Title: Process Gas Flow and Pipe Size Calculations

Project Name: Cochin Shipyard

Project Number: RA1158

Author: Fraser Sharp Date: 14/01/2016

Checked: Gordon Strang Date: 15/01/2016

Purpose: Calculations for flow and pipe sizing for industrial gases

Introduction
The purpose of the following basic calculations is to determine suitable pipe sizes and flow rates
for the process gases to be used at the new dry dock and grand assembly area to be
constructed at Cochin Shipyard.

At the time of producing these calculations detail srelating to gas consumption are under
discussion with CSL. More detailed calculations relating to pressure losses in the system will be
undertaken during the tender design stage using Fluid Flow software.
Yearly Consumption rates

As a basis for the following calculations yearly consumption rates for the proess gases have
been calculated by the Royal HaskoningDHV engineers based on 1, 2 and 3 LNG tankers being
built and 1 vessel being repaired.

Please refer to the following graphs

Summary

ARGON
Dry Dock and blocking area consumption only - ACET OXYGEN
(Liquid CO2 (Kg)
about 20%-30% of total requirement (M3) (M3)
LTRS)
Throughput of 3 LNG + Repair (RHDHV calc) 38,000 67,000 193,000 47,000
Throughput of 2 LNG + Repair (RHDHV calc) 27,000 45,000 129,000 32,000
Throughput of 1 LNG + Repair (RHDHV calc) 16,000 23,000 65,000 16,000

Current yard average yearly consumption for

8,725 24,995 73,647 73,784
comparison
Calculating Flow Rates

Assumptions

The yearly consumption will be equally divided amongst 250 day to account for weekends and holidays.
Each day will be equally divided into 8 hour shifts.
A usage factor of 0.3 has been used.
It is assumed that the calculated hourly rate will be the peak flow rate.
RHDHV will assume for purpose of these calculations that 3 LNG vessles will be built at the facility.

Acetylene
3
Yearly 38,000.00 m
3
Daily 152.00 m
3
Hourly 19.00 m /hr
3
Flow rate 63.33 m /hr (Includes 0.3 usage factor)

Argon
3
Yearly 55,074.00 m Litres to m3 Expansion Ratio 0.822
3
Daily 220.30 m
3
Hourly 27.54 m /hr
3
Flow rate 91.79 m /hr (Includes 0.3 usage factor)

CO2
3
Yearly 103,062.00 m Kg to m3 Expansion ratio of 0.534 m 3/kg
3
Daily 412.25 m
3
Hourly 51.53 m /hr
3
Flow rate 171.77 m /hr (Includes 0.3 usage factor)

Oxygen
3
Yearly 47,000.00 m
3
Daily 188.00 m
3
Hourly 23.50 m /hr
3
Flow rate 78.33 m /hr (Includes 0.3 usage factor)

Compressed Air

Compressors to have a capacity of 1000cfm (request from CSL)

3
Flow rate 1,699.00 m /hr
Calculating Pipe Sizes

The following calculations are basic calculations to determine indicative pipe sizes
based on the information available. The calculations will only determine the
diameter of the ring main pipes as the RHDHV are not the designers of the existing
or new gas storage facilities.

Allowable gas velocities within the pipes are taken from the guidance provided by

Acetylene
2 3
A(m ) = Q(m /s) / V(m/s)
2 3
Therefore A(m ) = Q(m /hr) / 3600xV(m/s)
Q= 63.00 m/hr
V= 72,000.00 m/hr 20m/s
A= 0.0009 m
D= 0.0334 m (Internal diameter)
For the given flow and velocity a 50mm DN pipe will be required.

Argon
2 3
A(m ) = Q(m /s) / V(m/s)
Therefore A(m2) = Q(m3/hr) / 3600xV(m/s)
Q= 92.00 m/hr
V= 72,000.00 m/hr 20m/s
A= 0.0013 m
D= 0.0403 m (Internal diameter)
For the given flow and velocity a 50mm DN pipe will be required.

CO2
2 3
A(m ) = Q(m /s) / V(m/s)
Therefore A(m2) = Q(m3/hr) / 3600xV(m/s)
Q= 172.00 m/hr
V= 72,000.00 m/hr 20m/s
A= 0.0024 m
D= 0.0552 m (Internal diameter)
For the given flow and velocity a 50mm DN pipe will be required.

Oxygen
2 3
A(m ) = Q(m /s) / V(m/s)
Therefore A(m2) = Q(m3/hr) / 3600xV(m/s)
Q= 78.00 m/hr
V= 54,000.00 m/hr 15m/s (BCGA guidance)
A= 0.0014 m
D= 0.0429 m (Internal diameter)
 For the given flow and velocity a 50mm DN pipe will be required.

Compressed Air
2 3
A(m ) = Q(m /s) / V(m/s)
Therefore A(m2) = Q(m3/hr) / 3600xV(m/s)
Q= 1,699.00 m/hr
V= 54,000.00 m/hr 20m/s
A= 0.0315 m
D= 0.2002 m (Internal diameter)
For the given flow and velocity a 200mm DN pipe will be required.