PROJECT REPORT

(JUNE~AUGUST 2011)

ENGINEERS INDIA LIMITED

PROCESS DESIGN OF COOLING WATER SYSTEM

ANUJ KUMAR Roll No.: 0813351401 N.I.E.T(UPTU)

ACKNOWLEDGEMENT

I would like to express my gratefulness to Engineers India Limited (EIL) for providing me with this golden opportunity to be a part of their esteemed organization. I believe that what I gained at EIL I could not have achieved elsewhere and my industrial attachment term here was completely capitalized. I am very grateful to Mr. Satyavir Singh, Sr. Manager, HR Department for giving me this opportunity to do my Project Semester in Engineers India Limited, New-Delhi. I express my sincere thanks to Mr. K.Vardharajan, Manager, Process Design Dept.; and Mr. Alok kumar, Sr. Engineer, Process Design Dept., Engineers India Limited, New Delhi, who had kindly consented to be my mentors throughout the training period. I am grateful to them for their continued encouragement, spontaneous assistance and support provided. Their vast experience and immense knowledge of the field aided my learning route. At last, but not the least, I extend my thanks to all those who directly or indirectly were the source of knowledge and inspiration to me & thus helped me in completing this project within time.

ANUJ KUAMR B.TECH FINAL year Chemical Engineering

0813351401 N.I..E.T , GR NOIDA

PREFACE

This training report is based on the Process Engineering activities/ training done by me at Engineers India Ltd, New Delhi. These included designing of Cooling water system with the help of process pump sizing, line sizing, Vessel sizing, cooling tower sizing. Engineers India Ltd. is presently engaged in the execution of a number of Petrochemical Refinery Projects, both overseas and domestic. In addition, EIL has executed a large number of revamp / modernization projects for most of the Refining companies in India.

CONTENTS

1. INTRODUCTION TO COOLING WATER SYSTEM a) APPLICATIONS b) TYPES OF COOLING WATER SYSTEM c) ADVANTAGES AND DIS ADVANTAGES 2. COOLING TOWER a) TYPES OF COOLING TOWERS b) CALCULATION METHOD OF COOLING TOWER c) COOLING TOWER REQIREMENT FOR COMPLEX 3. COOLING TOWER PUMP
a) CLASSIFICATION OF PUMPS

b) CALCLATION OF PUMP DESIGN

4. SIDE STREAM FILTER

a) CALCULATION OF SIDE STREAM FILTER 5. DOSING SYSTEM a) CONTROL OF pH AND ALKALINITY b) CALCULATION METHOD FOR DOSING SYSTEM 6. COOLING TOWER HEADER DESIGN a) LINE SIZING

b) PRESSURE DROP CALCULATION METHOD

COOLING WATER SYSTEM

INTRODUCTION Cooling towers are heat removal devices used to transfer process waste heat to the atmosphere. Cooling towers may either use the evaporation of water to remove process heat and cool the working fluid to near the wet-bulb air temperature or in the case of closed circuit dry cooling towers rely solely on air to cool the working fluid to near the dry-bulb air temperature. Common applications include cooling the circulating water APPLICATION Process Plants Cooling water is required in refinery, petrochemical, fertilizer & other process plants for cooling & condensing various process streams. Power Plants In power plants for condensing exhaust steam from the steam turbines. Refrigeration Plants In refrigeration plants for condensing refrigerant vapors

TYPES OF COOLING WATER SYSTEMS

ONCE THROUGH CW SYSTEM

Raw water (from river, lake, tube well, sea etc) is pumped directly through heat exchange equipment & return hot water is discharged as effluent from the plant. Such system is used where water is available at very low cost.

RECIRCULATING CW SYSTEM An open recirculating cooling system uses the same water repeatedly to cool process equipment. Heat absorbed from the process must be dissipated to allow reuse of the water. Cooling towers, spray ponds, and evaporative condensers are used for this purpose. Open recirculating cooling systems save a tremendous amount of fresh water compared to the alternative method, once-through cooling. The quantity of water discharged to waste is greatly reduced in the open recirculating method, and chemical treatment is more economical. However, open recirculating cooling systems are inherently subject to more treatmentrelated problems than once-through systems cooling by evaporation increases the dissolved solids concentration in the water, raising corrosion

and deposition tendencies the relatively higher temperatures significantly increase corrosion potential. In the longer retention time and warmer water in an open recirculating system increase the tendency for biological growth .

Airborne gases such as sulfur dioxide, ammonia or hydrogen sulfide can be absorbed from the air, causing higher corrosion rates . microorganisms, nutrients, and potential foulants can also be absorbed into the water across the tower. SUPPLY PRESSURE Supply pressure should be enough to meet pressure requirements of supply / return headers, heat exchange equipment along with supply / return sub headers , static head of cooling tower & mass flow meter. COOLING OF RETURN HOT WATER Return hot water from various process unit is collected in the return header & is then cooled in cooling tower by contact with air for sensible heat transfer & by evaporation. RE CIRCULATION OF WATER CW is pumped back to various heat exchange equipments in different units again. CONCENTRATION OF SOLIDS Due to continuous evaporation of water in the cooling tower, concentration of both dissolved & suspended solids in the water increases. MAKE UP WATER Raw water is added to account for the evaporation & other water losses from the system depending on the return temperature, raw water analysis etc. CHEMICAL TREATMENT

Characteristics of re circulating cooling water are controlled by addition of chemicals, filtration system and by blow down. Re circulating water is maintained in CW headers as non- corrosive and non-scaling at the temperature of operation .

CLOSED CIRCUIT TEMPERED COOLING WATER SYSTEM

TYPICAL SYSTEM Return hot water is cooled in a heat exchanger by a secondary cooling water system. Cooled water flows down to a tank from where it is pumped again.

ADVANTAGES Negligible water loss

Being close system, water loss is negligible, treated water like DM water or soft water can be used. Minimum chemical treatment Problem of scaling & corrosion due to dissolved solids can totally be eliminated. High Supply temperature Supply temp is higher because return hot water is indirectly cooled in a heat exchanger.

DISADVANTAGES Applicable for small capacity systems only Cooling high temperature fluids Possible to cool high temp (45 oC) process fluids without corrosion and scaling problem. Heat exchange Better heat exchange due to controlled quality of re-circulating water

COMPLETE PFD DIAGRAM IN THIS PAGE

COOLING TOWERS
TYPES OF COOLING TOWERS Natural circulation towers These are suitable for large cooling water duties and large cooling water quantities. Positive air movement in calm weather is ensured by providing a tall chimney. Typical towers

By natural flow of air or natural draft is set up by a specially shaped tower (hyperbolic tower). These depend mainly on natural wind movement through the structure for cooling effect. Draft requirement Fairly tall & narrow construction is used to produce draft as well as enough contact time at a small approach. Draft is created due to lower density of warm exit air as compared to cold inlet air.

Mechanical draft towers Use of fan Such systems use fans to have control over air supply .Towers used with packing have low pumping head & designed with 4oC approach (With wet bulb temp 29oC ,cooling tower designed from 45 to 33oC)

Depending upon the position of fan, towers can be forced or induced draft type

Forced draft type

Location of fan Fan is situated at or near the bottom of the tower, can be located outside the tower at an accessible place convenient for inspection, maintenance & repairs.

Performance No vibration problem. Better air-water contacts (because air from fan directly contacts water at high velocity) but hot & humid air leaving the tower at low velocity is sucked back by the fan, hence poor tower performance. Air distribution is not uniform.

Induced draft counter flow type Location of fan Fan situated at the top, creating a vertical movement up the tower across the packing in opposition to water flow. This makes the recirculation of used air impossible due to high outlet velocities.

Uniform air distribution .

Performance Inspection, maintenance or repair of fans is difficult due to their top location.

Maintenance cost of fans are more due to their hot & humid (corrosive) conditions.

Induced draft with cross flow Type of air flow Fans create horizontal air flow as water falls across the air stream. Air intake is across the full height of tower. Air quantity is increased but L/G ratio (ratio of mass flow rates of water to air) is decreased.

Performance Reduced L/G ratio gives better performance. Cross flow towers require more ground area than counter flow but requires less pumping head due to lower height of tower.

Type of packing Choice depends on effectiveness of packing, design conditions & cost of tower.

Packing is usually of wood or synthetic material for contact of air and water. The water is uniformly distributed from the top of the tower on the packing. The cooled water falls directly into the basin on which the cooling tower is located.

COOLING TOWER CALCULATIONS METHOD

CAPACITY OF COOLING TOWER (CT)

The capacity of CT may be taken as 10-15 % higher than the capacity of CW system. Margin is expected to take care of CT de rating with use in future. CT = 1.1 x C (OR 1.15 x C) (Where C is CW system capacity.) Number of cells are normally in multiples of 3500-4000 m3/hr capacity(close to highest capacity available). Basis of COC It is based on individual constituents like chlorides, calcium, TDS etc in make up water. Considerations for design

As alkalinity is normally controlled by acid dosing, the modified concentration of alkalinity and sulfate should be considered. The constituent giving the minimum value of COC is taken for design.

LOSSES IN CW SYSTEM
EVAPORATION LOSS (E) Contact of air and water in the cooling tower results in evaporation of water, thus taking heat from hot water. (This heat transfer depends on the temp which varies during day and night, hence effect of sensible heat transfer is not considered in the calculations.) Entire heat load is assumed to be removed by evaporation.Based on this,

E = Q/ = CT x (TI -TO ) /

Where E: evaporation loss from cooling tower, m3/hr Q: heat load to be removed per hour from the return cooling water, M.kcal/hr - latent heat, kcal/T (based on average of CW inlet & outlet temp) TI= inlet temp of water to cooling tower, OC TO= outlet temp of water to CT, OC Due to evaporation,water vapor is lost from the system, thus resulting in concentration of the recirculating water

DRIFT LOSS (D)

During the air/water contact in the CT, some quantity of water is entrained in to the exit air in the form of mist & minute droplets , which is finally lost from the system. This is known as drift loss. Typical loss is 0.10.2 % of the recirculating rate. D=(0.1 (or 0.2)/100) x RECIRCULATION RATE, M3/Hr

BLOW DOWN LOSS (B )

Some quantity of water is required to be blown down to maintain the concentration of dissolved solids in the circulating water with in acceptable limit. Blow down quantity, B in m3/hr can be calculated by solving following two equations. By water balance, M = E + D + B +X ----------------------(1)

By dissolved solid balance, M. x = (D + B + X).y ----------------------(2) Which gives,

B = (E / (CC-1) )- (D+X) Where M is total make up requirement, M3/HR X is other loss,if any, e.g. Water drained from equipment in the plant, M3/HR X is the concentration of dissolved solids in make up water, PPM y is concentration of dissolved solids in recirculating water, PPM

PROJECT : To Design Cooling Water System for Gas Processing Complex Cooling water requirement for the Complex: Cooling Water Requirement
Continuous Demand M3/HR Intermittent demand, m3/hr Duratio n Rat e 65 Typ e Total M3/HR

UNIT

GSU (Gas sweetening unit) GDU(Gas dehydration unit) DPDU(Dew point Depresssion unit) SRU(Sulphur recovery unit) CSU(condensate stabilization unit) BCW (Bearing cooling water) Total normal requirement

1060

1125 14

14

628

628

466

466

219

219

30

30

2488

65

2553

UNIT

Continuous Demand M3/HR

Intermittent demand, m3/hr Duratio n Rat e Typ e

Total M3/HR 320 3600

HVAC requirement CPP

320 3600 120 -

Utilities & Offsite Total requirement

120

6528

65

6593

Total maximum requirement

7180

65

7245

COC For Circulating Water = 5 CAPACITY OF COOLING TOWER (CT) CT = 1.2 x C C = 6528 (from the above data)

CT = 1.2 x 6528 = 7833 m3/hr Hence, Cooling tower capacity = 8000 m3/hr Cell capacity Number of cells = 4000 m3/hr = 2(operating) + 1(standby)

Heat Load

Heat load means the heat to be removed per hour from the return cooling water in the cooling tower Heat Load = mCp T m = mass flow rate Cp = specific heat of water T= change in temperature Heat Load = 8000 * 4.18 * 10 = 92.88 kJ LOSSES IN CW SYSTEM EVAPORATION LOSS (E) E = Q/ = CT x (TI -TO ) / Q = 4400 m3/hr CT = 7833 m3/hr TI = 43 0C TO = 33 0C = 575 Kcal/kg@390c E = 7833(43-33)/575 = 136.2 m3/hr BLOW DOWN LOSS BC = = = E/(CC - 1) 136.2/(5-1) 34 m3/hr

DRIFT LOSS (D) D = 7833 * .001

7.8 M3/Hr

MEASURED BLOWDOWN B = (E / (CC-1) )- (D+X) = 34 7.8 = 26.1 M3/Hr COOLING TOWER MAKE UP M = E + BC

= 136.2 + 34 = 170.2 M3/Hr

COOLING TOWER PUMP

INTRODUCTION OF PUMPS 1 PUMPS A pump is an apparatus or machine for raising, driving, exhausting, or compressing fluids or gases by means of a piston, plunger, or set of rotating vanes. Pumps fall into two major groups: positive displacement pumps and centrifugal pumps.

Classification of Pumps

Centrifugal Pump

Positive Displacement

Reciprocat ing

Rotar y

POSITIVE DISPLACMENT PUMP A positive displacement pump causes a fluid to move by trapping a fixed amount of it then forcing (displacing) that trapped volume into the discharge pipe. Positive displacement pumps deliver a definite quantity of fluid for each

stroke or revolution of the device. These pumps do not permit free flow of fluid through the pump except for leakage past the close fitting parts. In this class of pumps the volume of the liquid delivered is directly related to the displacement of piston and increases directly with speed. It is not much influenced by pressure. These pumps give a high discharge pressure and a constant discharge rate.

Characteristics of Positive Displacement Pump Positive Displacement Pumps, unlike a Centrifugal or Roto-dynamic Pumps, will produce the same flow at a given speed (RPM) no matter the discharge pressure. Positive Displacement Pumps are "constant flow machines" The dashed line shows actual positive displacement pump performance. This line reflects the fact that as the discharge pressure of the pump increases, some amount of liquid will leak from the discharge of the pump back to the pump suction, reducing the effective flow rate of the pump. The rate at which liquid leaks from the pump discharge to its suction is called slippage. No shutoff head exists in this type of pump, so care must be taken to ensure that the relief or safety valve is operational. The proper use of this valve ensures that the appropriate pressure balance is maintained within the pumping system. If the discharge cavity is closed, but the pump is operating, the line or pipe that the liquid is moving through may burst. This would be caused by the increasing amount of liquid being pushed toward the discharge cavity. If the line bursts, all the liquid that was attempting to move into the discharge cavity would pour out the pump, creating a large mess

1.2 CENTRIFUGAL PUMP

A centrifugal pump works by the conversion of the rotational kinetic energy, typically from an electric motor or turbine, to an increased static fluid pressure. This action is described by Bernoulli's principle. The rotation of the pump impeller imparts kinetic energy to the fluid as it is drawn in from the impeller eye (centre) and is forced outward through the impeller vanes to the periphery. As the fluid exits the impeller, the fluid kinetic energy (velocity) is then converted to (static) pressure due to the change in area the fluid experiences in the volute section. Typically the volute shape of the pump casing (increasing in volume), or the diffuser vanes (which serve to slow the fluid, converting to kinetic energy in to

flow work) are responsible for the energy conversion. The energy conversion results in an increased pressure on the downstream side of the pump, causing flow

CENTRIFUGAL PUMP CURVES

PLUNGER PUMP plunger pump is a type of positive displacement pump where the highpressure seal is stationary and a smooth cylindrical plunger slides though the seal. This makes them different from piston pumps and allows them to be used at high pressures. Piston pumps and plunger pumps are reciprocating pumps that use a plunger or piston to move media through a cylindrical chamber. The plunger or piston is actuated by a steam powered, pneumatic, hydraulic, or electric drive. Piston pumps and plunger pumps are also called well service pumps, high pressure pumps, or high viscosity pumps. Piston pumps and plunger pumps use a cylindrical mechanism to create a reciprocating motion along an axis, which then builds pressure in a cylinder or working barrel to force gas or fluid through the pump. The pressure in the chamber actuates the valves at both the suction and discharge points. Plunger pumps are used in applications that could range from 70 to 2070 bars. Piston pumps are used in lower pressure applications. The volume of the fluid discharged is equal to the area of the plunger or piston, multiplied by its stroke length. The overall capacity of the piston pumps and plunger pumps can be calculated with the area of the piston or plunger,the stroke

length, the number of pistons or plungers and the speed of the drive. The power needed from the drive is proportional to the capacity of the pump.

Developing a Pump Performance Curve A pump's performance is shown in its characteristics performance curve where its capacity i.e. flow rate is plotted against its developed head. The pump performance curve also shows its efficiency (BEP), required input power (in BHP), NPSHr, speed (in RPM), and other information such as pump size and type, impeller size, etc.
This curve is plotted for a constant speed (rpm) and a given impeller diameter (or series of diameters). It is generated by tests performed by the pump manufacturer. Normal Operating Range: A typical performance curve is a plot of Total Head vs. Flow rate for a specific impeller diameter. The plot starts at zero flow. The head at this point corresponds to the shut-off head point of the pump. The curve then decreases to a point where the flow is maximum and the head minimum. This point is sometimes called the run-out point. The pump curve is relatively flat and the head decreases gradually as the flow increases. This pattern is common for radial flow pumps. Beyond the run-out point, the pump cannot operate. The pump's range of operation is from the shut-off head point to the run-out point. Trying to run a pump off the right end of the curve will result in pump cavitation and eventually destroy the pump.

1.3 CAVITATION Cavitation is the collapse of bubbles that are formed in the eye of the impeller due to low pressure. The implosion of the bubbles on the inside of the vanes creates pitting and erosion that damages the impeller. The design of the pump, the pressure and temperature of the liquid that enters the pump suction determines whether the fluids will cavitate or not

Avoiding Cavitation Cavitations can in general be avoided by increasing the difference between the actual local static pressure in the fluid - and the vapor pressure of the fluid at the actual temperature

This can be done by:

increasing the total or local static pressure in the system reducing the temperature of the fluid

1.4 NPSH NPSH (Net Positive Suction Head) shows the difference, in any crosssection of a generic hydraulic circuit, between the pressure and the liquid vapor pressure in that section. NPSH is an important parameter, to be taken into account when designing a circuit : whenever the liquid stagnation pressure drops below the vapor pressure, liquid boiling occurs, and the final effect will be cavitation: vapor bubbles may reduce or stop the liquid flow. Centrifugal pumps are particularly vulnerable, whereas positive displacement pumps are less affected by cavitation, as they are better able to pump two-phase flow (the mixture of gas and liquid), The violent collapse of the cavitation bubble creates a shock wave that can literally carve material from internal pump components (usually the leading edge of the impeller) and creates noise that is most often described as "pumping gravel". Additionally, the inevitable increase in vibration can cause other mechanical faults in the pump and associated equipment. Considering the circuit shown in the picture,

where hL is the head loss between 0 and 1, p0 is the pressure at the water surface, pv is the vapor pressure (saturation pressure) for the fluid at the temperature T1 at 1, z is the difference in height z1 z0 (shown as H on the diagram) from the water surface to the location 1, and is the fluid density, assumed constant, and g is gravitational acceleration.

NPSH is of two types: NPSHa: It can essentially be defined as the total head available at the suction flange of pump. It includes the static suction head, losses in the line and the vapor pressure head of the fluid being pumped and is a function of the system. NPSHr: It can be defined as the minimum head required to overcome the frictional losses in the pump from the suction flange to the pump impeller eye, including the vapor pressure head. It is basically the minimum value of head at suction flange at which the cavitation occurs. It is specified by the pump vendor and hence is a property of only the pump and not the system.

1.8 PUMP DESIGN

Suction Pressure:

Suction pressure = (Source pressure) + (Static head) ( P in pump suction). Where, Source pressure =Operating pressure of the source vessel/ column/ tank. Static Head = Static pressure difference due to the liquid head between pump centre line and Source vessel/ column BTL. P in pump suction = ( P suction line) + (P suction strainer) + (P in heat exchangers, control valves, other instruments if any in suction) Where, P in suction line = line friction losses in the suction line.

Discharge Pressure: Discharge pressure = ( Destination pressure) + (static head) + (P in pump discharge Circuit) + (contingency)

Where, Static Head = Static pressure difference due to the liquid head between pump centre line and Destination vessel/ column BTL.

P in pump discharge = (P Discharge line) + (P in heat exchangers, control valves, other instruments if any in suction) P discharge line Contingency unforeseen = = line friction losses in the discharge line. 1.0 kg/cm2. This is kept to take care of any

additional requirement of P in the discharge circuit.

Differential Pressure: Differential pressure = Discharge pressure- Suction pressure. Differential Head: Differential head (in metres) = [ (Diff. Pressure in kg/cm2) / (density in kg/m3)/*104

NPSH NPSHa = { [(Suction pressure Vapour pressure) in kg/cm2] /[Density in kg/m3]}*104 DESIGN PRESSURE Design pressure differential pressure. Where, Maximum suction pressure Where, Maximum source pressure = Design pressure of source vessel Maximum differential pressure = 1.25 * Differential pressure. COOLING TOWER PUMP CALCULATION PUMP TYPE : CENTRIFUGAL (As per the requirement of the sytem) = Max source pressure + static head = Maximum suction pressure + Maximum

RATED CAPACITY ESTIMATION Capacity of each pump Operating 1stand by) = 4000 m3/hr (2 DISCHARGE

SUCTION PRESSURE, NPSHA ESTIMATION & PRESSURE OF PUMP 1 & 2 Calculation of suction pressure source Pressure static head meter Pump centre line from grade Suction pipe pressure drop Pump suction pressure: =1.013-0.107 =0.906 :

1.013 kg/cm2 a : 3000 mm or 3.000

: 1.0 meter : 0.107 kg/cm2

Maximum Pump Suction Pressure = Source Pressure + Static Head = 1.013 + 0.3 = 1.313 kg/cm2a NPSHA calculation Operating Pressure Vapour Pressure : Suction pipe pressure drop So, NPSHA = Suction pressure - vapour pressure = 0.906 - 0.09 =0.816 kg/cm2 a = 8.16 metere Calculation of Discharge pressure Destination Pressure = 4.5 kg/cm2g : 0.09 : 0.107 kg/cm2 a 1.0 meter 1.013kg/cm2 a

Pump centre line from grade :

Pressure drop in discharge line = 0.23 kg/cm2 Pressure drop in Flow elements Contingency velocity head So total discharge pressure is = destination pressure + losses+ static head +Contingency + velocity head = 4.5 + 0 .05 + 0.23 + 0. 5 + 1 +0 .0097 = 7.28 kg/cm2a Calculation of Differential head Pump discharge pressure = Pump suction pressure Differential pressure a Differential head = = 6.374*10 63.7metre = = 6.28 kg/cm2 a 0.906 kg/cm2 a 7.28 .906 = 6.374 kg/cm2 = = = 0.05 kg/cm2 1 kg/cm2 .0097 kg/cm2g

Calculation of Maximum Differential pressure = 1.20 * differential pressure = 1.20 * 6.374 = design pressure of pump = Maximum suction pressure + Maximum differential pressure - 1 = = 1.313 + 7.6488 1 7.9618 kg/cm2 a 7.6488 kg/cm2 a

Calculation of Hydraulic power Hydraulic Power, hp flow (m3/hr) = 0.0365 x Diff. pressure (in kg/cm2) x max.

= 0.0365 x 6.374 x 4000 = 930.6hP

CONCLUSION Maximum rated Flow Differential head NPSHA Hydraulic power Number of pumps = 4000 m3/hr = 64meters = 8.16 meter = 930.6 hp = two (One working+ One standby)

SIDE STREAM FILTER

Purpose:Used to keep the concentration of suspended matter in the re circulating water with in permissible limit. Methodology:A part of the re circulating water about 0.5 2 % (depending on climatic conditions of site , dust storm & suspended solids in make up water) is continuously passed through pressure sand filter. Filtered water practically free from suspended matter is returned to the CW sump.

CALCULATION FOR SIDE STREAM FILTER

SMMS has recommended 1% of circulation rate for side stream filter side stream filtration rate = 0.01* Ct m3/hr = 0 .01 * 8000 m3/hr = 80 m3/hr number of side stream filter considered = 2 capacity of each side stream filter = 40 m3/hr

ACID DOSING AND pH CONTROL

Control of pH & alkalinity Acid (H2SO4) is dosed to reduce the alkalinity of make up water It is required when cycle of concentration of re- circulating water depends on adjustment of alkalinity to fix COC. It is also used to reduce pH of recirculating water Main & day tank: Main storage Acid through road tanker is unloaded in to a storage tank with unloading arm cum transfer pumps. Day tank

From storage tank, acid is transferred to an elevated day tank with the same pump.. Day tank is usually horizontal cylindrical type with height not exceeding 1.5 meter to minimize variation in acid flow due to change in the level in the tank. CALCULATION METHOD FOR ACID DOSING TREATMENT CHEMICALS REQUIREMENT SULPHURIC ACID Steps for calculating the acid requirement are as follows: Possible reactions are as below H2SO4+ Ca(OH)2 Ca SO4+2H2O H2SO4+ CaCO3 CaSO4+ CO2 +H20 (2) (3) (1)

H2SO4 +Ca (HCO3)2 CaSO4 +2CO2 + 2H2O

Alkalinity may be due to OH-, HCO3- AND CO3-- groups with alkaline metals like Ca, Mg and Na. All three anions groups can not be present at a time in water. Alkalinity is reported in terms of CaCO3, reaction is presented by equation (2). The acid required to remove alkalinity from cooling water may be calculated as follows: A = K x 98 / (1OO x 0.98 ) (OR A=K )

where A= CONCENTRATION OF SULPHURIC ACID REQUIRED (98 %) K= TOTAL ALKALANITY REMOVED, KG/HR K=[W- Z/Cc ] x M x 10-3 WHERE M=MAKE UP WATER ,M3/HR W=ALKALANITY IN MAKE UP WATER, PPM

Z =ALKALANITY IN CIRCULATING WATER, PPM Raw water and Treated Water data for the Complex: Raw/ Treated Water Quality r. 1. 2. Parameter PH Turbidity NTU Unit Raw Water Treated Water Specification Specification 8 <40 (500 during monsoon) <40 (500 during monsoon) 200 - 250 130-160 60-75 154-190 15-20 8-15 <20 <5 15 <1.5 8-10 7.5 - 7.8 <1

3.

Suspended Solids

ppm

< 0.5

4. 5. 6. 7. 8. 9. 10. 11 12 13. 14.

Total Dissolved Solids (TDS) MO Alkalinity as CaCO3 Calcium Hardness as CaCO3 Total Hardness as CaCO3 Chlorides as Cl Sulphates as SO4 Total Silica as SiO2 Colloidal Silica as SiO2 Reactive Silica as SiO2 Total Iron as Fe Organic Matter as KMn O4

ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm

200-250 95-120 60-75 154-190 20 - 25 35 - 45 <20 <5 15 < 0.1 <5

Recirculating Cooling Water Quality

Sr. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Parameter PH Turbidity TDS

Unit

Specificatio Specificatio n (Normal) n (Max) 7.5 - 8.0 8.0 30 800

NTU ppm

10 - 15 400 - 650

MO alkalinity as CaCO3 ** ppm Ca hardness as CaCO3 Total hardness as CaCO3 Chlorides as Cl Sulphates as SO4 Silica as SiO2 Organophosphate as PO4 Zinc Sulphate as Zn Polymeric dispersant Free residual oxidising bioside Polyphosphate as PO4 Azole (BZT) KmnO4 consumption at 100 oC Oil Total iron as Fe ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm 260 - 340 360 - 500 55 - 65 200-250 35 - 40 8 - 10 1-2 20 - 30 0.2 - 0.5 4-6 0.2-0.5 30 - 40 40 10 1.0 3 10 0.6 450 650 75 300 50

COOLING WATER TREATMENT SULPHURIC ACID DOSING Alkalinity present in make-up water W = 120 ppm as CaCO3

Allowable alkalinity in circulating water Z = nil therefore alkalinity to be removed = W Z/CC = 120 - 0 = 120 ppm Amount = (W Z/CC ) * M *.001 kg/h = 120 * 166 * .001 kg/h = 19.92 kg/h = 478.08 kg/day

= 487 .83 kg/day (98% H2SO4 ) Volume of acid required per day = 487 .83/1870 m3 = 0 .2608 m3

H2SO4 Dosing vessel Acid dosing has been designed for 7 days to reduce frequency of operation of H2SO4 pump Dosing vessel volume required = 0.2608 * 7 m3 = 1.825 considering 80% max fill m3

= 2.28 m3

lets assume the diameter of vessel = 1100 mm and L/D = 2.5 Vt = 2.99 H1 = 150 m3 (from graph) m3

H1 /D = 150/1100 = .136 V1/Vt = .65 (from graph) V1 = .65 * 2.99 = .194 m3 H2 = 200 mm H2 /D = 200/1100 = .1818 V2/Vt = .125 (from graph) V2 = .125 * 2.99 = .373 m3 hold up volume = vt - v1 - v2 = 2.99 - .194 - .373 = 2.42 >2.28

since the size of drum is less than the assume dia hence dia = 1100 mm length = 2750 mm

H2SO4 STORAGE TANK Acid storage tank has been designed for storing 1 tanker of 12 tonnes acid = 12 tonnes = 12*1000 kg

= 12000/1870 m3 = 6.417 m3

considering 80% fill tank volume required = 8.02 m3 assume l/d = 1 volume = 8.02 m3 D = 2170 mm = 2200 mm Height of the vessel = 2200 mm Height of liquid level in the tank = 1800 mm

PUMP sytem)

TYPE : CENTRIFUGAL (As per the requirement of the

RATED CAPACITY ESTIMATION Capacity of pump 1stand by) = 5 m3/hr ( 1 Operating , DISCHARGE

SUCTION PRESSURE, NPSHA ESTIMATION & PRESSURE OF TRANSFER PUMP Calculation of suction pressure source Pressure Pump centre line from grade Suction pipe pressure drop Pump suction pressure: =1.013-0.07 :

1.013 kg/cm2 a : 1.0 meter : 0.07kg/cm2

=0.943 Maximum Pump Suction Pressure = Source Pressure + Static Head = 1.013 kg/cm2a = 1.313 kg/cm2a NPSHA calculation Operating Pressure Vapour Pressure : Suction pipe pressure drop So, NPSHA = Suction pressure - vapour pressure = 0.943 - 0.09 =0.853kg/cm2 a = 4.56 metre Calculation of Discharge pressure Destination Pressure = 2.5 kg/cm2a Pressure drop in discharge line = 0.35kg/cm2 static head = 1.5 m Contingency = 1 kg/cm2 : 0.09 : 0.07 kg/cm2 a 1.0 meter 1.013kg/cm2 a

Pump centre line from grade :

So total discharge pressure is = destination pressure + losses+ static head +Contingency + velocity head = 2.5+0.35+1 +0.2805 = 4.13kg/cm2a Calculation of Differential head Pump discharge pressure = Pump suction pressure Differential pressure = = 4.13 kg/cm2 a .943kg/cm2 a 4.13 .943 =3.19 kg/cm2 a Differential head = 3.19*1870/10000

0.596 metre

Calculation of Maximum Differential pressure = 1.20 * differential pressure = 1.20 * 3.19 kg/cm2 a = design pressure of pump = Maximum suction pressure + Maximum differential pressure - 1 = = 1.013 + 3.82 1 3.833 kg/cm2 a 3.82 kg/cm2 a

Calculation of Hydraulic power Hydraulic Power, hp flow (m3/hr) = 0.0365 x Diff. pressure (in kg/cm2) x max.

= 0.0365 x 3.19x 5 = .582 hP

CONCLUSION Maximum rated Flow Differential head NPSHA Hydraulic power Number of pumps = 5m3/hr = .596meters = 4.56meter = 0.582hp = two (One working+ One standby)

PUMP sytem)

TYPE : PLUNGER (As per the requirement of the

RATED CAPACITY ESTIMATION Capacity of pump 1stand by) = 0.01m3/hr ( 1 Operating , DISCHARGE

SUCTION PRESSURE, NPSHA ESTIMATION & PRESSURE OF TRANSFER PUMP Calculation of suction pressure source Pressure Pump centre line from grade Pump suction pressure: =1.013 kg/cm2 a Maximum Pump Suction Pressure = Source Pressure + Static Head = 1.013kg/cm2a NPSHA calculation Operating Pressure Vapour Pressure So, NPSHA : : 0.09 1.0 meter :

1.013 kg/cm2 a : 1.0 meter

1.013kg/cm2 a

Pump centre line from grade :

= Suction pressure - vapour pressure = 1.013 - 0.09 =1.013-0.09 kg/cm2 a = 0.923 kg/cm2 a

=4.935 metre Calculation of Discharge pressure Destination Pressure = 2.5 kg/cm2a Pressure drop in discharge line = 0.1kg/cm2 static head = 2 m Contingency So total discharge pressure is = 1 kg/cm2

= destination pressure + losses+ static head +Contingency + velocity head = 2.5+0.1+1 +0.3740 = 3.974 kg/cm2a Calculation of Differential head Pump discharge pressure =3.974kg/cm2 a Pump suction pressure Differential pressure =1.013kg/cm2 a =3.974 1.013 =2.96 kg/cm2 a Differential head = = 32.96*1870/10000 0.5540 metre

Calculation of Maximum Differential pressure = 1.20 * differential pressure = 1.20 * 2.96 kg/cm2 a = design pressure of pump = Maximum suction pressure + Maximum differential pressure - 1 = = 1.013 +3.52 1 3.56 kg/cm2 a 3.52 kg/cm2 a

Calculation of Hydraulic power Hydraulic Power, hp flow (m3/hr) = 0.0365 x Diff. pressure (in kg/cm2) x max.

= 0.0365 x 3.56x 0.01 = 0..0013 hP

CONCLUSION Maximum rated Flow Differential head NPSHA Hydraulic power Number of pumps = 0.01m3/hr = 0.5540meters =4.935meters = 0.0013hp = two (One working+ One standby)

COOLING TOWER HEADER

LINE SIZING The term Line sizing literally refers to Calculation of pipe diameter for a given flow of a particular fluid through a pipe under specific operating temperature & pressure.

Pipe sizing is one of the most important jobs of a process engineer. Piping is a major cost component in any process plant. It may vary between 5 to 15% of the total plant investment and optimum design may result in considerable cost reduction. Therefore, it becomes necessary that extreme care should be taken while sizing process piping. Economic Consideration Economics play a major role in pipe sizing especially when a pump or compressor is required to impart the energy for flow to take place. As pipe size increases, investment for piping increases but pipe line has less pressure drop resulting in less pumping cost. An economic balance for two counteracting effects is required to be made. Recommended economic velocity and pressure drop for various conditions are given in Table below. Generally these values should be used to get an economic pipe size. However, in case of long lines, special materials of construction etc., it may become necessary to do economic evaluation for individual cases. Velocity and Pressure Drop Considerations These considerations become important when fluid flow under gravity, under its own pressure or certain pressure has to be dropped in flow system. A simple example could be a pump discharge line branching to a high pressure as well as low pressure destinations. The branch line to low pressure destination has to absorb the pump discharge pressure rated on the basis of pressure required for high pressure destinations. Sometimes it may not be possible to absorb entire pressure in pipe line because of excessive velocity and additional restrictions to flow may be necessary. In such cases the size of the line is not governed by economic considerations. Structural & Mechanical Requirements Mechanical strength of pipe reduces as diameter decreases. Small size pipes have greater tendency to sag when they are erected and additional supports / guides become necessary to keep them in position. It is, therefore, recommended to use 1.5 as minimum pipe size on pipe rack and sleepers. Only in exceptional cases (like very costly material of construction, etc.) lower sizes should be considered. However, short lines, which do not run on racks like piping vents, drains, miscellaneous connections for process pumps, sample connections etc can be of smaller pipe diameter.

Unusual Flow Situations

Unusual flow situations which can occur in process piping should be avoided as far as possible by properly selecting the pipe size. Some of these unusual situations are described below: (a) Vortexing Liquid drawn from a vessel can entrap vapours (or lighter liquid if two liquid phases exist) by a vortex if velocity in the pipe line is more than certain limit. Vortexing is undesirable because it not only affects the performance of components like pumps and control valves, but may damage them also. Liquid outlet lines from vessels should be sized for less than vortexing velocity. (b) Vibrations: There is little known at present about the effects of flow conditions on vibration, because factors other than flow conditions (like piping supports) are also important. But it is evident that higher velocity will favor vibrations. The most common instances of vibration in piping are following: Lines with very high velocity Transfer lines from heaters to columns Two phase flow lines having many changes in flow direction Lines downstream of control valves in flashing service or having high pressure drop A bend very close to pump discharge line, Pulsating / fluctuating flow lines, etc The occurrences are completely unpredictable. Normally it can be known only after start up and rectified by mechanical or structural reinforcement. ( c ) Water Hammer Shock due to water hammer generally prevails in lines equipped with check valves, quick closing valves (plug, butterfly, ball valves) or in lines connected to reciprocating pumps. Improper sizing of condensate lines, malfunctioning of steam traps can also cause water hammering. In lines prone to frequent water hammer viz. product loading lines, shock absorbers should be provided. Velocity Limitations In certain situations, minimum and maximum velocity limits are dictated by process conditions rather than economics etc. These situations are described below: (a) Erosion Velocity Velocity in any piping system should be below erosion velocity limit otherwise pipe material will start eroding and will soon lead to a failure. Erosion velocity for single

phase line is too high to occur in practice. For two phase hydrocarbon liquid and vapour lines, erosion velocity is given by V Ero = 122 / (Density in kg/M3)1/2 M/sec for continuous service = 195 / (Density in kg/M3)1/2 M/sec for intermittent service (b) Erosion of Protective Layer Sometimes certain corrosion inhibitors are used in flowing material which form a protective layer on the inner surface of pipes. If velocity exceeds certain limits, the protective layer gets eroded and corrosion inhibitor becomes ineffective. Velocity limitations in such cases come from the manufacturers of corrosion inhibitors. ( c ) Settling of Solid Particles If solid particles are suspended in a liquid phase, they should not be allowed to settle down in the pipe line. To avoid such settling, a minimum velocity of about 0.9 M/S should be maintained in the pipe. Equipment Limitations Sometimes equipment specifications govern line size. For example pump suction lines should be sized to take care of pump NPSH requirements. In some cases where a new pipe is to be provided in existing plant, the available space may dictate pipe size. This consideration becomes very important in expansion / debottlenecking projects. Availability of Pipe Sizes The line sizes shall be limited to available standard sizes of pipes. In general these are 0.25, 0.5, 0.75, 1, 1.5, 2, 3, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 36, 42, 48 inches etc. Basic Data Required 1. State of Fluid Designer should know if fluid is liquid or vapour or mixed phase. It is important because the physical properties are widely different depending on the state of the fluid. Separate charts are to be used for liquid, vapour and two phase flow lines. 2. Flow Rate

The flow rates for line sizing shall correspond to the maximum fluid quantities established by process design conditions. Flow rate shall be expressed in M3/Hr for liquids and in kg/Hr for vapour lines. If line has to handle different flow rates or different materials at different times, line size shall be calculated for all cases independently and then proper size which will suit to all conditions shall be selected. Lower flow rates are not to be ignored without proper analysis. Sometimes they govern design conditions. 3. Fluid Properties The fluid properties namely density and viscosity shall be specified at the following conditions. Generally these shall be average values for the length of the line. In cases where extreme variations occur in these properties over the pipe length, the total length of pipe shall be divided appropriately in small sections and average properties over small sections shall be used for purpose of line sizing. This is specifically required in case of compressible fluids 4. Equivalent Length of Pipeline To calculate total pressure drop in pipeline, its equivalent length is required. Equivalent length consists of two components namely straight length of pipe and equivalent straight length of various pipe fittings and valves. The later component takes care of additional pressure drop due to valves and pipe fittings. Determine the total length of all horizontal and vertical pipe runs Determine the number of valves and fittings in the pipe Determine the means of incorporating the valves and fittings into the Darcy equation To accomplish this most engineers use a table of equivalent lengths this table lists the valves and fittings and an associated length of straight pipe of the same diameter, which will incur the same pressure loss as that valve or fitting The total equivalent length is usually added to the total straight pipe length to give total pipe equivalent length This total equivalent length is substituted for L in Darcy equation to obtain the pressure loss in pipe PRESSURE DROP CALCULATION METHOD

Pressure drop is a term used to describe the decrease in pressure from one point in a pipe or tube to another downstream. This is usually the result of friction of the fluid against the tube. Tube convergence, divergence, turns and other physical properties will affect the pressure drop. High flow rates in small tubes give larger pressure drop. Low flow rates in large tubes give lower pressure drop

DarcyWeisbach equationIn fluid dynamics, the DarcyWeisbach equation is a phenomenological equation, which relates the head loss or pressure loss due to friction along a given length of pipe to the average velocity of the fluid flow.
The DarcyWeisbach equation contains a dimensionless friction factor, known as the Darcy friction factor. This is also called the DarcyWeisbach friction factor or Moody

friction factor. The Darcy friction factor is four times the Fanning friction factor, with which it should not be confused. Head loss form Head loss can be calculated with

Where, hf is the head loss due to friction; L is the length of the pipe; D is the hydraulic diameter of the pipe (for a pipe of circular section, this equals the internal diameter of the pipe); V is the average velocity of the fluid flow, equal to the volumetric flow rate per unit crosssectional wetted area; g is the local acceleration due to gravity & f is a dimensionless coefficient called the Darcy friction factor. It can be found out from a Moody diagram. Pressure loss form

Given that the head loss hf expresses the pressure loss p as the height of a column of fluid,

Where is the density of the fluid, the DarcyWeisbach equation can also be written in terms of pressure loss:

Where the pressure loss due to friction p is a function of:

the ratio of the length to diameter of the pipe, L/D; the density of the fluid, ; the average velocity of the flow, V, as defined above; a (dimensionless) coefficient of laminar, or turbulent flow, f.

The basic chart plots DarcyWeisbach friction factor against Reynolds number for a variety of relative roughnesss and flow regimes. The relative roughness being the ratio of the mean height of roughness of the pipe to the pipe diameter or /d.

COOLING TOWER HEADER CALCULATION suction line of Pump 1 & 2 Q= 4400m3/hr; = .77cst; Density= 1000 kg/m3 Assume line diameter = 40 inch

Flow rate

= 4400 m3/hr

From Moody Chart f= 0.012

V = Q * 4 /(.36 * 3.14 D2) P = (6370x (Flow)2. f. SP Gr )/((dia)5) Where, V = velocity P = Kg/cm2 per kilometre of pipe Q = Flow: M3/h D= Dia: cm Viscosity : Cs f: friction factor P = 6370 * 44002 * .012 * 1 /(101.6^5) = .13 Kg/cm2 V = 4400 * 4 /(.36 * 3.14 101.62) = 1.507 m/s This is not in allowable limits, hence new assumed dia = 42 inch P = .11 Kg/cm2 V = 1.38 m/s

this is in allowable limits hence suction inlet diameter of pipe is 42 inches Discharge line of Pump 1 & 2 Q= 4400m3/hr; = .77cst; Density= 1000 kg/m3

Assume line diameter

= 34 inch

Flow rate

= 4400 m3/hr

From Moody Chart f= 0.012 V = Q * 4 /(.36 * 3.14 D2) P = (6370x (Flow)2. f. SP Gr )/((dia)5) Where, V = velocity P = Kg/cm2 per kilometre of pipe Q = Flow: M3/h D= Dia: cm Viscosity : Cs f: friction factor P = 6370 * 44002 * .012 * 1 /(86.36^5) = .3 Kg/cm2 V = 4400 * 4 /(.36 * 3.14 86.362 ) = 2.08 m/s This is not in allowable limits, hence new assumed dia = 36 inch P = .23 Kg/cm2

V = 1.86m/s this is in allowable limits hence discharge diameter of pipe is 36 inches for the common header of discharge of both pumps Q= 8800m3/hr; = .77cst; Density= 1000 kg/m3 Assume line diameter Flow rate = 48 inch = 8800 m3/hr

From Moody Chart f= 0.012 V = Q * 4 /(.36 * 3.14 D2) P = (6370x (Flow)2. f. SP Gr )/((dia)5) Where, V = velocity P = Kg/cm2 per kilometre of pipe Q = Flow: M3/h D= Dia: cm Viscosity : Cs f: friction factor P = 6370 * 88002 * .012 * 1 /(121.92^5) = 0.219 Kg/cm2 V = 8800 * 4 /(0.36 * 3.14 *121.922 ) = 2.09 m/s This is in allowable limits, hence dia = 48 inches

discharge line of transfer Pump Length of pipe =100 m ; Q= 5m3/hr; = 8.6cst; Density= 1870 kg/m3 Assume line diameter Flow rate From Moody Chart f= 0.04 P = (6370x (Flow)2. f. SP Gr )/((dia)5) = 1 inch = 5 m3/hr

Where, P = Kg/cm2 per kilometre of pipe Flow: M3/h Dia: cm Viscosity : Cs f: friction factor = 6370 * 25 * .04 * 1.87 /(2.54^5) = 112.6 Kg/cm2 This is not in allowable limits, hence new assumed dia = 2 inch P = 3.5 Kg/cm2

so for length of 100 metre P = .35 Kg/cm2 this is in allowable limits hence diameter of pipe is 2 inches suction line of transfer pump length of pipe = 20 m P=0.35*20

P =.07 kg/cm2 therefore diameter is 2 inch discharge line of dosing Pump Length of pipe =50 m Q= .01m3/hr; = 8.6cst; Density= 1870 kg/m3 Assume line diameter Flow rate From Moody Chart f= 0.04 P = (6370x (Flow)2. f. SP Gr )/((dia)5) = 1 inch = .01 m3/hr

Where, P = Kg/cm2 per kilometre of pipe Flow: M3/h Dia: cm Viscosity : Cs f: friction factor = 6370 * 10^-4 * .04 * 1.87 /(2.54^5) = 4.5 * 10^-4 Kg/cm2 so for length of 50 metre P = 2.25 10^-5 Kg/cm2 this is in allowable limits hence diameter of pipe is 1 inch suction line of transfer pump length of pipe = 20 m P =.09 * 10^-4 kg/cm2 therefore diameter is 1 inch

CONCLUSION