CHEMICAL-DOSING-PLANTS-

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CHEMICAL-DOSING-PLANTS-

© All Rights Reserved

Als XLS, PDF, TXT **herunterladen** oder online auf Scribd lesen

- Effects of Incineration Variables on the Quality of Silica From Rice Husk
- Two Phase Line Sizing
- Calorific Values and Proximate Analysis Of
- Electricity From Rice Husk
- pH Calculation
- Mass Balance With Excel
- Rice Husk Ash
- Capitive Power Plant For Rice Mill
- Rice Hull Gasifier
- Rice-Husk Generation in NIckerie, Suriname
- Feasibility Report on From Rice Husk
- Rice Husk Plant
- Power
- Rice Husk Boiler.doc
- 4. Silica From Rice Husk - Brazil - 040505
- Effect rice husk ash
- abu sekam padi
- Electricity From Rice-Husk
- RICE_HUSK
- Physical and Chemical Properties of Rice Straw Ash and Its Effect

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Owner

Contractor

Consultant

System

System supplier

Document No.

Ref Drwg / Doc.

2 Technical Specification # SPML-S10IRJ01-DD-ME-009 for CW Chlorination Plant

CHLORINATOR

As per Technical Specification Appendix - III, Clause 5.00.000 A) & B) ii following capcity has been confirmed.

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

Chlorinator Capacity

Kg/h

65

ppd

3466.666632

Kg/h

120 Rated capacity

Quantity

Nos.

2 Operating

2 Common Standby

Solution Concentration

ppm

3500

Minimum Ejector Water flow required

m/h

18.57

lpm

309.5238095238 lps

5.15873

EVAPORATOR SIZING

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.

Capacity

Quantity

Kg/h

Nos.

65

ppd

2 Operating

3466.666632

2 Standby

EXPANSION TANK

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 out to maximum 75 meters. Practically, it is much less.

m2

Area of 25 NB Line

0.00049

Volume of 25 NB Line

m3

lit

lit

0.03675

36.75

37

Let us say

Expansion Chamber Size = Minimum 20% of Piping volume.

Therefore

lit

Hence Expansion Chamber Size of 10 litres Capacity is Suitable

7.4

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.

Accordingly solution flowrate required

Chlorinator Capacity

Kg/h

65

ppd

3466.666632

Quantity

Nos.

2 Operating

2 Standby

Solution Concentration

ppm

3500

Minimum Ejector Water flow required

m/h 18.571429

lpm

309.5238095238 lps

5.15873

Above flow is the minumum flow required for the stated capacity & concentration, but we have to design the system as per ejector sizing

Ejector Sizing

Bulletin

Ref.

Nozzle

Throat

Back Pressure

Inlet

capability

Pressure

(Kg/cm)

(Kg/cm)

122.3081.0 1.000

1.500

1

Back Pressure capability

Kg/cm

1

Ejector Inlet Pressure required

Kg/cm

3

I.e.

30 m head

Flow through each ejector

lpm

590

m/h

35.4

Quantity of ejectors operating per solution

Nos.

2 Standby

2

header

Combined Flow for the system

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

0.019667 m3/s

Nos.of diffuser

2

Nos.

Flow through each diffuser

35.4

m/h

0.009833 m3/s

Velocity through diffuser

1.891

m/s

Flow through each perforation should be 4-7 lpm at 3-4 m/sec as per Capital Controls design standard.

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

C.S. Area of perforation

Velocity through Perforation

Hence the Diffuser Design is Suitable.

Date: 9th May, 2011

0.393

m/h

2.8285713E-005 m2

3.8627012605 m/s

Flow

(lpm)

Flow m/h

590

35.4

590 lpm

### m/sec

(considering diameter = 6mm)

Checked by:

NMK

REV NO. - 00

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

D = Diameter of pipe in which orifice is placed = 81.4

K = 0.75 (Discharge coefficient)

mm

mm

This is less than 0.3,

so k =

0.0737100737

0.75

Qt =

No. of Perforation =

Q=

ead Loss at Diffuser Inlet

h=

h=

590

90

1.731

lpm

4.1625

1.2687

ft

m

0.24

155.76

gpm

gpm

inch

SUMMARY

Diffuser

Total nos. of diffuser

MOC

Size

Diffuser perforation size

Perforation in each diffuser

Flow through perforation

Velocity through perforation

Location

2

Nos.

uPVC

PN 10

90 OD

6

mm

90

Nos.

0.393

m/h

3.9

m/s

CW Forebay

Solution header pipe

MOC

Velocity through pipe

Length of solution line

m3/h

m/s

m

uPVC IS

4985

Size

125 OD

ID

113

Friction

Factor

(C

Value)

140

Friction

Factor

(C

Value)

140

70.8

1.961 This is less than 2.4m/s, hence acceptable.

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

Maximum Elevation of solution line

Pressure @ point of dosing

Loss in Valves

Loss in diffuser

Total Loss

Chlorine Solution Line Calculations, Ejector downstream

Ejector downstream pipe

m

2.691

m

2

m

0

m

0 Loss (m)

0.03 Quantity

0

m 1.2687273

m 5.9595033 This is well within the back pressure capability. Hence, O.K.

to solution header (Indoor line)

uPVC IS

4985

MOC

Size

90 OD

ID

81.4

m3/h

35.4

Velocity through pipe

m/s

1.890 This is less than 2.0m/s, hence acceptable.

Length of pipe upto solution header

m

12 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 =

1.89 m/s

C = Constant for Pipe =

140

D = Inside diameter of pipe =

81.40 mm

Hence, on substituting valves on above formula, we get,

J =

0.0438515 mtr/mtr length of pipe

Head loss in solution pipe =

0.53 m

Considering a 20% margin on

Frictional Loss it works to be

0.631 m

Frictional Loss in solution line

Loss in Butterfly Valves

Loss in Diaphragm Valves

Loss in NRVs

Maximum Elevation

Total Loss

Back Pressure on Ejector

m 0.6314614

m

0.008 Loss (m)

0.008 Quantity

1

m

0 Loss (m)

0.03 Quantity

0

m

0.015 Loss (m)

0.015 Quantity

1

m

1

m 1.6544614

m 7.6139647 This is within the permissible back pressure of 10m or 1kg/cm 2. Hence, O.K.

Motive Water Line Calculations, Pump Discharge header upto Ejector upstream

Booster Pump Discharge

Header line

Flow through pipe

Velocity through pipe

Length of pipe, from pump discharge header

upto ejector

MOC MS IS 1239

m /h

m/s

3

Size

80 NB

ID

Friction

Factor

(C

Value)

78.4

100

35.4

2.037 Velocity limit range (1.5-2.4m/s).This is less than 2.4m/s, hence acceptable.

12 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 =

2.04 m/s

C = Constant for Pipe =

100

D = Inside diameter of pipe =

78.40 mm

Hence, on substituting valves on above formula, we get,

J =

0.0981864 mtr/mtr length of pipe

Head loss in solution pipe =

1.18 m

Considering a 10% margin on

Frictional Loss it works to be

1.296 m

Frictional Loss

m

1.296

Loss in Butterfly Valves

m

0.016 Loss (m)

Loss in NRVs

m

0.015 Loss (m)

Prepared By: Bhavesh

Date: 9th May, 2011

Checked by:

NMK

0.008 Quantity

0.015 Quantity

2

1

REV NO. - 00

Loss in Flowmeter

Maximum Elevation

Total Loss

Date: 9th May, 2011

m

m

m

5

2

8.327

Checked by:

NMK

REV NO. - 00

Motive Water Line Calculations, Pump Discharge line upto Discharge header

Booster Pump Discharge line

MOC MS IS 1239

Velocity through pipe

Length of pipe, from pump discharge header

upto ejector

m3/h

m/s

Size

100 NB

ID

Friction

Factor

(C

Value)

102.3

100

70.80

2.393 Velocity limit range (3m/s). This is less than 3m/s, hence acceptable.

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 =

2.39 m/s

C = Constant for Pipe =

100

D = Inside diameter of pipe =

102.30 mm

Hence, on substituting valves on above formula, we get,

J =

0.0969769 mtr/mtr length of pipe

Head loss in solution pipe =

1.16 m

Considering a 10% margin on

Frictional Loss it works to be

1.280 m

Frictional Loss

m

1.280

Loss in Butterfly Valves

m

0.008 Loss (m)

0.008 Quantity

Loss in NRVs

m

0.015 Loss (m)

0.015 Quantity

Total Loss

m

1.303

B

Total

Pressure required @ pump discharge

Discharge

39.6

Ejector Inlet pressure +A + B X 10%Margin

Head (m)

1

1

MOC MS IS 1239

Size

125 NB

ID

129.5

Friction

Factor

(C

Value)

100

Friction

Factor (C

Value)

100

m /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

m

12 Max length taken for design porpose, in practical it will be less.

upto pump suction

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 =

1.49 m/s

C = Constant for Pipe =

100

D = Inside diameter of pipe =

129.50 mm

3

J =

0.0307543 mtr/mtr length of pipe

Head loss in solution pipe =

0.37 m

Considering a 10% margin on

Frictional Loss it works to be

0.406 m

Frictional Loss

Loss in Butterfly Valves

Total Loss

m

0.406

m

0.0025

m 0.4084573

Loss (m)

C

0.0025 Quantity

Motive Water Line Calculations, motive water header from tapping point upto pump suction line

Booster pump suction Header

MOC MS IS 1239

Velocity through pipe

Length of pipe from tapping

point

m3/h

m/s

Size

100 NB

ID

104.2

70.8

2.306 Velocity limit range (1.5-2.4m/s). This is less than 2.4m/s, hence acceptable.

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 =

2.31 m/s

C = Constant for Pipe =

100

D = Inside diameter of pipe =

104.20 mm

Hence, on substituting valves on above formula, we get,

J =

0.0886623 mtr/mtr length of pipe

Head loss in solution pipe =

0.89 m

Considering a 10% margin on

Frictional Loss it works to be

0.975 m

Frictional Loss

Maximum Elevation

Loss in Butterfly Valves

Loss in Strainers @ 50% choked condition

Total Loss

Total Loss in Motive Water Pipe from tapping

point upto pump suction

Water Pressure available at tapping point

Head available @ pump suction

m

0.975

m

2

m

0.024

m

5

m 7.9992849

m 8.4077422

m

0

m

-8.4

Loss (m)

Loss (m)

D

C+D

0.008 Quantity

5 Quantity

3

1

Pipe MOC

Flow m3/h

Velocity m/s

Velocity Limit

Remark

MS IS 1239

70.8

100 NB

104.2

2.31

2.4

MS IS 1239

70.8

125 NB

129.5

1.49

1.5

MS IS 1239

70.8

100 NB

102.3

2.39

Ejector Upstream

MS IS 1239

35.4

80 NB

78.4

2.04

2.4

outlet

uPVC IS 4985

35.4

90 OD

81.4

1.89

2.0

uPVC IS 4985

70.8

125 OD

113

1.96

2.4

hence selected line size is

ok

SUMMARY

Pipe

Location

Date: 9th May, 2011

Checked by:

NMK

REV NO. - 00

Date: 9th May, 2011

Checked by:

NMK

REV NO. - 00

Project

Owner

Contractor

Consultant

System

System supplier

Document

Document No.

Ref Drwg / Doc.

2 Technical Specification # SPML-S10IRJ01-DD-ME-009 for RW Chlorination Plant

CHLORINATOR

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.

Chlorinator Capacity

Quantity

Solution Concentration

Minimum Ejector Water flow required

Kg/h

Nos.

ppm

m/h

1.5

ppd

1 Operating

2500

0.60

lpm

79.9999992

Kg/h

1 Common Standby

10 lps

2 Rated capacity

0.166667

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

Accordingly solution flowrate required

Chlorinator Capacity

Kg/h

1.5

ppd

79.9999992

Quantity

Nos.

1 Operating

1 Standby

Solution Concentration

ppm

2500

Minimum Ejector Water flow required

m/h

0.6

lpm

10 lps

0.166667

Above flow is the minumum flow required for the stated capacity & concentration, but we have to design the system as per ejector sizing

Bulletin

Ref.

Ejector Sizing

Nozzle

Throat

Back

Pressure

capability

(Kg/cm)

1.5

122.3063.0 12.000

0.000

Reference Ejector Curve

Kg/cm

1.5

Back Pressure capability

Ejector Inlet Pressure required

Kg/cm

4

I.e.

40 m head

Flow through each ejector

lpm

27

m/h

1.62

Quantity of ejectors operating per solution

Nos.

1 Standby

1

header

Combined Flow for the system

m/h

1.62

DIFFUSER SIZING (Typ. for each unit)

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 m3/s

Nos.of diffuser

1

Nos.

Flow through each diffuser

1.62

m/h

0.00045 m3/s

Velocity through diffuser

0.970801212

m/s

Flow through each perforation should be 4-7 lpm at 3-4 m/sec as per Capital Controls design standard.

So, considering a flow

through the diffuser perforation

6

lpm

Therefore:

No of Perforations in diffuser

4.5

Nos. of Perforation each diffuser

Selected

5

Nos. of Perforation of 6mm diameter size

Perforation dia.

6

mm

Flow through each perforation /orifice

C.S. Area of perforation

Velocity through Perforation

Hence the Diffuser Design is Suitable.

0.32400000

m/h

2.8285713E-005 m2

3.1818183264 m/s

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

D = Diameter of pipe in which orifice is placed =24.3

K = 0.75 (Discharge coefficient)

0.2469135802

0.75

Qt =

No. of Perforation =

Q=

ead Loss at Diffuser Inlet

h=

h=

27

5

1.426

lpm

2.8244

0.8609

ft

m

Flow (lpm)

Flow m/h

27

1.62

27 lpm

### m/sec

(considering diameter = 6mm)

mm

mm

This is less than 0.3,

so k =

Inlet

Pressure

(Kg/cm)

0.24

7.128

gpm

gpm

inch

SUMMARY

Diffuser

Total nos. of diffuser

MOC

Size

Diffuser perforation size

Perforation in each diffuser

Flow through perforation

Velocity through perforation

Location

1

uPVC

1"

6

5

0.324

3.2

CW Forebay

Nos.

Sch 80

mm

Nos.

m/h

m/s

Solution header pipe

uPVC

MOC Schedule

80

Velocity through pipe

Length of solution line

m3/h

m/s

m

Size

1"

ID

24.3

Friction

Factor

(C Value)

140

1.62

0.970 This is less than 2.4m/s, hence acceptable.

24 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

Prepared By: Bhavesh

Date: 17th May, 2011

Checked by:

NMK

REV NO. - 0

V = Velocity =

C = Constant for Pipe =

D = Inside diameter of pipe =

0.97 m/s

140

24.30 mm

J =

0.0523137 mtr/mtr length of pipe

Head loss in solution pipe =

1.26 m

Considering a 20% margin on

Frictional Loss it works to be

1.507 m

Frictional Loss in solution line

Maximum Elevation of solution line

Pressure @ point of dosing

Loss in Valves

Loss in diffuser

Total Loss

Chlorine Solution Line Calculations, Ejector downstream

Ejector downstream pipe

m

1.507

m

2

m

0

m

0.03 Loss (m)

0.03 Quantity

1

m 0.8608685

m 4.3975029 This is well within the back pressure capability. Hence, O.K.

to solution header (Indoor line)

uPVC

MOC Schedule

80

Size

1"

ID

Friction

Factor

(C Value)

24.3

140

1.62

m /h

Velocity through pipe

m/s

0.970 This is less than 2.0m/s, hence acceptable.

Length of pipe upto solution header

m

12 Max length taken for design porpose, in practical it will be less.

Now, calculating friction loss in the pipe by using Williams & Hazenss Formula,

1.852

-1.167

J = 6.815 [V/C]

* (D)

Where,

J = Head loss in mtr/mtr length of pipe

V = Velocity =

0.97 m/s

C = Constant for Pipe =

140

D = Inside diameter of pipe =

24.30 mm

3

J =

0.0523137 mtr/mtr length of pipe

Head loss in solution pipe =

0.63 m

Considering a 20% margin on

Frictional Loss it works to be

0.753 m

Frictional Loss in solution line

Loss in Butterfly Valves

Loss in Diaphragm Valves

Loss in NRVs

Maximum Elevation

Total Loss

Back Pressure on Ejector

m 0.7533172

m

0 Loss (m)

0.008 Quantity

0

m

0 Loss (m)

0.03 Quantity

0

m

0 Loss (m)

0.015 Quantity

0

m

1

m 1.7533172

m 6.1508202 This is within the permissible back pressure of 10m or 1kg/cm2. Hence, O.K.

Motive Water Line Calculations, Pump Discharge header upto Ejector upstream

Booster Pump Discharge

Header line

Flow through pipe

Velocity through pipe

Length of pipe, from pump discharge header

upto ejector

uPVC

MOC Schedule

80

m3/h

m/s

m

Size

1"

ID

Friction

Factor

(C Value)

24.3

140

1.62

0.970 Velocity limit range (1.5-2.4m/s).This is less than 2.4m/s, hence acceptable.

12 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 =

0.97 m/s

C = Constant for Pipe =

140

D = Inside diameter of pipe =

24.30 mm

Hence, on substituting valves on above formula, we get,

J =

0.0523137 mtr/mtr length of pipe

Head loss in solution pipe =

0.63 m

Considering a 10% margin on

Frictional Loss it works out to be

m

0.691

Frictional Loss

m

0.691

Loss in Butterfly Valves

m

0.016 Loss (m)

Loss in NRVs

m

0.015 Loss (m)

Loss in Flowmeter

m

0

Maximum Elevation

m

2

Total Loss

m

2.722

A

0.008 Quantity

0.015 Quantity

2

1

Motive Water Line Calculations, Pump Discharge line upto Discharge header

Booster Pump Discharge line

Flow through pipe

Velocity through pipe

Length of pipe, from pump discharge header

upto ejector

uPVC

MOC Schedule

80

m3/h

m/s

m

Size

1"

ID

Friction

Factor

(C Value)

24.3

140

1.62

0.970 Velocity limit range (3m/s). This is less than 3m/s, hence acceptable.

6 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 =

0.97 m/s

C = Constant for Pipe =

140

D = Inside diameter of pipe =

24.30 mm

Hence, on substituting valves on above formula, we get,

J =

0.0523137 mtr/mtr length of pipe

Head loss in solution pipe =

0.31 m

Considering a 10% margin on

Frictional Loss it works to be

0.345 m

Frictional Loss

m

0.345

Loss in Butterfly Valves

m

0.008 Loss (m)

Prepared By: Bhavesh

Date: 17th May, 2011

Checked by:

NMK

0.008 Quantity

1

REV NO. - 0

Loss in NRVs

Total Loss

Pressure required @ pump discharge

m

m

Total

Discharge

Head (m)

0.015

0.368

43.1

Loss (m)

B

0.015 Quantity

uPVC

MOC Schedule

80

Size

1"

ID

Friction

Factor

(C Value)

24.3

140

m /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

m

6 Max length taken for design porpose, in practical it will be less.

upto pump suction

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 =

0.97 m/s

C = Constant for Pipe =

140

D = Inside diameter of pipe =

24.30 mm

3

J =

0.0523137 mtr/mtr length of pipe

Head loss in solution pipe =

0.31 m

Considering a 10% margin on

Frictional Loss it works to be

0.345 m

Frictional Loss

Loss in Butterfly Valves

Total Loss

m

0.345

m

0.0025

m 0.3477704

Loss (m)

C

0.0025 Quantity

Motive Water Line Calculations, motive water header from tapping point upto pump suction line

uPVC

MOC Schedule

80

Flow through pipe

Velocity through pipe

Length of pipe from tapping

point

m3/h

m/s

Size

1"

ID

Friction

Factor (C

Value)

24.3

140

1.62

0.970 Velocity limit range (1.5-2.4m/s). This is less than 2.4m/s, hence acceptable.

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 =

0.97 m/s

C = Constant for Pipe =

140

D = Inside diameter of pipe =

24.30 mm

Hence, on substituting valves on above formula, we get,

J =

0.0523137 mtr/mtr length of pipe

Head loss in solution pipe =

0.63 m

Considering a 10% margin on

Frictional Loss it works to be

0.691 m

Frictional Loss

Maximum Elevation

Loss in Butterfly Valves

Loss in Strainers @ 50% choked condition

Total Loss

Total Loss in Motive Water Pipe from tapping

point upto pump suction

Water Pressure available at tapping point

Head available @ pump suction

m

0.691

m

2

m

0.024

m

5

m 7.7145408

m 8.0623112

m

5

m

-3.1

Loss (m)

Loss (m)

D

C+D

0.008 Quantity

5 Quantity

3

1

SUMMARY

Pipe

Location

Flow m3/h

uPVC Schedule 80

1.62

1"

24.3

0.97

2.4

uPVC Schedule 80

1.62

1"

24.3

0.97

1.5

uPVC Schedule 80

1.62

1"

24.3

0.97

uPVC Schedule 80

1.62

1"

24.3

0.97

2.4

outlet

uPVC Schedule 80

1.62

1"

24.3

0.97

2.0

uPVC Schedule 80

1.62

1"

24.3

0.97

2.4

Pumps

Ejectors operating per pump

Pump rating

Hence, pump selected

Pump Quantity

SUMMARY

Pump

Service

Type

Quantity

Flow

Differential Head

Date: 17th May, 2011

Nos.

m/h @ m head

m/h @ m head

LPM @ m Head

Nos.

1

1.944

m/h @

2

m/h @

33.33

LPM

1 Operating

46

50

50

1

Velocity m/s

m Differential head

m Differential head

m Differential head

Standby

hence selected line size is

ok

Pipe MOC

2900 RPM

Centrifugal Horizontal

1

Working

1

Standby

2

m/h

50

m

Checked by:

NMK

REV NO. - 0

Project

Owner

Contractor

Consultant

System

System supplier

Document

Document No.

Ref Drwg / Doc.

1

2

A. VOLUME CALCULATION FOR SULPHURIC ACID STORAGE TANK

Quantity

1

No.

Capacity

15

m3

Material of construction:

Construction Type:

MS as per IS 2062

Atmospheric Horizontal cylinder with dished ends

where,

Effective volume required:

15 cu.m

H= height of cylindrical tank

Calculated volume

2.5 m OD

3.5 m

V

MOC:

MS as per IS 2062

Design Code:

IS:803

Tank Diameter

m

Tank Height

m

17.187 m3

2.5

3.5

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

H= Height from the bottom of the course under consideration to the bottom of the overflow which limits tank filli

G = Specific Gravity of liquid to be stored

S = Allowable Stress in kg/cm2 for IS:2062 as per clause No. 5 of IS" 803

E = Joing Efficiency

2500 mm

3500 mm

1.82

1680 kg/cm2

0.7

2.5

3.5

T

=

Further, we are considering a corrosion allowance =

Therefore total thickness

=

Hence 5 mm thick plate can be used as per Clause No 6.3.3.2 of IS: 803.

Selected thickness

T

=

Summary:

Construction

MOC:

Thickness

Tank Diameter

Tank height

Free board

0.62 mm

2 mm

2.62 mm

5

mm

MS as per IS 2062

5 mm

2.5 m

3.5 m

0.445 m

1. Sulphuric Acid unloading pump Suction header:

MOC:

Flow of stream

Velocity in pump suction header

MS IS:1239

m3/hr

m/sec

Size

65 NB

10

0.80

ID in mm

66.3

0.0028

Size

65 NB

10

0.80

ID in mm

66.3

m3/sec

Size

50 NB

10

1.38

ID in mm

50.7

m3/sec

ID in metres

0.0663

m3/sec

MOC:

Flow of stream

Velocity in pump suction header

MS IS:1239

m3/hr

m/sec

ID in metres

0.0663

0.0028

MOC:

Flow of stream

Velocity in pump suction header

MS IS:1239

m3/hr

m/sec

ID in metres

0.0507

0.0028

m

m

MOC:

MS IS:1239

Flow of stream

Velocity in pump suction header

m3/hr

m/sec

Size

50 NB

10

1.38

ID in mm

50.7

m3/sec

Size

65 NB

m3/hr

m/sec

ID in mm

66.3

0.0028

ID in metres

0.0507

0.0028

1. Head loss in acid unloading pump suction header

A. Selected pipe specifications:

MOC

Flow of stream

Velocity in pump suction header

MS IS:1239

V

10

0.8043

ID in metres

0.0663

m3/sec

metres.

---------

0.342

metres.

---------

II

Equivalent length =

342

mm

(Refer the enclosed table for equivalent length of fittings)

0.342

metres.

---------

III

Rounded off length

Constant

I + II + III

---------

---------

---------

Length of pipe from sulphuric acid unloading point upto suction line of unloading pumps

Equivalent length of

65 NB

No of elbows.

Equivalent length =

342

No. of Tees.

pipe-fittings:

mm

Nos. 3000# socket weld

Qty:

Flow through valve

5.684 metres.

6 metres.

100

6.815(V/C)^1.852*(D)^(-1.167)

0.02136 mWC

0.12815 mWC

65 NB

1 No.

10 m3//hr

0.024 mWC

=

=

1+2

0.15215 mWC

0.152151115 mWC

A. Selected pipe specifications:

MOC

Flow of stream

Velocity in pump suction header

Size

65 NB

MS IS:1239

V

10

0.8043

m3/hr

m/sec

ID in mm

66.3

0.0028

ID in metres

0.0663

m3/sec

metres.

---------

0.228

metres.

---------

II

Equivalent length =

228

mm

(Refer the enclosed graph for equivalent length of fittings)

0.228

metres.

---------

III

Rounded off length

Constant

I + II + III

---------

---------

Length of pipe from pump suction header upto pump suction point

Equivalent length of

No of elbows.

Equivalent length =

No. of Tees.

65 NB

pipe-fittings:

2

228

2

mm

Nos. 3000# socket weld

Qty:

Flow through valve

Loss through valve

2.456 metres.

3 metres.

100

6.815(V/C)^1.852*(D)^(-1.167)

0.02136 mWC

0.06408 mWC

65 NB

1 No.

10 m3//hr

0.024 mWC

2 mWC

=

=

1+2+3

2.08808 mWC

2.08808 mWC

=

A+B

2.24023

---------

---------

mWC

A. Selected pipe specifications:

MOC

Size

50 NB

MS IS:1239

Flow of stream

Velocity in pump suction header

10

1.4

m3/hr

m/sec

ID in mm

50.7

0.0028

ID in metres

0.0507

m3/sec

metres.

---------

0.216

metres.

---------

II

Equivalent length =

216

mm

(Refer the enclosed graph for equivalent length of fittings)

0.216

metres.

---------

III

selected length

Constant

I + II + III

---------

---------

---------

---------

Length of pipe from tank discharge point upto pump discharge header

Equivalent length of

50 NB

No of elbows.

Equivalent length =

pipe-fittings:

2

216

No. of Tees.

mm

Nos. 3000# socket weld

B. Head Loss through Non Return Valve of

Qty:

Flow in stream

Velocity in pump discharge line

2.432 metres.

3 metres.

100

6.815(V/C)^1.852*(D)^(-1.167)

0.07890 mWC

0.23670 mWC

50 NB

C. Head loss through ballvalve of

Qty:

Flow through valve

=

=

=

1 No.

10 m3/hr

1.4 m/sec

0.275 mWC

50 NB

1 No.

10 m3//hr

0.1 mWC

=

=

1+2+3

0.61170 mWC

0.61170 mWC

A. Selected pipe specifications:

MOC

Flow of stream

Velocity in pump suction header

Size

50 NB

m3/hr

m/sec

MS IS:1239

V

10

1.4

ID in mm

50.7

0.0028

ID in metres

0.0507

m3/sec

metres.

---------

0.216

metres.

---------

II

Equivalent length =

216

mm

(Refer the enclosed graph for equivalent length of fittings)

0.216

metres.

---------

III

selected length

Constant

I + II + III

Length of pipe from tank discharge point upto pump discharge header

Equivalent length of

No of elbows.

Equivalent length =

No. of Tees.

50 NB

2

216

2

pipe-fittings:

Nos. 3000# socket weld

mm

Nos. 3000# socket weld

=

=

2.432 metres.

3 metres.

100

6.815(V/C)^1.852*(D)^(-1.167)

0.078898685 mWC

Qty:

Flow through valve

0.236696055 mWC

---------

---------

---------

50 NB

1 No.

10 m3//hr

0.1 mWC

Head loss from pump discharge line upto sulphuric acid storage tank inlet p

=

=

1+2

0.336696055 mWC

0.33670 mWC

C+D

0.94839211 mWC

SUMMARY:

Pump Head requirement shall be calculated as under:

1. Total Head Loss at Sulphuric Acid Unloading Pump suction

2. Head Loss at Unloading Pump Discharge

3. Pressure available at tank discharge point

= 2.24022667 mWC

= 0.94839211 mWC

=

0 mWC

Selected Value

Pump Capacity

Pump Head Selected

= 3.18861878 mWC

=

4 mWC

=

10 m3/hr.

=

10 mWC

A. VOLUME CALCULATION FOR SULPHURIC ACID DAY / MEASURING TANK:

Qty.

Capacity

2

2.5

Nos.

m3

Material of construction:

Construction Type:

MS as per BS 2594

Vertical cylindrical type with cover

where,

Effective volume required:

2.5 cu.m

H= height of cylindrical tank

Calculated Volume

1.5 m OD

1.72 m

V

MOC:

MS as per BS 2594

Design Code:

IS:803

Tank Diameter

m

Tank Height

m

3.041 m3

1.5

1.72

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

H= Height from the bottom of the course under consideration to the bottom of the overflow which limits tank filli

G = Specific Gravity of liquid to be stored

S = Allowable Stress in kg/cm2 for IS:2062 as per clause No. 5 of IS" 803

E = Joing Efficiency

1500 mm

1720 mm

1.82

1680 kg/cm2

0.7

T

=

Further, we are considering a corrosion allowance =

Therefore total thickness

=

Hence 5 mm thick plate can be used as per Clause No 6.3.3.2 of IS: 803.

Selected thickness

T

=

Summary:

Construction

MOC:

Thickness

Tank Diameter

Tank height

Free board

MS as per BS 2594

5 mm

1.5 m

1.72 m

0.306 m

0.16 mm

2 mm

2.16 mm

5

mm

1.5

1.72

m

m

V. PIPE SIZING:

1. Sulphuric Acid Transfer Line:

MOC

MS IS:1239

Flow of stream

Velocity in pump suction header

Size

50 NB

m3/hr

m/sec

ID in mm

50.7

1

0.14

Size

15 NB

m3/hr

m/sec

ID in mm

14.6

0.00002

ID in mtrs.

0.0507

0.00028

m3/sec

1. Head Loss Metering pump Suction Header:

A. Selected pipe specifications:

MOC

MS IS:1239

Flow of stream

Velocity in pump suction header

0.075

0.124

No of elbows.

Equivalent length =

15 NB

3

156

metres.

---------

0.156

metres.

---------

II

0.156

metres.

---------

III

---------

---------

---------

pipe-fittings:

Nos. 3000# socket weld

mm

No. of Tees.

3

Nos. 3000# socket weld

Equivalent length =

156

mm

(Refer the enclosed graph for equivalent length of fittings)

Total Equivalent length

selected length

Constant

I + II + III

Qty:

Flow through ball valve

m3/sec

Length of pipe from tank discharge point upto pump suction line

Equivalent length of

ID in metres

0.0146

5.312 metres.

6 metres.

100

6.815(V/C)^1.852*(D)^(-1.167)

0.00394 mWC

0.02362 mWC

15 NB

1 No.

0.075 m3//hr

0.1 mWC

Head loss in metering pump suction header

=

=

1+2

0.123624655 mWC

0.123624655 mWC

A. Selected pipe specifications:

MOC

Size

15 NB

m3/hr

m/sec

MS IS:1239

Flow of stream

Velocity in pump suction line

0.075

0.1243908459

ID in mm

14.6

0.00002

ID in metres

0.0146

m3/sec

metres.

---------

0.104

metres.

---------

II

Equivalent length =

104

mm

(Refer the enclosed graph for equivalent length of fittings)

0.104

metres.

---------

III

selected length

Constant

I + II + III

---------

---------

Length of pipe from pump suction header upto pump suction point

Equivalent length of

No of elbows.

Equivalent length =

No. of Tees.

15 NB

2

104

2

pipe-fittings:

Nos. 3000# socket weld

mm

Nos. 3000# socket weld

Qty:

Flow through ball valve

Loss through ball valve

refer enclosed graph for ball valve

2.208 metres.

3 metres.

100

6.815(V/C)^1.852*(D)^(-1.167)

0.003937443 mWC

0.011812328 mWC

15 NB

1 No.

0.075 m3//hr

0.1 mWC

2 mWC

=

=

1+2+3

2.111812328 mWC

2.111812328 mWC

=

---------

---------

A+B

2.235436983 mWC

A. Selected pipe specifications:

MOC

Size

15 NB

m3/hr

m/sec

MS IS:1239

Flow of stream

Velocity in pump suction header

0.075

0.124

ID in mm

14.6

0.00002

ID in metres

0.0146

m3/sec

100

metres.

---------

0.104

metres.

---------

II

Equivalent length =

104

mm

(Refer the enclosed graph for equivalent length of fittings)

0.104

metres.

---------

III

selected length

Constant

I + II + III

---------

---------

---------

---------

Length of pipe from tank discharge point upto pump discharge header

Equivalent length of

15 NB

No of elbows.

Equivalent length =

104

No. of Tees.

pipe-fittings:

Nos. 3000# socket weld

mm

Nos. 3000# socket weld

B. Head Loss through Non Return Valve of

Qty:

Flow in stream

Velocity in pump discharge line

100.208 metres.

101 metres.

100

6.815(V/C)^1.852*(D)^(-1.167)

0.003937443 mWC

0.397681701 mWC

15 NB

C. Head loss through ball valve of

Qty:

Flow through ball valve

=

=

=

1 No.

0.075 m3/hr

0.124 m/sec

0.125 mWC

15 NB

1 No.

0.075 m3//hr

refer enclosed graph for ball valve

0.01 mWC

=

=

1+2+3

0.532681701 mWC

0.532681701 mWC

A. Selected pipe specifications:

MOC

Size

15 NB

m3/hr

m/sec

MS IS:1239

Flow of stream

Velocity in pump suction header

0.075

0.124

ID in mm

14.6

0.00002

ID in metres

0.0146

m3/sec

metres.

---------

0.26

metres.

---------

II

Equivalent length =

260

mm

(Refer the enclosed graph for equivalent length of fittings)

0.26

metres.

---------

III

selected length

Constant

I + II + III

---------

Length of pipe from tank discharge point upto pump discharge header

Equivalent length of

No of elbows.

Equivalent length =

No. of Tees.

15 NB

5

260

5

pipe-fittings:

Nos. 3000# socket weld

mm

Nos. 3000# socket weld

6.52 metres.

7 metres.

100

6.815(V/C)^1.852*(D)^(-1.167)

0.00394 mWC

0.02756 mWC

Qty:

Flow through ball valve

15 NB

1 No.

0.075 m3//hr

0.01 mWC

Head loss from pump discharge line upto sulphuric acid storage tank inlet p

=

=

0.03756 mWC

C.S. Area of perforation

Velocity through Perforation

Hence the Diffuser Design is Suitable.

---------

C+D

0.57024 mWC

through the diffuser perforation

Therefore:

No of Perforations in diffuser

Selected

Perforation dia.

1+2

0.03756 mWC

Location

CD Forebay

MOC

Size

ID

Flow through solution line to diffuser

Nos.of diffuser

Flow through each diffuser

Velocity through diffuser

---------

MS

15NB

14.6

0.075

1

0.075

0.125

mm

m/h

Nos.

m/h

m/s

lpm

0.6

6

1

Nos. of Perforation of 6mm diameter size

mm

0.0146 m

2.08E-005 m3/s

1.25 lpm

2.08E-005 m3/s

1.25 lpm

65450140

0.013

m/h

7.8571E-007 m2

4.41919212 m/s

### m/sec

(considering diameter = 6mm)

SUMMARY:

Pump Head requirement shall be calculated as under:

1. Total Head Loss in Sulphuric Acid Metering Pump suction

2. Head Loss in sulphuric Acid Metering Pump Discharge

= 2.235436983 mWC

= 0.570243799 mWC

= 2.805680782 mWC

Selected Value

Pump Capacity

Pump Head Selected

=

=

=

0 mWC

3 mWC

75 LPH

10 mWC

Project

Owner

Contractor

Consultant

System

System supplier

Document

Document No.

A. VOLUME CALCULATION FOR INHIBITOR TANKS:

Qty.

Capacity

1

1

Material of construction:

Construction Type:

Volume of tank V=(/4)x D2 x L

where,

Effective volume required:

Nos.

m3

MSRL as per IS 2062

Vertical cylindrical type with cover

1 m3

H= height of cylindrical tank

Calculated Volume

1.1 m OD

1.225 m

V

1.165 m3

MOC:

MSRL as per IS 2062

Design Code:

IS:803

Tank Diameter

m

Tank Height

m

1.1

1.225

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

1100 mm

H= Height from the bottom of the course under consideration to the bottom of the overflow which l

1225 mm

G = Specific Gravity of liquid to be stored

1.1 Corrosion I

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

1.1

1.225

m

m

1.25 Scale Inhibitor

T

Further, we are considering a corrosion allowance =

Therefore total thickness

Hence 5 mm thick plate can be used as per Clause No 6.3.3.2 of IS: 803.

Selected thickness

T

=

Summary:

Construction:

MOC:

Thickness:

Tank Diameter:

Tank height:

Free board:

0.05 mm

2 mm

2.05 mm

=

5

mm

MSRL as per IS 2062

5 mm

1.1 m

1.225 m

0.173 m

1. Head Loss In Metering pump Suction Header:

A. Selected pipe specifications:

Size

ID in mm

ID in metres

uPVC

Schedule 80

0.05

0.0920

MOC

1/2"

13.86

m3/hr

m/sec

0.00001

m3/sec

metres.

---------

0.156

metres.

---------

II

Equivalent length =

156

mm

(Refer the enclosed graph for equivalent length of fittings)

0.156

metres.

---------

III

selected length

Constant

---------

---------

---------

Flow of stream

Velocity in pump suction header

Length of pipe from tank discharge point upto pump suction line

Equivalent length of

1/2"

No of elbows.

Equivalent length =

156

No. of Tees.

0.01386

pipe-fittings:

Nos. Schedule 80

mm

Nos. Schedule 80

I + II + III

C

6.815(V/C)^1.852*(D)^(-1.167)

=

Total head loss in pipeline

0.0012838 mWC

=

Qty:

Flow through ball valve

5.312 metres.

6 metres.

140

0.00770281 mWC

1/2"

1 No.

0.05 m3//hr

0.01 mWC

=

=

1+2

0.01770281 mWC

0.01770281 mWC

A. Selected pipe specifications:

ID in mm

uPVC

Schedule 80

0.05

0.0920

MOC

13.86

0.00001

m3/sec

metres.

---------

0.104

metres.

---------

II

Equivalent length =

104

mm

(Refer the enclosed graph for equivalent length of fittings)

0.104

metres.

---------

III

selected length

Constant

---------

0.01 mWC

---------

2 mWC

---------

Flow of stream

Velocity in pump suction line

1/2"

m3/hr

m/sec

ID in metres

Length of pipe from pump suction header upto pump suction point

Equivalent length of

1/2"

No of elbows.

Equivalent length =

104

No. of Tees.

pipe-fittings:

Nos. Schedule 80

mm

Nos. Schedule 80

I + II + III

C

Qty:

Flow through ball valve

Velocity in pump discharge line

0.0012838 mWC

=

0.00385141 mWC

1 No.

0.05 m3//hr

0.092 m/sec

1/2"

2.208 metres.

3 metres.

140

6.815(V/C)^1.852*(D)^(-1.167)

=

Total head loss in pipeline

0.01386

1/2"

=

=

1+2+3

2.01385141 mWC

2.01385141 mWC

=

=

---------

A+B

2.03155422 mWC

A. Selected pipe specifications:

ID in mm

uPVC

Schedule 80

0.05

0.0920187678

MOC

Flow of stream

Velocity in pump suction header

1/2"

m3/hr

m/sec

13.86

0.00001

m3/sec

100

metres.

---------

0.104

metres.

---------

II

0.104

metres.

---------

III

---------

---------

---------

---------

Length of pipe from tank discharge point upto pump discharge header

Equivalent length of

No of elbows.

Equivalent length =

No. of Tees.

1/2"

0.01386

pipe-fittings:

Nos. Schedule 80

104

mm

Nos. Schedule 80

Equivalent length =

104

mm

(Refer the enclosed graph for equivalent length of fittings)

Total Equivalent length

selected length

Constant

ID in metres

I + II + III

=

C

100.208 metres.

101 metres.

140

= 6.815(V/C)^1.852*(D)^(-1.167)

=

B. Head Loss through Non Return Valve of:

Qty:

Flow in stream

Velocity in pump discharge line

0.12966404 mWC

=

=

=

1 No.

0.05 m3/hr

0.09202 m/sec

0.125 mWC

1/2"

C. Head loss through ball valve of :

Qty:

Flow through ball valve

0.0012838 mWC

1/2"

0 No.

0.05 m3//hr

0.01 mWC

=

=

1+2

0.25466404 mWC

0.25466404 mWC

A. Selected pipe specifications:

ID in mm

uPVC

Schedule 80

0.05

0.0920187678

MOC

Flow of stream

Velocity in pump discharge header

1/2"

m3/hr

m/sec

13.86

0.00001

m3/sec

metres.

---------

0.26

metres.

---------

II

0.26

metres.

---------

III

Equivalent length of

No of elbows.

Equivalent length =

No. of Tees.

1/2"

5

260

5

ID in metres

0.01386

pipe-fittings:

Nos. Schedule 80

mm

Nos. Schedule 80

Equivalent length =

260

mm

(Refer the enclosed graph for equivalent length of fittings)

selected length

Constant

I + II + III

=

C

6.52 metres.

7 metres.

140

6.815(V/C)^1.852*(D)^(-1.167)

0.0012838 mWC

0.00898662 mWC

Qty:

Flow through ball valve

1 No.

0.05 m3//hr

0.01 mWC

Head loss from pump discharge line upto Inhibitor storage tank inlet point

=

=

=

=

Location

CD Forebay

MOC

uPVC

Size

1/2"

ID

14.6

Flow through solution line to diffuser

0.05

Nos.of diffuser

1

Flow through each diffuser

0.05

Velocity through diffuser

0.083

So, considering a flow

through the diffuser perforation

Therefore:

No of Perforations in diffuser

Selected

Perforation dia.

mm

m/h

Nos.

m/h

m/s

---------

---------

1+2

0.01898662 mWC

0.01898662 mWC

---------

C+D

0.27365065 mWC

0.0146 m

1.39E-005 m3/s

0.833333333 lpm

1.39E-005 m3/s

0.833333333 lpm

lpm

0.8

4

1

Nos. of Perforation of 1mm diameter size

mm

0.013

C.S. Area of perforation

7.8571425E-007

Velocity through Perforation

4.4191921201

Hence the Diffuser Design is Suitable.

m/h

m2

m/s

### m/sec

(considering diameter = 6mm)

SUMMARY:

Pump Head requirement shall be calculated as under:

1. Total Head Loss in Inhibitor Metering Pump suction

2. Total Head Loss in Inhibitor Metering Pump Discharge

3. Pressure available at tank discharge point

=

=

=

Value

Unit

2.03155 mWC

0.27365 mWC

0 mWC

Selected Value

Pump Capacity

Pump Head Selected

=

=

=

=

2.3052 mWC

3 mWC

50 LPH

10 mWC

Project

Owner

Contractor

Consultant

System

System supplier

Document

Document No.

Ref Drwg / Doc.

Annexure-3 Questionnaire

CAUSTIC TANK SIZING CALCULATION

2NaOH aq + Cl2 NaClaq + H2O +NaOClaq

1 Mol of chlorine (Molecular Weight = 70.91) requires 2 mole of NaOH (Molecular Weight = 40)

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

1000-Kg chlorine requires,

(1000x 2x 40) / 70.91 = 1128.19 Kg NaOH of 100% Purity

100% on weight basis of Pure NaOH corresponds to 1128.19 kg.

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/m3 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

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

Height of the tank = Height up to overflow inlet + Height of 300 mm Free Board

Height of the tank = 2100 mm + 300mm.

Total Height = 2400 mm.

Operating Capacity = 5.64 = / 4 *d2 *h

Diameter of the tank = 1.73 meter.

on # 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 3

So, we selecting 10Cu.m capacity with free board of 300mm of caustic solution tank

Selecting a tank Diameter of 2.5 meter.

10= ( / 4) x 2.52 x H (H= Height of the tank without free board)

Therefore,

H= 2050 mm

Adding 300 mm free board to the H

Now,

Total height of the tank including the free board is 2050+300 = 2350mm

The dimensions of the tank are as follows: 1. Diameter = 2.5 meters

2. Cylindrical portion Height = (operating Height + Free Board) = 2350 mm

Height of Conical Portion = 600 mm.

Effective Volume of the tank = 10 m3

Project

Owner

Contractor

Consultant

System

System supplier

Document

Document No.

Ref Drwg / Doc.

A. VOLUME CALCULATION FOR HYPOCHLORITE DOSING TANK:

Qty.

Capacity

Material of construction:

Construction Type:

1

0.1

PP+FRP

Vertical cylindrical type with flat bottom and cover

where,

Effective volume required:

H= height of cylindrical tank

T= Thickness of Tank =

Calculated Volume

Summary:

Construction:

MOC:

Thickness:

Tank Diameter:

Tank height:

Free board:

Nos.

m3

0.2

m3

0.1 m3

=

=

=

=

0.5

0.7

5

0.137

m OD

m OD

mm

m3

0.6

0.8

m OD

m OD

mm

m3

0.226

PP+FRP

0 mm

0.5 m

0.7 m

0.191 m

1. Head Loss in Metering Pump Discharge Line:

A. Selected pipe specifications:

uPVC

Schedule 80

0.005

0.0092

MOC

Flow of stream

Velocity in Pump Discharge line

Size

ID in mm

1/2"

m3/hr

m/sec

13.86

0.0000014

m3/sec

50

metres.

---------

0.624

metres.

---------

II

metres.

---------

III

---------

---------

Equivalent length of

1/2"

0.01386

pipe-fittings:

No of elbows.

12

Nos. Schedule 80

Equivalent length =

624

mm

No. of Tees.

Nos. Schedule 80

Equivalent length =

mm

selected length

Constant

ID in metres

I + II + III

6.815(V/C)^1.852*(D)^(-1.167)

=

Total head loss in pipeline

50.624 metres.

51 metres.

140

1.8050871E-005 mWC

=

0.0009205944 mWC

0.000921 mWC

Sodium Hypochlorite Solution Strength Available

Flow rate in line to be dosed

Desired Dosage Rate

Pressure in Line where Hypo is to be dosed

Metering Pump Capacity

Hypo Storage Required

m3/hr

PPM

lt/hr

Hr

Hypo Storage Tank Capacity Selected

Pump rating

Hence, pump selected

Pump Quantity

%

0.5

5

5

2

gm/ltr

5

83.3333

ppm

5000

lpm

5.00

12

66

70

lt/h @ m head

lt/h @ m head

Nos.

5.00

lt/h @

5.00

lt/h @

1 Operating

2 m Differential head

2 m Differential head

0 Standby

Project

Owner

Rev No.

Prepared by

Azam

Client

Consultant

System

JK

Approved by

KAW1-EPC-CHS-DM-H-014

JK

Document No.

Ref Drwg / Doc.

Date

25.04.2011

Date

25.04.2011

Date

25.04.2011

Date

25.04.2011

System supplier

Document

2 Technical Specification # K9B06-SPC-M-0039 for Chlorination Plant

CHLORINATOR

As per Technical Specification Appendix - III, Clause 5.00.000 A) & B) ii following capcity has been confirmed:

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

Chlorinator Capacity

Kg/h

120

Kg/h

120 Rated capacity

Quantity

Nos.

4 Operating

2 Common Standby

Solution Concentration

ppm

2500

m/h

48

lpm

800 lps

13.33333

Minimum Ejector Water flow required

EVAPORATOR SIZING

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.

Capacity

Kg/h

120

Quantity

Nos.

4 Operating

2 Standby

EXPANSION TANK

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.

Area of 25 NB Line

0.00049

m2

Volume of 25 NB Line

m3

0.03675

liters

36.75

Let us say

liters

37

Expansion Chamber Size = Minimum 20% of Piping volume.

Therefore

liters

7.4

Hence Expansion Chamber Size of 10 litres Capacity is Suitable

CHLORINE CONCENTRATION IN SOLUTION LINE

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.

Accordingly solution flowrate required :

Chlorinator Capacity

Quantity

Solution Concentration

Kg/h

Nos.

ppm

120

4 Operating

2500

2 Standby

m/h

48

lpm

800

lps

13.33

Above flow is the minumum flow required for the stated capacity & concentration, but we have to design the system as per

ejector sizing

Ejector Sizing

Reference Ejector Curve

Bulletin

Ref.

Nozzle

Throat

122.3087.0

1.125

1.687

Back

Pressure

capability

(Kg/cm)

1

The above water flow is more than the minimum ejector water flow required and hence acceptable.

Ejector Inlet Pressure required

Flow through each ejector

Quantity of ejectors operating per

solution header

Combined Flow for the system

Kg/cm

Kg/cm

lpm

1

3

820

I.e.

m/h

Nos.

Standby

m/h

196.8

30 m head

49.2

2

Inlet

Pressure

(Kg/cm)

Flow

(lpm)

Flow m/h

820

49.2

Location

CW Forebay

MOC

HDPE as per IS:4984 Pressure rating:

PN 10

Grade:

PE 80

Size

63 OD

ID

50

mm

0.05

m

Flow through solution line to diffuser 196.8

m/h

Nos.of diffuser

18

Nos.

Flow through each diffuser

10.933

m/h

0.0030 m3/s

182.222 lpm

Velocity through diffuser

1.548

m/s

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 9.0

So, considering a flow

through the diffuser perforation

5.55

lpm

Therefore:

No of Perforations in diffuser

32.8

Nos. of Perforation each diffuser

Selected

32

Nos. of Perforation of 6mm diameter size

Perforation dia.

6

mm

Flow each perforation /orifice

0.342

m/h

C.S. Area of perforation

2.8E-005 m2

Velocity through Perforation

3.36

m/s

Hence the Diffuser Design is Suitable.

### m/sec

(considering diameter = 6mm)

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

Velocity

Tag No.

Flow at DF-1

Pipe size size selected

maintaine

d

m/h

m/s

OD mm

ID mm

ID m

m/s

Flow at DF-1

98.4

0.027333 200 OD

163.6

0.1636

1.301

Flow at DF-2

87.467 0.024296 180 OD

147.2

0.1472

1.428

Flow at DF-3

76.533 0.021259 160 OD

130.8

0.1308

1.583

Flow at DF-4

65.600 0.018222 160 OD

130.8

0.1308

1.357

Flow at DF-5

54.667 0.015185 140 OD

114.4

0.1144

1.478

Flow at DF-6

43.733 0.012148 125 OD

102.2

0.1022

1.482

Flow at DF-7

32.800 0.009111 110 OD

90

0.09

1.433

Flow at DF-8

21.867 0.006074

90 OD

73.6

0.0736

1.428

Flow at DF-9

10.933 0.003037

63 OD

51.4

0.0514

1.464

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 inc 6

mm

0.24

inch

D = Diameter of pipe in which orifice 50

mm

K = 0.75 (Discharge coefficient)

SUMMARY

d (dia of orifice) / D(dia of diffuser) = 0.12

Diffuser

This is less than 0.3,

so k =

0.75

Total nos. of diffuser

18

Nos.

MOC

HDPE as pePN 10

Qt = 182.2222 lpm

48.10667 gpm

Size

63 OD

No. of Perforation = 32

Diffuser perforation size

6

mm

Q = 1.503

gpm

Perforation in each diffuser

32

Nos.

oss at diffuser orifice

Flow through perforation

0.342

m/h

h = 3.1408

ft

Velocity through perforation

3.36

m/s

h = 0.9573

m

Location

CW Forebay

Chlorine Solution Line Calculations (OUTDOOR LINE)

HDPE IS

Solution header pipe (Header of two nos.

MOC

of ejector)

4984

Flow through header pipe

Velocity through pipe

Length of solution line

m3/h

m/s

m

Size

200 OD

ID

163.6

Friction

Factor

(C

Value)

140

98.4

1.300 This is less than 2.0m/s, hence acceptable.

150 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 =

C = Constant for Pipe =

D = Inside diameter of pipe =

1.30 m/s

140

163.60 mm

J =

### mtr/mtr length of pipe

Head loss in solution pipe =

1.46 m

Considering a 10% margin on

Frictional Loss it works to be

1.603 m

Frictional Loss in solution

m

1.603

line

Maximum Elevation of solution line

m

2

Pressure @ point of dosing

m

0 Since dosing point elevation is below ground level, it is not considered.

Pressure drop in Diaphragm

Valves

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

Loss in diffuser

m

0.9573

Total Loss

m

4.58229 This is well within the back pressure capability. Hence, O.K.

Chlorine Solution Line Calculations, Ejector downstream to solution header (Indoor line)

Friction

Factor

Ejector downstream

HDPE IS

MOC

Size

160 OD

ID

130.8

140

pipe

4984

(C

Value)

Flow through pipe

m3/h

49.2

Velocity through pipe

m/s

1.017 This is less than 2.0m/s, hence acceptable.

Length of pipe upto solution header

m

6 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 =

1.02 m/s

C = Constant for Pipe =

140

D = Inside diameter of pipe =

130.80 mm

Hence, on substituting valves on above formula, we get,

J =

### mtr/mtr length of pipe

Head loss in solution pipe =

0.05 m

Considering a 10% margin on

Frictional Loss it works to be

0.053 m

Frictional Loss in solution

m 0.057642

line

Pressure drop in Diaphragm

Valves

Size

160 OD

Formula for calculating Pressure drop or loss ( DP):

DP=(Q/Kv)2 * SG

DP - Pressure drop in

meter

Q - Flow

m/h

49.2

kv - Flow Co-efficient

415 (please refer attached capital controls chart Bulletein no. CCIPL-KV-DV/BFV/NRV-001)

SG- Specific gravity

1.4

Loss in Diaphragm Valves

m

0.0197 Loss (m)

0.0197 Quantity

1

Pressure drop in NRVs

Size

160 OD

Formula for calculating Pressure drop or loss ( DP):

DP=(Q/Kv)2 * SG

DP - Pressure drop in

meter

Q - Flow (lpm)

kv - Flow Co-efficient

SG- Specific gravity

Loss in NRVs

Maximum Elevation

Total Loss

m/h

49.2

1050 (please refer attached capital controls chart Bulletein no. CCIPL-KV-DV/BFV/NRV-001)

1.4

m

0.0031 Loss (m)

0.0031 Quantity

1

m

1

m 1.080393

m 5.662683 This is within the permissible back pressure of 10m or 1kg/cm 2. Hence, O.K.

Motive Water Line Calculations, Pump Discharge header upto Ejector upstream

Booster Pump

Discharge Header line

MOC

Velocity through pipe

Length of pipe, from pump discharge

header upto ejector

m3/h

m/s

CS IS

3589

Size

219.1 OD

ID

208

Friction

Factor

(C

Value)

100

196.8

1.609 Velocity limit range (1.5-2.4m/s).This is less than 2.4m/s, hence acceptable.

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 =

1.61 m/s

C = Constant for Pipe =

100

D = Inside diameter of pipe =

208.00 mm

Hence, on substituting valves on above formula, we get,

J =

### mtr/mtr length of pipe

Head loss in solution pipe =

0.24 m

Considering a 10% margin on

Frictional Loss it works to be

0.268 m

Frictional Loss

m

0.268

Pressure drop in butterfly Valves

Size

219.1 OD

Formula for calculating Pressure drop or loss ( DP):

DP=(Q/Kv)2 * SG

DP - Pressure drop in

meter

Q - Flow

kv - Flow Co-efficient

SG- Specific gravity

Loss in butterfly valve

Loss in Flowmeter

Maximum Elevation

Total Loss

m/h

196.8

1122 (please refer attached capital controls chart Bulletein no. CCIPL-KV-DV/BFV/NRV-001)

1

m

0.062 Loss (m)

0.031 Quantity

2

m

5

m

2

m

7.330

A

Motive Water Line Calculations, Pump Discharge line upto Discharge header

Booster Pump

Discharge line

MOC

Velocity through pipe

Length of pipe, from pump discharge

header upto ejector

m3/h

m/s

m

CS IS

1239

Size

150 NB

ID

153.1

Friction

Factor

(C

Value)

100

98.4

1.485 Velocity limit range (3m/s). This is less than 3m/s, hence acceptable.

12 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 =

1.48 m/s

C = Constant for Pipe =

100

D = Inside diameter of pipe =

153.10 mm

Hence, on substituting valves on above formula, we get,

J =

### mtr/mtr length of pipe

Head loss in solution pipe =

0.30 m

Considering a 10% margin on

Frictional Loss it works to be

0.330 m

Frictional Loss

m

0.330

Pressure drop in butterfly Valves

Size

150 NB

Formula for calculating Pressure drop or loss ( DP):

DP=(Q/Kv)2 * SG

DP - Pressure drop in

meter

Q - Flow

kv - Flow Co-efficient

m/h

98.4

880 (please refer attached capital controls chart Bulletein no. CCIPL-KV-DV/BFV/NRV-001)

m

0.013

Pressure drop in NRVs

Size

150 NB

Formula for calculating Pressure drop or loss ( DP):

DP=(Q/Kv)2 * SG

DP - Pressure drop in

meter

Q - Flow (lpm)

kv - Flow Co-efficient

SG- Specific gravity

Loss in NRVs

Total Loss

Loss (m)

0.013 Quantity

m/h

98.4

1050 (please refer attached capital controls chart Bulletein no. CCIPL-KV-DV/BFV/NRV-001)

1

m

0.00878 Loss (m)

0.0088 Quantity

1

m

0.352

B

Total

Pressure required @ pump

Discharg

37.7 Ejector Inlet pressure + A + B

discharge

e Head

(m)

Motive Water Line Calculations, motive water header

Friction

Booster pump suction

CS IS

Factor

MOC

Size

150 NB

ID

153.1

100

line

3589

(C

Value)

Flow through pipe

98.4

m3/h

Velocity through pipe

m/s

1.485 Velocity limit range (1.5m/s). This is less than 1.5m/s, hence acceptable.

Length of pipe from

m

6 Max length taken for design porpose, in practical it will be less.

header upto pump suction

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 =

1.48 m/s

C = Constant for Pipe =

100

D = Inside diameter of pipe =

153.10 mm

Hence, on substituting valves on above formula, we get,

J =

### mtr/mtr length of pipe

Head loss in solution pipe =

0.15 m

Considering a 10% margin on

Frictional Loss it works to be

0.165 m

Frictional Loss

m

0.165

Pressure drop in butterfly Valves

Size

150 NB

Formula for calculating Pressure drop or loss ( DP):

DP=(Q/Kv)2 * SG

DP - Pressure drop in

meter

Q - Flow

kv - Flow Co-efficient

SG- Specific gravity

Loss in butterfly valve

Total Loss

m/h

98.4

880 (please refer attached capital controls chart Bulletein no. CCIPL-KV-DV/BFV/NRV-001)

1

m

0.013 Loss (m)

0.013 Quantity

1

m 0.177725

C

Motive Water Line Calculations, motive water header from tapping point upto pump suction line

Booster pump suction

Header

Flow through pipe

Velocity through pipe

Length of pipe from

tapping point

MOC

m3/h

m/s

m

CS IS

3589

Size

219.1 OD

ID

208

Friction

Factor (C

Value)

100

196.8

1.609 Velocity limit range (1.5-2.4m/s). This is less than 2.4m/s, hence acceptable.

100 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 =

1.61 m/s

C = Constant for Pipe =

100

D = Inside diameter of pipe =

208.00 mm

Hence, on substituting valves on above formula, we get,

Considering a 10% margin on

Frictional Loss it works to be

2.03 m

2.234 m

Frictional Loss

m

2.234

Maximum Elevation

m

2

Pressure drop in butterfly Valves

Size

219.1 OD

Formula for calculating Pressure drop or loss ( DP):

DP=(Q/Kv)2 * SG

DP - Pressure drop in

meter

Q - Flow

m/h

kv - Flow Co-efficient

SG- Specific gravity

Loss in butterfly valve

Loss in Strainers @ 50% choked

condition

Total Loss

Total Loss in Motive Water Pipe from

tapping

point upto

pump at

suction

Water

Pressure

available

tapping

point

Head available @ pump suction

Pumps

Ejectors operating per

pump

Pump rating

Hence, pump selected

Pump Quantity

Nos.

m/h @ m

m/h @ m

Nos.

196.8

1122 (please refer attached capital controls chart Bulletein no. CCIPL-KV-DV/BFV/NRV-001)

1

m

0.062 Loss (m)

0.031 Quantity

2

m

4 Loss (m)

4 Quantity

1

m 8.295883

D

m 8.473608

C+D

m

15

m

6.5

2

118.08

m/h @

120

m/h @

2 Operating

31 m Differential head

31 m Differential head

1 Standby

1500 RPM

SUMMARY

Pipe

Pipe MOC Flow m3/hSelected SizeID (mm) Velocity m/s

Velocity Limit Remark

Header

CS IS 3589

196.8

219.1 OD

208

1.61

1.8

CS IS 3589

98.4

150 NB

153.1

1.48

1.5

98.4

150 NB

153.1

1.48

CS IS 3589

196.8

219.1 OD

208

1.61

2.4

HDPE IS 4984

49.2

160 OD

130.8

1.02

2.0

HDPE IS 4984

98.4

200 OD

163.6

1.30

2.0

Header

Chlorine Solution Line at

ejector outlet

Chlorine Solution Header

Line

Pump

Service

Type

Quantity

Flow

Differential Head

Centrifugal Horizontal

2

Working

1

Standby

120

m/h

31

m

hence selected line size is

ok

Location

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