Académique Documents
Professionnel Documents
Culture Documents
INTRODUCTION
The plant and systems are designed to achieve the best possible efficiency under the
specified operating conditions. The Power Cycle shall be designed with one low pressure feed
water heater (de-aerator). The steam requirement of the de-aerator shall be met from the
bleed of the turbine.
The cooling medium is filtered water, which is circulated through a cooling tower. The water is
supplied by owner at the terminal point (Raw Water Tank) from where it will pumped at the
required pressure to the Cooling Tower. The cooling water temperature considered is 32 Deg
C with a temperature rise of 8 Deg C across the Condenser. The Design wet bulb temperature
for the cooling tower has been considered as 27 Deg C. The efficiency of the Power plant is
deepens upon the water.
The required quantity of raw water shall be stored in the raw water tank of capacity 1500 m3.
We have considered river water of low hardness as CaCO3 and negligible Silica as SiO3
for the water treatment plant design. This is the basis for the selection of the multi-grade filter /
RO plant and DM water treatment plant. Any change in the limits of this water analysis will
impact the water treatment plant design and cost. We have not considered water softening
plant for cooling tower.
The raw water after filtration and required dosing will be taken to the cooling tower (make up)
for the condenser cooling water system. For the boiler makeup, the filtered water will be taken
through the RO/DM Water treatment plant and then stored in the DM water storage tank of 20
m3. The boiler make up water stream is designed for 2 m3 / hr capacity. In case if any other
water source is available for the power plant, the same may be indicated to us for design.
INPUT CONDITIONS
Ambient conditions and other inputs (assumed)
Temperatures
:
Design temperature for performance
: 35 Deg C
Design Temperature for Electrical
: 45 Deg C
Relative Humidity
:
Plant Design Relative Humidity
: 65.0%
Design Wind Velocity
: As per IS: 875
Seismic Coefficient
: As per IS: 1893
Soil Bearing Capacity at 2.0 m Depth
: 20 T/m2
(To be reconfirmed after site location is finalized & soil investigations
are conducted)
Cooling Water temperature
: 32 Deg C
DEAERATION TANK
SPECFICATION
Type
:Horizontal spray type
Design code
:As per US standards
Design pressure
:22.0 Kg/cm
Design material temperature :200 Deg. C.
Storage tank capacity at NWLm316
Deaeration capacitym3/hr.60
Hydraulic test pressure
:24 Kg/cm
Operating temperature
:120 Deg.C.
Operating pressure
: 0.35 Kg/cm2
Deaerator water inlet temp. :45 Deg.C.
Deaerator water outlet temp. :120 Deg.C.
Oxygen content in deaerator water :0.01 ppm
WATER REQUIREMENT
The raw water shall be from the day storage hold up, under ground
tank (owners scope) of 2000 m3 capacity (1500 m3 for Power Plant
and 500 m3 for fire fighting) and supplied at the inlet to the raw
water pumps and passed through multi grade filter (MGF) at 3.5
kg/cm2. One stream of the filtered water shall be taken to the
Cooling Tower. The other stream shall be taken to RO / DM Plant as
per the scheme.
The chlorine dozing system shall be provided to prevent Algae
formation and Bacteria.
The Raw Water is pumped by the Filter Feed Pump through the
Multi Grade Sand Filter (MGF) for the removal of Suspended Solids.
The unit consists of quartz sand media for the purpose. The unit
should be backwashed in a day or whenever the pressure drop
exceeds 0.8 Kg/cm2, whichever is earlier.
WATER PROPERITES
Hardness (ppm)
:
0
pH @ 250C
:
8.8 9.2 (after pH correction)
Conductivity @ 250C
:
0.5 (microsiemen / Cm)
Total Silica (maximum) (ppm): 0.02
Residual Hydrazine (ppm) :
0.01 0.02
All piping system will be designed as per ASME B 31.1 and IBR.
Stress Analysis shall be carried out for all critical piping as per ASME B 31.1 / IBR
requirements.
Supports, Spring Supports, guides, directional anchors will be selected to satisfy all
the operating conditions.
Drains and traps will be provided as required.
PIPING
Codes, Standards & Regulations
ASME
DIN
TRD
BS
IBR
1. ASME B31.1
2. ASME B31.2
3. ASME B31.3
4. ASME B31.4
5. ASME B31.5
6. ASME B31.8
7. ASME B31.9
8. ASME B31.11
-Power Piping
-Fuel Gas Piping
-Process Piping
-Pipeline Transportation Systems for Liquid
Hydrocarbons and other Liquids.
-Refrigeration Piping
-Gas Transmission and Distribution Piping
Systems
- Building Services Piping
- Slurry Transportation Piping Systems.
Through the use of codes and standards, safety and uniform economy
are obtained. The codes and standards primarily cover the following
aspects:
1.
Factors safety
2.
Material property
3.
Thickness calculation
4.
Loads
5.
Load combinations
6.
Stress limits
7.
Stress intensification factors
8.
Flexibility factors
9.
Supports
10. Flexibility analysis.
COMPARISON OF CODES
DESIGN PRESSURE
IBR 1950
ASME SEC.I
BS 1113
DESIGN PRESSURE
WITH PRESSURE
DROP
DRUM DESIGN
PRESSURE
DRUM DESIGN
PERSSURE
DRUM DESIGN
PRESSURE
50C
50C
35C
35C
DESIGN
TEMPERATUE
ALLOWANCE
RADIATION
50C
CONVECTION
39C
ECONOMISER
11C
25C
(15 + 2 Se) C
Max. 50C
WATER WALL
28C
50C
50C
TUBE THICKNESS
FORMULA tmin
FACTOR OF SAFETY
ACTUAL METAL
TEMPERATURE
371C (MIN)
PD
--------- + *C
2f + P
PD
--------- + 0.005D
2f + P
PD
--------2f + P
Et
1.5 ,
SR
1.5
Et
1.5 ,
SR
1.5
Et
1.5 ,
SR
1.3
R
2.7
SC
R
3.5
SC
Et
1.5 ,
SR
1.0
Se - ACTUAL WALL
THICKNESS in mm.
P=DESIGN PR.
D=OUTSIDE DIA
f=ALLOWABLE STRESS
CORR. TO DESIGN
METAL TEMP.
PD
--------2f + P
R
2.7
REMARKS
R
2.4
Et = YIELD STRENGTH
R = TENSILE STRENGTH
SR = RUPTURE
STRENGTH
SC = CREEP STRENGTH
FOR ASME MATERIALS ALLOWABLE STRESS CAN BE TAKEN DIRECTLY FROM ASME SEC.II PART-D
*C = CORROSION ALLOWANCE = 0.75mm FOR P 70 bar; 0 mm FOR P > 70 bar
Nominal
No.
Composition
01.
Carbon Steel
MATERIAL SPECIFICATION
ASME Section-I
Temp.
BS 1113
Limit
C
SA209 T1
St 35.8
St 45.8
427
15 Mo3
----
482
02.
Mo
03.
1 Cr Mo
SA335 P12
SA213 T12
13 Cr Mo 44
BS3059 P2 S2 620
BS3604 P1 620 440
535
04.
1 Cr Mo
SA213 T11
SA335 P11
----
552
05.
2 Cr 1 Mo
SA213 T22
SA335 P22
10 Cr Mo 910
BS3059 P2 S2 622-490
BS3604 P1, 622
577
06.
9 Cr 1 Mo V
SA213 T91
SA335 P91
X 10 Cr Mo V
Nb91
-----
635
07.
12 Cr 1 Mo V
-----
X 20 Cr Mo V
121
BS3059 P2 S2 762
BS3604 P1 762
700
08.
18 Cr 8 Ni
SA213 TP304 H
-----
704
09.
18 Cr 10 Ni Cb
SA213 TP347 H
-----
704
AREA
Tube
thickness
IBR
ASME SEC.I
Dished end
thickness
Flat end
thickness
PD
PD
+ C
PR
+ 0.75
fE 0.5 P
PR
fE (1 Y) P
PDK
PR
+ 0.75
2f
d
+ C
f
CP
d
f
PD
2f + P
2f + P
PR
fE 0.5 P
PR
fE 0.5 PE
PDK
2f 0.2 P
CP
PD
+0.005D
2f + P
2f + P
Shell
thickness
BS 1113
2P
R 1+
1
2f
P
Cd
f
P
Cd
2f
P
f
PIPING
Diameter and Thickness:
The diameter of the piping is usually decided
based on flow and heat transfer considerations.
In normal practice, the outside diameter is
specified for procurement. These are based on
the convenience and convention in manufacture.
After finalizing the diameter, the thickness of the
piping is computed based on the imposed loads.
PIPING
Diameter
Based on flow requirements
Based on economic requirements
Based on size availability
PIPING
Thickness
Based on strength requirement
Based on process allowances
Based on thickness tolerances
Based on availability
PIPING
Fluids and Pressure Drop:
The piping under present discussion may carry a singlephase fluid or two-phase fluid. The following fluids are
commonly handled by the piping:
1.Liquid
2.Gas
3.Liquid-solid slurry
4.Gas-solid mixture
5.Liquid-vapor mixture.
PIPING
Mixture of solids, liquids and gases are rarely
used. In a maze of piping, flow distribution plays
a major role in the design of piping. To calculate
the flow in various branches of piping (in a maze
of piping), the pressure drop in various branches
are to be calculated. The following formula is
commonly used to calculate the pressure drop in
a fully developed flow in a hollow circular pipe.
PIPING
f W2 L
P = ---------
2gd
Where,
f = Coefficient of friction
PIPING
The following formula is commonly used calculate the pumping
power required:
P p WA
HP =
--------------
75 x 109
Where
HP = Pumping power, HP
PIPING
Flow = 100 tonne / hr = 100 cu. m / hr = 100 / 3600 = 0.0278 cu.m / sec
d
= 102.26 mm (for 4 STD pipe = 114.3 x 6.02 mm x mm)
W = 0.0278 / ( * 0.102262 / 4) = 3.38 m / sec = 3.380 mm / sec
L
= 100 m = 100,000 mm
f
= 0.02 (approximate)
p
= 1.0 gm / cc (for water at ambient temperature)
P = 0.02 * 33802 * 100,000 / (2 * 9806.65 * 102.26) = 11.392 mm water column
PpWA
HP
PIPING
Nominal Pipe Size (NPS):
Class of Fittings:
PIPING
I. Pipe sizing and Pressure drop Calculations:
Pipe Sizing:
PIPING
PIPING
PIPING
Velocity profile in Different System:
PIPING
= AW
= --------- d2
4
Where
354025 x Qv
= -------------------w
A = Area, mm2
PIPING
= inside diameter, mm
= Velocity, m/sec
PIPING
Pressure drop calculations are of prime necessity in
determining:
a)The selected inside diameter meets the available
pressure drop in the case of main steam, cold reheat,
hot reheat and auxiliary steam lines and miscellaneous
water lines.
PIPING
For finding the frictional pressure drop in pipelines
Darcys Formula can be universally used for almost all
the fluids. With suitable restrictions for gases and
vapours. As long as the pressure drop is around 10% of
starting point pressure (which is true in most of the
steam lines in thermal power station). Darcys formula
for pressure drop can be used since the specific volume
change in the line due to pressure loss will have little
effect on calculated pressure drop.
PIPING
Calculation to determine the pressure drop in the pipe is made
according to formula:
flw2
P = ----------------- kg/cm2
20000 g c dv
Kw2
P = ----------------- kg/cm2
20000 g c v
PIPING
Where,
f= Friction factor found from a graph between Reynolds No. and
Relative roughness.
K= resistance coefficient for fittings there are established based on
experiments and are available in a standard table in various books.
l= length of pipe in meters
V= velocity in m/sec
gc= gravitational constant 9.81 m/sec2
d= inside diameter of pipe in meter
v= specific volume in m3/sec.
PIPING
a)Water (non-expansive flow) in compressible fluids.
l
w2 x
P=
---- x ------------ h x
di
2g
P=
absolute pressure in
lb/ft2
PIPING