Unit Sizing Calc For Tanks & Pumps-CPU 040510

DOC. NO. PDRP0456-8110-CA-106-0002 REV.
O1
HDO DOC. NO. A4-2100866-106-BEP-Vol I-004
UNIT SIZING CALCULATIONS
PARADIP REFINERY PROJECT CRS UNIT
FOR
INDIAN OIL CORPORATION LIMITED
CONSULTANT: -
FOSTER WHEELER (INDIA)
SUBMITTED
BY
DORR-OLIVER HOUSE,
CHAKALA, ANDHERI (EAST), MUMBAI 400099
INDIA
TEL. NO. :-022 28359400
FAX NO. :- 022 28365659
O1 10.05.2010 ISSUED FOR APPROVAL AS RK JNP

PREPARED CHECKED APPROVED
REV. DATE REVISIONS
BY BY BY
[Type text]
INDIAN OIL CORPORATION LIMITED 2 UNIT SIZING CALCULATIONS FOR TANKS

PARADIP REFINERY PROJECT CRS UNIT DOC NO PDRP0456-8110-CA-106-0002 REV O1
[Type text]
UNIT SIZE CALCULATION

LEGENDS
EL : Epoxy Lined
TD : Total Depth
SWD : Side Water Depth
FB : Free Board
MOC : Material of Construction
HRT : Hydraulic Retention Time
DVD : Dead Volume Depth .
OWS : Oily Water Sewer .
CRWS : Contaminated Rain Water Sewer .
UNIT SIZE CALCULATION

CRS PLANT UNIT 106
[Type text]
CONDENSATE RECOVERY SYSTEM FEED WATER ANALYSIS

CRS Feed Water Characteristic
Sr. No. Description Unit Normal Design
as Such as Such as CaCO3
Physical Parameter
o
1 Temperature C 40 40 -
2 Total Dissolved Solids g/l 5000 5000 -
3 pH - 7.5 - 9.5 7.5 - 9.5 -
4 Oil mg/l <1 <1 -
o
5 KMnO4 Value @ 100 C mg/l Nil Nil -
Cations
6 Na + K as CaCO3 g/l 100.00 1000 2173.91
9 Ammonia g/l 500.00 1000 2941.18
7 Ca Hardness as CaCO3 g/l < 40 400 1000.00
8 Mg Hardness as CaCO3 g/l < 24 240 1000.00
10 Iron as Fe g/l 30.00 200 357.14
11 Copper g/l 10.00 100 154.93
11 Nickel g/l 30.00 200 0.00
Total Cation g/l - - 7627.16
Anions
12 Total alkalinity (as CaCO3) g/l 0.00 - 20.0000
13 Chlorides as Cl g/l 100.00 1000.00 2445.011
14 Sulphates as SO4 g/l 100.00 1000.00 1041.667
Total Anion g/l - - 3506.68
Others
15 Total Silica as SiO2 g/l 120.60 603.00 500.00
16 Carbon dioxide g/l < 200 1000.00 1136.36
Ionic Load
17 MB Cation Load mg/l - - 7.627
18 MB Anion Load based on Total Anion mg/l - - 5.143
19 MB Anion Load based on SiO2 mg/l - 0.603 -

[Type text]
OIL COALESCER
Total flow to be treated = 1100 m3/hr
Total oil in the inlet = 20 ppm (for Design)
Dissolved oil in the inlet = 2 ppm (for Design)
Total oil in the inlet = 2 ppm ( Normal)
Dissolved oil in the inlet = 0.5 ppm (Normal)
pH = 7.5 9.5
Temperature = < 50 deg. C
Number of working units = 8 nos.
Number of standby units = 3 nos.
Total number of units = 11 nos.
Flow per unit = 1100 / 8

= 137.5 m3/hr (1)
Resin Grade = Coalescer grade
Resin size = 0.3 mm to 1.5 mm
Process conditions = Continuous
Operating pH range = 0 12
Velocity of condensate in oil = 11 m / hr (2)
Minimum Bed depth = 250 mm

Bed depth recommended = 400 mm
Area of oil coalesce unit required = Flow per unit (1)

___________
Velocity (2)
= 137.5 / 11
= 12.5 m2 (3)
Minimum diameter calculated D = 12.5 x 4/
= 3989 mm
Diameter provided = 4000 mm (4)

[Type text]
C/S area of each Coalescer unit = / 4 x 42
= 12.571 m2 (5)
Volume of resin required = C/S area of each coalescer x Depth of resin
= 12.571 m2 x 0.4 m
= 5.028 m3 (6)
Vessel height below the bottom

Strainer = 500 mm
= 0.5 m (7)
Height between resin

Top strainer = 500 mm
= 0.5 m (8)
Chimney height = 500 mm

= 0.5 m (9)
Space provided for collecting free

Oil = 1000 mm
= 1m (10)
Total ht. of vessel calculated = (7) + (8) + (9) + (10) + 0.4 m
= 0.5 + 0.5 + 0.5 + 1.0 + 0.4

= 2.9 m
Ht. of vessel provided = 3.0 m

[Type text]
CARTRIDGE FILTER
Design flow (total) = 1100 m3/hr (1)
No. of Cartridge Filters working = 2 nos. (2)
No. of Cartridge Filters standby = 1 no. (3)
Total No. of Cartridge Filters = 3 nos. (4)
Flow per filter = Design flow (1)

__________________
No. of Cartridge Filter working (2)
= 1100 / 2
= 550 m3/hr (5)
Micron rating of Cartridge Filter = 5 micron
Type of Cartridge = PP wound
MOC of Cartridge filter = SS 316

MOC of Cartridges = Polypropylene (PP)
Flow through each 10 Cartridge = 1.0 m3/hr

Flow through each 40 cartridge = 4.0 m3/hr
No. of cartridges of 40 long per filter= 550 / 4.0
= 137.5
138 Nos.
Size of cartridge filter = as per manufacturer model

[Type text]
ACTIVATED CARBON FILTER
Total flow to be treated = 1100 m3/hr (1)
Total No. of ACF provided = 09 nos. (6W + 3 S)
Flow rate per ACF = 1100/6

= 183.33 m3/hr (2)
Inlet oil = 5 ppm
Desired outlet oil = BDL
Total suspended solids = Nil
Service velocity = 15 m3/hr/m2

= 15 m/hr (3)
Minimum C/S area based on service

Velocity = (2) / (3)
= 183.33 m3/hr
___________
15 m/h
= 12.22 m2 (4)
Minimum retention time required = 10 min
Minimum carbon volume required = (2) x 10/60

(for each unit)
= 183.33 x 10/60
= 30.56 m3 (5)
Maximum specific flow rate = 6 m3/hr/m3
Minimum volume of carbon required = 183.33/6

For each unit = 30.56 m3 (6)
Maximum bed depth of carbon = 2.5 m (7)
Minimum C/S area based on Max. Bed depth = (6) / (7)
= 30.56 m3
_______
2.5 m
= 12.222 m2 (8)
[Type text]
Minimum cross section area required = Maximum of (4) & (8)

= 12.222 m2 (9)
Minimum diameter of vessel required = 12.222 x 4/
= 3.945 mm
Diameter of vessel provided = 4.0 mm (10)
C/S area of vessel provided = / 4 x 42
= 12.56 m2 (11)
Actual service velocity = Flow per unit (1)

_______________
C/S area provided (11)
= 183.33 / 12.56
= 14.6 m/hr (12)
Minimum carbon bed depth = 2.2 m
Carbon depth calculated = (6) / (11)
= 130.56 / 12.56
= 2.433 m (13)
Carbon bed depth provided = 2.433 mm (14)
Volume of activated carbon

Provided for each ACF = 30.56 m3 (15)
Actual specific flow rate = 6.0 m3/hr/m3
Supporting media layer depth (Silex) = 50 mm (fine 2 6 mm)

= 0.05 m (a)
Supporting media layer depth (Silex) = 50 mm (coarse 14 mm)

= 0.05 m (b)
Total supporting media depth = 100 mm

= 0.1 m
Supporting Media volume = C/S area x 0.1 m
= (11) x 0.1

[Type text]
= 12.56 x 0.1
= 1.256 m3 (16)
Total bed height provided = (14) + (a) + (b)
= 2.433 + 0.05 + 0.05

= 2.533 m (19)
Free board provided = 75% of bed ht.
Free board provided = 0.75 x 2.533

= 1.9 m (20)
Height on straight (HOS) calculated = (19) + (20)

= 2.533 + 1.9
= 4.433 m (21)
Height on straight provided = 4.5 m (22)
Backwash source = Treated condensate water
Backwash velocity = 12 m / hr
Back wash flow required = C/S area(11) x 12

= 12.56 x 12
= 150.72 m3/hr (23)
Back washing time = 10 minutes
Quantity of back wash waste

For each unit = 150.72 x 10 / 60
= 25.12 m3 (24)
Rinse flow rate = same as service flow rate

= 183.33m3/hr
Rinse time = 5 minutes
Quantity of rinse waste = 183.33 x 5/60

= 15.278 m3 (25)
Total waste per unit due to
Back washing & rinsing
of ACF = (24) + (25)
= 25.12 + 15.278
= 40.4 m3 (26)
Total waste from 6 ACFs = 40.4 x 6

= 242.4 m3

[Type text]
CONDENSATE POLISHING UNIT MIXED BED EXCHANGER

SIMULTANEOUS REGENERATION
Total no. of streams = 4 Nos. (2 working + 1 regeneration

Standby + 1 Normal standby)
Flow rate per stream = 550 m3/hr (1)
Regeneration mode = Simultaneous
Regenerant temperature = 40 deg. C
Exhaustion/operation time = 42 hrs (2)

Per cycle
Net output per cycle = 23100 m3 (3)
Waste water per cycle = 142.50 m3 (4)

(Refer regeneration
Calculation sheet)
Gross output per cycle = (3) + (4)
= 23100 + 142.59
= 23242.59 m3
Gross flow rate per Exchanger = 553.4 m3/hr (5)
Considering Cation Bed
Ionic Load on cation bed as CaCO3 = 7.63 mg/l

= 7.639 g/m3 (6)
Work done per cycle Gross O/P per x

Ionic
As CaCO3 = cycle m3 load
(g/ m3)
__________________________
1000
= 23242.59 x 7.63
_______________
1000
= 177.27 kgs (7)
Regeneration level (100%) = 60 kg/m3 of resin (8)
Exchange capacity = 39 kg of ionic load/m3 (9)

of resin
Correction factor due to ionic ratio = 1.0
Derating factor = 0.7

[Type text]
Total Correction factor = 0.7 (10)
Design exchange capacity = (9) x (10)

= 39 x 0.7
= 27.3 kg / m3 (11)
Work done per cycle = 177.27 kg (from 7)
Effective resin volume = (7) kg

Based on work done ____
(11) kg/m3
= 177.27 m3
_______
27.3
= 6.493 m3 (12)
Maximum specific Bed volume (BV) = 46 m3/hr (13)
Effective resin volume based on

specific bed volume = (5)
____
(13)
= 12.03 m3 (14)
Effective resin volume considered = Maximum of (12) & (14)
= 12.03 m3 .. (15)
Maximum surface flow rate = 60 m3/hr/m2 (16)
Minimum C/s area based on

Maximum surface flow = (5)
_____
(16)
= 9.223 m3/hr (17)
Maximum bed depth = 1000 mm

= 1.0 m (18)
Minimum C/s area based on max = effective resin volume (15)

Bed depth _____________________
Max bed depth (18)
[Type text]
= 12.03
_______
1.0
= 12.03 m2 .. (19)
Considering Anion Bed
Anionic Load on Anion Bed = 5.14 mg/l

= 5.14 g/m3 (20)
Work done per cycle Gross O/P per x 5.14 g/m3

As CaCO3 = cycle m3
__________________________
1000
= 23242.59 x 5.14
_______________
1000
= 119.54 kgs (21)
Regeneration level = 60 kg/m3 (22)
Anionic Exchange capacity = 26.5 kg/m3 (23)

Correction factor = 1.0 (a)
Derating factor = 0.9 (b)
Total Correction factor = (a) x (b)

= 1.0 x 0.9
= 0.9 (24)
Design exchange capacity = Exchange x Total

Capacity Correction factor
(23) x (24)
= 26.5 x 0.9
= 23.85 kg / m3 (25)
Effective resin volume = (21)

(25)
= 119.54
_______
[Type text]
23.85
= 5.012 m3 (26)
Maximum surface flow (bed volume = 46 m3/hr/m3
Effective resin volume = (5)

(46)
= 553.4
_______
46
= 12.03 m3 (27)
Silica load on Anion Bed
As CaCO3 = 0.6 mg/l (28)
Regeneration level = (22)

60 kg/m3 Refer Resin Mfr. data
Silica Exchange capacity = 2.1 kg/m3 (29)

Correction factor = 1.0 (a)
Derating factor = 0.9 (b)
Total Correction factor = (a) x (b)

= 1.0 x 0.9
= 0.9 (c)
Design exchange capacity = (29) x (c)

= 21 x 0.9
= 1.89 kg / m3 (30)
Work done per cycle = Gross O/P per x Ionic load

Due to silica load cycle m3
______________________________
1000
= 23242.59 m3 x 0.69 m3
_______________
1000
= 14.02 kgs (31)

[Type text]
Effective resin volume = Work done (31)

Based on work done _________________________
Design exchange capacity (30)
= 14.02
_______
1.89
= 7.415 m3
Total Effective resin volume based on

Anionic load + silica load = (26) + (31)
= 5.012 + 7.415
= 12.427 m3 (32)
Effective resin volume to be considered = Maximum of (27) & (32)

= Maximum of 12.03 m3& 12.427 m3
= 12.427 m3 .. (33)
Maximum surface flow rate = 60 m3/hr/m2 (34)
Minimum C/s area based on

surface flow = (5)
_____
(34)
= 553.4 m3/hr
______
60 m3/hr/m2
= 9.223 m2 (35)
Maximum bed depth = 1000 mm

= 1.0 m

[Type text]
Minimum C/s area based on max = (33)

Bed depth ____
(1.0)
= 12.42
_______
1.0
= 12.42 m2 .. (36)
Based on Cation & Anion calculations
Minimum C/s area to be considered = Maximum of (19) & (36)
= 12.427 m2 (37)
_______
2.5 m
Minimum unit diameter calculated = 12.427 x 4/
= 3.977 m
Unit Diameter provided = 4.0 m (38)
Considering rubber lining of thickness = 4.5 mm
C/S area of Mixed Bed provided = (4000 9)2 x /4

_________
1000
= 12.515 m2 (39)
Resin bed depth with effective resin volume = (15)

____
(39)
= 0.961 m (40)
Minimum resin depth criteria for

Cation bed = 0.5 m
Resin bed depth of 0.961 m ( 0.5 m) is OK
Anion Bed
[Type text]
Resin bed depth with effective

Resin volume = (33)
_____
(39)
= 0.993 M (41)
Minimum resin bed depth
Criteria for anion bed = 0.5 m
Resin bed depth of 0.993 m (> 0.5 m ) is OK
Total bed depth provided

Considering cation & Anion = (40) + (41)
= 0.961 + 0.993
= 1.954 m (42)
Considering free board of 100%
Free board required = 1.954 m (43)
Total height of Bed required = (42) + (43)
= 1.954 + 1.954
= 3.908 m
Total height of bed provided = 4.0 m (44)
Considering Cation Bed
Stoichiometric required as CaCO3 = Work done as CaCO3
= 177.27 kg
Regeneration level = 60 kg/m3
Resin volume = 12.03 m3
Therefore HCl required as 100% = 60 x 12.03

= 721.77 kg (45)
conversion factor = 1.37
HCl required as CaCO3 = 988.825 (46)
regeneration efficiency = 177.27

[Type text]
______ x 100
988.825
= 17.927%
Un-utilized Hcl as CaCO3 = 988.825 177.27
= 811.555 (47)
Considering Anion Resin
Stoichiometric required as CaCO3 = Work done as CaCO3
= 119.54 kg
Regeneration level = 60 kg/m3
Resin volume = 12.427 m3
NaOH required as 100% = 60 x 12.427

= 745.65 kg (48)
Conversion factor = 1.25
NaOH required as CaCO3 = 745.62 x 1.25

= 932.03 kg (49)
regeneration efficiency = 119.54

______ x 100
932,03
= 12.826%
Un-utilized NaOH as CaCO3 = 932.03 119.54
= 812.49 kg (50)
From (47) & (50)
Chemical required for neutralization = self neutralized
Chemical required for neutralization = 812.49 811.555
= 0.935 kg (HCl) as CaCO3
= 0.935 / 1.37
= 0.68 kg (HCl) as 100%.

[Type text]
SUMMARY OF CRS MIXED BED (MB) EXCHANGER

(i) Diameter of MB Exchanger : 4.0 metre
(ii) Height on Straight (HOS) of MB : 4.0 metre
(iii) Material of Construction of MB : CS with 4.5 mm thick Rubber
Lining
(iv)Total Cation Resin Volume for MB : 12.03 m3
(v) Total Anion Resin Volume for MB : 12.427 m3
(vi)Hydrochloric Acid Required
for Regeneration (as 100%) : 721.77 kg per MB per
Regeneration
(vii)Sodium Hydroxide (NaOH) Required
for Regeneration (as 100%) : 745.65 kg per SBA per
Regeneration

[Type text]
CRS Regeneration
Mixed Bed Regeneration = Simultaneous regeneration

Using HCl & NaOH
Size of Mixed Bed Exchanger = 4.0 m dia x 4.0 m HOS
C/S area of MB including

Rubberlining of thickness of 4.5 mm = {(4000 9)/1000}2 x /4
= 12.515 m2 (1)
In Mixed Bed, regeneration is carried out simultaneously by acid from bottom (counter current) and
Alkali from top (co flow). With this, compaction of Bed is maintained without any requirement of down
flow and up flow arrangement of water for bed compaction.
Quantity of Acid (100%) required per regeneration
= 721.77 kg (2)
Quantity of Alkali (100%) required per regeneration
= 745.65 kg (3)
Acid injection concentration = 4% w/v

= 40 kg/m3 (4)
Caustic injection concentration = 4% w/v

= 40 kg/m3 (5)
Step 1
Middle Collector Flush; Source: Feed
Basis of flow for Middle Collector Flush

= 9 m3/hr per unit C/S area of
Mixed Bed
= 9 m3/hr/m2
Middle collector flush flow rate = 9 x C/s area of MB (1)
= 9 x 12.515
= 112.635 m3/hr (6)
Duration of Middle Collector Flush = 5 minutes
= 5
[Type text]
____ = 0.08333 hrs (7)

60
Middle Collector Flush water = (6) x (7)
= 112.635 x 0.08333
= 9.39 m3 (8)
Step 2: Backwash
Basis of flow rate and water generated is as Step 1 , but duration of back wash is twice of that of Middle
Collector Flush, i.e. 10 min
Backwash waste generated = 9.39 x 2

= 18.78 m3 (9)
Step 3: Acid Pre-injection
Source: MB water
Flow Counter current
&
Alkali Pre-injection
Source: MB water
Flow Cocurrent
Acid pre-injection flow rate = 5

___ x Acid injection flow rate
6
5
___ x X m3/hr
6
Where X = Acid injection flow rate (10)
Duration of Acid pre-injection = Duration of Alkali pre-injection
= 2 min
= 2/60
= 0.0333 hr (11)
Acid pre-injection waste = (10) x (11)
Z1 = 5
__ x X x 0.0333 (12)
6
Alkali pre-injection flow rate = 5

[Type text]
___ x Alkali injection flow rate

6
5
___ x Y m3/hr (13)
6
Where Y = Alkali injection flow rate
Alkali pre-injection waste = 5

__ x Y x 0.0333 (14)
6
Step 4: Acid injection
Source: MB water
&
Alkali injection
Source: MB water
Flow Cocurrent
Quantity of Acid (100%) required per

Regeneration = 721.77 kg
Acid injection concentration = 4% w/v

= 40 kg/m3
Volume of 4% solution = 721.77 kg
_____
40 kg/m3
= 18.044 m3 (15)
Quantity of Alkali (100%) required per

Regeneration = 745.65 kg
Alkali injection concentration = 4% w/v

= 40 kg/m3
Volume of 4% solution = 745.65 kg

_____
40 kg/m3
= 18.64125 m3 (16)
Duration of Acid pre-injection = Duration of Alkali injection
= 15 min (17)
[Type text]
Acid injection flow rate = 18.044 m3

_______
15/60 hr
= 18.044 x 60/15
X = 72.176 m3/hr (18)
Alkali injection flow rate = 18.64125 m3

_______
15/60 hr
= 18.64125 x 60/15
Y = 74.565 m3/hr (19)
From (10) & (18)
Acid pre-injection flow rate = 5

__ x X
6
= 5
__ x 72.176
6
= 60.14667 m3/hr (20)
From (12)
Acid pre-injection waste = 5

__ x 72.176 x 0.0333
6
= 2.0 m3 (21)
From (13) & (19)
Alkali pre-injection flow rate= 5

__ x Y
6
= 5
__ x 74.565
6
= 62.1375 m3/hr (22)
From (14)
[Type text]
Alkali pre-injection waste = 5

__ x 74.565 x 0.0333
6
= 2.07 m3 (23)
Step 5: Acid Rinse
Source: MB water
&
Alkali Rinse
Source: MB water
Flow Cocurrent
From unit size calculation
Effective resin volume = 12.03 m3 (24)
Basis of Acid Rinse waste
= Alkali Rinse Waste
= 4 x effective resin volume

= 4 x 12.03 m3
= 48.12 m3 (25)
Acid Rinse flow rate = Acid pre-injection flow rate (20)
= 60.14667 m3/hr
Alkali Rinse flow rate = Alkali pre-injection flow rate (22)
= 62.1375 m3/hr
Duration of Acid rinse= Acid rinse waste (25)

_____________
Acid rinse flow rate (m3/hr)
= 48.12
_____
60.14667
= 48 min (26)

[Type text]
Duration of Alkali rinse = Alkali rinse waste (25)

_____________
Alkali rinse flow rate (m3/hr)
= 48.12
_____
62.1375
= 46.5 min (27)
Duration of Acid rinse= Duration of Alkali rinse

= Maximum of (26) & (27)
= 48 min (28)
Step 6: Drain Down
Duration of Drain Down = 5 min
Step 7: Air mixing
Basis of air mixing = 2 Nm3/hr per unit C/S area of mixed bed
= 2 Nm3/hr/m2
Air required = 2 Nm3/min/m2 x C/S area of Mixed Bed (1)
= 2 x 12.515
= 25.03 Nm3/min
= 25.03 x 60 Nm3/hr
= 1501.8 Nm3/hr (29)
Duration of air mixing = 10 minutes
Step 8: Force Settle
Source: Feed water

Flow Coflow
Duration of force settle = 3 minutes

Flow rate during force settle = Service flow rate
= 550 m3/hr

[Type text]
Waste due to force settle = 550 x 3/60

= 27.5 (30)
Step 9: Filling
Source: Feed
Flow Coflow
Flow rate during filling = Service flow rate

= 550 m3/hr
Duration of filling = 2 min
Waste due to filling = 550 x 2/60

= 18.33 m3 (31)
Step 10:
Final Source: Feed

Rinse Flow Coflow
Flow rate during final rinse = Service flow rate

= 550 m3/hr
Duration of final rinse = 10 min
Waste due to final rinse = 550 x 10/60 = 91.67 m3 (32)

[Type text]
Summary : Table (D) CRS MIXED BED (MB) EXCHANGER
Flow Time Volume Water

Sr. No. Operation Basis
m3/hr minutes m3 source
1. Middle Collector Flush 9 m3/hr/m2 112.635 5 9.39 Feed
2. Backwash 9 m3/hr/m2 112.635 10 18.78 Feed

5/6 injection MB
3. Acid pre-injection 60.14667 2 2.0
flow water
5/6 injection MB
4. Alkali pre-injection 62.1375 2 2.07
flow water
MB
5. Acid injection 72.176 15 18.044
water
MB
6. Alkali injection 74.565 15 18.64125
water
4 x effective MB
7. Acid Rinse 60.14667 48 48.12
resin volume water
4 x effective MB
8. Alkali Rinse 62.1375 48 48.12
resin volume water
9. Drain down 5
10. Air mixing 2 Nm3/hr/m2 1501.8 10 - -
11. Force Settle Service flow 550 3 27.5 Feed
12. Filling Service flow 550 2 18.33 Feed
13. Final Rinse Service flow 550 10 91.67 Feed
Total Time for Regeneration = 110 Minutes
Feed Water required = 165.67 m3
MB / CRS Water = 136.9953 m3
Total Waste Water for Regeneration = 302.6653 m3

[Type text]
UNIT SIZING CALCULATION FOR CRS UNIT- DOSING/STORAGE TANKS
1. ACID MEASURING TANK FOR MB (106-TK-003 A/B)

No of Tanks = 2
Feed requirement per regeneration = 9.63 m3/hr.
{Basis: Feed requirement is the actual dosing rate per MB. The details given in the Chemical
Consumption, Doc no. PDRP0456-8110-PD-106-0003}
Pumpable capacity of tank required
as per chemical consumption = 2.3 m3 .
{Basis: As per the Chemical Consumption Doc no. PDRP0456-8110-PD-106-0003}
Storage Time available
at feed flow = (2.3/9.63).
= ~ 15 Min.
Side Water Depth provided = 1.6 m .
Area Required = ( 2.3/1.6 )
= 1.43 m2 .
Diameter of Tank Required = 1.35 m.
Diameter of Tank Provided = 1.4 m.
Size of Tank provided = 1.4 m x 1.6 m SWD
+0.298 m FB +0.294 m DVD .
2. ALKALI MEASURING TANK FOR MB (106-TK-004A/B)

No of Tanks = 2
Feed requirement per regeneration = 14.92 m3/hr.
{Basis: Feed requirement is the actual dosing rate per MB. The details given in the Chemical
Consumption, Doc no. PDRP0456-8110-PD-106-0003}
Pumpable capacity of tank required
as per chemical consumption = 3.42 m3 .
{Basis: As per the Chemical Consumption Doc no. PDRP0456-8110-PD-106-0003}
Storage Time available

at feed flow = (3.42/14.92).
= ~ 15 Min.
Side Water Depth provided = 1.8 m

[Type text]
Area Required = (3.42/1.8)

= 1.89 m2
Diameter of Tank Required = 1.55 m
Diameter of Tank Provided = 1.6 m .
Size of Tank provided = 1.6 m x 1.8 SWD
+0.298 m FB +0.294 m DVD .
3. RESIN TRANSFER VESSEL(106-V-006)

No of Tanks = 1
{Basis: Resin requirement will be depend upon the no. of vessels in which resin used & the resin
life, for vessel design Effective Volume 40.85 m3 is considered}
Diameter of Tank Provided = 3.4 m
Height of Tank provided = 4.5 m.


Unit Sizing Calc For Tanks & Pumps-CPU 040510

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DOC. NO. PDRP0456-8110-CA-106-0002 REV.

O1 10.05.2010 ISSUED FOR APPROVAL AS RK JNP

INDIAN OIL CORPORATION LIMITED 2 UNIT SIZING CALCULATIONS FOR TANKS

UNIT SIZE CALCULATION

UNIT SIZE CALCULATION

CONDENSATE RECOVERY SYSTEM FEED WATER ANALYSIS

INDIAN OIL CORPORATION LIMITED 4 UNIT SIZING CALCULATIONS FOR TANKS

Total flow to be treated = 1100 m3/hr

Total oil in the inlet = 20 ppm (for Design)

Dissolved oil in the inlet = 2 ppm (for Design)

Total oil in the inlet = 2 ppm ( Normal)

Dissolved oil in the inlet = 0.5 ppm (Normal)

Temperature = < 50 deg. C

Number of working units = 8 nos.

Number of standby units = 3 nos.

Total number of units = 11 nos.

Flow per unit = 1100 / 8

Resin Grade = Coalescer grade

Resin size = 0.3 mm to 1.5 mm

Process conditions = Continuous

Velocity of condensate in oil = 11 m / hr (2)

Minimum Bed depth = 250 mm

Area of oil coalesce unit required = Flow per unit (1)

Diameter provided = 4000 mm (4)

C/S area of each Coalescer unit = / 4 x 42

Volume of resin required = C/S area of each coalescer x Depth of resin

Vessel height below the bottom

Height between resin

Chimney height = 500 mm

Space provided for collecting free

Total ht. of vessel calculated = (7) + (8) + (9) + (10) + 0.4 m

= 0.5 + 0.5 + 0.5 + 1.0 + 0.4

Ht. of vessel provided = 3.0 m

INDIAN OIL CORPORATION LIMITED 6 UNIT SIZING CALCULATIONS FOR TANKS

Design flow (total) = 1100 m3/hr (1)

No. of Cartridge Filters working = 2 nos. (2)

No. of Cartridge Filters standby = 1 no. (3)

Total No. of Cartridge Filters = 3 nos. (4)

Flow per filter = Design flow (1)

= 550 m3/hr (5)

Micron rating of Cartridge Filter = 5 micron

Type of Cartridge = PP wound

MOC of Cartridge filter = SS 316

Flow through each 10 Cartridge = 1.0 m3/hr

No. of cartridges of 40 long per filter= 550 / 4.0

Size of cartridge filter = as per manufacturer model

INDIAN OIL CORPORATION LIMITED 7 UNIT SIZING CALCULATIONS FOR TANKS

ACTIVATED CARBON FILTER

Total flow to be treated = 1100 m3/hr (1)

Total No. of ACF provided = 09 nos. (6W + 3 S)

Flow rate per ACF = 1100/6

Inlet oil = 5 ppm

Desired outlet oil = BDL

Total suspended solids = Nil

Service velocity = 15 m3/hr/m2

Minimum C/S area based on service

Minimum retention time required = 10 min

Minimum carbon volume required = (2) x 10/60

Maximum specific flow rate = 6 m3/hr/m3

Minimum volume of carbon required = 183.33/6

Maximum bed depth of carbon = 2.5 m (7)

Minimum C/S area based on Max. Bed depth = (6) / (7)

Minimum cross section area required = Maximum of (4) & (8)