Sizing of Gas Pressure Regulating and Metering Stations (GRMS)

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Design Parameters
Sizing of Gas Pressure Regulating and Metering Stations (GRMS)
Project Data
Date of issue: 30.06.2009 Person in charge: Heinrichs Quotation no.: 25050
Customer: MAN Ferrostaal Industrial Projects GmbH Revision: 1
Project: 892829 TGU Trinidad 720MW CCPP Language: EN
Inlet pressure Outlet pressure
min.: 31 barg min.: 25,8 barg
norm.: 31 barg norm.: 25,8 barg ►►► Setpoint
max.: 31 barg Flange pressure rating: max.: 25,8 barg Flange pressure rating:
Design pressure: 50 barg ANSI 300 RF Design pressure: 50 barg ANSI 300 RF
Flow Rate Qn: Medium
min.: 0,1 kg/s ≈ 472 Nm3/h Type of gas: Natural Gas
norm.: 16 kg/s ≈ 75541 Nm3/h Gas temperature T1: 26,6 °C
max.: 32 kg/s ≈ 151082 Nm3/h Normal density ρn: 0,7625 kg/m

3
► SG = 0,590
Design Temperature range: -20...+60 °C
RMG REGEL + MESSTECHNIK GMBH SizeMax/V2.4/AG---userID=philipp.heinrichs

Conversion of units Calculation Sheet
Doc.-no.: cs-25050-units-rev1
Customer: MAN Ferrostaal Industrial Projects GmbH

Project: 892829 TGU Trinidad 720MW CCPP
Pressure units
lb/in2 (=psi) bar lb/in2 (=psi) bar
450 31,005 375 25,8375
Flow units
Nm3/h scft/h Nm3/h scft/h
Temperature units
°F °C °C °F
80 26,66666667 35 95
Energy units
J kwh kwh J
Density units
SG (air=1) kg/m3 kg/m3 SG (air=1)
Volume units
ltr (=dm3) m3 m3 ltr (=dm3)
Length units
in m m ft
SizeMax/V2.4/AG---userID=philipp.heinrichs
Date of issue: 30.06.2009 RMG REGEL + MESSTECHNIK GMBH Heinrichs

Determination of Line Size Calculation Sheet
Doc.-no.: cs-25050-line-rev1
Basic Design Parameters
Operating pressure p
min.: norm.: max.:
Inlet: 31 barg 31 barg 31 barg
Outlet: 25,8 barg 25,8 barg 25,8 barg
Flow rate Qnmax: 151082 Nm3/h
Type of gas: Natural Gas
Maximum allowed velocity:

Inlet: 20 m/s
Outlet: 20 m/s
Calculation of inlet size
Operating pressure p Flow rate Qn: Required line size

[barg] [Nm3/h] [mm]
354 ⋅ Q n 31 151082 289
DN req =
V max ⋅ p 31 151082 289
31 151082 289
Selected line size: DN = 350 mm ⇔ 14"
pressures in the formula to be inserted in absolute values !
Calculation of outlet size
Required line size Operating pressure p Flow rate Qn: Required line size
[barg] [Nm3/h] [mm]
354 ⋅ Q n 25,8 151082 316
DN req =
V max ⋅ p 25,8 151082 316
25,8 151082 316
Selected line size: DN = 400 mm ⇔ 16"


Sizing of Filters Calculation Sheet
Doc.-no.: cs-25050-filt-rev1

Tag no.:
min.: norm.: max.:
31 barg 31 barg 31 barg
min.: norm.: max.:

Flow rate Qn: 472 Nm3/h 75541 Nm3/h 151082 Nm3/h
3
Normal density ρn: 0,7625 kg/m
correction factor for different gases than 0,83 kg

f = m3 =
Natural Gas with a normal density of ρ nGas 1,043
3
0,83 kg/m :
Performance
Manufacturer: Thielmann Energietechnik GmbH
Selected type: Thielmann
Size DN: Inlet: 350 mm Outlet: 350 mm
velocities:
354 ⋅ Q n Operating pressure p 31 bar 31 bar 31 bar
v= 75541 Nm3/h
DN 2 ⋅ p Flow rate Qn:
151082 Nm3/h
7 m/s
14 m/s
7 m/s
14 m/s
7 m/s
14 m/s
Pressure drop:
Operating pressure p 31 bar 31 bar 31 bar
75541 Nm3/h
Flow rate Qn:
151082 Nm3/h
acc. to supplier 50 mbar 50 mbar 50 mbar


Sizing of Heat Exchangers Calculation Sheet
Doc.-no.: cs-25050-heat-rev1

Tag no.:
Max. inlet pressure p1: 32,013 bar(abs) Normal density ρn: 0,7625 kg/m3
3
Min. outlet pressure p2: 26,813 bar(abs) Flow rate Qnmax: 151082 Nm /h
Inlet temperature t1: 26,6 °C Outlet temperature t2: 35 °C
Joule-Thomson coefficient µ: 0,44 K/bar Heater efficiency: 0,85
Specific heat capacity cp: 2,2 kJ/kg/K = 0,52546 kcal/kg/K
Water temperature (in), tvl: 90 °C Water temperature (out), trl: 70 °C
Spec. heat capacity water cw: 3,8 kJ/kg/K Max. flow velocity water: 1,5 m/s
Max. pressure drop water: 0,3 bar
Calculation
Δt = (p1 − p2)⋅ μ +t2 −t1 = 10,69 °C
Required Heating capacity:
W = qn ⋅ ρ n ⋅ Δt ⋅ c p = 2708767 kJ/h = 646854 kcal/h => 752 kW

3
Required fuel gas flow: 75,2 m /h
Water Consumption: 41,9 m3/h Water conn. (DN required): 99 mm
Required Kvs-value (water): 76,6 m3/h
Performance
Manufacturer: Otto Klein GmbH
Selected type: OKEV 400.40.2.6"/300.14"/300.15
Size DN: Inlet: 350 mm Outlet: 350 mm
Heating capacity: 750 kW
Pressure drop: min.: 100 mbarg max.: 960 mbarg
Size DN (water): Inlet: 4" mm Outlet: 4" mm

Sizing of Safety Shut-Off Valves (SSV) Calculation Sheet
Doc.-no.: cs-25050-ssv-rev1

Tag no.:
min.: norm.: max.:
29,99 barg 29,99 barg 29,99 barg
Flow rate Qn: norm.: 75541 Nm3/h max.: 151082 Nm3/h

3
Normal density ρn: 0,7625 kg/m Specific gravity (air = 1) SG: 0,590
correction factor for different gases than 0,83 kg 3

Natural Gas with a normal density of f = m = 1,043
0,83 kg/m : 3 ρ nGas
Performance
Selected type: RMG 711-200 (8")
Size DN: 200 mm Quantity of SSV: 2
KG = 76500 m3/h/bar Maximum allowed velocity: 80 m/s
velocities:
354 ⋅ Q n Operating pressure p 29,99 bar 29,99 bar 29,99 bar
v= 75541 Nm3/h
DN 2 ⋅ p Flow rate Qn:
151082 Nm3/h
22 m/s
43 m/s
22 m/s
43 m/s
22 m/s
43 m/s
Pressure drop:
2
Q 1 Operating pressure p 29,99 bar 29,99 bar 29,99 bar
Δp ≈ n
⋅ 75541 Nm3/h
KG ⋅ p f 2
2
Flow rate Qn:
151082 Nm /h3
58 mbar 58 mbar 58 mbar
231 mbar 231 mbar 231 mbar


Sizing of Gas Pressure Regulators Calculation Sheet
Doc.-no.: cs-25050-act-rev1

Tag no.:

3

Natural Gas with a normal density of f = m3 = 1,043
0,83 kg/m3 :
ρ nGas
min.: norm.: max.:

Inlet pressure pu: 29,76 barg 29,76 barg 29,76 barg
min.: norm. (setpoint): max.:

Outlet pressure pd: 25,8 barg 25,8 barg 25,8 barg
min.: norm.: max.:

Flow rate Qn: 2778 Nm3/h 75541 Nm3/h 151082 Nm3/h
Required valve flow koefficient KG upon min. inlet pressure, max. outlet pressure and max. flow:
Pressure drop (pdmax/pumin) = 0,87 Subcritical pressure drop !
KG (req.) = 14057 m3/h/bar Calculated, using formula no. I. , as shown below
Performance
Selected type: RMG 512-200/400 (8"/16") Silencer: --
DN (inlet): 200 mm Turn down ratio, r = 1 %
DN (outlet): 400 mm KG = 25850 m3/h/bar Δpmin: 0,5 bar
Available nominal flow Qn

I.) Formula for subcritical pressure drop pu [bar] pdmax/pu Qnmax [Nm3/h] Qnmin [Nm3/h]
(pdmax/pu ≥ 0,5): 29,8 0,87 277.840 2.778
29,8 0,87 277.840 2.778
Q n max = K G ⋅ f ⋅ pd ⋅ ( pu − pd )
29,8 0,87 277.840 2.778
II.) Formula for supercritical pressure drop 29,8 0,87 277.840 2.778
(pdmax/pu < 0,5): 29,8 0,87 277.840 2.778
29,8 0,87 277.840 2.778
K G ⋅ f ⋅ pu
Q n max = 29,8 0,87 277.840 2.778
2 277.840 2.778
29,8 0,87
III.) Formula for min. flow 29,8 0,87 277.840 2.778
29,8 0,87 277.840 2.778
Q n min = Q n max ⋅ r
pressures in the formula to be inserted in absolute values ! SizeMax/V2.4/AG---userID=philipp.heinrichs

Gas Pressure Regulator (Active)
Capacity Chart
RMG 512-200/400 (8"/16")
Doc.-no.: cs-25050-act-cht-rev1

Tag no.:

Norm. density ρn: 0,7625
Max. available flow Qnmax [Nm3/h]
Inlet pressure pu: Outlet pressure pd:

[barg] 25,8 barg 25,8 barg 25,8 barg
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382
31,0 318.382 318.382 318.382

Gas Pressure Regulator (Active)
Capacity Diagram
RMG 512-200/400 (8"/16")
Doc.-no.: cs-25050-act-dia-rev1

Tag no.:
pd = 25,8 bar pd = 25,8 bar pd = 25,8 bar
350.000
300.000
250.000
200.000
Qnmax [Nm3/h]
150.000
100.000
50.000
0
31,0 31,0 31,0 31,0 31,0 31,0 31,0 31,0
pu [bar]

Sizing of Safety Relief Valves Calculation Sheet
Doc.-no.: cs-25050-srv-rev1

Tag no.:

3

Natural Gas with a normal density of f = m3 = 1,043
0,83 kg/m3 :
ρ nGas
Setpoint 32,25 barg Max. operating pressure p: 25,8 barg
Outlet pressure pd: 0 barg
Flow rate Qn: 7554,1 Nm3/h
Required valve flow koefficient KG upon min. inlet pressure, max. outlet pressure and max. flow:
Pressure drop (pdmax/pumin) = 0,03 Supercritical pressure drop !
KG (req.) = 436 m3/h/bar Calculated, using formula no. II. , as shown below
Performance
Selected type: RMG 846
DN (inlet): ½" screwed (male)
DN (outlet): ½" screwed (female) KG = 28 m3/h/bar
Available nominal flow Qn

I.) Formula for subcritical pressure drop p [bar] Qnmax [Nm3/h]
(pdmax/pu ≥ 0,5): Setpoint SP 32,25 --
SP + 10 % 35,48 533
Q n max = K G ⋅ f ⋅ pd ⋅ ( pu − pd )
SP + 15 % 37,09 556
II.) Formula for supercritical pressure drop SP + 20 % 38,70 580
(pdmax/pu < 0,5): SP + 25 % 40,31 603
SP + 30 % 41,93 627
K G ⋅ f ⋅ pu
Q n max = SP + 35 % 43,54 651
2 45,15 674
SP + 40 %
SP + 45 % 46,76 698
SP + 50 % 48,38 721
pressures in the formula to be inserted in absolute values ! SizeMax/V2.4/AG---userID=philipp.heinrichs

Velocities / Line Size Calculation Sheet
Doc.-no.: cs-25050-vel-rev1

min.: norm.: max.:
Inlet: 31 barg 31 barg 31 barg
Outlet: 25,8 barg 25,8 barg 25,8 barg
norm.: max.:
3
Flow rate Qn: 75541 Nm /h 151082 Nm3/h
Velocities (approximate values)
Station inlet Operating pressure p Qn= 75541 Nm3/h Qn= 151082 Nm3/h
31 barg 7 m/s 14 m/s

DN: 350 mm 31 barg 7 m/s 14 m/s
31 barg 7 m/s 14 m/s
SSV Operating pressure p Qn= 75541 Nm3/h Qn= 151082 Nm3/h
31 barg 21 m/s 42 m/s

DN: 200 mm 31 barg 21 m/s 42 m/s
31 barg 21 m/s 42 m/s
Regulator inlet Operating pressure p Qn= 75541 Nm3/h Qn= 151082 Nm3/h
31 barg 21 m/s 42 m/s

DN: 200 mm 31 barg 21 m/s 42 m/s
31 barg 21 m/s 42 m/s
Regulator outlet Operating pressure p Qn= 75541 Nm3/h Qn= 151082 Nm3/h
25,8 barg 6 m/s 12 m/s

size DN: 400 mm 25,8 barg 6 m/s 12 m/s
25,8 barg 6 m/s 12 m/s
Meter run Operating pressure p Qn= 75541 Nm3/h Qn= 151082 Nm3/h
25,8 barg m/s m/s

DN: mm 25,8 barg m/s m/s
25,8 barg m/s m/s
Station outlet Operating pressure p Qn= 75541 Nm3/h Qn= 151082 Nm3/h
25,8 barg 6 m/s 12 m/s

DN: 400 mm 25,8 barg 6 m/s 12 m/s
25,8 barg 6 m/s 12 m/s

Sizing of Gas Pressure Regulating and Metering Stations (GRMS) Station Overview
Doc. no.: SO-25050-rev1

Basic Parameters:
min.: norm.: max.: max.:
Inlet pressure pu: 31 31 31 barg Outlet pressure pd: (Setpoint): 25,8 barg Flow rate Qn: 151082 Nm3/h
Line diagram:
Station inlet Station outlet
Type Thielmann/OKEV 400.40.2.6"/300.14"/300.15 RMG 711 RMG 512
DN 350/350 350/ 350 350/200 200/ 200 200/200 200/ 400 400/400
Filter/Heat Exchanger SSV (2 x) Active Regulator
Pu_max 31,00 bar 29,99 bar 29,76 bar 25,80 bar
Pu_min 31,00 bar 29,99 bar 29,76 bar 25,80 bar
Available nominal Inlet pressure pu: Inlet pressure pu: Inlet pressure pu:
flow Qn 31 bar 31 bar 31 bar 31 bar 31 bar 31 bar
Qnmax ----> 151.082 151.082 3 280.136 280.136 3 277.840 277.840 3
Nm /h Nm /h Nm /h
Qnmin ----> 0 0 3 0 0 3 2.778 2.778 3
Nm /h Nm /h Nm /h
Size DN Max. press. drop

Flow Meter
Inlet Outlet in [bar], upon KG
Type 3 Type
[m /h]
G
[mm] [mm] Pu_min Pu_max
Size DN [mm]
Filter/Heat Exchanger Thielmann/OKEV 400.40.2.6"/300.14"/300.15 350 350 ~ 1,01 ~ 1,01 0 Qbmin [m3/h]
SSV (2 x) RMG 711 200 200 ~ 0,23 ~ 0,23 76500 Qbmax [m3/h]
Active Regulator RMG 512 200 400 ~ 3,96 ~ 3,96 25850
Safety Relief Valve RMG 846 ½" ½" 28

Sizing of Gas Pressure Regulating and Metering Stations (GRMS)

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<< SizeMax >>

Date of issue: 30.06.2009 Person in charge: Heinrichs Quotation no.: 25050

Customer: MAN Ferrostaal Industrial Projects GmbH Revision: 1

Project: 892829 TGU Trinidad 720MW CCPP Language: EN

Inlet pressure Outlet pressure

min.: 31 barg min.: 25,8 barg

norm.: 31 barg norm.: 25,8 barg ►►► Setpoint

Flow Rate Qn: Medium

min.: 0,1 kg/s ≈ 472 Nm3/h Type of gas: Natural Gas

norm.: 16 kg/s ≈ 75541 Nm3/h Gas temperature T1: 26,6 °C

max.: 32 kg/s ≈ 151082 Nm3/h Normal density ρn: 0,7625 kg/m

Design Temperature range: -20...+60 °C

RMG REGEL + MESSTECHNIK GMBH SizeMax/V2.4/AG---userID=philipp.heinrichs

Customer: MAN Ferrostaal Industrial Projects GmbH

Date of issue: 30.06.2009 RMG REGEL + MESSTECHNIK GMBH Heinrichs

Basic Design Parameters

Flow rate Qnmax: 151082 Nm3/h

Type of gas: Natural Gas

Maximum allowed velocity:

Calculation of inlet size

Operating pressure p Flow rate Qn: Required line size

Selected line size: DN = 350 mm ⇔ 14"

pressures in the formula to be inserted in absolute values !

Calculation of outlet size

Selected line size: DN = 400 mm ⇔ 16"

pressures in the formula to be inserted in absolute values !

Date of issue: 30.06.2009 RMG REGEL + MESSTECHNIK GMBH Heinrichs

Customer: MAN Ferrostaal Industrial Projects GmbH

Basic Design Parameters

min.: norm.: max.:

Type of gas: Natural Gas

correction factor for different gases than 0,83 kg

Manufacturer: Thielmann Energietechnik GmbH

Selected type: Thielmann

Size DN: Inlet: 350 mm Outlet: 350 mm

pressures in the formula to be inserted in absolute values !

Date of issue: 30.06.2009 RMG REGEL + MESSTECHNIK GMBH Heinrichs

Customer: MAN Ferrostaal Industrial Projects GmbH

Basic Design Parameters

Type of gas: Natural Gas

Inlet temperature t1: 26,6 °C Outlet temperature t2: 35 °C

Joule-Thomson coefficient µ: 0,44 K/bar Heater efficiency: 0,85

Specific heat capacity cp: 2,2 kJ/kg/K = 0,52546 kcal/kg/K

Water temperature (in), tvl: 90 °C Water temperature (out), trl: 70 °C

Max. pressure drop water: 0,3 bar

Δt = (p1 − p2)⋅ μ +t2 −t1 = 10,69 °C

Required Heating capacity:

W = qn ⋅ ρ n ⋅ Δt ⋅ c p = 2708767 kJ/h = 646854 kcal/h => 752 kW

Water Consumption: 41,9 m3/h Water conn. (DN required): 99 mm

Required Kvs-value (water): 76,6 m3/h

Manufacturer: Otto Klein GmbH

Selected type: OKEV 400.40.2.6"/300.14"/300.15

Size DN: Inlet: 350 mm Outlet: 350 mm

Heating capacity: 750 kW

Pressure drop: min.: 100 mbarg max.: 960 mbarg

Size DN (water): Inlet: 4" mm Outlet: 4" mm

Date of issue: 30.06.2009 RMG REGEL + MESSTECHNIK GMBH Heinrichs

Customer: MAN Ferrostaal Industrial Projects GmbH