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Heat Transfer Systems Calculation

Technical Report · December 2016

DOI: 10.13140/RG.2.2.35221.12000

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 Error! No text of specified style in document. Calculation
Prakash Thapa
Centre for Risk, Integrity and Safety Engineering (C-RISE)
Faculty of Engineering & Applied Science
Memorial University, St John’s, NL, A1B 3X5, Canada

Introduction

The following information is necessary to design a heat transfer system:

1. Number of heat users.
2. Heat duty or information required to calculate the heat duty for each user.
3. Operating temperature of each user.
4. Design pressure drop through the heat exchange equipment for each user.
Heat Transfer Fluid
The following information is required for the selected heat transfer fluid:
1. Specific gravity, viscosity, heat capacity, vapor pressure, and thermal conductivity for the
temperature range being considered.
2. Any manufacturers' curves for film coefficients and/or pressure drops that may be
available.
Heat Transfer System
The following procedure describes the design of a heat transfer system. This shall be used as a
guideline and is not meant to replace the design engineer's judgment and experience.
1. Determine the design parameters for the heat users.
2. Calculate the heat duty and set the maximum temperature of each user.
The heat duty of each user shall be calculated or set for design. Equations (23) and/or (24) may be
used to calculate the process heat duty if it is unknown. The heat loss from each user and the heat
loss from the piping system may be calculated from Equation (5) with Equations (31), (32) and (33),
and added. Alternatively, the heat loss could be estimated as 10 percent of the process heat if
uninsulated and zero if insulated. The maximum temperature of each user shall also be set for
design.
3. Set system minimum operating temperature.
The system minimum operating temperature can now be set and shall be approximately 30C
(50F) above the highest user operating temperature. The approach temperature on
individual heat exchangers shall be set at approximately 15C (25F).
4. Select heat transfer fluid.
Select either steam or a liquid heat transfer fluid, with the system operating temperature at
least 30C (50F) below the bulk fluid maximum allowable temperature stated by the fluid
manufacturer.
5. Estimate total system heat duty.
Estimate the system heat duty by summing the process duties of all users and adding 10 to 15
percent for heat losses in the system piping.
6. Calculate the flow rate of the heat transfer fluid at several maximum fluid temperatures.
7. Calculate the fluid flow rate to each user.
Calculate the fluid flow rate to each user, with the heat transfer fluid cooling from the normal
operating temperature and using the approach temperature set in step 3. For steam systems,
since only latent heat is used, the fluid outlet temperature remains the same. Calculate the
 system heat transfer fluid flow rate (liquid systems), by summing the fluid flow rates to all
users. Minimum flow rates are limited by available heater sizes to a minimum flow
approximately 3.4 m3/hr (15 gpm).
8. Size flow lines.
Size all flow lines for a liquid velocity between 1.2 and 3 m/sec (4 and 10 ft/sec) for liquid
media and 45 m/sec (150 ft/sec) velocity for steam. Choose the next standard pipe size
above the calculated diameter.
9. Calculate heat lost to atmosphere.
Estimate the surface area of each size of pipe, each user exchanger, and the heater. Then
calculate the heat lost to atmosphere for the system by applying Equations (5), (31) (32), and
(33) to each pipe size and exchanger. The total of the individual heat losses is the system
heat loss.
10. Calculate total system heat duty.
Add the system heat loss to the sum of the user duties and compare this to the estimated heat
duty from step 5. If the calculated system heat duty is greater than the estimated value from
step 5, then add 10 percent to the calculated total system heat duty and proceed to step 11.
Otherwise use the original estimate.
11a. Calculate pressure drops. (Liquid Systems)
For liquid heat transfer fluids, calculate the heater pressure drop and each user loop
pressure drop. Use the loop with the largest pressure drop to specify the pump flow
rate and differential pressure. Be sure to allow for any elevation changes within the
system and for pressure drop through control valves.
11b. Calculate pressure drops. (Steam Systems)
For steam systems, calculate the pressure drops of the mains and branch lines. Check temperatures
at the calculated pressures to verify that they remain above user temperatures. For gravity flow
systems, verify that pressure drops do not prevent flow of condensate back to the heater.
12. Estimate system volume and size expansion tank.
Estimate the system volume and obtain the fluid density at the ambient temperature, the
system minimum temperature, and the system maximum temperature. Size an expansion
tank that is approximately one third full at the system minimum temperature and less than
two thirds full at the system maximum temperature.
User Required Heat Transfer Surface Areas
The surface areas of the various users in a heat transfer system are generally calculated by the
manufacturer. However, it is good engineering practice to check this calculation when equipment is
being quoted for purchase. As stated previously, the shell-and-tube exchanger is the most common
heat user on production units and therefore will be used as an example for checking user required
surface areas.
To perform this check, the following information is required:
1. Heat duty being exchanged
2. Temperature of the fluid entering and leaving the shell side of the exchanger
3. Temperature of the fluid entering and leaving the tube side of the exchanger
4. Type of fluids involved
5. Flow rate of each fluid
6. Size and number of tubes
7. Baffle spacing and number of tube runs

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The surface area will be checked by using the size and number of tubes being supplied and then
calculating the heat transfer rate. This rate will then be compared to the required rate.
The following procedure describes a method for checking the surface area of a shell-and-tube
exchanger:
1. Check the required heat load using the equations for sensible and latent heat [Equations
(23) and (24)].
2. Calculate the Log Mean Temperature Difference (LMTD) using Equation (9).
3. Calculate the inside film coefficient using Equation (10).
4. Calculate the outside film coefficient using Equation (17).
5. Calculate the tube wall resistance using Equation (22).
6. Calculate the overall heat transfer coefficient using Equation (6).
7. Calculate the heat duty by using Equation (5).
8. Compare the results of step 7 with the required heat load.

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Appendix A: Nomenclature
A Heat transfer area, m2 (ft2)
Ai Tube inside surface area per unit length of pipe, m2/m (ft2/ft)
Ao Tube outside surface area, m2/m (ft2/ft)
BL Baffle leakage factor
bs Baffle spacing, cm (in)
C Fluid heat capacity, J/kg C (Btu/lb F)
c Tube clearance, cm (in)
Cg Gas heat capacity, J/std m3 C (Btu/MSCF F)
Co Oil heat capacity, J/kg F (Btu/lb F)
Cp Heat capacity at constant pressure, J/kg C (Btu/lb F)
D Pipe diameter, m (ft)
De Equivalent diameter, m (ft)
Di Tube or shell inside diameter, m (ft)
dI Shell or pipe inside diameter, cm (in)
Do Outside diameter of circular tube, m (ft)
do Pipe outside diameter, cm (in)
Ef Fin efficiency for finned tubes
f Moody friction factor
G Mass velocity of fluid, kg/hr m2 (lb/hr ft2)
Gmax Maximum mass velocity of fluid, kg/hr m2 (lb/hr ft2)
h Film coefficient, W/m2 C, (Btu/hr ft2 F)
ha Atmospheric film coefficient, W/m2 C (Btu/hr ft2 F)
hi Inside film coefficient, W/m2 C (Btu/hr ft2 F)
ho Outside film coefficient, W/m2 C (Btu/hr ft2 F)
K Constant
k Thermal conductivity, W/m C (Btu/hr ft F)
ki Insulation thermal conductivity, W/m C (Btu/hr ft F)
ko Thermal conductivity at 0F, W/m C (Btu/hr ft F)
ks Pipe wall or plate thermal conductivity, W/m C (Btu/hr ft F)
L Length of tubes (pipe), m (ft)
lc Baffle cut, cm (in)
Le Equivalent length of pipe, m (ft)
LMT Log mean temperature difference, C (F)
D
NR Number of tube rows
NT Number of tubes
P Gas pressure, kpa (psia)
Pc Gas pseudo-critical pressure, kpa (psia)
pP Center-to-center spacing of tubes measured parallel to flow, cm (in)
Pr Gas reduced pressure
Pt Tube pitch, cm (in)
q Heat transfer rate, W (Btu/hr)
Qg Gas flow rate, std m3/hr (MMSCFD)
qg Gas heat duty, W (Btu/hr)
Ql Liquid flow rate, m3/hr (BPD)
qlh Latent heat duty, W (Btu/hr)
Qo Oil flow rate, m3/hr (BPD)
qo Oil heat duty, W (Btu/hr)
qp Overall heat duty, W (Btu/hr)
qsh Sensible heat duty, W (Btu/hr)
Qw Water flow rate, m3/hr (BPD)
qw Water heat duty, W (Btu/hr)
Re Reynolds number
Ri Inside fouling resistance, m2 C/W (hr ft 2 F/Btu)
Ro Outside fouling resistance, m2 C/W (hr ft 2 F/Btu)
Rw Tube wall resistance, m2 C/W (hr ft2 F/Btu)
S Gas specific gravity
SG Oil specific gravity
t Distance heat energy is conducted, m (ft)
T1 Hot fluid inlet temperature, C (F)
T2 Hot fluid outlet temperature, C (F)
T3 Cold fluid inlet temperature, C (F)
T4 Cold fluid outlet temperature, C (F)
Ta Gas average temperature, K (R)
Tc Gas pseudo-critical temperature, K (R)
Tf Film temperature at inside tube wall, C (F)
Tib Cold inside bulk temperature, C (F)
ti Insulation thickness, m (ft)
Tob Hot outside bulk temperature, C (F)
Tr Gas reduced temperature
ts Pipe wall thickness, m (ft)
Tw Tube wall temperature, C (F)
U Overall heat transfer coefficient, W/m2 C (Btu/hr ft2 F)
Uw Overall heat transfer coefficient, W/m2 C (Btu/hr ft2 F)
V Fluid velocity, m/sec (ft/sec)
V Specific volume for fluid, m3/kg (ft3/lb)
Vw Wind velocity, m/sec (ft/sec)
W Mass flow rate, kg/hr (lb/hr)
y Coefficient of thermal expansion, 1/C (1/F)
y Constant denoting change in thermal conductivity per degree change in temperature
Cp Heat capacity correction factor for pressures other than atmospheric pressure, J/kg-mol C
(Btu/lb-mol F)
P Pressure drop, kpa (psi)
T Temperature difference, C (F)
T1 Larger temperature difference, C (F)
T2 Smaller temperature difference, C (F)

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 Pipe roughness, cm (in)
 Latent heat, J/kg (Btu/lb)
 Viscosity, Pa-sec (cp)
e Fluid viscosity, Pa-sec (lb/hr ft)
ew Fluid viscosity at tube wall, Pa-sec (lb/hr ft)
v Kinematic viscosity, mm2/sec (cs)
 Density, kg/m3 (lb/ft3)
 Density, kg/m3 (lb/gal)

Appendix B: Heat Transfer System Example Problem (Metric)

The following is an example design of a heat transfer system for an offshore platform.
Required:
Design a heat transfer system to provide a platform with all necessary heating.
Solution:
Step 1: Determine Design Parameters for Heat Users
Heat users in system.
Glycol reboiler - One
1.70 m3/hr glycol reboiler requiring 5.575 x 108 J/m3 at 204C
HP flowline heaters - Six
7150 std m3 at 0.63 SG
T1 = 54C
T2 = 79C
Cp = 3470 J/kgk
LP flowline heaters - Four
7150 std m3/hr at 0.63 SG
T1 = 43C
T2 = 63C
Cp = 3180 J/kgk
Watermaker - One
The 0.151 m3/hr water at 2.509 x 109 J/m3 boils at 82C
All equipment except the glycol reboiler is on the same deck at what will be called zero elevation.
The glycol reboiler is on the upper level at an elevation of plus 9.1 m.
Step 2: Calculate Heat Duty and Maximum Temperature of Each User
Glycol reboiler
  
q  5.575  10 8 J / m 3 1.70m 3 / hr
Joules hr
 9.48  10 8  263,000W
hr 3600sec
Maximum Temperature = 204F
HP flowline heaters
0.6329lb
q sh  7150 std m 3 / hr
mole
3
mole
0.4536 kg / lb 
3470 J
o
79 - 54 o C
hr
3600 sec
10.87 std m kg C
= 131,400 W each
Maximum Temperature = 79C
LP flowline heaters

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 0.63 29 lb
q sh  7150 std m 3 / hr
mole
3
mole
  
0.4536 kg / lb  3180 J / kg o C 63 - 43o C
hr
3600 sec
10.87 std m
= 96,300 W each
Maximum Temperature = 63C
Watermaker
q = (2.509 x 109 J/m3) (0.151 m3/hr)
Joules hr
 3.789  108
hr 3600 sec
= 105,000 W
Maximum Temperature = 82C.
Step 3: Set Minimum System Temperature
Maximum user temperature = 204C (Glycol Reboiler)
Set the minimum system temperature at 232C
Step 4: Select Heat Transfer Fluid
Select Monsanto Therminol 66. (From vendor data, Therminol 66 has a maximum bulk temperature
of 343C)
Step 5: Estimate Total System Heat Duty
System of the heat duty estimate
q  1.15 263 kW   6 131 kW   4 96.3 kW   105 kW 
 1,770 kW
 1,770,000 W
Step 6: Calculate the Flow Rate of the Heat Transfer Fluid at Several Maximum Fluid
Temperatures
Therminol 66
Maximum Bulk Temperature = 343C
W C p T2 - T1 
q sh 
3600
q sh
W  3600
C p T2 - T1 
At a system maximum of 260C (500F) (from vendor data)
Btu 1054 J 1 lb  9o F  J
C p  0.568 o  o   2376
lb F 1 Btu 0.4536 kg  5 C  kg o C
3600 sec 1,770,000 kg o C 1
W
hr sec 2376 J 260 - 232 C
W = 95,800 kg/hr
At a system maximum of 288C (550F)
Btu 1054 J 1 lb  9o F  J
C p  0.580 o  o   2426
lb F 1 Btu 0.4536 kg  5 C  kg o C
3600 sec 1,770,000 kg o C 1
W
hr sec 2426 J 288 - 232 C
W = 46,900 kg/hr

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At a system maximum of 316C (600F)
Btu 1054 J 1 lb  9o F  J
C p  0.592 o  o   2476
lb F 1 Btu 0.4536 kg  5 C  kg o C
3600 sec 1,770,000 kg o C 1
W
hr sec 2476 J 316 - 232 C
W = 30,600 kg/hr
Use a system maximum temperature of 316C.
T1 = 316C
T2 = 232C
W = 30,500 kg/hr
Cp = 2476 J/kgC (0.592 Btu/lbF)
 = 6.73 lb/gal = 806.5 kg/m3
Step 7: Calculate the Fluid Flow Rate to Each User
Glycol reboiler
263,000 m 3 kg  C 1 3600 sec
Q1 
sec 806.5 kg 2476 J 316 - 232 C 
hr
3
Q1 = 5.64 m /hr
HP flowline heater
Q1 = 2.79 m3/hr each
LP flowline heater
Q1 = 2.07 m3/hr each
Watermaker
Q1 = 2.25 m3/hr
Step 8: Size Flow Lines
Use pressure drop chart for Therminol 66, supplied by vendor.
Header: 40 m3/hr (180 gpm) = 4 in S/40
Glycol reboiler: 5.64 m3/hr (25 gpm) = 2 in S/40
HP flowline heaters: 2.79 m3/hr (12 gpm) = 2 in S/40
LP flowline heaters: 2.07 m3/hr (9 gpm) = 2 in S/40
Watermaker: 2.25 m3/hr (10 gpm) = 2 in S/40
Note, minimum 2 in flange piping is used to avoid leakage that can be expected with screwed
pipe and this fluid at high temperature.
Step 9: Calculate Heat Lost to Atmosphere
Supply header = 91 m at 316C
Return header = 91 m at 232C
Branch to each user = 30.5 m at 316C
Branch from each user = 30.5 m at 232C
Heater = 3.05 m diameter x 6.1 m at 316C
Glycol reboiler = 1.06 m diameter x 5.2 m at 204C
HP flowline heater = 0.91 m diameter x 6.1 m at 274C
LP flowline heater = 0.91 m diameter x 0.51 m at 274C
Watermaker = negligible at 82C
Supply header

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4 inch Schedule 40 with 2 inch insulation (0.0508 m)
ts = 0.237 in = (6.02 x 10-3 m)
Ao = 0.359 m2/m
Vw = 9.1 m/s
tha = 7.79(9.1)0.8 = 45.7 W/m2 C
1 6.02  10 -3 0.0508 1
  
U 52 0.052 45.7
U = 1.0 W/m2 C
same for all 4 in S/40
Ao = 0.359 m2/m (91 m) = 32.7m2
T = 316 - 21 = 295C
q = 1(32.7)(295) = 10,000 W
Return header
4 in Schedule 40 with 2 in insulation
U = 1.0 W/m2 C
Ao = 0.359 m2/m (91 m) = 32.7 m2
T = 232 - 21 = 211C
q = 1.0(32.7)(211) = 6900 W
Branch supply lines
2 in Schedule 40 with 2 in insulation
ts = 0.154 in = 3.91 x 10-3 m
Ao = 0.1896 m2/m
1 3.91  10 -3 0.0508 1
    1.0
U 52 0.052 45.7
U = 1.0 W/m2 C
T = 316 - 21 = 295C
q = 1.0(5.78)(295) = 1700 W each
Branch return lines
2 in Schedule 40 with 2 in insulation
T = 232 - 21 = 211C
q = 1.0(5.78)(211) = 1200 W each
Heater
3
/8 in plate = 9.5 x 10-3
with 2 in insulation
U = 1W/m2 C
Ao = (3.05)(6.1) = 58.4 m2
T = 295C
q = 1(58.4)(295) = 17,200 W
Glycol reboiler
U = 1.0W/m2 C
Ao = (1.06)(5.2) = 17.3 m2
T = 204 - 21 = 183C
q = 1.0(17.3)(183) = 3200 W
HP flowline heaters
U = 1.0W/m2 C

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 Ao = (0.91)(6.1) = 17.4 m2
T = 274 - 21 = 253C
q = 1.0(17.4)(253) = 4400 W each
LP flowline heaters
U = 1.0W/m2 C
Ao = (0.91)(6.1) = 17.4 m2
T = 274 - 21 = 253C
q = 1.0(17.4)(253) = 4400 W each
Total heat lost to atmosphere

Supply header 10,000

Return header 6,900
Branch supply 12 x 1,700 = 20,400
Branch return 12 x 1,200 = 14,400
Heater 17,200
Glycol reboiler 3,200
HP flowline heaters 6 x 4,400 = 26,400
LP flowline heaters 4 x 4,400 = 17,600
q= 116,10 W
0
Step 10: Calculate Total System Heat Duty
Total system duty
qr = 263 + 6(130) + 4(96.3) + 105 + 116.1
= 1650 kW
This is less than the estimated duty in Step 5 and is therefore acceptable. Note the heater duty shall
be specified at approximately 1800 kW to provide a 10 percent excess for peak loads.
Step 11: Calculate Pressure Drops
See Example Problem - Customary Units
Step 12: Estimate System Volume and Size Expansion Tank
Headers
4 in Schedule 40 with 0.00821 m3/m
L = 182 m
Vol = 0.00821 m /m (182m) = 1.49 m3
3

Branch lines
2 in Schedule 40 with 0.00216 m3/m
L = 61 m each of 12
Vol = 12(0.00216 m3/m)(61m) = 1.58 m3
Equipment volumes shall be taken from the equipment data sheets after each piece has been
designed.
Heater = 0.99 m3
Glycol reboiler = 0.05 m3
HP flowline heater = 0.03 m3 each
LP flowline heater = 0.03 m3 each
Watermaker = 0.04 m3
System total volume
Vol = (1.49 + 1.58) + 0.99 + 0.05 + 6(0.03) + 4(0.03) + 0.04

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 Vol = 4.45 m3
at 21 C, = 1011 kg/m3
Total charge = 4.45 m3 (1011) = 4500 kg
Volume at 316C when  = 769 kg/m3
Vol = 4500/769 = 5.85 m3
Expansion Volume = 5.85 - 4.45 = 1.4 m3
Try 48 in diameter tank (1.22 m)
Area = (0.61)2 = 1.17 m2
 1.4 m 3   3 
L     
 1.17   2 
L = 1.8 m (5.9 ft)
Try 42 in diameter tank (1.07 m)
Area = (0.535)2 = 0.899 m2
 1.4   3 
L  
 0.899   2 
L = 2.3 m (7.7 ft)
Use 42 in diameter x 10 ft seam-to-seam expansion tank.
Appendix C: Heat Transfer System Example Problem (Customary)
The following is an example design of a heat transfer system for an offshore platform.
Required:
Design a heat transfer system to provide a platform with all necessary heating.
Solution:
Step 1: Determine Design Parameters for Heat Users
Heat users in system
Glycol reboiler - One
450 gph glycol reboiler requiring 2000 Btu/gal at 400F
HP flowline heaters - Six
6 MMSCFD at 0.63 SG
T1 = 130F
T2 = 175F
Cp = 0.83 Btu/lb F
LP flowline heaters - Four
6 MMSCFD at 0.63 SG
T1 = 110F
T2 = 145F
Cp = 0.76 Btu/lb F
Watermaker - One
40 gph water at 9000 Btu/gal of boil at 180F
All equipment except the glycol reboiler is on the same deck at what will be called zero elevation.
The glycol reboiler is on the upper level at an elevation of plus 30 ft.
Step 2: Calculate Heat Duty and Maximum Temperature of Each User
Glycol reboiler
q = (2000 Btu/gal) 450 gph
= 900 MBtu/hr

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Maximum Temperature = 400F
HP flowline heaters
lb - mole .6329lb .83 Btu 175 - 130 F

6 MMSCF D
q sh 
D 24 hr 379 SCF lb - mole lb  F
= 450 Btu/hr each
Maximum Temperature = 175F
LP flowline heaters
lb - mole .6329lb .76 Btu 145 - 110 F

6 MMSCF D
q sh 
D 24 hr 379 SCF lb - mole lb  F
= 320 Btu/hr each
Maximum Temperature = 145F
Watermaker
q = (9000 Btu/gal) 40 gph
= 360 MBtu/hr
Maximum Temperature = 180F
Step 3: Set Minimum System Temperature
Maximum user temperature = 400F (Glycol Reboiler)
Set the minimum system temperature at 450F
Step 4: Select Heat Transfer Fluid
Select Monsanto Therminol 66. (From vendor data, Therminol 66 has a maximum bulk temperature
of 650F)
Step 5: Estimate Total System Heat Duty
System heat duty estimate
q = 1.15[(900) + 6(450) + 4(320) + (360)]
= 6,026 MBtu/hr
= 6.03 MMBtu/hr
Step 6: Calculate the Flow Rate of the Heat Transfer Fluid at Several Maximum Fluid
Temperatures
Therminol 66
Maximum Bulk Temperature = 650F
qsh = WCF(T2 - T1)
q sh
W
C p T2 - T1 
Where:
W = Q1
q sh
Ql 
C p T2 - T1 
At a system maximum of 500F (from vendor data)
Cp = 0.568 Btu/lb F
 = 6.90 lb/gal
6.03 MMBTU gal lb  F 1 hr
Ql 
hr 6.90 lb 0.568 Btu 500 - 450 F 60 min


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 = 513 gpm
At a system maximum of 550F
Cp = 0.580 Btu/lb F
 = 6.75 lb/gal
6.03 MMBTU gal lb  F 1 hr
Ql 
hr 6.75 lb 0.580 Btu 550 - 450 F 60 min


Q1 = 257 gpm
At a system maximum of 600F
Cp = 0.592 Btu/lb F
 = 6.73 lb/gal
6.03 MMBTU gal lb  F 1 hr
Ql 
hr 6.73 lb 0.592 Btu 600 - 450 F 60 min


Q1 = 168 gpm
Use a system maximum temperature of 600F.
T1 = 600F
T2 = 450F
Q1 = 168 gpm
Cp = 0.592 Btu/lb F
 = 6.73 lb/gal
Step 7: Calculate the Fluid Flow Rate to Each User
Glycol reboiler
900 MBTU gal lb  F 1 hr
Ql 
hr 6.73 lb 0.592 Btu 600 - 450 F 60 min


Q1 = 25.1 gpm
HP flowline heater
Q1 = 12.5 gpm each
LP flowline heater
Q1 = 8.9 gpm each
Watermaker
Q1 = 10.0 gpm each
Step 8: Size Flow Lines
Use pressure drop chart for Therminol 66, supplied by vendor.
Header (168 gpm) = 4 in S/40
Glycol reboiler (25.1 gpm) = 2 in S/40
HP flowline heaters (12.5 gpm) = 2 in S/40
LP flowline heaters (8.9 gpm) = 2 in S/40
Watermaker (10.0 gpm) = 2 in S/40
Note, minimum 2 in flange piping used to avoid leakage that can be expected with screwed pipe and
this fluid at high temperature.
Step 9: Calculate Heat Lost to Atmosphere
Supply header = 300 ft at 600F
Return header = 300 ft at 450F
Branch to each user = 100 ft at 600F
Branch from each user = 100 ft at 450F

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 Heater = 10 ft dia x 20 ft at 600F
Glycol reboiler = 42 in dia x 17 ft at 400F
HP flowline heater = 36 in dia x 20 ft at 525F
LP flowline heater = 36 in dia x 20 in at 525F
Watermaker = negligible at 180F
Supply header
4 in Schedule 40 with 2 in insulation
2
t i   0.167 ft
12
ki  0.03
ts = 0.237 = 0.0198 ft
Ao = 1.178 ft2/ft
Vw = 30 ft/s = 20 mph
ha = 0.53(30)0.8 = 8.05 Btu/hr ft2 F
1 0.0198 0.167 1
  
U 30 0.03 8.05
U = 0.176 Btu/hr ft2 F same for all 4 in S/40
Ao = 1.178 ft2/ft (300 ft) = 353 ft2
T = 600 - 700 = 530 F
q  0.176 353530  32.9
MBtu
hr
Return header
4 in Schedule 40 with 2 in insulation
U = 0.176 Btu/hr ft2 F
Ao = 1.178 ft2/ft (300 ft) = 353 ft2
T = 450 - 70 = 380 F
q = 0.176(353)(380) = 23.6 MBtu/hr
Branch supply lines
2 in Schedule 40 with 2 in insulation
ts = 0.154 in = 0.0128 ft
Ao = 0.622 ft2/ft
1 0.0128 0.167 1
  
U 30 0.03 8.05
U = 0.176 Btu/hr ft2 F
Ao = 0.622 ft2/ft (100 ft) = 62.2 ft2
T = 600 - 70 = 530 F
q = 0.176(62.2)(530) = 5.8 MBtu/hr each
Branch return lines
2 in Schedule 40 with 2 in insulation
T = 450 - 70 = 380 F
q = 0.176(62.2)(380) = 4.1 MBtu/hr each
Heater
3
in plate  0.0313 ft
8

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With 2 in insulation
U = 0.176 Btu/hr ft2 F
Ao = (10)(20) = 628 ft2
T = 530 F
q = 0.176(628)(530) = 58.6 MBtu/hr
Glycol reboiler
U = 0.176 Btu/hr ft2 F
Ao = (3.5)(17) = 187 ft2
T = 400 - 70 = 330 F
q = 0.176(187)(330) = 10.9 MBtu/hr
HP flowline heaters
U = 0.176 Btu/hr ft2 F
Ao = (3)(20) = 188 ft2
T = 525 - 70 = 455 F
q = 0.176(188)(455) = 15.0 MBtu/hr each
LP flowline heaters
U = 0.176 Btu/hr ft2 F
Ao = (3)(20) = 188 ft2
T = 455 F
q = 15.0 MBtu/hr each

Supply header 32.9

Return header 23.6
Branch supply 12 x 5.8
Branch return 12 x 4.1
Heater 58.6
Glycol reboiler 10.9
HP flowline heaters 6x 15.0
LP flowline heaters 4x 15.0
q= 394.8 MBtu/hr
Step 10: Calculate Total System Heat Duty
Total system duty
qr = 900 + 6(450) + 4(320) + 360 +395 = 5.6 MMBtu/hr
This is less than the estimated duty in Step 5 and is therefore acceptable. Note the heater duty shall
be specified at approximately 6 MMBtu/hr to provide a 10 percent excess for peak loads.
Step 11: Calculate Pressure Drops
Supply header pressure drop for Therminol 66, supplied by vendor.
4 in Schedule 40
Q1 = 170 gpm
Le = 1500 equivalent ft
 P  0.85
1500  12.8psi
100
Return header pressure drop
4 in Schedule 40
Q1 = 170 gpm

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 Le = 1500 equivalent ft
P = 12.8 psi
Glycol reboiler loop
2 in Schedule 40
Q1 = 25.1 gpm
Le = 600 equivalent ft
 P  0.5
600  3psi
100
Control valve = 5 psi
Reboiler (spec) = 10 psi
Elevation change of 30 ft
 at 600 F = 48.1 lb/ft3
30 ft 48.1 lb ft 2
P  10 psi
1 ft 3 144 in 2

HP flowline heater

Control valve = 5 psi

Exchanger (spec) = 5 psi

LP flowline heater
Same as above

Watermaker

Control valve = 5 psi

Exchanger (manufacturers std.) = 10 psi

The flow loop with the largest pressure drop is the glycol reboiler loop, which gives the following
system pressure drop.

Specify pumps as follows:

Flow = 170 gpm

Temp = 600F
Fluid density 48.1 lb/ft3
Fluid viscosity = 0.34 cp
Step 12: Estimate System Volume and Size Expansion Tank
Headers
4 in Schedule 40 with 0.0884 ft3/ft
L = 600 ft
Vol = 0.0884 ft3/ft (600 ft) = 53 ft3
Branch lines
2 in Schedule 40 with 0.0233 ft3/ft
L = 200 ft each of 12
Vol = 12(0.0223 ft3/ft) (200 ft) = 56 ft3

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 Equipment volumes shall be taken from the equipment data sheets after each piece has been
designed.
Heater = 262 gals
Glycol reboiler = 12 gals
HP flowline heater = 8 gals each
LP flowline heater = 8 gals each
Watermaker = 10 gals
System total volume
Vol = (56+53) 7.48 + 262 + 12 + 6(8) + 4(8) + 10
Vol = 1179 gals
At 70F,  = 8.44 lb/gal
Total charge = 1179 gal (8.44) = 9950 lb
Volume at 600F when  = 6.42 lb/gal
Vol = 9950/6.42 = 1550 gal
Expansion Volume = 1550 - 1179 = 371 gals = 50 ft3
Try 48 in diameter tank
Area = (2)2 = 12.57 ft2
 50 ft 3   3 
L   
2  
 12.57 ft   2 
L = 6.0 ft
Try 42 in diameter tank
Area = (1.75)2 = 9.62
 50   3 
L  
 9.62   2 
L = 7.8 ft
Use 42 in diameter x 10 ft seam-to-seam expansion tank.

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