Sanstar Bio-Polymers Ltd

Line sizing calculations

Design Calculations for Line sizing and pressure drop for Steam Turbine and Process steam lines

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Sanstar Bio-Polymers Ltd

Line sizing calculations

Contents
1. Steam Turbine Line Design Calculations: ............................................................................................ 3 1.1 1.2 HP steam line thickness calculation from boiler outlet to turbine inlet: ................................ 3 Line sizing and pressure drop calculation: .............................................................................. 4

2. Process steam pressure drop calculations:......................................................................................... 5 2.1 Pressure drop calculations for external lines................................................................................ 5 2.2 Pressure drop calculation for MP and LP steam lines inside the process block: .......................... 8 3. Break-up of Piping BOQ: ................................................................................................................... 10 Option 1: ........................................................................................................................................... 10 Option 2: ........................................................................................................................................... 10 Process block distribution lines: ....................................................................................................... 11

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Line sizing calculations

1. Steam Turbine Line Design Calculations:

1.1 HP steam line thickness calculation from boiler outlet to turbine inlet:
Steam line from Power boiler outlet to the turbine inlet is a High pressure critical line, for which thickness calculations are required to be dons as ASME B31.1, calculation sheet is given below.
Pipe size Working Pressure 1.0Pipe Material= 2.0Type/Class of Pipe= 3.0Operating Temperature=495 deg c 4.0O.D. of Pipe( D )= 5.0Schdule of pipe selected= 6.0Designated Thickness as per Sch.No. less 12.5 % thickness mill under tolerance DESIGN DATA: *Min.Tensile strength at room Temp(R).= Therefore,R/2.7 *Yield Point(Et) = Et/R20 ratio at 500 deg c Et Therefore,Et/1.5 Formula: allowable working Pr. W= 60000 22222.222 0.23 13800.000 9200.000 2fe(t-C) D-t+C Allowable Working Pr.in Kg/Cm2 = Actual Working Pressure in Kg/cm2 g= 76.30284028 68 in psi in psi 200 NB 68 kg/cm2 g Working Temp.above 495 degC(925 degF)

A335 P11 Seamless 925 8.625 Sch 100 0.594 0.51975 in Inch in Deg.F in INCH.

in psi in psi in psi

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Line sizing calculations

1.2 Line sizing and pressure drop calculation:

Line sizing from boiler outlet to turbine inlet is as given below: 8inch line 100SCH 68 barg 490 degC 35000 kg/h 202.72 mm 53 m 4 1 1 8 188.45 m

Steam Pressure Steam Temperature Req'd capacity Pipe size Pipe length No. of gate valves No. of strainers No. of lift check valves No of 90o elbows Equivalent pipe length

Results Pressure at end of pipe 67.68 bar Upstream velocity 11.42 m/s Downstream velocity 11.48 m/s

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Line sizing calculations

2. Process steam pressure drop calculations:

Pressure drop and line sizing is done for two options viz. 1)Single extraction turbine, and 2)Extraction cum back pressure turbine. Pressure drop calculations for the external lines would vary for each of the case whereas pressure drop for internal lines will remain the same. Therefore Calculations are worked out separately for external lines and internal lines i.e. MP and LP steam lines from turbine house to process block, and Steam distribution from process headers to individual equipment which are the internal lines.

2.1 Pressure drop calculations for external lines

Option 1: Below given is the pressure drop calculation for external lines and internal lines considering Extraction cum back pressure turbine with extraction at 10.5barg and backpressure at 4.5barg pressures. a. Pressure drop calculation across MP steam line from turbine house to Process header: Inlet Pressure Barg Flow TPH Size From 10 25 250NB Turbine MP header 9.61 18 200NB Starch Block Steam Header (Dryer section) 4 16 1.8 14.4 140 154.4 185.28 8 24 72 86.4 271.68 0.39 28 9.22

To Starch Block Expansion loops 7 No of bends 28 Loop vertical length 2.5 Total length for exp. Loops 35 Actual Pipe length 238 Total pipe length 273 20% margin 327.6 Additional bends 4 total bends 32 Eq length 120 20% margin 144 Total eq length 471.6 Pr drop 0.39 Velocity (m/s) 25 Pressure at end point 9.61

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Line sizing calculations

b. Pressure drop calculations across LP steam line from LP header in Turbine house to LP header at the process block: Pressure Barg Flow TPH Size From To Expansion loops No of bends Loop vertical length Exp. Loop vertical length Actual Pipe length Total pipe length 20% margin Additional bends total bends Eq length 20% margin Total eq length Pr drop Velocity (m/s) Pressure at end point 4.5 10 250NB Turbine DSH/ LP header in Turbine house LP header in Process 9 36 2.5 45 308 353 423.6 6 42 157.5 189 612.6 0.17 18 4.33

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Line sizing calculations

Option 2: Below given are the pressure drop calculations for main lines considering single extraction turbine with extraction at 10.5barg pressure a. Pressure drop calculation across MP steam line from turbine house to steam header at the process block: Pressure Barg Flow TPH Size From To Expansion loops No of bends Loop vertical length Exp. Loop vertical length Actual Pipe length Total pipe length 20% margin Additional bends total bends Eq length 20% margin Total eq length Round off length Pr drop Velocity (m/s) Pressure at end point 10 35 300NB Turbine DSH Starch Block 7 28 3 42 238 280 336 4 32 144 172.8 508.8 510 0.32 24 9.68 9.68 28 250NB Starch Block Inlet of 4.5barg PRS 2 8 2.5 10 70 80 96 6 14 52.5 63 159 160 0.17 29 9.51 9.51 18 200NB Inlet of 4.5barg PRS Steam Header (Dryer section) 2 8 1.8 7.2 70 77.2 92.64 2 10 30 36 128.64 130 0.19 27 9.32

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Line sizing calculations

2.2 Pressure drop calculation for MP and LP steam lines inside the process block:
a. Pressure drop calculations for MP steam lines Pressure Barg 9.32 Flow TPH 1.2 Size From To Final evaporators Expansion loops 2 No of bends 8 Loop vertical length 1 Exp. Loop vertical length 4 Actual Pipe length 78 Total pipe length 82 20% margin 98.4 Additional bends 4 total bends 12 Eq length 12 20% factor 14.4 Total eq length 112.8 Round off length 115 Pr drop 0.3 Velocity (m/s) 19 Pressure at end point 9.02 9.2 21 0.12 70 65.52 10.8 9 6 2 54.72 45.6 43 2.6 1.3 4 1 Jet cooker 65NB Steam Header (Dryer section) 100NB Steam Header (Dryer section) 3.1 9.32

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Line sizing calculations

b. Pressure drop calculations for LP steam lines inside process block Pressure Barg Flow TPH Size 4.33 0.2 40NB LP header in Process DMH dryers 4 16 0.8 6.4 146 152.4 182.88 3 19 0.6 11.4 13.68 196.56 215 0.4 17 3.93 4.33 1.2 80NB LP header in Process Near dryers header 1 4 1.2 2.4 58 60.4 72.48 2 6 1.2 7.2 8.64 81.12 90 0.14 21 4.19 4.19 1 65NB Near dryers header Steeping section 2 8 1 4 76 80 96 3 11 1 11 13.2 109.2 110 0.4 31 3.79 4.19 1 80NB Near dryers header Steeping section 2 8 1.2 4.8 76 80.8 96.96 3 11 1.2 13.2 15.84 112.8 115 0.13 18 4.06 4.33 1.4 80NB LP header in Process Hydrocyclo ne 2 8 1.2 4.8 74 78.8 94.56 3 11 1.2 13.2 15.84 110.4 115 0.27 28 4.06

From

To Expansion loops No of bends Loop vertical length Exp. Loop vertical length Actual Pipe length Total pipe length 20% margin Additional bends total bends Eq length per bend (mtr) Eq length 20% factor Total eq length Round off length Pr drop Velocity (m/s) Pressure at end point

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Line sizing calculations

3. Break-up of Piping BOQ:

Option 1:
Descripton Boiler to turbine inlet Boiler to bypass pRS inlet bypass Prs O/L to DSH I/L Turbine exhaust to DSH I/L MP DSH Outlet to MP header MP header to LP PRS I/L Size Pressure 200NB 68 200NB 68 300NB 10.5 250NB 10.5 250NB 10.5 150NB 10.5 Flow 35 35 35 25 35 10 Sch 100 100 40 40 40 40 Material Pipe length Bends P11 46 8 P11 23 8 CS 23 8 P11 23 8 CS 5 3 CS 10 3

Turbine exhaust to DSH I/L to LP header LP header(turbine) to LP header (process) MP Header (turbine) to Starch Block Starch block to MP header(Process) MP header(turbine) LP header(turbine)

250NB 250NB 250NB 200NB 350NB 300NB

4.5 4.5 10.5 10.5 10.5 4.5

10 10 25 17.5

40 40 40 40 40 40

CS CS CS CS CS CS

23 423.6 327.6 185.28 5 5

8 42 32 24

Option 2:
Descripton Boiler to turbine inlet Boiler to bypass pRS inlet bypass Prs O/L to DSH I/L Turbine exhaust to DSH I/L DSH O/L to DA I/L Main line to LP PRS DSH O/L to Process(Starch block) Starch Block to MP header Size 200NB 200Nb 300NB 300NB 100NB 150NB 300NB 250NB Pressure 68 68 10.5 10.5 10.5 10.5 10.5 10.5 Flow 35 35 35 35 5 10 35 28 Sch 100 100 40 40 40 40 40 40 Material P11 P11 CS CS CS CS CS CS Pipe length 46 23 23 23 37 10 336 96 Bends 8 8 8 8 8 3 32 14

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Line sizing calculations

Process block distribution lines:

LP Lines - header to equipment I/L Process LP hdr to Hydro cyclone 80NB 4.5 Process LP Hdr to LG evaporator 100NB 4.5 Process LP Hdr to DMH and DAH evaporator 40NB 4.5 Process LP Hdr to LG batch evap 40NB 4.5 Process LP hdr to DMH dryers HDR 40NB 4.5 DMH HDR to I/L 25NB 4.5 Process LP hdr to Near MP Hdr 80NB 4.5 LP line near MP Hdr to Steeping tanks LP line near MP Hdr to 2.5barg PRS I/L 2.5barg PRS O/L to Saccfn. HDR HDR to sacrfn. Tanks I/L 80NB 40NB 40NB 25NB** 20NB** 1.4 4.7 1.6 0.6 0.2 0.1 1.2 40 40 40 40 40 40 40 CS 95 11 CS 14 4 CS 28 8 CS 14 4 CS 183 19 CS 30 6 CS 72 6 97 11 15 3 5 3 75 9 30 30

4.5 1 40 CS 4.5 0.2 40 CS 2.5 0.2 40 CS 2.5 40 CS 2.5 40 CS

MP lines - Header to equipment I/L MP header to Final evaporators 65NB 10.5 1.2 40 CS MP header to Jet Cooker 100NB 10.5 3.1 40 CS MP header to rotary dryers I/L 80NB 10.5 40 CS

98 12 55 6 25 15

LP header(Evaporator) LP header(DMH)

LP headers 300NB 50NB MP headers 250NB 80NB 150NB

4.5 4.5

40 CS 40 CS

7 5

MP header(Dryer section) MP header(Final evap) MP header(Starch dryers)

10.5 10.5 10.5

40 CS 40 CS 40 CS

7 5 5

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