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CONTENTS PAGE
1.0 GENERAL 1
CONTENTS PAGE
4.0 INTERNALS 21
CONTENTS PAGE
LIST OF TABLES
LIST OF FIGURES
1.0 GENERAL
Process drums are provided to perform certain functions. Some of the more
common functions are listed below:
This standard applies primarily to those drums that are provided for the
separation of fluid phases or for surge.
Distillate drums
Surge drums
Steam drums
Settling drums
Flare knockout drums
TABLE 1.1
GENERAL FOSTER WHEELER PRACTICE
FOR LENGTH TO DIAMETER RATIOS
1.3 Slope
This section on drum sizing includes general design principles which are
applicable to drums in a wide variety of services which have a vapor space.
Section 6.0 includes instructions for designing drums for a number of specific
services.
The formula for critical velocity is derived from Newton’s Law for
the velocity of a spherical particle of a certain size falling through
a motionless fluid. Theoretically, if a vapor stream were moving
upward at this velocity, liquid droplets of a certain size would
remain suspended in the vapor and no entrainment of this size
droplet would occur.
ρl
V c = 0.15 -1 (See Note)
ρg
SpGr x T
V c = 4.05
MW x P
P = pressure, psia
ρl
V c = 4.57 -1
ρg
VA = Factor x Vc
TABLE 2.1
Diameter = area/0.785
R11 See Appendix 30 for the required distances for 90o elbows.
TABLE 2.2
Reflux to Tower 5
Product to Storage 2
Flow to Heat Exchanger 2
Flow to Sewer or Drain 1
In case surge must be provided for both product and reflux, the
larger volume is used, not the sum of the two volumes.
Horizontal Drums
Vertical Drums
A. Diameter
“
Normal” Procedure
A. Diameter (continued)
TABLE 2.3
TABLE 2.4
5 to 8 150 to 240 18 45
inclusive inclusive
disengaging
A. Diameter (continued)
B. Length
B. Length (continued)
Occasionally, at low “treat“ rates, drawoff pots are employed. The design is
then the same as when drawoff pots are employed with distillate accumulators.
Drum size is a function of settling rate and flow rate. The volume must be such
as to provide holdup time for a drop to move from the top or bottom of the
drum to the interface of the two fluids and coalesce.
Separation is due to gravity and results from the differential density of the two
fluids. The other variables involved are the viscosity of the continuous phase
and the drop size.
Studies of the vertical rise or fall of liquid droplets in another liquid have
shown that eventually the drop velocity, which varies with particle size
and density difference, attains a limiting value known as the “terminal
velocity.” Analyses of data collected in studying these systems have
shown that these data can be correlated in a similar manner to the
Reynolds number vs. Fanning friction factor in fluid flow through pipes.
Instead of plotting Reynolds number vs. Fanning friction factor, the
Reynolds number of the droplet is plotted against the Drag Coefficient
and this relationship, though developed for rigid particles, appears valid
for small droplets which are nearly spherical in shape. Figure 14 in the
Appendix presents this correlation which as been zoned to show the
limitations of Stokes’ law, Intermediate law and Newton’s law.
TABLE 3.1
DROPLET SIZES
Droplet Diameter
System Inches Centimeters
Caustic - 0.85 specific gravity oils 0.005 each phase 0.012 each phase
Water - Naphtha or heating oils 0.005 each phase 0.012 each phase
Propane - oil deresining 0.004 each phase 0.010 each phase
High settling rates above 10 inches per minute (25 centimeters per
minute) can be obtained on systems such as water-light
hydrocarbon liquids and it is recommended that for design
purposes, rates be limited to no more than 10 inches per minute
(25 centimeters per minute). This limitation is necessary since
disturbing factors such as convection currents, eddies and
hindered settling effects are present in all settling drums.
Whenever possible, it is desirable to obtain laboratory data to
confirm design settling rates. For designing settlers in H2SO4
extraction of isobutylene, a settling rate of 0.2 inches per minute
(0.5 centimeters per minute) was used. Satisfactory settlers have
been designed for sulfuric acid alkylation based on the following
settling rates.
3.1.3 Emulsions
TABLE 3.2
SETTLING TIMES OF SOME WATER SYSTEMS*
English System
flow rate
D = 2 + 1.7
V
where “flow rate“ = that of light phase, cubic feet per minute
Metric System
flow rate
D = 60 + 63
V
where flow rate = that of light phase, cubic meters per hour
The above applies when the separation of heavy liquid from light is more
important than that of light from heavy. When the latter is of equal
importance, a rate must be calculated for the movement of the light
droplets, and the heavy phase space sized in essentially the manner
discussed below for the light phase.
Divide the height from the top of the drum to the interface (upper
interface) by the settling rate to determine the settling time required.
Also calculate the hydrocarbon residence time provided by the
“preliminary“ drum by dividing the volume of the drum above the upper
interface by the hydrocarbon feed rate. If the residence time does not
equal (or slightly exceed) the settling time, the drum diameter must be
adjusted accordingly.
4.0 INTERNALS
The main criteria governing the use of internals are cost, efficiency of
entrainment removal, and guarantees (e.g. on steam from a steam drum).
Chevrons represent the most expensive type of internal and are only used
when a guarantee must be met on the amount of entrainment and when
wire mesh cannot be used.
Since the use of a crinkled wire mesh pad or screen would not
permit a large reduction in vessel size, and since a crinkled wire
mesh pad or screen is fairly expensive, it is not used much in this
range of diameters. When used, it would be to prevent large slugs
of liquid from going to the compressor.
A. Thickness
B. Pressure Drop
Where
D. Entrainment Removal
4.1.2 Chevrons
4.1.3 Baffles
4.2.2 Baffles
4. Also provide two slots, 1" wide and 1/4th as long as the
drum, located between drum and baffle, at each side of the
inlet end of the baffle.
Vessel nozzles are usually oriented by the Drafting Room to meet piping
or structural requirements. However, the orientation of some nozzles are
significant to the Process Department. When this is the case, the
Process Engineer must show these significant orientations on all vessel
sketches transmitted to the Project Department.
The top vapor outlet is generally located at the opposite end to the
inlet.
TABLE 5.1
Vessel Volume
Cu. ft. Vent Drain Pumpout Steamout Blowdow
n
The vent is also used to admit air when draining a drum after a
hydrotest. In certain cases, the draining rate will set the vent size.
If a larger than minimum drain size is chosen, the vent size must
also be checked where draining time or maximum external
pressure are limitations.
P1 + P12 - P22
V ln
P2
θ=
5
D T
632
fLM
where,
2
M P1 + P12 - P22
D
5
= V ln
5
10 T P2
where,
The nozzle size is specified by the Instrument Group when the safety
valve is mounted on the vessel. The process engineer should check that
the requirements of the Process Standards for safety valves are not
violated.
TABLE 5.2
Flanged Screwed
Connection Coupling
LG or GG 1" ¾”
All other Level Instruments 2" ¾”
All Pressure & Temp. Instruments 1" ¾”
Foster Wheeler Engineering Standard 60A1 calls for the use of the
displacer type instruments for pressure vessels with level ranges of 48"
or less. In addition, some of our clients require the use of displacer type
instruments with even greater ranges. A copy of Engineering Standard
65B14.22, which shows the standard ranges for displacer type
instruments is located in the Appendix (Figure 13). If Foster Wheeler
Standards are used on a job, DP cells will be used for ranges in excess of
48" unless the Process Department specifies the use of a displacer type
instrument on the Instrument Process Data, Form Number (110)-25.
When the required operating range of the level instrument is 48" or less,
the Process Engineer should take care to specify the vessel so as to
utilize one of the standard ranges, namely, 14", 32" or 48" if possible.
1. All vessels less than 18 inches and over 12 inches inside diameter
shall have at least two handholes or two plugged threaded
inspection openings of not less than 1.5” pipe size.
FOSTER WHEELER ENERGY LIMITED 2002
PROCESS STD 101
FOSTER AWHEELER VESSELS PAGE 40
REV 11
PROCESS PLANTS DIVISION DRUMS DATE SEPT 2003
A. Surge Volume
D. Liquid Levels
E. Vapor Space
F. Water Pot
a) Inlets
b) Outlets
2.1.4.A.
6.0 SPECIFIC DRUM DESIGNS (CONTINUED)
C. Water Settling
Knockout drums are generally made vertical with a maximum L/D ratio of
3:1. Lower L/D ratios can be used for large diameter drums as long as
sufficient liquid volume is available.
B. For spill
Flash drums separate gases from a liquid, usually after a sharp reduction
in pressure. The drums are usually made vertical, with an L/D ratio of 3
or 4:1,
c. Locate the feed inlet nozzle 2-3 ft. below the upper T.L.
Appropriate feed inlet arrangements are discussed in Section
5.1.1. See Figure 22 for nozzles and connections.
This type of drum serves to dry steam from waste heat boilers, slurry
steam boilers and other small steam-producing units.
The Process Department will size smaller drums requiring only a dry pipe
if horizontal, or CWM screen if vertical.
Drums less than 3'-6" in diameter should be vertical, while larger drums
will normally be horizontal.
B. Dry pipe
W KV s
AH =
300 2g ∆ PH
where
A. Diameter
B. Steam volume
TABLE 6.1
100 290
150 340
200 390
250 430
300 460
350 490
L/D ratio is usually kept between 3:1 to 4:1. Directions for drum
sizing are given below. For propane deasphalting blowdown
drums, see Propane Deasphalting Manual, Page II, D-14 (Dec. 66
Issue).
A. Horizontal Drums
gD(ρ L - ρ v )
VD = 1.15
ρvc
where VD is in ft/sec
g is 32.2 ft/(sec) sec
D is particle diameter in ft
are densities of vapor or liquid in lb/cu ft
c is drag coefficient and is taken as 1.0(It
normally depends on Reynolds number but
becomes 1.0 or lower for high Reynolds
numbers.)
ρL
VD = 0.21 -1 ft/sec
ρV
Drum Sizing
d1 d2
L=x+d1+d2 d1 x d2
Outlet: Vapor
Liquid
Settled water (if required)
Nozzles (continued)
Auxiliary connections:
B. Vertical Drums
Drum Sizing
2. Use VA = VD
Nozzles: )
)
Steam Coil: ) See above, under
) Paragraph A,
Design Pressure: ) Horizontal Drums.
)
Maximum Operating Temperature: )
Drum Sizing
Sp.Gr. x T
V C = 4.05
MW x P
VA = 1.7 VC
P : Pressure, psia
Step 7.(continued)
Step 7. (continued)
AS = Q/(U x LMTD)
Minutes
Fuel gas K.O. drums are used to disengage any liquid from the
vapor stream. These drums are sized following the same
procedure given in Paragraph 6.2 for knockout drums. Calculate
the critical velocity using the liquid specific gravity of the
component in the vapor that can exist as liquid phase at the drum
operating temperature and pressure (see Figure 29).
Fuel gas mix drums are used to collect tail gas from various
process units and give enough residence time to obtain an outlet
vapor stream of reasonable constant composition and heating
value. When required, natural gas or revaporized LPG is added to
the mix drum to make up the fuel gas system or to adjust the
heating value.
The process engineer is responsible for the process specification of drums. One
of the following forms should be used.
135-2B Vertical Drum with Data Box (see Appendix, Figure 18)
135-3C Horizontal Drum with Data Box (see Appendix, Figure 17)
135-59A Blank Vessel Sheet with Data Box (see Appendix, Figure 19)
The revision, date and process engineer’s initials should be added to the
revisions box.
Each form has a space for a sketch of the drum. The process engineer is
required to make a sketch of the drum showing the following information:
Details of internals.
Each form has a vessel data column and the process engineer is required
to fill in all information indicated by dotted lines. The following should be
used as guidance in supplying the information required for the vessel data
column:
Line Data
Line Data
Each form has a nozzle chart and the process engineer is required to
number and list all the nozzles indicated on the sketch. The nozzles
should normally be numbered so that the manway(s) appears first,
followed by the process connections, then the auxiliary nozzles and,
lastly, the instrument connections. Generally the Vessel Group will
determine the number and size the manway(s). The process engineer is
required to size the process and auxiliary nozzles. The Instrument Group
will size the instrument connections.
Each form should have stamped upon it a block with the following
imprint:
If the form does not have this imprint, the process engineer is responsible
for obtaining the stamp from the Process File room or a Chief Process
Engineer and stamping the form.
The set pressure and location of the relief valve protecting the
drum must be considered in specifying a minimum design
pressure. If, for example, a vessel that had a maximum normal
operating pressure of 20 psig were protected by a relief valve set
at 50 psig (due to pressures in the flare header system), this
would override the “10% or 25 psi“ rule. If the relief valve is not
located on the vessel, the pressure drop ( at relieving conditions)
to the relief valve must also be considered. As a check, the
process engineer is required to list alongside the stamp, the
location and set pressure of the relief valve protecting the drum. If
there are other process criteria to be considered, these also should
be evaluated when setting this “minimum design pressure“. It
should be pointed out that this pressure is not necessarily the
same as the maximum relieving pressure at top since this latter
pressure is a vessel designers maximum pressure value for the
vessel.
V a = 1.7 V c
ρl
V a = 1.7 x 0.15 −1
ρg
27.2 x 215
ρg = = 1.232 lb/ ft3
10.73 x 0.79 x 560
39.81
V a = 1.7 x 0.15 - 1 = 1.43 ft/sec
1.232
5 x 87,400
i.e. 5 mins. on reflux = = 183 ft3
60 x 39.81
5 x (87,400 + 28,300)
i.e. = 242 ft3
60 x 39.81
4. Drum Diameter
4V
V = (L/D) x D x π D2 /4 or D = 3
π x (L/D)
i.e. D = 5.38 ft
Use an 8 inch diameter short radius elbow at the inlet and a 4 inch
thick mist eliminator at the vapor outlet. (These internals are not
required but are used for purposes of this example).
20
i.e. = 0.30D > 0.27D
66
Chord 18
= = 0.55
Radius 33
Height
From Figure 8: < 0.04
Radius
Since this is less than 10 inches per minute, use 1" - 6" diameter
boot (1.77 ft2). Distance between high and low interface levels
for 4 minutes hold up:
8. Drum Length
242
Fraction of area below LLL: x (1 - 0.25) = 0.43
425
From Figure 7
Liquid Vapor
77,160 ft3/Hr
21.4 ft3/Sec
ρl
Va = 1.0 x 0.15 -1
ρv
62.4
= 1.0 x 0.15 -1
0.324
= 2.08 ft/Sec
Use 4' - 0 “
Area 12.57 ft2
3. Drum Height
Allow 18" between low liquid level and high liquid level.
The top tangent line should be a minimum of 2" - 6" above the
top of the inlet nozzle, or above a CWMS, if used. The high
high liquid level should be a minimum of 1" - 0" below the
bottom of the feed inlet.
For this example, use a feed inlet size of 6" with a 90° long-
radius elbow (total height 1'-0").
Allow an additional 18" between the high liquid level and high
high liquid level. This space is used as safety in case the
operator does not empty the drum one day. An alarm and a
compressor shutdown switch are located in this space. 18"
was selected since it allows adequate time for operator action
before the compressor will shut down, and it also will result in
an L/D = 2, a common practice but not a requirement.
drum.
ρ
VA = 2.0 x 0.15 l -1
ρg
13.3 x 630
ρg = = 0.822 Lb/ft 3
10.73 x 1.0 x 950
41.67
VA = 2.0 x 0.15 - 1 = 2.11 ft/sec
0.822
41.67
VA = 0.15 - 1 = 1.06 Ft/Sec
0.822
2 x 278,000
= = 222 ft3
60 x 41.67
222
HLL-LLL Height = = 14.0 ft
15.9
3. Drum Height
Total 19'-0"
1. Drum Diameter
2. Liquid Hold-up
2. Liquid Hold-up
50,000 2 x 1.7422
= in 2
300 2 x 32.2 x 0.25
= 77.5 in2
19 x 39.7
ρV = = 0.0901 lb/cu.ft.
10.731 x 780
646,825
CFS = = 1994.2
3,600 x 0.0901
2. Dropout Velocity
37.4
VD = 0.21 - 1 = 0.21 x 20.35 = 4.3 ft/sec
0.0901
3. Allowable Velocity
VA = VD = 4.3 ft/Sec
4. Assume h = 15'
9. HLL = 0
10. D = h = 15 ft.
π D2 X
= VT
4
π 15 2 X
= 6,980 X = 39.5' say 40'
4
48 48
L = 40 + + = 48 ft. minimum
12 12
Drum pressure at design flow: 2 psig (Pressure drop through drum will
be neglected)
54,000 Lb/h
Sp. Gr. @ 60oF: 0.734
FOSTER WHEELER ENERGY LIMITED 2002
PROCESS STD 101
FOSTER AWHEELER VESSELS PAGE 90
REV 11
PROCESS PLANTS DIVISION DRUMS DATE SEPT 2003
22,000 Lb/Hr
MW: 86.2
1. Vapor feed:
76,000 Lb/Hr
119.7 MW
650°F
2. Heat loads:
3. Water required:
27.6 - 13.5
Water temperature: 100 + 70 = 136oF
27.6
(HC liquid sensible heat ignored)
Lb/h Sp.Gr. at
136°F
HC Condensed 0.700
54,000
448,00 0.940
0
HC 0.687
54,000
448,00 0.934
0
448,000 + 394,000
= 421,000 lb/h
2
448,000 Lb/Hr
16.7 x 86.2
= = 0.2199 lb/cu.ft.
10.731 x 610
Temperature: 325°F
16.7 x 119.7
= = 0.2373
10.731 x 785
76,000 + 22,000
lb/h = = 49,000
2
90.1 + 27.8
CFS = = 59.0
2
lb/h = 76,000
90.1 + 125.8
CFS = = 108.0
2
6. Drum diameter
0.687 x 1,110
VC = 4.05 = 2.50 ft/sec
119.7 x 16.7
7.6 LMTD
Desuperheating:
use 3 elements
use 5 elements
FOSTER WHEELER ENERGY LIMITED 2002
PROCESS STD 101
FOSTER AWHEELER VESSELS PAGE 98
REV 11
PROCESS PLANTS DIVISION DRUMS DATE SEPT 2003
CFM: 128.15
LLL to HLL min. distance: 11.6 ft. (based on 33.18 Sq. ft. cross
sect. area drum)
3. Naphtha rate = 6,000 B/D. Flow rate in cubic feet per minute =
ft3 / min .
6000B / D 0.0039 = 23.4ft 3 / min
B/D
4. Caustic rate for 1,500 B/D. Flow rate in cubic feet per minute =
ft3 / min .
1500B / D 0.0039 = 5.85ft 3 / min
B/D
flow rate
D = 2 + 1.7
v
23.4
D = 2 + 1.7 = 4.6ft .
10
Check L/D
19 ft/4.5 ft = 4.2:1
See Section 3.4 for heavy phase space. Twelve inches are
allowed from the bottom of the drum.
Height 12 inches
= = 0.444
Radius 27 inches
4.9 ft 2 x 19 ft
= = 15.9 min
5.85 ft 3 / min .
(100% - 47.8%)
= 15.9 = 8.3 ft2
100
157.7 ft 3
= = 6.7 min
23.4 ft 3 / min .
The light space residence time of 6.7 minutes is greater than the
required light space settling time of 2.8 minutes, therefore, this
design is acceptable.
Settling time:
12 in.
= = 1.8 min
6.6 in / min
Residence time:
16.8%
15.9 ft 2 x x 19 ft
100
= 8.7 min
5.85 ft 3 / min .
Figure 6
Volume of Ellipsoidal Head of Horizontal Drums