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Document No.
Ref Drwg / Doc.

P&ID FOR CW CHLORINATION SYSTEM, Dwg. No. 3059-E01-002-00 Rev 0


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

CHLORINE CONCENTRATION IN SOLUTION LINE


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)

Reference Ejector Curve


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.

Prepared By: Bhavesh


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

HEAD LOSS IN DIFFUSER


Refer Capital Control document 123.3005.0 attached.
Head Loss at diffuser orifice h = (Q/ 19.636 Kd2)2
Qt = Total Flow in GPM through diffuser
Q = Flow in GPM through each orifice
d = Diameter of diffuser orifice in inches =
6
D = Diameter of pipe in which orifice is placed = 81.4
K = 0.75 (Discharge coefficient)

mm
mm

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


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

Chlorine Solution Line Calculations (OUTDOOR LINE)


Solution header pipe

MOC

Flow through header pipe


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

Flow through pipe


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

Prepared By: Bhavesh


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

Flow through pipe


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.

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 =
2.39 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

Motive Water Line Calculations, motive water header


MOC MS IS 1239

Booster pump suction line

Size

125 NB

ID

129.5

Friction
Factor
(C
Value)

100

Friction
Factor (C
Value)

100

Flow through pipe


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

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


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

Flow through pipe


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.

10 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 =
2.31 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

Booster Pump Suction Line

MS IS 1239

70.8

100 NB

104.2

2.31

2.4

Booster Pump Suction Header

MS IS 1239

70.8

125 NB

129.5

1.49

1.5

Booster Pump Discharge Line

MS IS 1239

70.8

100 NB

102.3

2.39

Ejector Upstream

MS IS 1239

35.4

80 NB

78.4

2.04

2.4

Chlorine Solution Line at ejector


outlet

uPVC IS 4985

35.4

90 OD

81.4

1.89

2.0

Chlorine Solution Header Line

uPVC IS 4985

70.8

125 OD

113

1.96

2.4

This within velocity limit,


hence selected line size is
ok

SUMMARY
Pipe
Location

Prepared By: Bhavesh


Date: 9th May, 2011

Selected Size ID (mm)

Checked by:
NMK

REV NO. - 00

Prepared By: Bhavesh


Date: 9th May, 2011

Checked by:
NMK

REV NO. - 00

Project
Owner
Contractor
Consultant
System
System supplier
Document
Document No.
Ref Drwg / Doc.

P&ID FOR CW CHLORINATION SYSTEM, Dwg. No. 3059-E01-001-00 Rev 0


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

CHLORINE CONCENTRATION IN SOLUTION LINE


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

HEAD LOSS IN DIFFUSER


Refer Capital Control document 123.3005.0 attached.
Head Loss at diffuser orifice h = (Q/ 19.636 Kd2)2
Qt = Total Flow in GPM through diffuser
Q = Flow in GPM through each orifice
d = Diameter of diffuser orifice in inches =
6
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

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


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

Chlorine Solution Line Calculations (OUTDOOR LINE)


Solution header pipe

uPVC
MOC Schedule
80

Flow through header pipe


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

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


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

Flow through pipe


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

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 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

Ejector Inlet pressure +A + B X 10%Margin

Motive Water Line Calculations, motive water header


uPVC
MOC Schedule
80

Booster pump suction line

Size

1"

ID

Friction
Factor
(C Value)

24.3

140

Flow through pipe


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

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
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

Booster pump suction Header


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.

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 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

Booster Pump Suction line

uPVC Schedule 80

1.62

1"

24.3

0.97

1.5

Booster Pump Discharge Line

uPVC Schedule 80

1.62

1"

24.3

0.97

Booster Pump discharge Header

uPVC Schedule 80

1.62

1"

24.3

0.97

2.4

Chlorine Solution Line at ejector


outlet

uPVC Schedule 80

1.62

1"

24.3

0.97

2.0

Chlorine Solution Header Line

uPVC Schedule 80

1.62

1"

24.3

0.97

2.4

Pumps
Ejectors operating per pump
Pump rating
Hence, pump selected
Pump Quantity
SUMMARY
Pump
Service
Type
Quantity
Flow
Differential Head

Prepared By: Bhavesh


Date: 17th May, 2011

Nos.
m/h @ m head
m/h @ m head
LPM @ m Head
Nos.

Selected Size ID (mm)

1
1.944
m/h @
2
m/h @
33.33
LPM
1 Operating

46
50
50
1

Velocity m/s

Velocity Limit Remark

m Differential head
m Differential head
m Differential head
Standby

This within velocity limit,


hence selected line size is
ok

Pipe MOC

Booster Pump Suction Header

2900 RPM

Water Booster pump


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

I. STORAGE TANK SIZING:


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

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


where,
Effective volume required:

15 cu.m

D= diameter of cylindrical tank


H= height of cylindrical tank
Calculated volume

2.5 m OD
3.5 m
V

B. THICKNESS CALCULATION FOR SULPHURIC ACID STORAGE TANKS


MOC:
MS as per IS 2062
Design Code:
IS:803
Tank Diameter
m
Tank Height
m

17.187 m3

2.5
3.5

1. Shell plate Thickness:


The minimum thickness of shell plates shall not be less than the calculations from the folowing formula
T = (50(H-0.3)*D*G/(SE))
Where,
T= minimum thickness in mm
D= Nominal diameter of the tank
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

Shell Plate Thickness:


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

Atmospheric Horizontal cylinder with dished ends


MS as per IS 2062
5 mm
2.5 m
3.5 m
0.445 m

II. PIPE SIZING:


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

2. Unloading Pump suction line:


MOC:
Flow of stream
Velocity in pump suction header

MS IS:1239
m3/hr
m/sec

ID in metres
0.0663
0.0028

3. Unloading Pump Discharge Line


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

4. Unloading Pump Discharge Header:


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

III. ACID UNLOADING PUMP HEAD SIZING:


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

Total Equivalent length


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 =

Nos. 3000# socket weld

342

No. of Tees.

pipe-fittings:

mm
Nos. 3000# socket weld

Head loss per meter length

Total head loss in pipeline

B. Head loss through valve of


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

Loss through valve

0.024 mWC

Head loss in acid unloading pump header

=
=

Head loss in Sulphuric acid unloading pump suction header:

1+2
0.15215 mWC
0.152151115 mWC

2. Head loss in acid unloading pump suction line:


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

Total Equivalent length


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

Nos. 3000# socket weld


mm
Nos. 3000# socket weld

Head loss per meter length

Total head loss in pipeline

B. Head loss through valve of


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

C. Head loss through Y-type strainer

2 mWC

Head loss in unloading pump suction line

=
=

1+2+3
2.08808 mWC

Head Loss in Sulphuric Acid unloading pump suction line:

2.08808 mWC

Total Head Loss in Sulphuric Acid Unloading Pump Suction side:


=

A+B
2.24023

---------

---------

mWC

3. Head loss in acid unloading pump discharge line:


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

Total Equivalent length


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

Nos. 3000# socket weld

216

No. of Tees.

mm
Nos. 3000# socket weld

Total head loss in pipeline

Total head loss in pipeline


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

Loss through NRV


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

Loss through valve

0.1 mWC

Total Head loss in unloading pump discharge line

=
=

Head Loss in Sulphuric Acid unloading pump Discharge line:

1+2+3
0.61170 mWC
0.61170 mWC

4. Head loss in acid unloading pump discharge header:


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

Total Equivalent length


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.

Head loss per meter length

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

Total head loss in pipeline

B. Head loss through ballvalve of


Qty:
Flow through valve

0.236696055 mWC

---------

---------

---------

50 NB
1 No.
10 m3//hr

Loss through valve

0.1 mWC

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

=
=

1+2
0.336696055 mWC

Head Loss in Sulphuric Acid unloading pump Discharge header:

0.33670 mWC

Total loss in Sulphuric Acid Unloading Pump Discharge side:

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

Pump Head requirement


Selected Value
Pump Capacity
Pump Head Selected

= 3.18861878 mWC
=
4 mWC
=
10 m3/hr.
=
10 mWC

IV. DAY / MEASURING TANK SIZING


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

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


where,
Effective volume required:

2.5 cu.m

D= diameter of cylindrical tank


H= height of cylindrical tank
Calculated Volume

1.5 m OD
1.72 m
V

B. THICKNESS CALCULATION FOR SULPHURIC ACID DAY / MEASURING TANK


MOC:
MS as per BS 2594
Design Code:
IS:803
Tank Diameter
m
Tank Height
m

3.041 m3

1.5
1.72

1. Shell plate Thickness:


The minimum thickness of shell plates shall not be less than the calculations from the folowing formula
T = (50(H-0.3)*D*G/(SE))
Where,
T= minimum thickness in mm
D= Nominal diameter of the tank
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

Shell Plate Thickness:


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

Vertical cylindrical type with cover


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

VI. ACID METERING PUMP HEAD SIZING:


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

Head loss per meter length

Total head loss in pipeline

B. Head loss through ball valve of


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

Loss through ball valve

0.1 mWC

refer enclosed graph for ball valve


Head loss in metering pump suction header

=
=

Head Loss in Sulphuric Acid Metering Pump Suction Header

1+2
0.123624655 mWC
0.123624655 mWC

2. Head Loss in Metering Pump Suction Line:


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

Total Equivalent length


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

Head loss per meter length

Total head loss in pipeline

B. Head loss through ball valve of


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

C. Head loss through Y-type strainer

2 mWC

Head loss in metering pump suction line

=
=

1+2+3
2.111812328 mWC

Head Loss in Sulphuric Acid Metering Pump Suction Line

2.111812328 mWC

Total loss in Sulphuric Acid Metering Pump Suction line:


=

---------

---------

A+B
2.235436983 mWC

3. Head Loss in Metering Pump Discharge Line:


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

Total Equivalent length


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

Head loss per meter length

Total head loss in pipeline


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

Loss through NRV


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

Loss through ball valve


refer enclosed graph for ball valve

0.01 mWC

Total Head loss in metering pump discharge line

=
=

Head Loss in Sulphuric Acid Metering Pump Discharge Line

1+2+3
0.532681701 mWC
0.532681701 mWC

4. Head loss in dosing pump discharge header:


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

Total Equivalent length


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.

Head loss per meter length

Total head loss in pipeline

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

B. Head loss through ballvalve of


Qty:
Flow through ball valve

15 NB
1 No.
0.075 m3//hr

Loss through ball valve

0.01 mWC

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

=
=

0.03756 mWC

Total Head loss in Sulphuric Acid Metering Pump Discharge side:

Flow each perforation /orifice


C.S. Area of perforation
Velocity through Perforation
Hence the Diffuser Design is Suitable.

---------

C+D
0.57024 mWC

So, considering a flow


through the diffuser perforation
Therefore:
No of Perforations in diffuser
Selected
Perforation dia.

1+2
0.03756 mWC

Head Loss in Sulphuric Acid Metering Pump Discharge Header

DIFFUSER SIZING (Typ. for each unit)


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 each diffuser


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

3. Pressure available at tank discharge point

Pump Head requirement

= 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.

I. STORAGE TANK SIZING:


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

D= diameter of cylindrical tank


H= height of cylindrical tank
Calculated Volume

1.1 m OD
1.225 m
V

1.165 m3

B. THICKNESS CALCULATION FOR INHIBITOR STORAGE TANKS


MOC:
MSRL as per IS 2062
Design Code:
IS:803
Tank Diameter
m
Tank Height
m

1.1
1.225

1. Shell plate Thickness:


The minimum thickness of shell plates shall not be less than the calculations from the folowing formula
T = (50(H-0.3)*D*G/(SE))
Where,
T= minimum thickness in mm
D= Nominal diameter of the tank
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

Shell Plate Thickness:


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

Vertical cylindrical type with cover


MSRL as per IS 2062
5 mm
1.1 m
1.225 m
0.173 m

II. METERING PUMP HEAD SIZING:


1. Head Loss In Metering pump Suction Header:
A. Selected pipe specifications:

Size

ID in mm

ID in metres

uPVC
Schedule 80
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

Total Equivalent length


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

Head loss per meter length

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

=
Total head loss in pipeline

0.0012838 mWC
=

B. Head loss through Ball valve of


Qty:
Flow through ball valve

5.312 metres.
6 metres.
140

0.00770281 mWC

1/2"
1 No.
0.05 m3//hr

Loss through ball valve

0.01 mWC

Head loss in metering pump suction header

=
=

Head loss in Inhibitor Tank Metering Pump Suction Header:

1+2
0.01770281 mWC
0.01770281 mWC

2. Head Loss In Metering Pump Suction Line:


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

Total Equivalent length


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

Head loss per meter length

B. Head loss through ball valve of


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"

Loss through ball valve

C. Head loss through Y-type strainer

2.208 metres.
3 metres.
140

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

=
Total head loss in pipeline

0.01386

1/2"

Total Head loss in metering pump suction line

=
=

Head loss in Inhibitor Metering Pump Suction Line:

1+2+3
2.01385141 mWC
2.01385141 mWC

Total head loss in Inhibitor Pump Suction line:

=
=

---------

A+B
2.03155422 mWC

3. Head Loss in Metering Pump Discharge Line:


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

Head loss per meter length

100.208 metres.
101 metres.
140

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

Total head loss in pipeline


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"

Loss through NRV of Metering pump


C. Head loss through ball valve of :
Qty:
Flow through ball valve

0.0012838 mWC

1/2"
0 No.
0.05 m3//hr

Loss through ball valve

0.01 mWC

Total Head loss in metering pump discharge line

=
=

Head loss in Inhibitor Metering Pump Discharge Line:

1+2
0.25466404 mWC
0.25466404 mWC

4. Head loss in Metering pump discharge header:


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

Length of pipe from tank discharge point upto pump discharge header
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)

Total Equivalent length


selected length
Constant

I + II + III

=
C

Head loss per meter length

6.52 metres.
7 metres.
140

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

0.0012838 mWC

Total head loss in pipeline

0.00898662 mWC

B. Head loss through ball valve of : 1/2"


Qty:
Flow through ball valve

1 No.
0.05 m3//hr

Loss through ball valve

0.01 mWC

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

=
=

Head loss in Inhibitor Metering Pump Discharge Header:


=
=

DIFFUSER SIZING (Typ. for each unit)


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

Total loss in Metering Pump Discharge side:

---------

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 each diffuser


Nos. of Perforation of 1mm diameter size
mm

Flow each perforation /orifice


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

Pump Head requirement


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

5.64 = / 4 *d2 *2.4.


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.

I. STORAGE TANK SIZING:


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

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


where,
Effective volume required:

D= diameter of cylindrical tank


H= height of cylindrical tank
T= Thickness of Tank =
Calculated Volume

Summary:
Construction:
MOC:
Thickness:
Tank Diameter:
Tank height:
Free board:

Nos.
m3

Hypo sol. Preparation tank


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

Vertical cylindrical type with flat bottom and cover


PP+FRP
0 mm
0.5 m
0.7 m
0.191 m

METERING PUMP HEAD SIZING:


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

---------

---------

Length of from pump discharge to dosing point:


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

Total Equivalent length


selected length
Constant

Head loss per meter length

ID in metres

I + II + III

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

=
Total head loss in pipeline

Head loss in Inhibitor Tank Metering Pump Delivery line:

50.624 metres.
51 metres.
140

1.8050871E-005 mWC
=

0.0009205944 mWC

0.000921 mWC

METERING PUMP SELECTION:


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


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

1320 MW (Phase-I : 2 X 660 MW) Kawai Thermal Power Project

Owner

Adani Power Rajasthan Ltd.

Rev No.

Adani Infra (India) Ltd.

Prepared by

Development Consultants Pvt. Ltd., Kolkata

Azam

Client
Consultant
System

Capital Control India Pvt. Ltd

JK

Sizing Calculation for CW Chlorination system

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

6 x 120kg/h CW Chlorination and Absorption system Checked by

System supplier
Document

P&ID FOR CW CHLORINATION SYSTEM, Dwg. No. KAW1-EPC-CHS-DM-D-007 Rev 0


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

Minimum Ejector Water flow required


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.

Back Pressure capability


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

DIFFUSER SIZING (Typ. for each unit)


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)

For Flow through Diffusers header:


As flow progresses the flow rate through diffusers header reduces by each diffuser and hence, the diffuser header size reduced progressively
manintaining the flow by keeping velocity range of 1.6 -1.8 m/s
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

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


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

Back Pressure on Ejector

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

Flow through pipe


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.

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 =
1.61 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

Flow through pipe


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)

SG- Specific gravity

Loss in butterfly valve


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,

### mtr/mtr length of pipe

Head loss in solution pipe =


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

Booster Pump Suction


Header

CS IS 3589

196.8

219.1 OD

208

1.61

1.8

Booster Pump Suction line

CS IS 3589

98.4

150 NB

153.1

1.48

1.5

Booster Pump Discharge Line CS IS 1239

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

Booster Pump discharge


Header
Chlorine Solution Line at
ejector outlet
Chlorine Solution Header
Line

Pump
Service
Type
Quantity
Flow
Differential Head

Water Booster pump


Centrifugal Horizontal
2
Working
1
Standby
120
m/h
31
m

This within velocity limit,


hence selected line size is
ok

Location