Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
DESIGN GUIDES
CONTENTS
DESIGN GUIDES
CONTENTS
2
Qv = 12,400 - 2100 d
%H = 26 - 15d
Qp = Qv - 50.45 X %H
Where,
Where Qv’ = Higher Heating Value at constant volume per unit quantity of fuel oil
containing water, ash, sulphur. Final products being ash, gaseous
Co 2 , So 2 and liquid water.
Qp’ = Net heat of combustion (LHV) at constant pressure per unit quantity
of fuel oil containing water, ash and sulphur. Final products being
ash, gaseous Co 2 , So 2 and H 2 O.
X & Y are constants which vary in value depending upon the units in which heating
value is reported.
UNIT X Y
kcal/kg 22.5 5.85
Flue gas Dew point temperature is determined from the following correlation :
1000
------- = 1.7842 + 0.0269 * log(Pw) - 0.1031 * log(PS03) +
Tdp
0.0329 * log (Pw) * log (PSo3)
DEW POINT :
Dew point is the temperature at which an un-saturated gas vapour mixture becomes
saturated as a result of iso-baric cooling at constant absolute humidity. The dew point
is also the saturation temperature corresponding to the initial partial pressure of the
vapour. If the cooling proceeds further, both temperature and the absolute humidity
decrease and rapid condensation of water vapour takes place.
If however, the temperature of stack gases is lowered below the dew point, sulphuric
acid will condense out and cause corrosion of metal.
The fan power consumption depends on the gas quantity and the resistance through
the boiler gas passes which will be dependant on the particular boiler design and the
range of fuels to be burned.
In selecting a fan, one is guided by the maximum capacity Q and head H required of
the fan as applied to a given air or gas duct work. A margin in pressure and volume
over normal requirements is necessary to compensate for boiler fouling, adverse
combustion conditions, poor fuel and to provide cover for possible slight errors in the
estimates of draught system requirements. The margin is usually about 20% for
volume and about 50% for system resistance. The cost of
providing margins in fan duty, is higher than for most other items of plant owing to the
square law relating volume to pressure and to the cube law relating volume to
b) Fan Speed
The capacity of the forced draft fans is to be determined at the lowest density
condition prevailing at the site.
For the same heat input to boilers, the air quantity required in mass flow units
(kg/hr) remains the same irrespective of the ambient conditions.
W = 60 ρq
where
w = mass flow, kg/hr
ρ = density, kg/m
3
3
q = Volumetric flow, m /hr
Fans discharge constant volumetric flow at any density. Hence if the fan is
sized to give a particular volumetric flow at the high density condition, the
mass flow would decrease when density decreases as can be seen in the
equation above. Hence the fan must be sized to deliver the volumetric flow at
the lowest density condition, in which case the output will be higher at the
higher density condition, which can be then controlled.
Also, the gas pressure drop ∆p in mmwc across the wind box is proportional
2
to w /l. If the air density decreases as at high-temperature conditions, the
pressure drop increases, because W remains unchanged for a given heat
input. Considering the fact that H/ρ is a constant for a given fan, where H is
the static head in mmwc, using the lowest ensures that the head available at
higher density will be larger.
Diameter = `D’ m.
Height = `H’ m.
π DH m
2
5. Surface area of the tank =
Temperature = T °C
Enthalpy = Hs kcal/kg
Temperature = T °C
Enthalpy = Hs kcal/kg.
Pressure = pata
Temperature = T °C
Enthalpy = Hs kcal/kg
HHV in kcal/kg
LHV in kcal/kg
Where,
% WT NOTA-
TION
COMPOSITION % MOL. xiMi HHV LHV
VOL WT (KCAL/KG) (KCAL/KG)
xnMn / 100
∑
n= CH 4 , C 2 H6 etc
i =cons for which % wt conversion to be
done
x4 x5 x6
+
100 *( HHV ) C 4 H 10 + 100 *( HHV ) C 4 H 10 + 100 *( HHV ) C 5 H 12
x7 x9
+
100 *( HHV ) C 5 H 12 + 100 *( HHV ) Hexane plus
HHV is in kcal/kg. HHV in kcal/Nm3 = HHV(kcal/kg) x gas density (kg/m3).
x4 x5 x6
+
100 *( LHV ) C 4 H 10 +
100 *( LHV ) C 4 H 10 + 100 *( LHV ) C 5 H 12
x7 x9
+
100 *( LHV ) C 5 H 12 + 100 *( LHV ) Hexane Plus
O2 O2
REQUIRED REQUIRED
CONSTI- FRACTION PER KG OF PER KG
TUENT CONSTITUENT OF FUEL
Oxygen - - -
Nitrogen - - -
Moisture - - -
Total *T
% by wt (c)
Description % by Vol. Mol. Wt of XiMi
∑
comp. Dry Air
XnMn / 100
th
Where N is the N number of constituent in the gas.
1 HARDNESS 1 -
5 CONDUCTIVITY
micro s/cm 10 1000
6 HYDRAZINE - -
RESIDUAL ppm
7 PHOSPHATE -
RESIDUAL ppm 20.0-40.0
10 COPPER,TOTAL,ppm 0.01 -
11 SODIUM SULPHATE - 20-40
AS Na 2 SO 3 ppm
1 HARDNESS 0.5 -
5 CONDUCTIVITY
micro s/cm 5 400
6 HYDRAZINE
RESIDUAL ppm - -
7 PHOSPHATE
RESIDUAL ppm - 20.0-40.0
10 COPPER,TOTAL,ppm 0.01 -
11 SODIUM SULPHATE
AS Na 2 SO 3 ppm - 5-10
1 HARDNESS NIL -
5 CONDUCTIVITY
micro s/cm 2 300
6 HYDRAZINE
RESIDUAL ppm 0.02-0.04 -
7 PHOSPHATE
RESIDUAL ppm - 15.0-25.0
10 COPPER,TOTAL,ppm 0.01 -
11 SODIUM SULPHATE
AS Na 2 SO 3 PPM - -
1 HARDNESS NIL -
5 CONDUCTIVITY
micro s/cm 0.5 200
6 HYDRAZINE
RESIDUAL ppm 0.01-0.02 -
7 PHOSPHATE
RESIDUAL ppm - 15.0-25.0
10 COPPER,TOTAL,ppm 0.01 -
11 SODIUM SULPHATE
AS Na 2 SO 3 PPM - -
1 HARDNESS NIL -
5 CONDUCTIVITY
micro s/cm 0.3 <100
6 HYDRAZINE
RESIDUAL ppm 0.01-0.02 -
7 PHOSPHATE
RESIDUAL ppm - 5.0-10.0
10 COPPER,TOTAL,ppm 0.005 -
11 SODIUM SULPHATE
AS Na 2 SO 3 ppm - -
3 Total hardness as
CaCO 3 ppm 0.300 -
6 Specific conductance
micro s/cm - 7000
3 Total hardness as
CaCO 3 ppm 0.200 -
6 Specific conductance
micro s/cm - 5000
3 Total hardness as
CaCO 3 ppm 0.100 -
6 Specific conductance
micro s/cm - 3000
3 Total hardness as
CaCO 3 ppm 0.050 -
6 Specific conductance
micro s/cm - 2000
DEFINITION
Boiler Blowdown is defined as the process of removal of a fraction of water from boiler
unit and its replacement by feed water. This is done to prevent build up of excessive
Intermediate Blowdown is carried out to reduce the sludge level in the Boiler Water
rate.
next (h).
Continuous Blowdown
C1 = C
BA = B
d =t
B = 100 x [S/(C-S)]
The above relationship is valid for various constituents of water like Alkalinity, salt
content, silica etc., Check for the Blowdown rate for each constituent separately and
the minimum value of Blowdown rate shall be considered and the corresponding
constituent shall be the governing factor. Refer document no. 100/11 for Boiler Water
Intermittent Blowdown
B = tsv x 100/[d(CV-0.5SE(t-d)-VS)]
Q = EtSV/[CV-0.5SE(t-d)-VS]
C 1 = C - [(t-d) SE/V]
B A = Q x 100/tE
CHIMNEY SIZING
Introduction
Chimneys, as we know them today, are tall slender structures which fulfill an
important function. They had a humble beginning as house hold vents and over the
years, as vents grew larger and taller, they came to be known as chimneys. A cluster
of them is a stack.
Function
A chimney is a means by which flue gases are discharged at a high elevation so that
after dilution due to atmospheric turbulence, their concentration and that of their
entrained solid particulates is with in acceptable limits on reaching the ground. A
chimney achieves simultaneous reduction in concentration of a number of pollutants
(such as SO 2 , NO x , CO, Suspended\Particulate Matter (SPM), Respirable Particulate
Matter (RPM). Size less than 10 µm, lead etc) and being highly reliable it does not
require a stand by, while these are its merits, it is well to remember that a chimney is
not the complete solution to the problem of pollution control.
Chimney classification
Chimney are classified based on their height (tall or short), number of flues (single or
multi), material of construction (Brick, RCC, steel, FRP), structural support (Guyed or
self supporting), lining (Lined or unlined). When Multiflue chimney is selected ?
often, a single chimney serves more than one boiler. In such a case when one of the
gas sources is shut down for maintenance the gas exit velocity will reduce because of
a reduction in the total volume of gases to be handled. This can lead to heavy
pollution and in order to overcome this problem, a chimney serving more than one
boiler can be provided with a separate flue for each gas source with such flues
housed in a common enclosing concrete wind shield. These are called as Multi-flue
chimneys.
Exit Velocity
Flue gases emerging from a chimney experience a field of increasing wind speed,
soon a speed will be reached (termed critical wind speed) when the wind will shear off
the emerging gas plume and this can lead to excessive pollutant deposition. If the exit
velocity is low, it can permit cold air to flow down a part of the chimney causing acids
contained in flue gases to condense on the walls and cause damage. In order to
avoid this, the flue gas velocity (ie. when chimney is operating in part load) should be
such that 1.5 times the wind velocity.
A part from this, a larger exit velocity will result in higher plume rise which in turn will
lead to a diminished GLC of pollutants. For the above reasons, a high exit velocity is
preferred but this can damage the lining due to erosion. With steel liners, velocities
upto 45 m/s can be used and with brick liners velocities higher than 30 m/s is not
recommended.
3
For power plant chimneys handling more than 2000 M /min of flue gases, exit
velocities will be in the range of 20-25 m/s.
In general for our calculations purpose we use flue gas velocity as 1.5 times the
wind velocity, which is recommended in IS 4998 and Tall chimneys by S.N
Manohar.
Physical Dimensions
Shape
Any shape for the chimney, other than circular, offers greater resistance to wind
currents and is more prone to oscillation. Hence circular shape is recommended.
Exit size
The top dimensions of a flue are fixed such that a given volume of gases can be
discharged at the design exit velocity. A 20% increase in the cross sectional area
shall be provided for the effect of reduced velocity near the inner surface of the
chimney due to friction. If a chimney has to handle a range of gas volumes, then the
exit velocity should be high at minimum load and at the same time should not exceed
the limiting values when operating at full load.
Physical height
1. To generate a draft which will cause gases to flow out with the desired exit velocity.
Step : 1
1/ 2 1/ 6
AQFK n
Height of the chimney `H’ = *
CP V∆T
where
K = a coefficient accounting for the effect of flue gas exit velocity for the chimney
V o . The values are given below.
10-15 1
20-25 0.9
30-35 0.8
3
C p = Maximum expected concentration of the pollutant at grade level (mg/M )
n = Number of chimneys
3
V = Total volume of flue gases discharged from chimneys (M /s )
∆ T = Temperature difference between flue gas Tg and ambient air temperature Ta (°C)
= Tg - Ta
Step - 2
1/ 2
Cp
Hc = H
Cp − Ce
Where
Step - 3
However, as per pollution control norms the stack height requirement for sulphur di-
oxide control shall be as follows.
0.3
H = 14 (Q)
Where
Chimney height calculated based on the above two methods has to be compared, and
the tallest one shall be selected.
Stack height requirement as per pollution control norms for larger capacity power
plants is as follows. For Boiler size less than 200 MW above steps shall be followed, if
Boiler size is above 200 MW & less then 500 MW then 220 M height chimney shall be
selected if the Boiler size is more than 500 MW then 275 M height chimney shall be
selected.
Step - 4
CHIMNEY DIAMETER
4V
De =
π V0
Where
De c = 1.2 x De
Where
After finishing the above calculation, stack draft calculation shall be done and draft
available shall be checked. The following are the procedure to calculate the net draft
available.
Net draft available is nothing but theoretical draft calculated less the dynamic head
loss due to kinetic energy of gases leaving a chimney and the head lost in overcoming
friction along the internal surface of a flue.
1 1
Net draft = 13.6 * 0.029 BH d − −
Ta Va Tg Vg
Tgm Tgt Tge
-9
15.4x10 x Q
2
g x Vg Hd f + − MM of H 2 O
BmD m BE D t BeD 4 e
5 4
where
T a = air temperature (° K)
3
V a = Sp. volume of air at STP = 0.775 (m /kg)
Clearances
2. Environmental clearance from state pollution control board and from Ministry of
Environment & Forest, Government of India.
Particulate emission data are needed to size dust collectors for coal-fired boilers. In
coal-fired boilers, about 75% of the ash is carried away by the flue gases and 25%
drops into the ash pit. The following expression may be used for determining the Ash
concentration in the flue gas.
Ca = 2,40,000 x (% ash/100)
------------------------------------------------------------------
-6
T x [7.6 x 10 x HHV x (100+E) + 1 - (% ash/100)]
Where
E = excess air %
O
T = gas temperature, R
Ca = 0.01 x A x 7000 x ρ
3
Ash concentration in lb/ft = Ca
----
70
3
Ash concentration (kg/m ) = Ca
---- * 16.033
70
t = gas temperature , °F
The expression for density is based on atmospheric flue gases having molecular
weight of 28.8
3
The ESP is sized to achieve an outlet dust concentration of 150 mg/Nm
SO 2 Emission LEVEL
4
Emission of S0 2 in lb/mmBtu (e) = 2 x 10 S
-------
HHV
HHV 100
The value of V obtained with Eq-1 must be converted to 15% Oxygen on dry basis to
give ppmvd of No x at 15% O 2 .
6
V * (21-15) * 16
Vn(ppmvd 15% 02) =
21 - 100%02/(100-%H 2 O) ------- (2)
=V*F
where %O 2 = Oxygen present in the wet exhaust gases. Factor F converts V to 15%
Oxygen basis, which is the usual basis for reporting emissions.
Co-Emission in ppmvd
During normal operating conditions (70% load to 100% load), the noise level
around the equipments shall not exceed 90 db (A) measured at a distance of
1 m from the nearest surface of the machine and at a height of 1.2 m from the
floor level.
The noise level at the Control property boundary shall be limited to the values
as given in the table below:-
The noise levels at the property boundary line shall be specified as per the above
table which should remain within the prescribed limits throughout the plant operating
range (i.e) 70% load to 100% load. It is to be noted that the noise limit is for total
noise (background noise + plant noise)
The noise level limitations as stipulated in the above table shall be demonstrated
around the following equipments:
1. Gas Turbine
2. Steam Turbine
7. Pulverising Mills
For equipments inside the building, the noise monitoring should be done for 8 hours
continuously as the worker is exposed to the noise of 8 hours during a shift. The
noise limits for industrial workers has been prescribed as 90dB(A)
Noise measurements should be done on the prescribed paths. After carrying out the
pilot survey, detailed baseline noise data should be collected. These should be
atleast four key measuring points which depend upon the size of the machine and the
symmetry of the acoustic radiation. The noize measurement should be done at 4 key
measuring points and successive measuring locations. The successive measuring
locations should be on the prescribed path at intervals of not more than 1 meter
commencing from the 4 key measuring points.
EXCLUSIONS
Noise levels during plant transients, upset conditions and noise levels resulting from
the actuation of safety devices may exceed the limits specified for a short period of
time.
MONITORING OF NOISE
The monitoring of noise shall be done inaccordance with the following IS standards.
1.0.0 Introduction
This document is a guide line applied to ash handling facilities for solid fuel fired
steam generators, extending from ash collection points of the combustion residues
upto the places of dispatch from the power station area.
The fuels normally considered are solid fuels like coal/lignite/washery middlings etc.
When other fuels are used appropriate considerations are to be made. A decisive
influence on the properties of ash is exerted by the physical, chemical and
technological conditions of combustion. Generally either fluidized bed furnaces or
pulverised coal fired furnaces are adopted depending on the generating capacity of
the plant. Normally it is considered that for coal the total ash percentage will be about
45% and for lignite about .....% for designing the ash handling system. The correct
data shall be obtained from the design spec for fuel.
The type of ash produced due to burning of solid fuel such as coal/lignite is Bed ash /
Bottom ash, Cyclone ash and fly ash. The bed / bottom ash is a coarse ash
discharged from the boiler bed area or furnace hopper. Normally the quantity of bed
ash is about 20% of total ash content of the fuel. The density of bed ash is about 800
3
to 1100 kg/m . The average particle size range is 1.0 to 10mm and maximum is
30mm. The fly ash is entrained in the flue gas and collected in the Economiser / Air
preheater hoppers, downstream electrostatic precipitator hoppers and in the chimney
ash hopper. Normally the quantity of fly ash is about 80% of total ash content of the
3
fuel. The density of fly ash is about 500 to 900 kg/m . The average particle size
range is 0.1 to 3.0 mm. Maximum is 10 mm.
The ash handling system is distinguished according to the type of ash such as.
- Belt conveyors
Pneumatic conveying systems are specifically used for collection points where dust is
obtained. The system uses air as the conveying medium.
The boiler outlet is sealed off by means of a submerged chute immersing in the water
bath. Boiler downward expansion must be considered in the immersion depth. The
maximum cooling water outlet temperature shall not exceed 50°C. Depending on the
water temperature difference the required amount of water is about 6 to 20 times of
the amount of ash generated. The drainage water is polluted with fine ash and hence
the overflow / drain pipe shall be adequately sized and necessary down stream
classifying equipment is installed.
Belt conveyors are provided when longer distance conveying is required. Care must
be taken to ensure that sufficiently cool bed ash is conveyed. Maximum inclinet of
belt conveyor is limited to 16°.
3.2.1 The hydraulic handling system of ash consists of slurry pumps. Ejectors, sluiceways,
sump etc. The bottom ash collected is normally stored in a water impounded ash
hopper for 8hrs. Then the ash is crushed to a handling particle size of maximum
50mm and pumped to disposal site by slurry pumps. Because of high heat dissipation
rate water must be fed in continuously as the water temperature is limited to 60°C.
The water impounded hopper is a steel shell with a temperature resistant lining on the
inside.
3.2.2 The slurry pumps used for conveying are normally of single stage non-clog centrifugal
pumps having a maximum speed of 1000 rpm for transport distance upto 3 km.
(horizontal). When the distance is more 2 to 3 pumps are connected in series or
intermediate pump stations are provided.
3.2.3 Ejectors
When Ejectors are used ash to water ratio is 1:4 to 1:10 depending on the ash size,
feeding configuration. The necessary water pressure upstream is about 6 to 8 times
the pressure in the delivery piping after the ejector. This pressure level depends on
ejector efficiency, delivery length, delivery head and piping resistance. Ejectors are
simple in design, replacement is easy and less maintenance compared to slurry
pumps. Ejector system is normally adapted for fly ash conveying.
Sluiceways conveyance is adapted for bed ash / coarse ash. Sluiceways are suitable
only for short distance up to the slurry sump from where the ash slurry is conveyed by
pumps. The slope of sluiceway is about 2 to 3% and water requirement is about 20
times the ash handled.
a) Long distance conveying so that storage can be located for off from the plant.
b) Ash can be conveyed directly from multiple hoppers to the disposal point.
3) Pressure feeders attached to the collection hoppers to feed into the conveying
pipe.
4) Storage bin.
In Dilute phase / lean phase conveying system the gas velocities are much greater
than the settling velocity of the individual grain.
The velocity of conveying air in lean phase is about 15 m/sec to 20 m/sec at a mass
flow ratio about 10 and pressure loss is about 0.1 to 1 bar/100m. The particle velocity
is about 0.9-1 m/sec.
In dense phase conveying the velocity of conveying is low but higher pressure is used
where the material to be transported completely fills the pipe and transported in
separate plugs.
The velocity of coveying air in dense phase is 1 to 10m/s with mass flow ratio 20 to
150 and the pressure loss is about 0.5 to 1 bar/100m. The particle velocity is 0.5 to
0.9 m/sec.
The bedash / flyash collected would be fed into the individual transmitter vessel
located below the hoppers. At each hopper level probe shall be provided for initiating
the conveying cycle. The system can operated both in level / timer mode. The ash
collecting surge hopper shall be provided with water cooling arrangement whenever
hotash (generally for / bedash / cycloneash) is handled. The isolation seal valves are
also water cooled.
The operation of the system is fully automatic. When the system is operated in auto -
timer mode the system shall have continuous cycle after a preset interval of time. In
level mode level prope provided in the surge hopper shall initiate the conveying cycle.
The isolation valve shall open and allow ash by gravity into the transmitter vessel by
gravity till it is closed automatically by the timer preset as per process parameters. On
closure of the isolation valve. The valve seal gets inflated and the conveying air is
injected into the vessel. The vessel is pressurised and the material resistance helps
pressure build up which conveys the material to the destination silo. When conveying
is complete the pressure drop down to nearly atmospheric pressure and is sensed by
the control system, the air supply to the system is stopped. The transmitter vessel is
ready for the next cycle.
Ash is conveyed by M.S ERW pipes conforming to is............ heavy grade with long
radius allow CI bends upto the terminal box located on top of the silo. The terminal
box help the ash to be discharged into the silo. The conveying air escapes by the
vent provided on top of the silo. The vent is provided with reverse pulsejet type bag
filter to filter the vent air. The size of the ash silo is depending upon the quantity of
ash generated and the silo discharging operation cycle.
The ash conveying pipe line should have minimum number of bends as far as
possible to avoid choking of the line and reduce maintenance problems. The bends
should have long radius about 10 D of the pipe dia.
Incase two or more silos are to be used for collecting the ash from single line
pneumaticaly operated divertor valves are used to divert the ash to the required silo.
3.3.2 The lean phase conveying system also functions similar to the dense phase system
only with the difference of high volume air supply source at low pressure.
Raw Water contains impurities which can be classified as Suspended Solids and
Dissolved Solids. Suspended solids can be removed by Filtration. The Dissolved
Solids can be removed only by Distillation, Reverse osmosis and Ion Exchange
process.
The constituents of Dissolved solids are salts of Calcium, Magnesium, Sodium and
Potassium existing in the form of CaCO 3 , MgCO 3 , CaSO 4 , Na 2 , SO 4 , etc.
The most popularly used scale for measurement of Ionic load is mg/l or Parts Per
Million (PPM). The constituents are measured on the basis of “As CaCO 3 ” or “As
such”. The actual load of constituent Ion measured on “As such” basis are converted
to “As CaCO3” basis by multiplying the PPM “As such” by the factor” Atomic weight of
constituent / Atomic weight of CaCO 3 ”. Atomic weight of CaCO 3 is 100.
It is imperative to convert all Ionic loads to “As CaCO 3 ”. Basis in order to check for
Ionic balance. Ionic balance is achieved if total Cation load is equal to total Anion load.
Another scale for measurement of Ionic load is Equivalent Mass/I (Eq.m/l). The
Equivalent Mass of given substance is the quantity of the substance that will combine
with or replace in a given reaction one atom of Hydrogen (or another monovalent
element as the amount of the substance corresponding to the transition of one
electron (in oxidising – reducing reactions).
Eq = M/n.
But this scale is not used extensively because the equivalent of many chemical
compositions is not constant as it depends on the type of reaction involved.
The multiplication factors for conversion of Ionic load from “AS SUCH” to “AS CaCO 3 ”
are as follows:
Sl.No.1 to 7 gives the Cation part and Sl.No.8 to Sl.No.11 indicates the Anion part.
Total cationic load shall be equal to Total anionic load which is called ionic balance.
Add the Cation load, Anion load, Iron and Silica in “AS SUCH” basis to obtain “Total
Dissolved Solids” (TDS).
Raw water available at the site shall be analysed in a laboratory and its physical,
chemical and Bacteriological Characteristics shall be furnished as per the format
given below. These data shall be obtained for four seasons over one year. To work
out the seasonal average water analysis over a period of atleast 3 years shall be
made available.
These details are important to decide the treatment scheme for the raw water to make
it suitable for the end user.
Source of water
1. Bore Well
2. Open Well
3. River
4. Sea
5. Others
Physical Characteristics
1. Colour
2. Taste
3. Odour
4. Temperature (°C)
Chemical characteristics
1. Ph
2. Specific conductance (micro siemens / cm)
3. Turbidity (NTU)
4. Total Dissolved solids in ppm
5. Total Suspended Solids in ppm
6. Total Alkalinity as CaCO 3 in ppm
7. Bicarbonates as HCO 3 in ppm
8. Calcium as CaCO 3 in ppm
9. Magnesium as CaCO 3 in ppm
11. Sodium as CaCO 3 in ppm
Bacteriological Characteristics
COOLING TOWER
BLOW DOWN, EVAPORATION & DRIFT LOSS CALCULATIONS
DEFINITION
The Circulating Water of the Cooling Water System gains heat in the Condenser &
other Auxiliaries and rejects the same in the Cooling Tower. In the Cooling Tower the
spray of water comes in contact with air. A part of the Water is evaporated and the
remaining water is cooled. The latent heat for evaporating a part of Water is obtained
In the Cooling Water System Water loss takes place in three different ways.
1. Evaporation loss
2. Blowdown loss
3. Drift loss
Evaporation loss
A part of Water evaporated in order to cool the remaining Water is Evaporation loss.
E = ∆T/6.11
E - Evaporation loss in %
∆T - Temperature of Cooling in the tower. (Difference between Inlet & Outlet Temp.)
Drift Loss
Drift loss is the loss of Water in the Cooling Tower by entertainment of Water particles
along with the Water vapour. Drift eliminators are installed in the Cooling Tower to
minimise the Drift loss. Normally Drift loss is in the range of 0.1% to 0.2% of System
flowrate.
Blowdown loss
The Water which is evaporated does not carry any dissolved solids with it. The
dissolved solids are getting concentrated in the Bulk Water. Over a period of time, the
Concentration levels reaches a limit above which the solids tend to precipitate and
form scales on the pipes and heat transfer surfaces. The process of removing
calculated quantity of Water and adding fresh Water in order to maintain the
B = [E/(C-1)] - D
D - Drift loss %
C - Cycle of concentration
Make up of Losses
The losses in the Cooling Water System due to Evaporation, Drift and Blowdown has
to be made up using fresh Water. The quantity of fresh Water make up is addition of
M =E+B+D
= E + {[E/(C-1)] - D} + D
= E + E/(C-1)
M = EC/(C-1)
C - Cycle of concentration.
Introduction
Pumps may be classified on the basis of the applications they serve, the materials from
which they are constructed, the liquid they handle, and even their orientation in space.
All such classifications, however, are limited in scope and tend to substantially overlap
each offer.
1. Dynamic.
2. Displacement.
Dynamic : In which energy is continuously added to increase the fluid velocities within the
machine to values in excess of those occurring at the discharge such that
subsequent velocity reduction within or beyond the pump produces a pressure
increase.
PUMPS
DYNAMIC DISPLACEMENT
CENTRIFUGAL
AXIAL FLOW
OPEN IMPELLER
MULTISTAGE
MIXED FLOW
RADIAL FLOW SELF PRIMING OPEN IMPELLER
PERIPHERAL
JET REDUCTOR
GAS LIFT
SPECIAL TYPE
HYDRAULIC RAM
ELECTROMAGNETIC
PUMPS
DISPLACEMENT DYNAMIC
RECIPROCATING
PISTON PLUNGER
SIMPLEX
STEAM-DOUBLE ACTING
DUPLEX
SIMPLEX
SINGLE ACTING
POWER DUPLEX
DOUBLE ACTING
TRIPLEX
MULTIPLEX
DIAPHRAGM
ROTARY
VANE
PISTON
SINGLE ROTOR FLEXIBLE MEMBER
SCREW
PERISTALTIC
GEAR
LOBE
MULTIPLE ROTOR
CIRCUMFERENTIAL PISTON
SCREW
1. Liquid to be handled.
2. Requirements.
3. Sealing
4. Safety
6. Scale - up problems.
The parameters that establish the maximum head (in metre of fluid) that a centrifugal
pump can develop are the pump speed (rpm), impeller diameter, and the number of
impellers in series combination. Impeller design and blade angle mainly affect the slope
and shape of the head - capacity curve and normally have no or little effects on the
developed head.
Normal and maximum viscosity ranges are a major consideration in pump selection
because of possible deterioration in performance with increasing viscosity. Deterioration
can be both continuous and gradual. The table can serve as a guide in selecting the
proper centrifugal pump type for an application.
Most centrifugal pump types are not self-priming, meaning that they are not capable of
evacuating vapour from the suction line so that liquid can flow into the line and into the
pump casing without external assistance. The impellers on centrifugal pumps are
designed specifically for efficient liquid pumping and are not operated at high enough tip
speeds to convert them into vapour compressors. The differential head that the pump
impeller can deliver in the same on vapour as on liquid. However, the equivalent
differential pressure rise capability in much lower with vapour. Thus, centrifugal pump
impellers are not capable of generating a significant reduction in the pressure exerted by
the vapour in the suction line to permit liquid flow.
To prime a centrifugal pump before starting, the suction line and pump casing must be
filled with liquid. When the suction source is at positive pressure or is positioned above
the pump, priming is done by opening the suction valve and releasing (venting) the
trapped vapour from a valued connection on the pump casing or discharge line (located
inside the discharge block valve). Liquid then will flow into the suction line and pump
casing to displace the venting vapour.
Most centrifugal pumps have a self-venting feature small amounts of vapour trapped
within the casing at start-up (after suction, priming in complete) are swept out into the
discharge line when the pump is started. Horizontally split casings are not arranged to
be self-venting, however, and are equipped with specially designed valved vent
connections requiring manual operation. single-stage centrifugal pumps with top
discharge connections have good self-venting performance eventhough the casing
shape places a small high - point vapour pocket in the top of the discharge volute.
There are a variety of design features applied to the different construction styles of
centrifugal pumps. A summary of the main features follows.
Pump have diverging channels called volutes which are cast into the discharge zone of
the casing. This casing section collects the liquid discharged by the impeller and
converts velocity energy into the pressure energy. A centrifugal pump volute increases
in area from its initial point until it encompasses the full 360° around the impeller and
then flares out to the final discharge opening. Single-valves passages are simple type
of design causes an unbalanced load on the impeller because of the variation in
pressure around the periphery when the pump is operated at capacities other than
design condition. Double - volute configurations are employed when the unbalanced
force level threaten to cause significant shaft deflection. Twin/Double Volute design
consists of two 180° volutes a passage external to the second joins the two into a
common discharge.
Vaned diffusers for pressure conversion offer the advantages of balanced radial force,
compact size, and peak efficiency at high head and low flow. But they are more difficult
to fabricate and repair than volute pumps.
IMPELLER
Semi open impellers have a full back disc but no front shrouds
Fully open impellers have vanes but little or no disc material. They are employed
accordingly in low - head, solids - handling service.
The vane surfaces are generated by straight lines parallel to the axis of rotation.
These are also called single curvature vane.
The vane surfaces of francis - vane impeller have double curvature lower
specific speeds less than 4200 are called francis vane impeller.
An impeller design that has both a radial and axial flow components is called a
mixed-flow impeller. It is generally resticated to single - suction design with a
specific speed above 4200.
Mixed flow impellers with a very small radial flow components are usually
referred to as propellers. In a true propeller or axial-flow impeller the flow strictly
parallels to the axis of rotation.
Further the impeller can be clasified into (a) Single - suction impeller (b) Double suction
impeller
In a single-suction impeller, the liquid enters the suction eye on one side only. As a
double-suction impeller, the liquid enters the impeller simultaneously from both sides.
Wearing Rings
Wearings are generally fitted at the close - clearance position in the pump casing and at
an apposing position on the impeller, which allows easy restoration of the design
clearnace to separate the discharge pressure zone of the pump from the suction
pressure areas and to minimise back leakage. Many high - pressure centrifugal pumps
are fitted with wearing rings at the back sides (disc) of the impeller. This reduces the
thrust force on the impeller, at the same time minimizing the stiffing box pressure.
Nozzles
Many horizantal pumps all provided with suction and discharge nozzles on the top of the
casings. In some horizontal pumps, suction nozzles are located at the end of the pump
co-axial with the shaft centre line. In horizontally split pumps positioning of the nozzles in
the bottom half of the casing so that the bottom half does not have to be disturbed
during maintenance.
Stuffing boxes
Stuffing boxes have the primary function of protecting the pump against leakage at the
point where the shaft passes out through the pump casing. If the pump handles a
suction lift and the pressure at the interior stuffing box end is below atmospheric, the
stuffing box function is to prevent air leakage in to the pump. If this pressure above
atmospheric, the function is to prevent liquid leakage out of the pump. Conventional
stuffing boxes are filled with either packing material, such as braided rope or with a
mechanical shaft seal.
Bearings
The function of bearings in the centrifugal pumps is to keep the shaft or rotor in correct
alignment with the stationary parts under the action of radial and transverse loads.
Those that give radial positioning to the rotor are known as line bearings, where as
those that locate the rotor axially are called thrust bearings. All types of bearings have
been used in centrifugal pumps.
HORIZONTAL VERTICAL
5 Mechanical cost :
cost of piping & valves is higher for all The same is not required.
application due to additional shut off
valve and expansion bellow in the
suction line.
For all application horizontal pumps Vertical pumps can be directly located
have to be located below the minimum inside the respective reservoir sumps
water level of respective reservoir to and requires excavation (sum pit) for
facilitate flooded suction of pump and submergence of pump below
this requires excavation (Dry pit) of minimum water level within the
soil adjacent to respective reservoir reservoir sump, which is nominal
sump. compared to excavation required for
horizontal pump dry pit.
Cost of substruction like dry pit for Cost of substruction like pump resting
horizontal pump is high slab and sump pit is low.
HORIZONTAL VERTICAL
General :-
The plate type heat exchanger is an assembly of corrugated plates held between the
stationary and follower plate with the help of long tie bolds.
g. Plate evaporator
Low investment cost : High efficiency and their sheet Materials result in
economical units, practically when expensive
Materials are required.
Low hold up volume : The thin channels mean that the liquid volume is low
in comparison to other types of heat exchangers.
This ensure quick process control and reduces total
installation weight.
Introduction
Power plant condenser receives exhaust steam from the low pressure turbine and
condenses it to liquid for reuse. The surface condenser serves three important
functions :
# Conserves the high purity water for reuse in the boiler-turbine system to
minimise water treatment costs.
Design consideration
The base thermal load to be handled by condenser is set by the turbine heat balance
at maximum load conditions. Unless otherwise specified, the condenser duty for
turbine service is assumed to be the product of the steam flow in kg/sr and 527
kcal/kg.
Condenser back pressure usually range from 0.034 to 0.152 bar with higher
pressures possible where the cooling water temperature is elevated.
Condensers are also sized to handle transient thermal load conditions which can
exceed the maximum load conditions which would be part load or full load turbine
steam bypass to the condenser from the boiler.
Cooling water velocity can be in the range of 2 to 2.4 m/s taking into consideration
fouling, water quality, erosion potential and tube material. Velocity below 0.9 m/s are
not recommended because of the potential for poor tube side flow distribution.
The cooling water temperature increase is frequently between 8 and 14°C. It is very
important to take care in the design of condenser, is the minimum terminal
temperature difference. The minimum terminal temperature difference shall not be
less than 3°C.
Q = UA LMTD
T1 - T2
LMTD =
l n (T1 - T2)
A = π Do nNL
Where,
2
A - Surface area -m
n - Number of passes
L - Tube length -m
2
U - Overall heat transfer coefficient - w/m K
Q - Heat duty -w
CONTENTS
1.0.0 INTRODUCTION 2
1.0.0 Introduction
Due to the increasing cost of good quality fresh water and also the decreased
availability in sufficient quantities at various plant locations ,continuous supply of fresh
cooling water to the industrial plants and processes becomes more and more an
acute problem, and hence the available fresh water can rarely be wasted. Thus it is
necessary to use an internal circuit of fresh cooling water as the heat transfer
medium which picks up the heat from the processes and equipments in the plant and
consequently has to be cooled again for recirculation.
Therefore the best solution for fresh water cooling is by an Air Cooled Heat
Exchanger.
The circulating fresh water is cooled indirectly by air in a heat exchanger in which the
water passes inside tubes which are finned on the outside in order to obtain surface
extension. The water is indirectly cooled by means of air which is forced through the
heat exchanger by fans.
The system shall be designed for automatic control of the turbine back pressure for
the entire range of steam flows and various ambient temperature. The system is
equipped with a number of fans driven by electric motors. The control is achieved by
switching fan individually or in groups from full to off. With the pressure control system
in operation, a satisfactory variability is obtainable for continuous and stable operation.
Especially in case of minor temperature fluctuation.
As far as performance guarantee test, the extrapolation from the design condition
shall not differ by more than plus or minus ten (10) percent on steam flow quantity and
plus or minus (5) degrees Celsius on air ambient temperature when all fans are
operating at full speed.
The auxiliary power consumption of the direct system being about 1.5% of the unit
power and is approximately 3 times higher than for the indirect system.
With the indirect system the turbine is condensed in a conventional, water cooled
surface condenser and the required cooling water flow is recooled in the closed circuit
via a natural draft dry cooling tower. The condensation heat transported with the
cooling water flow is transferred to the air in the cooling tower. This air heats up and
as a result of the chimney effect of the tower, generates the required cooling air flow.
Exhaust steam from the steam turbine flows through large diameter ducts to the air
cooled condenser. The steam distributed by manifolds is guided to the condenser
heat exchanger bundles consisting of finned tubes. The steam is condensed by
ambient air blown across the finned tubes by forced axial fans. The design value of
the condenser is 65 mm Hg.
The condenser is by far the biggest piece of requirement at site. The size of the
condenser (2 units) is about 100 m x 65 m and the height is 30 m. Its external
surface area is more than 1,000,000 m². There are a total of 40 fans each run by a
200 KW motor and equipped with two speed systems. In normal operation, there is no
need for water, as the heat is rejected to the ambient air One condenser consists of
four roof-type streets of finned tube elements. Twenty large axial flow fans, located
under the roofs force the cooling air through the fins.
Adequate optimisation of system does not merely compare different cooling systems
concerning the investment,operating and maintenance cost, but must also consider
the turbine design and differences in turbine investment too.
A Steam Turbine which is linked to a wet cooling system is subject to a relatively low
backpressure variations, whereas a steam turbine which operates together with a dry
cooling system has to cope with considerable backpressure differences depending on
the higher fluctuation of the air temperature. Thus, the design of turbine, particularly
the design of the LP section has to match the selected cooling system.
Higher back pressure levels result in smaller dimensions of the end blades and vanes
of the LP turbine and entail lower turbine investment cost. The difference in cost
between a “dry cooling” turbine and “wet cooling” turbine is an input of the
optimisation program.
Further to the turbine characteristic, the ambient air temperature range through a year
is an important input for the evaluation of dry cooling against wet cooling or the
evaluation within different dry cooling system. The consideration of merely the
average annual air temperature for dry cooling optimization and design is completely
inadequate, as far as large power plants are concerned.
To find the best suitable size of an air cooled condenser or indirect system with dry
cooling tower the duration of the different prevailing air temperature has to be taken
into account together with the turbine characteristic and the planned number of
operating hours.
Hence an optimisation study shall be performed in co-operation with the turbine and
ACC supplier, looking at temperature frequency curves for the area, load
characteristics and turbine back pressure. This will result in a set of design parameter
that will form the basis of design.
Prevailing winds and the locations and elevations of buildings, equipment, fired
heaters, etc., require consideration. All air-cooled heat exchangers in a bank are of
one type, i.e, all forced-draft or all induced-draft. Banks of air cooled exchangers must
be placed far enough apart to minimise air recirculation.
For winterization problems, provision must be made for heavy rain, strong winds,
freezing of moisture upon the fins, etc.,
4.4.0 Noise
Two identical fans have a noise level 3 dBa higher than one fan, while eight identical
fans have a noise level 9 dB(a) higher than a single fan. Noise level at the plant site is
affected by the exchanger position, the reflective surfaces near the fan, the hardness
of these surfaces, and noise from adjacent equipment. The extensive use of air
cooled heat exchangers contributes significantly to plant noise level.
Comparisons of the overall space requirements for plants using air cooling versus
water cooling are not consistent. Some air-cooled units are installed above other
equipment - pipe racks, shell and tube exchangers etc. Some plants avoid such
installation because of safety considerations.
4.6.0 Safety
Leaks in air cooled units are directly to the atmosphere and can cause fire hazards or
toxic-fume hazards. However, the large air flow through an air cooled exchanger
greatly reduces any concentration of toxic fluids.
Segal [pet. refiner, 38, 106 (April 1959)] reports that air-fin coolers “are not located
over pumps, compressors, electrical switchgear, control houses and, in general, the
amount of equipment such as drums, shell and tube exchangers located beneath
them are maximized”.
Pipe rack mounted Air Cooled Heat Exchangers with flammable fluids generally have
concrete fire decks which isolate the exchangers from the piping.
Air cooled heat exchangers should not be located where corrosive vapours and fumes
from vent stacks will pass through them.
Either Chemical or Mechanical cleaning on the inside of the tubes can readily be
accomplished.
The high pressure process fluid is always in the tubes. Tube side headers are
relatively small as compared with water cooled units when the high pressure is
generally on the shell side. High pressure design of rectangular headers is
complicated.
The plug type Header is normally used for design gauge pressures to 13790 Kpa
2 2
(2000 lb/in ) and has been used to 62000 Kpa (9000 lb/in ). The use of threaded
plugs at these pressures creates problems. Removable cover plate Headers are
2
generally limited to gauge pressures of 2068 Kpa (3000 lb/in ). The expensive billet
type header is used for high pressure service.
Vibration and thermal cycling affect the bond resistance of the various types of tubes
in different manners and thus affect the amount of heat transfer through the fin tube.
The approach temperature, which is the difference between the process-fluid outlet
temperature and the design dry-bulb air temperature, has a practical minimum value
of 8° to 14° C. When a lower process-fluid outlet temperature is required, an air-
humidification chamber can be provided to reduce the inlet air temperature toward the
wet bulb temperature. A 5.6° C approach is feasible. Since typical summer wet bulb
design temperatures in the United States are 8.3° C lower than dry bulb temperatures,
the outlet process-fluid temperature can be 3° C below the dry bulb temperature.
When the outlet temperatures of both fluids are identical, the MTD Correction factor
for a 1:2 shell and tube exchanger (one pass shell side, two or more passes tube
side) is approximately 0.8. For a single pass air cooled heat exchanger the factor is
0.91. A two pass exchanger has a factor of 0.96, while a three pass exchanger has a
factor of 0.99 when passes are arranged for counterflow.
Maintenance for air cooled equipment as compared with shell and tube coolers
(complete with cooling towers costs) indicates that air-cooling maintenance costs are
approximately 0.3 to 0.5 those for water cooled equipment.
Power requirements for air cooled heat exchangers can be lower than at the summer
design condition provided that an adequate means of air-flow control is used. The
annual power requirement for an exchanger is a function of the means of air flow
control, the exchanger service, the air temperature rise, and the approach
temperature.
When the mean annual temperature is 16.7°C lower than the design dry-bulb
temperature and when both fans in a bay have automatically controllable pitch of fan
blades, annual power required has been found to be 22, 36 and 54 percent
respectively of that needed at the design condition for three process services.
Alternatively, when fans have two speed motors, these deliver one half of the design
flow of air at half speed and use only one-eighth of the power of the full-speed
condition.
i) Generated power
ix) ITD : Initial temperature difference is the main design parameters of the dry
cooling system.
x) Space Limitations
a) Tube Diameter
b) Tube Material
a) Fin Type
b) Fin Height
c) Fin Thickness
d) Fin Material
API 661.
The principal parts of the tube bundle are the finned tubes and the header.
Most commonly used is the plug header which is a welded box. The second most
commonly used header is a cover plate header. The cover plate is bolted to the top,
bottom and end plates of the header. Removing the cover plate provides direct
access to the tubes without the necessity of removing individual threaded plugs.
Other types of headers include the bonnet type header, which is constructed similarly
to the bonnet construction of shell and tube heat exchangers ; manifold type headers,
which are made from pipe and have tubes welded into the manifold; and billet type
headers, made from a solid piece of material machined channels for distributing the
fluid. Serpentine type tube bundles are some times
used for very viscous fluids. A single continuous flow path through pipe is provided.
Tube bundles are designed to be rigid and self contained and are mounted so that
they expand independently of the supporting structure.
The face area of the tube bundle is its length times width. The net free area for air
flow through the bundle is about 50% of the face area of the bundle. The standard air
face velocity (FV) is the velocity of standard air passing through the tube bundle and
generally ranges from 1.5 to 3.6 m/s.
The maximum and minimum design temperature and minimum design metal
temperature for pressure parts shall be specified by the purchaser.
1. # For pressure parts that are not tubes and that are constructed of carbon and low
alloy steel as indicated in Section-VIII, Division.1, Part UCS of the ASME code, the
maximum design temperature shall be atleast 343°C ; if otherwise dictated by
flange ratings, the maximum design temperature shall be atleast the specified
process fluid inlet temperature plus 28°C.
For pressure parts that are not tubes and that are constructed of materials other
than those indicated in (1) #, the maximum design temperature shall be the
specified process fluid inlet temperature plus 28°C.
The design temperature for pressure parts, as listed on the air cooled heat
exchanger specification sheet, are intended to govern fin type selection or to apply
in determining exposure temperatures of mechanical and instrumentation
# If the design pressure is not specified, it shall be the greater of the following
b) The inlet pressure plus 25 pounds per sq.inch (172 kilo pascals).
The diameter of the plug holes shall be equal to the nominal outside diameter of the
tube plus atleast 0.8 mm.
7.4.0 Tubes
The recommended minimum tube outside diameter is 25.4 mm. Fin heights vary
from 12.7 mm to 15.9 mm, fin spacing from 3.6 mm to 2.3 mm (7 to 11 per linear
inch) and tube triangular pitch from 50.8 to 63.5 mm. Ratio of extended surface to
bare tube outside surface varies from about 7 to 20. The 38 mm (1½”) tube has been
used for flue gas and viscous oil service. Tube size, fin heights and fin spacing can
be further varied.
Tube lengths vary and may be as great as 18.3 m (60 ft). when tube length exceeds
12.2 m (40 ft), three fans are generally installed in each bay. Frequently used tube
lengths vary from 6.1 to 12.2 m (20 to 40 ft).
The total unfinned length of a finned tube between tube sheets after assembly shall
not exceed 1.5 times the thickness of one tube sheet.
The wall thickness for tubes with an outside diameter of 1-1½” (25.4 - 38.1 mm) shall
not be less than the following.
For embedded fin tubes, the thickness furnished below shall be measured from the
bottom of the groove.
A) For carbon steel or ferritic low alloy steel (maximum 9 percent chrome),
2.11 mm
Greater wall thickness may be appropriate for severe services or certain tube
configurations.
The following are several types of commonly used finned tube construction.
For fins that are wrapped under tension or embedded and that have fin heights not
exceeding 12 mm, the minimum stock thickness shall be 0.35 mm. For those that
have fin heights exceeding 12 mm the minimum stock thickness shall be 0.40 mm.
# Flattening in the bend of ‘U’ tubes shall not exceed 10% of the tube’s nominal
outside diameter.
# When ‘U’ bends formed from tube materials with low ductility or materials that are
susceptible to work hardening may require special consideration. If cold working
induces embrittlement or susceptibility to stress corrosion in some materials or
environments, then heat treatment should be considered.
Typical metal design temperatures for these finned tube constructions are 399°C
embedded, 288°C integral, 232° C overlapped footed and 177° C footed. Tube ends
are left bare to permit insertion of the tubes into appropriate holes in the header or
tube sheets. Tube ends are usually roller expanded into these tube holes.
Environmental factors such as weather, terrain, mounting, and adjacent buildings and
equipment influence the air side performance of an air cooled heat exchanger. These
factors shall be notified to the Vendor/Bidder for consideration in the air side design.
Fan selection at design condition shall ensure that at constant speed the fan can
provide by an increase in blade angle, a 10% increase in air flow and a corresponding
pressure increase. Since this requirement is to prevent stall and in
efficient operation of the fan, the resulting increased power requirement need not
govern the drive rating.
The vendor may estimate the design exposure temperature for mechanical
components by conventional heat transfer analyses and submit the same for approval
from consultant. As an alternative, these temperatures may be estimated by the
following and furnished to the Bidder/Vendor.
2. The heating coil inlet temperature less 56°C. (The heating coil inlet
temperature is not the heating coil mechanical design temperature).
3. For units with exhaust air louvers, automatically controlled pitch fans,
or two speed fan motors, the inlet temperature stated above less
28° C.
In no case shall the minimum design exposure temperature be less than the design
dry bulb temperature.
The forced draft unit, pushes air across the finned tube surface. The fans are located
below the tube bundles. The induced draft design has the fan above the bundle, and
the air is pulled across the finned tube surface. In theory, a primary advantage of the
forced draft unit is that less power is required. This is true when the air temperature
rise exceeds 30°C.
Air cooled heat exchangers are generally arranged in banks with several exchangers
installed side by side. The height of the bundle above ground must be one half of the
tube length to produce an inlet velocity equal to the face velocity. This requirements
applies both to ground mounted exchangers and to those pipe rack installed
exchangers which have a fire deck above the pipe rack.
The forced draft design offers better accessibility to the fan for on stream
maintenance and fan blade adjustment. The design also provides a fan and V belt
assembly, which are not exposed to the hot air stream that exits from the unit.
Structural costs are less and mechanical life is longer.
Induced draft design provides more even distribution of air across the bundle, since
air velocity approaching the bundle is relatively low. This design is better suited for
exchangers designed for a close approach of product outlet temperature and ambient
air temperature.
Induced draft units are less likely to recirculate the hot exhaust air since the exit air
velocity is several times that of the forced draft unit. Induced draft design more readily
permits the installation of the air cooled equipment above other mechanical
equipment, such as pipe racks or shell and tube exchangers.
8.1.0 FANS
Two or more fans aligned in the direction of tube length shall be provided for each
bay. Single fan arrangements are acceptable when agreed on by the
Consultant/Purchaser and vendor.
# Fans shall be of the axial flow type, Axial flow types fans are large volume, low
pressure devices. Each fan shall be sized so that the area occupied by the fan is
atleast 40 percent of the bundle face area served by that fan.
# Usually fans are provided with four or six blades. Larger fans may have more
blades. Fan diameter is generally slightly less than the width of the bay.
# The axial flow fan is inherently a device for moving a consistent volume of air when
blade setting and speed of rotation are constant. The variation in the amount of air
flow can be obtained by adjusting the blade angle of the fan and speed of rotation.
The blade angle can be either a) permanently fixed b) hand adjustable or c)
automatically adjusted. Air delivery and fan power are a direct function of blade pitch
angle.
# Fan blades can be made of aluminum, molded plastic, laminated plastic, carbon
steel, stainless steel, and monel.
# Fan noise level shall be in accordance with API recommended practice 631 M.
At the fan tip speed required for economical performance, a large amount of noise is
produced. The predominant source of noise is vortex shedding at the trailing edge of
the fan blade. Noise control of air-cooled exchangers is required by the Occupational
Safety and Health Act (OSHA) API 661 has the purchaser specifying sound pressure
level (SPL) values per fan at a location designated by the purchaser and also
specifying sound power level (PWL) values per fan. These are designated at the
following octave band center frequency 31, 63, 125, 250, 500, 1000, 2000, 4000 &
8000 and also the dB (A) value (the dB(a) is the weighted single value sound
pressure level).
Reducing the fan tip speed results in a straight-line reduction in air flow while the
noise level decreases. The API Std 661 limits fan tip speed to 61 m/s for typical
construction. Fan design changes which reduce noise include increasing the number
of fan blades, increasing the width of the fan blades and reducing the clearance
between fan tip and fan ring. In no case shall fan tip speed exceed 81 m/s.
The air must be distributed from the circular fan to the rectangular face of the tube
bundle. The air velocity at the fan is between 3.8 and 10.2 m/s. The plenum chamber
depth (from fan to tube bundle) is dependent upon the fan dispersion angle which
should have a maximum value of 45°.
Fan performance is directly affected by the increased clearance between fan ring and
blade tip and adequate provision in design must be made for the reduction in air flow.
API 661 requires that fan tip clearance be a maximum of 0.5 percent of the fan
diameter (for diameters between 1.9 and 3.8 ) max. clearance in 9.5 mm for smaller
fans and 19 mm for larger fans.
The depth of the fan ring is critical. Worsham (ASME, Pap 59-PET-27 Petroleum
Mechanical Engineering Conference, Houston, 1959) reports an increase in flow
varying from 5 to 15 percent with the same power consumption when the depth of a
fan ring was doubled. The percentage increase was proportional to the volume of air
and static pressure against which the fan was operating. When making a selection,
the stall out condition, which develops when the fan cannot produce any more air
regardless of power input, should be considered.
Winterization is the provision of design features, procedures, or systems for air cooled
heat exchangers to avoid process fluid operating problems resulting from low-
temperature inlet air. These include fluid freezing, pour point, wax formation, hydrate
formation, laminar flow and condensation at the dew point (which may initiate
corrosion).
Table
The cost data that appear in table are unchanged from those published in the 1963
edition of perry’s handbook. In 1969 Guthrie [Chem Eng., 75, 114 (Mar, 24, 1969)]
presented cost data for field-erected air cooled exchangers. These costs are only
25% greater than those of table and include the costs of steel stairways, indirect sub-
contractor charges, and field-erection charges. Since minimal field costs would be
this high (i.e 25% of purchase price), the basic costs appear to be unchanged.
(Guthrie indicated a cost band of plus or minus 25%).
Book Reference :
1) Perry’s Chemical Engineers Handbook.
2) API 661
3) Technical Papers.
1.0.0 INTRODUCTION
1.1.0 Fire protection systems are installed in various industries like power plants, petrochemical
complexes, chemical manufacturing units, textile plants, pulp-paper mills, automobile industry
etc. and commercial / housing complex to protect high and low value assets, costly chemicals,
raw materials, processed goods etc. from fire hazards occurring due to
1.2.0 The fire protection system is generally designed to fight two fires simultaneously.
a. To detect fire and create an alarm through fire detection and alarm system
b. To control and extinguish fire by fire fighting equipment / system
1.4.0 Though fire protection system are installed in various industries and commercial / residential
complex, this design basis covers the fire protection system only for power and chemical
plants.
2.1.0 Following fire fighting systems are used in industries either individually or in combinations
depending on the type and intensity of hazards.
b. Foam system
- CO 2 flooding system
- Halon alternate system
- FM200 system
2.2.1 Fire water system uses water for fire extinguishing, fire control, cooling of equipment and
protection of equipment and personnel from heat radiation. For these purposes water is used
in various forms such as straight jet, water fog, water curtain, water spray, deluge/sprinkler,
foam etc. The main components of the Fire water system are fire water storage tank, fire
water pumps and distribution piping network.
Fire hydrant system is provided for entire plant protection and is complete with fire hydrants,
hoses, branch pipes and nozzles. The design of the hydrant piping network shall be as per
the stipulations of Tariff Advisory Committee (TAC). Hydrant points in case of light &
ordinary hazard are generally single headed. Incase of tank farm storing inflammable
chemicals/fuels in a plant classified as ordinary hazard the tank farm area alone shall be
provided with water monitors/double hydrants based on the layout. Based on the equipment
height and provision of staircase for approach etc. monitor/landing valves (single hydrant)
shall be provided.
Fixed water sprinkler system is generally provided inside buildings for fire extinguishing and
cooling a particular area in case of fire. Some of the area & where sprinkler system are used
are buildings/ sheds storing combustible and flammable materials. The water spray density
and the design of piping system shall be as per TAC regulations. Fixed water sprinkler in most
cases is provided as detection system for medium/high velocity water spray system.
Water spray system are categorized into High Velocity and Medium Velocity water spray
systems.
The medium velocity water spray system is generally provided for surface cooling to prevent
heat build up. However in case of cable trays it is used for fire extinguishing. Generally
medium velocity water spray system is provided for the following facilities in a power/chemical
plant.
The high velocity water spray is used for fire extinguishing by formation of inflammable mist
due to emulsion of water droplets and smoke.
High velocity water spray system is provided for the following facilities in a power/chemical
plant.
i. Transformers
The water spray density and piping design shall be as per relevant TAC regulations. Generally
FORMT10 REV-B
the medium velocity water spray is tapped off from the hydrant network and the high velocity
water spray system is independent. However based on the size of the equipment and the
water requirement for various systems, medium velocity water spray may be tapped from high
velocity water spray system.
Gas based fire extinguishing system is used to protect those equipment on which water based
fire fighting system cannot be used.
Following are the areas where gas based system are widely used.
i) Turbogenerators, switch gear rooms, cable ducts, false ceiling voids, false flooring voids,
control room etc.
v) IG 55 system
Carbon-di-oxide systems and FM 200 systems are presently used widely. The other systems
are also being used as alternate systems. However carbon-di-oxide system is not preferred
for areas involving human presence. Relevant NFPA codes shall be followed for design of the
above system. Where codes are not available manufacturers recommendation has to be
followed.
Foam system is provided for fighting fuel / inflammable liquid fires. The fire is suppressed by
formation of stable foam on the surface of the burning liquid which cuts off oxygen supply
there by extinguishing the fire.
There are various types of foams available. Broadly they are classified into protein foam and
synthetic foam. Synthetic foams are generally preferable than protein foam.
First aid fire fighting equipment are provided at convenient locations and shall at all times be
readily accessible and clearly visible. The equipment are.
i. Portable fire extinguishers – Dry chemical powder fire extinguishers / carbon dioxide
extinguishers / Soda acid extinguishers.
ii. Wheeled fire fighting equipment – wheeled portable water or foam monitor / Foam
compound trolley / Dry chemical power trolley.
FORMT10 REV-B
3.1 Fire detection & alarm system is provided for actuation of fire fighting system, warning and
evacuation of plant personnel. The fire detection system responds to four indications of fire
viz. Temperature rise, smoke, flame and gases. However the fire should always be detected
in the incipient stages for effective fire fighting. The fire detection & alarm system should
preferably be addressable analog type on the conventional detection system have proven to
be in effective in Indian conditions.
3.2 Basically there are four types of detectors viz, temperature, smoke, flame and gas detector.
Each type of detector operates on different principle for detecting fire.
In each type of detector there are varieties of detectors categorized based on the principle of
detection.
The fixed temperature detector are installed where the anticipated rate of rise is not drastic.
The rate of rise detectors are used where the rate of rise is temperature is drastic.
The rate compensation detectors are also used where the rate of rise of temperature is drastic
but it is more reliable than rate of rise detector.
The linear heat sensing cable are basically fixed temperature detectors and are widely used in
places like cable gallery / coal conveyors etc.
The ionization smoke detector is usually effective for invisible particles produced by most fires
and hence are suitable for detection of incipient fires.
Other types are detectors are effective for detection of smoldering fires.
The infra red and ultra violet detectors are the widely used flame detectors which are suitable
for detecting smoldering, static and moving fires.
The comparison chart of UV & IR detector is as follows based on which the detectors can be
selected.
UV IR
Sensitive Sensitive
The gas detectors are provided for detecting inflammable and toxic gases. The selection of
type & detector is generally based on the type of gas prevailing in the area of hazard and as
per manufacturers recommendation.
3.3.0 Fire Detector Selection Guide Given Below Compare the Various Detectors
Abbreviations
NFPA 11 - Standard for Low Expansion Foam and Combined Agent Systems.
NFPA 11A - Standard for Medium and High Expansion Foam Systems.
NFPA 16 - Standard for Deluge Foam – water Sprinkler and Foam water Spray
systems.
TAC
OISD
OISD 116 - Fire Protection Facilities for Petroleum Refineries / Process Plants
OISD 117 - Fire Protection Facilities for Petroleum Depots and Terminals.
Miscellaneous
FORMT10 REV-B
PROJECT
TANK SIZE
Diameter in m 20
Height in m 14.5
Capacity in m³ 4241.0
8 Painting
Inernal (1539.38 cm² Rs. 215 / m²) 330966.70
External (1225.22 m² Rs. 215 / m²) 263422.30
Anti corosive (314.16m² Rs. 95/m²) 29845.20
Surface preparation & painting strt. 40477.50
(Rs. 4500 / Ton for tons)
PROJECT
TANK SIZE
Diameter in m 20
Height in m 14.5
Capacity in m³ 4241.0
8 Painting
Inernal (1539.38 cm² Rs. 215 / m²) 330966.70
External (1225.22 m² Rs. 215 / m²) 263422.30
Anti corosive (314.16m² Rs. 95/m²) 29845.20
Surface preparation & painting strt. 40477.50
(Rs. 4500 / Ton for tons)
CONTENTS
1. DESIGN PROCEDURE 3
3. COMPUTER PROGRAM 11
DESIGN PROCEDURE
1. DESIGN PROCEDURE
INTRODUCTION
This calculation is a continuation of the calculation (Heat Loss Calculation for Storage Tanks)
given in document WI-ME-DSN-180-004. Here, the size (Length & diameter) of the coil required
for the compensating the heat loss which is calculated in WI-ME-DSN-180-004 is calculated.
ASSUMPTIONS
2. The fluid inside the coil (fluid in coil) is flowing and the outside fluid is stationary.
ρr
3
- Density of liquid, lb/ft
β
-1
- Coefficient of thermal expansion, °F
3
m Fcoil - Mass flow rate of fluid in coil, m /sec.
α
2
- Surface area per linear feet, ft /ft. (From Table-1)
INPUT REQUIREMENTS
T f can be calculated as
t Ftank + t Fcoil °F
Tf = -----------------
2
∆t = t Fcoil - t Ftank °F
-1
expansion (β) °F
Q x V SP
3
m Fcoil = ------------ m /sec
hfg
The area required based on the Assumed velocity (Vs) and mass flow rate (m Fcoil ) can be
calculated as
2
A s = m Fcoil / V s inch
Now match this value (As) in the Table-1 and select the nearest flow area available and
corresponding OD, ID and α value.
2
12. Flow area from chart (As) inch .
The actual velocity has to be calculated for the selected size and has to be verified with
allowable velocity listed in document WI-ME-196-1 for different services.
m Fcoil
VA = -----------
2
(π/4) (di)
If V A is not with in permissible limits then select a different size and recalculate until a
acceptable value reached.
Since the coil is immersed in the fluid, and metal wall temperature is almost equal to fluid
temperature. The conductive and radiative heat transfer coefficient’s are neglected. Only the
convective heat transfer coefficient is calculated.
The dimensional calculation for free convective coefficient h c for gasses and liquids is
0.25
K 3f ρ 2f c f β ∆t
hc = 116 from ref (1)
µ' f d o
hio × hc
Uc = 2
Btu/hr. ft °F, from Ref (1)
hio + hc
U C × (1 / Rd )
UD = 2
But/hr. ft f, from Ref (1).
U C + (1 / Rd )
Q
S = ft 2 From Ref (1)
U D ∆t
L = Sα ft
References :
i. Donald Q Kern, “Process Heat Transfer”. Mcgraw Hill Book Company, 1965.
TABLE - 2
++ Ratings in the last two columns are based on a temperature of the heating medium of 240 to 400°F. If
the heating medium temperature is over 400°F, and the cooling medium is known to scale these ratings
should be modified accordingly.
Petroleum Fractions
COMPUTER PROGRAM
3. COMPUTER PROGRAM
F:\MECH\ISO\TANK\COILSIZE.XLS
1. Capabilities of Program
1. Uses American Unit Systems. Hence check the units of inputs before inputing
the value.
2. Do not enter invalid data or O’ in the cells. It may lead to fatal errors.
Features
i. Save as Button
Since space is limited in the computers, you can not save this Excel worksheet. This
is only a template but you can save your entered data.
Press `SAVE AS’ Button. A dialog appears, give the path and filename with
. dat extension depending upon where you want to save.
Ex - F:\MECH\GACL\TANK1.DAT
With this “OPEN” button you can (open) retrieve the saved data.
Press `open’ button. Open dialog appears. Give the name of the file with path.
Ex - F:\MECH\GACL\TANK1.DAT
Pressing this button will close the work book with out saving, hence ensure that the
datas entered are saved before pressing this button.
The pressing this button will lead you to the actual calculating.
Will lead you to the print preview mode press`Print’ there to take the printout.
Leads to the help sheet, where you can get technical help and tables refered in the
program.
Input:
= 34.39 CP
β
-1
Coefficient of thermal expansion = 1.396 °F
m steam = QxVsp / h fg
160 x 0.2766
3
= ----------------- = 0.02143 m /sec
2064.9
AS = m steam / Vs
= 0.02143 / 20
2
= 0.0010715 m
2
= 1.6610 inch
= 1.76
OD = 1.90 inch
ID = 1.5 inch
α
2
= 0.498 ft / ft
0.02143
V = ------------
2
(π/4) (1.5x0.0254)
= 18.79 m/sec.
The actual velocity value lies with in the allowable range. Hence size is OK.
3 2 6 0.25
= 116 [ (0.085 x 53.68 x 0.51 x 1.39 x 10- / 34.39) x (207/1.9) ]
2
= 5.185 Btu/hr ft °F
h io x h c
Uc = -----------
h io + h c
1500 x 5.185
2
= ------------------- = 5.167 Btu / hr ft °F
(1500 + 5.185)
Uc x 1/Rd
UD = ---------------
Uc + 1/Rd
5.167 x (1/0.005)
= ------------------------
(5.167 + (1/0.005)
2
= 5.0368 Btu/hr ft °F
Q
S = -----------
Up x ∆T
545942.4
= ------------------
5.0368 x 207
2
= 523.6 ft
L = S/α
= 523.6 / 0.498
= 1051.4 ft.
= 320.3 m
The following Values are tobe selected from Table1 Given in Help
CONTENTS
1. DESIGN PROCEDURE 2
3. COMPUTER PROGRAM 13
This procedure has been verified with sample datas (i) manually as described in section (4) and
(ii) through program as described in section (5) and it is noted that the results are matching in
both cases. Though the procedure is checked for errors, users are requested to check the input
before calculation. Read section (3) ‘Computer Program” thoroughly before performing the
calculation in computer.
1. DESIGN PROCEDURE
INTRODUCTION
Heating or cooling storage tanks in power or process plants can be a major energy expense.
Hence a detailed study of heat transfer involved in tanks is required to bring down the costs.
This design procedure determines the heat transfer to or from a vertical cylindrical storage tank
seated on the ground. It includes the effects of tank configuration, physical properties of liquid &
vapour in the tank, liquid level, ambient temperature, outside air, wind speed as well as
temperature variations within the tank between air and ground.
ASSUMPTIONS
1. This procedure assumes a tank with configuration shown in fig. 1 [Section (2) Fig1]. The
surfaces from which heat can be transferred are as follows.
2. The temperature of vapour above liquid level is 5°F less than the liquid temperature
and the temperature of ground is 5°F greater than the ambient temperature.
2
hF Fouling coefficient, Btu/ft -h °F
2
h Fw for liquid at the walls, Btu/ft -h °F
2
h Fb for liquid at the bottom, Btu/ft -h °F
2
h Fv for vapour at the wall, Btu/ft -h °F
2
h Fr for vapour at the roof, Btu/ft -h °F
2
hG heat transfer coefficient for ground, Btu/ft -h °F
2
hI heat transfer coefficient for insulation, Btu/ft -h °F
2
hM heat transfer coefficient for metal, Btu/ft -h °F
2
hR - heat transfer coefficient for radiation, Btu/ft -h °F
h Rb for bottom
h Rd for dry wall
h Rw for wet wall
h Rr for roof
2
K - Thermal conductivity, Btu/ft -h °F
KG for ground
KI for insulation
KM for metal wall
L - Total length for heat transfer surface, ft
Lw - Total length for wetted surface, ft
Grashof number, L ρ g β∆T/µ
3 2 2
N Gr -
N NU - Nusselt number = hD/k or hL/k
N Pr - Prandtl number = C p µ/k
Q - Rate of heat transfer, Btu/h
q - Individual rate of heat transfer Btu/h
qb for bottom
qr for roof
qw for wet wall
qd for dry wall
T Temperature °F
TA for ambient air
TV for vapour
TG for ground
TL for bulk liquid
∆T Temperature difference, °F
t Surface thickness, ft
tI for insulation
tM for metal
2
U Overall heat transfer coefficient Btu/ft h°F
Ub for bottom
Ud for dry wall
Uw for wet wall
Ur for roof
Wf Wind enhancement factor
β
-1
Volumetric co-efficient for thermal expansion, °F
µ Viscosity of fluid, lb/ft-h
ρ
3
Density of fluid, lb/ft
ε Emmissivity
INPUT REQUIREMENTS
Tank Details
Temperature
Bult Liquid TL °F
Vapour TV °F
Ground TG °F
Ambient TA °F
Thermal Conductivities
Surface Emmisivity
Roof εR
Wall εR
Fouling Coefficients
2
Dry wall h Fd Btu/ft h-°F
2
Wet wall h Fw Btu/ft h-°F
2
Roof h Fr Btu/ft h-°F
2
Ground h FG Btu/ft h-°F
Miscellaneous Data
2
Acceleration due to gravityg ft/hr
Physical Properties
:ρ
3
Density (lb/ft )
Viscosity lb/ft-h :µ
Coefficient of volumetric
:β
-1
expansion of air, °F
The basic approach is to calculate the heat loss from each of the four categories of surfaces,
and then add the individual heat losses to get the total heat loss. Thus :
When using these equations in design or rating problems, the various temperatures are
assumed for typical conditions or determined by measurement. The area values are also easily
obtained :
Ad = πD (L - L w ) ---------- (6)
Aw = πDL w ---------- (7)
πD /4
2
Ab = ---------- (8)
2 2 ½
Ar = (πD/2) (D / 4 + d ) ---------- (9)
The overall heat-transfer coefficient for the dry sidewall of the tank (U d ) is calculated as the sum
of the resistances of vapor film, fouling, metal wall, insulation (if any), and outside air
(convection plus radiation).
stuhlbarg and Boyen. With a little bit of manipulation, their data were replotted yielding the “wind
enhancement factor” (W f ). By definition.
Wf = h AW / h’ AW = h Ar /h’ Ar - - - - - - - - (10)
Therefore, once the outside-air coefficient for still air (h’ AW ) is known, the overall dry-sidewall
coefficient at various wind velocities can be computed as :
Similarly, the overall coefficients for the wet sidewall, bottom and roof surfaces are :
Eq. 13 and 14 assume that the roof and bottom are uninsulated, which is generally the case in
temperature estimates.
These apply to the inside wall (wet or dry) and the outside wall (still air). For vertical plates and
cylinders, Kato et al have recommended the following for liquids and vapors :
N Nu = 0.36
0.138 N Gr 0.175
( N Pr − 0.55) - - - - - - - - - - (15)
9
Where 0.1 < N Pr < 40 and N Gr > 10 .
For isothermal vertical plates, Ede reported the following for liquids :
0.25
N Nu = 0.495 (N Gr N Pr ) - - - - - - - - - - (16)
4 9
Where N Pr > 100 and 10 < (N Gr N pr ) < 10 , and for gases :
N Nu = 0.0295 N Gr
0.40
N Pr0.47 (1 + 0.5 N Pr0.67 ) −0.40 - - - - - - - - - - (17)
≈ 5 and (N Gr N Pr ) > 10 .
9
Where N Pr
4 9
Where 10 < (N Gr N Pr ) < 10 .
These coefficients apply to the roof and inside-bottom surface of the tank. The bottom is
assumed to be flat. For surfaces facing up :
0.33
N Nu = 0.14 (N Gr N Pr ) - - - - - - - - - - (19)
The wall and insulation coefficients are derived from the thermal Conductivities :
hM = k M / tM - - - - - - - (21)
hI = k I / tI - - - - - - - - (22)
The coefficient for heat transfer to and from the ground is the coefficient for heat conduction
from a semi-infinite solid :
H g = 8 k G / πD - - - - - - - - (23)
Fouling coefficients
The coefficients h Fd , h Fw and h Fb apply to the vapor and liquid at the wall, and the liquid at the
bottom of the tank, respectively. These are empirical, and depend on the type of fluid and other
factors such as tank cleaning. Generally, h Fd is the greatest, of the three, and h Fb the least,
indicating that the greatest fouling resistance is at the bottom of the tank.
The coefficient for sidewalls and roof depends on the emmisivity of these surfaces and is given
by :
01713
. ε TWs + 460 4 TA + 460 4
hR = − - - - - - - - - - - - (24)
Tws − TA 100 100
With these relationships, heat transfer to or from the tank can be calculated.
To begin the calculation, it is assumed that the outside wall temperatures are related to the bulk-
fluid temperatures by.
In order to calculate accurate coefficients for heat transfer, better estimates of these wall
temperatures must be obtained. This requires an iterative procedure that can be programmed
and run on a computer.
For dry wall, the rate of heat loss is given by all three of the following :
qd = U d A d (T V - T A ) - - - - - - - - - - (25)
= h vw A d (T V - T W ) - - - - - - - - - - (26)
= (h Rd + h Aw ) A d (T ws - T A ) - - - - - - - - - - (27)
T ws = {U d / (h Rd + h Aw )} (T V - T A ) + T A - - - - - - - - - - (28)
T w = T v - (U d / h vw ) (T V - T A ) - - - - - - - - - - (29)
Using the same approach, T w and T ws can be calculated for the wet wall, and Tw for the roof
and bottom of the tank.
To find the correct wall temperatures, initial estimates of U and h values are used in Eq. 28 and
29 (and in the parallel equations for the other surfaces) to get new T w and T ws values. Using
these new temperatures, Grashof numbers, individual heat-transfer coefficients and overall
coefficients, are recomputed and then iterated again to get a new set of T w and T ws values.
When the current and previous iteration’s temperature estimates are the same (within a
specified tolerance = 0.0001), the iteration is completed.
References :
i. Jimmy D. Kumana and Samir P. Kothari, Henningson & Durham and Richardson, Inc.
“Predict storage-tank heat transfer precisely”. Chemical Engineering Journal. March
22, 1982, PP : 127 - 132.
ii. Perry, R.H, and Chitton, C.H, “Chemical Engineers Handbook” Mcgraw-Hill Newyork,
1973.
TABLE - 1
Table for Wind Enhancement factor *
Chemicals
Inorganic
Gases ( oil - bearing or dirty) 500
Liquids (heating or vaporization) 500
Refrigerant brines 1000
Organic
Gases
Process 1000
Utility (Oil - bearing , refrigerant, etc ) 500
Condensing vapors (condensers) 1000
Liquids
Process 1000
Vaporizing Liquids(reboilers) 500
Heat transfer media 1000
Refrigerant Liquids 1000
Polymer forming Liquids 200
Oils ( vegetable and heavy Gas Oil) 330
Asphalt and residuum 100
* Taken from “Perry’s Chemical Engineer’s hand book” by Robert H. Perry - (Table 10-9 , Page 10-43)
q r Air
d
Vapour
q
d
Liquid Lw
q w
D
q b
FIG:1
COMPUTER PROGRAM
3. COMPUTER PROGRAM
This design procedure has been computerised using Microsoft Excel. The following sections
are briefly describing the interface of the program.
- This program automatically does the iteration procedure once the required
inputs are entered.
- Has a unit conversion section for converting units from SI to American unit
system.
- Has a `Print’ utility through which print outs can be taken section wise, ie.
Input, Calculation and Output.
1.2 Limitations
1. This program is divided into two parts “Insulated” and “Uninsulated” use
specific sections as required.
2. This program uses American unit system (For this conversion utility has been
provided).
3. Do not enter invalid data into the cells. It may lead to fatal errors.
Features
1. Save as Button
Since space is limited in the computers, you can not save this Excel worksheet. This
is only a template but you can save your entered data.
Press `SAVE AS’ Button. A dialog appears, give the path and filename with
. dat extension depending upon where you want to save.
Ex - F:\MECH\GACL\TANK1.DAT
2. Open Button
With this “OPEN” button you can (open) retrieve the saved data.
Press `open’ button. Open dialog appears. Give the name of the file with path.
Ex - F:\MECH\GACL\TANK1.DAT
3. Calculate Button
After entering the required input datas press this button to perform the calculation with
iteration.
Press this button when you want to see a descriptive fig. of tank. Now the caption of
button is “Hide Picture”. Press the same button again, the picture will be hidden.
5. Convert Button
Pressing this button will lead you to a unit conversion table where you can perform
unit conversion calculations from SI units to American unit system.
6. Print Button
(i) Input
(ii) Calculation
(iii) Output
Press this Button. It will lead you to preview mode press “PRINT” to take the print
outs.
7. Exit Button
Pressing this button will close the work book with out saving so, ensure that the datas
entered are saved before pressing this button.
8. Help Button
Note : 1. This program has been developed according to the design procedure given in
section - 1. The results can be verified with the manual calculation provided in
section-4 and computer outputs provided in section - 5.
F:\MECH\SOFTWARE\HEATLOSS.XLS
Input Details
Tank Details :
Tank diameter D - 20 ft
Temperatures
Ambient TA - 35°F
Thermal Conductivities
Surface Emmissivity
Miscellaneous Data
Note :
L ρ² g β ∆ T / µ²
3
NGr -
L x (4.68)² x 4.17 x 10 x 1 x 10 x ∆ T
3 8 -6
-
96.8²
0.9747 L ∆ T
3
-
Npr - CP µ / k
- 0.6 x 96.8
0.12
1.862 x 10 L ∆ T
7 3
-
N pr - 0.25 x 0.01693
0.011
- 0.28
Tw - TV + TA = 50 + 35 = 42.5°F
2 2
1.9 x 10 x L x ∆ T
7 3
NGR -
7
= 1.9 x 10 x (24) ³ x (50-42.5)
12
= 1.97 x 10
= 921.1
Na = h.L/K
Therefore, h VW = KN u / L
= 0.0151 x 921.1
24
Tw = TL + TA / 2
= 45°F
= 0.9747 L³ ∆ T
0.75 0.25
= (0.45 K/L w ) x (N Gr P r )
0.75 5 0.25
= (0.45 x 0.12 / (24) ) x (1.34 x 10 x 484)
Tw = TV + TA / 2
= 50 + 35 / 2
= 42.5
Tw = TL + TG / 2
= 55 + 40 / 2
= 47.5°F
0.9747 x L x ∆ T
3
N Gr =
= 58482
Na = 40.29
Tw T ws = 50 + 35 / 2
= 42.5
1.9 x 10 x L³ ∆ T
7
N Gr =
7 3
= 1.9 x 10 x 20 x (42.5 – 35)
12
= 1.14 x 10
Nu = 0.14 (N Gr N pr ) 0.33
12 0.33
= 0.14 (1.14 x 10 x 0.28)
= 875.92
= 0.6613 Btu/ft² h °F
1
6) COEFF. FOR OUTSIDE AIR AT WALL (h AW)
Note : Here both liquid and vapour included. Hence it is assumed that, Temperature drop
across the film is ¼ of the temp. drop from inside fluid to outside Air (Averaged for
both)
T1 = T L -T A = 55-35=20°F; T 2 = T V -T A = 50-35=15°F
∆T = T 1 + T 2 / 2x 4
∆T = 20 + 15 / 4 x 2
= 4.375 °F
1.9 x 10 x L³ ∆ T
7
N Gr =
7
= 1.9 x 10 x 48³ x 4.375
12
= 9.19 x 10
= 1603.73
= 0.0151 x 1603.73 / 48
i) For ground (h G )
hG = 8 KG / π D
= 8 x 0.8 / π x 20
= 0.102 Btu/ft² h °F
hM = KM / tM
= 10 / 0.0156
hI = KI / tI
= 0.028 / 0.125
T ws = T A + 0.25 (T bulk – T A )
= 35 + 0.25 (50-35)
T WS = 38.75
T WS = T A + 0.25 (T bulk – T A )
= 35 + 0.25 (55-35)
= 40°F
4 4
h RW = 0.1713 x 0.9 / (40-35) x [(40+460) – (35-460)
100 100
Roof is uninsulated
Hence assuming
T WS = TA + 0.5 (T V – T A )
= 42.5 °F
4 4
h Rr = 0.1713 x 0.9 / 42.5 – 35) x [(42.5+460) – 35+360) ]
100 100
I. Dry Area
= 6.597
Ud = 0.1516
= 7.114
UW = 0.140
= 6.835
Ur = 0.1463
1/ Ub = 1/h Lb + t M /K M + 1/ ha + 1/h Fb
1/U b = 13.99
Ub = 0.0716
RECALCULATION OF T W AND T WS
Since the wall temperatures are assumed initially. It has to be recalculated to obtain a closer heat
transfer co-efficient based on the following formula :
T ws = (Ud / (h Rd + h AW ) x (T V – T A ) + T A
Tw = T V –(Ud/h VW ) (T V -T A )
T WS = (0.1504/(0.757+051)) x (50-35) + 35
= 36.78 °F
= 46.12 °F
T WS = (U w / (h RW + h AW ) x (T L -T A ) + T A
= 37.21 °F
TW = T L – (U W / h LW ) (T L -T A )
TW = T V – (U r / h Vr ) (T V -T A )
= 50 – (0.1453/0.154) (50-35)
= 35.84 °F
TW = TL – (Ub / h Lb ) (T L – T G )
= 50.54 °F
Based on the above Recalculated temperatures . The overall coeffs should be calculated
again through alteration. When the difference is within a limit , iteration can be stopped. The
iterated value and final results are tabulated as below.
Coeff for H LW
liquidat wall
Coeff. For h Vr
vapour at Roof
Coeff.for liquid h Lb
bottom
Coeff for h’ Ar
outside air at
roof
Conduction
coefficients
For ground hG 0.10 0.10 0.10 0.10 0.10 0.10
For metal hM 641.03 641.03 641.03 641.03 641.03 641.03
For Insulation hI 0.22 0.22 0.22 0.22 0.22 0.22
Radiation
coefficients
Over all heat 1/Ur 6.94 8.25 7.93 8.01 7.99 7.99
Transfer
Coeff.
Ur 0.1440 0.1213 0.1261 0.1249 0.1252 0.1251
For bottom
area
i) Dry side
Ad = πD (L-Lw)
= π x 20 x (48.24)
= 1507.96 ft²
Aw = πDL W
= π x 20 x 24
= 1507.96 ft²
= (π x 20/2) ((20)² / 4)
= 314.16 ft²
Ab = π D² / 4
= π x (20)² / 4
= 314.16 ft²
qd = U d A d (T V -T A )
= 3529.45 Btu/hr.
qW = U w A w (T L – T A )
= 4119.74 Btu/hr
qr = U r A r (T V -T A )
qb = U b A b (T L – T A )
= 282.74 Btu/hr.
Q = qd + qw + qr + qb
= 8251.45 Btu/hr
= 2082.96 / 566.3
= 3.68 Kg/hr.
THERMAL INSULATION
1.0.0 Introduction
Heat is transfered by radiation, conduction, and convection, Radiation is the primary mode
and can occur even in vacuum. The amount of heat transferred for a given area is relative to
the temperature differential and emissivity from the radiating to the absorbing surface. The
prime purpose of a thermal insulation system is to minimise the amount of heat transferred
and for personnel protection.
IS 8183
IS 9842
The properties of insulation is necessary for selection of the proper insulation for specific use.
Many times in a given installation, a certain property may be of little importance whereas the
same property may be of utmost importance in a different application. The important
properties and their significance are as under.
The insulating material should not fail mechanically, chemically, or thermally within the
limits of temperature provided. It is necessary to consider the following items.
a) Linear Shrinkage
b) Loss of Compressive Strength
c) Internal self heating for deciding on the limiting temperature of the product.
2. Thermal Resistance
3. Thermal Diffusivity
4. Mechanical properties
5. Chemical properties
6. Economics.
Materials conform to IS 9842, ASTM C 547 and BS 3958 Part 4 and density equal to 144
3
kg/m . The temperature limit is between - 100° C to 750° C. Material totally incombustible.
For thermal conductivity, refer IS. The rigid pipe sections is chemically neutral and neither
causes nor accelerates corrosion. The pipe sections are water repellant and non
hygroscopic.
Application
They are suitable for steam and process pipe insulation operating at temperature upto 750° C
with a maximum diameter of pipe of 400 NB Due to high rigidity and compressive strength,
lightly bonded rigid pipe section can be used where high temperature and vibration is
encountered.
Resin Bonded Mattresses conform to IS 8183. These are available in standard densities as
3
50, 80, 100, 125, 150 kg/m and temperature limit is between - 100°C to 750°C and material
is totally in combustible when tested as per BS 476 part 4. The resin bonded mattresses are
water repellant and non hygroscopic. It is also chemically netural and neither causes nor
accelerates corrosion. For thermal conductivity, refer IS values.
Application
Due to wide range of densities available they are the preferred choice for various applications
like ESP’s, Chimneys, Air Preheaters, Boiler Walls, Ducts, Steam Turbines, Columns etc.,
Resin Bonded Slabs conforms to IS 8183 and BS 3958 part 5. It is manufactured by using
select Basalt rocks. The precise control at every stage of manufacturing ensures that the
slabs offer maximum resistance to heat transfer. The insulation material thus manufactured
has built-in characteristics for superior thermal performance. The density ranges from 50 to
3
200 kg/m to suit various application requirements and the temperature range is - 100°C to
750°C. The material is totally incombustible.
Application
They are suitable for a wide range of applications for thermal and Acoustical insulations.
5.0.0 Formula
The formula given below is used to determine the heat loss from the surface for a specified
insulation thickness. Loss due to radiation is not considered as the same may be negligible.
∆T overall
Heat Flow Q =
R
2
hi, ho = Convective heat transfer co-efficient, w/m k. (Refer heat transfer data book,
Kothandaraman).
l = length, m
r 1 , r 2 , r 3 = radius, m
Refer Annexure -1 for insulation thickness for indoor and out door installation.
A. INDOOR INSTALLATION
A. INDOOR INSTALLATION
18 800 50 50 75 75 75 75 100 100 125 125 150 150 175 175 200 200 225 225 250
19 900 50 50 75 75 75 75 100 100 125 125 150 150 175 175 200 200 225 225 250
20 1000 50 50 75 75 75 75 100 100 125 125 150 150 175 200 200 225 225 225 250
Notes : 1. Insulating Material : Bonded Mineral Wool as per IS : 8183, Group 2 for temp. upto 350°C, Group 3 for temp. between 350°C & 500°C, Group 4 for
temp. between 500°C & 550°C.
3. Insulation surface temperature restricted within 60-62°C for ambient temp. of 45°C, and heat loss through insulation restricted within 140 Kcal/hr. at a
minimum ambient temperature of
(-) 2°C and maximum wind velocity of 3000 M/min.
4. Insulated pipes will be jacketted by aluminium sheets conforming to IS : 737 or approved equivalent. The recommended thickness of aluminium
sheets is as follows :-
B. OUTDOOR INSTALLATION
B. OUTDOOR INSTALLATION
18 800 50 50 75 75 75 75 75 75 75 100 100 100 125 125 125 150 150 150 175
19 900 50 50 75 75 75 75 75 75 75 100 100 100 125 125 125 150 150 150 175
20 1000 50 50 75 75 75 75 75 75 75 100 100 100 125 125 125 150 150 150 175
Notes : 1. Insulating Material : Bonded Mineral Wool as per IS : 8183, Group 2 for temp. upto 350°C, Group 3 for temp. between 350°C & 500°C, Group 4 for
temp. between 500°C & 550°C.
2. Minimum wind velocity considered for indoor installations : 300 M/min
3. Insulation surface temperature restricted within 60-62°C for ambient temp. of 46°C, and heat loss through insulation restricted within 220 Kcal/hr. at a
minimum ambient temperature of
(-) 2°C and maximum wind velocity of 3000 M/min.
4. For temperature upto 175°C, same insulation thickness as for Indoor installations retained.
5. Insulated pipes will be jacketted by aluminium sheets conforming to IS : 737 or approved equivalent. The recommended thickness of aluminium
sheets is as follows :-
CONTENTS
1.0.0 INTRODUCTION 2
7.0.0 REFERENCE 7
8.0.0 FORMULA 7
1.0.0 Introduction
Steam Generated in a Steam Generator loses its heat in heating, process application,
pipe radiation loss and in doing so, the steam returns to its condensate (i.e., liquid
state). If condensate is not drained immediately or “trapped” from the system, it
reduces the operating efficiency by slowing the heat transfer process and cause
physical damage through the phenomenon known as Water Hammer. Water Hammer
is caused due to accumulation of condensate in the pipe which is swept by the
velocity of steam when suddenly stopped by a pipe bend, fitting or valve. To avoid
water pockets, piping must be designed to drain properly. A trap is therefore required
at all locations when condensate is formed and collected.
i) Air Venting
The air and other non condensible gases such as CO 2 etc present in the system
shall also be purged by the trap or alternatively by an auxiliary air vent.
The Steam Trap is an automatic drain valve which shall sense the difference
between the steam and condensate, operate under varying inlet and back
pressures, changing condensate loads and shall also release non condensible
gases while not wasting any steam.
The different types of steam traps operate by sensing the difference between steam
and condensate using one or more of three basic physical properties. When classified
according to these operating principles, each design has advantages and limitations
which must be considered when selecting a steam trap.
i) Float
ii) Inverted Bucket
a) Liquid Expansion
b) Bimetal Expansion
4.2 Pressure at inlet of trap. This may be significantly less than the pressure in the steam
supply main. Select a trap with pressure rating equal to or greater than the steam line
pressure, but with a capacity based on the estimated pressure at the trap inlet. For
example, in a heat exchanger, if all the steam is condensed in the coil, the trap will
2
only be pressurised by the hydraulic leg of water ahead of it. This is 0.1 kg/cm
for each 1 metre drop from the coil to the trap inlet.
4.3 Back pressure against which the trap must operate. In many installations the piping
from the outlet of the trap is connected into a common return system which may
contain some pressure. The trap will have to operate against this pressure plus any
static head created if the trap is required to lift the condensate to an overhead return.
Advantages :
Limitations
• Cannot be used where trap is fitted with air vent bellows & degree of
superheat > 100° C.
• Applications subjected to freezing must be protected with insulation & SLR.
• Water hammer can damage float.
Applications
Air unit heaters, Hot water heaters, Heat exchangers, Reboilers, etc.,
Advantages :
Limitations
• Low thermal efficiency under varying loads and pressures, some steam loss
for operation.
• Must maintain water seal to avoid continuous discharge of steam.
• Must be protected from freezing.
• Cannot discharge condensate continuously as rapidly as it forms.
• Bleed hole in bucket has very limited air venting capacity.
• Bimetal auxiliary air vent must be factory set at low temperature not self
adjusting.
Applications
High pressure indoor steam main drops and submerged heating coils.
Advantages
Limitations
Applications
Low and medium pressure submerged heating coils, steam tracer, steam
radiators.
Advantages
• Withstands hammer.
• Very high thermal efficiency
• Low temperature discharge eliminates flash steam around operating stations.
• Will not freeze when given free discharge.
• Generally fails in an open position.
Limitations
• Limited to applications such as storage tanks and some tracer lines where
condensate can be held back and subcooled before discharge.
• Corrosive condensage can attack bronze bellows in thermostatic element.
• Not self-adjusting to pressure changes.
• Must have an open discharge outlet.
Applications
Steam tracing lines, storage tank coils, open tank heating coils.
Advantages
Limitations
Applications
Steam tracing lines which can tolerate partial flooding, storage tank coils.
Advantages
Limitations
Applications
Steam main drips, High pressure and superheat, steam tracer lines, unit heaters.
Impulse Traps
Advantages
• Small, light-weight.
• All stainless steel construction.
• Good resistance to superheat and water hammer.
Limitations
Applications
Not recommended.
7.0.0 Reference :
8.0.0 Formula
litres/hr
Heating water : kgs. condensate/hr = ---------- x rise in °C
500
litres/hr
Heating fuel oil : kgs. condensate/hr = ---------- x rise in °C
1000
3
NM /min.
W x Cp X ∆T
kg. Cond./hr = ----------------------
Lxt
Heating Air:
A x U x ∆T
kg. Cond./hr = -------------------
L
2
A = heating surface area (m )
2
U = heat transfer coefficient (K Cal./m °C)
(2 for free convection)
∆T = temp. rise of material in °C
L = latent heat of steam (K Cal./kg.)
2.2 16Cr-12Ni-2Mo 2-2.2 A 182 Gr. F316 A 351 Gr. CF3M A 240 Gr. 316 2.2
A 182 Gr. F316H A 351 Gr. CF8M A 240 Gr. 316H
18Cr-13Ni-3Mo A 240 Gr. 317
19Cr-10Ni-3Mo A 351 Gr. CG8M
2.3 18Cr-8Ni 2-2.3 A 182 Gr. F304L A 240 Gr. 304L 2.3
16Cr-12Ni-2Mo A 182 Gr. F316L A 240 Gr. 316L
2.4 18Cr-10Ni-Ti 2-2.4 A 182 Gr. F321 A 240 Gr. 321 2.4
A 182 Gr. F321H A 240 Gr. 321H
2.5 18Cr-10Ni-Cb 2-2.5 A 182 Gr. F347 A 351 Gr. CF8C A 240 Gr. 347 2.5
A 182 Gr. F347H A 240 Gr. 347H
A 182 Gr. F348 A 240 Gr. F348
A 182 Gr. F348H A 240 Gr. F348H
2.6 25Cr-12Ni 2-2.6 A 351 Gr. CH8 2.6
A 351 Gr. CH20
A 240 Gr. 310S
A 240 Gr. 310H
2.7 25Cr-20Ni 2-2.7 A 182 Gr. F310 A 351 Gr. CK20 A 240 Gr. 310S 2.7
A 240 Gr. 310H
2.8 20Cr-18Ni-6Mo 2-2.8 A 182 Gr. F44 A 351 Gr. A 240 Gr. S31254 2.8
CK3MCuN
22Cr-5Ni-3Mo-N A 182 Gr. F51 A 240 Gr. S31803
25Cr-7Ni-4Mo-N A 182 Gr. F53 A 240 Gr. S32750
3.1 35Ni-35Fe-20Cr-Cb 2-3.1 B 462 Gr. N08020 B 463 Gr. N08020 3.1
28Ni-19Cr-Cu-Mo A 351 Gr. CN7M
3.2 99.0Ni 2-3.2 B 160 Gr. N02200 B 162 Gr. N02200 3.2
3.3 99.0Ni-Low c 2-3.3 B 160 Gr. N02201 B 162 Gr. N02201 3.3
3.4 67Ni-30Cu 2-3.4 B 564 Gr.N04400 B 127 Gr. N04400 3.4
67Ni-30Cu-S B 164 Gr.N04405
3.5 72Ni-15Cr-8Fe 2-3.5 B 564 Gr.N06600 B 168 Gr. N06600 3.5
3.6 33Ni-42Fe-21 Cr 2-3.6 B 564 Gr.N08800 B 409 Gr. N08800 3.6
3.7 65Ni-28Mo-2Fe 2-3.7 B 335 Gr. N10665 B 333 Gr. N10665 3.7
3.8 54Ni-16Mo-15Cr 2-3.8 B 564 Gr. N10276 B 575 Gr. N10276 3.8
60Ni-22Cr-9Mo-3.5Cb B 564 Gr. N06625 B 443 Gr. N06625
62Ni-28Mo-5Fe B 335 Gr. N100001 B 333 Gr. N10001
70Ni-16Mo-7Cr-5Fe B 573 Gr. N100003 B 434 Gr. N10003
61Ni-16Mo-16Cr B 574 Gr. N06455 B 575 Gr. N06455
42Ni-21.5Cr-3Mo-2.3Cu B 564 Gr. N08825 B 424 Gr. N08825
3.9 47Ni-22Cr-9Mo-18Fe 2-3.9 B 572 Gr. N06002 B 435 Gr. N06002 3.9
3.10 25Ni-46Fe-21Cr-5Mo 2-3.10 B 672 Gr. N08700 B 599 Gr. N08700 3.10
3.11 44Fe-25Ni-21Cr-Mo 2-3.11 B 649 Gr. N08904 B 625 Gr. N08904 3.11
3.12 26Ni-43Fe-22Cr-5Mo 2-3.12 B 621 Gr. N08320 B 620 Gr. N08320 3.12
47Ni-22Cr-20Fe-7Mo B 581 Gr. N06985 B 582 Gr. N06985
3.13 49Ni-25Cr-18Fe-6Mo 2-3.13 B 581 Gr. N06975 B 582 Gr. N06975 3.13
Ni-Fe-Cr-Mo-Low Cu B 564 Gr. N08031 B 625 Gr. N08031
3.14 47Ni-22Cr-19Fe-6Mo 2-3.14 B 581 Gr. N06007 B 582 Gr. N06007 3.14
3.15 33Ni-42Fe-21Cr 2-3.15 B 564 Gr. N08810 B 409 Gr. N08810 3.15
3.16 35Ni-19Cr-1¼Si 2-3.16 B 511 Gr. N08330 B 536 Gr. N08330 3.16
NOTE :
(1) ASME Boiler and Pressure Vessel Code, Section II materials, which also meet the
requirements of the listed ASTM specifications, may also be used.
GROUP
CLASS 150#
TEMP.°F 1.1 1.2 1.3 1.4 1.5 1.7 1.9 1.10 1.13 1.14 2.1 2.2 2.3 2.4 2.5 2.6 2.7
(-)20to100 285 290 265 235 265 290 290 290 290 290 275 275 230 275 275 260 260
200 260 260 250 215 260 260 260 260 260 260 230 235 195 245 255 230 235
300 230 230 230 210 230 230 230 230 230 230 205 215 175 230 230 220 220
400 200 200 200 200 200 200 200 200 200 200 190 195 160 200 200 200 200
500 170 170 170 170 170 170 170 170 170 170 170 170 145 170 170 170 170
600 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140
650 125 125 125 125 125 125 125 125 125 125 125 125 125 125 125 125 125
700 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110
750 95 95 95 95 95 95 95 95 95 95 95 95 95 95 95 95 95
800 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80
850 65 65 65 65 65 65 65 65 65 65 65 65 65 65 65 65 65
900 50 50 50 50 50 50 50 50 50 50 50 50 _ 50 50 50 50
950 35 35 35 35 35 35 35 35 35 35 35 35 _ 35 35 35 35
1000 20 20 20 20 20 20 20 20 20 20 20 20 _ 20 20 20 20
1050
1100
1150
1200
1250
1300
(-)20to100 740 750 695 620 695 750 750 750 750 750 720 720 600 720 720 670 670
200 675 750 655 560 680 750 750 750 745 750 600 620 505 645 660 605 605
300 655 730 640 550 655 720 720 730 715 730 540 560 455 595 615 570 570
400 635 705 620 530 640 695 695 705 705 705 495 515 415 550 575 535 535
500 600 665 585 500 620 665 665 665 665 665 465 480 380 515 540 505 505
600 550 605 535 455 605 605 605 605 605 605 435 450 360 485 515 480 480
650 535 590 525 450 590 590 590 590 590 590 430 445 350 480 505 465 470
700 535 570 520 450 570 570 570 570 570 570 425 430 345 465 495 455 455
750 505 505 475 445 530 530 530 530 530 530 415 425 335 460 490 445 450
800 410 410 390 370 510 510 510 510 510 510 405 420 330 450 485 435 435
850 270 270 270 270 485 485 485 485 485 485 395 420 320 445 485 425 425
900 170 170 170 170 450 450 450 450 370 450 390 415 440 450 415 420
950 105 105 105 105 280 315 320 375 275 375 380 385 385 385 385 385
1000 50 50 50 50 165 200 215 260 200 255 320 350 355 365 335 345
1050 160 145 175 145 170 310 345 315 360 290 335
1100 95 110 100 115 255 305 270 325 225 260
1150 60 70 60 75 200 235 235 275 170 190
1200 40 40 35 50 155 185 185 170 130 135
1250 115 145 140 125 100 105
1300 85 115 110 95 80 75
1350 60 95 85 70 60 60
1400 50 75 65 55 45 45
1450 35 60 50 40 30 35
1500 25 40 40 35 25 25
(-)20to100 990 1000 925 825 925 1000 1000 1000 1000 1000 960 960 800 960 960 895 895
200 900 1000 875 750 905 1000 1000 1000 995 1000 800 825 675 880 880 805 810
300 875 970 850 730 870 965 965 970 955 970 720 745 605 795 820 760 760
400 845 940 825 705 855 925 925 940 940 940 660 685 550 735 765 710 715
500 800 885 775 665 830 885 885 885 885 885 620 635 510 685 720 670 675
600 730 805 710 610 805 805 805 805 805 805 580 600 480 650 685 635 640
650 715 785 695 600 785 785 785 785 785 785 575 590 470 635 670 620 625
700 710 755 690 600 755 710 755 755 755 755 565 580 460 620 660 610 610
750 670 670 630 590 710 675 710 710 705 710 555 570 450 610 655 595 600
800 550 550 520 495 675 650 675 675 675 675 540 565 440 600 650 580 580
850 355 355 355 355 650 600 650 650 645 650 530 555 430 595 645 565 575
900 230 230 230 230 600 420 600 600 495 600 520 555 590 600 555 555
950 140 140 140 140 375 270 425 505 365 505 510 515 515 515 515 515
1000 70 70 70 70 220 210 290 345 265 340 430 465 475 485 450 460
1050 190 235 190 230 410 460 415 480 390 450
1100 130 145 135 150 345 405 360 430 300 345
1150 80 90 80 100 265 315 315 365 230 250
1200 50 55 45 70 205 245 245 230 175 185
1250 150 195 185 165 135 135
1300 115 155 145 125 105 100
1350 80 130 115 90 80 80
1400 65 100 85 75 60 60
1450 45 80 70 55 40 45
1500 35 55 50 45 30 35
(-)20to100 1480 1500 1390 1235 1390 1500 1500 1500 1500 1500 1440 1440 1200 1440 1440 1345 1345
200 1350 1500 1315 1125 1360 1500 1500 1500 1490 1500 1200 1240 1015 1290 1320 1210 1215
300 1315 1455 1275 1095 1305 1445 1445 1455 1430 1455 1080 1120 910 1190 1230 1140 1140
400 1270 1410 1235 1060 1280 1385 1385 1410 1410 1410 995 1025 825 1105 1145 1065 1070
500 1200 1330 1165 995 1245 1330 1330 1330 1330 1330 930 955 765 1030 1080 1010 1015
600 1095 1210 1065 915 1210 1210 1210 1210 1210 1210 875 900 720 975 1025 955 960
650 1075 1175 1045 895 1175 1175 1175 1175 1175 1175 960 890 700 955 1010 930 935
700 1065 1135 1035 895 1135 1135 1135 1135 1135 1135 850 870 685 930 990 910 910
750 1010 1010 945 885 1065 1065 1065 1065 1055 1065 830 855 670 915 985 895 900
800 825 825 780 740 1015 1015 1015 1015 1015 1015 805 845 660 900 975 870 875
850 535 535 535 535 975 975 975 975 965 975 790 835 645 895 970 850 855
900 345 345 345 345 900 900 900 900 740 900 780 830 885 900 830 835
950 205 205 205 205 560 630 640 755 550 755 765 775 775 775 775 775
1000 105 105 105 105 330 405 430 520 400 505 640 700 715 725 670 685
1050 315 290 350 290 345 615 685 625 720 585 670
1100 190 220 200 225 515 610 545 645 445 520
1150 125 135 125 150 400 475 465 550 345 375
1200 75 80 70 105 310 370 370 345 260 275
1250 225 295 280 245 200 205
1300 170 235 220 185 160 150
1350 125 190 170 135 115 115
1400 95 150 130 110 90 90
1450 70 115 105 80 60 65
1500 55 85 75 70 50 50
(-)20to100 2220 2250 2085 1850 2085 2250 2250 2250 2250 2250 2160 2160 1800 2160 2160 2015 2015
200 2025 2250 1970 1685 2035 2250 2250 2250 2235 2250 1800 1860 1520 1935 1980 1815 1820
300 1970 2185 1915 1640 1955 2165 2165 2185 2150 2185 1620 1680 1360 1785 1845 1705 1705
400 1900 2115 1850 1585 1920 2080 2080 2115 2115 2115 1490 1540 1240 1655 1720 1600 1605
500 1795 1995 1745 1495 1865 1995 1995 1995 1995 1995 1395 1435 1145 1545 1620 1510 1520
600 1640 1815 1600 1370 1815 1815 1815 1815 1815 1815 1310 1355 1080 1460 1540 1435 1440
650 1610 1765 1570 1345 1765 1765 1765 1765 1765 1765 1290 1330 1050 1435 1510 1395 1405
700 1600 1705 1555 1345 1705 1705 1705 1705 1705 1705 1275 1305 1030 1395 1485 1370 1370
750 151 1510 1420 1325 1595 1595 1595 1595 1585 1595 1245 1280 1010 1375 1475 1340 1345
800 1235 1235 1175 1110 1525 1525 1525 1525 1525 1525 1210 1265 985 1355 1460 1305 1310
850 805 805 805 805 1460 1460 1460 1460 1450 1460 1190 1255 965 1340 1455 1275 1280
900 515 515 515 515 1350 1350 1350 1350 1110 1350 1165 1245 1325 1350 1245 1255
950 310 310 310 310 845 945 955 1130 825 1130 1145 1160 1160 1160 1160 1160
1000 155 155 155 155 495 605 650 780 595 760 965 1050 1070 1090 1010 1030
1050 475 430 525 430 515 925 1030 940 1080 875 1010
1100 290 330 300 340 770 915 815 965 670 780
1150 185 205 185 225 595 710 710 825 515 565
1200 115 125 105 155 465 555 555 515 390 410
1250 340 440 420 370 300 310
1300 255 350 330 280 235 225
1350 185 290 255 205 175 175
1400 145 225 195 165 135 135
1450 105 175 155 125 95 100
1500 80 125 115 105 70 75
(-)20to100 3705 3750 3470 3085 3470 3750 3750 3750 3750 3750 3600 3600 3000 3600 3600 3360 3360
200 3375 3750 3280 2810 3395 3750 3750 3750 3725 3750 3000 3095 2530 3230 3300 3025 3035
300 3280 3640 3190 2735 3260 3610 3610 3640 3580 3640 2700 2795 2270 2975 3070 2845 2845
400 3170 3530 3085 2645 3200 3465 3465 3530 3530 3530 2485 2570 2065 2760 2870 2665 2675
500 2995 3325 2910 2490 3105 3325 3325 3325 3325 3325 2330 2390 1910 2570 2700 2520 2530
600 2735 3025 2665 2285 3025 3025 3025 3025 3025 3025 2185 2255 1800 2435 2570 2390 2400
650 2685 2940 2615 2245 1940 2940 2940 2940 2940 2940 2150 2220 1750 2390 2520 2330 2340
700 2665 2840 2590 2245 2840 2840 2840 2840 2840 2840 2125 2170 1715 2330 2470 2280 2280
750 2520 2520 2365 2210 2660 2660 2660 2660 2640 2660 2075 2135 1680 2290 2460 2230 2245
800 2060 2060 1955 1850 2540 2540 2540 2540 2540 2540 2015 2110 1645 2255 2435 2170 2185
850 1340 1340 1340 1340 2435 2435 2435 2435 2415 2435 1980 2090 1610 2230 2425 2125 2135
900 860 860 860 860 2245 2245 2245 2245 1850 2245 1945 2075 2210 2245 2075 2090
950 515 515 515 515 1405 1575 1595 1885 1370 1885 1910 1930 1930 1930 1930 1930
1000 260 260 260 260 825 1010 1080 1305 995 1270 1605 1750 1785 1820 1680 1720
1050 790 720 875 720 855 1545 1720 1565 1800 1460 1680
1100 480 550 495 565 1285 1525 1360 1610 1115 1305
1150 310 345 310 375 995 1185 1185 1370 860 945
1200 190 205 170 255 770 925 925 855 650 685
1250 565 735 705 615 495 515
1300 430 585 550 465 395 375
1350 310 480 430 345 290 290
1400 240 380 325 275 225 225
1450 170 290 255 205 155 165
1500 135 205 190 170 120 130
GROUP
CLASS 2500#
TEMP.°F 1.1 1.2 1.3 1.4 1.5 1.7 1.9 1.10 1.13 1.14 2.1 2.2 2.3 2.4 2.5 2.6 2.7
(-)20to100 6170 6250 5785 5145 5785 6250 6250 6250 6250 6250 6000 6000 5000 6000 6000 5600 5600
200 5625 6250 5470 4680 5660 6250 6250 6250 6250 6250 5000 5160 4220 5380 5500 5040 5060
300 5470 6070 5315 4560 5435 6015 6015 6070 5965 6070 4500 4660 3780 4960 5120 4740 4740
400 5280 5880 5145 4405 5330 5775 5775 5880 5880 5880 4140 4280 3440 4600 4780 4440 4260
500 4990 5540 4850 4150 5180 5540 5540 5540 5540 5540 3880 3980 3180 4285 4500 4200 4220
600 4560 5040 4440 3805 5040 5040 5040 5040 5040 5040 3640 3760 3000 4060 4280 3980 4000
650 4475 4905 4355 3740 4905 4905 4905 4905 4905 4905 3580 3700 2920 3980 4200 3880 3900
700 4440 4730 4320 3740 4730 4730 4730 4730 4730 4730 3540 3620 2860 3880 4120 3800 3800
750 4200 4200 3945 3685 4430 4430 4430 4430 4430 4430 3460 3560 2800 3820 4100 3720 3740
800 3430 3430 3260 3085 4230 4230 4230 4230 4230 4230 3360 3520 2740 3760 4060 3620 3640
850 2230 2230 2230 2230 4060 4060 4060 4060 4030 4060 3300 3480 2680 3720 4040 3540 3560
900 1430 1430 1430 1430 3745 3745 3745 3745 3085 3745 3240 3460 3680 3745 3460 3480
950 860 860 860 860 2345 2630 2655 3145 2285 3145 3180 3220 3220 3220 3220 3220
1000 430 430 430 430 1370 1685 1800 2170 1655 2115 2675 2915 2970 3030 2800 2865
1050 1315 1200 1455 1200 1430 2570 2865 2605 3000 2430 2800
1100 800 915 830 945 2145 2545 2265 2685 1860 2170
1150 515 570 515 630 1655 1970 1970 2285 1430 1570
1200 315 345 285 430 1285 1545 1545 1430 1085 1145
1250 945 1230 1170 1030 830 855
1300 715 970 915 770 660 630
1350 515 800 715 570 485 485
1400 400 630 545 455 370 370
1450 285 485 430 345 260 275
1500 230 345 315 285 200 215
OBJECTIVE
PROCEDURE
Procedure for calculating the total inch length welded by calculating no. of joints shall
be as per the following steps.
CLASSIFICATION
Carbon steel
Alloy steel
Stainless steel
PIPE SIZES
In each class of above material note the pipe sizes and no. of joints.
WELD LENGTH
OBJECTIVE
This procedure is to find out total Liquid Penetrat Test quantity calculation
PROCEDURE
LPT shall be carried out for atleast 10% of the total pipe welding joints based on
services. For the additional liquid penetrant tests following procedure shall be carried
out to calculate its total quantity.
PIPE SIZES
WELD LENGTH
TOTAL
NOM OD SCH PIPE PIPE PIPE PIPEW PIPEWT WIND WIND MOM SECTIO MAXIMUM ALLOWABLE SPAN BARE PIPE
PIPE WT WT WT T OF N
+ INSUL +WAT +WAT+I FORCE FORCE INERTI MODUL 21-93°c 94- 150- 205- 261- 317- 371-
ER NS A US 149°c 204°c 260°c 316°c 371°c 427°c
SIZE, IN MM N/M KG/M KG/M KG/M KG/M N/M KG/M 'I Z CM3 CM CM CM CM CM CM CM
CM4
10S 360.1 36.01 49.97 114 127.95 163.8 16.38 5848 361 883 879 872 871 865 857 845
12 323.9 20 496.7 49.67 63.63 126 139.95 163.8 16.38 7987 493 881 877 870 869 863 855 843
30 651.3 65.13 79.09 139 152.95 163.8 16.38 10343 539 878 874 867 866 860 852 840
40 796.5 79.65 93.61 152 165.95 163.8 16.38 12487 772 875 871 864 863 857 850 837
80 1317 131.7 145.56 197 210.95 163.8 16.38 19771 1221 866 862 855 854 848 841 828
20 679.7 67.97 82.33 159 173.35 177.8 17.78 13070 936 921 917 910 908 902 894 881
14 355.6 30 812 81.2 95.56 170 184.35 177.8 17.78 15525 873 919 915 908 907 901 893 880
40 942.9 94.29 108.65 182 196.35 177.8 17.78 17856 1003 917 913 906 905 899 891 878
80 1579.2 157.92 172.28 237 251.36 177.8 17.78 28595 1609 907 903 896 895 889 881 868
20 779.1 77.91 93.91 198 214 200.2 20.02 19688 970 986 982 974 972 966 957 943
16 406.4 30 931.2 93.12 109.12 211 227 200.2 20.02 23392 1152 984 980 973 971 965 956 942
40 1231.6 123.16 139.6 237 253 200.2 20.02 30468 1499 981 976 969 967 961 952 938
80 2030.5 203.05 218.5 307 323 200.2 20.02 48158 2370 970 966 959 957 951 942 929
20 878.4 87.84 105.94 241 259.1 222.6 22.26 28220 1237 1047 1042 1034 1033 1026 1017 1002
18 457 30 1221.1 122.11 140.21 271 289.1 222.6 22.26 38751 1694 1044 1039 1031 1029 1023 1014 999
40 1558.7 155.87 173.97 300 318.1 222.6 22.26 48782 2134 1040 1035 1028 1026 1019 1010 995
80 2540.8 254.08 272.18 386 404.1 222.6 22.26 76337 3340 1029 1025 1017 1015 1009 1000 985
20 1169.6 116.96 134.5 304 323.54 245 24.5 46368 1826 1103 1098 1090 1088 1081 1072 1056
20 508 30 1549.5 154.95 174.48 338 357.5 245 24.5 60645 2388 1100 1095 1087 1085 1078 1068 1053
40 1828.9 182.89 202.43 362 381.54 245 24.5 70926 2792 1097 1092 1084 1082 1075 1066 1050
20 1407.9 140.79 163.88 414 437 289.8 28.98 80873 2653 1211 1205 1196 1194 1186 1176 1158
24 610 30 2095.1 209.51 232.68 475 498 289.8 28.98 118209 3884 1205 1200 1191 1189 1181 1170 1153
40 2547 254.7 277.79 514 537.89 289.8 28.98 142351 4670 1202 1197 1188 1186 1178 1168 1151
20 2344.8 234.48 262.67 550 588.27 355.5 35.55 209780 5506 1352 1346 1336 1334 1325 1313 1294
28 711 30 0 0 0 0 0
40 0 0 0 0 0
80 0 0 0 0 0
NOM OD SCH PIPE PIPE PIPE PIPEW PIPEWT WIND WIND MOM SECTIO MAXIMUM ALLOWABLE SPAN PIPE + WATER
PIPE WT WT WT T OF N
+ INSUL +WAT +WAT+I FORCE FORCE INERTI MODUL 21-93°c 94- 150- 205- 261- 317- 371-
ER NS A US 149°c 204°c 260°c 316°c 371°c 427°c
SIZE, IN MM N/M KG/M KG/M KG/M KG/M N/M KG/M 'I Z CM3 CM CM CM CM CM CM CM
CM4
10S 360.1 36.01 49.97 114 127.95 163.8 16.38 5848 361 662 659 654 653 648 643 633
12 323.9 20 496.7 49.67 63.63 126 139.95 163.8 16.38 7987 493 698 695 689 688 684 678 668
30 651.3 65.13 79.09 139 152.95 163.8 16.38 10343 539 726 723 717 716 712 705 695
40 796.5 79.65 93.61 152 165.95 163.8 16.38 12487 772 744 741 735 734 729 723 712
80 1317 131.7 145.56 197 210.95 163.8 16.38 19771 1221 783 779 773 772 767 760 749
20 679.7 67.97 82.33 159 173.35 177.8 17.78 13070 936 745 741 736 734 730 723 713
14 355.6 30 812 81.2 95.56 170 184.35 177.8 17.78 15525 873 764 761 755 754 749 742 732
40 942.9 94.29 108.65 182 196.35 177.8 17.78 17856 1003 778 775 769 768 763 756 745
80 1579.2 157.92 172.28 237 251.36 177.8 17.78 28595 1609 820 816 810 808 803 796 784
20 779.1 77.91 93.91 198 214 200.2 20.02 19688 970 781 777 771 770 765 758 747
16 406.4 30 931.2 93.12 109.12 211 227 200.2 20.02 23392 1152 802 799 793 791 786 779 768
40 1231.6 123.16 139.6 237 253 200.2 20.02 30468 1499 833 829 823 821 816 809 797
80 2030.5 203.05 218.5 307 323 200.2 20.02 48158 2370 875 871 865 863 857 850 837
20 878.4 87.84 105.94 241 259.1 222.6 22.26 28220 1237 813 810 804 802 797 790 778
18 457 30 1221.1 122.11 140.21 271 289.1 222.6 22.26 38751 1694 855 851 845 843 838 830 818
40 1558.7 155.87 173.97 300 318.1 222.6 22.26 48782 2134 883 879 872 871 865 858 845
80 2540.8 254.08 272.18 386 404.1 222.6 22.26 76337 3340 927 923 916 915 909 901 887
20 1169.6 116.96 134.5 304 323.54 245 24.5 46368 1826 869 865 859 857 851 844 832
20 508 30 1549.5 154.95 174.48 338 357.5 245 24.5 60645 2388 905 901 894 893 887 879 866
40 1828.9 182.89 202.43 362 381.54 245 24.5 70926 2792 925 921 914 912 906 898 885
20 1407.9 140.79 163.88 414 437 289.8 28.98 80873 2653 924 920 913 912 906 898 885
24 610 30 2095.1 209.51 232.68 475 498 289.8 28.98 118209 3884 982 978 970 969 962 954 940
40 2547 254.7 277.79 514 537.89 289.8 28.98 142351 4670 1009 1004 997 995 988 980 965
20 2344.8 234.48 262.67 550 588.27 355.5 35.55 209780 5506 1093 1088 1080 1078 1071 1061 1046
28 711 30 0 0 0 0 0
40 0 0 0 0 0
80 0 0 0 0 0
NOM OD SCH PIPE PIPE PIPE PIPEW PIPEWT WIND WIND MOM SECTIO MAXIMUM ALLOWABLE SPAN PIPE + WATER + INSULATION
WT WT WT T OF N
PIPE + INSUL +WAT +WAT+I FORCE FORCE INERTI MODUL 21-93°c 94- 150- 205- 261- 317- 371-
ER NS A US 149°c 204°c 260°c 316°c 371°c 427°c
SIZE, IN MM N/M KG/M KG/M KG/M KG/M N/M KG/M 'I Z CM3 CM CM CM CM CM CM CM
CM4
10S 360.1 36.01 49.97 114 127.95 163.8 16.38 5848 361 643 640 635 634 630 624 615
12 323.9 20 496.7 49.67 63.63 126 139.95 163.8 16.38 7987 493 680 677 671 670 666 660 650
30 651.3 65.13 79.09 139 152.95 163.8 16.38 10343 539 709 706 701 699 695 689 679
40 796.5 79.65 93.61 152 165.95 163.8 16.38 12487 772 728 725 720 718 714 707 697
80 1317 131.7 145.56 197 210.95 163.8 16.38 19771 1221 769 766 760 759 754 747 736
20 679.7 67.97 82.33 159 173.35 177.8 17.78 13070 936 729 725 720 719 714 708 697
14 355.6 30 812 81.2 95.56 170 184.35 177.8 17.78 15525 873 749 746 740 739 734 727 717
40 942.9 94.29 108.65 182 196.35 177.8 17.78 17856 1003 764 760 754 753 748 742 731
80 1579.2 157.92 172.28 237 251.36 177.8 17.78 28595 1609 808 804 798 797 791 784 773
20 779.1 77.91 93.91 198 214 200.2 20.02 19688 970 766 762 757 755 750 744 733
16 406.4 30 931.2 93.12 109.12 211 227 200.2 20.02 23392 1152 788 784 778 777 772 765 754
40 1231.6 123.16 139.6 237 253 200.2 20.02 30468 1499 819 816 809 808 803 796 784
80 2030.5 203.05 218.5 307 323 200.2 20.02 48158 2370 864 860 854 852 847 839 827
20 878.4 87.84 105.94 241 259.1 222.6 22.26 28220 1237 799 795 789 788 783 776 764
18 457 30 1221.1 122.11 140.21 271 289.1 222.6 22.26 38751 1694 841 838 831 830 824 817 805
40 1558.7 155.87 173.97 300 318.1 222.6 22.26 48782 2134 870 866 860 858 853 845 833
80 2540.8 254.08 272.18 386 404.1 222.6 22.26 76337 3340 917 913 906 904 898 890 877
20 1169.6 116.96 134.5 304 323.54 245 24.5 46368 1826 856 852 845 844 838 831 819
20 508 30 1549.5 154.95 174.48 338 357.5 245 24.5 60645 2388 892 888 882 880 874 867 854
40 1828.9 182.89 202.43 362 381.54 245 24.5 70926 2792 913 909 902 901 895 887 874
20 1407.9 140.79 163.88 414 437 289.8 28.98 80873 2653 912 908 901 900 894 886 873
24 610 30 2095.1 209.51 232.68 475 498 289.8 28.98 118209 3884 971 966 959 957 951 943 929
40 2547 254.7 277.79 514 537.89 289.8 28.98 142351 4670 997 993 985 984 977 969 954
20 2344.8 234.48 262.67 550 588.27 355.5 35.55 209780 5506 1075 1070 1062 1060 1053 1044 1028
28 711 30 0 0 0 0 0
40 0 0 0 0 0
80 0 0 0 0 0
NOM OD SCH PIPE PIPE PIPE PIPE PIPEW PIPEW PIPEW PIPEW WIND WIND MOM SECTIO MAXIMUM ALLOWABLE SPAN BARE PIPE
PIPE WT WT WT WT T T T T OF N
+ + +WAT +WAT +WAT +WAT FORCE FORCE INERTI MODUL 21-93°c 94- 150- 205- 261- 317- 371-
INSUL INSUL ER ER +INS +INS A US 149°c 204°c 260°c 316°c 371°c 427°c
SIZE, IN MM N/M KG/M N/M KG/M N/M KG/M N/M KG/M N/M KG/M 'I Z CM3 CM CM CM CM CM CM CM
CM4
10S 360.1 36.01 499.7 49.97 1140 114 1279.5 127.95 163.8 16.38 5848 361 606 603 598 597 594 588 580
12 323.9 20 496.7 49.67 636.3 63.63 1260 126 1399.5 139.95 163.8 16.38 7987 493 656 654 649 647 643 638 628
30 651.3 65.13 790.9 79.09 1390 139 1529.5 152.95 163.8 16.38 10343 539 702 699 694 693 688 682 672
40 796.5 79.65 936.1 93.61 1520 152 1659.5 165.95 163.8 16.38 12487 772 739 735 730 729 724 717 707
80 1317 131.7 1455.6 145.56 1970 197 2109.5 210.95 163.8 16.38 19771 1221 838 834 828 826 821 814 802
20 679.7 67.97 823.3 82.33 1590 159 1733.5 173.35 177.8 17.78 13070 936 710 707 701 700 696 690 679
14 355.6 30 812 81.2 955.6 95.56 1700 170 1843.5 184.35 177.8 17.78 15525 873 742 739 733 732 727 721 710
40 942.9 94.29 1086.5 108.65 1820 182 1963.5 196.35 177.8 17.78 17856 1003 771 767 761 760 755 748 737
80 1579.2 157.92 1722.8 172.28 2370 237 2513.6 251.36 177.8 17.78 28595 1609 877 873 866 865 859 851 839
20 779.1 77.91 939.1 93.91 1980 198 2140 214 200.2 20.02 19688 970 735 731 726 725 720 713 703
16 406.4 30 931.2 93.12 1091.2 109.12 2110 211 2270 227 200.2 20.02 23392 1152 768 765 759 758 753 746 735
40 1231.6 123.16 1396 139.6 2370 237 2530 253 200.2 20.02 30468 1499 824 820 814 813 807 800 788
80 2030.5 203.05 2185 218.5 3070 307 3230 323 200.2 20.02 48158 2370 933 929 922 921 915 906 893
20 878.4 87.84 1059.4 105.94 2410 241 2591 259.1 222.6 22.26 28220 1237 757 754 748 747 742 735 724
18 457 30 1221.1 122.11 1402.1 140.21 2710 271 2891 289.1 222.6 22.26 38751 1694 822 818 812 811 805 798 787
40 1558.7 155.87 1739.7 173.97 3000 300 3181 318.1 222.6 22.26 48782 2134 874 870 863 862 856 849 836
80 2540.8 254.08 2721.8 272.18 3860 386 4041 404.1 222.6 22.26 76337 3340 987 983 975 974 967 959 945
20 1169.6 116.96 1345 134.5 3040 304 3235.4 323.54 245 24.5 46368 1826 813 810 803 802 797 790 778
20 508 30 1549.5 154.95 1744.8 174.48 3380 338 3575 357.5 245 24.5 60645 2388 872 869 862 861 855 847 835
40 1828.9 182.89 2024.3 202.43 3620 362 3815.4 381.54 245 24.5 70926 2792 909 905 898 897 891 883 870
20 1407.9 140.79 1638.8 163.88 4140 414 4370 437 289.8 28.98 80873 2653 852 848 842 840 835 827 815
24 610 30 2095.1 209.51 2326.8 232.68 4750 475 4980 498 289.8 28.98 118209 3884 941 937 929 928 922 914 900
40 2547 254.7 2777.9 277.79 5140 514 5378.9 537.89 289.8 28.98 142351 4670 988 983 976 974 968 959 945
20 2344.8 234.48 2626.7 262.67 5500 550 5882.7 588.27 355.5 35.55 209780 5506 968 963 956 954 948 940 926
28 711 30 0 0 0 0 0 0 0 0 0 0 0 0
40 0 0 0 0 0 0 0 0 0 0 0 0
80 0 0 0 0 0 0 0 0 0 0 0 0
Steam piping
From Boiler to
Primemover or None
other Equipment
or both
Yes Pr. Part Non IBR
Yes No
Down stream
Yes
of Valves No
Yes
Yes
Up stream No
ID>254
of Valves
Yes
IBR
Pipe size
50 NB & below
No approval
Submit Calculations
Required
MEDIUM 1/8 0.411 10.4 0.386 9.8 0.08 2.03 0.273 0.124 0.406
1/4 0.547 13.9 0.522 13.3 0.092 2.34 0.437 0.198 0.650
3/8 0.685 17.4 0.66 16.8 0.092 2.34 0.573 0.260 0.853
1/2 0.856 21.7 0.831 21.1 0.104 2.64 0.822 0.373 1.22
3/4 1.072 27.2 1.047 26.6 0.104 2.64 1.06 0.481 1.58
1 1.346 34.2 1.316 33.4 0.128 3.25 1.64 0.744 2.44
1¼ 1.687 42.8 1.657 42.1 0.128 3.25 2.11 0.957 3.14
1½ 1.919 48.7 1.889 48.0 0.128 3.25 2.43 1.10 3.62
2 2.394 60.8 2.354 59.8 0.144 3.66 3.42 1.55 5.09
2½ 3.014 76.6 2.969 75.4 0.144 3.66 4.38 1.99 6.52
3 3.524 89.5 3.469 88.1 0.16 4.06 5.69 2.58 8.47
4 4.524 114.9 4.459 113.3 0.176 4.47 8.14 3.69 12.11
5 5.534 140.6 5.459 138.7 0.192 4.88 10.9 4.94 16.22
6 6.539 166.1 6.459 164.1 0.192 4.88 12.9 5.85 19.20
HEAVY 1/8 0.411 10.4 0.386 9.8 0.104 2.64 0.331 0.150 0.493
1/4 0.547 13.9 0.522 13.3 0.116 2.95 0.517 0.235 0.769
3/8 0.685 17.4 0.66 16.8 0.116 2.95 0.686 0.311 1.02
1/2 0.856 21.7 0.831 21.1 0.128 3.25 0.977 0.443 1.45
3/4 1.072 27.2 1.047 26.6 0.128 3.25 1.27 0.576 1.89
1 1.346 34.2 1.316 33.4 0.16 4.06 2 0.907 2.98
1¼ 1.687 42.8 1.657 42.1 0.16 4.06 2.58 1.170 3.84
1½ 1.919 48.7 1.889 48.0 0.16 4.06 2.98 1.35 4.43
2 2.394 60.8 2.354 59.8 0.176 4.5 4.14 1.88 6.16
2½ 3.014 76.6 2.969 75.4 0.176 4.5 5.31 2.41 7.90
3 3.524 89.5 3.469 88.1 0.192 4.88 6.76 3.07 10.06
4 4.524 114.9 4.459 113.3 0.212 5.4 9.71 4.40 14.45
5 5.534 140.6 5.459 138.7 0.212 5.4 12 5.44 17.86
6 6.539 166.1 6.459 164.1 0.212 5.4 14.3 6.49 21.28
NOTES: Maximum & Minimum OD of MS Pipe are based on mfg.tol. as per code/vendor catalogue.
CALCULATION
1) P= 2Se *(t-c) ……… Eqn.91 of IBR 2) P= 2Se *(t-c) ….. Eqn. 91 A of IBR
D-t+c D + t-c
Hence Hence
t= PD +c t= Pd +c
2Se + P 2Se – P
P Kg/cm² 18.28 16.17 14.06 11.95 9.84 8.79 7.73 6.68 5.62
Temp. °C 93.3 149 204 260 316 343 371 399 427
S Kg/cm² 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
Minimum thickness calculated
80 88.9 1.76 1.68 1.59 1.50 1.41 1.37 1.34 1.32 1.33
100 114.3 1.98 1.87 1.76 1.64 1.53 1.47 1.43 1.42 1.42
150 168.3 2.45 2.28 2.11 1.95 1.78 1.70 1.64 1.61 1.62
200 219.1 2.88 2.67 2.45 2.23 2.02 1.91 1.83 1.80 1.81
250 273.1 3.35 3.08 2.81 2.54 2.27 2.13 2.04 1.99 2.01
300 323.9 3.78 3.46 3.14 2.82 2.50 2.34 2.23 2.18 2.19
350 355.6 4.06 3.71 3.35 3.00 2.65 2.48 2.35 2.29 2.31
400 406.4 4.49 4.09 3.69 3.29 2.89 2.69 2.55 2.48 2.50
450 457 4.93 4.48 4.03 3.57 3.12 2.90 2.74 2.66 2.68
500 508 5.36 4.86 4.36 3.86 3.36 3.11 2.93 2.85 2.87
550 559 5.80 5.25 4.70 4.15 3.60 3.32 3.13 3.04 3.06
600 608 6.22 5.63 5.03 4.43 3.82 3.52 3.31 3.21 3.24
P Kg/cm² 47.36 46.05 44.65 42.19 38.67 37.62 37.62 35.35 28.83
Temp. °C 93.3 149 204 260 316 343 371 399 427
S Kg/cm² 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
Minimum thickness calculated
OD in OD in MM
NB
50 60.3 2.32 2.29 2.25 2.18 2.09 2.06 2.10 2.14 2.12
80 88.9 2.95 2.90 2.84 2.74 2.60 2.56 2.62 2.69 2.66
100 114.3 3.51 3.44 3.37 3.24 3.06 3.00 3.09 3.17 3.13
150 168.3 4.70 4.60 4.49 4.30 4.03 3.95 4.07 4.19 4.14
200 219.1 5.81 5.68 5.54 5.30 4.94 4.84 5.00 5.16 5.08
250 273.1 7.00 6.84 6.66 6.36 5.92 5.79 5.98 6.18 6.09
300 323.9 8.11 7.92 7.71 7.35 6.83 6.68 6.91 7.14 7.03
350 355.6 8.81 8.60 8.37 7.97 7.40 7.23 7.49 7.75 7.62
400 406.4 9.92 9.68 9.42 8.97 8.32 8.12 8.42 8.71 8.57
450 457 11.04 10.76 10.47 9.96 9.23 9.01 9.34 9.67 9.51
500 508 12.16 11.85 11.53 10.96 10.15 9.90 10.27 10.64 10.46
550 559 13.28 12.94 12.59 11.96 11.06 10.80 11.20 11.60 11.41
600 608 14.35 13.99 13.60 12.92 11.95 11.65 12.09 12.53 12.33
550 559 28.60 28.60 28.60 28.60 28.60 28.60 28.60 28.60 28.60
600 608 31.00 31.00 31.00 31.00 31.00 31.00 31.00 31.00 31.00
* sch 60(16.05) can be used if ** sch 60 can be used if available
available
P Kg/cm² 69.6 61.52 59.41 56.24 51.32 50.27 49.92 47.11 38.66
Temp. °C 93.3 149 204 260 316 343 371 399 427
S Kg/cm² 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
Minimum thickness calculated
OD in OD in MM
NB
40 48.3 2.54 2.37 2.32 2.25 2.15 2.12 2.16 2.21 2.20
50 60.3 2.93 2.71 2.65 2.57 2.43 2.40 2.45 2.51 2.50
80 88.9 3.84 3.52 3.44 3.31 3.11 3.07 3.14 3.23 3.21
100 114.3 4.65 4.24 4.13 3.97 3.72 3.66 3.75 3.87 3.84
150 168.3 6.38 5.77 5.61 5.37 5.00 4.92 5.05 5.23 5.18
200 219.1 8.00 7.21 7.00 6.69 6.20 6.10 6.27 6.50 6.44
250 273.1 9.72 8.74 8.48 8.09 7.49 7.36 7.57 7.86 7.78
300 323.9 11.35 10.18 9.87 9.41 8.69 8.54 8.80 9.14 9.04
350 355.6 12.36 11.08 10.74 10.24 9.45 9.28 9.56 9.93 9.83
400 406.4 13.98 12.52 12.13 11.55 10.65 10.46 10.78 11.21 11.09
450 457 15.60 13.95 13.52 12.87 11.86 11.64 12.00 12.48 12.34
500 508 17.23 15.40 14.92 14.19 13.07 12.83 13.23 13.76 13.61
550 559 18.86 16.84 16.31 15.52 14.28 14.01 14.46 15.04 14.88
600 608 20.42 18.23 17.66 16.79 15.44 15.15 15.63 16.28 16.09
500 **508 32.50 32.50 32.50 26.20 26.20 26.20 26.20 26.20 26.20
550 559 34.90 34.90 34.90 28.60 28.60 28.60 28.60 28.60 28.60
600 608 38.90 38.90 38.90 31.00 31.00 31.00 31.00 31.00 31.00
600 608
P Kg/cm² 142.37 138.51 133.59 126.2 115.31 113.2 112.5 106.11 86.8
Temp. °C 93.3 149 204 260 316 343 371 399 427
S Kg/cm² 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
Minimum thickness calculated
OD in OD in MM
NB
80 88.9 6.62 6.48 6.30 6.02 5.61 5.53 5.68 5.88 5.81
100 114.3 8.23 8.04 7.81 7.45 6.92 6.82 7.02 7.27 7.18
150 168.3 11.64 11.37 11.02 10.50 9.72 9.57 9.86 10.23 10.10
200 219.1 14.85 14.50 14.05 13.37 12.36 12.16 12.54 13.02 12.85
250 273.1 18.27 17.83 17.27 16.42 15.16 14.91 15.38 15.98 15.77
300 323.9 21.48 20.96 20.29 19.29 17.79 17.50 18.06 18.77 18.51
350 355.6 23.49 22.91 22.18 21.08 19.43 19.11 19.72 20.51 20.23
400 406.4 26.70 26.04 25.21 23.94 22.07 21.70 22.40 23.30 22.97
450 457 29.90 29.16 28.22 26.80 24.69 24.28 25.06 26.07 25.71
500 508 33.12 32.30 31.26 29.68 27.33 26.88 27.75 28.87 28.47
550 559 36.35 35.45 34.30 32.56 29.98 29.47 30.43 31.67 31.22
600 608 39.44 38.47 37.22 35.32 32.52 31.97 33.01 34.36 33.87
CONTENTS
1. DESIGN PROCEDURE
DESIGN PROCEDURE
1. DESIGN PROCEDURE
INTRODUCTION
The aim of this procedure is to calculate the pipe diameter and thickness for a given flow,
pressure and temperature of a steam line.
νs
3
= Specific volume of steam at given pressure and temperature, m /kg
T = Operating temperature, °C
3
Q' = Rated flow, m /sec.
tr = Required thickness, mm
Y = Co-efficient
CALCULATION :-
1. Diameter Calculation :-
3
(i) Convert flow from kg/hr to m /sec
Select specific volume (V s ) from the steam tables for the given Pressure and
Temperature
3600
d= [ 4 x Q’/ π x V] x 1000 mm
Assumed velocity ‘V’ can be selected from Document No. WI-ME-DSN-196-014. For Quick
Reference it is attached in this document as Annexure I.
Select a higher size than the calculated diameter from the Document No.WI-ME-DSN-196-
015. For Quick Reference it is attached in this document as Annexure – II.
3. Thickness Calculation
(i) Select a Allowable Stress for the given pressure and temperature from ASME B31.1.
For Quick Reference, some of the materials frequently used are listed in Annexure III.
(ii) Select a coefficient (Y) from table 104.1.2 (A) from B31.1 for Quick Reference the
same table is reproduced in this document as Annexure IV.
PD
tr = +A
2(S E + PY )
Since the above processes involves selection of available diameters and thicknesses, it is
important to recalculate the Actual Velocity of the fluid. If the Actual Velocity is not within the
limit provided in Annexure I then all the calculations has to be repeated until a suitable Velocity
Diameter and Thickness is achieved.
References
Annexure - 1
SL No Service Velocity
M/S
STEAM LINES
1 High pressure live steam lines 50 m/s
2 Low pressure steam lines above 5 bar 35 m/s
3 Low pressure steam lines below 5 bar 30 m/s
4 Saturated steam lines 25 m/s
5 Vacuum lines 60 m/s
6 Turbine bypass system (After PRDS) 200 m/s
Water and Condensate Lines
1 Feed water suction 1.25 m/s
2 Feed water discharge 4.0 m/s
3 Water / Condensate suction 1.0 m/s
4 Water / Condensate discharge 2.2 m/s
Air Lines
1 Delivery line for reciprocating compressor 30 m/s
2 Suction / delivery line for rotary compressor 25 m/s
3 Suction line for reciprocating compressor 20 m/s
Oil Lines Suction
1 Naphtha 0.8 m/s
2 HSD / LDO 0.8 m/s
3 Lube oil 0.8 m/s
Oil Lines Discharge
1 Naphtha 1.8 m/s
2 HSD / LDO 1.8 m/s
3 Lube oil 1.8 m/s
Gas Lines
1 Fuel gas / Natural gas 25 m/s
Annexure - 2
Thickness Selection
LINE PIPE DIMENSIONS*
NOM OD SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH
PIPE mm 10 20 30 STD 40 XS 60 80 100 120 140 160 XXS
SIZE
¼ 13.7 Nul Nul Nul 2.24 2.24 3.02 Nul 3.02 Nul Nul Nul Nul Nul
17.1 Nul Nul Nul 2.31 2.31 3.20 Nul 3.20 Nul Nul Nul Nul Nul
½ 21.3 Nul Nul Nul 2.27 2.27 3.73 Nul 3.73 Nul Nul Nul 4.78 7.47
26.7 Nul Nul Nul 2.87 2.87 3.91 Nul 3.91 Nul Nul Nul 5.56 7.82
1 33.4 Nul Nul Nul 3.38 3.38 4.55 Nul 4.55 Nul Nul Nul 6.35 9.09
1¼ 42.2 Nul Nul Nul 3.56 3.56 4.85 Nul 4.85 Nul Nul Nul 6.35 9.70
1½ 48.3 Nul Nul Nul 3.68 3.68 5.08 Nul 5.08 Nul Nul Nul 7.14 10.15
2 60.3 Nul Nul Nul 3.91 3.91 5.54 Nul 5.54 Nul Nul Nul 8.74 11.07
2½ 73.0 Nul Nul Nul 5.16 5.16 7.01 Nul 7.01 Nul Nul Nul 9.53 14.02
3 88.9 Nul Nul Nul 5.49 5.49 7.62 Nul 7.62 Nul Nul Nul 11.13 15.24
3½ 101.6 Nul Nul Nul 5.74 5.74 8.08 Nul 8.08 Nul Nul Nul Nul Nul
4 114.3 Nul Nul Nul 6.02 6.02 8.56 Nul 8.56 Nul 11.13 Nul 13.49 17.12
5 141.3 Nul Nul Nul 6.55 6.55 9.53 Nul 9.53 Nul 12.70 Nul 15.88 19.05
6 168.3 Nul Nul Nul 7.11 7.11 10.97 Nul 10.97 Nul 14.27 Nul 18.26 21.95
8 219.1 Nul 6.35 7.0 8.18 8.18 12.70 10.31 12.70 15.09 18.26 20.62 23.01 22.23
10 273.1 Nul 6.35 7.8 9.27 9.27 12.70 12.70 15.09 18.26 21.44 25.40 28.58 25.40
12 323.9 Nul 6.35 8.4 9.53 10.31 12.70 14.27 17.48 21.44 25.40 28.58 33.32 25.40
14 355.6 6.35 7.92 9.5 9.53 11.13 12.70 15.09 19.05 26.83 27.79 31.75 35.71 Nul
16 406.4 6.35 7.92 9.5 9.53 12.70 12.70 16.66 21.44 26.19 30.96 36.53 40.49 Nul
18 457 6.35 7.92 11.1 9.53 14.20 12.70 19.05 23.83 29.36 34.93 39.67 45.24 Nul
20 508 6.35 9.53 12.7 9.53 15.09 12.70 20.62 26.20 32.50 38.10 44.40 50.00 Nul
22 559 6.35 9.53 12.7 9.53 Nul 12.70 Nul 28.60 34.90 41.30 47.60 54.00 Nul
24 610 6.35 9.53 14.3 9.53 17.48 12.70 24.61 31.00 38.90 46.00 52.40 59.50 Nul
26 660 7.92 12.7 Nul 9.53 Nul 12.70 Nul Nul Nul Nul Nul Nul Nul
28 711 7.92 12.7 15.9 9.53 Nul 12.70 Nul Nul Nul Nul Nul Nul Nul
+Annexure – 3
Selection of Allowable Stress from B31.1 – 1995 Edition in ksi for frequently used Materials
Material 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200
A 106 Gr B 15 15 15 15 15 15 15 15 15 15 15 15 15 15 14.4 13 10.8 Nul Nul Nul Nul Nul Nul Nul Nul
A 335 P 11 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 14.8 14.4 14 13.6 9.3 6.3 4.2 2.8 Nul Nul
A 335 P 22 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 14.4 13.1 11 7.8 5.8 4.2 Nul Nul
A 312 TP 304 18.8 17.8 17.8 17.8 17.8 16.6 16.6 16.2 16.2 15.9 15.9 15.9 15.9 15.9 15.9 15.6 15.2 14.9 14.7 14.4 13.8 12.2 9.8 7.7 6.1
A 312 TP 316 18.8 18.8 18.8 18.8 18.8 18.4 18.4 18.1 18.1 18 18 17 17 16.7 16.3 16.1 15.9 15.7 15.6 15.4 15.3 14.5 12.4 9.8 7.4
Annexure - 4
Material = SA 335 P 11
Temperature T = 487 °C
Flow Q = 90000 kg / hr
1.Diameter Calculation:
Q’ = (Q x s )/3600
= 1.281 m³ / sec
2. Calculating Diameter:
D = 4 x Q’ / x V x 1000
= 4 x 1.281 / x 50 x 1000
= 180.62 mm
3. Selection of Available Diameter:
From Annexure II the next immediate available Diameter is 200 NB ( 219.1 mm OD )
4. Thickness Calculation:
(i) Allowable Stress value for the given Temperature = 13385 psi – from B31.1
(ii) The Coefficient Y = 0.4 from B31.1
(iii) Thickness
= 8.98 mm
(iv) Selection of available Thickness
From Annexure II the next immediate available thickness is 12.7 mm
ID = 219.1 – 2 x 12.7
= 193.7
Q = VA
V = Q/A
= 43.3 m / sec
CONTENTS
1. DESIGN PROCEDURE 3
INTRODUCTION
The water hammer problems due to pump tripping, power failure, valve opening and closing etc. in water
services, especially in cooling water services are very important in pipe thickness calculations. This
procedure calculates pipe thickness considering the above said phenomenons.
ASSUMPTIONS
1. The maximum allowable velocity for cooling water services is 2.4 m/sec.
D = Selected diameter, mm
C = Corrosion Allowance, mm
Calculation :-
1. Diameter Calculation :-
4 x (Q' / 3600)
Calculated Diameter D cal = mm
π xV
2. Thickness Calculation :-
P. D
Calculated thickness t c1 = mm
2S
t1 = tc1 + c
mm
12 k / ρ
a = ft/sec
1 + ( K / E ) ( d / t ) C1
2L
TCR = Sec
a
if T CR < valve opening time then the formula
aV
∆H = can be used to calculate surge pressure refer “Piping
g
Hand Book” page 21 - 21.
If is assumed that 66% of the rated flow will persist when one pump trips
Q1 = 0.66 x Q’ m3/hr
4 x Q1
V1 = m / sec
π x d2
a v1 x 3.2808
∆H1 = ft of H 2 O
g
a x v1 x 3.2808
x 302.79 kg / m
2
=
g
a x v1 x 0.09934
kg / cm
2
=
g
∆H1 x D
Calculated thickness tc2 =
2xS
and t 2 = tc 2 + C mm
It is assumed that at 85% of valve closure 62.7% of the rated flow will persist.
Q 2 = 0.627 x Q’
4 x Q2
V2 = m / sec
π x d2
a V x 3.2808
∆H1 = 2 ft of H 2 O
g
a x V2 x 3.2808
x 302.79 kg / m
2
=
g
a x V2 x 0.09934
kg / cm
2
=
g
∆H2 x D
Calculated thickness tc 3 =
2xS
mm
t3 = tc3 + C
V Tripping of all pumps due to power failure :
It is assumed that at this condition the surge pressure will be 1.5 times of the rated
pump pressure
∆H 3 = 1.5 x P
∆H3 x D
Calculated thickness tc4 = mm
2xS
mm
t4 = tc4 + C
(iii) Live Loads & Dead Loads (For Burried Pipes Only)
This calculation is based on the tables 2,3 & 4 (Extracted from piping Hand Book - By CROKER)
Step 1 : The Dead Load for a particular Depth can be directly selected from table 3
based on depth and Nominal Diameter of pipe.
Step 2 : Based on the wheel load applied the percentage of wheel load transmitted
can be calculated using table 4.
Adding Dead Load and Live Load (Wheel Load) we can get Total Load.
Step 3 : Matching this load with the pipe diameter, the thickness can be directly
selected from Table 5.
The maximum thickness from the above calculations should be selected as the final thickness.
References :-
3. American Water Works Association, “Steel Pipe - A guide for design and Installation “ -
standard M-II
Table-1
in. mm mm
1 8 219.1 5.56
2 6.35
3 7.04
4 7.92
5 8.18
6 8.74
7 9.52
8 10 273.1 6.35
9 7.087
10 7.798
11 8.738
12 9.271
11.125
13 12 323.1 6.35
14 7.137
15 7.925
16 8.382
17 8.738
18 9.525
19 10.312
20 11.125
21 14 355.6 6.35
22 7.137
23 7.925
24 8.738
25 9.525
26 11.125
27 11.913
28 12.7
29 16 406.4 6.35
30 7.14
31 7.92
32 8.74
33 9.52
34 11.13
35 11.91
36 12.7
in. mm mm
37 18 457.2 6.35
38 7.137
39 9.925
40 8.738
41 9.525
42 11.125
43 11.913
44 12.7
Table-2
Table-3
Cov 3 4 6 8 10 12 15 18 21 24 27 30 33 36 39 42 48 54 60
(ft)
2 145 180 240 290 340 390 450 500 560 610 700 750 820 875 940 1000 1140 1280 1380
3 220 270 370 460 550 630 750 860 950 1040 1120 1200 1300 1400 1480 1580 1740 1970 2080
4 300 370 520 650 780 920 1080 1230 1400 1520 1630 1750 1850 2000 2100 2220 2500 2730 2980
5 380 470 660 830 1000 1160 1420 1610 1810 2010 2200 2340 2500 1630 2800 2950 3250 3600 3820
6 460 570 800 1000 1200 1430 1710 2000 2230 2500 2700 2950 3180 3350 3500 3650 4030 4420 4700
7 540 670 950 1180 1420 1700 2050 2400 2700 3050 3300 3570 3900 4100 4300 4440 4900 5450 5780
8 620 780 1080 1370 1620 1960 2400 2780 3200 3550 3900 4200 4500 4800 5050 5300 5900 6430 6880
(Values show percentage of Wheel load applied to one liner foot of pipe)
Table-4
Table-5
= 1.592 m
= 1592 mm
Corrosion allowance C = 2 mm
= 6.00 x 1620
2 x 1673.0
= 2.91 mm
= 2.91 + 2
= 4.91 mm
= 63.53 in.
= 12 x √ 313000/1.94
√1+(313000/30000000)(6.53/0.12)
= 1888.02 ft/sec.
= 328.1 ft
= 2 x 328.1 / 1888.02
= 0.34 sec.
Since TCR < valve opening time, the surge pressure can be calculated
using the following formula
H = a V ft of water column
g
It is assumed that when one pump is tripping the flow will be 66% of the rated flow
ie. Q1 = 0.66 Q’
= 0.66 x 9000
= 5940 m³/hr
V1 = Q1 x 4
π x d²
= 5940/3600 x 4 / π x 1.614²
= 0.81 m/sec.
Surge pressure
H1 = aV 1
g
= 4.71 kg/cm²
Calculated thickness
tc 2 = H1 x d
2xS
= 4.71 x 1614
2 x 1673
= 2.27 mm
t2 = tc2 + c
2.27 + 2 = 4.27 mm
Q2 = 0.627 x Q
= 0.627 x 9000
= 5643 m³/hr
V2 = Q2 x 4
π x d²
= 5643 x 4
π x 1.614² x 3600
= 0.77 m/sec.
Surge pressure,
H2 = aV
g
= 4.46 kg/cm²
Calculated thickness
tc3 = H2 x d
2xS
= 4.46 x 1614
2 x 1673
= 2.15 mm
t3 = tc3 + c
= 2.15 + 2
= 4.15 mm
It is assumed that during power failure, the surge pressure developed will not exceed 1.5 times
of the rated pump pressure.
H3 = 1.5 x P
= 1.5 x 1.7
= 2.55 kg/cm²
Calculated thickness
tc4 = H3 x d
2xS
= 2.55 x 1614
2 x 1673
= 1.23 mm
t4 = tc4 + 6
=1.23 + 2
= 3.23 mm
When load = 0
Applied
CONTENTS
1. DESIGN PROCEDURE 3
DESIGN PROCEDURE
1. DESIGN PROCEDURE
INTRODUCTION
The main of this procedure is to calculate the pipe diameter and thickness for a given flow,
pressure and temperature of a Air line.
2. The fluid inside the coil (fluid in coil) is flowing and the outside fluid is stationary.
T - Operating temperature, °C
1
Q - Rated flow, m³/sec.
lr - Required thickness, mm
A - Additional thickness, mm
Y - Co-efficient
ρa
1
- Density of Air at operating pressure, kg/m³
CALCULATIONN
1. Diameter Calculation
Select density of Air at required temperature from Annexure-I. Note that the values
given are for atmospheric pressure of 1.013 bar. Hence for the given pressure the
density can be calculated as follows.
Va - 1/ρ a
P 1 V a1 - P V a2
P - Operating pressure
V a2 - P 1 V a1 / P
- 1.013 x V a1 / P
ρa
1
- 1/V a2 Kg/cm³
1
Q / ρ a x 3600 m³sec.
1
Q -
(√4 x Q / π x V) x 1000 mm
1
D -
The velocity ‘V’ can be taken from the document WI-ME-DSN-196-014. For quick
reference it is attached as Annexure-II in this document.
Select a higher size (D) than the calculated diameter from the document wI-ME-DSN-196-015.
For quick reference the same is attached as Annexure-III in this document.
3. THICKNESS CALCULATION (t r )
i) The material for Air line is assumed as IS 1239 or IS 3589. Hence a allowable stress
t
of 164 M pa which is 23785 Psi (S )
(Refer IS 1239 or IS 3589 for more details)
ii) For IS 1239 & IS 3589 ‘Y’ factor can be taken as 0.4 (Refer B31.1 for more details)
tr - PD / 2 (S E + PY ) + A mm
1
tn - P D / 2 Se mm
Since a higher diameter and higher thickness is selected, it is necessary to recalculate the
actual velocity and make sure that it is within permissible limits. It values are not within limits
then a lesser thickness or a lesser diameter can be considered.
∇ Q / π (d/1000)²
1
VA -
References
2. IS 1239
3. IS 3589
--------------------------------------------------------------------------------------------------------------------------
SL SERVICE Velocity
NO. m/s
--------------------------------------------------------------------------------------------------------------------------
A) STEAM LINES
C) Air Lines
--------------------------------------------------------------------------------------------------------------------------
SL SERVICE Velocity
NO. M/S
--------------------------------------------------------------------------------------------------------------------------
F) Gas Lines
4 Boiler feed pump sizing calculation (HP & LP) BFP-DSGN.XLS KPCL
DSN-700-015.doc
FICHTNER India
Note :
For working on the above calculations, Engineers shall copy the required file(s) to his/her working
directory and do the calculation in the copy only. Calculations should not be performed on the file(s)
listed above directly.
FORM T10 REV-B
DSN-700-015.doc
FICHTNER India
DSN-700-015.doc