entered into an agreement for the expansion, rehabilitation and operation of the Afam Power Plants
(APP). Following this agreement SPDC will Lease, Operate and Transfer the 276MW Afam V Power
Plant and Build, Operate and Transfer a new 650MW Afam VI Power Plant.
The 240MMscf/d Okoloma Gas Plant and Pipelines scope of the Afam Integrated Project has been
initiated to supply the base load gas requirement of the Afam Power Plants (190MMscf/d) and about
50MMscf/d swing supply to the Aluminum Smelting Company of Nigeria (ALSCON – through the
existing NGC manifold and pipeline).
The scope of work for the Okoloma Gas Plant and Pipelines comprise the following:
• Construction of a new 240MMscf/d gas plant based on the LTX process. The gas plant will
consist of a 240MMscf/d JT-LTX High Pressure train and a 120MMscf/d Twister-LTX Low
Pressure train, condensate stabilisation with off-gas compression, metering, storage and export
facilities.
• Installation of a new Afam Field NAG Manifold and 5 Nos. DN 200 (8’’) flowlines from the Afam
wells to the Afam Field NAG Manifold.
• Installation of a DN 300 (12’’) x 10.6 km NAG Bulkline from the Afam Field NAG Manifold to the
new gas plant.
• Installation of a DN 150 (6”) x 3.1 km Oil Flowline from the Afam Umuosi oil well to Okoloma
Gas Plant.
• Installation of a DN 200 (8”) x 1.2 km flowline from the Obeakpu well to the Okoloma Gas Plant.
• Installation of 2 Nos. DN 200 (8”) x 6.4 km flowlines from the Okoloma wells to the Okoloma
Gas Plant.
• Installation of a DN 400 (16’’) x 2.0 km Sales Gas Line.
• Installation of a DN 200 (8’’) x 11.7 km Condensate Evacuation Pipeline.
• Installation of a DN 100 (4”) x 2.0 km Condensate Return Line from APP.
• Installation of a DN 300 (12”) x 1.6 km Gas Export Line for ALSCON gas supply through the
existing NGC Afam manifold.
Date: 06.02.2007
Page 6 of 13
2.2 OBJECTIVE
This calculation has been performed in response to Utility HAZOP action 8.
If bypass valve on 69-LCV-150 is left open the pressure in the downstream system may rise above the
design pressure by gas blow-by. DEP 80.45.10.10 section 2.2.1 (Ref. 3) states that if a manual bypass
is provided around a control valve then the downstream relief valve should not be sized for coincident
failure of the control valve with the bypass open. However if this were to occur then the test pressure
of the downstream equipment should not be exceeded. Therefore the relief valve should be sized
adequate.
The aim is to demonstrate that the relief valve 51/52-RV-400 on the AP Condensate Flash Drum can
release the mass flow from the fuel gas system if outlets on AP Condensate Flash Drum are blocked
and gas blow-by on 69-LCV-150 and its bypass occur.
2.3 ABBREVATIONS
API American Petroleum Institute
DEP Design and Engineering Practice
DN Diameter Nominal
HCV Hand Control Valve
LCV Level Control Valve
SDV Shutdown Valve
RO Restriction Orifice
RV Relief Valve
Date: 06.02.2007
Page 7 of 13
3 BASIS
Excess flow from the high pressure source ‘fuel gas system’ to the low pressure interface ‘AP
Condensate Flash Drums’ might occur. The design pressure of the fuel gas system is 16.5 barg
whereas the downstream AP Condensate Flash Drums V-5104/5204 are designed to 10 barg. Gas
blow-by across the fuel gas drum level control valve 69-LCV-150 with the restriction orifice 69-RO-150
and its bypass may lead to over pressuring the downstream AP Condensate Flash Drums if their
outlets are blocked. For this highly improbable event that gas breakthrough takes place when both
control valve and the fully open bypass are fully open, the capacity of the relief valve shall be such that
the downstream pressure shall not exceed the hydrotest pressure of the downstream system (Ref. 3).
3.1 METHOD
The rated capacity of the relief valves 51/52-RV-400 on the AP Condensate Flash Drums is 14,701
kg/h each for the fire case (Ref. 1). The set pressure of the relief valves is 10 barg. The permitted
overpressure for the fire case is 121%. For gas breakthrough overpressure of 110% only needs to be
considered. Hence the relief valve capacity is recalculated. Then the maximum gas blow-by rate
through 69-RO-150 and the bypass control valve 69-HCV-002 is calculated. Mass rates below the
relief valve capacity shows that the downstream system is adequate sized to handle the gas blow-by
case. Conservative assumptions are made.
3.2 ASSUMPTIONS
• The maximum pressure in the fuel gas system is 14.5 barg which is the high high pressure alarm
(69-PZAHH-102) which leads to a closure of the shut down valve in the fuel gas supply lines.
• The shut down valve 69-SDV-150 and the level control valve 69-LCV-150 are fully open.
• The orifice size of the restriction orifice 69-RO-150 is assumed with 10 mm (see Attachment 1).
• For the hand control valve 69-HCV-002 a typical valve flow coefficient of 62 is taken (Ref. 2). The
GPSA Data Book gives a Cv of 62 for globe valves, with a body size of 50 mm and a linear flow
characteristic (this is conservative). An equal percentage globe valve has a much lower typical Cv
of 25. The manufacturer of the hand control valve indicated that the Cv value is 21.5 (Ref. 6)
however a Cv of 62 is taken to be conservative.
• The hand control valve 69-HCV-002 is fully open.
• Gas blow-by flow is based on a back pressure of 11 barg.
Date: 06.02.2007
Page 8 of 13
• It is considered that only one AP Condensate Flash Drum is connected to the liquid outlet of the
Fuel Gas Drum V-6901.
• No further hydraulic losses are considered.
Date: 06.02.2007
Page 9 of 13
4 CALCULATION
All calculations are performed with MathCAD Professional 2000.
The correlation between the relief mass flow rate W and the relieving pressure P1 is directly
proportional (see Ref. 7). The relieving pressure for an overpressure of 110% is 12.01 bara and 13.11
bara at 121% (Ref. 1). Hence the actual relief valve capacity is calculated with (14,701 kg/h x 12.01
bara)/13.11 bara = 13,468 kg/h.
The mass rate which flows through the restriction orifice 69-RO-150 is determined by adaptation of
relief valve sizing equations for subcritical vapour flow as per API RP 520 (see Attachment 2).
The mass rate which flows through the hand control valve 69-HCV-002 is calculated by the method
described in the GPSA Data Book (Ref. 2). The calculation is located in Attachment 3.
Both calculated mass rates are added together. The total mass rate is compared to the relief valve capacity
of 13,468 kg/h.
Date: 06.02.2007
Page 10 of 13
5 RESULT
The gas mass flow rate through the restriction orifice 69-RO-150 is 620 kg/h and 10,390 kg/h through
the bypass control valve 69-HCV-002. In total the gas breakthrough from the liquid outlet of the fuel
gas system to the AP Condensate Flash Drum is 11,010 kg/h. However the capacity of the relief valve
on the AP Condensate Flash Drum is 13,468 kg/h. Hence the downstream equipment is sufficient
protected against over pressurisation.
Date: 06.02.2007
Page 11 of 13
6 CONCLUSION
The relief valve size on the AP Condensate Flash Drums 51/52-RV-400 are adequately sized for worst
case gas blow-by from the fuel gas system.
Date: 06.02.2007
Page 12 of 13
7 REFERENCES
1. Safety Valve Data Sheets, AFM-OKL-22662-C08-00001-R03
2. GPSA Data Book, 11. Edition, section 4
3. Shell DEP 80.45.10.10-Gen., Pressure Relief, Emergency Depressuring, Flare and Vent Systems
4. Fuel Gas System Sizing, AFM-IMP-OKL-G10-00052-C01
5. Datasheet for Restriction Orifices, AFM-IMP-OKL-H01-00203-A01
6. Email M. Jurriëns (Hoogveld) to L. Böck (IMPaC), PP41.2: HAZOP actions on Fuel Gas Package,
06.02.2007
7. AP Condensate Flash Drum Relief Valves 51/52-RV-400 Sizing Calculation, AFM-IMP-OKL-G10-

00047-C01
Date: 06.02.2007
Page 13 of 13
8 ATTACHMENTS
Attachment 1: Orifice size sizing of 69-RO-150 for liquid service
Attachment 2: Mass Flow through 69-RO-150
Attachment 3: Mass Flow through 69-HCV-002
IMPaC Offshore Engineering
ORIFICE SIZING ATTACHMENT 1
Okoloma Gas Plant and Pipelines
DOC. NO: AFM-IMP-OKL-G10-00078 06.02.2007
IMPaC DOC. NO: CLC-1460-PR-087 Rev. A / R01
Page 1 of 1
ORIFICE SIZING
in Liquid Service
69-RO-150
In accordance to Bernoulli's principle
5
bar ≡ 10 ⋅ Pa
Input data:
3
m
Actual volume flow: Q := 8.684 ⋅ acc. to Ref. 4, Attachment 3
hr
Effective coefficient of discharge: Cd := 0.65 NOTE: For preliminary sizing use.
kg
Mass density: ρ := 658.6 ⋅ acc. to Ref. 5
3
m
Orifice inlet pressure: P1 := 11.5 ⋅ bar acc. to Ref. 5
Orifice outlet pressure: P2 := 0.5 ⋅ bar acc. to Ref. 5
Calculation:
Q 2
Required orifice diameter: A := A = 64.210 mm
2
Cd ⋅
ρ
(
⋅ P1 − P2 )
Q⋅4
Orifice diameter: dRO := dRO = 9.04 mm
2
πCd ⋅
ρ
(
⋅ P1 − P2 )
Selected: dRO := 10 ⋅ mm
2
π ⋅ dRO 2
Orifice diameter: ARO := ARO = 78.540 mm
4
GAS MASS FLOW THROUGH ATTACHMENT 2
Okoloma Gas Plant and Pipelines ORIFICE
acc. to API RP 520 Rev. A / R01
IMPaC DOC. NO: CLC-1460-PR-087
Page 1 of 2
Determination of Gas Mass Flow through

Restriction Orifice in Event of Gas Breakthrough
69-RO-150
In accordance to API RP 520 Part I
For Subcritical Flow
Input data: 5
bar ≡ 10 ⋅ Pa
Process data:
2
Orifice diameter: ARO := 78.54 ⋅ mm see Attachment 1
Molecular weight of the fluid at inlet

conditions: M := 19.82 acc. to Ref. 4
Compressibility factor at inlet Z := 0.93934 acc. to Ref. 4

conditions:
Ratio of specific heats (Cp/Cv): k := 1.2412 acc. to Ref. 4
Relieving temperature of the inlet T := 10 ⋅ K + 273.15 ⋅ K acc. to Ref. 4 T = 283.15 K

fluid:
Atmospheric pressure: p0 := 1.01325 ⋅ bar
Set pressure (gauge): PS := 14.5 ⋅ bar Pressure of 69-PZAHH-102
Superimposed back pressure: PsB := 0 ⋅ bar assumed
Relief valve set pressure of 51/52-RV-400 plus

Built-up back pressure: PbB := 11 ⋅ bar 10% accumulation
Back pressure: PB := PsB + PbB PB = 11.000 bar
Permitted accumulation acu := 0% conservativ assumption

(overpressure):
Correction factors:
Combination correction factor for Kc := 1.0

installations with a rupture disk
upstream of the pressure relief valve:
Effective coefficient of discharge: Kd := 1 most conservative assumption

Okoloma Gas Plant and Pipelines ORIFICE
acc. to API RP 520 Rev. A / R01
Page 2 of 2
Calculation:
Upstream relieving pressure: P1 := P S ⋅ ( 1 + acu) + p0 P1 = 15.513 bar
k
k− 1
Pcf := P1 ⋅ 
 2 
Critical flow nozzle pressure:  Pcf = 8.634 bar
 k + 1
CHECK flow behavior: Check := "Critical flow" if PB ≤ Pcf − p0
"Subcritical flow" otherwise
Check = "Subcritical flow"
k+ 1
Coefficient determined by the ratio
k− 1
of the specific heats of the fluid at
C := 520 ⋅ k ⋅ 
 2 
inlet relieving conditions:  C = 341
 k + 1
NOTE: Where k cannot be determined, it is
suggested that a value of C equal to
315 be used.
Permitted built-up back pressure: PBper := 10% ⋅ PS PBper = 1.450 bar
Total back pressure: P2 := P B + P Bper P2 = 12.450 bar
P2 + p0
Ratio of back pressure to upstream r := r = 0.868
relieving pressure: P1
k− 1
2
k
 k  ⋅r k ⋅ 1 − r
F2 := 
Coefficient of subcritical flow:  F2 = 0.918
 k − 1 1−r
Gas mass flow rate through ARO ⋅ 735 ⋅ F2 ⋅ Kd ⋅ Kc lb

W := ⋅ kg
restriction orifice: 2 2 W = 619.745
Z ⋅ T ⋅ 1.8 ⋅ psi hr ⋅ in hr
(
M ⋅ P1 ⋅ P 1 − P2 − p0 ⋅ K )
NOTE: Formula with unit correction.
Okoloma Gas Plant and Pipelines CONTROL VALVE
acc. to GPSA Data Book Rev. A / R01
Page 1 of 2
GAS BLOW-BY
at Control Valve in Liquid Service
69-HCV-002
acc. to GPSA Data Book, section 4
Unit converters:
5
bar ≡ 10 ⋅ Pa
gal
USgpm :=
min
Input data:
Valve flow coefficient: Cv := 62 ⋅ USgpm typical Cv as per GPSA Data Book
Numerical constant (N eight): N8 := 0.948 NOTE: acc. to GPSA, 11. Ed., Fig. 4-31
Piping geometry factor: FP := 1 conservative assumption
Upstream static pressure (abs): P1 := 15.513 ⋅ bar Pressure of 69-PZAHH-102
Relief valve set pressure of 51/52-RV-400 plus

Downstream static pressure (abs): P2 := 12.013 ⋅ bar 10% accumulation
Ratio of specific heats [Cp /(Cp -R)]: k := 1.2412 acc. to Ref. 4
Compressibility factor: Z := 0.93934 acc. to Ref. 4
Molecular weight: M := 19.82 acc. to Ref. 4
Absolute temperature of gas at T := 10 ⋅ K + 273.15 ⋅ K acc. to Ref. 4 T = 283.150 K

inlet:
conservative assumption
Valve flow characteristic: linear
Nominal body size: DN := 50
Pressure drop ratio for the subject

valve at critical flow, with Fk = 1.0: Xc := 0.7 typical Xc as per GPSA Data Book
Okoloma Gas Plant and Pipelines CONTROL VALVE
acc. to GPSA Data Book Rev. A / R01
Page 2 of 2
Calculation of Mass Flow for Gas Blow-by Case:

k
Ratio of specific heats factor: Fk := Fk = 0.887
1.4
Ratio of pressure drop to  P1 − P2 

absolute inlet pressure: X := min  , Fk ⋅ Xc X = 0.226
 P1 
Expansion factor, ratio of flow

coefficient for a gas to that for a  X 
Y := max  0.67 , 1 −  Y = 0.879
liquid at the same Reynolds number:  3 ⋅ Fk ⋅ X c 
X ⋅M kg
Mass flow: w := N8 ⋅ FP ⋅ Cv ⋅ P1 ⋅ Y ⋅ ⋅K ⋅
T ⋅Z 3
10 ⋅ Pa ⋅ USgpm ⋅ hr
NOTE: Formula with Unit correction. kg

w = 10389.9
hr

AFM-IMP-OKL-G10-00078-R01 Overpressure Protection of AP Condensate Flash Drum From Fuel Gas System

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THE SHELL PETROLEUM

DEVELOPMENT COMPANY OF NIGERIA

CLIENT THE SHELL PETROLEUM

PROJECT OKOLOMA GAS PLANT AND

PROJECT NO. P1460

TITLE OVERPRESSURE PROTECTION OF

IMPAC DOC NO. CLC-1460-PR-087

SPDC DOC NO. AFM-IMP-OKL-G10-00078

SPDC REVISION R01

Hohe Bleichen 5 No. 2B Evo Road, GRA

CLIENT: THE SHELL PETROLEUM DEVELOPMENT COMPANY OF NIGERIA

R01 A 06.02.07 Issued for Review / Comment LB GHO TS

Review Code and Status (to be filled in by Client)

Code 1 Final – Do not resubmit unless modified.

Revise and Resubmit – Incorporate Comments, Up-Rev and

Code 3 Review Not Required – Do not resubmit

Rejected – Incorporate Comments, Up-Rev and resubmit. Work

This calculation has been performed in response to Utility HAZOP action 8.

• Installation of a DN 400 (16’’) x 2.0 km Sales Gas Line.

• Installation of a DN 200 (8’’) x 11.7 km Condensate Evacuation Pipeline.

• Installation of a DN 100 (4”) x 2.0 km Condensate Return Line from APP.

This calculation has been performed in response to Utility HAZOP action 8.

API American Petroleum Institute

DEP Design and Engineering Practice

HCV Hand Control Valve

LCV Level Control Valve

SDV Shutdown Valve

• The hand control valve 69-HCV-002 is fully open.

• Gas blow-by flow is based on a back pressure of 11 barg.

• No further hydraulic losses are considered.

All calculations are performed with MathCAD Professional 2000.

1. Safety Valve Data Sheets, AFM-OKL-22662-C08-00001-R03

2. GPSA Data Book, 11. Edition, section 4

4. Fuel Gas System Sizing, AFM-IMP-OKL-G10-00052-C01

5. Datasheet for Restriction Orifices, AFM-IMP-OKL-H01-00203-A01

7. AP Condensate Flash Drum Relief Valves 51/52-RV-400 Sizing Calculation, AFM-IMP-OKL-G10-

Attachment 1: Orifice size sizing of 69-RO-150 for liquid service

Attachment 2: Mass Flow through 69-RO-150

Attachment 3: Mass Flow through 69-HCV-002

Effective coefficient of discharge: Cd := 0.65 NOTE: For preliminary sizing use.

Orifice inlet pressure: P1 := 11.5 ⋅ bar acc. to Ref. 5

Orifice outlet pressure: P2 := 0.5 ⋅ bar acc. to Ref. 5

Determination of Gas Mass Flow through

For Subcritical Flow

Molecular weight of the fluid at inlet

Compressibility factor at inlet Z := 0.93934 acc. to Ref. 4

Ratio of specific heats (Cp/Cv): k := 1.2412 acc. to Ref. 4

Relieving temperature of the inlet T := 10 ⋅ K + 273.15 ⋅ K acc. to Ref. 4 T = 283.15 K

Atmospheric pressure: p0 := 1.01325 ⋅ bar

Set pressure (gauge): PS := 14.5 ⋅ bar Pressure of 69-PZAHH-102

Superimposed back pressure: PsB := 0 ⋅ bar assumed

Relief valve set pressure of 51/52-RV-400 plus

Back pressure: PB := PsB + PbB PB = 11.000 bar

Permitted accumulation acu := 0% conservativ assumption

Combination correction factor for Kc := 1.0

Effective coefficient of discharge: Kd := 1 most conservative assumption

CHECK flow behavior: Check := "Critical flow" if PB ≤ Pcf − p0

"Subcritical flow" otherwise

Check = "Subcritical flow"

Permitted built-up back pressure: PBper := 10% ⋅ PS PBper = 1.450 bar

Total back pressure: P2 := P B + P Bper P2 = 12.450 bar

Gas mass flow rate through ARO ⋅ 735 ⋅ F2 ⋅ Kd ⋅ Kc lb

Piping geometry factor: FP := 1 conservative assumption