A.

LINE SIZING CALCULATION - Pump Discharge

I. River Water Intake & Water Treatment System
(Ref Dwg : P3FH -PR-4100-PFD -1001)

No. Fluid & Piping Segment Flow rate (m3/hr) Design Fluid velocity (m/s) Required Piping ID (mm) Selected Pipe Size (A) Selected Pipe ID (mm) Actual Fluid velocity (m/s) Pump Head (m) Pump Power (kW) (absorbed) Line Loss (kgf/cm2) Remarks

1 Fresh Water (River to Clarifier) 195.0 2.0 185.7 100 A 102.3 6.59 111.80 91.4 9.59
Pump Discharge Side 195.0 2.0 185.7 150 A 154.1 2.90 29.80 24.3 1.39
195.0 2.0 185.7 200 A 202.7 1.68 19.80 16.2 0.40 selected
195.0 2.0 185.7 250 A 254.5 1.07 17.30 14.1 0.14

2 NSW Water (Clarifier to Highest Piperack) 195.0 2.0 185.7 100 A 102.3 6.59 169.40 138.5 14.98
Pump Discharge Side 195.0 2.0 185.7 150 A 154.1 2.90 39.80 32.6 2.02
195.0 2.0 185.7 200 A 202.7 1.68 25.10 20.5 0.55 selected
195.0 2.0 185.7 250 A 254.5 1.07 21.50 17.6 0.19

3 NSW Water (Water Pond to Sand Filter) 60.0 2.0 103.0 80 A 77.9 3.49 41.90 10.5 1.74
Pump Discharge Side 60.0 2.0 103.0 100 A 102.3 2.03 29.90 7.5 0.53 selected
60.0 2.0 103.0 150 A 154.1 0.89 25.50 6.4 0.10

4 NSW Water (Water Pond to Softener) 60.0 2.0 103.0 80 A 77.9 3.49 41.00 10.30 1.66
Pump Discharge Side 60.0 2.0 103.0 100 A 102.3 2.03 29.00 7.40 0.49 selected
60.0 2.0 103.0 150 A 154.1 0.89 25.00 6.4 0.08

II. Circulation Water System

(Ref Dwg : P3FH -PR-4000-PFD -1001)

No. Fluid & Piping Segment Flow rate (m3/hr) Design Fluid velocity (m/s) Required Piping ID (mm) Selected Pipe Size (A) Selected Pipe ID (mm) Actual Fluid velocity (m/s) Pump Head (m) Pump Power (kW) (absorbed) Line Loss (kgf/cm2) Remarks

NSW Circulation System

1 NSW Water ( NSW Circulation Pond to Plant) 495.0 2.0 295.9 250 A 254.5 2.70 66.30 137.50 2.06
Pump Discharge Side 495.0 2.0 295.9 300 A 304.7 1.89 54.30 112.70 0.87 selected
495.0 2.0 295.9 350 A 333.3 1.58 51.30 106.50 0.57

2 NSW Water ( NSW Circulation Pond to NSW head tank) 495.0 2.0 295.9 250 A 254.5 2.70 62.70 130.00 0.55
Pump Discharge Side 495.0 2.0 295.9 300 A 304.7 1.89 59.70 123.90 0.26 selected
495.0 2.0 295.9 350 A 333.3 1.58 58.90 122.20 0.18

3 NSW Water (NSW -Return Pond to NSW -Cooling Tower) 400.0 2.0 266.0 200 A 202.7 3.44 25.70 43.10 1.50
Pump Discharge Side 400.0 2.0 266.0 250 A 254.5 2.18 16.60 27.80 0.59 selected
400.0 2.0 266.0 300 A 304.7 1.52 13.50 22.70 0.28

SW Circulation System (Cold)

4 SW Water ( SW -Circulation Pond to plant area) 600.0 2.0 325.8 350 A 333.3 1.91 48.80 122.80 0.42 selected
Pump Discharge Side 600.0 2.0 325.8 400 A 381.0 1.46 46.90 118.00 0.23
600.0 2.0 325.8 450 A 428.5 1.16 46.00 115.63 0.14

5 SW Water ( SW -Circulation Pond to SW head tank) 600.0 2.0 325.8 350 A 333.3 1.91 59.70 150.10 0.26 selected
Pump Discharge Side 600.0 2.0 325.8 400 A 381.0 1.46 58.60 147.30 0.15
600.0 2.0 325.8 450 A 428.5 1.16 58.00 145.90 0.09

6 SW Water ( SW -Return Pond to SW -Cooling Tower) 550.0 2.0 311.9 350 A 333.3 1.75 14.20 32.80 0.37 selected
Pump Discharge Side 550.0 2.0 311.9 400 A 381.0 1.34 12.70 29.20 0.21
550.0 2.0 311.9 450 A 428.7 1.06 11.90 27.40 0.13

7 SW -CC Circulation System (Hot)

2350.0 2.0 644.8 500 A 476.2 3.67 61.10 601.29 1.37
2350.0 2.0 644.8 550 A 524.0 3.03 56.35 555.01 0.90
8 SW -CC Water ( SW -CC Circulation Pond to plant area) 2350.0 2.0 644.8 600 A 575.0 2.51 53.37 525.59 0.60 selected
Pump Discharge Side 2350.0 2.0 644.8 650 A 640.9 2.02 51.13 503.55 0.37
2350.0 2.0 644.8 700 A 691.9 1.74 50.08 493.25 0.27

2350.0 2.0 644.8 500 A 476.2 3.67 69.67 686.18 1.03

2350.0 2.0 644.8 550 A 524.0 3.03 66.28 652.79 0.69
9 SW -CC Water ( SW -CC Circulation Pond to head tank) 2350.0 2.0 644.8 600 A 575.0 2.51 64.08 631.10 0.47 selected
Pump Discharge Side 2350.0 2.0 644.8 650 A 640.9 2.02 62.40 614.51 0.30
2350.0 2.0 644.8 700 A 691.9 1.74 61.59 606.60 0.22

1980.0 2.0 591.9 500 A 476.2 3.09 21.40 177.58 1.00

1980.0 2.0 591.9 550 A 524.0 2.55 18.16 150.72 0.67
10 SW -CC Water ( SW -CC Return Pond to Header Pipe) 1980.0 2.0 591.9 600 A 575.0 2.12 16.04 133.10 0.46 selected
Pump Discharge Side 1980.0 2.0 591.9 650 A 640.9 1.70 14.40 119.49 0.30
1980.0 2.0 591.9 700 A 691.9 1.46 13.61 112.94 0.22

III. Sea Water Intake

(Ref Dwg : P3FH -PR-4900-PFD -1001)

No. Fluid & Piping Segment Flow rate (m3/hr) Design Fluid velocity (m/s) Required Piping ID (mm) Selected Pipe Size (A) Selected Pipe ID (mm) Actual Fluid velocity (m/s) Pump Head (m) Pump Power (kW) (absorbed) Remarks

3000.0 2.0 728.6 600 A 575.0 3.21 48.23 606.32

1 Sea Water (Mainline to slag pond) 3000.0 2.0 728.6 650 A 640.9 2.58 42.30 531.81 selected
3000.0 2.0 728.6 700 A 691.9 2.22 39.58 497.63
3000.0 2.0 728.6 800 A 778.0 1.75 36.89 463.78

IV. Fuel Oil System

(Ref Dwg : P3FH -PR-4300-PFD -1001)

No. Fluid & Piping Segment Flow rate (m3/hr) Design Fluid velocity (m/s) Required Piping ID (mm) Selected Pipe Size (A) Selected Pipe ID (mm) Actual Fluid velocity (m/s) Pump Head (m) Pump Power (kW) (absorbed) Remarks

1 Fuel Oil (MFO Tank to Plant) 30.0 1.0 103.0 100 A 102.3 1.01 136.97 16.35
Pump Discharge Side 30.0 1.0 103.0 125 A 128.2 0.65 65.30 7.79
30.0 1.0 103.0 150 A 154.1 0.45 39.54 4.72 selected

2 Fuel Oil (HSD Tank to Plant) 30.0 1.0 103.0 100 A 102.3 1.01 46.66 4.91 selected
Pump Discharge Side 30.0 1.0 103.0 125 A 128.2 0.65 28.15 2.96
30.0 1.0 103.0 150 A 154.1 0.45 22.54 2.37
B LINE SIZING CALCULATION - Pump Suction
I. River Water Intake & Water Treatment System
(Ref Dwg : P3FH -PR-4100-PFD -1001)

No. Fluid & Piping Segment Flow rate (m3/hr) Design Fluid velocity (m/s) Required Piping ID (mm) Selected Pipe Size (A) Selected Pipe ID (mm) Actual Fluid velocity (m/s) Line Loss (kgf/cm2) Remarks

1 NSW Water (Clarifier to Plant Area) 195.0 1.0 262.7 200 A 202.7 1.68 0.088
Pump Suction Side 195.0 1.0 262.7 250 A 254.5 1.06 0.035 selected
195.0 1.0 262.7 300 A 304.7 0.74 0.017

2 NSW Water (Water Pond to Sand Filter) 60.0 1.0 145.7 100 A 102.3 2.03 0.188
Pump Suction Side 60.0 1.0 145.7 150 A 154.1 0.89 0.035 selected
60.0 1.0 145.7 200 A 202.7 0.52 0.012

3 NSW Water (Water Pond to Softener) 60.0 1.0 145.7 100 A 102.3 2.03 0.188
Pump Suction Side 60.0 1.0 145.7 150 A 154.1 0.89 0.035 selected

II. Circulation Water System

(Ref Dwg : P3FH -PR-4000-PFD -1001)

No. Fluid & Piping Segment Flow rate (m3/hr) Design Fluid velocity (m/s) Required Piping ID (mm) Selected Pipe Size (A) Selected Pipe ID (mm) Actual Fluid velocity (m/s) Line Loss (kgf/cm2) Remarks

NSW Circulation System

1 NSW Water ( NSW Circulation Pond to NSW head tank) 495.0 1.0 418.5 450 A 428.7 0.95 0.03
Pump Suction Side 495.0 1.0 418.5 400 A 381.0 1.21 0.05 selected

2 NSW Water (NSW -Return Pond to NSW - Cooling Tower) 400.0 1.0 376.2 400 A 381.0 0.97 0.03
Pump Suction Side 400.0 1.0 376.2 350 A 333.3 1.27 0.05
400.0 1.0 376.2 300 A 304.74 1.52 0.08 selected

SW Circulation System (Cold)

3 SW Water ( SW -Circulation Pond to SW head tank) 600.0 1.0 460.8 500 A 476.2 0.94 0.03
Pump Suction Side 600.0 1.0 460.8 450 A 428.5 1.16 0.04 selected
600.0 1.0 460.8 400 A 381.0 1.46 0.07
600.0 1.0 460.8 350 A 333.34 1.91 0.12

4 SW Water ( SW -Return Pond to SW -Cooling Tower) 550.0 1.0 441.2 500 A 476.2 0.86 0.02
Pump Suction Side 550.0 1.0 441.2 450 A 428.5 1.06 0.04 selected
550.0 1.0 441.2 400 A 381 1.34 0.06
550.0 1.0 441.2 350 A 333.34 1.75 0.10

SW -CC Circulation System (Hot)

5 SW -CC Water ( SWCC Circulation Pond to header pipe) 470.0 1.0 407.8 550 A 524.0 0.61 0.01
Pump Suction Side 470.0 1.0 407.8 500 A 476.2 0.73 0.02 selected
470.0 1.0 407.8 450 A 428.46 0.91 0.03
470.0 1.0 407.8 400 A 381.00 1.15 0.04
470.0 1.0 407.8 350 A 333.34 1.50 0.07

6 SW -CC Water ( SW -CC Return Pond to Header pipe) 1090.0 1.0 621.1 550 A 524.0 1.40 0.06
Pump Suction Side 1090.0 1.0 621.1 500 A 476.2 1.70 0.09
1090.0 1.0 621.1 650 A 640.9 0.94 0.03 selected

III. Fuel Oil System

(Ref Dwg : P3FH -PR-4900-PFD -1001)

No. Fluid & Piping Segment Flow rate (m3/hr) Design Fluid velocity (m/s) Required Piping ID (mm) Selected Pipe Size (A) Selected Pipe ID (mm) Actual Fluid velocity (m/s) Remarks

1 Fuel Oil (MFO Tank to Plant) 30.0 1.0 103.0 150 A 154.1 0.45 selected
Pump Suction Side 30.0 1.0 103.0 100 A 102.3 1.01

3 Fuel Oil (HSD Tank to Plant) 30.0 1.0 103.0 150 A 154.1 0.45 selected
Pump Suction Side 30.0 1.0 103.0 100 A 102.3 1.01

C LINE SIZING CALCULATION - Gravity Flow

No. Fluid & Piping Segment Flow rate (m3/hr) Design Fluid velocity (m/s) Required Piping ID (mm) Selected Pipe Size (A) Selected Pipe ID (mm) Actual Fluid velocity (m/s) Line Loss (kgf/cm2) Remarks

1 NSW Water (Plant Area to NSW Return Pond) 182.5 1.0 254.1 200 A 202.7 1.57 7.52
182.5 1.0 254.1 250 A 254.5 1.00 2.48
182.5 1.0 254.1 300 A 304.7 0.70 1.04 selected

2 Side wall cooling service to NSW Return pond 180.0 1.0 252.4 300 A 304.7 0.69 0.13 selected
180.0 1.0 252.4 250 A 254.5 0.98 0.29

3 SW Water (Plant Area to SW -Return Pond) 672.0 1.0 487.6 450 A 428.7 1.29 0.13 selected
672.0 1.0 487.6 500 A 476.2 1.05 0.09
672.0 1.0 487.6 550 A 524.0 0.87 0.06

4 SW -CC Water (ESF System And Receiving Pan to SW-CC Return Pond) 1980.0 1.0 837.0 650 A 641.4 1.70 0.32
1980.0 1.0 837.0 700 A 691.9 1.46 0.23 selected
1980.0 1.0 837.0 750 A 742.9 1.27 0.17

D LINE SIZING CALCULATION - Compressed Air System

(Ref Dwg : P3FH -PR-4700-PFD -1001)

No. Fluid & Piping Segment Flow rate (Nm3/hr) Design Fluid velocity (m/s) Required Piping ID (mm) Selected Pipe Size (A) Selected Pipe ID (mm) Actual Fluid velocity (m/s) Remarks

Compressed Air System - System 1

1 Compressed Air (Main header) 3246.0 20.0 239.6 250 A 254.5 17.73 selected
3246.0 20.0 239.6 200 A 202.7 27.94

2 Compressed Air (Main header to Ore Drying Equipment Air Receiver) 756.0 20.0 115.7 150 A 154.1 11.26 selected
756.0 20.0 115.7 100 A 102.3 25.57

3 Compressed Air (Main header to Dust Treatment Equipment Air Receiver) 150.0 20.0 51.5 50 A 52.5 19.25
150.0 20.0 51.5 65 A 62.7 13.49
150.0 20.0 51.5 80 A 77.9 8.74 selected

4 Compressed Air (Main header to Exhaust Gas Treatment Equipment Air Receiver) 180.0 20.0 56.4 65 A 62.7 16.19
180.0 20.0 56.4 50 A 52.5 23.10
180.0 20.0 56.4 80 A 77.9 10.49 selected

5 Compressed Air (Main header to Rotary Kiln Equipment Air Receiver) 1224.0 20.0 147.2 150 A 154.1 18.23 selected
1224.0 20.0 147.2 100 A 102.3 41.40

6 Compressed Air (Main header to Coal Firing Equipment Air Receiver) 390.0 20.0 83.1 80 A 77.9 22.71 selected
390.0 20.0 83.1 100 A 102.3 13.18

Compressed Air System - System 2 & 3 546.0 20.0 98.3 80 A 77.9 31.82
1 Compressed Air (Main header) 546.0 20.0 98.3 100 A 102.5 18.38
546.0 20.0 98.3 250 A 254.5 2.98 selected

2 Compressed Air (Main header to Electric Smelting Equipment Air Receiver) 287.0 20.0 71.3 80 A 77.9 16.71
287.0 20.0 71.3 65 A 62.7 25.82 selected

3 Compressed Air (Main header to System 3) 102.0 20.0 42.5 40 A 40.9 21.58 selected
102.0 20.0 42.5 50 A 52.5 13.09
102.0 20.0 42.5 65 A 62.7 9.18

HP Compressed Air System - System 2

1 Compressed Air (Main header) 108.0 20.0 43.7 40 A 40.9 22.85 selected
108.0 20.0 43.7 65 A 62.7 9.72

E LINE SIZING CALCULATION - Nitrogen & Oxygen

(Ref Dwg : P3FH -PR-4600-PFD -1001)

No. Fluid & Piping Segment Flow rate (Nm3/hr) Design Fluid velocity (m/s) Required Piping ID (mm) Selected Pipe Size (A) Selected Pipe ID (mm) Actual Fluid velocity (m/s) Remarks

1 Nitrogen main line 100.0 20.0 42.1 100 A 102.26 3.38 selected
100.0 20.0 42.1 80 A 77.90 5.83
100.0 20.0 42.1 65 A 62.70 9.00

2 Nitrogen Supply to Ore Drying Equipment 100.0 20.0 42.1 100 A 102.26 3.38 selected
100.0 20.0 42.1 80 A 77.90 5.83
100.0 20.0 42.1 65 A 62.70 9.00

3 Nitrogen Supply to Coal Firing Equipment 100.0 20.0 42.1 100 A 102.26 3.38 selected
100.0 20.0 42.1 80 A 77.90 5.83
100.0 20.0 42.1 65 A 62.70 9.00

1 Oxygen main line 200.0 20.0 59.5 80 A 77.9 11.65 selected

2 Oxygen Supply to Tapping Metal and Slag 5.0 20.0 9.4 25 A 26.6 2.49 selected
5.0 20.0 9.4 50 A 52.5 0.64

3 Oxygen Supply to Cover Blowing 160.0 20.0 53.2 50 A 52.5 20.55 selected
160.0 20.0 53.2 65 A 62.7 14.39

4 Oxygen Supply to Runner Shot Making & Ladle Maintenance 3.0 20.0 7.3 25 A 26.6 1.50 selected
3.0 20.0 7.3 50 A 52.5 0.38

F LINE SIZING CALCULATION - Steam

(Ref Dwg : P3FH -PR-4300-PFD -1001)

No. Fluid & Piping Segment Flow rate (Nm3/hr) Design Fluid velocity (m/s) Required Piping ID (mm) Selected Pipe Size (A) Selected Pipe ID (mm) Actual Fluid velocity (m/s) Remarks

Main line 435.97 20 87.8 150 A 154.1 6.49 selected

435.97 20 87.8 100 A 102.3 14.75