Selection of Diameter and thickness: I.

Pipe sizing and Pressure drop Calculations: Pipe Sizing: Before proceeding beyond a preliminary / design of piping system, it is necessary to determine the pipe inside diameter which allow reasonable velocities and friction losses. The maximum allowable velocities of the fluid in pipeline is that which corresponds to the permissible pressure drop from the point of supply to the point of consumption or is that which does not result in excessive pipe line erosion. Trade Practice Steel pipes are designated by their OD or their Nominal ID. Due to manufacturing conditions, OD is constant. Slight deviations from normal wall thickness, modify only the ID also called clear width. Why a pipe is generally not referred to by its ID. Common Engineering practice to use nominal bore NB to indicate the proper size of the individual parts employed in a pipeline (pipes, flanges, fittings and valves). Nominal bore = actual inside diameter. Selection of the diameter (flow rate anticipated pressure head available). Pressure head (provided by booster pumps, compressors, natural head as in the case of gravity main). Pressure head is necessary for transmission to overcome losses in the flow rate due to internal friction in the moving fluid or to rough inside surfaces of pipe. Pressure drop increased through turbulence and separation of flow of bends or in branch connections, fittings, valves and similar parts (reduce the economy of any pipe line.

Velocity profile in Different System: The mean velocities of steam and water in different system shall be as follows: Medium Superheated steam Main steam 140 bar 500 / 530C 180 bar 530 / 550C 250 bar 530 / 550C Hot Reheat 25 bar 530 / 540C 40 bar 530 / 540C 60 bar 530 / 540C Cold Reheat 25 bar 300C 40 bar 340C 60 bar 380C Extraction Steam 10 - 25 bar 0 - 5 bar Saturated Steam High pressure 80 100 bar Medium pressure 12 20 bar Low pressure 4 8 bar Condensate Intake of condense (before the condensate pumps) Intake of feed water tank Pump discharge Discharge of pipe (MC)25-35 bar Discharge of pipe (FW)100-150 bar Discharge of pipe (FW)200-400 bar Mean velocity M/Sec. Nb 150 200 400 Nb 40 50 60 Nb 30 40 50 Nb 25 35 45 Nb 300 500 800 Nb 40 50 60 Nb 35 45 55 Nb 30 40 50 Nb 300 500 800 Nb 30 40 50 Nb 25 35 45 Nb 20 30 40 Nb 150 200 400 Nb 30 40 50 Nb 35 45 55 Wetness

0.5 1.0 1.5 2.5 Nb 100 200 400 2.5 2.5 3.0 3.0 3.5 4.0 3.0 4.0 5.0

= AW = --------- d2 4 354025 x Qv = -------------------w = Area, mm2 = inside diameter, mm = flow rate, Tonnes/hr. = Velocity, m/sec = Volume of medium, Kg/m3

d Where A d Q w

Pressure drop calculation: The pipe sizes calculated based on the above recommended velocities do not relieve the designer to check the adequacy of pipe size from the flow friction consideration. Pressure drop calculations are of prime necessity in determining: a) The selected inside diameter meets the available pressure drop in the case of main steam, cold reheat, hot reheat and auxiliary steam lines and miscellaneous water lines. The discharge pressure of the pump (boiler feed pump and condensate extraction pump).

b)

For finding the frictional pressure drop in pipelines Darcys Formula can be universally used for almost all the fluids. With suitable restrictions for gases and vapours. As long as the pressure drop is around 10% of starting point pressure (which is true in most of the steam lines in thermal power station). Darcys formula for pressure drop can be used since the specific volume change in the line due to pressure loss will have little effect on calculated pressure drop. Calculation to determine the pressure drop in the pipe is made according to formula: a) For straight pipe

flw2 P = ----------------- kg/cm2 20000 g c dv b) For bends, elbows, tees, valves, etc. Kw2 P = ----------------20000 g c v Where, f= K= l= V= gc= d= v= c) Friction factor found from a graph between Reynolds No. and Relative roughness. resistance coefficient for fittings there are established based on experiments and are available in a standard table in various books. length of pipe in meters velocity in m/sec gravitational constant 9.81 m/sec2 inside diameter of pipe in meter specific volume in m3/sec. Water (non-expansive flow) in compressible fluids. l w2 x ---- x ------------ h x di 2g absolute pressure in length of pipe line in ft. inside diameter of pipe in ft. velocity of flow in ft/sec specific gravity in lb/cu.ft (water = 62 lb/cu.ft) lb/ft2

kg/cm2

P= P= l= di= w= =

g= h= = += =
0

acceleration due to gravity (=32.2 ft/sec2) geodesic height in ft for lines other than horizontal friction factor number dimension ascending lines descending lines for horizontal lines.

Pressure decreases in linear perspective with the length of the line, while the velocity remains unchanged. Reynolds Number: * dimension less ratio characterizing the dynamic state of fluid. The inertia forces present in the fluid passing thro the pipe Re = --------------------------------------------------------------------------------forces of viscosity w di Re = -------------xg = w= Re= V= G= = lb sec * independant of Pr dynamic viscosity -----------ft2 * influids with T velocity, ft/sec Vx G 11 x --------- = 11 x -----------104 di 104 di cu.ft/hr. weight of blow in lb/hr. f(Re)

Variation of friction factors with relation di ---K K = roughness of pipe interior natural wall roughness through formation of rust, sediment and similar influences.

Suggested Approximate values for the Roughness Coefficient K Kind of pipe Condition of pipe wall Values of roughness coefficient (K) 0.0008 to 0.002 0.002 to 0.006

Drawn steel pipe

New Pipes New pipe, bitumen coated

Used pipes, with rust spots or moderately 0.006 to 0.02 encrusted Welded steel pipe After some years of service (main value for 0.02 to 0.04 cross counting gas supply lines) Pipes with big nest spots or badly 0.04 to 0.12 encrusted Pipes for water supply lines with big rust 0.06 to 0.14 spots Riveted steel pipe Varying riveting conditions New pipe, bitumen coated New pipe, non-bitumen coated Used pipes, with rust spots Cast Iron pipe Pipes showing incrustations Pipes cleaned after some years of service Laminar Flow: Re 2300 depends only on Re without the effect of the roughness of the pipe wall entering into its value. 0.04 to 0.32 0.004 to 0.006 0.01 to 0.02 0.04 to 0.06 0.06 to 0.12 0.06

Turbulence:

Transition zone between hydraulically smooth and rough behaviour. varies both with Re and di/K.

Turbulence:

Hydraulically rough behaviour.. depends only on di/K and is independent of Re.