Hydraulic Study Report Rev.1 Dated 31-3-2019

REPORT PAGE 2 OF 54
PETRODARA 4836-407-10-RT-001
TECHNICAL CONSULTATION FOR WATER
WEST BAKR HANDLING PROJECT AT K&H STATIONS REV.1
EGYPT HYDRAULICS VERIFICATION REPORT MAR., 2019
REVISION RECORD:
Rev.
Date Changed by Description of Change
No.
Name Title Initial
Prepared By Mohamed Reda Process Engineer M.R.M
Checked By Mohamed Shawwal Senior Lead Process Egineer M.S.S
Approved By Khaled El-Badry General Manger K.EL.

(10/13)
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HOLD LIST:
Hold
Location Description Status
No.
1 11 Suction Damper Size and Pre-charge Pressue.
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CONTENTS
PAGE
EXECUTIVE SUMMARY 5
1.0 INTRODUCTION 7
2.0 SCOPE OF REPORT 7
3.0 ABBREVIATIONS 7
4.0 PROJECT DESCRIPTION 8
5.0 INPUT DATA FOR HYDRAULIC VERIFICATION 10
6.0 MODE OF OPERAITONS 12
7.0 VERIFICATION STUDY METHODOLOGY & DESIGN CRITERIA 14
8.0 HYDRAULIC CALCULATIONS 16
9.0 RECOMMENDATION 33
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EXECUTIVE SUMMARY
West Bakr Petroleum Company requested Enppi to prepare a technical report to study the
water injection project at K&H stations and advise the solution(s) to rectify current
problems and put the water handling system at both stations in service again properly.
The main problem that stations K and H are facing are the vibration and unstable operation
of stations upon operation of multi pumps per station.
Enppi performed a site visit and observed that pumps individual suction line is the same
size as pump nozzle while it should be at least one or two pipe sizes larger than pump
suction connection. That results in higher velocities in pumps common suction header and
individual suction lines higher than recommended values, in addition pump common
suction header equipped with numerous numbers of elbows, that by its turn generates a
measurable pressure drop while the common practice in this service is to have minimum
number of turns in the section piping.
Based on the above Enppi recommended two ways forward as follows (a) short term
solutions “No Mechanical Modifications” to operate the pumps at reduced flow rates and
(b) long term solutions “With Mechanical Modifications” to operate pump stations at
maximum allowable pumps speeds (310 RPM), resulting in the following.
• Short Term Solutions

o For K Station, operating three injection pumps at discharge flow rate (~ 43.5
M3/hr) this is equivalent to pump speed of ~ 250 RPM, resulting in calculated
velocity of (2.34 FPS) in the 10” header and (2.13 FPS) in the 6” pump suction
line.
o
(10/13)
For H Station, operating two injection pumps at discharge flow rate (~54 M3/hr)
this is equivalent to pump speed of ~ 310 RPM, resulting in calculated velocity of
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(1.937 FPS) in the 10” line and (2.644 FPS) in the 6” pump suction line.
This solution is subject to field trial for adjusting of velocity and pumped rate.
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• Long Term Solutions

For K Station, three proposed alternatives are recommended as follows:
o Modify injection pump suction header and individual suction lines sizes as
follows to accommodate the total pumping station capacity as shown in table
below:
Pump Total pump
K- Recommended line size (Inch)
Speed rate
Station
(RPM) (M3/hr) Header individual
3 pumps 310 162 18 8
4 pumps 310 216 20 8
o Operating two pumps from existing tanks via 10” header and operating other
three pumps from a new tank via a new 18” header. Resulting in (a) Operating
two injection pumps at discharge flow rate (48.7 M3/hr) this is equivalent to
pump speed of ~ 280 RPM through the existing 10” header and (b) Operating
three injection pumps at maximum discharge flow rate (54 M3/hr) this is
equivalent to pump speed of ~ 310 RPM through a new 18” header and new 8”
individual lines.
o Installing a new booster pumps upstream injection pumps to accommodate
the effect of acceleration head (assuming no pulsation damper in place),
resulting in installation of two centrifugal pumps (2X100%) of rated
capacity 220 M3/hr and required pump differential head of (79 Meter).
All long-term solutions above requires detailed engineering activities prior

implementing at site
• It is worth to mention that W.B requested Enppi to check the visibility to relocate the
(10/13)
current installed booster pumps close to injection pumps skids, while pumps are
sucking from a concrete sump; therefore, relocating the pumps shall results in a very
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long suction header (~ 250 Meter). Therefore, this solution is not a recommended
solution by Enppi.
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1.0 INTRODUCTION
West Bakr Petroleum Company requested Enppi to prepare a report to study the water
injection project at K&H stations and advise the solution(s) to rectify current problems and
put the water handling system at both stations in service again properly.
2.0 SCOPE OF REPORT
The scope of this report is to review the hydraulics for the actual configuration of piping at
site and to propose suitable recommendations (if any) from process point of view to allow
steady operation of both Booster and Injection pumps.
3.0 ABBREVIATIONS
FPS : Foot per Second
GPM : Gallon per Minute
NPIPA : Net Positive Inlet Pressure Available
NPIPR : Net Positive Inlet Pressure Required
USG : U.S. Gallon
WB : WEST BAKR
(10/13)
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4.0 PROJECT DESCRIPTION
4.1 K-Station Injection System

K-station water injection system comprises of:
• Two self-priming pump packages with flow rate of 200 M3/Hr each, designed to
operate for transfer of produced water from drain pit to the surge tanks.
• One Surge tank with 6500 mm ID and 7000 mm T/T.
• Five positive displacement plunger pumps with flow rate of 66.25 M3/Hr each, for
water injection to wells
The centrifugal self-priming pumping system operates such that its suction is from a drain-
pit. The centrifugal pumps are (2) booster pumps (one in operation and the other is stand-
by) that fill a surge tank to provide surge volume for the injection pumping system.
A system of injection pumps comprised of five (5) parallel pumps directs the water from
the tank to the injection wells via flow lines.
Below sketch illustrate K-station water injection

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4.2 H-Station Injection System

H-station water injection system comprises of:
• Two self-priming pump packages with flow rate of 200 M3/Hr each, designed to
operate for transfer of produced water from drain pit to the surge tanks.
• One Surge tank with 6500 mm ID and 7000 mm T/T.
• Five positive displacement plunger pumps with flow rate of 66.25 M3/Hr each, for
water injection to wells
The centrifugal self-priming pumping system operates such that its suction is from a drain-
pit. The centrifugal pumps are (2) booster pumps (one in operation and the other is stand-
by) that fill a surge tank to provide surge volume for the injection pumping system.
A system of injection pumps comprised of three (3) parallel pumps directs the water from
the tank to the injection wells via flow lines.
Below sketch illustrate H-station water injection

(10/13)
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5.0 INPUT DATA FOR HYDRAULIC VERIFICATION
The following data represents a summary of the extracted data received from both client
documents and the collected data during site visit dated January 28-30th, 2019.
5.1 K-Station Injection System

• Booster pump(s) flow rate is 200 M3/Hr per each pump, and pump head at specified
flow rate is 14M, as per pump data sheet. (Appendix No.1).
• Injection pump(s) maximum flow rate is ~54 M3/Hr per each pump, and pump
discharge pressure at rated flow rate is 1100 PSI, as per pump data sheet. (Appendix
No.2).
• Water Density is 1022 Kg/M3 as per received water analysis. (Appendix No.3).
• Surge tank is equipped with high liquid level set at 6.5 M which will send a signal to
the booster pump to stop and start again at level 6 M inside tank. (Appendix No.4).
• Elevation difference between Discharge tank nozzle and injection pumps suction
nozzle is 0.7 M, based on ONSPEC hydraulic study report sketch. (Appendix No.5).
• Booster pumps suction line is 6” and common discharge line is 10” up to the tank
inlet nozzle.
• Injection pumps common suction header from tank outlet nozzle is 10” and common
Discharge header is 12”.
5.2 H-Station Injection System
• Booster pump(s) flow rate is 200 M3/Hr per each pump, and pump head at specified
flow rate is 14M, as per pump data sheet. (Appendix No.1)
• Injection pump(s) maximum flow rate is ~54 M3/Hr per each pump, and pump
discharge pressure at rated flow rate is 1100 PSI, as per pump data sheet. (Appendix
No.2)
(10/13)
• Water Density is 1038 Kg/M3 as per received water analysis. (Appendix No.3)
•
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Surge tank is equipped with high liquid level set at 6.5 M which will send a signal to
the booster pump to stop and start again at level 6 M inside tank. (Appendix No.4)
• Elevation difference between Discharge tank nozzle and injection pumps suction
nozzle is 0.7 M, based on ONSPEC hydraulic study report sketch. (Appendix No.5)
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• Booster pumps suction line is 6” and common discharge line is 10” up to the tank
inlet nozzle.
• Injection pumps common suction header from tank outlet nozzle is 10” and common
Discharge header is 12”.
5.3 Other Available Data
• Verification report, document No. OSP082-PR-REP-14601, Rev A, dated 15/7/2018.
• Injection pumps supplier recommendations via e-mail.
• Injection pumps installation manual.
5.4 Missed data
• Injection pumps dampers size and pre-charge pressure (HOLD-1).
• As-built isometrics for both K & H stations.
(10/13)
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6.0 MODE OF OPERAITONS
Water injection system is running mainly following two modes of operation.
Operating Mode No.1: Booster pumps are delivering flow directly to Injection pumps
through by-passing the surge tank.
Operating Mode No.2: Booster pumps are delivering flow to surge tank, while injection
pumps feed from the tank simultaneously.
6.1 Operational Mode No.1

Booster pumps are delivering flow directly to Injection pumps through by-passing the
surge tank.
During the site visit the following operational mode, was conducted via unit operators,
where one booster pump was running at flow rate of 200 M3/Hr and the total flow was
directed back to the drain pit via 4” gate valve, while the injection pumps were not
running. Once centrifugal pump is in steady state operation the flow was directed to
injection pump through by-passing the surge tank (via 10” by-pass line) simultaneously
operators (a) starts one injection pump with flow rate of 54 M3/HR and (b) close the 4”
booster pumps manual spill-back gate valve.
The above results in activation of High High discharge pressure switch (installed on pump
discharge) that has a set pressure of 1.5 bar causing trip for the booster pump and
consequently suction pressure for injection pumps reaches low low switch trip values
causing injection pumps to be tripped as well.
CASE ANALYSIS
Enppi believes, that this system can be operated through the 4” gate valve on the spill back
line to drain pit via manipulate closing valve gradually (not fully close) to ensure flow
directed to injection pump(s) is not exceeding pump(s) max flow rate to avoid trip of
booster pump on high high discharge pressure, however this solution requires skilled
operators to sensitively manipulate the 4” gate valve against pumps rated/Flow Rates.
The optimum solution to overcome tripping the booster/injection pumps during start-up is
(10/13)
via replacing the manual gate valve with a min. flow control loop to adjust the flow based
on injection pump flow requirement meanwhile excess flow will be directed through spill
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back line to drain pit.

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6.2 Operational Mode No.2

Booster pumps are delivering flow to surge tank, while injection pumps feed from the tank
simultaneously.
WB started operating of the 1st injection pump at total speed of (1100 RPM) with a flow
rate of 54 M3/Hr, the system was operated steadily with no vibration or fluctuation in
pressure observed.
Then WB started operating the 2nd injection pump and gradually increase the speed to
reach (1100 RPM). The system was operating steady and no vibration or fluctuation in
pressure observed as well.
Upon starting the third pump a fluctuation in suction pressure was observed and pump was
operating with a high noise, hence operators decided to stop the pumping system due to
previous experience in vibrations leading to instruments damage.
CASE ANALYSIS
Analyzing above trail Enppi believed that root cause for the upset operation (upon starting
third pump) is mainly the size selection of the injection pumps (a) Common suction line
and/or (b) Individual pumps suction line.
Consequently, detailed hydraulic verifications were conducted as described in section

below.
(10/13)
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7.0 VERIFICATION STUDY METHODOLOGY & DESIGN CRITERIA
The methodology of the study is to perform the necessary hydraulic calculations to verify:
• The piping sizes, this includes the following:

- Specifying Design flow rate
- Defining stream physical properties.
- Calculated velocity versus limit velocity
- Calculated pressure drop versus Limit pressure drop in line.
• NPIP calculations, this includes the following:
- Studying the pressure drop in system at different modes of operation (depend on
running number of pumps).
• Velocity Limitations
Centrifugal Pumps discharge piping velocity limit is (15 FPS), however in case
Centrifugal pump discharge line is Reciprocating pump suction line, the limit velocity
on centrifugal pump discharge line shall comply with Reciprocation pump suction
piping limit velocity.
- For Reciprocating Pumps suction piping should have a velocity

- Less than, 2.0 FPS for speeds up to 250 RPM
- Less than, 1.5 FPS for speeds up to 330 RPM
- Less than, 1.0 FPS for speeds above 330 RPM
Typically, Low velocities limits for reciprocating pumps leads to higher suction line
sizes and consequently results in suction flow rate of (150% - 200%) of operating
pump discharge rate to avoid cavitation due to pump pulsation nature.
(10/13)
• Pressured drop calculations and pressure drop profile preparations:

- Pressure drop calculations and pressure drop profiles are prepared utilizing IN-
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PLANT software version 4.5

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• Acceleration Head
Enppi shall calculated acceleration head following supplier manual as follows:
Ha = (LVRC) / (Kg)
Where
Ha = acceleration head, feet

L = actual line length, feet
V = mean velocity in line, (FPS)
R = pump speed, (RPM)
C = 0.066 for Triplex Single or Double-acting
K = 1.4 for water
g = Gravitational constant = 32.2 ft/sec/sec
If the acceleration head is determined to be excessive, the following should be

evaluated:
(a) Shorten suction line, where Acceleration head is directly proportional to line
length, L.
(b) Use larger suction pipe to reduce velocity. This is very helpful since velocity
varies inversely with the square of pipe inside-diameter. Acceleration head is
directly proportional to fluid velocity.
(c) If the above remedies are unacceptable using a pulsation dampener is the
optimum solution. The results obtainable by using a dampener in the suction
system depend on the size, type, location, and pre-charge pressure used, that
shall be defined by pump supplier. The above is in line with pump supplier e-
mail (Appendix No.6) confirming that “NPSHR for supplied pump model BD-
165LC pump with 3.875-inch plunger running at minimum speed of 230 and
max speed of 380 rpm shall be well covered by 8 feet head above vapor
pressure of the fluid being handled is required at the inlet of the pump. This
(10/13)
suction head is in addition to atmospheric pressure (14.7 psia) and when

using a suction dampener”.
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8.0 HYDRAULIC CALCULATIONS
8.1 Discharge Line from Booster Pump to Surge Tank (K-station)

One booster pump was operated at flow rate of 200 M3/hr with directing the flow to the
surge tank, Enppi performed hydraulic calculations are as follows:
• Velocity Calculations and velocity limits are as follows:

- Calculated Velocity in 6” line : 9.821 FPS
- Limit Velocity (General Centrifugal pump discharge case) : 15 FPS
• Pressure drop calculations are as follows:

- Pressure drop in (6” line of length 2.2 Meter) : 5.175 PSI
- Pressure drop in (10” line of length 150 Meter) : 1.956 PSI
- Accumulated pressure drops in 6” and 10” lines : 7.131 PSI
: 4.9 M
- Static head in tank riser up to HHLL : 6.50 M
- Total Required head at pump discharge nozzle : 11.4 M
• Calculations analysis
In case of booster pumps discharge is directed only to the surge tank, the line size is
adequately selected from velocity point of view. In addition, based on pressure drop
calculations the total discharge head calculated for K-station booster pump is 11.4
Meter. While supplied pump discharge head is 14 Meter, accordingly line size is
adequately selected from pressure drop point of view.
Based on the above pressure drop calculations, total discharge head calculated via
booster pump is 11.4 Meter. Following W,B. request to install a filtration system with
(10/13)
differential pressure of (5 PSI = 3.44 Meter), accordingly the pump new calculated
differential pressure is (11.4 M + 3.44 M) is 14.84 Meter. While supplied pump
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discharge head is 14 Meter at 200 M3/hr, hence booster pumps need to operate at
lower flowrate to achieve the new target differential head with an acceptable margin.
For example, if pumps operated at high head (~ 16 Meter) this will result in a pumping
rate of ~170 M3/hr, consequently, only three injection pumps shall be in service.
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8.2 Discharge Line from Booster Pump to Surge Tank (H-station)

One booster pump was operated at flow rate of 200 M3/hr with directing the flow to the
surge tank, Enppi performed hydraulic calculations are as follows:

- Limit Velocity (General Centrifugal pump discharge case) : 15 FPS
• Pressure drop calculations are as follows:

- Pressure drop in (6” line of length 1.08 Meter) : 4.98 PSI
: 4.05 M
- Static head in tank riser up to HHLL : 6.50 M
- Total Required head at pump discharge nozzle : 10.55 M
In case of booster pumps discharge is directed only to the surge tank, the line size is
adequately selected from velocity point of view. In addition, based on pressure drop
calculations the total discharge head calculated for K-station booster pump is 10.55
Meter. While supplied pump discharge head is 14 Meter, accordingly line size is
adequately selected from pressure drop point of view.
Based on the above pressure drop calculations, total discharge head calculated via
booster pump is 10.55 Meter. Following W,B. request to install a filtration system
with differential pressure of (5 PSI = 3.44 Meter), accordingly the pump new
calculated differential pressure is (10.55 M + 3.44 M) is 13.99 Meter. While supplied
(10/13)
pump discharge head is 14 Meter at 200 M3/hr, hence booster pumps need to operate
at lower flowrate to achieve the new target differential head with an acceptable
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margin.
For example, if pumps operated at high head (~ 16 Meter) this will result in a pumping
rate of ~170 M3/hr, which will not be a concern as only two injection pumps are
required in service.
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8.3 Injection pumps suction line from booster pumps (K-station)

Hydraulic calculation is based on operating one booster pump with total flow rate of 200
M3/hr, and the flow is directed through (by-pass line of the surge tank) to operate three
injection pumps with a total flow rate 162 M3/hr, assuming balance flowrate (38 m3/hr) is
directed back to drain pit via minimum flow line.

- Calculated Velocity in 10” header (flow rate 162 M3/hr) : 2.906 FPS
- Calculated Velocity in 6” branch (flow rate 54 M3/hr) : 2.644 FPS
- Limit Velocity : 1.5 FPS
• Pressure drop calculations and pressure drop profile are as follows:

- Pressure drop (booster pump 6” - 2 Meter, rate 162 M3/hr) : 2.94 PSI
- Pressure drop in (10” header - 190 Meter, rate 162 M3/hr) : 1.47 PSI
- Pressure drop in (Injection pump 6” - 2 Meter, rate 54 M3/hr) : 0.07 PSI
- NPIPA at inlet of Injection Pump No.5 : 15.86 PSI
NPIPA at inlet of injection pump No.5 is (15.86 PSI) and the NPIPR specified by pump
supplier (8 PSI), the difference is (7.86 PSI), comparing this value to supplier suction
pressure considerations “The pressure available should exceed the pressure required
by at least 1 PSI”, accordingly the system is adequate from hydraulics pressure drop
point of view.
However Individual pump suction line has the same size of pump suction nozzle,
which by its turns leads to higher calculated velocity for individual pump suction line
(2.644 FPS) that exceeds the recommended limit values (1.5 FPS for pumps with
speeds up to 330 RPM). This statement is applicable for all pumps, hence shall not be
(10/13)
repeated in the analysis in other examined cases below.

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8.4 Injection pumps suction line from booster pumps (H-station)

Hydraulic calculation is based on operating one booster pump with total flow rate of 200
M3/hr, and the flow is directed through (by-pass line of the surge tank) to operate two
injection pumps with a total flow rate 108 M3/hr. assuming balance flowrate (92 m3/hr) is
directed back to drain pit via minimum flow line.

- Calculated Velocity in 10” header (flow rate 108 M3/hr) : 1.937 FPS
- Calculated Velocity in 6” branch (flow rate 54 M3/hr) : 2.644 FPS

- Pressure drop (booster pump 6” - 1 Meter, rate 200 M3/hr) : 1.11 PSI
- Pressure drop in (10” header - 90 Meter, rate 108 M3/hr) : 0.4 PSI
- Pressure drop in (Injection pump 6” - 3 Meter, rate 54 M3/hr) : 0.078 PSI
- NPIPA at inlet of Injection Pump No.3 : 18.75 PSI
NPIPA at inlet of injection pump No.3 is (18.75 PSI) and the NPIPR specified by pump
supplier (8 PSI), the difference is (10.75 PSI), comparing this value to supplier suction
pressure considerations “The pressure available should exceed the pressure required
by at least 1 PSI”, accordingly the system is adequate from hydraulics pressure drop
point of view.
However, the calculated velocities exceed the limit velocity (as the booster pump
discharge line is reciprocating pump suction line).
(10/13)
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8.5 Injection pumps Suction line from Surge tank

Based on Enppi recommendations to install a spill-back control valve on the spill back line
from booster pumps to drain-pit, Enppi believes that operating a booster pump (flow rate
200 M3/hr) can take place while operating one or more water injection pumps, as the spill-
back control valve can accommodate the by-passing of excess water higher than injection
pumps rate (based on number of running pumps) Consequently accumulation of water in
tank by this solution is not applicable and tank flooding is not foreseen.
Based on the above Enppi studied scenarios for running injection pumps as follows for K-
Station:
- One injection pump in operation with flow rate 54 M3/hr
- Two injection pumps in operation with total flow rate 108 M3/hr
- Three injection pumps in operation with total flow rate 162 M3/hr
- Four injection pumps in operation with total flow rate 216 M3/hr
- Above considers that pump configuration is (N+1) where one pump only is stand-by,
however this assumption needs to be double confirmed versus calculations as shown
below.
In addition, Enppi studied scenarios for running injection pumps as follows for H-Station:
- One injection pump in operation with flow rate 54 M3/hr
- Two injection pumps in operation with total flow rate 108 M3/hr
- Above considers that pump configuration is (N+1) where one pump only is stand-by,
however this assumption needs to be double confirmed versus calculations as shown
below.
(10/13)
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8.5.1 Injection pumps Suction line from Surge tank (K-station)

A- One Injection Pump in operation
Hydraulic calculation is based on operating one injection pump with total flow rate of
54 M3/hr (RPM-310). (Pump No.5), the last pump from the header inlet point is
considered to calculate the maximum pressure drop through the longest route.

- Calculated Velocity in 10” header : 0.969 FPS
- Calculated Velocity in 6” branch : 2.644 FPS

- Sketch Below shows pressure drop from the discharge nozzle of surge
tank to the suction nozzle of pump No.5.

(10/13)
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• Injection pump NPIPA calculations (Pump No 5):

- Total Flow Rate in 10” header : 54 m3/hr
- Flow Rate in 6” branch : 54 m3/hr
- Static suction head : 0.68 kg/cm2
- Suction line pressure drops : 0.009 kg/cm2
- Pump suction pressure : 1.704 kg/cm2a
- Acceleration head (total length) : 34.36 PSI
- Acceleration head (15 D) : 21.21 PSI
- NPIPA (based on total length) : -15.12 PSI
- NPIPA (based on 15 D) : 9.85 PSI
NPIPA at inlet of injection pump No.5 based on calculated acceleration head
resulted from the total length of suction line is (-15.12 PSI). However, based on
API RP 14E stating that “A good, properly located dampener, if kept properly
charged, may reduce L, the length of pipe used in acceleration head equation, to
a value of 5 to 15 nominal pipe diameter”. The calculated acceleration head
resulted from 15 D will lead to NPIPA of (9.85 PSI) and the NPIPR specified by
pump supplier is (8 PSI), the difference is (1.85 PSI), comparing this value to
supplier suction pressure considerations “The pressure available should exceed
the pressure required by at least 1 PSI”, accordingly the system is adequate from
hydraulics pressure drop point of view.
Meanwhile the calculated velocity in 10” header (0.969 FPS) is adequate, while
for individual pump suction line the velocity is (2.644 FPS) exceeds the limit
velocity as specified in section 7.0.
Based on the above calculations, the system can be operated smoothly if

(10/13)
pulsation damper is adequately installed (size and pre-charge).

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Pump supplier shall avail the damper size and pre-charge pressure required to
accommodate acceleration head effect in suction piping.
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B- Two Injection Pumps in operation
Hydraulic calculation is based on operating two injection pumps with total flow rate of
108 M3/hr. (Pump No.4 & No.5), the last pumps from the header inlet point are
considered to calculate the maximum pressure drop through the longest route.


tank to the suction nozzle of pumps No.4 & No.5.

(10/13)
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pump supplier is (8 PSI), the difference is (– 0.74 PSI), comparing this value to
the pressure required by at least 1 PSI”, accordingly the system is considered not
adequate from hydraulics pressure drop point of view.
Meanwhile the calculated velocity in 10” header (1.937 FPS) and individual
pump suction lines is (2.644 FPS) exceed the limit velocity as specified in
section 7.0.
Based on the above calculations, the system cannot be operated smoothly and
(10/13)
required mechanical modifications or operating at reduced speeds.

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C- Three Injection Pumps in operation
Hydraulic calculation is based on operating three injection pumps with total flow
rate of 162 M3/hr. (Pump No.3, No.4 & No.5), the last pumps from the header inlet
point are considered to calculate the maximum pressure drop through the longest
route.


tank to the suction nozzle of pumps No.3, No.4 & No.5.

(10/13)
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pump supplier is (8 PSI), the difference is (- 3.57 PSI), comparing this value to
section 7.0.
(10/13)
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PETRODARA 4836-407-10-RT-001
D- Four Injection Pumps in operation
Hydraulic calculation is based on operating four injection pumps with total flow
rate of 216 M3/hr. (Pump No.2, No.3, No.4 & No.5), the last pumps from the
header inlet point are considered to calculate the maximum pressure drop through
the longest route.


tank to the suction nozzle of pumps No.2, No.3, No.4 & No.5.
(10/13)
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PETRODARA 4836-407-10-RT-001

pump supplier is (8 PSI), the difference is (- 6.11 PSI), comparing this value to
section 7.0.
(10/13)

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PETRODARA 4836-407-10-RT-001
8.5.2 Injection pumps Suction line from Surge tank (H-station)

A- One Injection Pumps in operation
Hydraulic calculation is based on operating one injection pump with total flow rate
of 54 M3/hr. (Pump No.5), the last pump from the header inlet point are considered
to calculate the maximum pressure drop through the longest route.


tank to the suction nozzle of pump No.3.

(10/13)
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PETRODARA 4836-407-10-RT-001

resulted from the total length of suction line is (- 2.97 PSI). However, based on
Meanwhile the calculated velocity in 10” header (0.969 FPS) is adequate, while
for individual pump suction line the velocity is (2.644 FPS) exceeds the limit
velocity as specified in section 7.0.

(10/13)

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PETRODARA 4836-407-10-RT-001
B- Two Injection Pumps in operation
Hydraulic calculation is based on operating two injection pumps with total flow rate
of 132.5 M3/hr. (Pump No.2 & No.3), the last pumps from the header inlet point
are considered to calculate the maximum pressure drop through the longest route.


tank to the suction nozzle of pumps No.2 & No.3.

(10/13)
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PETRODARA 4836-407-10-RT-001

resulted from the total length of suction line is (- 20.26 PSI). However, based on
pump suction line is (2.644 FPS) exceed the limit velocity as specified in section
7.0.

(10/13)

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PETRODARA 4836-407-10-RT-001
9.0 RECOMMENDATION
9.1 Booster pump system proposed modifications (K and H Stations)

ENPPI recommends installing new control loop (as clouded on sketch below)
This includes replacing the 4” gate valve with a (Flow Control Valve) on spill back line,
controlled via a flow controller installed on the common booster pumps discharge header,
the flow controller can be adjusted via level in tank.
(10/13)
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PETRODARA 4836-407-10-RT-001
9.2 Injection pumps system proposed modifications (K and H Stations)

In this section, ENPPI proposes (a) short term solutions and (b) long term solutions, the
short-term solution targets operating the unit with limited cost impact and allow operating
the existing system with no mechanical modifications. Meanwhile the long-term solution
targets operating the station at full design capacity, which will require additional investment
for implementation.
A- Short Term Solutions

In short term solution, operating the unit shall take place at reduced flow rates.
This solution is subject to field trial for adjusting of velocity and pumped rate.
• (K Station) Short Term Solution

Operating three injection pumps at minimum discharge flow rate (~ 43.5 M3/hr) this is
equivalent to pump speed of ~ 250 RPM, resulting in calculated velocity of (2.34 FPS)
in the 10” header and (2.13 FPS) in the 6” pump suction line.
The resulted velocities are exceeding the limits. This can be waved subject to pumps
smooth operation at specified flow rates and speed above. Consequently, if high noise
is observed operator can reduce pumping rate.
Reference to API RP 14E stating that “A good, properly located dampener, if kept
properly charged, may reduce L, the length of pipe used in acceleration head equation,
to a value of 5 to 15 nominal pipe diameter”. Enppi calculated the acceleration head
considering suction length is 15 D resulted in 21 FT (9.3 PSI).
Reference to supplier recommendation stating that “The pressure available should

exceed the pressure required (8 PSI) by at least 1 PSI” this leads to limit accepted
suction pressure = 9 PSI.
Calculating the pressure available equals to 9.76 PSI, accordingly three pumps at flow
rate of 43.5 M3/hr (250 RPM) can be operated from calculation point of view
considering adequately installed pulsation damper (size and pre-charge).
Consequently, if pulsation damper is not adequately fit, Pumped flow rates may need
to be reduced.
(10/13)
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PETRODARA 4836-407-10-RT-001
Based on the above operating pumps in this mode of operation shall be subject to field
trial for adjusting of velocity and pumped rate to ensure smooth operation.
• (H Station) Short Term Solution

Operating two injection pumps at minimum discharge flow rate (~54 M3/hr) this is
equivalent to pump speed of ~ 310 RPM, resulting in calculated velocity of (1.937
FPS) in the 10” line and (2.644 FPS) in the 6” pump suction line.
The resulted velocities are exceeding the limits. This can be waved subject to pumps
smooth operation at specified flow rates and speed above. Consequently, if high noise
is observed operator can reduce pumping rate.
Reference to API RP 14E stating that “A good, properly located dampener, if kept
properly charged, may reduce L, the length of pipe used in acceleration head equation,
to a value of 5 to 15 nominal pipe diameter”. Enppi calculated the acceleration head
considering suction length is 15D resulted in total acceleration head of 22.8 FT (10
PSI).
Reference to supplier recommendation stating that “The pressure available should

exceed the pressure required (8 PSI) by at least 1 PSI” this leads to limit accepted
suction pressure = 9 PSI.
Calculating the pressure available equals to 9.3 PSI, accordingly two pumps at
maximum flow rate of 54 M3/hr (310 RPM) can be operated from calculation point of
view considering adequately installed pulsation damper (size and pre-charge).
Consequently, if pulsation damper is not adequately fit, Pumped flow rates may need
to be reduced.
Based on the above operating pumps in this mode of operation shall be subject to field
trial for adjusting of velocity and pumped rate to ensure smooth operation
(10/13)
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PETRODARA 4836-407-10-RT-001
B- Long Term Solutions

Long term solutions require mechanical modifications in individual pumps suction line and
common headers from (booster pumps) and/or (Surge tanks) to injection pumps.
In this section, ENPPI studied proposed alternatives targets operating the station at full
design capacity, which will require additional investment for implementation. It worth to
highlight that acceleration head is an important factor in the application of reciprocating
pumps because of the pulsating nature of the flow in the pump suction line. Accordingly,
Pump supplier shall avail the damper size and pre-charge pressure required to accommodate
acceleration head effect in suction piping in cases below.
(K Station) Recommended Solution

Alternative No. 1
Replacing the individual pump suction line by (8” instead of 6”) and common pumps
suction header to (20” instead of 10”) allows operating individual pump at maximum flow
rate of (54 M3/hr = 310 RPM) and subsequently operating four pumps at total flow rate
(216 M3/hr). In this case the velocity in 8” line shall be (1.527 FPS) and velocity in 20”
header shall be (1.099 FPS). The resulted velocities are almost matching with the limit
velocity (1.5 FPS for pumps operating up to 330 RPM).
Reference to API RP 14E stating that “A good, properly located dampener, if kept properly
charged, may reduce L, the length of pipe used in acceleration head equation, to a value of 5
to 15 nominal pipe diameter”. Enppi calculated the acceleration head considering suction
length is 15D resulted in total acceleration head of 21.55 FT (9.67 PSI).
Reference to supplier recommendation stating that “The pressure available should exceed
the pressure required (8 PSI) by at least 1 PSI” this leads to limit accepted suction pressure
= 9 PSI.
Calculating the pressure available equals to 9.73 PSI, accordingly four pumps at maximum
flow rate of 54 M3/hr (310 RPM) can be operated from calculation point of view
considering adequately installed pulsation damper (size and pre-charge). Consequently, if
pulsation damper is not adequately fit, Pumped flow rates may need to be reduced.
(10/13)
Based on the above operating pumps in this mode of operation shall be subject to field trial
for adjusting of velocity and pumped rate to ensure smooth operation
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PETRODARA 4836-407-10-RT-001
Alternative No. 2
Install a new surge tank parallel to the existing tank with equal dimensions and liquid
levels. And to construct a new 18” discharge header that will be connected only to three
injection pumps (with individual line size of 8” instead of 6”). Consequently, this leads to
having two parallel trains (one surge tank connected through the existing 10” header with
individuals 6” lines connected only to two injection pumps and the new 18” header with
new individuals 8” lines connected to the other three injection pumps).
The above modification will lead to:
• Operating two injection pumps at discharge flow rate (48.7 M3/hr) this is equivalent to
pump speed of ~ 280 RPM through the existing 10” header, resulting in calculated
velocity of (1.747 FPS) in the 10” header and (2.384 FPS) in the 6” pump suction line.
• Operating three injection pumps at maximum discharge flow rate (54 M3/hr) this is
equivalent to pump speed of ~ 310 RPM through the new 18” header and new 8”
individual lines, resulting in calculated velocity of (1.024 FPS) in the 18” header and
(1.527 FPS) in the 8” pump suction line.
The resulted velocities are exceeding the limits. This can be waved subject to pumps smooth
operation at specified flow rates and speed above. Consequently, if high noise is observed
operator can reduce pumping rate.
Reference to API RP 14E stating that “A good, properly located dampener, if kept properly
charged, may reduce L, the length of pipe used in acceleration head equation, to a value of 5
to 15 nominal pipe diameter”. Enppi calculated the acceleration head considering suction
length is 15D resulted in
• Total acceleration head of 21.75 FT (9.62 PSI) in the existing 10” header & 6”
individual lines.
• Total acceleration head of 19.54 FT (8.64 PSI) in the new 18” header & new 8”
individual lines.
Reference to supplier recommendation stating that “The pressure available should exceed
(10/13)
the pressure required (8 PSI) by at least 1 PSI” this leads to limit accepted suction pressure
= 9 PSI.
10000-Z-000-GE1-TMP-0004
Calculating the pressure available by supplier equation above resulted in available pressure
equals to 9.56 PSI in the existing 10” header and 10.62 PSI in the new 18” header,
accordingly two pumps at flow rate of 48.7 M3/hr (280 RPM) in the existing train and 3
pumps at maximum flow rate of 54 M3/hr (310 RPM) in the new train giving a total flow
rate of 260 M3/hr can be operated from calculation point of view considering adequately
PETRODARA 4836-407-10-RT-001
installed pulsation damper (size and pre-charge). Consequently, if pulsation damper is not
adequately fit, Pumped flow rates may need to be reduced.
Based on the above operating pumps in this mode of operation shall be subject to field trial
for adjusting of velocity and pumped rate to ensure smooth operation.
Alternative No. 3
Using a centrifugal booster pump installed upstream injection pumps to charge the suction
of the reciprocating pump.
PETRODARA requested Enppi to study the possibility to install a new booster pump to
overcome the acceleration head in injection pump suction line assuming no pulsation
damper installed and making use of 10” common suction header and 6” branch sizes for
injection pumps (i.e. No major modifications in injection pumps pipping configuration).
Enppi believes that this will results in injection pump high suction pressure, consequently
(10/13)
PETRODARA should ensure the following:
• Injection pump mechanical seal can withstand new booster pump discharge pressure
10000-Z-000-GE1-TMP-0004
(9.4 Kg/cm2a) and max pump discharge pressure (13 Kg/cm2a), that should be
performed by consulting injection pumps supplier.
PETRODARA 4836-407-10-RT-001
• Injection pumps suction header and individual suction lines can withstand new booster
pump estimated shut-off pressure specified below. that should be performed by
checking injection pump suction header and branches hydrostatic leak test pressure.
If any of the above is not achievable this solution cannot be considered an acceptable
alternative.
As per PETRODARA requirements, the new pump shall be defined to overcome total
acceleration head as if there is no pulsation damper installed. The calculated acceleration
head in case operating four pumps at maximum flow rate (54 M3/hr = 310 RPM) will lead
to acceleration head of 117 PSI = 8.2 Kg/cm2.
Reference to supplier recommendation stating, “The pressure available should exceed the
pressure required (8 PSI) by at least 1 PSI”, and adding pressure drop due to friction losses
which is 0.15 Kg/cm2 to the acceleration head so the total pressure drop through the system
is 8.35 Kg/cm2.
ENPPI performed preliminary pump hydraulics calculation to define the required

centrifugal pump and below data were obtained
• Pump configuration : (2 X 100 %)

• Pump flow rate : 220 M3/hr
• Suction line size : 12 Inch
• Discharge line size : 10 Inch
• Suction pressure : 1.4 Kg/cm2a
• NPSHA : 10 Meter
• Pump Discharge pressure : 9.5 Kg/cm2a
• Pump differential head : 79 Meter
• Discharge line design pressure : 13 Kg/cm2
(10/13)
The above values are based on estimated new centrifugal pump location where detailed
engineering contractor shall be responsible to specify and confirm values above.
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PETRODARA 4836-407-10-RT-001
Premises for implementing above recommendations

1- Pump supplier shall avail the damper size and pre-charge pressure required to
accommodate acceleration head effect in suction piping in cases above.
2- Piping system design shall follow the design check list mentioned in Pump Vendor
IOM section 1.1 items (1.1.1 to 1.1.13). Highlighting the following:
- Pulsation study for the piping system is essential as per requirements of API 674,
the pulsation study shall be held by arrangement between WB and NOV.
3- Suction piping system shall follow section 1.4 of Pump Vendor IOM particularly
section 1.4.3 “Suction Piping Design” highlighting the following:
- Eliminate any rise or summit in the suction line where air or vapor can collect, No
high points unless vented.
- Use eccentric reducer at pump cylinder with flat side up.
- Minimize the number of turns (Elbows) in the suction piping. Utilizing long radius
elbows (if needed).
- The suction manifold diameter and the piping from the supply tank to manifold
must be such that it has a cross sectional area equal to or greater than the area of
the combined individual suction pipes for each pump.
4- Discharge piping system shall follow section 1.5 of Pump Vendor IOM highlighting
the following:
- Any bend in discharge line should be made with long radius bends avoiding the
use of 90o bends if possible.
- The discharge line should be at least one or two pipe sizes larger than pump
discharge connection.
- Discharge line size should be sufficient so that discharge flow does not exceed 10
FPS.
- Be as short and direct as possible.
(10/13)
5- In additions, it is recommended to install a vent connection at every high point on

10000-Z-000-GE1-TMP-0004
injection pumps suction line to be periodically checked to vent any hydrocarbons vapor
flashed in the suction line.
PETRODARA 4836-407-10-RT-001
APPENDIX NO.1
(10/13)
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(10/13)
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PETRODARA 4836-407-10-RT-001
APPENDIX NO.2
(10/13)
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(10/13)
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APPENDIX NO.3
(10/13)
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PETRODARA 4836-407-10-RT-001
K- station water analysis

(10/13)
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H- station water analysis

(10/13)
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APPENDIX NO.4
(10/13)
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(10/13)
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APPENDIX NO.5
(10/13)
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K- Station sketch
(10/13)
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PETRODARA 4836-407-10-RT-001
H- Station sketch
(10/13)
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APPENDIX NO.6
(10/13)
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PETRODARA 4836-407-10-RT-001
(10/13)
10000-Z-000-GE1-TMP-0004

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REPORT PAGE 2 OF 54

Name Title Initial

Prepared By Mohamed Reda Process Engineer M.R.M

Checked By Mohamed Shawwal Senior Lead Process Egineer M.S.S

Approved By Khaled El-Badry General Manger K.EL.

2.0 SCOPE OF REPORT 7

4.0 PROJECT DESCRIPTION 8

5.0 INPUT DATA FOR HYDRAULIC VERIFICATION 10

6.0 MODE OF OPERAITONS 12

7.0 VERIFICATION STUDY METHODOLOGY & DESIGN CRITERIA 14

8.0 HYDRAULIC CALCULATIONS 16

• Short Term Solutions

• Long Term Solutions

All long-term solutions above requires detailed engineering activities prior

2.0 SCOPE OF REPORT

FPS : Foot per Second

GPM : Gallon per Minute

NPIPA : Net Positive Inlet Pressure Available

NPIPR : Net Positive Inlet Pressure Required

USG : U.S. Gallon

4.0 PROJECT DESCRIPTION

4.1 K-Station Injection System

Below sketch illustrate K-station water injection

4.2 H-Station Injection System

Below sketch illustrate H-station water injection

5.0 INPUT DATA FOR HYDRAULIC VERIFICATION

5.1 K-Station Injection System

6.0 MODE OF OPERAITONS

Water injection system is running mainly following two modes of operation.

6.1 Operational Mode No.1

back line to drain pit.

6.2 Operational Mode No.2

Consequently, detailed hydraulic verifications were conducted as described in section

7.0 VERIFICATION STUDY METHODOLOGY & DESIGN CRITERIA

• The piping sizes, this includes the following:

- For Reciprocating Pumps suction piping should have a velocity

• Pressured drop calculations and pressure drop profile preparations:

PLANT software version 4.5

Ha = acceleration head, feet

If the acceleration head is determined to be excessive, the following should be

suction head is in addition to atmospheric pressure (14.7 psia) and when

8.0 HYDRAULIC CALCULATIONS

8.1 Discharge Line from Booster Pump to Surge Tank (K-station)

• Velocity Calculations and velocity limits are as follows:

- Calculated Velocity in 10” line : 3.598 FPS

- Limit Velocity (General Centrifugal pump discharge case) : 15 FPS

• Pressure drop calculations are as follows:

- Pressure drop in (10” line of length 150 Meter) : 1.956 PSI

- Accumulated pressure drops in 6” and 10” lines : 7.131 PSI

- Static head in tank riser up to HHLL : 6.50 M

- Total Required head at pump discharge nozzle : 11.4 M

8.2 Discharge Line from Booster Pump to Surge Tank (H-station)

• Velocity Calculations and velocity limits are as follows:

- Calculated Velocity in 10” line : 3.543 FPS

- Limit Velocity (General Centrifugal pump discharge case) : 15 FPS

• Pressure drop calculations are as follows:

- Pressure drop in (10” line of length 65 Meter) : 0.96 PSI

- Accumulated pressure drops in 6” and 10” lines : 5.94 PSI

- Static head in tank riser up to HHLL : 6.50 M

- Total Required head at pump discharge nozzle : 10.55 M

8.3 Injection pumps suction line from booster pumps (K-station)

• Velocity Calculations and velocity limits are as follows: