ORF1

1 of 25 document.xls/Current Flange Spec Sheet_Monel

ITEM REV. QTY. TAG. NO. SCH. SERVICE

1 2 1 20FO-057 2 80 0.084 250 60 57 a 17.00 100 300 Pilot gas to acid relief header.

2

3

4

5

6

7

8

9

10

1. The actual flow of 20FO-057 is about 110 SCFH for a bore diameter of 0.084.

PIPE SIZE (IN.)

ORIFICE (IN.)

FLOW QUANTITY (SCFH)

UPSTREAM PRESSURE

(PSIG)DP

(PSI)MW

SG

TEMP. (F)

FLANGE RATING

INSTRUMENT SPECIFICATION

Citgo Petroleum Corporation135th Street & New AvenueLemont, IL 60439

Flange-type Restrictive Orifices

No. DATE REVISION SHEET NO. REV.

ISSUED: CHECK:

P.O. No.:

ISSUE DATE:

MANUFACTURER:

ALL ITEMS SHALL COMPLY WITH GENERAL SPECIFICATION SHEETS

MATERIAL: Monel

Installation notes:1. Orifice dia. As specified to suit required conditions.2. Gaskets furnished by vendor.

2 of 25 document.xls/Current Union Spec Sheet


1 1 1 20FO-184 1-1/2 80 0.285 60 57 a 0.586 100 3000 Acid pump vent header purge.

2

3

4

5

6

7

8

9

10

1. Item 1 is made of monel.

PIPE SIZE (IN.)

ORIFICE (IN.)


UPSTREAM PRESSURE

(PSIG)DP

(PSI)MW

SG

TEMP. (F)

FLANGE RATING



Union Restrictive Orifices


ISSUED: CHECK:

P.O. No.:

ISSUE DATE:

MANUFACTURER:


MATERIAL: 316SS

Installation notes:1. Unless otherwise specified, the only markings on the orifice tab shall be the orfice diameter indicated by a decimal fraction as shown on the drawing with 1/16-in. figure stamping hand dies.2. Where lines are to be insulated, the insulated material covering the union shall be applied in such a manner that the markings on the tab will be fully exposed.3. No asbestos-bearing material is acceptable; vendor to provide TFE gaskets.

3 of 25 document.xls/Current Flange Spec Sh_SS


1 1 1 20FO-175 2 80 0.135 60 55 a 17.00 100 150 Pilot gas to 20F-527.

2

3

4

5

6

7

8

9

10

PIPE SIZE (IN.)

ORIFICE (IN.)


UPSTREAM PRESSURE

(PSIG)DP

(PSI)MW

SG

TEMP. (F)

FLANGE RATING





ISSUED: CHECK:

P.O. No.:

ISSUE DATE:

MANUFACTURER:


MATERIAL: 316SS


4 of 25 document.xls/New Union Spec Sheet


1 1 1 2 80 a 100

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7

8

9

10

PIPE SIZE (IN.)

ORIFICE (IN.)


UPSTREAM PRESSURE

(PSIG)DP

(PSI)MW

SG

TEMP. (F)

FLANGE RATING



Union Restrictive Orifices


ISSUED: CHECK:

P.O. No.:

ISSUE DATE:

MANUFACTURER:


MATERIAL: 316SS

Installation notes:1. Unless otherwise specified, the only markings on the orifice tab shall be the orfice diameter indicated by a decimal fraction as shown on the drawing with 1/16-in. figure stamping hand dies.2. Where lines are to be insulated, the insulated material covering the union shall be applied in such a manner that the markings on the tab will be fully exposed.3. No asbestos-bearing material is acceptable; vendor to provide TFE gaskets.

Yellow is an input cell: Green is a calculation:P1: 60 psig W = 11.12 PPH

Underline is value actually used: Green in grey is a look-up value:0.603 tp = 2.500.607

White in black is a final answer:

D2 = 0.106 in.

Important reference information about a cell is in violet:From Fluor table

Cell for iteration with goal seek: Target (To) cell for goal seek: Changing cell for goal seek:[1st Cell] [2nd Cell] [3rd Cell]

4.87 4.93 0.084

Changing cell for goal seek:

7 of 25 document.xls/New Flange Spec Sheet_SS


1 1 1 2 80 a 100

2

3

4

5

6

7

8

9

10

PIPE SIZE (IN.)

ORIFICE (IN.)


UPSTREAM PRESSURE

(PSIG)DP

(PSI)MW

SG

TEMP. (F)

FLANGE RATING





ISSUED: CHECK:

P.O. No.:

ISSUE DATE:

MANUFACTURER:


MATERIAL: 316SS


8 of 25 document.xls/New Flange Spec Sheet_Monel


1 1 1 2 80 a 100

2

3

4

5

6

7

8

9

10

PIPE SIZE (IN.)

ORIFICE (IN.)


UPSTREAM PRESSURE

(PSIG)DP

(PSI)MW

SG

TEMP. (F)

FLANGE RATING





ISSUED: CHECK:

P.O. No.:

ISSUE DATE:

MANUFACTURER:


MATERIAL: Monel


Gas Properties

y Tc, K Pc, atm Zc wHydrogen 0 33.20 12.80 65.00 0.31 -0.22Methane 0.94 190.60 45.40 99.00 0.29 0.01Ethane 0.05 305.40 48.17 148.00 0.29 0.10Propane 0.01 369.80 41.95 203.00 0.28 0.15Propylene 0 365.00 45.60 181.00 0.28 0.15Butane

Average, Mixture: 1.0000 198.13 45.65 102.49 0.29 0.01k =

R, atm-cm^3/(K-gmole): 8.21E+01Temperature, F: 100 311Pressure, psig.: 90 Use initial (1) properties.Viscosity, cP: 0.01151

100 120 100 120Methane 0.011661 0.012008 0.011659 0.012006Ethane 0.00986 0.010179 0.009882 0.010201Propane 0.00853 0.008836 0.008547 0.008853Propylene 0.009013 0.009347 0.009039 0.009372Butane 0.009254 0.012779

Caution: this sheet calculates properties based on yellow-highlighted cells. The viscosities will change and are a function of pressure and temperature, however, the NIST values for pure components will change so if T or P change update with NIST.

Properties using coresponding states

Vc, cm3/mol-

1

From VISC Sheet - manual entry-- use NIST website for individual m, then use Wilke's method in spreadsheet to calculate mixture m.

m, cP @ 78 psig m, cP @ 90 psig

G12

Citgo Employee: k = Cp/(Cp-R) only for ideal gases, i.e., adiabatic flow of an ideal gas. For real gases, Cp and Cv must be derived individually.

M6.91 2.02 0.009198.66 16.04 0.01167

12.98 30.07 0.0098818.30 44.10 0.0085515.78 42.08 0.00904

8.98 17.021.28

Caution: this sheet calculates properties based on yellow-highlighted cells. The viscosities will change and are a function of pressure and temperature, however, the NIST values for pure components will change so if T or P change update with

Cpo, cal/gmol-

K m, cP

From VISC Sheet - manual entry-- use NIST website for , then use Wilke's method in spreadsheet to calculate

11 of 25

Lemont, Illinoisdocument.xls/RO1

RESTRICTIVE ORIFICE ---- Method 1Rough method provided originally in an article in Chemical Engineering magazine tb/bore diameter = 0.93P2/P1 = 0.05 Thin plate, no choked flow.

Calculation not applicable: refer to Kirk-Cunningham method.

D, inches; Qg, gas flow in SCFH (60 F, 1 atm); DP, P1, P2, psia; Sg = Mg/Mair Line Size tp,mm

T1, R; tp, plate thickness. 0.5 1.5

0.75 1.5Qg: 250 SCFH @ 60 F, 1 atm Complete Property Sheet 1 1.5

57.00 Tr = 2.51 from sheet 1.5 2P1: 60 psig Pr = 0.11 2 2.5P2: 3 psi 3 3Mw: 17 4 3Sg = 0.59 manual allowed 6 3T: 100 deg. F k = 1.28 8 6Plate Rate 300 300, 600# ANSI 10 6tp = 2.50 mm From Fluor table 12 6Z: 1.00 0.98 Calculated using virial equations 14 9D1, nom: 2.00 in. Sch.: 80 16 9

18 12Sat. Curve Test: 0.749 Test: OK Abbott Equations are acceptable 20 12

Hot Gas Test: 0.433 Saturated Area 24 16B1 = 0.135 Pr/Tr = 0.044 Z = 1.00B0 = -0.014

Thin plate orifice Low-Moderate DP

Using table from Fluor specification: "Flange Type Restrictive Orifice"

DP =

Using initial properties @ P1, T1

P1:D =

Qg/SQRT( DP(P1 +P2)/(2SgT1)7 8

X 5440

(tp/0.125) X 1/5

Method assumes, implicitly, that gas is ideal gas mixture or perfect gas.Flow through a thin plate is never choked flow. For this to apply, the ratio of tb/bore diameter must be < 6. (Reference: pg. 13.22, Richard Miller's "Flow Measurement Engineering Handbook," 3rd ed., McGraw Hill, 1996. Page 13-22 refers to the work of Cunningham (1951) and Ward-Smith (1979).Kirk-Cunningham applies when P2<0.63P1. Cunningham showed that choked flow (critical, i.e., M =1 @ throat) does not occur for thin orifice plates.

12 of 25

Lemont, Illinoisdocument.xls/RO1

Pcf = 40.98 psig Choked Flow - for thick plate D2 = 0.106 in. Beta = 0.055

13 of 25Lemont, Illinois

document.xls/RO2

RESTRICTIVE ORIFICE ---- Method 2tb/db = 7.41 Thick plate method applies: choked flow. Min. Pressure is: 40.98 psig

A: throat cross-sectional area, sq. ft; W: #/s; Co = 0.72; P1: inlet pressure, psf; gc = 32.174T1: inlet temperature, F; R = 1545.3 ft-#f/#mole-R.

Qg: 250 SCFH @ 60 F, 1 atm St. T = 60 FW = 11.22 PPH 14.696 psia

0.04 lbs./cf Co: 0.72D1: 1.939 in.P1: 60 psig k = 1.28 Property Sheet

exp. = 8.03Mw: 17.02 Property Sheet

Pcf = 40.98 psig Choked FlowT: 100 deg. F

A = 0.004 sq. in. Complete Property SheetTr = 2.51 Using initial properties @ P1, T1

D = 0.067 in. Pr = 0.11Beta = 0.0348 Sat. Curve Test: 0.749 Below: use chartstp = 0.50 in. Hot Gas Test: 0.433 Saturated Area

Test: OK Abbott Equations are acceptableB1 = 0.135B0 = -0.014

Pr/Tr = 0.044

Thick plate orifice or flow nozzle, Choked Flow

Choked Flow: eq. 4-40, pg. 100, Daniel Crowl, Joseph Louvar, "Chemical Process Safety Fundamentals with Applications, Prentice-Hall, 1990.

r = Crowl/Louvar recommends 1.0 for Co with sharp-edged orifices with Re1 >30,000; seldom does this occur.

P1: A = W

Co P1 k gc M RT1

X 2k + 1

(k+1)/(k-1)

4-40Crowl & Louvar assume a thick orifice plate, or flow nozzle, not a thin plate.

Also found in Perry's 6th edition of "Chemical Engineering Handbook," pg. 5-14, equation 5.27. Assumes Beta < 0.2. (Ideal gas also assumed and implicite in solution using isentropic expansion).

This sheet is most useful in estimating flow from nozzles and holes in vessels or pipe.

A12

DW: Based on standard conditions and Qg.

F14

DW: Based on ideal gas at inlet flow temperature. Slight error can be expected for saturated conditions near critical point. K affects Y so a significant deviation will be a problem. Ideal gas k should not be used if residuals are large.

D23

DW: For the Abbott equations to apply, an error curve was prepared relating Tr(y) to Pr(x): Figure 3.16, Smith & Van Ness, "Introduction to Chemical Engineering Thermodynamics," 4th edition. Above the curve, the Abbott equations apply, below the curve, the charts for Zo, Z1 must be used. The curve has a break but can be approximated by two straight line sections: "sat curve" and "hot gas curve."

H25

DW: M.M. Abbott developed equations for Z in terms of a truncated virial coefficient equation.


document.xls/RO2

Z = 1.00

04/08/2023 Calculation for North American Mfg. Co. Combustion Air FE

D. Willard International Steel Services, Inc. document.xls

ORIFICE DATA SHEET

Type of Orifice Plate: Standard

Drain Hole (for Condensate): None

MAXIMUM (URV-Ranged) DIFFERENTIAL PRESSURE = 40 IWC Pipe Diameter?

MAXIMUM FLOW RATE REQUIRED = 10,000 PPH

131,510 SCFH

DP (Required ) AT REQUIRED MAX. FLOW RATE = 29.78 IWC Y-Equation?

CALCULATED MAXIMUM FLOW RATE (At URV) = 11,589 PPH hw-O.K. Turndown O.K 0.895

152,400 SCFH Y-O.K.

PERMANENT PRESSURE LOSS AT MAX. RATE (At URV) = 1.35 PSIG

37.53 IWC

ORIFICE INLET MAX. CALC. REYNOLDS NUMBER = 1,050,626

Orifice Re?

NOMINAL DIFFERENTIAL PRESSURE = 7.45 IWC Re--tubulent--O.K.

NOMINAL FLOW RATE = 5,000 PPH Safe Min. Rate?

65,750 SCFH Min.---O.K.

MINIMUM DIFFERENTIAL PRESSURE = 0.30 IWC

MINIMUM (Practical) FLOW RATE = 1,000 PPH Mach No. OK?

13,150 SCFH Gas Orifice velocity is O.K.

MINIMUM ORIFICE INLET REYNOLDS NUMBER = 10,000

Change in Physical Properties?

FLUID: Change in properties --O.K

INITIAL GAS TEMPERATURE = 70 F

INITIAL GAS PRESSURE = 30 psig

GAS COMPRESSIBILITY COEFFICIENT, Z, = 1.000

GAS SPECIFIC HEAT RATIO, k, = 1.39817842048393

GAS VISCOSITY @ FLOW CONDITIONS = 0.01634555005 cP

BASE TEMPERATURE = 60 F

BASE PRESSURE = 14.696 psig

BASE COMPRESSIBILITY FACTOR, Z, = 1.000

NOMINAL PIPE DIAMETER, INCHES = 24" CS Pipe

PIPE INTERNAL DIAMETER, INCHES = 23.5 Inches

FLANGE ORIFICE DIAMETER, do, INCHES , = 4.26222527388441 Inches

ORIFICE BETA = 0.1814

PLATE MATERIAL = SS

PLATE BASE THERMAL EXPANSION = 0.0000097 1/F

PLATE THERMAL EXPANSION = 0.0000089 1/F

CHANGE IN GAS DENSITY OVER PLATE = -0.94%

CHANGE IN GAS TEMPERATURE = -4.9 F

DISCHARGE MACH NO., M=1 IS CRITICAL, = 0.126

For Maximum Flow CalculationC' (PPH) = 274.091 K = 0.5972 Y1 = 0.9905

Ftb = 1.003 C' (SCFH) = 3604.474 Fpv = 1.0000

Fm = 1.000 FG = 0.99857 FPb = 1.0000

Fa = 1.000 FTf = 0.9896 Fl = 0.9998

Flowing conditions were used to calculate the discharge rate of the orifice.

04/08/2023 Calculation for FE-344'A' Reactor Toluene Atomizing Nitrogen

D. Willard

ORIFICE DATA SHEET

Type of Orifice Plate: Integral

Drain Hole (for Condensate): None

MAXIMUM (URV-Ranged) DIFFERENTIAL PRESSURE = 60.2 IWC Pipe Diameter?

MAXIMUM FLOW RATE REQUIRED = 172 PPH

2,320 SCFH

DP (Required ) AT REQUIRED MAX. FLOW RATE = 60.20 IWC Y-Equation?

CALCULATED MAXIMUM FLOW RATE (At URV) = 171 PPH hw-O.K. Turndown O.K 0.416

2,320 SCFH Y-O.K.

PERMANENT PRESSURE LOSS AT MAX. RATE (At URV) = 1.56 PSIG

43.30 IWC

ORIFICE INLET MAX. CALC. REYNOLDS NUMBER = 176,990

Orifice Re?

NOMINAL DIFFERENTIAL PRESSURE = 15.03 IWC Re--tubulent--O.K.

NOMINAL FLOW RATE = 86 PPH Safe Min. Rate?

1,160 SCFH Min.---O.K.

MINIMUM DIFFERENTIAL PRESSURE = 0.60 IWC

MINIMUM (Practical) FLOW RATE = 17 PPH Mach No. OK?

230 SCFH Gas Orifice velocity is O.K.

MINIMUM ORIFICE INLET REYNOLDS NUMBER = 10,000

Change in Physical Properties?

FLUID: Change in properties --O.K

INITIAL GAS TEMPERATURE = 70 F

INITIAL GAS PRESSURE = 130 psig

GAS COMPRESSIBILITY COEFFICIENT, Z, = 1.000

GAS SPECIFIC HEAT RATIO, k, = 1.3

GAS VISCOSITY @ FLOW CONDITIONS = 0.018 cP

BASE TEMPERATURE = 60 F

BASE PRESSURE = 14.696 psig

BASE COMPRESSIBILITY FACTOR, Z, = 1.000

NOMINAL PIPE DIAMETER, INCHES = 1/2" Sch-40 CS

PIPE INTERNAL DIAMETER, INCHES = 0.664 Inches

FLANGE ORIFICE DIAMETER, do, INCHES , = 0.34 Inches

ORIFICE BETA = 0.5120

PLATE MATERIAL = SS

PLATE BASE THERMAL EXPANSION = 0.0000097 1/F

PLATE THERMAL EXPANSION = 0.0000089 1/F

CHANGE IN GAS DENSITY OVER PLATE = -0.35%

CHANGE IN GAS TEMPERATURE = -1.8 F

DISCHARGE MACH NO., M=1 IS CRITICAL, = 0.096

This method is more general.


document.xls/RO3

RESTRICTIVE ORIFICE ---- Method 3Crane TP 410, "Flow of Fluids Through Valves, Fittings, and Pipe," 23rd printing. tb/bore diameter = 0.67P2/P1 = 0.016667 Thin plate, no choked flow.

Standard Conditions: P, psia = 14.696 T, F = 60

Complete Property Sheet

Flange taps Tr = 1.43 from sheetQg: 86 SCFH Y = 0.72 Kirk-Cunningham Pr = 0.11

0.06 k = 1.2859.00

P1: 60 psig 0.607 ASME, Crane 410 Sat. Curve Test: 0.749 Test:P2: 1 psi 0.607 Cunningham Hot Gas Test: 0.433 OKMw: 24 0.607 manual allowed Pr/Tr = 0.078

0.01 manual allowed B1 = 0.100T: 120 deg. F B0 = -0.156Plate Rate 300 300, 600# ANSI Abbott Equations are acceptabletp = 1.50 mm From Fluor table Z = 0.99Z: 0.99 manual allowedD1, nom: 0.75 in. Sch.: 160

0.01151 manual allowed 4,874

56 psig

Wd = 5.44 PPH Wcalc = 5.47 PPH Problem solved with goal seekMatch Qg: 4.93 PPH

Pcf = 40.98 psig Choked Flow - for thick plate Do = 0.088 in. Beta = 0.144

Thin plate orifice All flow conditions

ASME calculation not practical --- P2/P1 too low ---Kirk-Cunningham method.

W: lbs./hr; Y: dimensionless; C: 1/ft; do: inches; DP: psi; r: #mass/cf

@ 14.696 psia & 1 atm.r, #/cf = Using initial properties @

P1, T1DP =

C, ft-1 =

Saturated Arear, #/cf =

mg, cP= Re1 =

DPp =

P1:W =

DP r

Equation 2-24, Crane TP 410, adapted on 3.24 of text.

1891 Y C d 2 0

Flow through a thin plate is never choked flow. For this to apply, the ratio of tb/bore diameter must be < 6. (Reference: pg. 13.22, Richard Miller's "Flow Measurement Engineering Handbook," 3rd ed., McGraw Hill, 1996. Page 13-22 refers to the work of Cunningham (1951) and Ward-Smith (1979). In 2005, Kirk explored the limits of Cunningham's work. He found that ASME formulas worked fine with adjustment of Y; C could be defined using ASME and other methods.Kirk-Cunningham applies when P2<0.63P1. Cunningham showed that choked flow (critical, i.e., M =1 @ throat) does not occur for thin orifice plates.

B10

DW: Target flow rate.

F10

DW: Cunningham showed that a thin plate orifice is not restricted by choked flow. Until 2005, it was assumed that Y and C would be different than for unchoked flow. Kirk presented a new Y equation for conditions below Pcritcal, whn P2/P1 are below 0.63. Without these new equations, an error of up to 40%, or more, can be expected by using standard ASME equations for Y and C.

F12


I14


A17

DW: Real gas density at upstream conditions.

A18

Citgo Employee: Temperature upstream of orifice, i.e., for D1. Final temperature will decrease as a result of throttling. Usually, adiabatic expansion yields the lowest pressure drop and temperature drop but isothermal expansion has been assumed. Isothermal really only applies for long runs of small pipe.

J19


A20

DW: Calculated from Fluor table at the end of the spreadsheet. tP must be small: tb/Do must be < 6 for the sonic vena cava to form beyond the bore diameter. If the sonic barrier forms in the orifice as it does for thick plates (tb ratio > 6), then the flow is choked and a larger orifice will be required to flow the same mass.

A21

DW: Manual input is allowed for Z. (Although program will calculate Z, calculated Z will be ignored if yellow cell has value.) In some circumstances Z will not be calculated: if the Abbott equations do not apply. In this unlikely event, read the Zo, Z1 values from the appropriate curves, calculate Z by hand and enter here.

F22

DW: "Sch." affects the diameter, i.e., D1.

A23

DW: This viscosity is the mixture viscosity from the "Properties" sheet --- from "VISC." VISC calculates mixture viscosity using the Wilke equation.

A25

DW: Not all of the pressure drop across the orifice is lost. As the Beta is decreased, the permanent loss approaches the tap measurement, which is always the larger of the two.

A27

DW: Wd is the mass flow rate based on Qg and SC density.

D27

DW: Wcalc is the mass flow rate based on Crane equation 2-24.

A29

DW: Below the calculated pressure, Pcf, a vena contracta will form, beyond it, the gas passes through a sonic barrier. As the pressure is reduced further, the vena contracta will approach the bore.

G29

DW: Calculate Do with goal seek by selecting Wcalc for set, typing in the value for Wd, and using the value of Do for the change cell.

This method is more general.


document.xls/R04

RESTRICTIVE ORIFICE ---- Method 4Crane TP 410, "Flow of Fluids Through Valves, Fittings, and Pipe," 23rd printing. tb/bore diameter = 1.82P2/P1 = 0.033333 Thin plate, no choked flow.

Complete Property Sheet

Estimated Compressibility Factor (Z) for Base and Inlet Conditions

Standard Conditions: P, psia = 14.696 T, F = 60 For (b): 1.46 Sat. Curve Test: 0.714 Test:

OK

0.04 Hot Gas Test: 0.400 OK

Flange taps 1 Cunningham Pr/Tr = 0.030 Saturated Area

Qg: 250 SCFH 0.66 Cunningham recommended Zb = 0.980 B1 = 0.1040.05 k = 1.28 manual 0.980 B0 = -0.14887.0 Abbott Equations are acceptable

P1: 90 psig 0.595 ASME, Crane 410 Zf = 0.980P2: 3 psi 0.607 Cunningham

Mw: 17 manual allowed For (1): 1.57 Sat. Curve Test= 0.772 Test:

0.02 manual allowed 0.16 Hot Gas Test= 0.455 OK

T: 100 deg. F Pr/Tr = 0.100Saturated Area

Plate Rate 300 300, 600# ANSI B1 = 0.113tp = 2.50 mm From Fluor table B0 = -0.122Z1: 0.991 manual allowed Abbott Equations are acceptableD1, nom: 2.00 in. Sch.: 80 Zf = 0.991

0.01151 manual allowed 3,233

86 psig

Wd = 11.43 PPH Wcalc = 11.31 PPH Problem solved with goal seekMatch Qg: PPH Qcalc = 247 SCFH

Pcf = 57.43 psig Choked Flow - for thick plate Do = 0.054 in. Beta = 0.028

Thin plate orifice All flow conditions

ASME calculation not practical --- P2/P1 too low ---Kirk-Cunningham method.

W: lbs./hr; Y: dimensionless; C: 1/ft; do: inches; DP: psi; r: #mass/cf

Trb =

Choose Cunningham (1),Miller (2), or Fluor (3) for Y1: Prb =

Y1 =rb, #/cf =DP =

C, ft-1 =

Tr1 =

r1, #/cf = Pr1 =

mg, cP= Re1 =

DPp =

P1: W = DhPf1

Adapted from equation 9.68, "The AGA equation," in Richard Miller's Flow Measurement Engineering Handbook, 3rd ed., McGraw Hill , CR 1996 (This equation was adapted originally from equation 2-24, Crane TP 410.)

Flow through a thin plate is never choked flow. For this to apply, the ratio of tb/bore diameter must be < 6. (Reference: pg. 13.22, Richard Miller's "Flow Measurement Engineering Handbook," 3rd ed., McGraw Hill, 1996. Page 13-22 refers to the work of Cunningham (1951) and Ward-Smith (1979). In 2005, Kirk explored the limits of Cunningham's work. He found that ASME formulas worked fine with adjustment of Y; C could be defined using ASME and other methods.Kirk-Cunningham applies when P2<0.63P1. Cunningham showed that choked flow (critical, i.e., M =1 @ throat) does not occur for thin orifice plates.

P2: 338.178 rb K d2 Y1 FPb FTb FTf1 FPvGr FGr

L8


F9

DW: Cunningham will produce the largest diameter, followed by Miller (eq. 9.56, for restrictive orifices). Fluor will produce the largest Y and therefore the smallest orifice bore.

B11

DW: Target flow rate.

E11

DW: Y1: the upstream gas expansion factor. Y2 is the downstream gas expansion factor.

F11

DW: Cunningham showed that a thin plate orifice is not restricted by choked flow. Until 2005, it was assumed that Y and C would be different than for unchoked flow. Kirk presented a new Y equation for conditions below Pcritcal, whn P2/P1 are below 0.63. Without these new equations, an error of up to 40%, or more, can be expected by using standard ASME equations for Y and C.

J11

Citgo Employee: Calculate Z for the gas at standard (b) conditions. A lazy man would let the program calculate Zf then calculate Zb if necessary, i.e., Zf < 0.99.

K11

Citgo Employee: Add 1 to oversize the orifice, since ideal gases always occupy more space than real gases. Type the calculated value in the yellow cell to avoid a circular logic error when using goal seek to calculate the required bore diameter.

B13

DW: Includes Zb --- pb is not an ideal gas density it is a real gas density.

F13


M14


M17


A18

DW: Real gas density at upstream conditions.

A19

Citgo Employee: Temperature upstream of orifice, i.e., for D1. Final temperature will decrease as a result of throttling. Usually, adiabatic expansion yields the lowest pressure drop and temperature drop but isothermal expansion has been assumed. Isothermal really only applies for long runs of small pipe.

A21

DW: Calculated from Fluor table at the end of the spreadsheet. tP must be small: tb/Do must be < 6 for the sonic vena cava to form beyond the bore diameter. If the sonic barrier forms in the orifice as it does for thick plates (tb ratio > 6), then the flow is choked and a larger orifice will be required to flow the same mass.

A22

DW: Manual input is allowed for Z. (Although program will calculate Z, calculated Z will be ignored if yellow cell has value.) In some circumstances Z will not be calculated: if the Abbott equations do not apply. In this unlikely event, read the Zo, Z1 values from the appropriate curves, calculate Z by hand and enter here.

M22


F23

DW: "Sch." affects the diameter, i.e., D1.

A24

DW: This viscosity is the mixture viscosity from the "Properties" sheet --- from "VISC." VISC calculates mixture viscosity using the Wilke equation.

A26

DW: Not all of the pressure drop across the orifice is lost. As the Beta is decreased, the permanent loss approaches the tap measurement, which is always the larger of the two.

B26

DW: The permanent pressure loss is the goal of sizing the RO not Do! The premanent pressure loss will never quite match the desired drop but you can adjust P2 to get it close.

A28

DW: Wd is the mass flow rate based on Qg and SC density.

B28

D W: To calculate the required flow through a fixed Do use the following procedure. (2007 Excel is different than 2004): 1. Click on B28, the value for Wd. This will be the "Set Cell" for Goal Seek. 2. Go to Tools (in 2004) and select Goal Seek. (In 2007, you will need to add in the analysis tool pak. Go to the office button, select options, then add-ins and look for the analysis tool pac. Once you've loaded the add-in, Goal Seek will be in the Data pull-down menu under the Data Tools section. For 2007 users: click Goal Seek.) 3.Type in the value for Wd calculated for Do (fixed) in the "To value" entry. 4. For the "Change Cell" entry, click on B11, for Qg. This will be the value adjusted. 5. When done, click the start button at the bottom of the Goal Seek menu. 6. Goal Seek should calculate a value after 50 or so iterations. Check the value and accept or reject. If you reject, review the sheet for other errors.

D28

DW: Wcalc is the mass flow rate based on Crane equation 2-24.

E29

DW: Qg @ Wcalc.

A30

DW: Below the calculated pressure, Pcf, a vena contracta will form, beyond it, the gas passes through a sonic barrier. As the pressure is reduced further, the vena contracta will approach the bore.

G30

DW: Calculate Do with goal seek by selecting Wcalc for set, typing in the value for Wd, and using the value of Do for the change cell.

VISC

D. Willard 04/08/2023 Plant I RELSIZE.XLS(VISC)

G A S M I X T U R E V I S C O S I T Y

This sheet talks with the Properties Sheet.

Manual input values are in "Green."

Temperature 38 C 100 F

Program assumes that gases are perfect and form an ideal vapor solution. Program will deviate slightly for high pressure (>150 psig & presence of wet gas.Wilke method shows some deviations where molecular weights are significantly different, i.e., Mi>>Mj.

Wilke Gas Mixture Viscosity Calculation for Ideal Gases or Real Gases @ Low-Moderate Pressures

Component Man M N

Hydrogen 0.00 Yes 0.009189 - 2.02 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 1

Methane 0.94 Yes 0.011672 0.0117 16.04 0.000 1.000 1.473 1.899 0.000 0.000 0.000 0.000 0.000 0.000 1.033 0.011 2

Ethane 0.05 Yes 0.009882 0.0099 30.07 0.000 0.665 1.000 1.300 0.000 0.000 0.000 0.000 0.000 0.000 0.689 0.001 3

Propane 0.01 Yes 0.008547 0.0085 44.10 0.506 0.506 0.766 1.000 0.000 0.000 0.000 0.000 0.000 0.000 0.524 0.000 4

Propylene 0.00 Yes 0.009039 - 42.08 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 5

Gas 6 1.00 Yes 0.000000 - 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 6

Gas 7 0.00 Yes 0.000000 - 0.00 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 7

Gas 8 0.00 Yes 0.000000 - 0.00 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 8

Gas 9 0.00 Yes 0.000000 - 0.00 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 9

Gas 10 0.00 Yes 0.000000 - 0.00 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 10

Total 2.00 0.0115

Gas a b c Mwt. a b c d e fAlCl2 97.89 9.04015 8.68E-03 ### 1.72E-09 ### 0AlCl3 -0.0006 1.365E-05 -7.11E-10 133.34 ### 2.40E-02 ### 4.81E-08 ### 5.57E-15Carbon Dioxide 0.00187 2.39E-05 -1.27E-09 44.009 6.21415 5.12E-03 ### 0 0 0Carbon Monoxide 0.00628 2.16E-05 -1.70E-09 28.01 6.42043 8.88E-04 ### 0 0 0Chlorine 0.00215 2.014E-05 2.33E-09 70.9 6.02127 6.56E-03 ### 3.01E-09 0.00000 0Hydrogen Sulfide ### 2.40E-05 -3.40E-10 33.068 6.66150 2.85E-03 ### 0 0 0Nitrogen 0.00344 4.28E-05 7.15E-09 28.013 6.89500 7.62E-04 ### 0 0 0Oxygen 0.00624 2.59E-05 -2.71E-09 31.998 6.44284 1.25E-03 ### 0 0 0HCl 0.00177 2.26E-05 3.95E-09 36.461 6.51457 ### 0 0 0 0Sulfur Dioxide ### 2.12E-05 -1.44E-09 64.058 7.11595 5.93E-03 1.08E-06 0 0 0TiCl4 0.0071 0.000073 1.157E-08 189.69 ### 2.92E-02 ### 1.32E-08 ### 2.62E-16Water -0.00096 1.97E-05 -3.84E-09 18.015 7.08976 1.55E-03 0 0 0 0

Information Alligned for MBAL & VISC for auto entries.MAT-MATRIX Mwt a b c d e f

#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

Enter values in "Yellow." Calculated values in "Light Green".

y i Manual h i h i F i1 F i2 F i3 F i4 F i5 F i6 F i7 F i8 F i9 F i10 Sum F ij Sum y ih i

mm =

m = a + b(T) + c(T)2 +d(T)3 Cp = a + b(T) + c(T)2 + d(T)3 + e(T)4 + f(T)5

Cp = a + b(T) + c(T)2 + d(T)3 + e(T)4 + f(T)5

a(m) b (m) c (m)

0 500 1,000 1,500 2,000 2,500 3,000 3,5000.000

0.010

0.020

0.030

0.040

0.050

0.060

0.070

0.080

0.090

0.100

0.110

0.120

. . . .- b v s Q for sq edged orifice plates

k = 1.2; M = 30

k=1.3; M = 17

k = 1.4; M = 2

Q, SCFH (60 F, 14.7 psia)

, (

./

)

bbore

dia

pip

eID

T1 = 100oF, DP = 87 psig, P1 = 90 psig, Using Cunningham calculation for Y1, as yielding the highest Q. The pressure drop is not "hw;" the drop is the permanent pressure loss.

W = Q(PM/RT) = QM/408.67PPH: pounds per hourQ = W(408.66/M)

Q, SCFH M1.2 50 0.0144 0.0144 301.2 250 0.0322 0.03221.2 500 0.0455 0.04551.2 1,000 0.0643 0.06431.2 1,500 0.0788 0.07881.2 2,000 0.0910 0.09101.2 3,000 0.1114 0.11141.2 4,000 0.1298 0.12981.2 5,000 0.1451 0.14511.3 50 0.0126 0.0126 171.3 250 0.0281 0.0281 0.02791.3 500 0.0397 0.03971.3 1,000 0.0561 0.05611.3 1,500 0.0688 0.06881.3 2,000 0.0794 0.07941.3 3,000 0.0973 0.09731.3 4,000 0.1317 0.13171.3 5,000 0.1472 0.14721.4 50 0.0072 0.0072 21.4 250 0.0163 0.01631.4 500 0.0230 0.02301.4 1,000 0.0325 0.03251.4 1,500 0.0398 0.03981.4 2,000 0.0460 0.04601.4 3,000 0.0563 0.05631.4 4,000 0.0660 0.06601.4 5,000 0.0737 0.0737

T1 = 100oF, DP = 87 psig, P1 = 90 psig, Using Cunningham

ko b, 2" b, 1"

A1

D W:

Documents

ORF1