1- Instrument Air Requirement

1.1 Calculation Objective

This calculation aims to do an estimation of total instrument air compressor capacity for the entire facility of Oil & Gas
and Steam & Water system for FEED.

1.2 Calculation Basis

1- Instrument air supply will be designed based on DEP 31.37.00.11-Gen and requirement of SP-1252
where applicable.

2- As a minimum design requirement the instrument Air Pressure shall be 7 barg under normal operation and never less
than 3.5 barg (Ref: SP-1252)

However as per DEP 30.75.10.31 for HRSG, the pressure of the air shall be 8 barg at HRSG's block valves so it is
assumed that working pressure of air receiver is 1.0 bar higher than HRSG's pressure requirement then:

- Min Operating Pressure 3.5 barg (Ref: SP-1252) for sizing of piping distribution
- Max Header Pressure 9.0 barg

3- Dryer will be Membrane type with dew point of -10° C (Ref: SP-1252)

4- consumption figures (valves include consumption per individual users) :

- Control valve 0.75 SCFM (30 Sm3/day) (Ref: ESSO design instruction Manual, Sec.3)
- On-off valve 0.75 SCFM (30 Sm3/day) (Ref: ESSO design instruction Manual, Sec.3)
- Flare Ignition system 10 SCFM
- HRSG's Observation window 10 SCFM
- HRSG's diverter dampeners 0 (Actuation is by hydraulic fluid)
1.3 I.A. Consumption Calculation:
Number of CVs and UZVs and XCVs extracted from Pre HAZOP PEFS as following:

- Total number of CVs 179 See attached sheet for list of control valves
- Total number of UZVs 170 See attached sheet for list of on/off valves
- Total number of XCVs 59
- Total CVs & UZVs & XCVs 408

- Required IA for CVs & UZVs & XCVs 337 SCFM (+10% design margin)
- AP & LP Flare Ignition system 20 SCFM
- HRSG's Observation Windows 60 SCFM (2 windows for each)
Total Net I.A. Consumption : 417 SCFM
Total I.A. consumption including 30% margin based as per DEP 31.37.00.11-Gen:
Design margin: 1.3 542 SCFM
920 Sm3/hr
872 Nm3/hr
1.4 Calculation wet air intake to compressor:
Considering maximum dry bulb temperature of 55°C and relative humidity 98%, from Perry’s handbook,
the moisture content of air is : 0.115 lb of water/lb of dry air

So, calculation for the total quantity of air at the compressor suction is:

Dry air standard density 1.29 kg/m3

total Mass of Dry Air 1125 kg/hr
Mass of Water 129 kg/hr
Mass of Water @ 5% over-saturation 136 kg/hr (as per DEP)
water vapor Density @ STD 0.8 kg/Sm3 (PM/RT) @ 0 °C and 1.0 bar.
volume of water vapor @STD 171 Sm3/hr
Total Air Intake to compressor 1091 Sm3/hr

1.5 Conclusions
- Required capacity for air compressor (wet): 1091 Sm3/hr 642 SCFM
- Dry Instrument air required for the plant (dry): 788 Sm3/hr 464 SCFM
- Utility air for HSRGs is (dry basis) : 133 Sm3/hr 78 SCFM
 Instrument Air Consumption
SR. EQUIPMENT CV UZV XCV REMARKS Area
NO. Oil & Gas Area
1 TEST SEPARATOR (V-2791/2/3) 9 15 oil separation area
2 FWKO SEPARATOR (V-2701/2/2790) 6 18 56 valve no.
3 Satellite SEPARATOR (V-2794) 2 6 60 SCFM
4 WET OIL SURGE TANK (T-2701) 3 2 oil production area
5 SATELLITE WET OIL SURGE TANK (T-2760) 3 2 52 valve no.
6 WET OIL TRANSFER PUMPS (P-2701A/B/C) 0 1 56 SCFM
7 SATELLITE WET OIL TRANSFER PUMPS (P-2760A/B) 2 3
8 SKIM TANK (T-2702A/B) 6 1
9 PRODUCED WATER DISPOSAL BOOSTER PUMP (P- 1 8
10 2770A/B/C/D)
PRODUCED WATER DISPOSAL PUMP (P-2703A/B/C/D) 7 13
11 SEAL WATER SEPARATOR (V-2721) & VRU COMPRESSOR 5 6 VRU PKG area
(K-2720) 11 valve no.
12 SCFM
12 PRODUCTION/Test MANIFOLD 0 14 Production Manifolds
13 APO WATER GATHERING MANIFOLD 0 1 67 valve no.
15 LIFT GAS MANIFOLD 51 1 72 SCFM
16 1ST STAGE SUCTION SCRUBBER (V-2730) 4 4 Gas Lift Compressor
17 2ND STAGE SUCTION SCRUBBER (V-2731) 1 1 26 valve no.
18 3RD STAGE SUCTION SCRUBBER (V-2732) 1 1 28 SCFM
19 4TH STAGE SUCTION SCRUBBER (V-2733) 1 1
20 4TH discharge SUCTION SCRUBBER (V-2734) 1 3
21 1ST STAGE COMPRESSOR (K-2730) 2 0
22 2ND STAGE COMPRESSOR (K-2730) 2 0
23 3RD STAGE COMPRESSOR (K-2730) 2 0
24 4th STAGE COMPRESSOR (K-2730) 2 0
Total Oil & gas Area 212 valve no.
227 SCFM

Utility Area
25 Fuel gas inlet area 2 7 FG Handline Area
26 Fuel gas Letdown 2 7 23 valve no.
27 HRSG Mixed FG 1 1 25 SCFM
28 BFW Heater FG 2 1
29 AP Flare pilot & ignition 1 0 Flare Stack Area
30 LP Flare drum 1 1 4 valve no.
31 LP Flare pilot & ignition 1 0 32 SCFM

Total Utility Area 27 valve no.

29 SCFM
Steam & Water Area
32 Filter Feed Pumps 1 0
33 S-2501 A-E 1 0 40
34 P-2502 A/B 1 0 0
35 1st RO PKG 3 0 8
36 2nd RO PKG 3 0 4
37 T-2601 1 0 2
38 P-2516 2 0 1
39 P-2588 A-C 3 3 0
40 T-2591 2 1 0
41 P-2591 2 1 0
42 P-2601 1 0 0
43 E-2602 A/B 0 2 0
44 F-2623 A/B 8 8 0
45 V-2603 A/B 4 0 0
46 P-2602 A-D 4 0 4
47 F-2620/21/22 (HRSG) 12 27 0
48 V-2620/21/22 7 6 0
49 V-2631/32 1 4 0
50 P-2505 A/B 1 0 0
51 Electroliser PKG 1 0 0
Total Water & Steam 169 valve no.
181 SCFM

TOTAL Number of CV/UZV/XCV 179 170 59 408

Typical I.A. Consumption for each item SCFM 0.75 0.75 0.75 SubTotal
CVs & XVs Consumption 134 128 44 306 SCFM
+10% margin 337 SCFM
AP & LP Flare Ignition system 20 SCFM
F-2620/21/22 Observation Window 60 SCFM
Total net 417 SCFM
 Instrument Air Consumption
SR. EQUIPMENT CV UZV XCV REMARKS Area
NO. Total Consumption (+30% margin) 542 SCFM
Note : This list is preliminary and need to be updated by the EPC contractor based on "issued for Hazop" PEFS.
2. RECEIVER SIZING (V2652)

2.1 Calculation Objective

To Size the Instrument air receiver

2.1 Calculation Basis

1- Instrument air supply will be designed based on DEP 31.37.00.11-Gen and requirement of SP-1252
where applicable.

2- based on DEP Instrument air shall be as a minimum requirement operation at 8 barg and never less than 4.2 barg,
however based on SP-1252 the air receiver shall be sized to maintain a minimum air pressure of 6 barg when switching
over to the standby compressor with the rated air off-take. Additionally in the event that all compressors fail, the receiver
shall be of sufficient capacity to maintain a minimum air pressure of 3.5 barg for 5 minutes at the rated air take-off,
starting at 6 barg. Air receiver is designed to supply air during that period.

water will be condensed when cooling at compressor discharge air cooler and separated, so the air volume requirements
of the receiver will be based on saturated air at cooler outlet conditions (T,P) .
Dry Instrument air flow rate : 920 Sm3/hr
I.A. Volume @ 5 minutes 76.7 Sm3/ five minnutes
Air density @ Std 1.29 kg/m3
Mass of Air in 5 minutes 98.9 kg

Let, V be the volume of air receiver then:

P1 6.0 barg Ref: SP-1252
P2 3.5 barg Ref: SP-1252
T1& T2 55.0 °C
ρ1 (density @T1,P1) 7.55 kg/m3
ρ = PM/RT
ρ2 (density @T2,P2) 4.85 kg/m3
ρ1 - ρ2 2.70 kg/m3
Vreceiver 37 m3 ( ρ1 - ρ2 ) x V = Mass of Air

Assume L/D 2.0

Vessel Diameter (D) 2.857 m
Vessel Length (L) 5.715 m

Selected Vessel size:

Vessel Diameter (D) 3.048 m (10 ft)
Vessel Length (L) 5.488 m (18 ft)

3. Air Receiver PRV Sizing

The Air receiver PRV design is based on the block discharge of air receiver, so total flow from air compressor to be relieved
through the 26-PRV-5210.

Refer to the PRV calculation sheet for detail data

3. Receiver PRV Sizing IfIf DP
DP << 0.5C
0.5Cf2f2PP11 then
then the
the flow
flow is
is subcritical.
subcritical.
Else
Else the
the flow
flow isis critical.
critical.
SAFETY RELIEF VALVES
VAPOURS OR GASES - Critical Flow ONLY
For 26-RV-5210 (Block Discharge Case.)
Description
Uint Value Unit Value
Required flow through the device W lbh-1 2480.6 kgh-1 1125
Required flow through the device V scfm 540.7
Mol Wt M 29
Specific Gravity (Air=1.0) G 1.001
Relieving Temperature °F 131 °C 55 Properties
Propertiesat
atrelief
reliefconditions
conditions
Abs. Temperature T °R 591
Compressibility (default=1.0) Z 0.997
Cp/Cv k 1.415
Coefficient calc from spec. heat ratio C 357.4 k 1
 2  k 1
Discharge Coefficient (default=0.975) Kd 0.975 C  520 k  
 k 1
Set Pressure Pset psig 152.25 barg 10.5
Overpressure (10% or 20%) P% % 10  P 
Relieving Pressure P1 psia 182.2 bar 12.6
P1  Pset 1  %   Patmosphere
 100 
Critical flow nozzle pressure Pcf psig 81.1 barg 5.6
PPcf isisthe
thecritical
critical flow
flow pressure
pressureififthethe down
downstream
stream
Back-pressure psig 0 k
cf
pressure
pressure isisless
lessthan
than or
or equal
equal toto the
the critical
critical flow
flow
% Gauge Back-pressure 0.00 pressure
pressure thenthen the
the system
system isiscritical.
critical. IfIf the
the down
 2  k 1 down
Pcf  P1   stream
stream pressure
pressure exceeds
exceeds thethe critical
criticalflowflow
Back Pressure Correction (default=1.0) Kb 1.00  k 1 pressure
pressure thenthen the
the system
system isissubcritical.
subcritical.

Combination correction factor Kc - 1

V TZM
Calculated Area A in2 0.176 mm2 113.62 A
1.175CK d P1 K b K c
Selected Orifice (D to T) E
Diameter ins 0.500 mm 12.69
Area in2 0.196 mm2 126.45
Possible PSV Size in 1x2
Additional Capacity Available 11.3%

Notes
1. Back Pressure Correction ONLY applies to Balanced Bellow Valves
 ORIFICE SIZES (Index is inverse area)
Index Size Diam (in) Area (in2) Usually
0.0384615 T 5.754 26.000 8 x 10
0.0625 R 4.514 16.000 6x8
0.0904977 Q 3.751 11.050 6x8
0.1567398 P 2.850 6.380 4x6
0.2304147 free 2.351 4.340 4x6
0.2777778 M 2.141 3.600 4x6
0.3505082 L 1.906 2.853 3x4
0.5440696 K 1.530 1.838 3x4
0.7770008 J 1.280 1.287 2x3
1.2738854 H 1.000 0.785 2x3
1.9880716 G 0.800 0.503 1.5 x 2.5
3.257329 F 0.625 0.307 1.5 x 2.5
5.1020408 E 0.500 0.196 1x2
9.0909091 D 0.374 0.110 1x2

Saturated steam properties in terms of pressure (Imperial Units) [Only up to 1500 psig - JCA 15/2/99]
Ref: Chemical Engineering / May 12, 1986 Y=Ax+B/x+Cx^0.5+Dln(
Constants A B C D
Temperature °F -0.17724 3.83986 11.48345 31.1311
Liquid Specific Volume ft³/lb -5.28E-07 2.995E-05 0.0001522 6.625E-05
Vapour Specific Volume (<200 psia) ft³/lb -0.48799 304.71761 9.8299035 -16.455274
Vapour Specific Volume (>200 psia) ft³/lb 0.002662 457.5802 -0.176959 0.826862
Liquid Enthalpy Btu/lb -0.1511557 3.671404 11.622558 30.832667
Latent Heat Btu/lb 0.0086762 -1.3049844 -8.2137368 -16.37649
Vapour Enthalpy Btu/lb -0.14129 2.258225 3.4014802 14.438078

Enter Pressure psia 250

Calculate:
Temperature °F 400.8
Liquid Specific Volume ft³/lb 0.0187
Vapour Specific Volume (<200 psia) ft³/lb 1.243
Vapour Specific Volume (>200 psia) ft³/lb 1.843
Liquid Enthalpy Btu/lb 375.84
Latent Heat Btu/lb 825.14
Vapour Enthalpy Btu/lb 1201.08

Flashing Condensate:
Input:
Upstream Pressure psia 185
Downstream Pressure psia 16
Calculate:
Upstream Enthalpy Btu/lb 348.473
Downstream Liquid Entyhalpy Btu/lb 184.35978
Downstream Steam Enthalpy Btu/lb 1152.028
Liquid Fraction 0.830
Vapour Fraction 0.170
 3.049

00 psig - JCA 15/2/99]

Y=Ax+B/x+Cx^0.5+Dln(x)+Ex^2+Fx^3+G
E F G Pressure 58 psia
8.763E-05 -2.788E-08 86.594 Temperature 290.53104 °F
8.509E-10 1.864E-14 0.01596 Liquid Density 57.60106 lb/ft3
0.0009475 -1.363E-06 19.53953 Vapour Density (<200 psia) 0.1340883 lb/ft3
-4.602E-07 6.318E-11 -2.3928 Vapour Density (>200 psia) 0.1305633 lb/ft3
8.741E-05 -2.623E-08 54.55 Liquid Enthalpy 259.84426 Btu/lb
-4.304E-05 9.763E-09 1045.81 Latent Heat 917.09807 Btu/lb
4.223E-05 -1.57E-08 1100.5 Vapour Enthalpy 1177.013 Btu/lb
 4 Bar A
143.62835 °C
922.68157 kg/m3
2.1478919 kg/m3
2.0914258 kg/m3
604.39774 kJ/kg
2133.1701 kJ/kg
2737.7322 kJ/kg
4. I.A Main Header and sub-headers Line Sizing

Design Basis:

1-Main header and distribution piping design is based on minimum pressure of 3.5 barg as per SP-1252.
2-DP< 1.0 bar between dryer and furthest user is applied as per DEP.

Calculation:

1- The main Instrument air header is assumed to be routed along the oil and gas area pipe rack and then goes towards the
water treatment and steam generation area.

Total plant I.A requirement 464 SCFM OR 1016 kg/hr

Plot Length 400 m (from inst air PKG up to T-2701 area)
Pressure (min) 350 Kpag (as per SP-1252)
Pipe size 100 mm
Total DP 11 Kpa (20% margin included)
Outlet velocity 7.40 m/sec

2- The furthest Instrument air users in oil and gas area is P-2703 A/D (Produced water disposal pumps).

Total I.A Flow for oil/gas & utility Area 256 SCFM OR 562 kg/hr
Plot Length 250 m (from T-2701 to P-2703 A-D area)
Pressure (min) 350 Kpag (as per SP-1252)
Pipe size 3 inch
Total DP 9 Kpa (20% margin included)
Outlet velocity 7.0 m/sec

3- The furthest Instrument air users in Water and steam area are HRSGs.

Total I.A Flow for water & Steam Area 181 SCFM OR 397 kg/hr
Plot Length 650 m (from T-2701 to water treatment and steam generation area)
Pressure (min) 350 Kpag (as per SP-1252)
Pipe size 3 inch
Total DP 12 Kpa (20% margin included)
Outlet velocity 5.0 m/sec

4- The furthest Utility air user is F-2622 (HRSG Frame 9)

Utility air consumption 78 SCFM OR 171 kg/hr
Plot Length 1000 m (from inst air PKG to HRSGs area)
Pressure (min) 350 Kpag (as per SP-1252)
Pipe size 2 inch
Total DP 27 Kpa (20% margin included)
Outlet velocity 5 m/sec

For distribution arrangement refer to PEFS no : QSP-1-2620-002-A1, Rev B