P&ID FOR CW CHLORINATION SYSTEM

Project
Owner
Contractor
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Document No.
Ref Drwg / Doc.
P&ID FOR CW CHLORINATION SYSTEM, Dwg. No. 3059-E01-002-00 Rev 0

2 Technical Specification # SPML-S10IRJ01-DD-ME-009 for CW Chlorination Plant
CHLORINATOR
As per Technical Specification Appendix - III, Clause 5.00.000 A) & B) ii following capcity has been confirmed.
4 x 100% capacity streams have been provided; hence Chlorinator capacity selected is 65 kg/hr x 4 streams, 2Nos. Working + 2 Nos. Stand by as per specification,
sheet SS-M0:6, clause 4.00.00A
Chlorinator Capacity
Kg/h
65
ppd
3466.666632
Kg/h
120 Rated capacity
Quantity
Nos.
2 Operating
2 Common Standby
Solution Concentration
ppm
3500
Minimum Ejector Water flow required
m/h
18.57
lpm
309.5238095238 lps
5.15873
EVAPORATOR SIZING
According to the technical specifications the capacity of the Chlorinator works out to 65 kg/hr .To achieve a continuous flow of 65 kg/hr of Chlorine Gas; the evaporator capacity should not be less than the
capacity of the Chlorinator. Therefore an evaporator of Capacity of 65 kg/hr is selected.
Capacity
Quantity
Kg/h
Nos.
65
ppd
2 Operating
3466.666632
2 Standby
EXPANSION TANK
We have selected 10 litres Capacity standard cylinder having dimensions 139.8 OD x 4.2 mm wall thickness x 845 mm long.
As per our proposed Equipment Layout the length of the 25NB Liquid Chorine works out to maximum 75 meters. Practically, it is much less.
m2
Area of 25 NB Line
0.00049
Volume of 25 NB Line
m3
lit
lit
0.03675
36.75
37
Let us say
Expansion Chamber Size = Minimum 20% of Piping volume.
Therefore
lit
Hence Expansion Chamber Size of 10 litres Capacity is Suitable
7.4
CHLORINE CONCENTRATION IN SOLUTION LINE

Two stream operating @ 65 kg/hr for each unit. As per technical specifications, there is no maximum limit on the Chorine concentration in the solution line. However, as the solubility of
chlorine in water is 2500 ppm , we limit the chlorine solution concentration to 2500 ppm maximum.
Accordingly solution flowrate required
Kg/h
65
ppd
3466.666632
Quantity
Nos.
2 Operating
2 Standby
ppm
3500
m/h 18.571429
lpm
309.5238095238 lps
5.15873
Above flow is the minumum flow required for the stated capacity & concentration, but we have to design the system as per ejector sizing
Ejector Sizing
Bulletin
Ref.
Nozzle
Throat
Back Pressure
Inlet
capability
Pressure
(Kg/cm)
(Kg/cm)
Reference Ejector Curve

122.3081.0 1.000
1.500
1
Back Pressure capability
Kg/cm
1
Ejector Inlet Pressure required
Kg/cm
3
I.e.
30 m head
Flow through each ejector
lpm
590
m/h
35.4
Quantity of ejectors operating per solution
Nos.
2 Standby
2
header
Combined Flow for the system
m/h
70.80
DIFFUSER SIZING (Typ. for each unit)
Location
CW Forebay
MOC
uPVC
PN 10
Size
90 OD
ID
81.4
mm
0.0814 m
Flow through solution line to diffuser
70.8
m/h
0.019667 m3/s
Nos.of diffuser
2
Nos.
Flow through each diffuser
35.4
m/h
0.009833 m3/s
Velocity through diffuser
1.891
m/s
Flow through each perforation should be 4-7 lpm at 3-4 m/sec as per Capital Controls design standard.
So, considering a flow
through the diffuser perforation
6.5
lpm
Therefore:
No of Perforations in diffuser
90.8
Nos. of Perforation each diffuser
Selected
90
Nos. of Perforation of 6mm diameter size
Perforation dia.
6
mm
Flow each perforation /orifice
C.S. Area of perforation
Velocity through Perforation
Hence the Diffuser Design is Suitable.
Prepared By: Bhavesh

Date: 9th May, 2011
0.393
m/h
2.8285713E-005 m2
3.8627012605 m/s
Flow
(lpm)
Flow m/h
590
35.4
590 lpm
### m/sec
(considering diameter = 6mm)
Checked by:
NMK
REV NO. - 00
HEAD LOSS IN DIFFUSER

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

This is less than 0.3,
so k =
0.0737100737
0.75
Qt =
No. of Perforation =
Q=
ead Loss at Diffuser Inlet
h=
h=
590
90
1.731
lpm
4.1625
1.2687
ft
m
0.24
155.76
gpm
gpm
inch
SUMMARY
Diffuser
Total nos. of diffuser
MOC
Size
Diffuser perforation size
Perforation in each diffuser
Flow through perforation
Velocity through perforation
Location
2
Nos.
uPVC
PN 10
90 OD
6
mm
90
Nos.
0.393
m/h
3.9
m/s
CW Forebay
Chlorine Solution Line Calculations (OUTDOOR LINE)

Solution header pipe
MOC
Flow through header pipe

Velocity through pipe
Length of solution line
m3/h
m/s
m
uPVC IS
4985
Size
125 OD
ID
113
Friction
Factor
(C
Value)
140
Friction
Factor
(C
Value)
140
70.8
1.961 This is less than 2.4m/s, hence acceptable.
70 Max length taken for design porpose, in practical it will be less.
Now, calculating friction loss in the pipe by using Williams & Hazenss Formula,
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
J = Head loss in mtr/mtr length of pipe
V = Velocity =
1.96 m/s
C = Constant for Pipe =
140
D = Inside diameter of pipe =
113.00 mm
Hence, on substituting valves on above formula, we get,
J =
0.0320330 mtr/mtr length of pipe
Head loss in solution pipe =
2.24 m
Considering a 20% margin on
Frictional Loss it works to be
2.691 m
Frictional Loss in solution line
Maximum Elevation of solution line
Pressure @ point of dosing
Loss in Valves
Loss in diffuser
Total Loss
Chlorine Solution Line Calculations, Ejector downstream
Ejector downstream pipe
m
2.691
m
2
m
0
m
0 Loss (m)
0.03 Quantity
0
m 1.2687273
m 5.9595033 This is well within the back pressure capability. Hence, O.K.
to solution header (Indoor line)
uPVC IS
4985
MOC
Size
90 OD
ID
81.4
Flow through pipe

m3/h
35.4
m/s
Length of pipe upto solution header
m
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
V = Velocity =
1.89 m/s
140
81.40 mm
J =
0.53 m
0.631 m
Loss in Butterfly Valves
Loss in Diaphragm Valves
Loss in NRVs
Maximum Elevation
Total Loss
Back Pressure on Ejector
m 0.6314614
m
0.008 Loss (m)
0.008 Quantity
1
m
0 Loss (m)
0.03 Quantity
0
m
0.015 Loss (m)
0.015 Quantity
1
m
1
m 1.6544614
m 7.6139647 This is within the permissible back pressure of 10m or 1kg/cm 2. Hence, O.K.
Motive Water Line Calculations, Pump Discharge header upto Ejector upstream
Booster Pump Discharge
Header line
Flow through pipe
Length of pipe, from pump discharge header
upto ejector
MOC MS IS 1239
m /h
m/s
3
Size
80 NB
ID
Friction
Factor
(C
Value)
78.4
100
35.4
2.037 Velocity limit range (1.5-2.4m/s).This is less than 2.4m/s, hence acceptable.
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
V = Velocity =
2.04 m/s
100
78.40 mm
J =
1.18 m
1.296 m
Frictional Loss
m
1.296
m
0.016 Loss (m)
Loss in NRVs
m
0.015 Loss (m)
Date: 9th May, 2011
Checked by:
NMK
0.008 Quantity
0.015 Quantity
2
1
REV NO. - 00
Loss in Flowmeter
Maximum Elevation
Total Loss

Date: 9th May, 2011
m
m
m
5
2
8.327
Checked by:
NMK
REV NO. - 00
Motive Water Line Calculations, Pump Discharge line upto Discharge header
Booster Pump Discharge line
MOC MS IS 1239
Flow through pipe

upto ejector
m3/h
m/s
Size
100 NB
ID
Friction
Factor
(C
Value)
102.3
100
70.80
2.393 Velocity limit range (3m/s). This is less than 3m/s, hence acceptable.
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
V = Velocity =
2.39 m/s
100
102.30 mm
J =
1.16 m
1.280 m
Frictional Loss
m
1.280
m
0.008 Loss (m)
0.008 Quantity
Loss in NRVs
m
0.015 Loss (m)
0.015 Quantity
Total Loss
m
1.303
B
Total
Pressure required @ pump discharge
Discharge
39.6
Ejector Inlet pressure +A + B X 10%Margin
Head (m)
1
1
Motive Water Line Calculations, motive water header

MOC MS IS 1239
Booster pump suction line
Size
125 NB
ID
129.5
Friction
Factor
(C
Value)
100
Friction
Factor (C
Value)
100
Flow through pipe

m /h
70.80
m/s
1.493 Velocity limit range (1.5m/s). This is less than 1.5m/s, hence acceptable.
Length of pipe from header
m
upto pump suction
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
V = Velocity =
1.49 m/s
100
129.50 mm
3

J =
0.37 m
0.406 m
Frictional Loss
Total Loss
m
0.406
m
0.0025
m 0.4084573
Loss (m)
C
0.0025 Quantity
Motive Water Line Calculations, motive water header from tapping point upto pump suction line
Booster pump suction Header
MOC MS IS 1239
Flow through pipe

Length of pipe from tapping
point
m3/h
m/s
Size
100 NB
ID
104.2
70.8
2.306 Velocity limit range (1.5-2.4m/s). This is less than 2.4m/s, hence acceptable.
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
V = Velocity =
2.31 m/s
100
104.20 mm
J =
0.89 m
0.975 m
Frictional Loss
Maximum Elevation
Loss in Strainers @ 50% choked condition
Total Loss
Total Loss in Motive Water Pipe from tapping
point upto pump suction
Water Pressure available at tapping point
Head available @ pump suction
m
0.975
m
2
m
0.024
m
5
m 7.9992849
m 8.4077422
m
0
m
-8.4
Loss (m)
Loss (m)
D
C+D
0.008 Quantity
5 Quantity
3
1
Pipe MOC
Flow m3/h
Velocity m/s
Velocity Limit
Remark
Booster Pump Suction Line
MS IS 1239
70.8
100 NB
104.2
2.31
2.4
Booster Pump Suction Header
MS IS 1239
70.8
125 NB
129.5
1.49
1.5
Booster Pump Discharge Line
MS IS 1239
70.8
100 NB
102.3
2.39
Ejector Upstream
MS IS 1239
35.4
80 NB
78.4
2.04
2.4
Chlorine Solution Line at ejector

outlet
uPVC IS 4985
35.4
90 OD
81.4
1.89
2.0
Chlorine Solution Header Line
uPVC IS 4985
70.8
125 OD
113
1.96
2.4
This within velocity limit,

hence selected line size is
ok
SUMMARY
Pipe
Location

Date: 9th May, 2011
Selected Size ID (mm)
Checked by:
NMK
REV NO. - 00

Date: 9th May, 2011
Checked by:
NMK
REV NO. - 00
Project
Owner
Contractor
Consultant
System
System supplier
Document
Document No.
Ref Drwg / Doc.
P&ID FOR CW CHLORINATION SYSTEM, Dwg. No. 3059-E01-001-00 Rev 0

2 Technical Specification # SPML-S10IRJ01-DD-ME-009 for RW Chlorination Plant
CHLORINATOR
As per Technical Specification following capcity has been confirmed.
2 x 100% capacity streams have been provided; hence Chlorinator capacity selected is 1.5 kg/hr x 2 streams, 1No. Working + 1 No. Stand by as per specification.
Quantity
Kg/h
Nos.
ppm
m/h
1.5
ppd
1 Operating
2500
0.60
lpm
79.9999992
Kg/h
1 Common Standby
10 lps
2 Rated capacity
0.166667

Two stream operating @ 65 kg/hr for each unit. As per technical specifications, there is no maximum limit on the Chorine concentration in the solution line. However, as the solubility of
chlorine in water is 2500 ppm , we limit the chlorine solution conc
Accordingly solution flowrate required
Kg/h
1.5
ppd
79.9999992
Quantity
Nos.
1 Operating
1 Standby
ppm
2500
m/h
0.6
lpm
10 lps
0.166667
Above flow is the minumum flow required for the stated capacity & concentration, but we have to design the system as per ejector sizing
Bulletin
Ref.
Ejector Sizing
Nozzle
Throat
Back
Pressure
capability
(Kg/cm)
1.5
122.3063.0 12.000
0.000
Kg/cm
1.5
Kg/cm
4
I.e.
40 m head
lpm
27
m/h
1.62
Quantity of ejectors operating per solution
Nos.
1 Standby
1
header
m/h
1.62
Location
CW Forebay
MOC
uPVC
Sch 80
Size
1"
ID
24.3
mm
0.0243
m
1.62
m/h
0.00045 m3/s
Nos.of diffuser
1
Nos.
1.62
m/h
0.00045 m3/s
0.970801212
m/s
Flow through each perforation should be 4-7 lpm at 3-4 m/sec as per Capital Controls design standard.
6
lpm
Therefore:
4.5
Selected
5
Perforation dia.
6
mm
Flow through each perforation /orifice
0.32400000
m/h
2.8285713E-005 m2
3.1818183264 m/s

d = Diameter of diffuser orifice in inches =
6
D = Diameter of pipe in which orifice is placed =24.3
0.2469135802
0.75
Qt =
No. of Perforation =
Q=
ead Loss at Diffuser Inlet
h=
h=
27
5
1.426
lpm
2.8244
0.8609
ft
m
Flow (lpm)
Flow m/h
27
1.62
27 lpm
### m/sec
mm
mm
d (dia of orifice) / D(dia of diffuser) =

so k =
Inlet
Pressure
(Kg/cm)
0.24
7.128
gpm
gpm
inch
SUMMARY
Diffuser
MOC
Size
Location
1
uPVC
1"
6
5
0.324
3.2
CW Forebay
Nos.
Sch 80
mm
Nos.
m/h
m/s

Solution header pipe
uPVC
MOC Schedule
80

m3/h
m/s
m
Size
1"
ID
24.3
Friction
Factor
(C Value)
140
1.62
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
Date: 17th May, 2011
Checked by:
NMK
REV NO. - 0
V = Velocity =
0.97 m/s
140
24.30 mm

J =
1.26 m
1.507 m
Loss in Valves
Loss in diffuser
Total Loss
Chlorine Solution Line Calculations, Ejector downstream
Ejector downstream pipe
m
1.507
m
2
m
0
m
0.03 Loss (m)
0.03 Quantity
1
m 0.8608685
m 4.3975029 This is well within the back pressure capability. Hence, O.K.
to solution header (Indoor line)
uPVC
MOC Schedule
80
Size
1"
ID
Friction
Factor
(C Value)
24.3
140
Flow through pipe

1.62
m /h
m/s
m
1.852
-1.167
J = 6.815 [V/C]
* (D)
Where,
V = Velocity =
0.97 m/s
140
24.30 mm
3

J =
0.63 m
0.753 m
Loss in NRVs
Maximum Elevation
Total Loss
m 0.7533172
m
0 Loss (m)
0.008 Quantity
0
m
0 Loss (m)
0.03 Quantity
0
m
0 Loss (m)
0.015 Quantity
0
m
1
m 1.7533172
m 6.1508202 This is within the permissible back pressure of 10m or 1kg/cm2. Hence, O.K.
Booster Pump Discharge
Header line
Flow through pipe
upto ejector
uPVC
MOC Schedule
80
m3/h
m/s
m
Size
1"
ID
Friction
Factor
(C Value)
24.3
140
1.62
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
V = Velocity =
0.97 m/s
140
24.30 mm
J =
0.63 m
Frictional Loss it works out to be
m
0.691
Frictional Loss
m
0.691
m
0.016 Loss (m)
Loss in NRVs
m
0.015 Loss (m)
Loss in Flowmeter
m
0
Maximum Elevation
m
2
Total Loss
m
2.722
A
0.008 Quantity
0.015 Quantity
2
1
Booster Pump Discharge line
Flow through pipe
upto ejector
uPVC
MOC Schedule
80
m3/h
m/s
m
Size
1"
ID
Friction
Factor
(C Value)
24.3
140
1.62
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
V = Velocity =
0.97 m/s
140
24.30 mm
J =
0.31 m
0.345 m
Frictional Loss
m
0.345
m
0.008 Loss (m)
Checked by:
NMK
0.008 Quantity
1
REV NO. - 0
Loss in NRVs
Total Loss
Pressure required @ pump discharge
m
m
Total
Discharge
Head (m)
0.015
0.368
43.1
Loss (m)
B
0.015 Quantity
Ejector Inlet pressure +A + B X 10%Margin

uPVC
MOC Schedule
80
Booster pump suction line
Size
1"
ID
Friction
Factor
(C Value)
24.3
140
Flow through pipe

m /h
1.62
m/s
Length of pipe from header
m
upto pump suction
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
V = Velocity =
0.97 m/s
140
24.30 mm
3

J =
0.31 m
0.345 m
Frictional Loss
Total Loss
m
0.345
m
0.0025
m 0.3477704
Loss (m)
C
0.0025 Quantity
uPVC
MOC Schedule
80
Booster pump suction Header

Flow through pipe
Length of pipe from tapping
point
m3/h
m/s
Size
1"
ID
Friction
Factor (C
Value)
24.3
140
1.62
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
V = Velocity =
0.97 m/s
140
24.30 mm
J =
0.63 m
0.691 m
Frictional Loss
Maximum Elevation
Loss in Strainers @ 50% choked condition
Total Loss
Total Loss in Motive Water Pipe from tapping
point upto pump suction
Water Pressure available at tapping point
m
0.691
m
2
m
0.024
m
5
m 7.7145408
m 8.0623112
m
5
m
-3.1
Loss (m)
Loss (m)
D
C+D
0.008 Quantity
5 Quantity
3
1
SUMMARY
Pipe
Location
Flow m3/h
uPVC Schedule 80
1.62
1"
24.3
0.97
2.4
Booster Pump Suction line
uPVC Schedule 80
1.62
1"
24.3
0.97
1.5
Booster Pump Discharge Line
uPVC Schedule 80
1.62
1"
24.3
0.97
Booster Pump discharge Header
uPVC Schedule 80
1.62
1"
24.3
0.97
2.4
Chlorine Solution Line at ejector

outlet
uPVC Schedule 80
1.62
1"
24.3
0.97
2.0
Chlorine Solution Header Line
uPVC Schedule 80
1.62
1"
24.3
0.97
2.4
Pumps
Ejectors operating per pump
Pump rating
Hence, pump selected
Pump Quantity
SUMMARY
Pump
Service
Type
Quantity
Flow
Differential Head

Nos.
m/h @ m head
m/h @ m head
LPM @ m Head
Nos.
Selected Size ID (mm)
1
1.944
m/h @
2
m/h @
33.33
LPM
1 Operating
46
50
50
1
Velocity m/s
Velocity Limit Remark
m Differential head
m Differential head
m Differential head
Standby

ok
Pipe MOC
Booster Pump Suction Header
2900 RPM
Water Booster pump

Centrifugal Horizontal
1
Working
1
Standby
2
m/h
50
m
Checked by:
NMK
REV NO. - 0
Project
Owner
Contractor
Consultant
System
System supplier
Document
Document No.
Ref Drwg / Doc.
1
2
I. STORAGE TANK SIZING:

A. VOLUME CALCULATION FOR SULPHURIC ACID STORAGE TANK
Quantity
1
No.
Capacity
15
m3
Material of construction:
Construction Type:
MS as per IS 2062
Atmospheric Horizontal cylinder with dished ends
Volume of tank V=(/4)x D2 x L

where,
Effective volume required:
15 cu.m
D= diameter of cylindrical tank

H= height of cylindrical tank
Calculated volume
2.5 m OD
3.5 m
V
B. THICKNESS CALCULATION FOR SULPHURIC ACID STORAGE TANKS

MOC:
MS as per IS 2062
Design Code:
IS:803
Tank Diameter
m
Tank Height
m
17.187 m3
2.5
3.5
1. Shell plate Thickness:

The minimum thickness of shell plates shall not be less than the calculations from the folowing formula
T = (50(H-0.3)*D*G/(SE))
Where,
T= minimum thickness in mm
D= Nominal diameter of the tank
H= Height from the bottom of the course under consideration to the bottom of the overflow which limits tank filli
G = Specific Gravity of liquid to be stored
S = Allowable Stress in kg/cm2 for IS:2062 as per clause No. 5 of IS" 803
E = Joing Efficiency
2500 mm
3500 mm
1.82
1680 kg/cm2
0.7
2.5
3.5
Shell Plate Thickness:

T
=
Further, we are considering a corrosion allowance =
Therefore total thickness
=
Hence 5 mm thick plate can be used as per Clause No 6.3.3.2 of IS: 803.
Selected thickness
T
=
Summary:
Construction
MOC:
Thickness
Tank Diameter
Tank height
Free board
0.62 mm
2 mm
2.62 mm
5
mm
Atmospheric Horizontal cylinder with dished ends

MS as per IS 2062
5 mm
2.5 m
3.5 m
0.445 m
II. PIPE SIZING:

1. Sulphuric Acid unloading pump Suction header:
MOC:
Flow of stream
Velocity in pump suction header
MS IS:1239
m3/hr
m/sec
Size
65 NB
10
0.80
ID in mm
66.3
0.0028
Size
65 NB
10
0.80
ID in mm
66.3
m3/sec
Size
50 NB
10
1.38
ID in mm
50.7
m3/sec
ID in metres
0.0663
m3/sec
2. Unloading Pump suction line:

MOC:
Flow of stream
MS IS:1239
m3/hr
m/sec
ID in metres
0.0663
0.0028
3. Unloading Pump Discharge Line

MOC:
Flow of stream
MS IS:1239
m3/hr
m/sec
ID in metres
0.0507
0.0028
m
m
4. Unloading Pump Discharge Header:

MOC:
MS IS:1239
Flow of stream
m3/hr
m/sec
Size
50 NB
10
1.38
ID in mm
50.7
m3/sec
Size
65 NB
m3/hr
m/sec
ID in mm
66.3
0.0028
ID in metres
0.0507
0.0028
III. ACID UNLOADING PUMP HEAD SIZING:

1. Head loss in acid unloading pump suction header
A. Selected pipe specifications:
MOC
Flow of stream
MS IS:1239
V
10
0.8043
ID in metres
0.0663
m3/sec
metres.
---------
0.342
metres.
---------
II
Equivalent length =
342
mm
(Refer the enclosed table for equivalent length of fittings)
0.342
metres.
---------
III
Total Equivalent length

Rounded off length
Constant
I + II + III
---------
---------
---------
Length of pipe from sulphuric acid unloading point upto suction line of unloading pumps
Equivalent length of
65 NB
No of elbows.
Equivalent length =
Nos. 3000# socket weld
342
No. of Tees.
pipe-fittings:
mm
Head loss per meter length
Total head loss in pipeline
B. Head loss through valve of

Qty:
Flow through valve
5.684 metres.
6 metres.
100
6.815(V/C)^1.852*(D)^(-1.167)
0.02136 mWC
0.12815 mWC
65 NB
1 No.
10 m3//hr
Loss through valve
0.024 mWC
Head loss in acid unloading pump header
=
=
Head loss in Sulphuric acid unloading pump suction header:
1+2
0.15215 mWC
0.152151115 mWC
2. Head loss in acid unloading pump suction line:

MOC
Flow of stream
Size
65 NB
MS IS:1239
V
10
0.8043
m3/hr
m/sec
ID in mm
66.3
0.0028
ID in metres
0.0663
m3/sec
metres.
---------
0.228
metres.
---------
II
Equivalent length =
228
mm
(Refer the enclosed graph for equivalent length of fittings)
0.228
metres.
---------
III

Rounded off length
Constant
I + II + III
---------
---------
Length of pipe from pump suction header upto pump suction point
No of elbows.
Equivalent length =
No. of Tees.
65 NB
pipe-fittings:
2
228
2

mm
B. Head loss through valve of

Qty:
Flow through valve
Loss through valve
2.456 metres.
3 metres.
100
6.815(V/C)^1.852*(D)^(-1.167)
0.02136 mWC
0.06408 mWC
65 NB
1 No.
10 m3//hr
0.024 mWC
C. Head loss through Y-type strainer
2 mWC
Head loss in unloading pump suction line
=
=
1+2+3
2.08808 mWC
Head Loss in Sulphuric Acid unloading pump suction line:
2.08808 mWC
Total Head Loss in Sulphuric Acid Unloading Pump Suction side:

=
A+B
2.24023
---------
---------
mWC
3. Head loss in acid unloading pump discharge line:

MOC
Size
50 NB
MS IS:1239
Flow of stream
10
1.4
m3/hr
m/sec
ID in mm
50.7
0.0028
ID in metres
0.0507
m3/sec
metres.
---------
0.216
metres.
---------
II
Equivalent length =
216
mm
0.216
metres.
---------
III

selected length
Constant
I + II + III
---------
---------
---------
---------
Length of pipe from tank discharge point upto pump discharge header
50 NB
No of elbows.
Equivalent length =
pipe-fittings:
2
216
No. of Tees.
mm

B. Head Loss through Non Return Valve of
Qty:
Flow in stream
Velocity in pump discharge line
2.432 metres.
3 metres.
100
6.815(V/C)^1.852*(D)^(-1.167)
0.07890 mWC
0.23670 mWC
50 NB
Loss through NRV

C. Head loss through ballvalve of
Qty:
Flow through valve
=
=
=
1 No.
10 m3/hr
1.4 m/sec
0.275 mWC
50 NB
1 No.
10 m3//hr
Loss through valve
0.1 mWC
Total Head loss in unloading pump discharge line
=
=
Head Loss in Sulphuric Acid unloading pump Discharge line:
1+2+3
0.61170 mWC
0.61170 mWC
4. Head loss in acid unloading pump discharge header:

MOC
Flow of stream
Size
50 NB
m3/hr
m/sec
MS IS:1239
V
10
1.4
ID in mm
50.7
0.0028
ID in metres
0.0507
m3/sec
metres.
---------
0.216
metres.
---------
II
Equivalent length =
216
mm
0.216
metres.
---------
III

selected length
Constant
I + II + III
No of elbows.
Equivalent length =
No. of Tees.
50 NB
2
216
2
pipe-fittings:
mm
=
=
2.432 metres.
3 metres.
100
6.815(V/C)^1.852*(D)^(-1.167)
0.078898685 mWC
B. Head loss through ballvalve of

Qty:
Flow through valve
0.236696055 mWC
---------
---------
---------
50 NB
1 No.
10 m3//hr
Loss through valve
0.1 mWC
Head loss from pump discharge line upto sulphuric acid storage tank inlet p
=
=
1+2
0.336696055 mWC
Head Loss in Sulphuric Acid unloading pump Discharge header:
0.33670 mWC
Total loss in Sulphuric Acid Unloading Pump Discharge side:
C+D
0.94839211 mWC
SUMMARY:
Pump Head requirement shall be calculated as under:
1. Total Head Loss at Sulphuric Acid Unloading Pump suction
2. Head Loss at Unloading Pump Discharge
3. Pressure available at tank discharge point
= 2.24022667 mWC
= 0.94839211 mWC
=
0 mWC
Pump Head requirement

Selected Value
Pump Capacity
Pump Head Selected
= 3.18861878 mWC
=
4 mWC
=
10 m3/hr.
=
10 mWC
IV. DAY / MEASURING TANK SIZING

A. VOLUME CALCULATION FOR SULPHURIC ACID DAY / MEASURING TANK:
Qty.
Capacity
2
2.5
Nos.
m3
Construction Type:
MS as per BS 2594
Vertical cylindrical type with cover

where,
2.5 cu.m

Calculated Volume
1.5 m OD
1.72 m
V
B. THICKNESS CALCULATION FOR SULPHURIC ACID DAY / MEASURING TANK

MOC:
MS as per BS 2594
Design Code:
IS:803
Tank Diameter
m
Tank Height
m
3.041 m3
1.5
1.72

T = (50(H-0.3)*D*G/(SE))
Where,
H= Height from the bottom of the course under consideration to the bottom of the overflow which limits tank filli
1500 mm
1720 mm
1.82
1680 kg/cm2
0.7

T
=
=
Selected thickness
T
=
Summary:
Construction
MOC:
Thickness
Tank Diameter
Tank height
Free board

MS as per BS 2594
5 mm
1.5 m
1.72 m
0.306 m
0.16 mm
2 mm
2.16 mm
5
mm
1.5
1.72
m
m
V. PIPE SIZING:
1. Sulphuric Acid Transfer Line:
MOC
MS IS:1239
Flow of stream
Size
50 NB
m3/hr
m/sec
ID in mm
50.7
1
0.14
Size
15 NB
m3/hr
m/sec
ID in mm
14.6
0.00002
ID in mtrs.
0.0507
0.00028
m3/sec
VI. ACID METERING PUMP HEAD SIZING:

1. Head Loss Metering pump Suction Header:
MOC
MS IS:1239
Flow of stream
0.075
0.124
No of elbows.
Equivalent length =
15 NB
3
156
metres.
---------
0.156
metres.
---------
II
0.156
metres.
---------
III
---------
---------
---------
pipe-fittings:
mm
No. of Tees.
3
Equivalent length =
156
mm
selected length
Constant
I + II + III
B. Head loss through ball valve of

Qty:
Flow through ball valve
m3/sec
Length of pipe from tank discharge point upto pump suction line
ID in metres
0.0146
5.312 metres.
6 metres.
100
6.815(V/C)^1.852*(D)^(-1.167)
0.00394 mWC
0.02362 mWC
15 NB
1 No.
0.075 m3//hr
Loss through ball valve
0.1 mWC
refer enclosed graph for ball valve

Head loss in metering pump suction header
=
=
Head Loss in Sulphuric Acid Metering Pump Suction Header
1+2
0.123624655 mWC
0.123624655 mWC
2. Head Loss in Metering Pump Suction Line:

MOC
Size
15 NB
m3/hr
m/sec
MS IS:1239
Flow of stream
Velocity in pump suction line
0.075
0.1243908459
ID in mm
14.6
0.00002
ID in metres
0.0146
m3/sec
metres.
---------
0.104
metres.
---------
II
Equivalent length =
104
mm
0.104
metres.
---------
III

selected length
Constant
I + II + III
---------
---------
No of elbows.
Equivalent length =
No. of Tees.
15 NB
2
104
2
pipe-fittings:
mm

Qty:
2.208 metres.
3 metres.
100
6.815(V/C)^1.852*(D)^(-1.167)
0.003937443 mWC
0.011812328 mWC
15 NB
1 No.
0.075 m3//hr
0.1 mWC
2 mWC
Head loss in metering pump suction line
=
=
1+2+3
2.111812328 mWC
Head Loss in Sulphuric Acid Metering Pump Suction Line
2.111812328 mWC
Total loss in Sulphuric Acid Metering Pump Suction line:

=
---------
---------
A+B
2.235436983 mWC
3. Head Loss in Metering Pump Discharge Line:

MOC
Size
15 NB
m3/hr
m/sec
MS IS:1239
Flow of stream
0.075
0.124
ID in mm
14.6
0.00002
ID in metres
0.0146
m3/sec
100
metres.
---------
0.104
metres.
---------
II
Equivalent length =
104
mm
0.104
metres.
---------
III

selected length
Constant
I + II + III
---------
---------
---------
---------
15 NB
No of elbows.
Equivalent length =
104
No. of Tees.
pipe-fittings:
mm

B. Head Loss through Non Return Valve of
Qty:
Flow in stream
100.208 metres.
101 metres.
100
6.815(V/C)^1.852*(D)^(-1.167)
0.003937443 mWC
0.397681701 mWC
15 NB
Loss through NRV

C. Head loss through ball valve of
Qty:
=
=
=
1 No.
0.075 m3/hr
0.124 m/sec
0.125 mWC
15 NB
1 No.
0.075 m3//hr

0.01 mWC
Total Head loss in metering pump discharge line
=
=
Head Loss in Sulphuric Acid Metering Pump Discharge Line
1+2+3
0.532681701 mWC
0.532681701 mWC
4. Head loss in dosing pump discharge header:

MOC
Size
15 NB
m3/hr
m/sec
MS IS:1239
Flow of stream
0.075
0.124
ID in mm
14.6
0.00002
ID in metres
0.0146
m3/sec
metres.
---------
0.26
metres.
---------
II
Equivalent length =
260
mm
0.26
metres.
---------
III

selected length
Constant
I + II + III
---------
No of elbows.
Equivalent length =
No. of Tees.
15 NB
5
260
5
pipe-fittings:
mm
6.52 metres.
7 metres.
100
6.815(V/C)^1.852*(D)^(-1.167)
0.00394 mWC
0.02756 mWC
B. Head loss through ballvalve of

Qty:
15 NB
1 No.
0.075 m3//hr
0.01 mWC
Head loss from pump discharge line upto sulphuric acid storage tank inlet p
=
=
0.03756 mWC
Total Head loss in Sulphuric Acid Metering Pump Discharge side:

---------
C+D
0.57024 mWC

Therefore:
Selected
Perforation dia.
1+2
0.03756 mWC
Head Loss in Sulphuric Acid Metering Pump Discharge Header

Location
CD Forebay
MOC
Size
ID
Nos.of diffuser
---------
MS
15NB
14.6
0.075
1
0.075
0.125
mm
m/h
Nos.
m/h
m/s
lpm
0.6
6
1

mm
0.0146 m
2.08E-005 m3/s
1.25 lpm
2.08E-005 m3/s
1.25 lpm
65450140
0.013
m/h
7.8571E-007 m2
4.41919212 m/s
### m/sec
SUMMARY:
1. Total Head Loss in Sulphuric Acid Metering Pump suction
2. Head Loss in sulphuric Acid Metering Pump Discharge
= 2.235436983 mWC
= 0.570243799 mWC
= 2.805680782 mWC
Selected Value
Pump Capacity
Pump Head Selected
=
=
=
0 mWC
3 mWC
75 LPH
10 mWC
Project
Owner
Contractor
Consultant
System
System supplier
Document
Document No.

A. VOLUME CALCULATION FOR INHIBITOR TANKS:
Qty.
Capacity
1
1
Construction Type:
where,
Nos.
m3
MSRL as per IS 2062
1 m3

Calculated Volume
1.1 m OD
1.225 m
V
1.165 m3
B. THICKNESS CALCULATION FOR INHIBITOR STORAGE TANKS

MOC:
MSRL as per IS 2062
Design Code:
IS:803
Tank Diameter
m
Tank Height
m
1.1
1.225

T = (50(H-0.3)*D*G/(SE))
Where,
1100 mm
H= Height from the bottom of the course under consideration to the bottom of the overflow which l
1225 mm
1.1 Corrosion I
1680 kg/cm2
0.7
1.1
1.225
m
m
1.25 Scale Inhibitor

T
Selected thickness
T
=
Summary:
Construction:
MOC:
Thickness:
Tank Diameter:
Tank height:
Free board:
0.05 mm
2 mm
2.05 mm
=
5
mm

MSRL as per IS 2062
5 mm
1.1 m
1.225 m
0.173 m
II. METERING PUMP HEAD SIZING:

1. Head Loss In Metering pump Suction Header:
Size
ID in mm
ID in metres
uPVC
Schedule 80
0.05
0.0920
MOC
1/2"
13.86
m3/hr
m/sec
0.00001
m3/sec
metres.
---------
0.156
metres.
---------
II
Equivalent length =
156
mm
0.156
metres.
---------
III

selected length
Constant
---------
---------
---------
Flow of stream
Length of pipe from tank discharge point upto pump suction line
1/2"
No of elbows.
Equivalent length =
156
No. of Tees.
0.01386
pipe-fittings:
Nos. Schedule 80
mm
Nos. Schedule 80
I + II + III
C
6.815(V/C)^1.852*(D)^(-1.167)
=
0.0012838 mWC
=
B. Head loss through Ball valve of

Qty:
5.312 metres.
6 metres.
140
0.00770281 mWC
1/2"
1 No.
0.05 m3//hr
0.01 mWC
Head loss in metering pump suction header
=
=
Head loss in Inhibitor Tank Metering Pump Suction Header:
1+2
0.01770281 mWC
0.01770281 mWC
2. Head Loss In Metering Pump Suction Line:

ID in mm
uPVC
Schedule 80
0.05
0.0920
MOC
13.86
0.00001
m3/sec
metres.
---------
0.104
metres.
---------
II
Equivalent length =
104
mm
0.104
metres.
---------
III

selected length
Constant
---------
0.01 mWC
---------
2 mWC
---------
Flow of stream
Velocity in pump suction line
1/2"
m3/hr
m/sec
ID in metres
1/2"
No of elbows.
Equivalent length =
104
No. of Tees.
pipe-fittings:
Nos. Schedule 80
mm
Nos. Schedule 80
I + II + III
C

Qty:
0.0012838 mWC
=
0.00385141 mWC
1 No.
0.05 m3//hr
0.092 m/sec
1/2"
2.208 metres.
3 metres.
140
6.815(V/C)^1.852*(D)^(-1.167)
=
0.01386
1/2"
Total Head loss in metering pump suction line
=
=
Head loss in Inhibitor Metering Pump Suction Line:
1+2+3
2.01385141 mWC
2.01385141 mWC
Total head loss in Inhibitor Pump Suction line:
=
=
---------
A+B
2.03155422 mWC

ID in mm
uPVC
Schedule 80
0.05
0.0920187678
MOC
Flow of stream
1/2"
m3/hr
m/sec
13.86
0.00001
m3/sec
100
metres.
---------
0.104
metres.
---------
II
0.104
metres.
---------
III
---------
---------
---------
---------
No of elbows.
Equivalent length =
No. of Tees.
1/2"
0.01386
pipe-fittings:
Nos. Schedule 80
104
mm
Nos. Schedule 80
Equivalent length =
104
mm
selected length
Constant
ID in metres
I + II + III
=
C
100.208 metres.
101 metres.
140
= 6.815(V/C)^1.852*(D)^(-1.167)
=

B. Head Loss through Non Return Valve of:
Qty:
Flow in stream
0.12966404 mWC
=
=
=
1 No.
0.05 m3/hr
0.09202 m/sec
0.125 mWC
1/2"
Loss through NRV of Metering pump

C. Head loss through ball valve of :
Qty:
0.0012838 mWC
1/2"
0 No.
0.05 m3//hr
0.01 mWC
Total Head loss in metering pump discharge line
=
=
Head loss in Inhibitor Metering Pump Discharge Line:
1+2
0.25466404 mWC
0.25466404 mWC
4. Head loss in Metering pump discharge header:

ID in mm
uPVC
Schedule 80
0.05
0.0920187678
MOC
Flow of stream
Velocity in pump discharge header
1/2"
m3/hr
m/sec
13.86
0.00001
m3/sec
metres.
---------
0.26
metres.
---------
II
0.26
metres.
---------
III
No of elbows.
Equivalent length =
No. of Tees.
1/2"
5
260
5
ID in metres
0.01386
pipe-fittings:
Nos. Schedule 80
mm
Nos. Schedule 80
Equivalent length =
260
mm

selected length
Constant
I + II + III
=
C
6.52 metres.
7 metres.
140
6.815(V/C)^1.852*(D)^(-1.167)
0.0012838 mWC
0.00898662 mWC
B. Head loss through ball valve of : 1/2"

Qty:
1 No.
0.05 m3//hr
0.01 mWC
Head loss from pump discharge line upto Inhibitor storage tank inlet point
=
=
Head loss in Inhibitor Metering Pump Discharge Header:

=
=

Location
CD Forebay
MOC
uPVC
Size
1/2"
ID
14.6
0.05
Nos.of diffuser
1
0.05
0.083
Therefore:
Selected
Perforation dia.
mm
m/h
Nos.
m/h
m/s
---------
---------
1+2
0.01898662 mWC
0.01898662 mWC
Total loss in Metering Pump Discharge side:
---------
C+D
0.27365065 mWC
0.0146 m
1.39E-005 m3/s
0.833333333 lpm
1.39E-005 m3/s
0.833333333 lpm
lpm
0.8
4
1

mm

0.013
7.8571425E-007
4.4191921201
m/h
m2
m/s
### m/sec
SUMMARY:
1. Total Head Loss in Inhibitor Metering Pump suction
2. Total Head Loss in Inhibitor Metering Pump Discharge
=
=
=
Value
Unit
2.03155 mWC
0.27365 mWC
0 mWC

Selected Value
Pump Capacity
Pump Head Selected
=
=
=
=
2.3052 mWC
3 mWC
50 LPH
10 mWC
Project
Owner
Contractor
Consultant
System
System supplier
Document
Document No.
Ref Drwg / Doc.
Annexure-3 Questionnaire
CAUSTIC TANK SIZING CALCULATION
2NaOH aq + Cl2 NaClaq + H2O +NaOClaq
1 Mol of chlorine (Molecular Weight = 70.91) requires 2 mole of NaOH (Molecular Weight = 40)
1 Mol of chlorine (Molecular Weight = 70.91) requires 2 mole of NaOH (Molecular Weight = 40)
i.e. 70.91 Kg chlorine requires 80 kg of NaOH
1000-Kg chlorine requires,
(1000x 2x 40) / 70.91 = 1128.19 Kg NaOH of 100% Purity
100% on weight basis of Pure NaOH corresponds to 1128.19 kg.
20 % on weight basis of Pure NaOH corresponds to 5641 kg.
Specific Gravity of 20% NaOH = 1.2
Therefore density of 20% NaOH = 1200 kg/m3 at 40 deg C.
(Note: We have Considered Max Ambient Temperature as 40 Deg C. At 40 Deg C Specific Gravity of 20% Na OH Solution =1.2
Volume of 20% Caustic Solution = 5641/1200 = 4.7 m 3.
Adding 20% margin, volume works out to be = 1.2 x 4.7 = 5.64 m 3
Height of the tank = Height up to overflow inlet + Height of 300 mm Free Board
Height of the tank = 2100 mm + 300mm.
Total Height = 2400 mm.
Operating Capacity = 5.64 = / 4 *d2 *h
5.64 = / 4 *d2 *2.4.

Diameter of the tank = 1.73 meter.
on # PCT/K02K2007-08 Vol III: Mechanical works pg no. III:20 s.no.8.2.b, caustic solution storage tank capacity to be 10 cum (min) with free board of 3
So, we selecting 10Cu.m capacity with free board of 300mm of caustic solution tank
Selecting a tank Diameter of 2.5 meter.
10= ( / 4) x 2.52 x H (H= Height of the tank without free board)
Therefore,
H= 2050 mm
Adding 300 mm free board to the H
Now,
Total height of the tank including the free board is 2050+300 = 2350mm
The dimensions of the tank are as follows: 1. Diameter = 2.5 meters
2. Cylindrical portion Height = (operating Height + Free Board) = 2350 mm
Height of Conical Portion = 600 mm.
Effective Volume of the tank = 10 m3
Project
Owner
Contractor
Consultant
System
System supplier
Document
Document No.
Ref Drwg / Doc.

A. VOLUME CALCULATION FOR HYPOCHLORITE DOSING TANK:
Qty.
Capacity
Construction Type:
1
0.1
PP+FRP
Vertical cylindrical type with flat bottom and cover

where,

T= Thickness of Tank =
Calculated Volume
Summary:
Construction:
MOC:
Thickness:
Tank Diameter:
Tank height:
Free board:
Nos.
m3
Hypo sol. Preparation tank

0.2
m3
0.1 m3
=
=
=
=
0.5
0.7
5
0.137
m OD
m OD
mm
m3
0.6
0.8
m OD
m OD
mm
m3
0.226
Vertical cylindrical type with flat bottom and cover

PP+FRP
0 mm
0.5 m
0.7 m
0.191 m
METERING PUMP HEAD SIZING:

uPVC
Schedule 80
0.005
0.0092
MOC
Flow of stream
Velocity in Pump Discharge line
Size
ID in mm
1/2"
m3/hr
m/sec
13.86
0.0000014
m3/sec
50
metres.
---------
0.624
metres.
---------
II
metres.
---------
III
---------
---------
Length of from pump discharge to dosing point:

1/2"
0.01386
pipe-fittings:
No of elbows.
12
Nos. Schedule 80
Equivalent length =
624
mm
No. of Tees.
Nos. Schedule 80
Equivalent length =
mm

selected length
Constant
ID in metres
I + II + III
6.815(V/C)^1.852*(D)^(-1.167)
=
Head loss in Inhibitor Tank Metering Pump Delivery line:
50.624 metres.
51 metres.
140
1.8050871E-005 mWC
=
0.0009205944 mWC
0.000921 mWC
METERING PUMP SELECTION:

Sodium Hypochlorite Solution Strength Available
Flow rate in line to be dosed
Desired Dosage Rate
Pressure in Line where Hypo is to be dosed
Metering Pump Capacity
Hypo Storage Required
m3/hr
PPM
lt/hr
Hr
Hypo Storage Tank Capacity

Hypo Storage Tank Capacity Selected
Pump rating
Pump Quantity
%
0.5
5
5
2
gm/ltr
5
83.3333
ppm
5000
lpm
5.00
12
66
70
lt/h @ m head
lt/h @ m head
Nos.
5.00
lt/h @
5.00
lt/h @
1 Operating
2 m Differential head
0 Standby
Project
1320 MW (Phase-I : 2 X 660 MW) Kawai Thermal Power Project
Owner
Adani Power Rajasthan Ltd.
Rev No.
Adani Infra (India) Ltd.
Prepared by
Development Consultants Pvt. Ltd., Kolkata
Azam
Client
Consultant
System
Capital Control India Pvt. Ltd
JK
Sizing Calculation for CW Chlorination system
Approved by
KAW1-EPC-CHS-DM-H-014
JK
Document No.
Ref Drwg / Doc.
Date
25.04.2011
Date
25.04.2011
Date
25.04.2011
Date
25.04.2011
6 x 120kg/h CW Chlorination and Absorption system Checked by
System supplier
Document
P&ID FOR CW CHLORINATION SYSTEM, Dwg. No. KAW1-EPC-CHS-DM-D-007 Rev 0

2 Technical Specification # K9B06-SPC-M-0039 for Chlorination Plant
CHLORINATOR
As per Technical Specification Appendix - III, Clause 5.00.000 A) & B) ii following capcity has been confirmed:
6 x 120Kg/h capacity streams have been provided; 2working for unit-1, 2working for unit-2 and 2Nos. common
stand by as per specification,
sheet SS-M0:6, clause 4.00.00A
Kg/h
120
Kg/h
120 Rated capacity
Quantity
Nos.
4 Operating
2 Common Standby
ppm
2500
m/h
48
lpm
800 lps
13.33333
EVAPORATOR SIZING
According to the technical specifications the capacity of the Chlorinator works out to 120 kg/hr . To achieve a continuous flow of 120 kg/hr of
Chlorine Gas; the evaporator capacity should not be less than the capacity of the Chlorinator. Therefore an evaporator of Capacity of 120 kg/hr
is selected, as specified.
Capacity
Kg/h
120
Quantity
Nos.
4 Operating
2 Standby
EXPANSION TANK
We have selected 10 litres Capacity standard cylinder having dimensions 139.8 OD x 4.2 mm wall
thickness x 845 mm long.
As per our proposed Equipment Layout the length of the 25NB Liquid Chorine works will not exceed 75 meters.
Area of 25 NB Line
0.00049
m2
Volume of 25 NB Line
m3
0.03675
liters
36.75
Let us say
liters
37
Expansion Chamber Size = Minimum 20% of Piping volume.
Therefore
liters
7.4
Hence Expansion Chamber Size of 10 litres Capacity is Suitable
Two stream operating @ 120 kg/hr for each unit. As per technical specifications, there is no maximum limit on the Chorine
concentration in the solution line. However, as the solubility of chlorine in water is 5000 ppm , we have however limited the
chlorine solution concentration to 2500 ppm at maximum capacity.
Accordingly solution flowrate required :
Quantity
Kg/h
Nos.
ppm
120
4 Operating
2500
2 Standby

m/h
48
lpm
800
lps
13.33
Above flow is the minumum flow required for the stated capacity & concentration, but we have to design the system as per
ejector sizing
Ejector Sizing
Bulletin
Ref.
Nozzle
Throat
122.3087.0
1.125
1.687
Back
Pressure
capability
(Kg/cm)
1
The above water flow is more than the minimum ejector water flow required and hence acceptable.

Quantity of ejectors operating per
solution header
Kg/cm
Kg/cm
lpm
1
3
820
I.e.
m/h
Nos.
Standby
m/h
196.8
30 m head
49.2
2
Inlet
Pressure
(Kg/cm)
Flow
(lpm)
Flow m/h
820
49.2

Location
CW Forebay
MOC
HDPE as per IS:4984 Pressure rating:
PN 10
Grade:
PE 80
Size
63 OD
ID
50
mm
0.05
m
Flow through solution line to diffuser 196.8
m/h
Nos.of diffuser
18
Nos.
10.933
m/h
0.0030 m3/s
182.222 lpm
1.548
m/s
Flow through each perforation should be 4-7 lpm at 3-4 m/sec-As per Technical specification DCPL-K9B06, pg SS-M0:27, clause 9.0
5.55
lpm
Therefore:
32.8
Selected
32
Perforation dia.
6
mm
0.342
m/h
2.8E-005 m2
3.36
m/s
### m/sec
For Flow through Diffusers header:

As flow progresses the flow rate through diffusers header reduces by each diffuser and hence, the diffuser header size reduced progressively
manintaining the flow by keeping velocity range of 1.6 -1.8 m/s
Velocity
Tag No.
Flow at DF-1
Pipe size size selected
maintaine
d
m/h
m/s
OD mm
ID mm
ID m
m/s
Flow at DF-1
98.4
0.027333 200 OD
163.6
0.1636
1.301
Flow at DF-2
87.467 0.024296 180 OD
147.2
0.1472
1.428
Flow at DF-3
76.533 0.021259 160 OD
130.8
0.1308
1.583
Flow at DF-4
65.600 0.018222 160 OD
130.8
0.1308
1.357
Flow at DF-5
54.667 0.015185 140 OD
114.4
0.1144
1.478
Flow at DF-6
43.733 0.012148 125 OD
102.2
0.1022
1.482
Flow at DF-7
32.800 0.009111 110 OD
90
0.09
1.433
Flow at DF-8
21.867 0.006074
90 OD
73.6
0.0736
1.428
Flow at DF-9
10.933 0.003037
63 OD
51.4
0.0514
1.464
d = Diameter of diffuser orifice in inc 6
mm
0.24
inch
D = Diameter of pipe in which orifice 50
mm
SUMMARY
d (dia of orifice) / D(dia of diffuser) = 0.12
Diffuser
so k =
0.75
18
Nos.
MOC
HDPE as pePN 10
Qt = 182.2222 lpm
48.10667 gpm
Size
63 OD
No. of Perforation = 32
6
mm
Q = 1.503
gpm
32
Nos.
oss at diffuser orifice
0.342
m/h
h = 3.1408
ft
3.36
m/s
h = 0.9573
m
Location
CW Forebay
HDPE IS
Solution header pipe (Header of two nos.
MOC
of ejector)
4984
m3/h
m/s
m
Size
200 OD
ID
163.6
Friction
Factor
(C
Value)
140
98.4
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
V = Velocity =
1.30 m/s
140
163.60 mm

J =
### mtr/mtr length of pipe
1.46 m
1.603 m
Frictional Loss in solution
m
1.603
line
m
2
m
0 Since dosing point elevation is below ground level, it is not considered.
Pressure drop in Diaphragm
Valves
Size
200 OD
Formula for calculating Pressure drop or loss ( DP):
DP=(Q/Kv)2 * SG
DP - Pressure drop in
meter
Q - Flow
m/h
98.4
kv - Flow Co-efficient
1122 (please refer attached capital controls chart Bulletein no. CCIPL-KV-DV/BFV/NRV-001)
SG- Specific gravity
1.4
m
0.0215 Loss (m)
0.0108 Quantity
2
Loss in diffuser
m
0.9573
Total Loss
m
4.58229 This is well within the back pressure capability. Hence, O.K.
Chlorine Solution Line Calculations, Ejector downstream to solution header (Indoor line)
Friction
Factor
Ejector downstream
HDPE IS
MOC
Size
160 OD
ID
130.8
140
pipe
4984
(C
Value)
Flow through pipe
m3/h
49.2
m/s
m
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
V = Velocity =
1.02 m/s
140
130.80 mm
J =
0.05 m
0.053 m
Frictional Loss in solution
m 0.057642
line
Pressure drop in Diaphragm
Valves
Size
160 OD
DP=(Q/Kv)2 * SG
meter
Q - Flow
m/h
49.2
1.4
m
0.0197 Loss (m)
0.0197 Quantity
1
Pressure drop in NRVs
Size
160 OD
DP=(Q/Kv)2 * SG
meter
Q - Flow (lpm)
Loss in NRVs
Maximum Elevation
Total Loss
m/h
49.2
1.4
m
0.0031 Loss (m)
0.0031 Quantity
1
m
1
m 1.080393
m 5.662683 This is within the permissible back pressure of 10m or 1kg/cm 2. Hence, O.K.
Booster Pump
Discharge Header line
MOC
Flow through pipe

Length of pipe, from pump discharge
header upto ejector
m3/h
m/s
CS IS
3589
Size
219.1 OD
ID
208
Friction
Factor
(C
Value)
100
196.8
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
V = Velocity =
1.61 m/s
100
208.00 mm
J =
0.24 m
0.268 m
Frictional Loss
m
0.268
Pressure drop in butterfly Valves
Size
219.1 OD
DP=(Q/Kv)2 * SG
meter
Q - Flow
Loss in butterfly valve
Loss in Flowmeter
Maximum Elevation
Total Loss
m/h
196.8
1
m
0.062 Loss (m)
0.031 Quantity
2
m
5
m
2
m
7.330
A
Booster Pump
Discharge line
MOC
Flow through pipe

Length of pipe, from pump discharge
header upto ejector
m3/h
m/s
m
CS IS
1239
Size
150 NB
ID
153.1
Friction
Factor
(C
Value)
100
98.4
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
V = Velocity =
1.48 m/s
100
153.10 mm
J =
0.30 m
0.330 m
Frictional Loss
m
0.330
Size
150 NB
DP=(Q/Kv)2 * SG
meter
Q - Flow
m/h
98.4

m
0.013
Pressure drop in NRVs
Size
150 NB
DP=(Q/Kv)2 * SG
meter
Q - Flow (lpm)
Loss in NRVs
Total Loss
Loss (m)
0.013 Quantity
m/h
98.4
1
m
0.00878 Loss (m)
0.0088 Quantity
1
m
0.352
B
Total
Pressure required @ pump
Discharg
37.7 Ejector Inlet pressure + A + B
discharge
e Head
(m)
Friction
Booster pump suction
CS IS
Factor
MOC
Size
150 NB
ID
153.1
100
line
3589
(C
Value)
Flow through pipe
98.4
m3/h
m/s
Length of pipe from
m
header upto pump suction
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
V = Velocity =
1.48 m/s
100
153.10 mm
J =
0.15 m
0.165 m
Frictional Loss
m
0.165
Size
150 NB
DP=(Q/Kv)2 * SG
meter
Q - Flow
Total Loss
m/h
98.4
1
m
0.013 Loss (m)
0.013 Quantity
1
m 0.177725
C
Booster pump suction
Header
Flow through pipe
Length of pipe from
tapping point
MOC
m3/h
m/s
m
CS IS
3589
Size
219.1 OD
ID
208
Friction
Factor (C
Value)
100
196.8
J = 6.815 [V/C] 1.852 * (D) -1.167
Where,
V = Velocity =
1.61 m/s
100
208.00 mm

2.03 m
2.234 m
Frictional Loss
m
2.234
Maximum Elevation
m
2
Size
219.1 OD
DP=(Q/Kv)2 * SG
meter
Q - Flow
m/h
Loss in Strainers @ 50% choked
condition
Total Loss
Total Loss in Motive Water Pipe from
tapping
point upto
pump at
suction
Water
Pressure
available
tapping
point
Pumps
Ejectors operating per
pump
Pump rating
Pump Quantity
Nos.
m/h @ m
m/h @ m
Nos.
196.8
1
m
0.062 Loss (m)
0.031 Quantity
2
m
4 Loss (m)
4 Quantity
1
m 8.295883
D
m 8.473608
C+D
m
15
m
6.5
2
118.08
m/h @
120
m/h @
2 Operating
1 Standby
1500 RPM
SUMMARY
Pipe
Pipe MOC Flow m3/hSelected SizeID (mm) Velocity m/s
Velocity Limit Remark
Booster Pump Suction

Header
CS IS 3589
196.8
219.1 OD
208
1.61
1.8
Booster Pump Suction line
CS IS 3589
98.4
150 NB
153.1
1.48
1.5
Booster Pump Discharge Line CS IS 1239
98.4
150 NB
153.1
1.48
CS IS 3589
196.8
219.1 OD
208
1.61
2.4
HDPE IS 4984
49.2
160 OD
130.8
1.02
2.0
HDPE IS 4984
98.4
200 OD
163.6
1.30
2.0
Booster Pump discharge

Header
Chlorine Solution Line at
ejector outlet
Chlorine Solution Header
Line
Pump
Service
Type
Quantity
Flow
Differential Head
Water Booster pump

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

ok
Location

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

CHLORINE CONCENTRATION IN SOLUTION LINE

Reference Ejector Curve

Prepared By: Bhavesh

HEAD LOSS IN DIFFUSER

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

Chlorine Solution Line Calculations (OUTDOOR LINE)

Flow through header pipe

Flow through pipe

Prepared By: Bhavesh

Flow through pipe

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

Motive Water Line Calculations, motive water header

Booster pump suction line

Flow through pipe

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

Flow through pipe

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

Booster Pump Suction Line

Booster Pump Suction Header

Booster Pump Discharge Line

Chlorine Solution Line at ejector

Chlorine Solution Header Line

This within velocity limit,

Prepared By: Bhavesh

Selected Size ID (mm)

Prepared By: Bhavesh

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

CHLORINE CONCENTRATION IN SOLUTION LINE

HEAD LOSS IN DIFFUSER

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

Chlorine Solution Line Calculations (OUTDOOR LINE)

Flow through header pipe

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

Flow through pipe

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

Ejector Inlet pressure +A + B X 10%Margin

Motive Water Line Calculations, motive water header

Booster pump suction line

Flow through pipe

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

Booster pump suction Header

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

Booster Pump Suction line

Booster Pump Discharge Line

Booster Pump discharge Header

Chlorine Solution Line at ejector

Chlorine Solution Header Line

Prepared By: Bhavesh

Selected Size ID (mm)

Velocity Limit Remark

This within velocity limit,

Booster Pump Suction Header

Water Booster pump

I. STORAGE TANK SIZING:

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

D= diameter of cylindrical tank

B. THICKNESS CALCULATION FOR SULPHURIC ACID STORAGE TANKS

1. Shell plate Thickness:

Shell Plate Thickness:

Atmospheric Horizontal cylinder with dished ends

II. PIPE SIZING: