Chapter 12.1
12 cARGO
cALCULATION
12.1 CALCULATION OF MAXIMUM ALLOWED
LIQUID VOLUME
In this part, we will take a look at the
different methods in calculating cargo onboard. The quantities of cargo we will
load are specified in the charter party and this information is given directly
from the charter or from the operation in the ownerłs office. When we load and
transport liquefied gases there are some variables that we have to have in
mind, the setting of the safety valveÅ‚s “relief valve", the cargo temperature
when loading and at which temperature we should discharge the cargo. The type
of gas carrier and the equipment we have onboard is also important in the
flexibility of our transport.
12.4.1
Maximum filling limit
Maximum filling limit is the maximum volume
liquid we are allowed to load in the cargo tank. In chapter 15 of the IMO gas
code, we find that the maximum filling can be 98% of full tank volume. Filling
limit depends on the set point of relief valve and the density of the actual
cargo.
Formula for maximum volume liquid is as
follows:
Filling limit = rR
/ rL
* 98%
rR
Density of reference temperature
on the relief valve setting
rL
Density for actual cargo
temperature
This means that if the relief valve setting
is low, we can load more than if the setting is high. If there is a possibility
to take off one or more of the pilot valves, we can increase the liquid volume
loaded. We then have to calculate the difference between the pilot settings.
The time used for loading will also increase if we have a lower set point on
the cargo tankłs relief valves. What we always have to avoid is an uncontrolled
venting.
Uncontrolled venting is when we get such a
high pressure in the cargo tank that the relief valve opens.
If we look at some examples e.g. propane and
the first example relief valve setting is 4,5 bar and the other example relief
valve setting is 0,5 bar. Cargo temperature is
35oC.
Relief valve setting 4,5 bar
4,5 bar + 1 bar = 5,5 bar @
5oC
= 523,3 kg/m3
Relief valve setting 0,5 bar
0,5 bar + 1 bar = 1,5 bar @
-32oC
= 570,2 kg/m3
Cargo temperature
35oC
= 573,7 kg/m3
In our example with 1000 m3 tank,
we can see that the difference is about 45mt. With 4,5 bar setting we can load
513,259mt and with 0,5 bar setting we can load 558,900mt. If the freight rate
is 80 USD/mt we then miss USD 3651. If we are on a gas carrier on 10 000 m3
the loss of income will then be USD 36 510.
When we reduce the set point on cargo tank
relief valves, the time used for loading and discharging will increase. What we
have to avoid is letting the cargo tank fill 100% with liquid.
On semi-refrigerated gas carriers, normally
the lowest relief valve setting is 0,5 bar. There are two or more pilot valves
e.g. 3,6 bar and 5,2 bar. If we change the relief valve setting, we have to
mark that on the cargo tank and also note it in the deck-log book.
On fully refrigerated gas carriers the relief
valve setting is about 0,25 bar and there are often facilities for putting one
extra weight on the pilot, normally 0,2 to 0,3 bar. That means we have a relief valve setting of 0,45 bar. The extra
setter is allowed to be used only while loading or gas freeing.
In all cargo calculations in this compendium,
we use T0 = 273oC and atmospheric pressure to 1,013 bar
if nothing else is stated. In all calculations we have to use pressure in kilo
Pascal (kPA) that gives 1,013 bar Þ
101,3 kPa. For the cargo calculations, we use densities from thermodynamic
properties edited by Ocean Gas Transport.
When the vessel is at sea and we get a telex
that we are to set up to load propane at
30oC in Fawly. Our cargo
tank relief valve set point is 4,5 bar. To find out how mush we can load, we
then have to take a rough calculation. We can then use density for propane at
30oC and for 6oC, this only to get an overview of how
mush we can load.
At 6oC r
is 522,0 kg/m3 and at
30oC r
is 567,9 kg/m3
Then we get 98% * rR/rL
Þ
98% * 522,0/567,9 = 90,07%
To calculate the accurate filling limit, we
have to know the actual cargo temperature and we must use density table.
However, as long as we do not know the exact cargo temperature, we use the
nearest values in the table. When we
know the exact temperature of the cargo, we can calculate more accurately. Relief valve setting is 4,5 bar and
atmospheric pressure 1,013 bar gives absolute pressure 5,513 bar.
In the thermodynamic table we find:
5,45 bar
Þ 5oC
5,61 bar
Þ 6oC
We have to interpolate between 5,45 bar and
5,61 bar to find the correct reference temperature and the correct density. The
reference temperature is 5,39oC and reference density is 522,79 kg/m3.
Then
we use -30oC and we find density to 567,9 kg/m3.
Filling limit = rR / rL * 98%
= 522,79 kg/m3 / 567,9 kg/m3 x 98% = 90,22%
In this example the filling limit will be
90,17% when we load propane at a temperature on -30oC. If the
loading temperature is colder than -30oC the filling limit will be
less than 90,17% and higher if the temperature is above -30oC.
12.4.2
Example 1
Cargo Propane
Temp in
oC
-30
oC density
567,9
kg/m3
Temp. reference rel. valve R
5,39
oC density
522,79
kg/m3
Tank #1, 100% Volume
1182,18
m3
Relieve valve set point
4,5
bar
Atmospheric pressure
1,013
bar
Absolute pressure relieve valve
5,513
bar
Filling limit =
rR
/ rL x
98 %
Filling limit
522,793
/ 567,900 x
98,00 %
90,22 %
When we have loaded propane on
30oC to the limit 90,17% we
are then sure that if the pressure in the cargo tank increases to 4,5 bar and
the temperature in the liquid increases to 5,39oC the liquid volume will
be 98%.
When we have
calculated the filling limit we can find the maximum volume of liquid that we
can load.
VL
= 0,98 * V * rR/ rL
VL
Volume liquid
V
100% Volume of the cargo tank
rR
Density of reference temperature on the relief valve setting
rL
Density for actual cargo temperature
When we have found the correct filling limit,
we can find the maximum volume to be loaded.
We have to find the cargo tank at 100% volume and multiply with the
actual filling limit.
If we have a cargo tank on 1182,18 m3 volume
at 100%, we find the maximum volume to be loaded by multiplying with 90,17%
filling limit.
Cargo tank 100% volume in m3
Filling limit in %
Volume to be loaded in m3
1182,18
90,17
1065,943
When we do this calculation we use the
formula: VL = 0,98 x V x rR / rL.
12.4.3
Example 2
Filling
limit
522,793
/
567,900
98 %
90,216
%
Filling
volume = Filling limit * Cargo tank 100% vol.
Filling
volume
90,22 %
x
1182,18
m3 =
1065,972
m3
Or
Filling Volume VL=
0,98 x 1182,18 x 522,793 / 567,9 =
1066,517 m3
After we have found the filling volume, we
find the ullage or sounding in the vessels ullage/sounding table.
Sounding is the level from tank bottom to the
liquid surface. Ullage is the
level from liquid surface to deck level.
In the following examples, we use sounding.
In this example, we
find the correct sounding to be 8,1662 meters. We have to do this calculation
on each cargo tank before we start loading.
In this example, the filling volume is
1065,943 m3 and that is in between 8,16 meters and 8,17 meters, so we have to
interpolate to find the correct sounding.
12.4.4
Example 3
Filling volume = Filling limit * Cargo tank
100% vol.
Filling limit
90,17 %
1182,180
m3 =
1065,943 m3
sounding in
m
volume in m3
8,16
1065,25
m3
8,17
1066,36
m3
8,1662
1065,94
m3
When we have found the correct sounding/ullage
we have to find which corrections we must use to get the actual
sounding/ullage. The corrections can be found in the sounding/ullage table for
each vessel.
12.4.5
Corrections
There are normally four corrections to be
used: the correction on the float, correction on the sounding tape, list and
trim correction. The float correction depends on the liquid density; with a
higher density the float becomes lighter in the liquid. The tape correction
depends on the temperature in the vapour phase. List and trim correction depend
on how the vessel is in the water. We have to study the corrections carefully
so we use the correct sign character. Spherical floats have the highest
corrections on float. All corrections we do, we find in the sounding/ullage
table for each cargo tank. On the next page, we found an example of a spherical
float.
Example of a spherical float
The table for float correction is calculated
against different densities and when we have a cargo with density in between
the table values, we have to interpolate to find the correct correction.
Out of the table above we can see that
lighter liquid will give a higher correction.
The
Float correction table
Specific
gravity (kg/dm3) Corrections in
meter
If we have cargo density 0,55 kg/dm3,
we have to interpolate between 0,50 and 0,60 and
the correction will then be 0,160 meter.
Small floats will give the lowest corrections. A tank equipped with spherical
float will have higher corrections than tanks equipped with a flat float.
A correction on the sounding tape depends on
the temperature in the vapour phase in the tank. High temperature and a small
vapour volume give a small correction, low temperature and big vapour volume
gives a higher correction.
Correction on trim is either a correction to
be added or multiplied to the measured sounding/ullage or the volume table is
calculated with the trim directly. The trim correction is higher on long tanks
than on short tanks. This means that small transverse tanks have a trim
correction near to zero and long tank has higher corrections.
Correction on list is either correction to be
added or multiplied to the measured sounding/ullage or the volume table is
calculated with the list directly. The list corrections are highest on wide
transverse tanks and small on narrow longitudinal tanks.
How we should use the corrections are explained
in each sounding/ullage table. Earlier in this chapter, we found the corrected
sounding to be 8,1662 meter. We will now continue using this example to find
the sounding that we will read on the sounding tape. Normally the corrections
are used directly on the sounding measurement, but when we calculate the other
way we have to use the correctionłs signs the opposite way.
12.4.6
Example 4
Corrected sounding
8,1662
Trim correction from table
-0,021
List correction from table
0
Sounding w. 20oC
8,1872
Correction for vapour temperature
-0,001
Float correction from table
0,1564
Read sounding
8,0318
To find the correct corrections we have to
know the density of the cargo, in this case, propane at
30oC and
density 567,9 kg/m3 = 0,5679kg/dm3, aft trim on 0,5 meter
zero list and
15oC in the vapour phase. When we are completely loaded on this tank, we will have a
sounding of 8,0318 meter.
The 98% maximum filling is to prevent liquid
getting in the relief valve, if the tank pressure reaches the relief valve
setting.
On vessels with relief valve setting of 0,5
bar we do not have any possibilities to heat the cargo at sea. On
semi-refrigerated or fully pressurised vessels, we have opportunity to heat the
cargo while the vessel is at sea. When we are heating the cargo, we have to
follow the tank pressure carefully to avoid uncontrolled venting. Vessels with
a low relief valve setting can have a higher filling limit than vessels with a
high relieve valve setting.
The sketch below shows how the filling limit
changes with the cargo temperature, as long as the relief valvełs set point is
the same.
12.1
Calculation of cargo with use of ASTM-IP tables
In this chapter we will look at the tables
and corrections we use when calculating weight of cargo onboard gas carriers.
We then start to look at how we calculate weight in air at 15oC by
using the correct tables.
The tables we are using are the ASTM-IP-API
tables for light hydrocarbons. Density is mass divided by volume. The mass has
either kilo (kg) or metric ton (mt) as unit. Volume has either cubic meter (m3)
or litre (lt) as unit. Unit for density is either kg/m3 Þ
tonn/m3 or kg/dm3 Þ
kg/lt. Density and specific gravity is often given in vacuum, then we need tables
or calculations to convert to weight in air at 15oC.
12.4.7
Liquid calculation
We start calculation of the liquid in air and
then we look at the vapour calculation. For LPG cargoes and some chemical
cargoes it is normally accepted to calculate the weight in air at 15oC,
as we do in the crude oil trade. We then get either specific gravity 60/60oF
or density at 15oC from shore and we have to use the ASTM-IP-API
tables.
In table ASTM-IP no. 21, we find density at
15oC when the gravity 60/60oF is given. In table ASTM-IP
no. 54, we find the reduction factor to the actual cargo temperature compared
with density at 15oC. In table ASTM-IP no 56, we find the factor to
be used to find weight in vacuum from weight in air. If we take an example with
propane, liquid temperature is -25oC and specific gravity 0,5075, we
will calculate the weight in air at 15oC.
We then start with table ASTM-IP-API no. 21
to find density at 15oC from specific gravity 60/60oF
0,5075.
We look in
the column for Specific gravity 60/60oF 0,507 and find density at 15oC to
0,5073 kg/lt
We then look
in the column for specific gravity 60/60oF 0,508 an find density at 15oC
to
0,5083 kg/lt
The density
has now increased with
0,0010 kg/lt
Our Specific
gravity is 0,5075, we then have to interpolate as follows 0,5073 + (0,0010 /
0,001 x 0,0005) that give
0,5078 kg/lt
12.4.8
Example on table ASTM IP-API 21
Specific
API
Gravity
Gravity
Density
60/60oF
60oF
15oC
0,506
-
0,5063
0,507
-
0,5073
0,508
-
0,5083
Specific
gravity 60/60oF
0,5075
that gives
0,5078
kg/lt
We have now find the density at 15oC
to 0,5078 kg/lt which is equal to 507,8 kg/m3, which we use in table ASTM IP
no.54 to find the reduction factor to
25oC. In table ASTM IP no.54,
we look in the column for actual liquid temperature
25oC. The table
is divided in three columns and we have to interpolate between the 0,505 and
0,510 columns.
12.4.9
Example from table 54
Table 54C
Observed
Density 15 oC
temperature,
0,500
0,505
0,510
oC
Factor to reduce
volume to 15 oC
When we do the interpolation, we find the
reduction factor to 1,10432. When we
have different temperatures on the different cargo tanks, we have to do this
calculation on each tank. Below, we have an example on table ASTM IP no. 54
12.4.10
Example on table ASTM IP-API 54
Table 54C
Observed
Density 15 oC
temperature,
0,500
0,505
0,510
oC
Factor to
reduce volume to 15 oC
-26
1,111
3
1,108
3
1,105
-25,5
1,109
2
1,107
3
1,104
-25
1,108
2
1,106
3
1,103
-24,5
1,107
2
1,105
3
1,102
-24
1,106
3
1,103
2
1,101
-25
0,5078
1,10432
The next correction is the shrinkage factor,
which is a thermal factor on the tank steel. Shrinkage factor is normally 1 at
20oC and is less than one when the steel is colder than 20oC.
The shrinkage factor is the correction for
the thermal expansion on the cargo tank steel. It is the correction between 20oC
and the actual steel temperature. With different steel, we have different
shrinkage factors, but on one vessel the shrinkage factor is similar on all
cargo tanks if they are made of equal steel. Aluminium and invar steel have a shrinkage
factor near 0 and mild steel has higher factor. Shrink factor for a vessel
depends on the material of the cargo tank. There is a shrinkage table on each
vessel. Only vessels with equal quality of steel and tank thickness have equal
shrinkage factors. When we calculate cargo, we use shrinkage factor both on the
liquid and the vapour.
12.4.11
Example on shrinkage factor at
different temperatures
Temp.
Sh.fact.
Temp.
Sh.fact.
Temp.
Sh.fact.
20
1
-21
0,99879
-62
0,99759
19
0,99997
-22
0,99876
-63
0,99756
18
0,99994
-23
0,99873
-64
0,99753
17
0,99991
-24
0,99870
-65
0,99750
16
0,99988
-25
0,99868
-66
0,99747
The last table ASTM-IP no 56 is used to find
mass of liquid and vapour in air from mass in vacuum or vice versa. We have to
use the liquid density at 15oC, which in this example is 0,5078
kg/ltr, and find the factor for propane to 0,99775. We have to multiply this
factor with the mass in vacuum to get mass in air. If we have the mass in air
we must divide with the factor. When the cargo calculations are completed, on
the bill of lading and the other cargo papers we have to note if the loaded
mass is in vacuum or air. We must always use liquid density at 15oC
on the actual cargo to find the correct factor.
12.4.12
Example on table ASTM IP-API 56
Table
56
Density at 15oC
kg/ltr
Factor for mass in vacuum to mass in air
0,5000
to
0,5191
0,99775
0,5192
to
0,5421
0,99785
0,5422
to
0,5673
0,99795
0,5674
to
0,5950
0,99805
Factor
is
0,99775
We can look at one example where we have
loaded 1089,556m3 propane with specific gravity 60/60F 0,5075 and
liquid temperature is
25oC.
From table ASTM-IP-API no. 21 we find the
cargo density at 15oC to 0,5078 kg/ltr. Þ 507,8 kg/m3
From table ASTM IP no. 54, we find reduction
factor from 15oC to
25oC to 1,10432.
From table ASTM IP no. 56, we find factor
from mass in vacuum to mass in air to 0,99775.
From the cargo tank shrinkage table, we find
shrinkage factor to 0,99868 at
25oC.
The calculation gives us 610 994 kg in vacuum
at 15oC that gives us 609 619 kg in air. We have to note on all
cargo documents that the mass is in air and also note the specific gravity
60/60F.
12.4.13
Calculation of the liquidłs mass
Volume
loaded
1089,556
m3
Shrinkage
factor for -25oC
0,99868
Corrected
volume at -25oC
1088,118
m3
Reduction
factor to 15oC
1,10432
Volume at 15oC
1201,630
m3
Density at
15oC
507,8
kg/m3
Mass in
vacuum at 15oC
610188
kg
Factor from
table 56
0,99775
Mass in air
at 15oC
608815
kg
12.4.14
Calculation of vapour
We will now calculate mass of the vapour in
air at 15oC. We always have to calculate the density of the vapour
as the density change with the pressure. When we are calculating the mass in
air on the vapour we need the following values, 288 K which is equal to 15oC,
101,325 kPa which is equal to 1,013 bar. Molar volume of ideal gas at 288 K is
23,6382 m3/kmol. We also need molar weight of the actual cargo and
for propane it is 44,1 kg/kmol. Then we use the actual cargo temperature and
pressure. We can take an example with Propane with vapour temperature at
18oC
and cargo tank pressure at 1,5 bar.
·
Ts is standard temperature 288
K
·
Tv is average temperature on
vapour in K
·
Pv is absolute pressure of
vapour in kPa
·
Ps is standard pressure
101.325 kPa Þ
1,013 bar
·
Mm is molecular mass of the
product in kg/kmol
·
I is molar gas volume at 288 K and
standard pressure 1,013bar Þ 23,6382 m3/kmol
rv
= (Ts x Pv x Mm) / (Tv x Ps x
I) kg/m3
When we insert the values in the formula we
find the following vapour density.
·
Ts = 288 K
·
Tv = 273 + (-18) = 255 K
· Pv = (Ps + PT
) x 100 = (1,013 + 1,5) x 100 = 251.3 kPa
· Ps = 101.3 kPa
· Mm = 44,1 kg/kmol for
propane
·
I = 23,6382 m3/kmol
12.4.15
Density calculation of vapour
Ts
288
288
K
Ps
1,013
101,3
kPa
Pv
1,013
1,5
251,3
kPa
Mm
44,1
44,1
kg/kmol
I
23,6382
23,6382
m3/kmol
288
x
251,3
x
44,1
rv =
255
101,3
23,6382
=
5,227
kg/m3
When we have calculated the vapour density,
we have to calculate the mass of the vapour. We continue with the calculation
of propane loading. The cargo tank 100% volume is 1182,18m3 and we
have loaded 1089,556m3 liquid.
The vapour volume is then 100% cargo tank volume minus liquid
volume. That gives us 1182,18m3
1089,556m3 = 92,624m3.
We have a vapour temperature on
18oC,
which gives us a shrinkage factor (cargo tank expansion factor) on 0,99888
taken from the vesselłs shrinkage table. The vapour density is in kg/m3 and
the mass will then be in kilos.
When we calculate the mass of liquid in
kilos, we also calculate the mass of vapour in kilos. If we use mass of liquid
in metric ton, we have to calculate the vapour in metric ton also. In this
example, the vapour density is 5,227 kg/m3, which is equal to
0,005227 mt/m3. In this example, the mass of vapour is 484 kilos.
12.4.16
Calculation of vapour mass at 15oC
in kilo
Cargo tank
100% volume
1182,180
m3
Liquid volume
1089,556
m3
Gas volume
92,624
m3
Shrinkage
for - 18oC
0,99888
Corrected
Gas volume
92,520
m3
Density of
gas at 15oC
5,227
kg/m3
Mass of gas
in vacuum at 15oC
484
kg
To find the total mass of liquid and vapour
in the cargo tank, we have to add mass of liquid 610 994 kg + 484 kg = 611 478
kg. Then we use ASTM-IP table 56 and find the conversion factor to mass in air.
Cargo density at 15oC is 507,8 kg/m3 with a factor of
0,99775. Then we multiply total mass in vacuum 611 478 kg with 0,99775 which
gives us 610 102 kg in air.
12.4.17
Calculation of total mass in air at
15oC
Mass of
liquid in vacuum at 15oC
610 994
kg
Mass of gas
in vacuum at 15oC
484
kg
Total mass
in vacuum at 15oC
611 478
kg
Factor from
ASTM-IP 56 table
0,99775
Total mass
in air at 15oC
610 102
kg
We will take an example on a full calculation
and find the total mass in air, the cargo is propane and we have the following
information:
Molecular
mass
44,1
kg/kmol
Liquid
temperature
-24
oC
Vapour
temperature
-20
oC
Atmospheric
pressure
1,017
bar
Relief valve
setting
4,5
bar
Cargo tank
pressure
1,550
bar
Spes.Grav.60/60F
0,5072
Liquid density
at -24oC
560,6
kg/m3
Density at
Relief valve setting
522,756
kg/m3
Trim by
stern
1
meter
Sounding
8,152
meter
100 % Volume
of cargo tank
1468,180
m3
ROB before
loading
3114
kg
With a set point on the relief valve at 4,5
bar we can load maximum 91,38% with liquid temperature
24oC.
Maximum filling volume is, as follows:
Maximum filling volume = 0,98 x VT
x rR / rL
Maximum filling volume = 0,98 x 1468,18 x
522,7 / 560,6 = 1341,69 m3
We always have to start with the calculation
of maximum filling volume. This
calculation is based on figures we got before we start loading. If the
temperature and pressure changes, while we are loading, we have to recalculate
the maximum filling volume. Warmer cargo gives a higher filling volume; colder
cargo gives a lower filling volume. When the loading is completed, we do the
final calculation. We have to find the maximum filling limit on all tanks.
12.4.18
Example on a full calculation on mass
at 15oC
PROPAN Tank #
2
1
100 %Volume
cargo tank
1468,180
m3
2
Liquid
temperature
-24,0
oC
3
Sounding
8,152
m
4
Float
correction
0,158
m
5
Correction for vapour temperature
-0,001
m
6
List
correction
0,000
m
7
Trim
correction
-0,059
m
8
Sounding at
20oC
8,250
m
9
Liquid
volume at 20oC
1341,373
m3
10
Shrinkage
factor tank steel at
24oC
0,99871
11
Corrected
liquid volume
1339,643
m3
12
Reductions
factor from table 54C
1,102
13
Liquid
volume at 15oC
1476,287
m3
14
Liquid
density at 15oC table 21
507,5
kg/m3
15
Mass of
liquid in vacuum at 15oC
749 215
kg
16
Uncorrected
vapour volume
126,807
m3
17
Shrinkage
factor vapour phase
20oC
0,99882
18
Corrected
vapour volume
126,657
m3
19
Tank
pressure
1,550
bar
20
Atmospheric
pressure
1,017
bar
21
Molecular mass
Propane
44,1
kg/mol
22
Vapour
temperature
-20,0
oC
23
Vapour
density at 15oC
5,382
kg/m3
24
Mass of
vapour in vacuum at 15oC
682
kg
25
Total mass
of cargo in the tank in vacuum
749 897
kg
Mass in air 749
897 kg x 0,99775
748 210
kg
ROB in air
3 114
kg
Total loaded
in air at 15oC
745 096
kg
After we complete the cargo calculation, we
have a ships figure which is the one the chief officer must calculate and one
shore figures, which is the one that the surveyor has calculated. Those two
figures will be nearly equal or equal. The one we use in the Bill of Lading is
the surveyorłs figure. In our example, we have loaded 745 096 kg in air at 15oC
in the actual cargo tank. It must be specified on the Bill of Lading that the
mass is in air at 15oC.
When we discharge the cargo, we will have
311,4 kg vapour left in the tank. At a
minimum, we are allowed to discharge is 99,5% of Bill of Lading, in this example
741 370 kg. It is important for the
vessel to calculate which temperature and cargo tank pressures will remain when
we finish discharging. In this example,
we must have maximum 0,16 bar pressure and vapour temperature
27oC.
When we load on an atmosphere from a previous
cargo, we call that ROB (Remaining on Board) or heel. That means when we have calculated the total mass of cargo in a
tank we have to subtract the ROB. When
the discharging is completed, that means we are finished pumping liquid. We have blown hot vapour to shore and tank
pressure, and vapour temperature is equal to what we estimated before loading.
It is important to remember that the tank
pressure has a big influence on the vapour density. If we transport an ambient cargo, we have to remove the tank
pressure before we commence the calculation of the ROB. Tank pressure is removed with the vesselłs
compressors and the condensate is sent directly to the discharge line.
We can look at two examples on density
calculation of a cargo with equal temperature but different tank
pressures. We use propylene as example
and vapour temperature is
25oC molecular mass 42,08 kg/kmol.
The first example tank pressure is 0,3 bar
and the other example tank pressure 1,5 bar.
The atmospheric pressure is 1,020 bar vessels total volume is 12000m3.
12.4.19
Example of calculations on vapour
density with different tank pressures
r v
0,3bar =
288
x
134
x
42,08
243
101,3
23,6382
=
2,791
kg/m3
Volume
12000
x
2,791
kg/m3
33 490
kg
r v
1,5bar =
288
x
252
x
42,08
243
101,3
23,6382
=
5,249
kg/m3
Volume
12000
x
5,249
kg/m3
62 982
kg
Difference
in mass
29 492
kg
Difference in r
2,458
kg/m3
With a difference of tank pressure at 1,3 bar
on a 12 000 m3 vessel, we get 29 492 kg in mass difference. It is a good routine to always calculate the
maximum mass of vapour, which we can have as ROB to reach 99,5% of Bill of
Lading before we start discharging.
If we are onboard a fully refrigerated gas
carrier, we do not have any problem with high tank pressure when we have
completed discharging.
12.3
Calculation of cargo weight using density tables
When transport of chemical gases and also
sometimes LPG cargoes, we use density tables for the actual cargo. We get the
density tables from the surveyor, the shipper of the cargo or thermodynamic
properties of gases. The weight of cargo is calculated by use of the actual
cargo temperature and the density tables are either in vacuum or in air. On
clean cargoes, such as, ethylene, propylene, butadiene and VCM, we can use the
density tables composed by SGS or thermodynamic properties of gases. We have to
be sure that the density tables we are using are either in vacuum or in air and
it has to be noted on the Bill of Lading. The density table we are using in the
load port has to be used also in the discharge port. The only ASTM table we are
using is ASTM-IP table no.56 for converting weight in air to weight in vacuum
or vice versa.
When the calculation is completed, we have to
note that the weight is in vacuum or in air. We always have to calculate the
vapour density because the vapour temperature does not match the cargo tank
pressure. We should use the actual vapour temperature and actual tank pressure
in the calculation of vapour density. First we take a look at how we are
calculating the weight of liquid.
First of all we have to find out the maximum
filling volume on the actual cargo tanks that we have to load.
Maximum
filling volume is as follows:
Maximum filling volume = 0,98 x VT x rR
/ rL
The cargo tank 100% volume is 1182,18 m3,
safety valve set point is 4,5 bar Þ
5,5 bar ata, liquid temperature is
24oC. Liquid density at 5,5 bar
is 523,3 kg/m3 and density at
24oC is 560,6 kg/m3.
98%
Vt m3
r SV kg/m3
r c kg/m3
Maximum filling volume =
0.98
1182.18
523.3
560.6
Maximum filling volume =
1081.452
m3
We should calculate the weight of liquid
propane, cargo tank pressure is 1,1 bar. We have loaded 1089,556m3
liquid propane, density from density table and
24oC is 560,6 kg/m3.
Cargo tank expansion factor at -24oC is 0,99870. Weight in vacuum will then be 605 477 kg, weight in air 604 115 kg.
12.3.1
Example on calculation of weight in
air
Loaded volume
1081.452
m3
Correction factor for -24oC
0.99870
Corrected volume
1080.052
m3
Density at -24oC from table
560.6
kg/m3
Weight in vacuum at -24oC
605 477
kg
Factor from table 56
0.99775
Weight in air at -24oC
604 115
kg
12.3.2
Calculation of vapour density and
weight
To calculate the weight of vapour, we first
have to calculate density of the vapour on the actual temperature. The actual
vapour temperature has to be in K (Kelvin) and pressures in kPa (kilo Pascal).
Another factor we should use is molar gas constant which is 8,31441 J/(mol x
K). To find the pressure in kPa “kilo Pascal" we multiply the pressure in bar
with 100, that means 1 bar is equal to 100 kPa.
In all calculations in this manual, we use
273K as 0oC. When we do the calculations onboard we use 273,15K as 0oC.
We should now look at one example to find
vapour density on propane with vapour temperature on
25oC, tank
pressure is 1,4 bar and the atmospheric pressure is 1.013 bar. Molecular mass
on propane is 44,1 kg/kmol.
Vapour density at actual temperature formula:
(Tank pressure
in kPa + Atmospheric pressure in kPa) x Molecular mass molar gas
constant x (T0 K + Gas temperature in oC)
Tank pressure 1,4 bar is equal to 140 kPa and
the atmospheric pressure 1,013 bar is equal to 101,3 kPa. Vapour temperature DT
in K = 273 + - 25 = 248K Tank pressure plus atmospheric pressure DP
is equal to 241,3 kPa.
D P x Molecular mass
Molar gas const. x D T
( 140,0 +
101,30) x
44,1
8,31441 x
( 273,00 +
-25,00)
5,16075
kg/m3
We can take another example with ethylene and
calculate the vapour density, molecular mass is 28,05 kg/kmol, vapour
temperature is
99oC Þ
174K and tank pressure is 0,35 bar Þ 35 kPa. Atmospheric
pressure is 1,012 bar Þ 101,2 kPa.
D P x Molecular mass
Molar gas const. x D T
( 35,0 +
101,20) x
28,05
8,31441 x
( 273,15 +
-99,00)
2,638
kg/m3
Now when we have found the vapour density at
the actual vapour temperature, we can calculate the weight of vapour at the
actual temperature. We have loaded one
tank with ethylene, tank 100% volume is 1182,15 m3 and liquid volume
is 1088,6 m3. Liquid temperature is
100oC and vapour
temperature is
99,5oC shrinkage factor at
99,5oC are
0,99648. Tank pressure is 0,15 bar and the atmospheric pressure is 1.014 bar.
Vapour volume
93.55
m3 =
(1182.15 -
1088.60)
m3
Vapour density
2.263367
kg/m3 =
(D P x
28,05) / (8,31441 x D T)
Vapour weight at
99,5oC
210.99
kg =
103,55 x 0,99648 x 2,26337
We have now seen how to calculate weight of
liquid and weight of vapour and we should now calculate both liquid and vapour.
We should calculate one tank loaded with ethylene, relief valve set point is
4,5 bar and atmospheric pressure is 1,020 bar. After loading the vessel we have
1 meter by stern trim with the following values:
Vapour
-95oC and tank pressure 0,345
bar.
Liquid
-100,5oC, density 563,63 kg/m3,
liquid volume 1313,348 m3
Maximum filling limit is 89,45%, which is
equal to 1313,348 m3 with relief valve setting on 4,5 bar. Total
weight of cargo in the tank is 738 009 kg in vacuum.
12.3.3
Calculation of Ethylene set point 4,5
bar
Liquid volume
1313.35
m3
Shrinkage factor at -100,5oC
0.99645
Corrected liquid volume
1308.69
m3
Liquid density at -100,5oC
563.625
kg/m3
Weight of liquid in vacuum at
-100,5oC
737610
kg
Cargo tank 100% volume
1468.18
m3
Vapour volume
154.832
m3
Shrinkage factor at -95oC
0.99661
Corrected vapour volume
154.308
m3
Vapour density at -95oC
2.583
kg/m3
Weight of vapour in vacuum at
-95oC
399
kg
TOTAL LOADED IN VACUUM
738009
kg
When we change the relief valve set point to
0,5 bar the maximum allowable filling limit then increase to 97,0% that is
equal to 1424,127m3. We then get a total weight of cargo in the tank
on 799 940 kg, which is 61 931 kg more than with set point on 4,5 bar. First,
we have to calculate maximum allowed filling limit.
Set point is
0.5 bar
Absolute pres.
1.520 bar
Ref. temp.
-96.53 oC
Ref. dens.
557.87 kg/m3
Filling limit
rR/rL x 98%
97.00 %
12.3.4 Calculation of
Ethylene set point 0,5 bar
Liquid volume
1 424,13
m3
Shrinkage factor at -100,5oC
0,99645
Corrected liquid volume
1 419,08
m3
Liquid density from table at -100,5oC
563,625
kg/m3
Weight of liquid in vacuum at -100,5oC
799 827
kg
Cargo tank 100% volume
1 468,18
m3
Vapour volume
44,053
m3
Shrinkage factor at -95oC
0,99661
Corrected vapour volume
43,904
m3
Vapour density at -95oC
2,581
kg/m3
Weight of vapour in vacuum at -95oC
113,326
kg
TOTAL LOADED IN VACUUM
799 940
kg
When we are loading on ROB from previous
cargo, the total loaded cargo is total weight of liquid and vapour in the tank
minus ROB. If we, in this example, had ROB before loading and we surveyed the
tank atmosphere at
87oC and tank pressure 0,02 bar, atmospheric
pressure 1,019 bar, the ROB will then be 2758 kg in vacuum. Total loaded will
then be 799 940 kg
2 758 kg = 797 182 kg in vacuum.
12.3.4
Weight of ROB before loading at
temperature -87oC and tank pressure 0,02 bar
Vapour density
1,885
kg/m3
Tank volume 100%
1468,18
m3
D T =
186
K
Weight of vapour
2 758
kg
D P =
104
kPa
Shrinkage factor
0,99685
To find the weight in air we can either use
table ASTM-IP-API 56 if we know the density at 15oC or we have to
calculate a factor. The factor is, as follows:
(1
(r
air/ r cargo liquid)) / (1
( r
air/ r Brass)
(1
(1,2 kg/m3 /r
cargo liquid)) / ( 1
(1,2 kg/m3 / 8100kg/m3))
In our example we will get a factor, as
follows:
(1 - (1,2
kg/m3 /563,625 kg/m3)) / ( 1
(1,2 kg/m3 /
8100kg/m3)) = 0,997985
Then we have to multiply mass in vacuum with
the factor:
797 182 kg x 0,997985 = 795 575 kg in air
On a full-loaded tank, we can use the
following formula:
Mass in vacuum loaded - (Mass in vacuum
loaded x r
air / r liquid)
When we use the values from our last example it will be, as follows
Weight in air = Mass in vacuum - (Mass in
vacuum x 1,2/ r liquid)
Weight in air = 797 182 - (797 182 * 1,2/
563,625)
= 795 485
kg
Before we commence with cargo calculations,
we have to be sure that the density given is in air or in vacuum. With most
chemical gases, we get the density on the actual liquid temperature in vacuum.
Always note on the Bill of Lading that the quantity is either in vacuum or air.
On the calculation forms, we calculate both in vacuum and in air.
We should now do a full cargo calculation. We
start to calculate ROB before loading. Then we do calculations after we have
completed loading.
The vessel has three twin tanks numbered as
follows 1P, 1S, 2P, 2S, 3P and 3S. Cargo tanks 2 and 3 are equal and tank 1 is
a bit smaller.
12.3.5
Calculation of ROB before loading
Loading report
Cargo
Propylene
Port
Al Jubail
Molecular mass
42,08
Date
17.05.
1994
Atm.press.
1,015
Vessel
LPG Seagull
Liquid
Tank #
Sounding in meter
Volume from tab. in m3
Temp.
in oC
Pressure in bar
r liquid in kg/m3
Shrinkage factor
Mass of liquid in kg
1P
0,02
0
1S
0,02
0
2P
0,02
0
2S
0,02
0
3P
0,02
0
3S
0,02
0
Total
mass of Liquid
0
Vapour
Tank #
!00% vol.
in m3
Vapour volume in m3
Temp.
in oC
r vapour in kg/m3
Shrinkage factor
Mass of vapour in kg
1P
1182,18
1182,18
-27
2,129
0,99862
2 514
1S
1182,18
1182,18
-27
2,129
0,99862
2 514
2P
1468,18
1468,18
-27
2,129
0,99862
3 122
2S
1468,18
1468,18
-27
2,129
0,99862
3 122
3P
1468,18
1468,18
-25
2,112
0,99868
3 097
3S
1468,18
1468,18
-25
2,112
0,99868
3 097
Total
mass of vapour
17 465
Total
mass in vacuum
17 465
ROB
Total
loaded in vacuum
Total
loaded in air
12.3.6
Calculation of mass after loading
Loading report
Cargo
Propylene
Port
Al Jubail
Molecular mass
42,08
Date
18.05.
1994
Atm.press
1,020
Skip
LPG Seagull
Liquid
Tank #
Sounding in meter
Volume from tab. in m3
Temp.
in oC
Press in bar
r liquid in kg/m3
Shrinkage factor
Mass of liquid in kg
1P
8,74
1123,83
-39
0,6
601,2
0,99826
674 471
1S
8,76
1125,55
-39
0,6
601,2
0,99826
675 503
2P
8,72
1400,11
-39
0,6
601,2
0,99826
840 281
2S
8,73
1401,20
-39
0,6
601,2
0,99826
840 936
3P
8,76
1404,41
-38
0,6
600,0
0,99829
841 205
3S
8,75
1403,35
-38
0,6
600,0
0,99829
840 570
Total
mass of Liquid
4 712 967
Vapour
Tank #
100% vol.
in m3
Vapour volume in m3
Temp.
in oC
r vapour in kg/m3
Shrinkage factor
Masse of vapour in kg
1P
1182,18
58,35
-35
3,445
0,99838
201
1S
1182,18
56,63
-35
3,445
0,99838
195
2P
1468,18
68,07
-36
3,459
0,99835
235
2S
1468,18
66,98
-36
3,459
0,99835
231
3P
1468,18
63,77
-34
3,431
0,99841
218
3S
1468,18
64,83
-34
3,431
0,99841
222
Total
mass of
vapour
1 302
Total
mass in vacuum
4 714 269
ROB
17 465
Total
Loaded in vacuum
4 696 803
Total
loaded in air
4 687 973
12.4 Calculation of liquid to
be used for gassing up
There are some parameters we have to have in
mind to find out how much liquid we need to take onboard for gassing up our
cargo tanks. The first is the temperature of the liquid we will take onboard
then the temperature of the cargo tank steel and what volume we should gas up.
To change cargo and gas up costs lot money,
to minimise the cost we have to use all the available cargo equipment onboard
in the most efficient way. We have to be sure that the amount of liquid we
order for gassing up is enough to gas up and to commence cooling down the cargo
tanks. If we have some ROB in one tank, we can begin gassing up at sea if the
tanks are surveyed and approved by a surveyor. If we donłt have any ROB or not
enough, we have to order liquid to gas up the rest of the volume to be gassed
up. To minimise the consumption of cargo for gassing up, we need to heat the
cargo, as mush as possible. The amount of cargo lost when gassing up depends on
the people onboard, cargo equipment and the time we use for gassing up. For
cargoes with a heavy vapour, such as VCM, propane butane and propylene, the
loss of cargo is near to 0 when gassing up correctly. The only way to reduce
the loss of cargo is to control tank pressure when loading coolant, measure and
check when commence heating the coolant for gassing up.
12.4.1
Volume of liquid to be used for
gassing up
We have a cargo tank with volume 1182,18 m3
that we have to gas up. Our experience is that we need two times the tank
volume for gassing up and commence cooling the tank. We then have to order the
following amount cargo, 1182,18 m3 x 2 = 2364,36 m3. We
will take onboard propylene liquid for gassing up and it is two vital
temperatures we must recognise, tank steel temperature and liquid temperature
on the coolant. Liquid temperature on shore tank is
40oC and our
cargo tank steel 20oC. The formula is mass = r
vapour x total volume. From the table thermodynamic properties for propylene
superheated vapour, we find the vapour r
to 1,812 kg/m3 on 20oC and P=1 bar. Then we take the
total volume 2364,36 m3 and multiply with vapour r
1,812 kg/m3 = 4 283 kg, which is the minimum we need for gassing up
and commence cooling the tank. The loss of cargo and number of changes is
individual for each vessel and it is our duty to reduce the loss of cargo down
to a minimum.
12.4.2
Calculation of volume liquid we have
to order
Cargo
Propylene
100% Tank volume
1182,18
m3
r vapour at
atmospheric pressure from table
20
oC
1,812
kg/m3
r liquid from table
-40
oC
602,4
kg/m3
Number of changes
2
Total volume to be changed
2364,36
m3
Mass volume = Volume x r for vapour
Mass total volume =
4283,26
kg
Volume liquid to be loaded = Mass volume / r liquid
Volume to be loaded =
7,110
m3
We have to load 7,11 m3 propylene
at
40oC from shore tank to change the vapour atmosphere at 20oC
two times. This was a calculation for
one tank, if we gas up all tanks, the calculation has to be on the total volume
of the vesselłs cargo tanks.
After completion of the loading two Bill of
Lading will be made, one for what we have used for gassing up and one for the
quantity we have loaded.
12.4.3
Number of changes with a given amount
of liquid
To find the number of vapour changes with a
given amount of liquid in either a deck tank or a cargo tank, we then have to
know the liquid temperature and the temperature of the cargo tanks we have to
gas up. Then we have to calculate the mass of the liquid we have. When we know
the mass of liquid and the volume to be gassed up, we know if we then need to
order more liquid or if we can complete to gas up and commence cooling tanks
with the amount of liquid we have onboard. A cargo tank is completely gassed up
when we have more than 97% hydrocarbons in the vapour atmosphere.
We must remember that the tank we use for
gassing up will have a given amount of mass vapour left ROB, which we are
unable to get out. First, we have to calculate the mass of vapour we will have
ROB in our deck tank/cargo tank after we have gassed up the other tanks. When
we have calculated the mass of vapour we have left, we must subtract it from
the amount of liquid we have. How many changes we need depends on the cargo,
the cargo handling equipment we have onboard, temperature of the liquid and
temperature of the atmosphere that we should gas up. If we are able to heat the
vapour, we should have it as hot as possible to use as less liquid as possible.
We can use an example on the calculation of
vapour after gassing up. Average
temperature on the vapour is
10oC, total tank volume is 2564,36 m3
and tank pressure is 0 bar. We then find the density of the vapour, either
calculate the density or use the thermal property table to find it. When we
have found the vapour density, we have to multiply it with the tank shrinkage
factor and the tank volume.
12.4.4
Mass of vapour after gassing up
Cargo
Propylene
Tank volume #1 P/S
2364,36
m3
r for vapour at
atmospheric pressure
-10
oC
1,953
kg/m3
Mass of vapour in the tank
4 618
kg
We have now calculated that we should have 4
618 kg vapour left in tank #1 P and S when we are not able to get out any more
from the tanks. Before we order any liquid, we have to subtract 4 618 kg from
the amount of liquid we need to gas up the whole vessel.
We can continue with the example and have 15
m3 liquid propylene at
10oC, vapour temperature 0oC
and the pressure 3,3 bar in tank #1 P/S. Total volume of the vessel is 8237 m3
and atmospheric pressure is 1,015 bar. That means we have to gas up vesselłs
total volume
volume of tank #1 P/S, which is equal to 8237 m3
2364,36 m3 = 5872,64 m3 with an average temperature of 25oC.
Our experience is that we need 2,5 volume changes to reach 97% hydrocarbons in
the vapour atmosphere, 2,5 changes is 5872,64 m3 x 2,5 = 14681,6 m3.
It is always stated in the charter party how clean the atmosphere has to be
before loading and it depends on which cargo we have to load.
12.4.5
Mass we can use for gassing up
Cargo
Propylene
Tank volume #1 P/S
2364,36
m3
Volume liquid in tank #1 P/S
15,00
m3
Mass of liquid in tank #1 P/S
8 420
kg
Volume of vapour in tank #1 P/S
2349,36
m3
Mass of vapour in tank #1 P/S
18 783
kg
Total mass in tank #1 P/S
27 202
kg
Mass of vapour in tank #1 P/S after gassing
up
4 618
kg
Usable mass in tank #1 P/S
22 584
kg
We have 27202 kg available in tank #1 P/S,
but when we are completed gassing up, we have 4618 kg vapour left, that means
we have 22584 kg available for gassing up. Total volume to be gassed up is
vesselÅ‚s total volume minus volume of tank #1 P/S multiplied with 2,5. That gives Þ
8237 m3 - 2349,36 m3 Þ
5872,64 m3 x 2,5 = 14682 m3. We have to find the vapour
density equal to tank steel temperature 25oC, which is 1,724 kg/m3.
12.4.6
Calculation of volume needed
Volume vapour at 25oC of
available mass
13 101
m3
r for vapour with
atmospheric pressure at
25
oC
1,724
kg/m3
Total volume vapour 2,5 times tank volume
14 682
m3
Volume to be ordered
1 581
m3
In this example, we do not have enough liquid
to reach 2,5 times for gassing up. There was 1581 m3 vapour short,
so we have to order that 1581 m3 x 1,724 kg/m3 = 2726 kg.
12.4.7
Calculation of mass vapour at a given
temperature
Cargo
Propylene
Vesselłs total volume
8237
m3
Tank #1 P/S volume
2364,36
m3
Volume to be gassed up
5872,64
m3
Amount changes
2,5
Tank steel temperature
25
oC
Atmospheric pressure
1,015
bar
Vapour r at 25oC
1,724
kg/m3
Total volume to gas up 5872,64 x 2,5
14 682
m3
Mass of total volume to gas up
25 309
kg
Available mass
22 584
kg
Mass in kg to load to complete gassing up
2 725
kg
To hold the temperature of the vapour we use
for gassing up, we have to use either the compressors or heaters. If we are
able to increase the temperature on the vapour from 25oC to 60oC,
we do not need to supply any extra from shore.
12.4.8
Calculation of vapour at 60oC
Vapour r at 60oC
1,543
kg/m3
Total volume to gas up 5872,64 x 2,5
14 682
m3
Mass total volume to gas up
22 649
kg
Available mass
22 584
kg
Mass in kg difference
65
kg
It is important that we continue to heat the
tank we are taking the vapour from to hold a positive pressure.
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