Pressure Drop and Flow Rate Calculations based on the Karman Method- For current Situvation

Q flow rate L pipe length d pipe NPS fluid density fluid viscosity pipe roughness Q flow rate

100.00 m3/h 80000 m 11 in 890 kg/m3 1.00 cP 40.0 micron in BBL per day

15094
P friction 595.79 kPa 472.94 kPa Moody friction factor 0.0181
pressure drop P friction pressure
based on Ka 86.409 psi drop based on Moody Difference, Ka-Moody 20.6%

v flow velocity d, metres Reynolds No Flow category Flow type Karman No E = /d

0.453 m/s 0.2794 112,660 6 High Turbulent 4,517,763 0.00014

z = 6 + log E x = log Re y = log Ka =y-x u=z-3 v = x - 3,3

2.15583 5.0517712227 6.6549234646 1.6031522419 -0.84417 1.7517712227

a b a0 a1 a2 b0 b1 b2

Value 0.0123375054 0.9081178614 0 0 0

Laminar 0 0 0 0 0

Transition z<3 0 0 0.75 -2.5 14

Transition z>=3 0 0 0.7210359299 -3.2639632142 20.7117540764

Low Turbulent z<3 0.188 0.784906483 0.742 0.0005 0.009

Low Turbulent z>=3 0.2828983523 0.784906483 0.742 0.0005 0.009

High Turbulent 0.0123375054 0.9081178614 0.850 0.022 0.0023

 Pressure Drop and Flow Rate Calculations based on the Karman Method- 29000 BBl /day & 12 "
Q flow rate L pipe length d pipe NPS fluid density fluid viscosity pipe roughness Q flow rate

190.00 m3/h 80000 m 12 in 890 kg/m3 1.00 cP 40.0 micron in BBL per day

28679
P friction 1313.30 kPa 1005.44 kPa Moody friction factor 0.0165
pressure drop P friction pressure
based on Ka 190.471 psi drop based on Moody Difference, Ka-Moody 23.4%

v flow velocity d, metres Reynolds No Flow category Flow type Karman No E = /d

0.723 m/s 0.3048 196,217 6 High Turbulent 12,928,794 0.00013

z = 6 + log E x = log Re y = log Ka =y-x u=z-3 v = x - 3,3

2.11805 5.2927362628 7.1115580159 1.8188217531 -0.88195 1.9927362628

a b a0 a1 a2 b0 b1 b2

Value 0.0115792367 0.9069150545 0 0 0

Laminar 0 0 0 0 0

Transition z<3 0 0 0.75 -2.5 14

Transition z>=3 0 0 0.722372269 -3.35248586 21.3221500118

Low Turbulent z<3 0.188 0.7834340552 0.742 0.0005 0.009

Low Turbulent z>=3 0.2904791963 0.7834340552 0.742 0.0005 0.009

High Turbulent 0.0115792367 0.9069150545 0.850 0.022 0.0023

 Pressure Drop and Flow Rate Calculations based on the Karman Method- 29000 BBl /day & 8 5/8 "
Q flow rate L pipe length d pipe NPS fluid density fluid viscosity pipe roughness Q flow rate

190.00 m3/h 80000 m 8.50 890 kg/m3 1.00 cP 40.0 micron in BBL per day

28679
P friction 7360.75 kPa 5515.20 kPa Moody friction factor 0.0161
pressure drop P friction pressure
based on Ka 1067.550 psi drop based on Moody Difference, Ka-Moody 25.1%

v flow velocity d, metres Reynolds No Flow category Flow type Karman No E = /d

1.442 m/s 0.2159 277,012 6 High Turbulent 25,753,148 0.00019

z = 6 + log E x = log Re y = log Ka =y-x u=z-3 v = x - 3,3

2.26781 5.4424985831 7.4108303211 1.968331738 -0.73219 2.1424985831

a b a0 a1 a2 b0 b1 b2
Value 0.0149717577 0.9117205471 0 0 0

Laminar 0 0 0 0 0

Transition z<3 0 0 0.75 -2.5 14

Transition z>=3 0 0 0.7184009224 -3.0289901688 19.0590057922

Low Turbulent z<3 0.188 0.7894204552 0.742 0.0005 0.009

Low Turbulent z>=3 0.262112002 0.7894204552 0.742 0.0005 0.009

High Turbulent 0.0149717577 0.9117205471 0.850 0.022 0.0023

 Pressure Drop and Flow Rate Calculations based on the Karman Method- 6 5/8 " upto KK station and 8 5/8 " from KK station to A 100

Q flow rate L pipe length d pipe NPS fluid density fluid viscosity pipe roughness Q flow rate

100.00 m3/h 37000 m 6.50 890 kg/m3 1.00 cP 40.0 micron in BBL per day

15094
P friction 3822.34 kPa 2896.11 kPa Moody friction factor 0.0172
pressure drop P friction pressure
based on Ka 554.364 psi drop based on Moody Difference, Ka-Moody 24.2%

v flow velocity d, metres Reynolds No Flow category Flow type Karman No E = /d

1.298 m/s 0.1651 190,656 6 High Turbulent 12,930,295 0.00024

z = 6 + log E x = log Re y = log Ka =y-x u=z-3 v = x - 3,3

2.38431 5.2802505512 7.1116084239 1.8313578727 -0.61569 1.9802505512

a b a0 a1 a2 b0 b1 b2

Value 0.0183785611 0.9155302648 0 0 0

Laminar 0 0 0 0 0

Transition z<3 0 0 0.75 -2.5 14

Transition z>=3 0 0 0.7177621808 -2.8278964345 17.5869251288

Low Turbulent z<3 0.188 0.7943566893 0.742 0.0005 0.009

Low Turbulent z>=3 0.2431462966 0.7943566893 0.742 0.0005 0.009

High Turbulent 0.0183785611 0.9155302648 0.850 0.022 0.0023

 Q flow rate L pipe length d pipe NPS fluid density fluid viscosity pipe roughness Q flow rate

190.00 m3/h 40000 m 8.50 890 kg/m3 1.00 cP 40.0 micron in BBL per day

28679
P friction 3680.38 kPa 2757.60 kPa Moody friction factor 0.0161
pressure drop P friction pressure
based on Ka 533.775 psi drop based on Moody Difference, Ka-Moody 25.1%

v flow velocity d, metres Reynolds No Flow category Flow type Karman No E = /d

1.442 m/s 0.2159 277,012 6 High Turbulent 25,753,148 0.00019

z = 6 + log E x = log Re y = log Ka =y-x u=z-3 v = x - 3,3

2.26781 5.4424985831 7.4108303211 1.968331738 -0.73219 2.1424985831

a b a0 a1 a2 b0 b1 b2

Value 0.0149717577 0.9117205471 0 0 0

Laminar 0 0 0 0 0

Transition z<3 0 0 0.75 -2.5 14

Transition z>=3 0 0 0.7184009224 -3.0289901688 19.0590057922

Low Turbulent z<3 0.188 0.7894204552 0.742 0.0005 0.009

Low Turbulent z>=3 0.262112002 0.7894204552 0.742 0.0005 0.009

High Turbulent 0.0149717577 0.9117205471 0.850 0.022 0.0023

 Revised Idle cost per
Sl.no Equipment number Capacity Utilisation Factor
hour

in lits USD
1 SSRR-107 10,000 0.82 2268.33 USD per Hr
2 SSRR-105 12,000 0.54 1792.53 USD per Hr
3 SSRR-102 6,000 1.00 1659.75 USD per Hr
4 SSRR-118 6,000 0.98 1626.56 USD per Hr
5 SSRR-109 6,000 0.92 1526.97 USD per Hr
6 SSRR-110 4,000 0.79 874.14 USD per Hr
7 SSRR-117 3,000 1.00 829.88 USD per Hr
8 SSRR-106 3,000 0.96 796.68 USD per Hr
9 SSRR-108 3,000 0.80 663.90 USD per Hr
10 SSRR-116 2,000 1.00 553.25 USD per Hr
11 SSRR-119 2,000 0.95 525.59 USD per Hr
12 SSRR-104 4,000 0.40 442.60 USD per Hr
13 SSRR-112 1,600 0.95 420.47 USD per Hr
14 SSRR-113 2,000 0.73 403.87 USD per Hr
15 SSRR-101 2,000 0.67 370.68 USD per Hr
16 SSRR-103 1,600 0.72 318.67 USD per Hr
17 SSRR-115 1,600 0.48 212.45 USD per Hr
18 SSRR-111 1,000 0.62 171.51 USD per Hr
19 SSRR-114 500 1.00 138.31 USD per Hr
20 SSRR-120 1,000 0.50 138.31 USD per Hr

Total Capacity 72.30 KL

Fixed cost 100,000,000

Semi varible cost 60,000,000

Total 160,000,000

Total Capacity 72

Expected operation
hours in Year 8,000

Cost per KL per Hour 276.63 USD /HR/KL

Sl.no Equipment number Utilisation Hours Utilisation Factor

in lits USD
1 SSRR-101 5,320 0.67
2 SSRR-102 7,980 1.00
3 SSRR-113 5,852 0.73
Equipment
number Capacity 12 24 36 48 60 72 84 96 108 120 132 144
SSRR-101
SSRR-102
SSRR-113
144 156 168 180 192 204 216 228 240 252 264 276 288 300 312 324 336 348 360 372 384 396 408 420
420 432 444 456 468 480 492 504 516 528 540 552 564 576 588 600 612 624 636 648 660 672 684 696
708 720
 Pressure Drop and Flow Rate Calculations based on the Karman Method- Proposed Size with low production upto KK station

Q flow rate L pipe length d pipe NPS fluid density fluid viscosity pipe roughness Q flow rate

350.00 m3/h 75000 m 10 in 890 kg/m3 1.00 cP 40.0 micron in BBL per day

52830
P friction 9825.92 kPa 7297.28 kPa Moody friction factor 0.0151
pressure drop P friction pressure
based on Ka 1425.079 psi drop based on Moody Difference, Ka-Moody 25.7%

v flow velocity d, metres Reynolds No Flow category Flow type Karman No E = /d

1.919 m/s 0.254 433,742 6 High Turbulent 59,710,837 0.00016

z = 6 + log E x = log Re y = log Ka =y-x u=z-3 v = x - 3,3

2.19723 5.6372319522 7.7760531572 2.138821205 -0.80277 2.3372319522

a b a0 a1 a2 b0 b1 b2

Value 0.0132421404 0.9094429256 0 0 0

Laminar 0 0 0 0 0

Transition z<3 0 0 0.75 -2.5 14

Transition z>=3 0 0 0.7198310604 -3.1723399914 20.0736219549

Low Turbulent z<3 0.188 0.7865488429 0.742 0.0005 0.009

Low Turbulent z>=3 0.2749222297 0.7865488429 0.742 0.0005 0.009

High Turbulent 0.0132421404 0.9094429256 0.850 0.022 0.0023