BOP – FLARE SYSTEM CALCULATION NOTE

CALCULATION NOTE

INDEX

1. OBJECT ................................................................................................................................ 2
2. REFERENCES...................................................................................................................... 2
3. INTRODUCTION................................................................................................................... 2
3.1. DISPOSAL SYSTEM ......................................................................................................... 2
4. DESIGN CONSIDERATIONS ............................................................................................... 3
4.1. SYSTEM GEOMETRY....................................................................................................... 3
4.2. DESIGN CONDITIONS...................................................................................................... 3
4.3. INLET LINES ..................................................................................................................... 4
4.4. OUTLET LINES ................................................................................................................. 4
4.5. DISCHARGE SCENARIOS ............................................................................................... 5
4.5.1. DRY FIRE – FULL COMPRESSION TRAIN BLOWDOWN ............................................ 5
4.5.2. DRY FIRE – PRESSURE RELIEVING VALVES ............................................................ 5
5. INLET AND OUTLET LINES SUMMARY .............................................................................. 6
6. CALCULATIONS................................................................................................................... 7
6.1. INLET LINES ..................................................................................................................... 7
6.2. OUTLET LINES – ISOLATED RELIEFS ............................................................................ 7
6.3. OUTLET LINES – DRY FIRE RELIEF SCENARIOS .......................................................... 8
7. ANNEX I – BACK PRESSURE CALCULATIONS .................................................................. 9
BOP – FLARE SYSTEM
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1. OBJECT

The purpose of this document is to present the pressure relieving devices inlet and outlet lines sizing
calculations for the third compression train of the WHCP 2021 - Cashiriari Well Head Compression
Project for the Camisea asset.

Results presented in this document comprise only one train of compression (train #3), but can be
extended to train #4 due to their similarity.

Sizing calculations associated with the 30” warm flare header is out of present engineering scope of
work.

2. REFERENCES

I. Design Basis.
II. Mass & Energy Balance.
III. Pressure Devices Calculation Note.
IV. Blowdown System Calculation Note.
V. 3D Model – Trains #3 and #4
VI. API Standard 520 – Sizing, Selection and Installation of Pressure Relieving Devices in
Refineries - Part I (Sizing and Selection), Eight Edition, December 2008.
VII. API Standard 520 – Sizing, Selection and Installation of Pressure Relieving Devices in
Refineries - Part II (Installation), Fifth Edition, August 2003.
VIII. API Standard 521 – Pressure Relieving and Depressuring Systems, Sixth Edition,
January 2014.
IX. Compression train #3 and #4 / Inlet Separators – Lay out – Plant

3. INTRODUCTION

When Camisea Asset started production in 2003, production (gas with condensate and a small
fraction of produced water) was transported in a high pressure mode from clusters to the Malvinas
Plant.
Due to the natural decline of the reservoirs, the Camisea production plan considers wellhead
compression requirements for all fields. Compression phases are summarized below:
 Phase 1: Single compression stage for suction pressures from 1000 psia to 700 psia.
 Phase 2: Single compression stage for suction pressures from 700 psia to 400 psia.
 Phase 3: Two compression stages (in two casings) for suction pressures from 400 psia
to 200 psia.
 Phase 4: Three compression stages (in two casings) for suction pressures from 200 psia
to 100 psia.

All phases will be analyzed in order to size upstream and downstream lines of pressure relieving
devices.

3.1. DISPOSAL SYSTEM

A pressure relieving system allows the plant to be relieved of any source of overpressure before
damage to process equipment can occur. Part of this system involves the disposal of the fluids being
BOP – FLARE SYSTEM
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discharged. This system has to be designed for adequate fluid discharge from a system which is
building up abnormal pressures.

In this particular case, compression train #3 (and #4) pressure relieving devices discharge to the
existing 30” warm header (which already serves trains #1 and #2). As stated in par. 1. and in reference
I, complete flare system verification is out of present engineering scope of work.

4. DESIGN CONSIDERATIONS

4.1. SYSTEM GEOMETRY

Pressure relieving devices are located on a platform close to the 30” dic*/harge flare header. An
image showing all safety elements is presented below:

Figure 1. Pressure relieving devices location.

Line lengths are calculated based on reference V. A margin equal to 1,1 is applied to piping lengths
to account for possible differences between piping routing indicated during basic engineering design
and final routing.

4.2. DESIGN CONDITIONS

Inlet lines for all pressure relieving valves shall be calculated considering rated mass flow rates (in
accordance with reference VIII) and relieving conditions presented in reference III as sizing cases.
Outlet lines shall be calculated with conditions expected after fluid has been depressurized up to the
associated back pressure (iterative calculation).

Inlet lines for blowdown valves shall be calculated considering peak flow rates and relieving
conditions corresponding to fire scenarios (fire peak flows are higher that adiabatic peak flow rates).
Outlet lines shall be calculated with conditions expected after fluid has been depressurized up to the
associated back pressure (iterative calculation).

In all cases, an isenthalpic evolution is considered across blowdown and pressure relieving valves
in order to determine the temperature and properties of the fluid relieved to the disposal system.

Since no appreciable heat loss is expected in short lenght lines (all below 330 ft), temperatures are
considered constant.
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4.3. INLET LINES

Minimum line diameters shall be limited to 2”.

Pressure drop between the protected system and the pressure relieving valve shall be less than 3%
of the relieving valve set pressure, in accordance with reference VII. This restriction aims to avoid
chattering and to prevent decrease of relieving capacity.

The following criteria shall be followed for lines involving pressure relieving and blowdown valves:

Line diameter Set pressure 𝜌𝑣 2

𝑙𝑏 𝑘𝑔
(in) (psig) ( ) ( )
𝑓𝑡. 𝑠 2 𝑚. 𝑠 2
2 Any < 16800 < 25000

≤ 725 < 20160 < 30000

>2
> 725 < 33600 < 50000
Table 1. Inlet line sizing criteria.

Pressure relieving device inlet nozzle shall not be larger than line diameter.

4.4. OUTLET LINES

Maximum Mach number downstream of relieving devices (i.e., tail pipes) shall be limited to 0,7. This
value considers rated mass flows for pressure relieving valves and fire peak flows for blowdown valves.
𝑙𝑏 𝑘𝑔
Additionally, 𝜌𝑣 2 values shall be limited to 100800 (150000 ) in all cases.
𝑓𝑡.𝑠2 𝑚.𝑠2

Back pressure produced downstream of the relief devices shall be compatible with relief devices
type. Maximum back pressure at pressure safety valves discharge is:

 10% of set pressure for conventional valves.

 30% of set pressure for balanced valves
 50% of set pressure for pilot operated valves.

Maximum superimposed back pressure at 30” flare header tie in points that should be considered
for relieving scenarios is unknown and calculations associated with the 30” warm flare header or the
rest of the disposal system is out of present engineering scope of work. Please note that the assumption
of a back pressure value higher than the real one could lead to a relief restriction (with ultimate chocked
flow condition in the outlet line).

Therefore, expected back pressure at 30” flare header tie in points will be calculated based on the
value assumed for trains #1 and #2 (which was delivered by Pluspetrol):

 Relief flow: 700 MMSCFD

 Back pressure: 90 psig at header tie in point.

Considering that this pressure does not vary excessively when relief conditions change (the
conditions for the pressure drop informed are unknown), pressures for different flow rates will be
estimated based on the following equation:
BOP – FLARE SYSTEM
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∆𝑃 = 𝑘𝑄 2

∆𝑃 Pressure drop (psi)

𝑄 Flow rate (MMSCFD)
𝑘 Constant (psi/MMSCFD2)

The value of k is calculated based on known relief flow rate and back pressure. See Annex I for
further information regarding back pressure calculations. Nevertheless, Pluspetrol should update back
pressure information, especially if back pressures assumed herein are higher than expected (real)
values.

4.5. DISCHARGE SCENARIOS

All inlet and outlet lines shall be sized for the corresponding sizing cases defined in the precedent
paragraph. Additional scenarios will be analyzed in order to determine maximum expected reliefs.

4.5.1. DRY FIRE – FULL COMPRESSION TRAIN BLOWDOWN

Dry fire scenario was described in reference IV. In this case, simultaneous blowdown of the entire
compression train caused by a fire will be analyzed. On one hand, BDV-37362 and BDV-37382 will
open simultaneously (note that this is only possible during compression phase 3). On the other hand,
BDV-37362, BDV-37372 and BDV-37382 will open simultaneously (note that this is only possible during
compression phase 4).

4.5.2. DRY FIRE – PRESSURE RELIEVING VALVES

This scenario considers a hypothetical pool fire located near the first stage compressor suction
scrubber (VBF-37310). To define the combined relief loads under fire exposure, the probable maximum
extend of a fire should be estimated. As a conservative approach, consideration of a fire-impact area is
frequently limited to an area of 2500-5000 ft2 (in accordance with reference VIII). Please note that this
assumption is conservative, since for facilities that handle only flammable gases, it can be assumed
that more localized fires than a liquid pool fire are generated.

In this case, a hypothetical 39 ft radius circle is assumed to be the fire affected zone. This zone is
shown below:
BOP – FLARE SYSTEM
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Figure 2. Fire-impact area.

Figure 2 was extracted from reference IX.

Please note that during a fire, it is highly probable that not all pressure relieving valves reach
maximum relieving capacity simultaneously. Additionally, not all relieving systems will be able to sustain
the maximum relieving capacity during the same time period. In particular, this calculation considers
the worst scenario from a flare capacity point-of-view, which is all pressure relieving valves opening at
the same time and relieving the maximum (rated) flow rate simultaneously.

5. INLET AND OUTLET LINES SUMMARY

Inlet Line Outlet Line
Set pressure
Relieving Device Tag Diameter rv2 PD DP / Set P Diameter rv2 Max. Mach Back Press. BP / Set P
(psig) (in) (lb/(ft.s2)) (psi) (%) (in) (lb/(ft.s2)) Number (psig) (%)
PSV-37300 A/B 1415 2 4359 6,7 0,47 6 4928 0,25 0,7 0,05
PSV-37310 A/B 1415 2 13933 21,3 1,50 6 14673 0,44 2,2 0,16
PSV-37320 A/B 1300 2 3959 9,8 0,75 6 4143 0,23 0,6 0,05
PSV-37330 A/B 1350 2 4087 12,1 0,89 6 4386 0,23 0,7 0,05
PSV-37360 A/B/C/D/E 1508 10 25566 7,48 0,50 14 39219 0,15 293,4 19,46
PSV-37370 A/B/C 1508 8 29285 5,88 0,39 16 66559 0,53 33,8 2,24
PSV-37380 A/B 1350 10 21792 4,88 0,38 24 33689 0,49 13,2 0,97
BDV-37362 - 6 7148 - - 12 26600 0,58 - -
BDV-37372 - 3 9927 - - 6 34757 0,66 - -
BDV-37382 - 4 8560 - - 10 14965 0,43 - -
Table 2. Summary of results.

Notes:

1. PSV-37360 A/B/C/D/E outlet line is defined by phase 2 condition.

Back pressure to set pressure ratios for PSV-37300, PSV-37310, PSV-37320 and PSV-37330 are
acceptable for a conventional pressure relieving valve. Same comment applies for PSV-37360, PSV-
37370 and PSV-37380 and a pilot operated valve type.
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6. CALCULATIONS

Calculations are presented below.

6.1. INLET LINES

Initial Geometry Final
Stream Xvap Flow Press Temp r m ID Rug DL SK Press -DP rv2 Ma
[kg] [kg/h] [barg] [°C] [kg/m3] [cP] [mm] [mm] [±m] [barg] [bar] [kg/ms2] maximum
INLET LINES
2"-PG-3731218-C1A-H1 (PSV-37300 Inlet) 1 3747 118,10 318,0 46,29 0,021 49,2 0,046 26,1 3,9 117,64 0,46 6486 0,0218
2"-PG-3731106-C1A-H1 (PSV-37310 Inlet) 1 6653 118,10 321,6 45,99 0,021 49,2 0,046 26,3 3,8 116,63 1,47 20734 0,0391
2"-PG-3731169-C1A-H1 (PSV-37320 Inlet) 1 3026 108,46 472,9 33,31 0,024 49,2 0,046 47,0 4,1 107,79 0,67 5891 0,0218
2"-PG-3731184-C1A-H1 (PSV-37330 Inlet) 1 2939 112,63 574,4 30,47 0,026 49,2 0,046 58,0 4,1 111,80 0,83 6081 0,0218
24"-PG-3731110-D1A-PP1 1/2 (Compressor Discharge) 1 1213975 120,60 95,1 87,00 0,017 560,4 0,046 77,7 1,5 120,27 0,33 21538 0,0392
20"-PG-3731223-D1A-PP1 1/2 (PSV common suction header) 1 1213975 120,27 95,1 87,00 0,017 488,9 0,046 20,6 0,2 120,13 0,14 37112 0,0515
10"-PG-3731205-D1A-PP1 1/2 (PSV-37360A) 1 303494 120,13 95,1 87,00 0,017 242,9 0,046 0,6 0,2 120,08 0,05 38045 0,0522
18"-PG-3731187-D1A-PP1 1/2 (Compressor Discharge) 1 385918 120,60 130,5 75,95 0,017 419,1 0,046 78,5 2,1 120,42 0,18 7961 0,0238
12"-PG-3731229-D1A-PP1 1/2 (PSV common suction header) 1 385918 120,42 130,5 75,95 0,017 295,4 0,046 14,0 0,4 120,25 0,17 32270 0,0479
8"-PG-3731194-D1A-PP1 1/2 (PSV-37370A) 1 192959 120,25 130,5 75,95 0,017 193,7 0,046 0,6 0,2 120,19 0,06 43579 0,0556
18"-PG-3731224/1173-D1A-PP1 1/2 (Compressor Discharge) 1 242753 102,39 127,8 65,30 0,017 419,1 0,046 77,7 1,5 102,32 0,07 3661 0,0175
10"-PG-3731203-D1A-PP1 1/2 (PSV common suction header) 1 242753 102,32 127,8 65,30 0,017 242,9 0,046 20,6 0,2 102,10 0,23 32478 0,0521
10"-PG-3731211-D1A-PP1 1/2 (PSV-37380A) 1 242753 102,10 127,8 65,30 0,017 242,9 0,046 0,6 0,2 102,06 0,04 32429 0,0521
6"-PG-3731111-D1A-PP1 (BDV-37362) 1 50873 92,05 91,7 66,35 0,016 146,4 0,046 4,7 0,2 92,01 0,04 10637 0,0314
3"-PG-3731174-D1A-PP1 (BDV-37372) 1 12234 66,33 117,8 43,09 0,016 73,7 0,046 3,3 0,2 66,26 0,08 14772 0,0434
4"-PG-3731188-D1A-PP1 (BDV-37382) 1 22958 90,33 122,2 58,06 0,016 97,2 0,046 3,3 0,2 90,28 0,05 12738 0,0346

6.2. OUTLET LINES – ISOLATED RELIEFS

BDVs and PSVs outlet lines are connected directly to a 30” flare header which transports relief fluids
to the existing flare. Therefore, no sub-headers are required and only outlet line diameters are
calculated. Back pressure at this header is calculated based on Annex I.
Initial Geometry Final
Stream Xvap Flow Press Temp r m ID Rug DL SK Press -DP rv2 Ma
[kg] [kg/h] [barg] [°C] [kg/m3] [cP] [mm] [mm] [±m] [barg] [bar] [kg/ms2] maximum
OUTLET LINES
6"-FL-3731220-A1-B (PSV-37300) 1 3747 0,00 306,7 0,42 0,019 154,1 0,046 -11,0 0,1 0,05 -0,05 7333 0,2514
6"-FL-3731108-A1-B (PSV-37310) 1 6653 0,00 310,5 0,45 0,019 154,1 0,046 -11,0 0,1 0,15 -0,15 21835 0,4356
6"-FL-3731171-A1-B (PSV-37320) 1 3026 0,00 468,3 0,33 0,023 154,1 0,046 -11,0 0,1 0,04 -0,04 6166 0,2280
6"-FL-3731186-A1-B (PSV-37330) 1 2939 0,00 571,9 0,29 0,025 154,1 0,046 -11,0 0,1 0,05 -0,05 6527 0,2349
14"-FL-3731206-A1-B (PSV-37360A) 1 303494 20,1 60,78 15,39 0,013 336,5 0,046 -11,0 0,1 20,2 -0,16 58362 0,1539
16"-FL-3731230-A1-B (PSV-37370A) 1 192959 2,03 96,8 2,09 0,014 387,3 0,046 -11,0 0,1 2,33 -0,30 99046 0,5297
24"-FL-3731212-A1-B (PSV-37380A) 1 242753 0,80 97,4 1,21 0,014 590,5 0,046 -11,0 0,1 0,91 -0,10 50133 0,4866
12"-FL-3731113-A1-B (BDV-37362) 1 50873 0,04 56,4 0,95 0,012 304,8 0,046 -11,0 0,1 0,19 -0,16 39583 0,5771
6"-FL-3731176-A1-B (BDV-37372) 1 12234 0,00 95,8 0,64 0,014 154,1 0,046 -11,0 0,1 0,39 -0,39 51721 0,6579
10"-FL-3731190-A1-B (BDV-37382) 1 22958 0,01 94,0 0,71 0,013 254,6 0,046 -11,0 0,1 0,10 -0,09 22270 0,4336

Notes:

1. PSV-37360 A/B/C/D/E outlet line is defined by phase 2 condition. See calculation below.

Initial Geometry Final

Stream Xvap Flow Press Temp r m ID Rug DL SK Press -DP rv2 Ma
[kg] [kg/h] [barg] [°C] [kg/m3] [cP] [mm] [mm] [±m] [barg] [bar] [kg/ms2] maximum
OUTLET LINES - PHASE 2
14"-FL-3731206-A1-B (PSV-37360A) - PHASE 2 1 287434 10,13 90,38 7,38 0,014 336,5 0,046 -11,0 0,1 10,44 -0,31 109151 0,2893
BOP – FLARE SYSTEM
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6.3. OUTLET LINES – DRY FIRE RELIEF SCENARIOS

Initial Geometry Final
Stream Xvap Flow Press Temp r m ID Rug DL SK Press -DP rv2 Ma
[kg] [kg/h] [barg] [°C] [kg/m3] [cP] [mm] [mm] [±m] [barg] [bar] [kg/ms2] maximum
ADDITIONAL DISCHARGE SCENARIOS - OUTLET LINES
DRY FIRE - FULL COMPRESSION TRAIN BLOWDOWN - PHASE 3
12"-FL-3731113-A1-B (BDV-37362) - PHASE 3 1 22004 0,03 89,3 0,68 0,013 304,8 0,046 -11,0 0,1 0,06 -0,03 10282 0,2901
10"-FL-3731190-A1-B (BDV-37382) - PHASE 3 1 22958 0,03 94,0 0,71 0,013 254,6 0,046 -11,0 0,1 0,12 -0,09 22270 0,4287
DRY FIRE - FULL COMPRESSION TRAIN BLOWDOWN - PHASE 4
12"-FL-3731113-A1-B (BDV-37362) - PHASE 4 1 17019 0,03 107,4 0,65 0,014 304,8 0,046 -11,0 0,1 0,06 -0,02 6483 0,2294
6"-FL-3731176-A1-B (BDV-37372) - PHASE 4 1 12234 0,03 96,0 0,90 0,014 154,1 0,046 -11,0 0,1 0,30 -0,27 37075 0,5607
10"-FL-3731190-A1-B (BDV-37382) - PHASE 4 1 21314 0,03 83,2 0,73 0,013 254,6 0,046 -11,0 0,1 0,11 -0,08 18518 0,3895
DRY FIRE - PRESSURE RELIEVING VALVES - 1st FIRE AREA
6"-FL-3731220-A1-B (PSV-37300) - 1st FIRE AREA 1 3747 0,00 306,7 0,42 0,019 154,1 0,046 -11,0 0,1 0,05 -0,05 7333 0,2512
6"-FL-3731108-A1-B (PSV-37310) - 1st FIRE AREA 1 6653 0,00 310,5 0,45 0,019 154,1 0,046 -11,0 0,1 0,16 -0,15 21835 0,4354
DRY FIRE - PRESSURE RELIEVING VALVES - 2nd FIRE AREA
6"-FL-3731171-A1-B (PSV-37320) - 2nd FIRE AREA 1 3026 0,00 468,3 0,33 0,023 154,1 0,046 -11,0 0,1 0,04 -0,04 6166 0,2280
6"-FL-3731186-A1-B (PSV-37330) 1 2939 0,00 571,9 0,29 0,025 154,1 0,046 -11,0 0,1 0,05 -0,05 6527 0,2349
BOP – FLARE SYSTEM
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7. ANNEX I – BACK PRESSURE CALCULATIONS

As stated above, until further information is available, expected back pressure at 30” flare header tie
in points will be calculated based on the value assumed for trains #1 and #2 (which was delivered by
Pluspetrol):

 Relief flow: 700 MMSCFD

 Back pressure: 90 psig at header tie in point.

Considering that this pressure does not vary excessively when relief conditions change (the
conditions for the pressure drop informed are unknown), pressures for different flow rates will be
estimated based on the following equation:

∆𝑃 = 𝑘𝑄 2

∆𝑃 Pressure drop (psi)

𝑄 Flow rate (MMSCFD)
𝑘 Constant (psi/MMSCFD2)

The value of k is calculated based on known relief flow rate and back pressure and is equal to
0,00018376 𝑝𝑠𝑖⁄𝑀𝑀𝑆𝐶𝐹𝐷 2 (or 0,01579 𝑏𝑎𝑟⁄𝑀𝑀𝑆𝐶𝑀𝐷2).

Afterwards, back pressures were calculated. Results are presented below:

Mass flow Molecular STD Vol. Flow Back pressure

Relieving Device
(kg/h) (lb/h) Weight (MMSCMD) (MMSCFD) (barg) (psig)
PSV-37300 A/B 3747 8261 19,3 0,1 3,9 0,000 0,0
PSV-37310 A/B 6653 14667 19,3 0,2 6,9 0,001 0,0
PSV-37320 A/B 3026 6671 19,3 0,1 3,1 0,000 0,0
PSV-37330 A/B 2939 6479 19,3 0,1 3,0 0,000 0,0
PSV-37360 A/B/C/D/E 1213975 2676312 19,3 35,7 1259,0 20,073 291,1
PSV-37370 A/B/C 385918 850789 19,3 11,3 400,2 2,029 29,4
PSV-37380 A/B 242753 535170 19,3 7,1 251,8 0,803 11,6
BDV-37362 50873 112154 19,3 1,5 52,8 0,035 0,5
BDV-37372 12234 26970 19,3 0,4 12,7 0,002 0,0
BDV-37382 22958 50612 19,3 0,7 23,8 0,007 0,1
PSV DISCH. - FIRE 1ST AREA 10400 22928 19,3 0,3 10,8 0,001 0,0
PSV DISCH. - FIRE 2ND AREA 5965 13150 19,3 0,2 6,2 0,000 0,0
FULL BD - FIRE - PH3 44961 99121 19,3 1,3 46,6 0,028 0,4
FULL BD - FIRE - PH4 50566 111478 19,3 1,5 52,4 0,035 0,5
PSV-37360 A/B/C/D/E (PH2) 862301 1901016 19,3 25,3 894,3 10,128 146,9