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SERVICES FOR UTILITIES PIPING FOR AISHA STEEL MILLS LIMITED KARACHI
Job Order # 5530000004 Doc. No.: A003‐RP‐02
Hydraulic Analysis Report
Dated: 04/03/2018 Page 1 of 22 Rev. A
HYDRAULIC ANALYSIS REPORT
FOR
AISHA STEEL MILLS LIMITED KARACHI
ISSUED FOR
REVIEW
MARCH 09, 2018
CONSULTANCY SERVICES FOR UTILITIES PIPING FOR AISHA STEEL MILLS LIMITED KARACHI
Job Order # 5530000004 Doc. No.: A003‐RP‐02
Hydraulic Analysis Report
Dated: 09/03/2018 Page 2 of 22 Rev. A
REVISION RECORD
CONSULTANCY SERVICES FOR UTILITIES PIPING FOR AISHA STEEL MILLS LIMITED KARACHI
Job Order # 5530000004 Doc. No.: A003‐RP‐02
Hydraulic Analysis Report
Dated: 09/03/2018 Page 3 of 22 Rev. A
TABLE OF CONTENTS
1.0 INTRODUCTION 5
1.1 Scope 5
1.2 Definitions 5
1.3 Abbreviations 6
1.4 System Of Units 7
1.5 Referenced Documents 7
1.6 Codes & Standards 8
1.7 Site Data 8
2.0 HYDRAULIC ANALYSIS BASIS 9
2.1 General 9
2.2 Gas Composition 9
2.3 Line Sizing Criteria 10
2.3.1 Gas Lines 10
2.3.2 Liquid Lines 10
2.3.1 Steam Lines 11
2.4 Nitrogen Sizing Scenario I 11
2.5 Nitrogen Sizing Scenario II 12
2.6 Hydrogen Sizing 12
2.7 Protective Gas Sizing 13
2.8 Natural Gas Sizing 13
2.9 Compressed Air Sizing 14
2.10 Saturated Steam Sizing 14
2.11 Demineralized Water Sizing 14
2.12 Cooling Recycle Water Sizing 15
2.13 Hot Water Sizing 15
2.14 Potable Water Sizing 15
2.15 Sewage Waste Water Sizing 16
3.0 HYDRAULIC ANALYSIS RESULTS 17
3.1 Nitrogen Line Sizing Results Summary Scenario I 17
3.2 Nitrogen Line Sizing Results Summary Scenario II 17
3.3 Hydrogen Line Sizing Results Summary 18
3.4 Protective Gas Line Sizing Results Summary 18
3.5 Natural Gas Line Sizing Results Summary 19
3.6 Compressed Air Line Sizing Results Summary 19
3.7 Saturated Steam Line Sizing Results Summary 20
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Hydraulic Analysis Report
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3.8 Demineralized Water Line Sizing Results Summary 20
3.9 Cooling Recycle Water Line Sizing Results Summary 21
3.10 Hot Water Line Sizing Results Summary 21
3.11 Potable Water Line Sizing Results Summary 22
3.12 Sewage Waste Water Line Sizing Results Summary 22
1. Annexure‐A Nitrogen Simulation Model Scenario I
2. Annexure‐B Nitrogen Simulation Model Scenario II
3. Annexure‐C Hydrogen Simulation Model
4. Annexure‐D Protective Gas (N2 + H2) Simulation Model
5. Annexure‐E Natural Gas Simulation Model
6. Annexure‐F Compressed Air Simulation Model
7. Annexure‐G Saturated Steam Simulation Model
8. Annexure‐H Desalination / Demineralized Water Simulation Model
9. Annexure‐I Cooling Recycle Water Simulation Model
10. Annexure‐J Hot Water Simulation Model
11. Annexure‐K Potable Water Simulation Model
12. Annexure‐L Sewage Waste Water Simulation Model
CONSULTANCY SERVICES FOR UTILITIES PIPING FOR AISHA STEEL MILLS LIMITED KARACHI
Job Order # 5530000004 Doc. No.: A003‐RP‐02
Hydraulic Analysis Report
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1.0 INTRODUCTION
Aisha Steel Mills Limited (ASML) is a Group Company of Arif Habib. It is a state‐of‐the‐art cold
rolling complex with a nameplate capacity of 220,000 metric tons per year. ASML is one of the
largest private sector investments in the value added flat‐rolled steel industry in Pakistan. It is the
only Cold Rolled Coil (CRC) manufacturer in the country which is using brand new Japanese and
Austrian machinery for all of its main process, ensuring best quality production of CRC in the
country. ASML was incorporated in 2005 & started its commercial operation in 2012 and it sets
to become largest supplier of Cold Rolled and Steel Coils.
ASML has engaged M/s A2SK Engineering Private Limited to calculate the line sizes for the utilities
as Nitrogen (N2) with high flow rate, Nitrogen (N2) with low flow rate ‘Hydrogen (H2)
Protective Gas (N2 + H2) ‘Natural Gas (NG) ‘Compressed Air, Saturated Steam, Desalination /
Demineralized Water, Cooling Recycle Water, Hot Water, Potable Water and Sewage Waste
Water etc.
This document for the Project shall be considered as a guide for Contractor, and the requirements
referred to herein shall be taken as minimum requirements. The scope of works is not intended
to limit or restrict the obligations of contractor in respect of the execution of the works and no
part of the scope of works shall limit any other part of the scope of works or neither any of the
specifications nor the responsibilities of Contractor in respect thereof.
1.1 Scope
The purpose of this report is to determine utilities line sizes for Aisha Steel Mills Limited located
at DSU‐45 Downstream Industrial Estate Karachi. The line sizes need to be determined for the
plant in order to meet specified flow velocity and pressure drop criteria. Hydraulic analysis report
shall be applicable to utilities units and associated facilities located within plant fence except
where otherwise stated.
The line sizing scope shall be limited to the following utilities:‐
1. Nitrogen (N2) with high flow rate
2. Nitrogen (N2) with low flow rate
3. Hydrogen (H2)
4. Protective Gas (N2 + H2)
5. Natural Gas (NG)
6. Compressed Air
7. Saturated Steam
8. Desalination / Demineralized Water
9. Cooling Recycle Water
10. Hot Water
11. Potable Water
12. Sewage Waste Water
1.2 Definitions
The definitions used for this project are included in Table 1.1
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Hydraulic Analysis Report
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Table 1.1 Definitions
COMPANY/ CLIENT Aisha Steel Mills Limited
Firm / Organization nominated by COMPANY to perform Work. It
CONTRACTOR is the party which carries‐out all Procurement and Construction /
Installation of all Equipment after Engineering Design.
CONSULTANT A2SK Engineering (Pvt.) Limited.
Consultancy services for detailed design of utilities piping for Aisha
PROJECT
Steel Mills Limited Karachi.
SHALL Indicates a mandatory requirement.
1.3 Abbreviations
The abbreviations used for this project are included in Table 1.2
Table 1.2 Abbreviations
CA Compressed Air
CRW Cooling Recycled Water
DSW Desalination Water
EPC Engineering, Procurement, Construction
FW Fire Water
H2 Hydrogen
hr Hour
HW Hot Water
ID Inside Diameter
Kg Kilogram
KM Kilometre
m Meter
N2 Nitrogen
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NG Natural Gas
o
C Degree Celsius
P&ID Piping & Instrumentation Diagram
PFD Process Flow Diagram
PG Protective Gas (Nitrogen + Hydrogen)
PW Portable Water
St Saturated Steam
SW Sewage Waste Water
1.4 System Of Units
The SI units have been used and are included in Table 1.3.
Table 1.3 System of Units
Parameters Units
Density Kg/m3
Length m or km
Liquid Volumetric Flow Rate (Cubic meter per Hour) m3/hr (N m3/hr)
Pipe Diameter Inches
Pressure barg
o
Temperature C
Viscosity cP
Velocity m/s
1.5 Referenced Documents
The following documents as listed in Table 1.4 have been used as reference documents for
preparation of hydraulic analysis report.
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Hydraulic Analysis Report
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Table 1.4 Referenced Documents
Document Numbers Document Titles
Piping & Instrumentation Diagrams
‐ P&ID _ Nitrogen Distribution System Scenario I
‐ P&ID _ Nitrogen Distribution System Scenario II
‐ P&ID _ Hydrogen Distribution System
‐ P&ID _ Protective Gas (N2 + H2) Distribution System
‐ P&ID _ Natural Gas Distribution System
‐ P&ID _ Compressed Air Distribution System
‐ P&ID _ Saturated Steam Distribution System
‐ P&ID _ Cooling Recycle Water Distribution System
‐ P&ID _ Hot Water Distribution System
‐ P&ID _ Potable Water Distribution System
‐ P&ID _ Sewage Waste Water Distribution System
1.6 Codes & Standards
The overall design of the system is in compliance with the latest edition of the codes and
standards as included in Table 1.5.
Table 1.5 Codes & Standards
Code Description
Recommended Practice for Design and Installation of Offshore
API RP 14E
Production Platform Piping Systems.
GS‐EP‐ECP‐103 Total standard (Revision 02)
1.7 Site Data
The environmental conditions for terminal station are included in Table 1.6
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Table 1.6 Site Data
Average Relative Humidity (Max) % 90
Average Relative Humidity (Min) % 19
Site Elevation m ‐
2.0 HYDRAULIC ANALYSIS BASIS
2.1 General
Line size is determined based on the limiting velocities of the pipe, material used, length of the
pipe and the allowable line pressure drop. The velocity limitations are considered to keep in mind
the:‐
Required capacity/available driving pressure
Flow induced forces
Noise/vibration
Pressure surges
Material degradation ‐ erosion, corrosion and cavitation
Liquid accumulation/slug flow
Sand accumulation
2.2 Gas Composition
The natural gas composition for natural gas line sizing is included in Table 1.7
Table 1.7 Gas Composition
Components Mol %
Methane 91.35
Ethane 0.98
Propane 0.2
i-Butane 0.07
n-Butane 0.07
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Components Mol %
i-Pentane 0.04
n-Pentane 0.04
n-Hexane 0.15
Nitrogen 6.94
CO2 0.16
H2O 0.0
Hydrogen 0.0
Total 100
2.3 Line Sizing Criteria
Piping pressure drop calculations are to be based on pipe roughness, friction factors and pipe
lengths. These calculations are done using the Darcy equation and Colebrook equation. Pressure
drop considered across pump suction strainer is 0.068 bars as per FEED data sheet. The size of
each line is estimated based on the volumetric flow rate and in accordance with the velocity and
friction loss ranges criteria.
2.3.1 Gas Lines
Piping pressure drop calculations are to be based on pipe roughness, friction factors and pipe
lengths. These calculations are done using the Darcy equation and Colebrook equation. Line sizing
criteria for gas lines based on API RP 14E is as under:‐
Gas: Maximum velocity of 17 m/s (55.7 ft/s). Velocity can cause a noise problem if it shall exceed
the maximum value. Pressure drop shall not exceed 1.36 bar / 100 m
2.3.2 Liquid Lines
Liquid line sizing criteria based on API RP 14E and TOTAL standard GS‐EP‐ECP‐103, Revision 02 is
as under:‐
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Table 2.1 Liquid Line Sizing Criteria
Velocity ΔP
Parameters
m/s bar/100m
<2” 3” ‐ 6” 8”‐18” >20” Nor Max
Liquid Lines (Carbon Steel)
Large inter‐Unit Lines ‐ 1.5 3.0 ‐ 0.15 ‐
Long Lines 1.5 2.5 3.0 3.0 ‐ 0.15
Short Lines 1.5 2.5 3.0 3.0 ‐ 0.35
2.3.1 Steam Lines
Steam line sizing criteria based on engineering practice and TOTAL standard GS‐EP‐ECP‐103 is as
under:‐
Table 2.2 Steam Line Sizing Criteria
Velocity ΔP
Parameters
m/s bar/100m
Nor Max
Steam Lines
10 < P ≤ 30 bar g
2.4 Nitrogen Sizing Scenario I
The following nitrogen properties used for hydraulic analysis and are included in Table 2.3
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Table 2.3 Nitrogen Properties
o
Operating Temperature C 30
Compressibility ‐ 0.999
Ratio of Specific Heats ‐ 1.401
Molecular Weight ‐ 28.01
2.5 Nitrogen Sizing Scenario II
The following nitrogen properties used for hydraulic analysis and are included in Table 2.4
Table 2.4 Nitrogen Properties
o
Operating Temperature C 30
Compressibility ‐ 0.999
Ratio of Specific Heats ‐ 1.401
Molecular Weight ‐ 28.01
2.6 Hydrogen Sizing
The following hydrogen properties used for hydraulic analysis and are included in Table 2.5
Table 2.5 Hydrogen Properties
o
Operating Temperature C 30
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Operating Pressure barg 0.40
Compressibility ‐ 1.0
Ratio of Specific Heats ‐ 1.41
Molecular Weight ‐ 2.02
2.7 Protective Gas Sizing
The following protective gas properties used for hydraulic analysis and are included in Table 2.6
Table 2.6 Protective Gas Properties
o
Operating Temperature C 30
Compressibility ‐ 1.0
Ratio of Specific Heats ‐ 1.41
Molecular Weight ‐ 15.01
2.8 Natural Gas Sizing
The following natural gas properties used for hydraulic analysis and are included in Table 2.7
Table 2.7 Natural Gas Properties
o
Operating Temperature C 30
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Viscosity cP 0.0118
Compressibility ‐ 0.998
Ratio of Specific Heats ‐ 1.30
Molecular Weight ‐ 17.32
2.9 Compressed Air Sizing
The following compressed air properties used for hydraulic analysis and are included in Table 2.8
Table 2.8 Compressed Air Properties
o
Operating Temperature C 40
Compressibility ‐ 0.997
Ratio of Specific Heats ‐ 1.42
Molecular Weight ‐ 28.95
2.10 Saturated Steam Sizing
The following saturated steam properties used for hydraulic analysis and are included in Table 2.9
Table 2.9 Saturated Steam Properties
o
Operating Temperature C 150
Operating Pressure barg 5
Viscosity cP ‐
2.11 Demineralized Water Sizing
The following demin water properties used for hydraulic analysis and are included in Table 2.10
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Table 2.10 Demin Water Properties
o
Operating Temperature C 30
Operating Pressure barg 6
2.12 Cooling Recycle Water Sizing
The following cooling water properties used for hydraulic analysis and are included in Table 2.11
Table 2.11 Cooling Water Properties
o
Operating Temperature C 30
Operating Pressure barg 5
2.13 Hot Water Sizing
The following hot water properties used for hydraulic analysis and are included in Table 2.12
Table 2.12 Hot Water Properties
o
Operating Temperature C 90
2.14 Potable Water Sizing
The following potable water properties used for hydraulic analysis and are included in Table 2.13
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Table 2.13 Potable Water Properties
o
Operating Temperature C 30
Operating Pressure barg 4
2.15 Sewage Waste Water Sizing
The following sewage water properties used for hydraulic analysis and are included in Table 2.14
Table 2.14 Sewage Waste Water Properties
o
Operating Temperature C 30
Operating Pressure barg 4
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3.0 HYDRAULIC ANALYSIS RESULTS
The hydraulic analysis results have been included in below sections from Table 3.1 to 3.14.
3.1 Nitrogen Line Sizing Results Summary Scenario I
Nitrogen line sizing results summary for scenario I is provided in below Table 3.1.
Table 3.1 Nitrogen Line Sizing Results Summary
Service Process Volumetric Fluid Line Fluid Fluid Line Line Line Status
Fluid Flow Rate Temperature Pressure Density Viscosity ID Velocity Pressure
Drop
‐ ‐ ( Nm3/hr) (°C) (barg) (Kg/m3) (cp) (Inches) (m/s) (bar/100m) ‐
Nitrogen Gas 570 30 0.4 1.57 0.0186 6 6.77 0.005 Okay
3.2 Nitrogen Line Sizing Results Summary Scenario II
Nitrogen line sizing results summary for scenario II is provided in below Table 3.2.
Table 3.2 Nitrogen Line Sizing Results Summary
Service Process Volumetric Fluid Line Fluid Fluid Line Line Line Status
Fluid Flow Rate Temperature Pressure Density Viscosity ID Velocity Pressure
Drop
‐ ‐ ( Nm3/hr) (°C) (barg) (Kg/m3) (cp) (Inches) (m/s) (bar/100m) ‐
Nitrogen Gas 95 30 0.4 1.57 0.0186 3 4.41 0.016 Okay
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3.3 Hydrogen Line Sizing Results Summary
Hydrogen line sizing results summary is provided in below Table 3.3.
Table 3.3 Hydrogen Line Sizing Results Summary
Service Process Volumetric Fluid Line Fluid Fluid Line Line Line Status
Fluid Flow Rate Temperature Pressure Density Viscosity ID Velocity Pressure
Drop
‐ ‐ ( Nm3/hr) (°C) (barg) (Kg/m3) (cp) (Inches) (m/s) (bar/100m) ‐
Hydrogen Gas 280 30 0.4 0.11 0.0089 3 13 0.0037 Okay
3.4 Protective Gas Line Sizing Results Summary
Protective gas line sizing results summary is provided in below Table 3.4.
Table 3.4 Protective Gas Line Sizing Results Summary
Service Process Volumetric Fluid Line Fluid Fluid Line Line Line Status
Fluid Flow Rate Temperature Pressure Density Viscosity ID Velocity Pressure
Drop
‐ ‐ ( Nm3/hr) (°C) (barg) (Kg/m3) (cp) (Inches) (m/s) (bar/100m) ‐
Protective
Gas 370 30 0.4 0.84 0.0136 4 9.98 0.0089 Okay
Gas
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3.5 Natural Gas Line Sizing Results Summary
Natural Gas line sizing results summary is provided in below Table 3.5.
Table 3.5 Natural Gas Line Sizing Results Summary
Service Process Volumetric Fluid Line Fluid Fluid Line Line Line Status
Fluid Flow Rate Temperature Pressure Density Viscosity ID Velocity Pressure
Drop
‐ ‐ ( Nm3/hr) (°C) (barg) (Kg/m3) (cp) (Inches) (m/s) (bar/100m) ‐
Natural
Gas 1500 30 0.16 0.81 0.0118 8 11.74 0.0049 Okay
Gas
3.6 Compressed Air Line Sizing Results Summary
Compressed air line sizing results summary is provided in below Table 3.6.
Table 3.6 Compressed Air Line Sizing Results Summary
Service Process Volumetric Fluid Line Fluid Fluid Line Line Line Status
Fluid Flow Rate Temperature Pressure Density Viscosity ID Velocity Pressure
Drop
‐ ‐ ( Nm3/hr) (°C) (barg) (Kg/m3) (cp) (Inches) (m/s) (bar/100m) ‐
Compressed
Gas 5780 40 7 8.93 0.0199 8 7.19 0.0178 Okay
Air
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3.7 Saturated Steam Line Sizing Results Summary
Saturated Steam line sizing results summary is included in below Table 3.7.
Table 3.7 Saturated Steam Line Sizing Results Summary
Service Process Volumetric Fluid Line Fluid Fluid Line Line Line Status
Fluid Flow Rate Temperature Pressure Density Viscosity ID Velocity Pressure
Drop
3
‐ ‐ (kg/hr) (°C) (barg) (Kg/m ) (cp) (Inches) (m/s) (bar/100m) ‐
Sat
Gas 6000 90 5 2.67 ‐ 6 31.8 0.45 Okay
Steam
3.8 Demineralized Water Line Sizing Results Summary
Demin Water line sizing results summary is included in below Table 3.8.
Table 3.8 Demin Water Line Sizing Results Summary
Service Process Volumetric Fluid Line Fluid Fluid Line Line Line Status
Fluid Flow Rate Temperature Pressure Density Viscosity ID Velocity Pressure
Drop
3 3
‐ ‐ (m /hr) (°C) (barg) (Kg/m ) (cp) (Inches) (m/s) (bar/100m) ‐
Demin
Liquid 35 30 6 1004 0.8 3.5 1.52 0.28 Okay
Water
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3.9 Cooling Recycle Water Line Sizing Results Summary
Cooling Water line sizing results summary is included in below Table 3.9.
Table 3.9 Cooling Water Line Sizing Results Summary
Service Process Volumetric Fluid Line Fluid Fluid Line Line Line Status
Fluid Flow Rate Temperature Pressure Density Viscosity ID Velocity Pressure
Drop
3 3
‐ ‐ (m /hr) (°C) (barg) (Kg/m ) (cp) (Inches) (m/s) (bar/100m) ‐
Cooling
Liquid 997 30 5 1004 0.8 16 2.43 0.18 Okay
Water
3.10 Hot Water Line Sizing Results Summary
Hot Water line sizing results summary is included in below Table 3.10.
Table 3.10 Hot Water Line Sizing Results Summary
Service Process Volumetric Fluid Line Fluid Fluid Line Line Line Status
Fluid Flow Rate Temperature Pressure Density Viscosity ID Velocity Pressure
Drop
Hot
Liquid 42 90 2.5 956.3 0.31 4 1.42 0.22 Okay
Water
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3.11 Potable Water Line Sizing Results Summary
Potable Water line sizing results summary is included in below Table 3.11.
Table 3.11 Potable Water Line Sizing Results Summary
Service Process Volumetric Fluid Line Fluid Fluid Line Line Line Status
Fluid Flow Rate Temperature Pressure Density Viscosity ID Velocity Pressure
Drop
3 3
‐ ‐ (m /hr) (°C) (barg) (Kg/m ) (cp) (Inches) (m/s) (bar/100m) ‐
Potable
Liquid 16 30 4 1004 0.8 2 2.05 0.09 Okay
Water
3.12 Sewage Waste Water Line Sizing Results Summary
Sewage Water line sizing results summary is included in below Table 3.12.
Table 3.12 Sewage Water Line Sizing Results Summary
Service Process Volumetric Fluid Line Fluid Fluid Line Line Line Status
Fluid Flow Rate Temperature Pressure Density Viscosity ID Velocity Pressure
Drop
3 3
‐ ‐ (m /hr) (°C) (barg) (Kg/m ) (cp) (Inches) (m/s) (bar/100m) ‐
Waste
Liquid 114 30 4 1004 0.8 6 1.7 0.2 Okay
Water
Annexure-A
Nitrogen Simulation Model Scenario I
Annexure-B
Nitrogen Simulation Model Scenario II
Annexure-C
Hydrogen Simulation Model
Annexure-D
Protective Gas (N2 + H2) Simulation Model
Annexure-E
Natural Gas Simulation Model
Annexure-F
Compressed Air Simulation Model
Annexure-G
Saturated Steam Simulation Model
Annexure-H
Desalination / Demineralized Water Simulation Model
Demin Water Simulation Model
P-100
1 2
q-1
1
Temperature 30.00 C
Pressure 6.000 bar_g
Actual Liquid Flow 34.80 m3/h
Thu Mar 08 22:08:44 2018 Case: Simulation_ Demin Water.hsc Flowsheet: Case (Main)
Annexure-I
Cooling Recycle Water Simulation Model
Cooling Water Simulation Model
P-100
1 2
q-1
1
Temperature 30.00 C
Pressure 5.000 bar_g
Actual Liquid Flow 997.0 m3/h
Thu Mar 08 22:15:15 2018 Case: Simulation_ Cooling Water.hsc Flowsheet: Case (Main)
Annexure-J
Hot Water Simulation Model
Hot Water Simulation Model
P-100
1 2
q-1
1
Temperature 90.00 C
Pressure 2.500 bar_g
Actual Liquid Flow 43.83 m3/h
Thu Mar 08 22:16:51 2018 Case: Simulation_ Hot Water.hsc Flowsheet: Case (Main)
Annexure-K
Potable Water Simulation Model
Potable Water Simulation Model
P-100
1 2
q-1
1
Temperature 30.00 C
Pressure 4.000 bar_g
Actual Liquid Flow 16.01 m3/h
Thu Mar 08 22:18:44 2018 Case: Simulation_ Potable Water.hsc Flowsheet: Case (Main)
Annexure-L
Sewage Waste Water Simulation Model
Waste Water Simulation Model
P-100
1 2
q-1
1
Temperature 30.00 C
Pressure 4.000 bar_g
Actual Liquid Flow 114.0 m3/h
Thu Mar 08 22:20:23 2018 Case: Simulation_ Waste Water.hsc Flowsheet: Case (Main)