Sizing Calculations RW CW HD AD

Project
Owner
Contractor
Consultant
System
System supplier
Document No.
Ref Drwg / Doc. 1
2
CHLORINATOR
Kg/h 65 ppd 3466.666632 Kg/h 120 Rated capacity
Quantity Nos. 2 Operating 2 Common Standby
ppm 3500
m/h 18.57 lpm 309.5238095 lps 5.15873016
EVAPORATOR SIZING
Kg/h 65 ppd 3466.666632
Quantity Nos. 2 Operating 2 Standby
EXPANSION TANK
Area of 25 NB Line m
2
0.00049
Volume of 25 NB Line m
3
0.03675
lit 36.75
Let us say lit 37
Expansion Chamber Size = Minimum 20% of Piping volume.
Therefore lit 7.4
Hence Expansion Chamber Size of 10 litres Capacity is Suitable
CHLORINE CONCENTRATION IN SOLUTION LINE
Kg/h 65 ppd 3466.666632
ppm 3500
m/h 18.57142857 lpm 309.5238095 lps 5.15873016
Ejector Sizing Bulletin Ref. Nozzle Throat
Back Pressure
capability
(Kg/cm)
Inlet
Pressure
(Kg/cm)
Flow (lpm) Flow m/h
Reference Ejector Curve 122.3081.0 1.000 1.500 1 3 590 35.4
Back Pressure capability Kg/cm 1
Kg/cm 3 I.e. 30 m head
Flow through each ejector lpm 590 m/h 35.4
Nos. 2 Standby 2
m/h 70.80
DIFFUSER SIZING (Typ. for each unit)
Location CW Forebay
MOC uPVC PN 10
Size 90 OD
ID 81.4 mm 0.0814 m
Flow through solution line to diffuser 70.8 m/h 0.0196667 m
3
/s
Nos.of diffuser 2 Nos.
Flow through each diffuser 35.4 m/h 0.0098333 m
3
/s 590 lpm
Velocity through diffuser 1.891 m/s
So, considering a flow
through the diffuser perforation 6.5 lpm
Therefore:
No of Perforations in diffuser 90.8 Nos. of Perforation each diffuser
Selected 90 Nos. of Perforation of 6mm diameter size
Perforation dia. 6 mm
Flow each perforation /orifice 0.393 m/h 0.0001093 m/sec
C.S. Area of perforation 2.82857E-05 m
2
(considering diameter = 6mm)
Velocity through Perforation 3.862701261 m/s
Hence the Diffuser Design is Suitable.
P&ID FOR CW CHLORINATION SYSTEM, Dwg. No. 3059-E01-002-00 Rev 0
Technical Specification # SPML-S10IRJ01-DD-ME-009 for CW Chlorination Plant
Flow through each perforation should be 4-7 lpm at 3-4 m/sec as per Capital Controls design standard.
As per Technical Specification Appendix - III, Clause 5.00.000 A) & B) ii following capcity has been confirmed.
Minimum Ejector Water flow required
4 x 100% capacity streams have been provided; hence Chlorinator capacity selected is 65 kg/hr x 4 streams, 2Nos. Working + 2 Nos. Stand by as per specification, sheet SS-M0:6, clause 4.00.00A
According to the technical specifications the capacity of the Chlorinator works out to 65 kg/hr .To achieve a continuous flow of 65 kg/hr of Chlorine Gas; the evaporator capacity should not be less than the capacity of the Chlorinator. Therefore an
evaporator of Capacity of 65 kg/hr is selected.
Two stream operating @ 65 kg/hr for each unit. As per technical specifications, there is no maximum limit on the Chorine concentration in the solution line. However, as the solubility of chlorine in water is 2500 ppm , we limit
the chlorine solution concentration to 2500 ppm maximum.
Combined Flow for the system
Above flow is the minumum flow required for the stated capacity & concentration, but we have to design the system as per ejector sizing
Chlorinator Capacity
Solution Concentration
Quantity of ejectors operating per solution header
Ejector Inlet Pressure required
We have selected 10 litres Capacity standard cylinder having dimensions 139.8 OD x 4.2 mm wall thickness x 845 mm long.
Capacity
Accordingly solution flowrate required
As per our proposed Equipment Layout the length of the 25NB Liquid Chorine works out to maximum 75 meters. Practically, it is much less.
Capital Control India Pvt. Ltd
3059-E01-002-00
1 X 160MW CCPP, RRVUNL, RAMGARH, RAJASTHAN
RAJASTHAN RAJYA VIDYUT UTPADAN NIGAM LIMITED
SPML INFRA LTD.
TRENT CONSULTING ENGINEERS PVT. LTD.
4 X 65 KG/HR (2W+2S) CW CHLORIANTION SYSTEM
Prepared By: Bhavesh
Date: 9th May, 2011
Checked by:
NMK
REV NO. - 00
HEAD LOSS IN DIFFUSER
Refer Capital Control document 123.3005.0 attached.
Head Loss at diffuser orifice h = (Q/ 19.636 Kd2)2
Qt = Total Flow in GPM through diffuser
Q = Flow in GPM through each orifice
d = Diameter of diffuser orifice in inches = 6 mm 0.24 inch
D = Diameter of pipe in which orifice is placed = 81.4 mm
K = 0.75 (Discharge coefficient)
SUMMARY
d (dia of orifice) / D(dia of diffuser) = 0.073710074 Diffuser
This is less than 0.3, so k = 0.75 2 Nos.
uPVC PN 10
Qt = 590 lpm 155.76 gpm 90 OD
No. of Perforation = 90 6 mm
Q = 1.731 gpm 90 Nos.
Head Loss at Diffuser Inlet 0.393 m/h
h = 4.1625 ft 3.9 m/s
h = 1.2687 m CW Forebay
Solution header pipe MOC uPVC IS 4985 Size 125 OD ID 113
Friction
Factor
(C Value)
140
Flow through header pipe m
3
/h 70.8
Velocity through pipe m/s 1.961 This is less than 2.4m/s, hence acceptable.
Length of solution line m 70 Max length taken for design porpose, in practical it will be less.
Now, calculating friction loss in the pipe by using Williams & Hazenss Formula,
J = 6.815 [V/C]
1.852
* (D)
-1.167
Where,
J = Head loss in mtr/mtr length of pipe
V = Velocity = 1.96 m/s
C = Constant for Pipe = 140
D = Inside diameter of pipe = 113.00 mm
Hence, on substituting valves on above formula, we get,
J = 0.0320330 mtr/mtr length of pipe
Head loss in solution pipe = 2.24 m
Considering a 20% margin on
Frictional Loss it works to be 2.691 m
Frictional Loss in solution line m 2.691
m 2
Pressure @ point of dosing m 0
Loss in Valves m 0 Loss (m) 0.03 Quantity 0
Loss in diffuser m 1.268727286
Total Loss m 5.959503309 This is well within the back pressure capability. Hence, O.K.
Ejector downstream pipe MOC uPVC IS 4985 Size 90 OD ID 81.4
Friction
Factor
(C Value)
140
Flow through pipe m
3
/h 35.4
m 12 Max length taken for design porpose, in practical it will be less.
J = 6.815 [V/C]
1.852
* (D)
-1.167
Where,
Loss in Butterfly Valves m 0.008 Loss (m) 0.008 Quantity 1
Loss in Diaphragm Valves m 0 Loss (m) 0.03 Quantity 0
Loss in NRVs m 0.015 Loss (m) 0.015 Quantity 1
Maximum Elevation m 1
Total Loss m 1.654461425
Back Pressure on Ejector m 7.613964734 This is within the permissible back pressure of 10m or 1kg/cm
2
. Hence, O.K.
Booster Pump Discharge Header line MOC MS IS 1239 Size 80 NB ID 78.4
Friction
Factor
(C Value)
100
Flow through pipe m
3
/h 35.4
Velocity through pipe m/s 2.037 Velocity limit range (1.5-2.4m/s).This is less than 2.4m/s, hence acceptable.
J = 6.815 [V/C]
1.852
* (D)
-1.167
Where,
Frictional Loss m 1.296
Loss in Flowmeter m 5
Chlorine Solution Line Calculations, Ejector downstream to solution header (Indoor line)
Perforation in each diffuser
Diffuser perforation size
Size
MOC
Flow through perforation
Velocity through perforation
Location
Length of pipe, from pump discharge header upto ejector
Chlorine Solution Line Calculations (OUTDOOR LINE)
Maximum Elevation of solution line
Length of pipe upto solution header
Motive Water Line Calculations, Pump Discharge header upto Ejector upstream
Total nos. of diffuser
Date: 9th May, 2011
Checked by:
NMK
REV NO. - 00
Total Loss m 8.327 A
Date: 9th May, 2011
Checked by:
NMK
REV NO. - 00
Booster Pump Discharge line MOC MS IS 1239 Size 100 NB ID 102.3
Friction
Factor
(C Value)
100
Flow through pipe m
3
/h 70.80
Velocity through pipe m/s 2.393 Velocity limit range (3m/s). This is less than 3m/s, hence acceptable.
J = 6.815 [V/C]
1.852
* (D)
-1.167
Where,
Total Loss m 1.303 B
Total Discharge
Head (m)
39.6
Booster pump suction line MOC MS IS 1239 Size 125 NB ID 129.5
Friction
Factor
(C Value)
100
Flow through pipe m
3
/h 70.80
Velocity through pipe m/s 1.493 Velocity limit range (1.5m/s). This is less than 1.5m/s, hence acceptable.
Length of pipe from header upto
pump suction
J = 6.815 [V/C]
1.852
* (D)
-1.167
Where,
Total Loss m 0.408457316 C
Booster pump suction Header MOC MS IS 1239 Size 100 NB ID 104.2
Friction
Factor (C
Value)
100
Flow through pipe m
3
/h 70.8
Velocity through pipe m/s 2.306 Velocity limit range (1.5-2.4m/s). This is less than 2.4m/s, hence acceptable.
Length of pipe from tapping point m 10 Max length taken for design porpose, in practical it will be less.
J = 6.815 [V/C]
1.852
* (D)
-1.167
Where,
m 5 Loss (m) 5 Quantity 1
Total Loss m 7.999284921 D
m 8.407742237 C+D
m 0
m -8.4
SUMMARY
Pipe
Location Pipe MOC Flow m
3
/h Selected Size ID (mm) Velocity m/s Velocity Limit Remark
Booster Pump Suction Line MS IS 1239 70.8 100 NB 104.2 2.31 2.4
Booster Pump Suction Header MS IS 1239 70.8 125 NB 129.5 1.49 1.5
Booster Pump Discharge Line MS IS 1239 70.8 100 NB 102.3 2.39 3
Ejector Upstream MS IS 1239 35.4 80 NB 78.4 2.04 2.4
Chlorine Solution Line at ejector outlet uPVC IS 4985 35.4 90 OD 81.4 1.89 2.0
Chlorine Solution Header Line uPVC IS 4985 70.8 125 OD 113 1.96 2.4
Motive Water Line Calculations, motive water header from tapping point upto pump suction line
Motive Water Line Calculations, motive water header
Pressure required @ pump discharge
Motive Water Line Calculations, Pump Discharge line upto Discharge header
Head available @ pump suction
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Loss in Strainers @ 50% choked condition
Total Loss in Motive Water Pipe from tapping point upto
Water Pressure available at tapping point
Ejector Inlet pressure +A + B X 10%Margin
Date: 9th May, 2011
Checked by:
NMK
REV NO. - 00
Project
Owner
Contractor
Consultant
System
System supplier
Document
Document No.
Ref Drwg / Doc. 1
2
CHLORINATOR
Kg/h 1.5 ppd 79.9999992 Kg/h 2 Rated capacity
ppm 2500
m/h 0.60 lpm 10 lps 0.16666667
Kg/h 1.5 ppd 79.9999992
ppm 2500
m/h 0.6 lpm 10 lps 0.16666667
Back Pressure
capability
(Kg/cm)
Inlet
Pressure
(Kg/cm)
Flow (lpm) Flow m/h
Reference Ejector Curve 122.3063.0 12.000 0.000 1.5 4 27 1.62
Back Pressure capability Kg/cm 1.5
Nos. 1 Standby 1
m/h 1.62
Location CW Forebay
MOC uPVC Sch 80
Size 1"
ID 24.3 mm 0.0243 m
Flow through solution line to diffuser 1.62 m/h 0.00045 m
3
/s
3
/s 27 lpm
through the diffuser perforation 6 lpm
Therefore:
Flow through each perforation /orifice 0.32400000 m/h 0.0000900 m/sec
2
D = Diameter of pipe in which orifice is placed = 24.3 mm
SUMMARY
uPVC Sch 80
Qt = 27 lpm 7.128 gpm 1"
Q = 1.426 gpm 5 Nos.
Head Loss at Diffuser Inlet 0.324 m/h
h = 2.8244 ft 3.2 m/s
2 X 1.5 KG/HR (1W+1S) RW CHLORIANTION SYSTEM
SPML INFRA LTD.
As per Technical Specification following capcity has been confirmed.
2 x 100% capacity streams have been provided; hence Chlorinator capacity selected is 1.5 kg/hr x 2 streams, 1No. Working + 1 No. Stand by as per specification.
Two stream operating @ 65 kg/hr for each unit. As per technical specifications, there is no maximum limit on the Chorine concentration in the solution line. However, as the solubility of chlorine in water is 2500 ppm , we
limit the chlorine solution conc
Quantity of ejectors operating per solution header
Sizing Calculation for RW Chlorination system
3059-E01-001-00
P&ID FOR CW CHLORINATION SYSTEM, Dwg. No. 3059-E01-001-00 Rev 0
Technical Specification # SPML-S10IRJ01-DD-ME-009 for RW Chlorination Plant
Accordingly solution flowrate required
Location
MOC
Flow through each perforation should be 4-7 lpm at 3-4 m/sec as per Capital Controls design standard.
Size
Date: 17th May, 2011
Checked by:
NMK
REV NO. - 0
Solution header pipe MOC
uPVC
Schedule 80
Size 1" ID 24.3
Friction
Factor
(C Value)
140
3
/h 1.62
J = 6.815 [V/C]
1.852
* (D)
-1.167
Where,
m 2
Pressure @ point of dosing m 0
Loss in Valves m 0.03 Loss (m) 0.03 Quantity 1
Ejector downstream pipe MOC
uPVC
Schedule 80
Size 1" ID 24.3
Friction
Factor
(C Value)
140
Flow through pipe m
3
/h 1.62
J = 6.815 [V/C]
1.852
* (D)
-1.167
Where,
Loss in Butterfly Valves m 0 Loss (m) 0.008 Quantity 0
Loss in Diaphragm Valves m 0 Loss (m) 0.03 Quantity 0
Loss in NRVs m 0 Loss (m) 0.015 Quantity 0
2
. Hence, O.K.
Booster Pump Discharge Header line MOC
uPVC
Schedule 80
Size 1" ID 24.3
Friction
Factor
(C Value)
140
Flow through pipe m
3
/h 1.62
Velocity through pipe m/s 0.970 Velocity limit range (1.5-2.4m/s).This is less than 2.4m/s, hence acceptable.
J = 6.815 [V/C]
1.852
* (D)
-1.167
Where,
Frictional Loss it works out to be m 0.691
Loss in Flowmeter m 0
Total Loss m 2.722 A
Booster Pump Discharge line MOC
uPVC
Schedule 80
Size 1" ID 24.3
Friction
Factor
(C Value)
140
Motive Water Line Calculations, Pump Discharge header upto Ejector upstream
Motive Water Line Calculations, Pump Discharge line upto Discharge header
Checked by:
NMK
REV NO. - 0
Flow through pipe m
3
/h 1.62
Velocity through pipe m/s 0.970 Velocity limit range (3m/s). This is less than 3m/s, hence acceptable.
J = 6.815 [V/C]
1.852
* (D)
-1.167
Where,
Total Loss m 0.368 B
Total Discharge
Head (m)
43.1
Booster pump suction line MOC
uPVC
Schedule 80
Size 1" ID 24.3
Friction
Factor
(C Value)
140
Flow through pipe m
3
/h 1.62
Velocity through pipe m/s 0.970 Velocity limit range (1.5m/s). This is less than 1.5m/s, hence acceptable.
Length of pipe from header upto
pump suction
J = 6.815 [V/C]
1.852
* (D)
-1.167
Where,
Total Loss m 0.347770403 C
Booster pump suction Header MOC
uPVC
Schedule 80
Size 1" ID 24.3
Friction
Factor (C
Value)
140
Flow through pipe m
3
/h 1.62
Velocity through pipe m/s 0.970 Velocity limit range (1.5-2.4m/s). This is less than 2.4m/s, hence acceptable.
Length of pipe from tapping point m 12 Max length taken for design porpose, in practical it will be less.
J = 6.815 [V/C]
1.852
* (D)
-1.167
Where,
m 5 Loss (m) 5 Quantity 1
Total Loss m 7.714540806 D
m 8.062311209 C+D
m 5
m -3.1
SUMMARY
Pipe
Location Pipe MOC Flow m
3
/h Selected Size ID (mm) Velocity m/s Velocity Limit Remark
Booster Pump Suction Header uPVC Schedule 80 1.62 1" 24.3 0.97 2.4
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Motive Water Line Calculations, motive water header from tapping point upto pump suction line
Pressure required @ pump discharge
Water Pressure available at tapping point
Head available @ pump suction
Motive Water Line Calculations, motive water header
Loss in Strainers @ 50% choked condition
Ejector Inlet pressure +A + B X 10%Margin
Total Loss in Motive Water Pipe from tapping point upto
Checked by:
NMK
REV NO. - 0
Booster Pump Suction line uPVC Schedule 80 1.62 1" 24.3 0.97 1.5
Booster Pump Discharge Line uPVC Schedule 80 1.62 1" 24.3 0.97 3
Booster Pump discharge Header uPVC Schedule 80 1.62 1" 24.3 0.97 2.4
Chlorine Solution Line at ejector outlet uPVC Schedule 80 1.62 1" 24.3 0.97 2.0
Chlorine Solution Header Line uPVC Schedule 80 1.62 1" 24.3 0.97 2.4
Pumps
Ejectors operating per pump Nos. 1
Pump rating m/h @ m head 1.944 m/h @ 46 m Differential head
Hence, pump selected m/h @ m head 2 m/h @ 50 m Differential head 2900 RPM
LPM @ m Head 33.33 LPM 50 m Differential head
Pump Quantity Nos. 1 Operating 1 Standby
SUMMARY
Pump
Service Water Booster pump
Type Centrifugal Horizontal
Quantity 1 Working
1 Standby
Flow 2 m/h
Differential Head 50 m
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Checked by:
NMK
REV NO. - 0
Project
Owner
Contractor
Consultant
System
System supplier
Document
Document No.
Ref Drwg / Doc. 1
2
I. STORAGE TANK SIZING:
A. VOLUME CALCULATION FOR SULPHURIC ACID STORAGE TANK
Quantity 1 No.
Capacity 15 m3
Material of construction:
Construction Type:
Volume of tank V=(/4)x D2 x L
where,
Effective volume required: V = 15 cu.m
D= diameter of cylindrical tank 2.5 m OD
H= height of cylindrical tank 3.5 m
Calculated volume V = 17.187 m3
B. THICKNESS CALCULATION FOR SULPHURIC ACID STORAGE TANKS
MOC: MS as per IS 2062
Design Code: IS:803
Tank Diameter m 2.5
Tank Height m 3.5
1. Shell plate Thickness:
The minimum thickness of shell plates shall not be less than the calculations from the folowing formula
T = (50(H-0.3)*D*G/(SE))
Where,
T= minimum thickness in mm
D= Nominal diameter of the tank 2500 mm 2.5 m
H= Height from the bottom of the course under consideration to the bottom of the overflow which limits tank filling height = 3.15m 3500 mm 3.5 m
G = Specific Gravity of liquid to be stored 1.82
S = Allowable Stress in kg/cm2 for IS:2062 as per clause No. 5 of IS" 803 1680 kg/cm2
E = Joing Efficiency 0.7
Shell Plate Thickness:
T = 0.62 mm
Further, we are considering a corrosion allowance = 2 mm
Therefore total thickness = 2.62 mm
Hence 5 mm thick plate can be used as per Clause No 6.3.3.2 of IS: 803.
Selected thickness T = 5 mm
Summary:
Construction Atmospheric Horizontal cylinder with dished ends
MOC: MS as per IS 2062
Thickness 5 mm
Tank Diameter 2.5 m
Tank height 3.5 m
Free board 0.445 m
II. PIPE SIZING:
1. Sulphuric Acid unloading pump Suction header:
Size ID in mm ID in metres
65 NB 66.3 0.0663
Flow of stream m3/hr 10 0.0028 m3/sec
Velocity in pump suction header m/sec 0.80
2. Unloading Pump suction line:
65 NB 66.3 0.0663
Flow of stream m3/hr 10 m3/sec 0.0028
3059-E01-004-00
Technical Specification # SPML-S10IRJ01-DD-ME-009 for Chemical Dosing Plant
P&ID FOR SULPHURIC ACID DOSING SYSTEM, Dwg. No. 3059-E02-004-00 Rev
Sizing Calculation for Sulhpuric Acid Dosing system
Sulphuric Acid Dosing System
TRENT CONSULTING ENGINEERS
SPML INFRA LTD.
MS as per IS 2062
Atmospheric Horizontal cylinder with dished ends
MOC:
MOC: MS IS:1239
MS IS:1239
3. Unloading Pump Discharge Line
50 NB 50.7 0.0507
4. Unloading Pump Discharge Header:
50 NB 50.7 0.0507
III. ACID UNLOADING PUMP HEAD SIZING:
1. Head loss in acid unloading pump suction header
A. Selected pipe specifications:
65 NB 66.3 0.0663
Flow of stream 10 m3/hr 0.0028 m3/sec
Velocity in pump suction header V = 0.8043 m/sec
Length of pipe from sulphuric acid unloading point upto suction line of unloading pumps 5 metres. --------- I
Equivalent length of 65 NB pipe-fittings:
No of elbows. 3 Nos. 3000# socket weld
Equivalent length = 342 mm = 0.342 metres. --------- II
No. of Tees. 3 Nos. 3000# socket weld
Equivalent length = 342 mm = 0.342 metres. --------- III
(Refer the enclosed table for equivalent length of fittings)
Total Equivalent length = I + II + III = 5.684 metres.
Rounded off length 6 metres.
Constant C = 100
Head loss per meter length = 6.815(V/C)^1.852*(D)^(-1.167)
= 0.02136 mWC
Total head loss in pipeline = 0.12815 mWC --------- 1
B. Head loss through valve of 65 NB
Qty: 1 No.
Flow through valve 10 m3//hr
Loss through valve 0.024 mWC --------- 2
Head loss in acid unloading pump header = 1+2
= 0.15215 mWC
Head loss in Sulphuric acid unloading pump suction header: 0.15215111 mWC --------- A
2. Head loss in acid unloading pump suction line:
65 NB 66.3 0.0663
Length of pipe from pump suction header upto pump suction point 2 metres. --------- I
(Refer the enclosed graph for equivalent length of fittings)
Rounded off length 3 metres.
Constant C = 100
MOC:
MOC: MS IS:1239
MS IS:1239
MS IS:1239
MS IS:1239 MOC
MOC
= 0.02136 mWC
B. Head loss through valve of 65 NB
Qty: 1 No.
C. Head loss through Y-type strainer = 2 mWC --------- 3
Head loss in unloading pump suction line = 1+2+3
= 2.08808 mWC
Head Loss in Sulphuric Acid unloading pump suction line: 2.08808 mWC --------- B
Total Head Loss in Sulphuric Acid Unloading Pump Suction side: A+B
= 2.24023 mWC
3. Head loss in acid unloading pump discharge line:
50 NB 50.7 0.0507
Length of pipe from tank discharge point upto pump discharge header 2 metres. --------- I
selected length 3 metres.
Constant C = 100
Total head loss in pipeline = 6.815(V/C)^1.852*(D)^(-1.167)
= 0.07890 mWC
B. Head Loss through Non Return Valve of 50 NB
Qty: = 1 No.
Flow in stream = 10 m3/hr
Velocity in pump discharge line = 1.4 m/sec
Loss through NRV = 0.275 mWC --------- 2
C. Head loss through ballvalve of 50 NB
Qty: 1 No.
Total Head loss in unloading pump discharge line = 1+2+3
= 0.61170 mWC
Head Loss in Sulphuric Acid unloading pump Discharge line: 0.61170 mWC --------- C
4. Head loss in acid unloading pump discharge header:
50 NB 50.7 0.0507
MS IS:1239
MS IS:1239
MOC
MOC
Constant C = 100
= 0.07889868 mWC
B. Head loss through ballvalve of 50 NB
Qty: 1 No.
Head loss from pump discharge line upto sulphuric acid storage tank inlet point = 1+2
= 0.33669605 mWC
Head Loss in Sulphuric Acid unloading pump Discharge header: 0.33670 mWC --------- D
Total loss in Sulphuric Acid Unloading Pump Discharge side: C + D
= 0.94839211 mWC
SUMMARY:
Pump Head requirement shall be calculated as under:
= 2.2402267 mWC
= 0.9483921 mWC
= 0 mWC
= 3.1886188 mWC
= 4 mWC
= 10 m3/hr.
= 10 mWC
IV. DAY / MEASURING TANK SIZING
A. VOLUME CALCULATION FOR SULPHURIC ACID DAY / MEASURING TANK:
Qty. 2 Nos.
Capacity 2.5 m3
Construction Type:
where,
Effective volume required: V = 2.5 cu.m
Calculated Volume V = 3.041 m3
B. THICKNESS CALCULATION FOR SULPHURIC ACID DAY / MEASURING TANK
MOC: MS as per BS 2594
Design Code: IS:803
Tank Diameter m 1.5
Tank Height m 1.72
T = (50(H-0.3)*D*G/(SE))
Pump Head Selected
3. Pressure available at tank discharge point
2. Head Loss at Unloading Pump Discharge
1. Total Head Loss at Sulphuric Acid Unloading Pump suction
MS as per BS 2594
Vertical cylindrical type with cover
Selected Value
Pump Head requirement
Pump Capacity
Where,
G = Specific Gravity of liquid to be stored 1.82
T = 0.16 mm
Summary:
Construction Vertical cylindrical type with cover
MOC: MS as per BS 2594
Thickness 5 mm
Tank Diameter 1.5 m
Tank height 1.72 m
Free board 0.306 m
V. PIPE SIZING:
1. Sulphuric Acid Transfer Line:
Size ID in mm ID in mtrs.
50 NB 50.7 0.0507
Flow of stream m3/hr 1 0.00028 m3/sec
VI. ACID METERING PUMP HEAD SIZING:
1. Head Loss Metering pump Suction Header:
15 NB 14.6 0.0146
Flow of stream 0.075 m3/hr 0.00002 m3/sec
Velocity in pump suction header 0.124 m/sec
Length of pipe from tank discharge point upto pump suction line 5 metres. --------- I
Constant C = 100
= 0.00394 mWC
B. Head loss through ball valve of 15 NB
Qty: 1 No.
Flow through ball valve 0.075 m3//hr
Loss through ball valve 0.1 mWC --------- 2
refer enclosed graph for ball valve
Head loss in metering pump suction header = 1+2
= 0.12362466 mWC
Head Loss in Sulphuric Acid Metering Pump Suction Header 0.12362466 mWC --------- A
2. Head Loss in Metering Pump Suction Line:
MOC MS IS:1239
MOC MS IS:1239
15 NB 14.6 0.0146
Velocity in pump suction line 0.124390846 m/sec
Constant C = 100
= 0.00393744 mWC
B. Head loss through ball valve of 15 NB
Qty: 1 No.
C. Head loss through Y-type strainer = 2 mWC --------- 3
Head loss in metering pump suction line = 1+2+3
= 2.11181233 mWC
Head Loss in Sulphuric Acid Metering Pump Suction Line 2.11181233 mWC --------- B
Total loss in Sulphuric Acid Metering Pump Suction line: A+B
= 2.23543698 mWC
3. Head Loss in Metering Pump Discharge Line:
15 NB 14.6 0.0146
Constant C = 100
= 0.00393744 mWC
B. Head Loss through Non Return Valve of 15 NB
Qty: = 1 No.
Flow in stream = 0.075 m3/hr
Loss through NRV = 0.125 mWC --------- 2
C. Head loss through ball valve of 15 NB
MOC
MOC
MS IS:1239
MS IS:1239
Qty: 1 No.
Total Head loss in metering pump discharge line = 1+2+3
= 0.5326817 mWC
Head Loss in Sulphuric Acid Metering Pump Discharge Line 0.5326817 mWC --------- C
4. Head loss in dosing pump discharge header:
15 NB 14.6 0.0146
Constant C = 100
= 0.00394 mWC
B. Head loss through ballvalve of 15 NB
Qty: 1 No.
Head loss from pump discharge line upto sulphuric acid storage tank inlet point = 1+2
= 0.03756 mWC
Head Loss in Sulphuric Acid Metering Pump Discharge Header 0.03756 mWC --------- D
Total Head loss in Sulphuric Acid Metering Pump Discharge side: C + D
= 0.57024 mWC
Location CD Forebay
MOC MS
Size 15NB
ID 14.6 mm 0.0146 m
Flow through solution line to diffuser 0.075 m/h 2.0833E-05 m
3
/s 1.25 lpm
Flow through each diffuser 0.075 m/h 2.0833E-05 m
3
/s 1.25 lpm
So, considering a flow 65450140
Therefore:
2
MOC MS IS:1239
SUMMARY:
Pump Head requirement shall be calculated as under:
1. Total Head Loss in Sulphuric Acid Metering Pump suction = 2.23543698 mWC
2. Head Loss in sulphuric Acid Metering Pump Discharge = 0.5702438 mWC
3. Pressure available at tank discharge point = 0 mWC
= 2.80568078 mWC
= 3 mWC
= 75 LPH
= 10 mWC Pump Head Selected
Selected Value
Pump Capacity
Project
Owner
Contractor
Consultant
System
System supplier
Document
Document No.
Ref Drwg / Doc. 1
2
A. VOLUME CALCULATION FOR INHIBITOR TANKS:
Qty. 1 Nos.
Capacity 1 m3
Construction Type:
where,
Effective volume required: V = 1 m3
Calculated Volume V = 1.165 m3
B. THICKNESS CALCULATION FOR INHIBITOR STORAGE TANKS
MOC: MSRL as per IS 2062
Design Code: IS:803
Tank Diameter m 1.1
Tank Height m 1.225
T = (50(H-0.3)*D*G/(SE))
Where,
G = Specific Gravity of liquid to be stored 1.1 Corrosion Inhibitor 1.25 Scale Inhibitor
T = 0.05 mm
Summary:
Construction:
MOC: MSRL as per IS 2062
Thickness: 5 mm
Tank Diameter: 1.1 m
Tank height: 1.225 m
Free board: 0.173 m
Sizing Calculation for Scale Inhibitor/ Corrosion Inhibitor Dosing System
3059-E01-004-00
P&ID FOR SCALE INHIBITOR/CORROSION INHIBITOR SYSTEM, Dwg. No. 3059-E01-004-00
MSRL as per IS 2062
Technical Specification # SPML-S10IRJ01-DD-ME-009 for Chemical Dosing Plant
Scale Inhibitor Dosing System/Corrosion Inhibitor Dosing System
SPML INFRA LTD.
II. METERING PUMP HEAD SIZING:
1. Head Loss In Metering pump Suction Header:
A. Selected pipe specifications: Size ID in mm ID in metres
uPVC
Schedule 80
1/2" 13.86 0.01386
Length of pipe from tank discharge point upto pump suction line 5 metres. --------- I
Equivalent length of 1/2" pipe-fittings:
No of elbows. 3 Nos. Schedule 80
No. of Tees. 3 Nos. Schedule 80
Constant C = 140
= 0.0012838 mWC
B. Head loss through Ball valve of 1/2"
Qty: 1 No.
Head loss in metering pump suction header = 1+2
= 0.01770281 mWC
Head loss in Inhibitor Tank Metering Pump Suction Header: 0.01770281 mWC --------- A
2. Head Loss In Metering Pump Suction Line:
A. Selected pipe specifications: ID in mm ID in metres
uPVC
Schedule 80 1/2" 13.86 0.01386
Velocity in pump suction line 0.0920 m/sec
Constant C = 140
= 0.0012838 mWC
MOC
MOC
B. Head loss through ball valve of 1/2"
Qty: 1 No.
C. Head loss through Y-type strainer 1/2" = 2 mWC --------- 3
Total Head loss in metering pump suction line = 1+2+3
= 2.01385141 mWC
Head loss in Inhibitor Metering Pump Suction Line: 2.01385141 mWC --------- B
Total head loss in Inhibitor Pump Suction line: = A+B
= 2.03155422 mWC
uPVC
Schedule 80 1/2" 13.86 0.01386
Constant C = 140
= 0.0012838 mWC
B. Head Loss through Non Return Valve of: 1/2"
Qty: = 1 No.
Flow in stream = 0.05 m3/hr
Loss through NRV of Metering pump = 0.125 mWC --------- 2
C. Head loss through ball valve of : 1/2"
Qty: 0 No.
Total Head loss in metering pump discharge line = 1+2
= 0.25466404 mWC
Head loss in Inhibitor Metering Pump Discharge Line: 0.25466404 mWC --------- C
MOC
4. Head loss in Metering pump discharge header:
uPVC
Schedule 80 1/2" 13.86 0.01386
Velocity in pump discharge header 0.092018768 m/sec
Constant C = 140
= 0.0012838 mWC
B. Head loss through ball valve of : 1/2"
Qty: 1 No.
Head loss from pump discharge line upto Inhibitor storage tank inlet point = 1+2
= 0.01898662 mWC
Head loss in Inhibitor Metering Pump Discharge Header: 0.01898662 mWC --------- D
Total loss in Metering Pump Discharge side: = C + D
= 0.27365065 mWC
Location CD Forebay
MOC uPVC
Size 1/2"
ID 14.6 mm 0.0146 m
Flow through solution line to diffuser 0.05 m/h 1.3889E-05 m
3
/s 0.833333333 lpm
Flow through each diffuser 0.05 m/h 1.3889E-05 m
3
/s 0.833333333 lpm
Therefore:
2
SUMMARY:
MOC
Pump Head requirement shall be calculated as under: Value Unit
1. Total Head Loss in Inhibitor Metering Pump suction = 2.03155 mWC
2. Total Head Loss in Inhibitor Metering Pump Discharge = 0.27365 mWC
3. Pressure available at tank discharge point = 0 mWC
= 2.3052 mWC
= 3 mWC
= 50 LPH
= 10 mWC Pump Head Selected
Pump Capacity
Selected Value
Project
Owner
Contractor
Consultant
System
System supplier
Document
Document No.
Ref Drwg / Doc. 1
2
Annexure-3 Questionnaire
CAUSTIC TANK SIZING CALCULATION
1 Mol of chlorine (Molecular Weight = 70.91) requires 2 mole of NaOH (Molecular Weight = 40)
Therefore,

Now,
Total height of the tank including the free board is 2050+300 = 2350mm
Height of Conical Portion = 600 mm.
Effective Volume of the tank = 10 m
3
H= 2050 mm
Adding 300 mm free board to the H
The dimensions of the tank are as follows: -
1. Diameter = 2.5 meters
2. Cylindrical portion Height = (operating Height + Free Board) = 2350 mm
10= ( / 4) x 2.5
2
x H (H= Height of the tank without free board)
Total Height = 2400 mm.
Operating Capacity = 5.64 = / 4 *d
2
*h
5.64 = / 4 *d
2
*2.4.
Diameter of the tank = 1.73 meter.
So, we selecting 10Cu.m capacity with free board of 300mm of caustic solution tank
Selecting a tank Diameter of 2.5 meter.
Volume of 20% Caustic Solution = 5641/1200 = 4.7 m
3
.
Adding 20% margin, volume works out to be = 1.2 x 4.7 = 5.64 m
3
1000-Kg chlorine requires,
(As per Tender specification # PCT/K02K2007-08 Vol III: Mechanical works pg no. III:20 s.no.8.2.b, caustic solution storage tank capacity to be 10 cum (min) with free board of 300mm)
(1000x 2x 40) / 70.91 = 1128.19 Kg NaOH of 100% Purity
100% on weight basis of Pure NaOH corresponds to 1128.19 kg.
Height of the tank = Height up to overflow inlet + Height of 300 mm Free Board
Height of the tank = 2100 mm + 300mm.
20 % on weight basis of Pure NaOH corresponds to 5641 kg.
Specific Gravity of 20% NaOH = 1.2
Therefore density of 20% NaOH = 1200 kg/m
3
at 40 deg C.
(Note: We have Considered Max Ambient Temperature as 40 Deg C. At 40 Deg C Specific Gravity of 20% Na OH Solution =1.2
P&ID FOR CW CHLORINATION SYSTEM, Dwg. No. 3059-C02-002-00 Rev 0
Technical Specification # SPML-S10IRJ01-DD-ME-009 for CW Chlorination Plant
1 Mol of chlorine (Molecular Weight = 70.91) requires 2 mole of NaOH (Molecular Weight = 40)
i.e. 70.91 Kg chlorine requires 80 kg of NaOH
2NaOH
aq
+ Cl
2
NaCl
aq
+ H
2
O +NaOCl
aq
Sizing Calculation for CW Chlorination system
3059-E01-004-00
SPML INFRA LTD.
4 X 65 KG/HR (2W+2S) CW CHLORIANTION SYSTEM
Project
Owner
Contractor
Consultant
System
System supplier
Document
Document No.
Ref Drwg / Doc. 1
2
A. VOLUME CALCULATION FOR HYPOCHLORITE DOSING TANK:
Qty. 1 Nos.
Capacity 0.1 m3
Construction Type:
where,
Effective volume required: V = 0.1 m3 0.2 m3
D= diameter of cylindrical tank = 0.5 m OD 0.6 m OD
H= height of cylindrical tank = 0.7 m OD 0.8 m OD
T= Thickness of Tank = = 5 mm mm
Calculated Volume V = 0.137 m3 0.226 m3
Summary:
Construction: Vertical cylindrical type with flat bottom and cover
MOC: PP+FRP
Thickness: 0 mm
Tank Diameter: 0.5 m
Tank height: 0.7 m
Free board: 0.191 m
METERING PUMP HEAD SIZING:
A. Selected pipe specifications: Size ID in mm ID in metres
MOC
uPVC
Schedule 80 1/2" 13.86 0.01386
Velocity in Pump Discharge line 0.0092 m/sec
Length of from pump discharge to dosing point: 50 metres. --------- I
Equivalent length = 0 mm = 0 metres. --------- III
Constant C = 140
Head loss per meter length =
= 1.80509E-05 mWC
Head loss in Inhibitor Tank Metering Pump Delivery line: 0.000921 mWC --------- A
PP+FRP
Sizing Calculation for Sodium Hypochlorite Dosing system
3059-E01-004-00
6.815(V/C)^1.852*(D)^(-1.167)
Vertical cylindrical type with flat bottom and cover
P&ID FOR Sodium Hypochlorite Dosing System, Dwg. No. 3059-E01-004-00
Technical Specification # SPML-S10IRJ01-DD-ME-009 for Sodium Hypochlorite Dosing Plant
Hypo sol. Preparation tank
Sodium Hypochlorite Dosing System
SPML INFRA LTD.
METERING PUMP SELECTION:
% gm/ltr ppm
Sodium Hypochlorite Solution Strength Available 0.5 5 5000
Flow rate in line to be dosed m3/hr 5 83.3333 lpm
Desired Dosage Rate PPM 5
Pressure in Line where Hypo is to be dosed 2
Metering Pump Capacity lt/hr 5.00
Hypo Storage Required Hr 12
Hypo Storage Tank Capacity 66
Hypo Storage Tank Capacity Selected 70
Pump rating lt/h @ m head 5.00 lt/h @ 2
Hence, pump selected lt/h @ m head 5.00 lt/h @ 2 m Differential head
Pump Quantity Nos. 1 Operating 0 Standby
m Differential head
Project
Owner Rev No. 2 Date 25.04.2011
Client Prepared by
Consultant Azam Date 25.04.2011
System Checked by
System supplier JK Date 25.04.2011
Document Approved by
Document No. JK Date 25.04.2011
Ref Drwg / Doc. 1
2
CHLORINATOR
Kg/h 120 Kg/h 120 Rated capacity
ppm 2500
m/h 48 lpm 800 lps 13.3333333
Kg/h 120
EXPANSION TANK
Area of 25 NB Line m
2
0.00049
Volume of 25 NB Line m
3
0.03675
liters 36.75
Let us say liters 37
Therefore liters 7.4
Kg/h 120
ppm 2500
m/h 48 lpm 800 lps 13.33
Back Pressure
capability
(Kg/cm)
Inlet
Pressure
(Kg/cm)
Flow (lpm) Flow m/h
Reference Ejector Curve 122.3087.0 1.125 1.687 1 3 820 49.2
Back Pressure capability Kg/cm 1
Nos. 4 Standby 2
m/h 196.8
Two stream operating @ 120 kg/hr for each unit. As per technical specifications, there is no maximum limit on the Chorine concentration in the solution line.
However, as the solubility of chlorine in water is 5000 ppm , we have however limited the chlorine solution concentration to 2500 ppm at maximum capacity.
We have selected 10 litres Capacity standard cylinder having dimensions 139.8 OD x 4.2 mm wall thickness x 845 mm long.
As per our proposed Equipment Layout the length of the 25NB Liquid Chorine works will not exceed 75 meters.
Expansion Chamber Size = Minimum 20% of Piping volume.
Hence Expansion Chamber Size of 10 litres Capacity is Suitable
The above water flow is more than the minimum ejector water flow required and hence acceptable.
According to the technical specifications the capacity of the Chlorinator works out to 120 kg/hr . To achieve a continuous flow of 120 kg/hr of Chlorine Gas; the evaporator
capacity should not be less than the capacity of the Chlorinator. Therefore an evaporator of Capacity of 120 kg/hr is selected, as specified.
6 x 120Kg/h capacity streams have been provided; 2working for unit-1, 2working for unit-2 and 2Nos. common stand by as per specification,
sheet SS-M0:6, clause 4.00.00A
P&ID FOR CW CHLORINATION SYSTEM, Dwg. No. KAW1-EPC-CHS-DM-D-007 Rev 0
Technical Specification # K9B06-SPC-M-0039 for Chlorination Plant
EVAPORATOR SIZING
6 x 120kg/h CW Chlorination and Absorption system
As per Technical Specification Appendix - III, Clause 5.00.000 A) & B) ii following capcity has been confirmed:
Sizing Calculation for CW Chlorination system
KAW1-EPC-CHS-DM-H-014
1320 MW (Phase-I : 2 X 660 MW) Kawai Thermal Power Project
Adani Power Rajasthan Ltd.
Adani Infra (India) Ltd.
Development Consultants Pvt. Ltd., Kolkata
Capacity
Accordingly solution flowrate required :
Quantity of ejectors operating per solution
header
Location CW Forebay
MOC HDPE as per IS:4984 PN 10 Grade: PE 80
Size 63 OD
ID 50 mm 0.05 m
Flow through solution line to diffuser 196.8 m/h
3
/s 182.222 lpm
through the diffuser perforation 5.55 lpm
Therefore:
2
For Flow through Diffusers header:
As flow progresses the flow rate through diffusers header reduces by each diffuser and hence, the diffuser header size reduced progressively
manintaining the flow by keeping velocity range of 1.6 -1.8 m/s
Tag No.
Velocity
maintained
m/h m/s OD mm ID mm ID m m/s
Flow at DF-1 98.4 0.0273333 200 OD 163.6 0.1636 1.301
Flow at DF-2 87.467 0.0242963 180 OD 147.2 0.1472 1.428
Flow at DF-3 76.533 0.0212593 160 OD 130.8 0.1308 1.583
Flow at DF-4 65.600 0.0182222 160 OD 130.8 0.1308 1.357
Flow at DF-5 54.667 0.0151852 140 OD 114.4 0.1144 1.478
Flow at DF-6 43.733 0.0121481 125 OD 102.2 0.1022 1.482
Flow at DF-7 32.800 0.0091111 110 OD 90 0.09 1.433
Flow at DF-8 21.867 0.0060741 90 OD 73.6 0.0736 1.428
Flow at DF-9 10.933 0.003037 63 OD 51.4 0.0514 1.464
D = Diameter of pipe in which orifice is placed =50 mm
SUMMARY
HDPE as per IS:4984 PN 10
Qt = 182.22222 lpm 48.1066667 gpm 63 OD
Q = 1.503 gpm 32 Nos.
Head Loss at diffuser orifice 0.342 m/h
h = 3.1408 ft 3.36 m/s
Solution header pipe (Header of
two nos. of ejector)
MOC
HDPE IS
4984
Size 200 OD ID 163.6
Friction
Factor
(C Value)
140
3
/h 98.4
J = 6.815 [V/C]
1.852
* (D)
-1.167
Where,
MOC
Size
Flow through each perforation should be 4-7 lpm at 3-4 m/sec-As per Technical specification DCPL-K9B06, pg SS-M0:27, clause 9.00.06.
Location
Flow at DF-1 Pipe size size selected
Pressure rating:
m 2
Pressure @ point of dosing m 0 Since dosing point elevation is below ground level, it is not considered.
Size 200 OD
Formula for calculating Pressure drop or loss ( DP):
DP=(Q/Kv)
2
* SG
DP - Pressure drop in meter
Q - Flow m/h 98.4
kv - Flow Co-efficient 1122 (please refer attached capital controls chart Bulletein no. CCIPL-KV-DV/BFV/NRV-001)
SG- Specific gravity 1.4
Loss in Diaphragm Valves m 0.0215 Loss (m) 0.0108 Quantity 2
Ejector downstream pipe MOC
HDPE IS
4984
Size 160 OD ID 130.8
Friction
Factor
(C Value)
140
Flow through pipe m
3
/h 49.2
J = 6.815 [V/C]
1.852
* (D)
-1.167
Where,
Size 160 OD
DP=(Q/Kv)
2
* SG
Q - Flow m/h 49.2
Loss in Diaphragm Valves m 0.0197 Loss (m) 0.0197 Quantity 1
Size 160 OD
DP=(Q/Kv)
2
* SG
Q - Flow (lpm) m/h 49.2
2
. Hence, O.K.
Pressure drop in NRVs
Pressure drop in Diaphragm Valves
Pressure drop in Diaphragm Valves

Sizing Calculations RW CW HD AD

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