HYDRAULIC CALCULATION FOR HIGH EXPANSION FOAM …

STAR REFINERY

REFINERY FIREFIGHTING SYSTEM IMPROVEMENT

PROJECT

CONTRACT Nº STR-PRM-CTR-016

UNIT Nº 000

CONTRACTOR DOC No: 920858-FI-011-006

SH/OF 1/8

STAR DOCUMENT No. 000-A-ZE-0040006-015

REV 0

HYDRAULIC CALCULATION FOR HIGH EXPANSION FOAM SYSTEM OF LPG

IMPOUNDING BASEMENT

0 09-Dec.-19 Issue for Review ESS ESS OS

REV. ISSUE DATE REASON FOR ISSUE PREPARED

BY

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APPROVED

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TABLE OF CONTENTS

1 GENERAL ............................................................................................................................................... 3

1.1 PURPOSE ....................................................................................................................................... 3

1.2 OBJECTIVES ................................................................................................................................... 3

2 REFERENCES ......................................................................................................................................... 3

2.1 PROJECT DOCUMENTS ................................................................................................................. 3

2.1.1 Project Specifications ................................................................................................................... 3

2.1.2 Basis of Design and Project Documents ....................................................................................... 3

2.2 INTERNATIONAL STANDARDS AND CODES .................................................................................. 4

3 ABBREVIATIONS .................................................................................................................................... 4

4 DEFINITIONS ......................................................................................................................................... 4

4.1 GENERAL DEFINITIONS ................................................................................................................. 4

5 REQUIREMENTS .................................................................................................................................... 5

6 FORMULA AND CALCULATION DATA ................................................................................................... 5

6.1 GENERAL CRITERIA ....................................................................................................................... 5

6.2 FORMULA ..................................................................................................................................... 6

7 ATTACHMENT ....................................................................................................................................... 8

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1 GENERAL

1.1 PURPOSE

The scope of this document is the Fire Water Hydraulic Calculation of High Expansion Foam

System of LPG Impounding Basement within LPG Tanks Area (Unit 630) according to design

specification and standards used in the AEGEAN REFINERY project. 1.2 OBJECTIVES

The purpose of this document is to define and present the guidelines and requirements of fire

water hydraulic calculation for fire protection systems of plant, in conjunction with relevant

project specifications, which will be supplied for TAR AEGEAN REFINERY Fire Fighting

Improvement Project.

The following values are determined by means of hydraulic calculation within document;

Flow rates

Simultaneous system actuation

Friction losses

System pressures available

Velocities and line sizes

2 REFERENCES

The fire protection system shall be designed and installed in accordance with the following

referenced Codes, Standards and Technical Specifications. The editions of the listed codes are

the current revisions at the date of Contract signature.

2.1 PROJECT DOCUMENTS

2.1.1 Project Specifications

STGPS-S4 FIRE PROTECTION AND SAFETY FACILITIES

2.1.2 Basis of Design and Project Documents

920858-PC-105-001 FIRE PROTECTION SYSTEMS DESIGN BASIS

630-A-EB-050901-001 LPG STORAGE AREA (U-630)

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2.2 INTERNATIONAL STANDARDS AND CODES

NFPA 13 STANDARD FOR THE INSTALLATION OF SPRINKLER SYSTEMS

NFPA 14 STANDARD FOR THE INSTALLATION OF STANDPIPE AND HOSE SYSTEMS

NFPA 24 STANDARD FOR THE INSTALLATION OF PRIVATE FIRE SERVICE MAINS AND THEIR APPURTENANCES

API 2001 FIRE PROTECTION IN REFINERIES

API 2021 MANAGEMENT OF ATMOSPHERIC STORAGE TANK FIRES

3 ABBREVIATIONS

Lengths (L) Meters (m)

Time (T) Minutes (m)

Pipe Diameter (ø) Inch or mm

Pressure (P) Bar

Pressure loss (P) Bar/m

Flow Meter cubic per hour (m3/h) or gallon per minute (gpm)

Discharge Density Liters per minute and square meter (l/min/m2)

Velocity Meters per second (m/sec)

Temperature Degree centigrade (ºC)

Height elevate Meters (m)

C-factor Friction loss coefficient

4 DEFINITIONS

4.1 GENERAL DEFINITIONS

The following words and expressions used in the Specification have the following meanings:

OWNER shall mean STAR Refinery A.Ş. (STAR)

ENGINEER means ÇİMTAŞ.

VENDOR shall mean any part who delivers equipment and materials for FACILITIES/UNITS

PROJECT means Fixed Fire Fighting system rehabilitation and U-630/640 LPG unit &

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Impounding basin area Fire Fighting system rehabilitation of STAR Refinery A.Ş.(STAR) at

Aliağa, TURKEY

FACILITIES/UNITS shall mean the entire facilities, units, and plants where fire fighting

systems to be rehabilitated in conformity with the PROJECT requirements and scope that

ENGINEER meet its liabilities as defined in the agreement on, under, in or through

OWNER’s JOBSITE.

JOBSITE shall mean OWNER’s property land at IZMIR – ALIAĞA, TURKEY on, under, in or

through which the required FACILITIES for rehabilitation of fire fighting systems.

5 REQUIREMENTS

The Hydraulic calculation shall be performed considering the minimum pressure at nozzle on the remote controlled monitors.The minimum pressure at hose connections most remote nozzle is 7 bar (NFPA 24). The pressure and flow required by the system at the point of connection to the water supply system have been verified by Omnicadd HCS 2.3.The results are shown in Calculation Report table. For hydraulic calculation, the following general data has been considered for all calculation: • Minimum Pressure at Hose Connection = 7 bar

• Values “C” for Carbon Steel Pipe = 120 (Table 23.4.4.8.1 of NFPA 13)

• Maximum velocity allowable for Fire Water Mains = 3.5 m/sec.

6 FORMULA AND CALCULATION DATA

6.1 GENERAL CRITERIA

The calculations are performed by a hydraulic calculation software, the procedures described on

NFPA 13 and NFPA 24.

ASME-B36.10 ASTM A106 Grade B Seamless pipes shall be installed for aboveground fire

protection systems. Equivalent lengths of the used fittings as given in NFPA 13, are added to the

actual length of each pipe pathway for input into the pressure drop calculation. Pressure drop

due to friction is calculated for each pathway by using the Hazen-Williams pressure drop

method. All pressure drops through each critical pathway leading to a system are added for a

total pressure drop due to friction.

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6.2 FORMULA

Friction loss formula is described in item 23.4.2.1.1 of NFPA 13

𝑃𝑚 = 6.05 × (𝑄𝑚

1.85

𝐶1.85 × 𝑑𝑚4.87) × 105

where: Pm = frictional resistance (bar/m of pipe)

Qm = flow (L/min)

C = friction loss coefficient

dm = actual internal diameter (mm)

The minimum rate of discharge shall be calculated from the following formula 6.12.8.2.3 of NFPA 11

𝑅 = (𝑉

𝑇+ 𝑅𝑠) 𝑥 𝐶𝑁 𝑥 𝐶𝐿

where:

R = rate of discharge in m3/min

V = submergence volume in m3

T = submergence time in minutes

Rs = rate of foam breakdown by sprinklers in m3/min

CN = compensation for normal foam shrinkage

CL = compensation for leakage

Foam depth: Depth = 1.5 × 1.1 = 1.65 m (This depth is greater than minimum cover of 0.6 m.) Submergence volume: V = 72.5 × 12.5 × 1.65 = 1495 m3

Submergence time: T = 3 minutes (from Table 6.12.7.1)

Rate of foam breakdown by sprinklers:”0” Due to sprinkler system isn’t existed

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Normal foam shrinkage: CN = 1.15 [from 6.12.8.2.2(3)]

Leakage: CL = 1.2 (assumption)

𝑅 = (1495

3+ 0) 𝑥 1.15 𝑥 1.2

R = 688 m3/min

Foam output capacity of high expansion foam generator

A local application system shall consist of fixed foam-generating apparatus complete with a piped supply of foam concentrate and water that is arranged to discharge foam directly onto a fire or spill hazard.LPG Impounding Base is called as spill hazard area.

These very high expansion ratios produce large quantities of finished foam from relatively small amounts of water and foam concentrate. 2% proportioning is recommended for most medium to high expansion foam generators.

Determine High Expansion Foam Generator

Generator foam output capacity: 347 m3/min (Chemguard-CHX15000 @ 3.4 bar

Generator quantity: 688 m3/min / 347 m3/min = 2 ea.

Foam concentrate demand for generators: 347 m3/min x 2 = 694 m3/min

Foam Generator expansion ratio is indicated 1:745

Foam-water solution demand for generators: 694 m3/min / 0.745 = 932 lt/min.

Foam-water solution demand for 25 min: 932 lt/min. x 25 min. = 23.300 lt

Foam demand for 25 min: 23.300 lt x 0.02 = 466 lt x 1.1 (safety factor) = 150 gallon

100 % Reserve Capacity : 150 gal x 2 = 300 gallon

High-expansion foam concentrate and water shall be provided to permit continuous operation of the entire system for 25 minutes or to generate 4 (four) times the submergence volume,

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whichever is less, but in no case less than enough for 15 minutes of full operation. (Item 6.12.9.1 of NFPA 11)

Input Data

The following requirements has been considered as input to OmniCADD Software.

1. Assumed Terminal Point head is 932 lpm (247 gpm) at 9 bar.

2. Maximum velocity in the underground fire water network is 3.5 m/s

3. High Expansion Foam Generator is required flow and pressure 466 lpm (123 gpm) at 3.4 bar

for each one

Output Data

The following requirements has been calculated as output to OmniCADD Software.

1. Calculated head is 933 lpm (247 gpm) at 4.1 bar for water curtain system.

2. Calculated maximum velocity in the pipes is 3.6 m/s

7 ATTACHMENT

Hydraulic Calculation Report is indicated in attached.

HYDRAULIC CALCULATIONS

for

High Expansion Foam System

Contract No.

Date December 02, 2019

Design Data:

Remote Area Location U-630 LPG Impounding Basin

Occupancy Classification

Density 0.00 lpm/sq.m

Remote Area Size 0.0 sq.m

Coverage per Sprinkler 0.0 sq.m

Sprinkler K-Factor 253.00

No. of Sprinkler Calculated 2

In-Rack Demand 0.0 lpm

Source Hose Demand 0.0 lpm

Total Water Including Hose 933.0 lpm

Name of Contractor

Name of Designer Çimtas Boru Imalatlari ve Ticaret Ltd. Sti.

Address Ata Sb. Mah. Müge Cad. 16600, No: 17 Gemlik / Bursa, Turkey,

Authority Having Jurisdiction 920858-PC-105-001 - Design Basis

High Expansion Foam Generator flow rate and required pressure were assumed as 466 l/min @3.4 bar in accordance with Owner Requirements

OmniCADD Hydraulic Calculation Software v. 2.3

December 13, 2019 03:37 PM STR-PRM-CTR-016 Page: 2

GENERAL RESULTS

Total Water Including Hose 933.0 lpm

Additional Allowances 0.0 lpm

Discharge from Sprinklers 933.0 lpm

Source Hose Demand 0.0 lpm

Average Imbalance 0.000 lpm

Maximum Imbalance 0.2 lpm

Maximum Velocity @ Pipe: bl19 3.6 m/s

Maximum Fr. Loss @ Pipe: fm2 0.004 bar/m

Average Density -

Remote Area was not Peaked

Velocity pressures have been used for information only, and are not valid for balancing the system.

SOURCE : s2Static Pressure 9.0 barResidual Pressure 8.0 barFlow 932.0 lpmHose Allowance 0.0 lpmAvailable Pressure 8.0 barRequired Pressure 4.1 barSafety Factor 48.2%, 3.9 barWater Flowing 933.0 lpm



Water Curves for Src : s2

End Head Pressure Responce 0 @ 0 - E : 0 @ 933Demand Curve @ Src : s2 0 @ 0 - D : 4.1 @ 933Supply Curve @ Src : s2 A : 9 @ 0 - B : 8 @ 932 - C : 8 @ 933

Curve Values - X : bar @ lpm

0

0

500

500

1000

1000

0 0

1 1

2 2

3 3

4 4

5 5

6 6

7 7

8 8

9 9

10 10

BAR

LPM

A

B

C

D

E



NODES

# Type Value Elevationm

Xm

Ym

Res. Pres.bar

Dischargelpm

s2 Src [...] 0.0 -39.3 65.0 4.1 0.0h19 Head 253.00 0.0 -26.5 -25.0 3.4 466.5h20 Head 253.00 0.0 -52.0 -25.0 3.4 466.5n25 Node - 0.0 -25.0 10.0 3.7 -n24 Node - 0.0 -39.3 10.0 3.8 -n26 Node - 0.0 -53.5 10.0 3.7 -n29 Node - 0.0 -25.0 -25.0 3.5 -n28 Node - 0.0 -53.5 -25.0 3.5 -



PIPES

## Type Value Elevation

m

Res.Pres.

bar

Discharge

lpm

MaterialHWC

Fittings

SizeNom.Diam.Int.Diam.

LengthEq.Length

Total Lengthm

Fr.Loss

bar/m

Pres.Fr.LossPres.Elev.LossPres.Vel.Loss

bar

Flow

lpm

Velocity

m/s

TypeStart/End Nodes

bl19 h20 Head 253.00 0.0 3.4 466.5 Sch40 2 1.5 0.031 0.141 -466.5 3.6 Branch Linen28 Node - 0.0 3.5 - 120 50.761 3.0 0.000

2E 52.462 4.5 0.064 bl20 h19 Head 253.00 0.0 3.4 466.5 Sch40 2 1.5 0.031 0.141 -466.5 3.6 Branch Line

n29 Node - 0.0 3.5 - 120 50.761 3.0 0.000 2E 52.462 4.5 0.064

cm26 n29 Node - 0.0 3.5 - Sch40 3 35.0 0.005 0.169 -466.5 1.6 Cross Mainn25 Node - 0.0 3.7 - 120 76.142 2.1 0.000

E 77.868 37.1 0.013 cm24 n26 Node - 0.0 3.7 - Sch40 3 35.0 0.005 0.169 466.5 1.6 Cross Main

n28 Node - 0.0 3.5 - 120 76.142 2.1 0.000 E 77.868 37.1 0.013

cm27 n26 Node - 0.0 3.7 - Sch40 3 14.2 0.005 0.086 -466.5 1.6 Cross Mainn24 Node - 0.0 3.8 - 120 76.142 4.6 0.000

T 77.868 18.8 0.013 cm28 n24 Node - 0.0 3.8 - Sch40 3 14.3 0.005 0.086 466.5 1.6 Cross Main

n25 Node - 0.0 3.7 - 120 76.142 4.6 0.000 T 77.868 18.9 0.013

fm2 s2 Src [...] 0.0 4.1 0.0 Sch40 4 55.0 0.004 0.342 933.0 1.9 Feed Mainn24 Node - 0.0 3.8 - 120 101.523 23.0 0.000

4EBGS 102.183 78.0 0.018



FLOW DIAGRAM

n25

n24

n26

n29

n28

s2

h19

h20
