Oil & Gas Projects Quick Estimation

DRAFT March 2022

INTRODUCTION
Offshore and onshore process facilities have a number of utility systems. For preliminary sizing of the utility
systems, we need to estimate various users demands, then update based on vendors inputs at later project
stages. The following guidelines may help estimate preliminary utility demand. Update based on vendor data and
your industry practice.

1. WATER SYSTEMS
1.1 Cooling Water - Fresh
Based on Cooling Loads assuming 10°C temperature rise. For HP gas coolers, check that hydrate temperature is
above cooling water temperature

1.2 Desalination Plant

RO: 2.5 units of feed/ unit of product water

1.3 Firewater
Contact Safety/ Loss Prevention Engineers
 Wellhead 23 m³/h per well head or 0.6 m³/h per m² of well area
 Monitor 120 m³/h at 10 bar g each
 Water Spray 40 dm³/min/m² of ground surface for compression; 8.5 dm³/min/m² of equipment surface for
vessels, exchangers, columns

1.4 Deck Wash Water

2 hose stations at a time. 5 m³/h per hose station.

1.5 Potable Water

50 gal (200 liters) per person per day. Range: 135 to 300 l/d/p for based on population
 Bath = 55 Toilet = 30 Washing = 20 Mopping = 10 Utensils = 10 Cooking = 5 Drinking = 5. Total = 135 l/d/p
 Wash/WC = 190 Cooling = 50 Laundry = 30 Drinking = 2. Total = 272*1.1 = 300 lpd. 150 persons = 45 m³/d + 15
(others) = 60 m³/d. 3 to 7 days storage = 180 m³
 Drinking = 1 gpm Kitchen = 15 Laundry = 10 Shower = 24 Washing 20 Miscell = 5. Total = 75 gpm
 Typical Application Rate & Duration. WC: 2.3 l/s* 5 s Urinal 0.15 l/s*30 s Wash Basin 1¼” 0.6 l/s * 10 c Sink
1½” 1.1 l/s * 75s Washing Machine 0.7 l/s * 300 s

1.6 Sewage Treatment Plant

See Potable Water

1.7 Other Water Usages. Plant to Plant Basis

 Drilling. Flare radiation shield. Water injection
 Sewage plant = 1.5 AirCon = 60 FW Makeup = 10 Washdown hoses - 2 = 100. Potable Water = 30. Total = 300
gpm
 LQ = 70 gpm Battery Room 6 Topup Tank = 20 Chemical Injection = 2 Lab = 2. Total = 100 gpm
 DM Water for Gas Turbine: Fuel gas to diesel change over = 15 gallons/change over. Generator blades
washing = 25 gallons/wash. Compressor blades washing = 240 l/ wash

Tips on Seawater Intake System

 Intake 6 m below MSL

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 Typical Caisson Depth: North Sea 20 m. MidEast 16 m. India 30 m. China 17 m. Vietnam 40 m

 100 µ strainer before storage (150 ~ 500 µ range)
 To prevent marine growth: 100 ppm sodium hypochlorite solution injected to provide 3 ppm in the system
 Typical: SW Pumps 250,000 - 300,000 BWPD
Lift: 3*1,500 m³/h. 20” header. Coarse: 3*1,500 m³/h 16”. Fine Filter: 7*450 m³/h 10”. Deaerator: 2*1,100
m³/h 16”/20”. Vacuum Pump: 2*1,500 m³/h. Booster: 3*1,100 m³/h. Injection: 5*550 m³/h. 12”

Tips on Potable Water System

 Generated by RO or vacuum distillation. Storage for 14 days with 100% spare. Each tank with 2
compartments, in case one is accidentally contaminated
 Water pumped from storage tank through a filter (98.1% removal of >10 micron solids) to a pressurized tank
(Hydrocumulator). Pressure maintained by Instrument Air at 2.5 to 3 bar g

2. AIR SYSTEMS
2.1 Instrument Air
Instrument air required for controller pneumatic loop, on/off valve actuators, igniting flare pilots, pneumatic
motors etc. None of them are continuous demands. See Utility Air System Design.xlsx for details
 Typical cycle time: 10 minutes. 5 drying. 4 regen. 1 Repressurizations
 Be very liberal. Add 30% contingency and 10% leakage margins. Compressed air required may be 20% more,
depending on regeneration system. Air dried to 0°F dew point at operating pressure or (-) 40°F dew point at
atmospheric pressure

2.2 Plant Air

2 hose stations operating at a time. 170 Sm³/h per hose station. 15 minutes storage.

2.3 Starting Air

For large diesel engines or turbines. Surge tank sized for minimum of 3 starts of the largest piece of equipment.

101.3 * 3 * Vstart in Sm3

Volume of tank, m³ =
(Pinitial – Pmin) for start

Typical: 100 HP firewater pump, Vessel: 42” dia. * 8’ high

2.4 Other Users

Plant air used to provide blanket air on seawater surge tanks.

3. FUEL SYSTEMS
Note: Fuel gas Electrical Heater Flux = 3 W/sq.cm
3.1 For Drivers
Mechanical Engineering Department to provide site heat rates and demand.
 Gas turbine (35 - 45% efficiency). At 35% η = 270 sm³/MW-h
 Helicopters 650 lph * 5 hours flying * 2 helicopters = 6,500 l. 6 days storage = 39,000 l
3 tanks. 1 in use + 1 in settling (2 days) + 1 in filling (1 day)

3.2 Fired Heaters

 LHV - Typical fuel gas = 11,000 kcal/kg (1,000 Btu/SCF = 37.3 mJ/sm³)

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 LHV - typical fuel oil = 10,000 kcal/kg

 Smaller heaters less efficient < 2.5 MW = 140 sm³/MW-h @ 70% η; > 2.5 MW = 115 sm³/MW-h @ 85% η
 Glycol Regenerators Q = 2000 L (Btu/h). L = glycol rate (gal/h) = 0.74 Sm³/ kg water
 Heater treaters = 60 Sm³/°C rise/1000 m³ of oil

3.3 Flares
Purge gas flow on a minimum velocity based on header/ riser size. One purge point at every dead end. Purge flow
depends on flare tip seal type, as each seal results in different 02 level in stack. Go by Airrestor (Velocity) seal.

Seal Type Suggested Velocity, m/s In actual Operation, m/s Stack O2 Level, %
Mol Seal 0.005 - 0.01 0.02 1
Airrestor (Velocity Seal) 0.01- 0.04 0.02 6-8
Plain Stack 0.15 0.3 - 1 6-8

 Pilot gas = 3.0 sm³/h per pilot. Continuous

 Flare Panel Ignition gas (intermittent) = 4 sm³/h; Ignition air (intermittent) = 40 sm³/h
 Flare KODs sized for largest inflow of gas and liquid. When no liquid flow, assume liquid flow 20 m³/million
sm³ of gas in HP KOD and 100 m³/million sm³ in LP KOD

3.4 Miscellaneous
 Glycol Regenerator Stripping Gas: 6 SCF/gal TEG circulation
 Deaerator Stripping Gas: 1.0 sm³/m³ of injection water flow; 2 SCF/bbl of water. Typical O2 spec 20-50 ppbv
Deaerator exit. 5 ppbv after scavenger injection
 Gas Padding of Tanks: As per API-2000.
 Gas for Induced Gas Floatation Unit: 0.2 SCF/bbl of produced water

4. DIESEL
4.1 Diesel Engines
40% thermal efficiency. It is about 40 l/MW-h.

4.2 Batch Treating Pipeline

Liquid m³ = 0.016 * ID” * L km
 Liquid contains 15%-20% corrosion inhibitor, rest diesel or condensate.
 Injection rate 15 l per million Sm³ of gas or 100 ppm of oil flow.

4.3 Corrosion Inhibitors

2:1 diesel: chemical blend.

Tips on Diesel System

Diesel oil tank: 14 days’ storage. Minimum two compartments in tank. Diesel is used intermittently.
 1 hour/week test run of firewater pumps. ≈ 3 l/h.
 60 hours per month running of emergency generator.
 3 hours/day run of cranes. About 3 l/h.

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5. AVIATION FUEL
Specified by client, based on helicopter type and use. 3 tanks. First in use; second under settling for 2 days and
third under filling for a day. Turnaround time for topping the tanks = 9 with 6 idle days.
For 2 helicopters, each consuming 0.65 m³/h and flying for 5 hours.
 Daily consumption = 2 * 5 * 0.65 = 6.5 m³
 Storage capacity = 6.5 * 6 = 39 m³

6. GLYCOL SYSTEM
Assume a glycol circulation of 3 gal/lb of water absorbed. 25 l/kg

7. HYPOCHLORINATION
100 ppm chlorine solution injected into seawater pump intakes. Chlorine produced by electrolyzing NaCl in
seawater.
For 200 m³/h seawater flow,
 Chlorine demand at 1 ppm = 200 g/h
 Seawater flow to hypochlorination = 2 m³/h
 Chlorine concentration in effluent = 100 ppm
 Electric power required = 0.5 kW

NaCl + H2O  NaOCl + H2.

H2 which should be safely disposed off to atmosphere. Usually an air fan is provided to dilute the H2 below LEL
For the 200 m³/h seawater unit,
 H2 produced = 0.126 m³/h
 Air flow at 25% LEL = 12.6 m³/h
 Air fan head = 150 mm WC

8. FIRED HEATERS/ BOILERS

FD and ID fans sized based on ≈17 kg of air/10,000 kcal of fuel fired and 150-200 mm WC head. Efficiency of 65%.
Steam:
 Snuffing Steam. To purge firebox of unignited hydrocarbon, before light up and after every failed light up to
avoid an explosion. LP steam rate @ one firebox volume change in 5 minutes; or 12 Firebox Volume /hr. Run
FD fan for few minutes, if no LP steam OR use steam ejectors.
 Atomizing Steam. To shear and froth fuel oil. @ 25-45% oil flow
 Soot Blower Steam. 4,500 kg/h for retractable. Air: 80-100 Nm³/h for its pneumatic motor

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9. COMPRESSOR LUBE/ SEAL OIL HEATERS/ AIR COOLERS

Compressors have their own lube/seal oil system. The lube oil system is provided with a heater in the tank and an
air cooler. To estimate the power demand,

For a 10-MW Compressor

 Lube oil pump = 50 kW each
 Lube oil heater = 20 kW
 Lube oil cooler = 400 kW
 Cooler Fan duty = 33 kW
 Seal oil pump = 6 kW each

10. PSA INERT GAS PLANT

Air and power demand decided by the Nitrogen purity.
Nitrogen Purity, % Air : N2 Ratio Power, KW/Sm³
95 2 0.25
98 2.5 0.35
99 3.9 0.42
99.5 4.3 0.5
99.9 7 0.7

11. DESIGN FACTORS

°API of oil = 141.5/Sp.Gr – 131.5

Typical properties of petroleum products are:

MW °API Sp.gr Cp
LPG 50 0.56 0.59
Gasoline 110 60 0.74 0.56
Naphtha 155 50 0.78 0.55
Kero 185 45 0.80 0.57
Gas oil 240 40 0.83 0.59
Bottoms - 30 0.88 0.72

12. STRAINER SIZES

 Diesel Engine Lube Oil = 10 µ Duplex Full Flow Filters
 Aviation Turbine Fuel = 95% > 1 µ
 Compressor lube oil = 150 mesh
 Turbine flow meter = 30 - 150 mesh
 Fuel Gas line = 20 mesh. 20°C above Dew Point!
 Gas Turbine fuel gas = 10 µ
 Gas Turbine Filt Separator = 100% of solids > 3 µ. 99% of solids > 1 µ
ΔP = 2 psi 100% liquid droplets > 5 µ. 99% of droplets > 0.5 µ
 Diesel fuel = Raw 100 µ. Clean = 5 µ
 Seawater = 100 µ

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 Compressor seal gas = 3-5µ

 Instrument Air = 0.5 µ (0.01-1)
 Gear Pump = By Pump Vendor

Typical properties of petroleum products are:

Type Element Mesh/Filtration Size
Flat Disc Perforated Plates Coarse 1/8”
Conical Conical 20 to 200 mesh
“T” Type Half cone shaped 20 to 200 mesh
“Y” Type Cylindrical 20 to 200 mesh
Basket Type Cylindrical 2µ
Duplex Cylindrical 2µ
Cartridge Cartridge 0.2 µ
Self-Cleaning Plate type with cleaning blade 25 µ
• Oil < 5 cSt - 60 mesh; < 10 cSt - 40; < 20 cSt - 20; < 200 cSt - 1/8” perforations; < 500 cSt 3/16”; > 500 cSt 1/4”
• Strainer element open area 30 to 40%
• Air + Water 0.033 to 0.045” Perforated SS Screen. 100 mesh screen

• ΔP across a strainer = 1 - 30 kPa

• ΔP across an oil meter = 30 kPa

13. GAS TURBINE

Heavy fuel oil: Limited to Atmospheric or Long Residue. In intermittent services - ships, locomotives or peak load
shaving.

30 ppm Vanadium limits on-line time to ~ 1,200 hours; 50 ppm Va to ~ 800 hours. Then shut down for 8 hours for
water washing. Water washing may be required after every 200-300 hours of operating hours. In between
washing, nut shelling once in 2 days at 33-50% power for 15 minutes.

Water Washing: Removes deposits on hot paths due to metals and additives added to remove metals. Turbine is
cooled down with wheel space temp ~ 90°C. Fresh water injected thru a ring of nozzles at about 7 bar and 80°C
for 15 minutes, while turbine is at cranking speed.

Heavy oil: Heated to reduce viscosity/ increase settling rate. Washed with water to remove water soluble Na and
K. Inhibit Va with oil soluble Mg based components. Usually 3 parts of Mg per part of Va. Vanadium is not
removed by washing or mechanically. Centrifuge or ESP or hybrid to separate oil and water. Use an alternative
fuel to start and shutdown. Max ρ = 0.98 (13° API); μ ≤ 100CS and Na ≤ 150 ppm.

14. COMPRESSOR SEAL GAS

• Seal gas leakage to flare from dry seals of compressor ≈ 5-15 scfm (8-25 sm³/hr)
• Separation gas/ N2 to positively carry the leak flow ≈ 5 scfm (10 sm³/hr)
• Liquid seal 30 to 100 gpm (7-25 m³/hr) per casing / 2 seals. Gas loss with liquid ≈ 5-30 scfm (10-50 sm³/hr
max)

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15. HEAT EXCHANGERS

 Heat exchanger’s nozzle location: Hot fluid flow from top to bottom; cold fluid to flow from bottom to top.
 Fouling Resistance, ft2-°F-hr/BTU Source: TEMA and Others. To convert to m2°K/W, divide by 5.67826; To
m2°K-hr/kCal divide by 4.886

Gases and Vapors Fouling Resistance, ft2-°F-hr/BTU

Acid gas 0.001 - 0.003
Solvent Vapor 0.001
Stable Overhead Products 0.001 - 002
Natural Gas 0.001 - 0.002
Overhead Products 0.001
Light Naphtha 0.001
Light Hydrocarbon vapors (clean) 0.001
Vacuum Overhead Vapors 0.002
Recycle gas 0.001
Ammonia vapor 0.001
Chlorinated hydrocarbons vapors 0.001 - 0.0015
Chlorine Vapor 0.002
CO2 vapor 0.001
Compressed Air 0.001 - 0.002
Hydrogen 0.0005
Hydrogen (saturated with water) 0.002
Natural Gas Flue Gas 0.005
Nitrogen 0.0005
Polymerizable vapors (with inhibitor) 0.003 - 0.03
Refrigerant Vapors (oil bearing) 0.002
Steam (non-oil bearing) 0.0005
Steam (exhaust, oil bearing) 0.0015 - 0.002
Engine Exhaust 0.010
Oils Fouling Resistance, ft2-°F-hr/BTU
Fuel Oil #6 0.005
Transformer Oil 0.001
Engine Lube Oil 0.001
Quench Oil 0.004
Gasoline 0.001 - 0.002
Naphtha and Light Distillates 0.001 - 0.003
Kerosene 0.001 - 0.003
Light cycle oil 0.002
Heavy cycle oil 0.003
Light coker gas oil 0.003
Heavy coker gas oil 0.004
Bottom slurry (> 1.5 m/s) 0.003
Bottom liquid products 0.002
Reformer charge 0.002
Reformer effluent 0.002

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Hydrocracker charge and effluent 0.002

HDS charge and effluent 0.002
Liquid product > 50 API 0.001
Liquid product 30 to 50 API 0.002
Lube oil processing streams 0.003
Feed stock 0.002
Solvent feed mix 0.002
Solvent 0.001
Extract 0.002
Raffinate 0.001
Asphalt 0.005
Wax slurries 0.003
Refined lube oil 0.001
Light Gas Oil 0.002 - 0.003
Heavy Gas Oil 0.003 - 0.005
Fuel Oil #2 0.002
Stable Side or Bottom Products 0.001
Heavy Fuel Oils 0.005 - 0.007
Asphalt & Residuum 0.010
Vegetable Oil 0.003
Liquids Fouling Resistance, ft2-°F-hr/BTU
Refrigerant Liquids 0.001
Hydraulic Fluid 0.001
Organic Heat Transfer Liquids 0.001
Molten Heat Transfer Salts 0.0005
MEA & DEA Solutions 0.002
DEG & TEG Solutions 0.002
Ethylene Glycol Solutions 0.002
Lean Oil 0.002
Rich Oil 0.001
Natural Gasoline & Liquefied Petroleum 0.001
Gases
Absorption oils 0.002
Alkylation trace acid streams 0.003
Reboiler streams 0.003
Ammonia Liquid 0.001
Ammonia Liquid (oil bearing) 0.003
CO2 Liquid 0.001
Chlorinated hydrocarbons liquid 0.001 - 0.002
Chlorine Liquid 0.002
Light hydrocarbon liquid (clean) 0.001
Caustic 0.002

Crude Oil Fouling Resistance, ft2-°F-hr/BTU

Temperature ≤ 199°F 200 - 299°F

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Velocity, fps ≤2 2-4 ≥4 ≤2 2-4 ≥4

Dry 0.003 0.002 0.002 0.003 0.002 0.002
Salt 0.003 0.002 0.002 0.005 0.004 0.004
Temperature 300 - 499°F > 500°F
Velocity, fps ≤2 2-4 ≥4 ≤2 2-4 ≥4
Dry 0.004 0.003 0.002 0.005 0.004 0.003
Salt 0.006 0.005 0.004 0.007 0.006 0.005

Water Fouling Resistance, ft2-°F-hr/BTU

Water temperature ≤ 125°F >125°F
Water velocity, fps ≤3 >3 ≤3 >3
Sea Water 0.0005 0.0005 0.001 0.001
Brackish Water 0.002 0.001 0.003 0.002
Cooling Tower Water (treated) 0.001 0.001 0.002 0.002
Cooling Tower Water (untreated) 0.003 0.003 0.005 0.004
River Water (minimum) 0.002 0.001 0.003 0.002
River Water (average) 0.003 0.002 0.004 0.003
River Water (muddy or silty) 0.003 0.002 0.004 0.003
Hard Water 0.003 0.003 0.005 0.005
Engine Jacket 0.001 0.001 0.001 0.001
Distilled/ DM/ Condensate 0.0005 0.0005 0.0005 0.0005
City or Well Water 0.001 0.001 0.002 0.002
Treated Boiler Feed Water 0.001 0.0005 0.001 0.001
Boiler Blowdown Water 0.002 0.002 0.002 0.002

16. TYPICAL CONTROL VALVE

Size 2 2 3 3 4 4 6 6 8 8
Rating 9-25 3-6 25 3-15 25 3-15 25 1-15 25 1-15
Cv - 100% 30 50 65 95 120 145 200 210 300 500

Liquid - Subcritical ΔP < Cf 2(ΔPs)

Cv = 1.16q(SG/ΔP)0.5 or Cv = 1.16*W/(SG*ΔP)0.5

Liquid - Critical/ Cavitating/Flashing ΔP ≥ Cf 2(ΔPs)

Cv = 1.16q(SG/ΔPs)0.5/Cf or Cv = 1.16*W/(SG*ΔPs)0.5/Cf
Where ΔPs = P1 - (0.96 - 0.28(Pv /PC)0.5)PV or PV <0.5 P1, ΔPv = P1 - Pv

Gas and Vapor - Subcritical ΔP < Cf 2 0.5P1

Cv = Q/295(SG.T.z/ΔP/(P1+P2))0.5 or 47.2W(z/SGf/ΔP/(P1+P2))0.5

Gas and Vapor - Critical ΔP ≥ Cf 2 0.5P1

Cv = Q (SG.T.z)0.5 /(257CfP1) OR 54.5W(z/SGf) 0.5 /(CfP1)

Cv = Valve Coeft Cf = Critical Flow Factor

P1 = Upstream Pressure, bar a P2 = Downstream Pressure, bar a ΔP = P1 - P2
PC = Critical Pressure, bar a PV = Liquid Vapor Pressure, bar a
q = m³/h W = 1,000 kg/h SG = Sp. Gravity

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G = Gas Sp Gravity (air = 1) Gf = Gas Sp Gravity at flowing temperature = G.288/T

Q = Nm³/h T = t + 273

Example:
P1 = 75 bara T = 30°C = 303°K Flow = 40,000 kg/h Mol Wt = 25.0 z = 0.95 Cf = 0.9

Case 1: P2 = 60 bara Pc = 41.6 bara. or (75-60) = 15 <0.92*0.5*75 = 30.4 Flow is sub-critical

Cv = 47.2*40(0.95/(25/28.97*288/303)/(75-60)/(75+60))0.5 = 45 .. 2”valve

Case 2: P1 = 75 bara P2 = 35 bara Pc = 41.6 bara. OR (75-35) = 60 > 0.92*0.5*75 = 30.4 Flow is critical
Cv = 54.5*40(0.95/(25/28.97*288/303)) 0.5 /(0.9*75) = 34.8 .. 2” valve

17. CV VALVE into Equivalent Length

Reference Crane Example 4 -2
6” Globe Valve Cv = 600
Cv = 29.9 d2/K0.5 OR K = 894d4/Cv2 d in inches = 891*6.0674/6002 = 3.36
L/D = K/f, f limiting friction factor = 3.36/0.015 = 224 L = 224*0.154 = 34.5m

Size, in 1 2 3 4 6 8 -10 10 12-16 18-24

f 0.023 0.019 0.018 0.017 0.015 0.014 0.0135 0.013 0.012

Cv of 2” Globe Valve L/D = 340 K = 340*0.019 = 6.46 Cv = 29.9*22/6.460.5 = 47

18. TYPICAL SDV LEAK RATE

All valves leak, including SDV. Allowable leak rates are in API 14C Ed 2001 Table D2
 Gas = 15 SCFM (0.4 Nm³/min). Liquid = 400 cc/min
 Assume Pup = SITP or PSV Set Pressure and Pdown = Atmosphere or PSV Relief Pressure
 Field Test of Leak Rates of 24” Ball Valve/ SDV with upstream at 80 bar. Ball valve = 0.2-0.5 Nm³/min (Hole dia
≈ 0.03”). SDV = 1.5-3.0 Nm³/min (Hole dia = ≈ 0.08”). SDV leaked more than manual ball valve
 PSV provided in LP section to cater to 2-10*allowable leak rate. Some go for highest PSV size that would
within release rates/ header sizes of the zone

19. SHELL SIZE AND TUBE COUNT ESTIMATION - FROM GPSA

Use typical U and find likely Area. Assuming ¾ or 1” tubes, find total lengths. Assuming 6-9m long tubes, find the
number of tubes. Then based on GPSA Figure 9-26 find Shell ID against Tube Count, Tube Diameter and Tube
Pitch. Figure 9-27/28 give corrections - based on number of tube passes and type of tube bundle. Check example
9-3. Fig 9-13 gives a typical shell details. Will help in preliminary plot plans and tube rupture cases sizing

20. ADDITIONAL CHARTS/ TABLES - ADD

 Vapor Pressure of Hydrocarbons
 Viscosity of Hydrocarbon Vapors/ Miscellaneous Gases/ Liquid Petroleum Products
 Standard Pipe and Tube Tables
 Pressure Rating Tables for 150, 300, 600, 900, 1500 and 2500 flanges
 Partial Volume of Horizontal and Vertical Storage Tanks

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 Heat Exchangers - TEMA Classification Chart

 Typical U, Overall Heat Transfer Coefficients - Perry pages 11-25 thru 11-27
 Standard Relief Valve Sizes Table
 Conversion Factors - Perry Tables 1-5 thru 1-7

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