DI PipeRoutingDP 01 X CFD Simulation Report R1

VOLTAS LIMITED PREP N.S NO.
DOMESTIC PROJECT GROUP DWMW/BSP/02/BE/07014

CHCK P.K.M
VOLTAS PRESSURE DROP APVD A.K.R BSP/VL/10/078A/15/005/02/BE/07014

CALCULATION OF DW & IW 58 SHTS INCL COVER SHT.
DATE 15.12.17
NETWORK
CLIENT: SAI L BHILAI CONSULTANT: MECON RANCHI
PLANT : BALANCE WORK MAKE UP WATER & DRINKING WATER SYSTEM FOR 7 MTPA EXPANSION STEEL
AUTHORITY OF INDIA LIMITED BHILAI STEEL PLANT ( BSP ) BHILAI_Pkg.078A
PROJECT : BALANCE WORK MAKE UP WATER & DRINKING WATER SYSTEM FOR 7
MTPA EXPANSION STEEL AUTHORITY OF INDIA LIMITED BHILAI STEEL PLANT ( BSP )
BHILAI_Pkg.078A
PROJECT NO : Pkg No. 078A
CLIENT : BHILAI STEEL PLANT
CONSULTANT : MECON RANCHI
1 ISSUED FOR REFERENCE N.S A.K.R 15.12.2017

0 ISSUED FOR REFERENCE N.S A.K.R 18.10.2017
REV LINE DESCRIPTION BY APVD DATE
THIS DRG IS CONFIDENTIAL AND IS THE PROPERTY OF VOLTAS LIMITED. IT MUST NOT BE DISCLOSED TO A THIRD PARTY,
COPIED OR LENT WITHOUT THE WRITTEN CONSENT OF VOLTAS LIMITED.
Drinking Water & Industrial Water Pipeline Analysis
Prepared for
MECON LIMITED
On Behalf of
VOLTAS LIMITED
Index
1. Introduction................................................................................................................ 5
2. CFD Data ..................................................................................................................... 6
2.1 Geometry Details................................................................................................... 6
2.1.1 Main Header Pipeline ......................................................................................... 7
2.1.2 Branching-1 Pipeline ........................................................................................... 9
2.1.3 Branching-2 Pipeline ......................................................................................... 10
2.1.10 Branching-9 Pipeline ....................................................................................... 21
2.1.11 Branching-10 Pipeline ..................................................................................... 23
2.2 Boundary Conditions & Material Properties ......................................................... 26
2.2.1 Material Properties ........................................................................................... 26
2.2.2 Boundary Conditions ........................................................................................ 26
2.3 Assumptions for simulation ................................................................................. 28
3. CFD Cases Description ............................................................................................... 28
4. Pipeline Analysis Cases Observations ........................................................................ 28
Appendix A – Pipeline Analysis Model Layout ............................................................... 29
Appendix B – Main Header Pipeline Package’s .............................................................. 30
Appendix C – Results of Branching-1 Pipeline ................................................................ 32
Appendix D – Results of Branching-2 Pipeline................................................................ 34
Appendix E – Results of Branching-3 Pipeline ................................................................ 36
Appendix F – Results of Branching-4 Pipeline ................................................................ 38
Appendix G – Results of Branching-5 Pipeline................................................................ 40
Appendix H – Results of Branching-6 Pipeline................................................................ 42
Appendix I – Results of Branching-7 Pipeline ................................................................. 44
Appendix J – Results of Branching-8 Pipeline ................................................................. 46
Appendix K – Results of Branching-9 Pipeline ................................................................ 48
Appendix L – Results of Branching-10 Pipeline .............................................................. 50
15-Dec-17 Page 3 of 57
Annexure-A – Result Verification .................................................................................. 53

A.1 1D CFD Simulation in FlowMaster ........................................................................ 53
A.2 Theoretical Pressure Drop Calculation ................................................................. 56
A.3 Comparison of 1D CFD & Theoretical Results ....................................................... 57
Abbreviations
CFD Computational Fluid Dynamics
1. Introduction
Network of Pipelines are mandatory for fluid transportation. Here, the Water is supplied
from pumps to the branching’s & then to the consumer packages with the help of pipelines, which
contains bends, valves, reducers, etc. In perspective of a complex system, pressure drop across
the pipeline network is an essential factor which is unavoidable and accounts the efficiency of the
complete system. Pressure drop is also necessary to estimate the pumping power required to
overcome the head losses and bring out the desired volumetric flow rates as per the requirement.
1D CFD can be used to investigate the pressure drop across Pipeline networks. 1D CFD
can be a tool to ensure effective design of Pipelines. Using 1D CFD package, it is possible to
easily estimate critical parameters at initial stages of design. CFD can be used to address
problems with existing geometrical or performance errors like Low or high pressure drop between
inlet and outlet. Such problems may lead to lower efficiency of the equipment and also increase
the cost of performance. Therefore, 1D CFD can provide insight in the behavior of the system and
contribute in resolving the problem along with ensuring cost effective and optimum design.
Software Overview:
The analysis is conducted using advanced FlowMaster tool. FlowMaster is the leading
general purpose 1D computational fluid dynamics (CFD) solution for the modeling and analysis
of fluid mechanics in complex piping systems of any scale. 1D FlowMaster has been applied
extensively worldwide for different engineering applications. 1D FlowMaster solves numerically
the Darcy’s Equation which is phenomenological equation relates the head loss, or pressure loss,
due to friction along a given length of pipe to the average velocity of the fluid flow.
Friction factor for pressure loss calculation is evaluated based on Colebrook-White and Hazen
William equation’s. The FlowMaster version 7.9.3 is used in the 1D CFD simulation.
2. CFD Data
2.1 Geometry Details

The geometry contains two pipelines; Drinking water pipeline & Industrial water pipeline.
Drinking water pipeline starts at MARODA PLANT-2 and supplies drinking water to various
packages in branching systems. Industrial water pipeline starts at MARODA PLANT-1 and
supplies make-up water to various packages in branching systems. Blue and white colored lines
shown in fig 2.1.1 are main header pipeline of drinking and industrial water pipeline which is
supplying water to various branching’s. There are total ten consumer package branching’s
connected to main header pipeline as shown in fig 2.1.2.
All Pipeline contains straight pipes, bends/elbows, reducers and valves, which are
considered for pressure analysis.
Fig 2.1.1 Geometry Details-Overall Pipeline System

Fig 2.1.2 Geometry Details- Branching’s of Drinking & Industrial Water Pipeline
2.1.1 Main Header Pipeline

Main header has Drinking & Industrial water pipeline. Main header of both drinking water
& industrial water pipeline is supplying water to ten branching’s which has consumer packages at
the end. Main header of drinking & industrial water pipeline is supplying water to total 83 & 69
consumer packages respectively in various branching’s. Pipeline view and number of components
are as given below:
Fig 2.1.1.1 Plot View of Main Header Pipeline

Table 2.1.1.1: Components of Main Header Pipeline

Description Quantity
Component
Drinking Water Industrial Water Drinking Water Industrial Water
DN600 DN900 5 27
DN500 DN800 30 16
DN450 DN600 13 10
DN300 DN500 10 7
Straight Pipe DN200 DN400 8 5
DN50 DN350 5 17
- DN250 - 2
- DN200 - 5
- DN50 - 3
DN600xDN50 DN900xDN50 1 1
DN500xDN50 DN900xDN300 1 1
DN500xDN80 DN800xDN450 1 1
DN500xDN250 DN800xDN200 1 1
DN500xDN200 DN800xDN800 1 1
DN500xDN150 DN800xDN150 2 1
DN500xDN300 DN600xDN80 1 1
DN500xDN100 DN600xDN50 1 1
T-Junctions DN500xDN500 DN600xDN600 1 1
DN450xDN100 DN500xDN350 1 1
DN450xDN150 DN500xDN200 1 1
DN200xDN200 DN500xDN450 1 1
DN300xDN65 DN400xDN150 1 1
DN300xDN50 DN350xDN350 1 1
DN300xDN250 DN350xDN50 1 2
DN200xDN150 DN250xDN150 1 1
Bends/Elbows - - 65 63
DN500xDN450 DN900xDN800 1 1
DN500xDN300 DN800xDN600 1 1
DN450xDN200 DN800xDN500 1 1
Reducers DN300xDN200 DN600xDN250 1 1
- DN250xDN200 - 1
- DN500xDN400 - 1
- DN400xDN350 - 1
Table 2.1.1.2: Packages of Main Header Pipeline

Drinking Water Industrial Water
Branching-6 Package Flow Rate Flow Rate
Condition Condition
3
(m /hr) (m3/hr)
071A HTSS-48 SUBSTATION (6/18) On 1 On 4
FWPH for MARODA-I On 26 Off -
077-02 FWPH OHP-A On 26 Off -
061 OHP Part-B On 17 On 392
2.1.2 Branching-1 Pipeline

Branching-1 has Drinking & Industrial water pipeline. Drinking water pipeline of Branching-
1 is supplying water to five consumer package’s and Industrial water pipeline is supplying water
to three consumer package’s. Pipeline view and number of components are given below:
Fig 2.1.2.1 Isometric View of Branching-1 Pipeline

15-Dec-17 Page 10 of 57
Table 2.1.2.1: Components of Branching-1 Pipeline

Component
DN100 DN450 8 8
DN80 DN50 10 16
Straight Pipe
DN65 - 3 -
DN50 - 9 -
T-Junctions
DN80xDN50 - 1 -
Reducers
DN80xDN65 - 1 -
Table 2.1.2.2: Packages of Branching-1 Pipeline

Condition Condition
(m3/hr) (m3/hr)
011-01A-PBS (STB) On 5 On 10
011-01B PBS (STG) On 2 Off -
117 Welfare building On 5 Off -
116B Tap Hole Mass Shop On 5 On 5
011-01B PBS - CT On 2 On 835

2 is supplying water to five consumer package’s and Industrial water pipeline is supplying water
to three consumer package’s. Pipeline view and number of components are given below:
15-Dec-17 Page 11 of 57

Component
DN200 DN350 9 14
DN150 DN150 21 6
Straight Pipe
DN65 DN50 2 -
DN50 - 4 4
DN200xDN200 DN350xDN350 1 2
T-Junctions DN150xDN65 - 1 -
DN150xDN50 - 2 -
DN200xDN150 DN350xDN150 2 1
Reducers
- DN350xDN50 - 1
15-Dec-17 Page 12 of 57

Condition Condition
3
(m /hr) (m3/hr)
61 OHP Part-B On 21 On 58
071-A HTSS-46 SUBSTATION (3/18) On 1 On 4
60 ORE Handling Plant On 10 On 100
077-02 FWPH OHP-B On 26 Off -

Branching -3 has Drinking & Industrial water pipeline. Drinking water pipeline of Branching
-3 is supplying water to seven consumer package’s and Industrial water pipeline is supplying
water to seven consumer package’s. Pipeline view and number of components are given below:
Fig 2.1.4.1 Isometric View of BRANCHING-3 Branching

15-Dec-17 Page 13 of 57

Component
DN65 DN80 11 11
- DN50 - 4
Reducers
- DN80xDN50 - 2

Condition Condition
3
(m /hr) (m3/hr)
25 BOF On 5 On 5
27 HMDS On 5 On 15
077-1 WTP-1 On 10 On 5
026-CCP On 5 On 10
123- FERRO ALLOY STORAGE YARD On 2 On 2

4 is supplying water to three consumer package’s and Industrial water pipeline is supplying water
to two consumer package’s. Pipeline view and number of components are given below:
15-Dec-17 Page 14 of 57

Component
Reducers - - - -

Condition Condition
(m3/hr) (m3/hr)
071-A HTSS-71A SUBSTATTION (16/18) On 1 On 4
071-A HTSS-71A SUBSTATION (17/18) On 1 On 4
077-02 FWPH for MARODA-II On 26 Off -

15-Dec-17 Page 15 of 57

5 is supplying water to eleven consumer package’s and Industrial water pipeline is supplying
water to ten consumer package’s. Pipeline view and number of components are given below:

Component
DN200 DN300 13 13
DN150 DN200 13 15
DN80 DN80 1 1
- DN50 - 1
DN200xDN200 DN300xDN300 1 1
T-Junctions
DN150xDN150 DN200xDN200 1 1
DN200xDN150 DN300xDN200 2 2
DN150xDN100 DN200xDN150 2 2
Reducers
- DN200xDN80 - 1
15-Dec-17 Page 16 of 57

Condition Condition
3
(m /hr) (m3/hr)
77-02 EXTERNAL WATER SYSTEM for

On 18.3333 On 50
WTP-1 (URM)
077-02 EXTERNAL WATER SYSTEM FOR
On 18.3333 On 50
WTP-3 & 4 (URM)
077-02 EXTERNAL WATER SYSTEM FOR
On 18.3333 On 50
WTP-2 (URM)
117 PROJECT BUILDING WELFARE On 5 On 0
47 (URM) C-35 SUBSTATION On 7 On 7
70 AUGMENTATION OF EXISTING MSDS On 2 On 10
49-03 REHEATING FURNACES FOR

On 5 On 50
UNIVERSAL RAIL MILL
125-02 (URM) ACVS FOR URM & RAIL
On 5 On 50
WELDING, RAIL MILL
077-02 FWPH for URM AREA On 26 Off -

6 is supplying water to three consumer package’s and Industrial water pipeline is supplying water
to two consumer package’s. Pipeline view and number of components are given below:
15-Dec-17 Page 17 of 57

Component
T-Junctions - - - -
Reducers - - - -

Condition Condition
3
(m /hr) (m3/hr)
20 SINTER PLANT On 15 On 150
077-02 FWPH for SINTER PLANT-III On 26 Off -

15-Dec-17 Page 18 of 57

7 is supplying water to ten consumer package’s and Industrial water pipeline is supplying water
to nine consumer package’s. Pipeline view and number of components are given below:

15-Dec-17 Page 19 of 57

Component
DN250 DN450 28 28
DN50 DN50 8 8
T-Junctions
DN250xDN65 DN450xDN100 1 1
DN250xDN65 DN450xDN100 1 1
Reducers

Condition Condition
(m3/hr) (m3/hr)
Pump House-3 BASE BLENDING
On 8 On 31
PACKAGE
62 NEW COAL HANDLING PLANT On 20 On 380
122 LAB RMP-III On 1 On 1
28 LDP On 2 On 15
140 PIPE CONVEYOR On 2 On 6
077-02 FWPH for REMP-III On 26 Off -

15-Dec-17 Page 20 of 57

8 is supplying water to eleven consumer package’s and Industrial water pipeline is supplying
water to eight consumer package’s. Pipeline view and number of components are given below:

Component
DN150 DN200 5 4
DN50 DN50 8 3
DN150xDN150 DN200xDN200 1 1
DN65xDN50 - 2 -
15-Dec-17 Page 21 of 57
DN150xDN65 DN200xDN150 1 1
Reducers

Condition Condition
3
(m /hr) (m3/hr)
114 COMPRESSED AIR STATION-4 On 5 On 130
117 PROJECT WELFARE BUILDING On 5 Off -
117 PROJECT BUILDING DNW On 5 Off -
077-02 FWPH for BLAST FURNACE On 26 Off -
090A-LAB BLDG On 1 On 1
076-GAS BOOSTING STATION On 2 On 40
011-01C PBS DM PLANT On 500 On 15
031-HMHS (TLRS) On 5 On 15
010-BLAST FURNACE-8 On 120 On 1230

9 is supplying water to nine consumer package’s and Industrial water pipeline is supplying water
to eight consumer package’s. Pipeline view and number of components are given below:
15-Dec-17 Page 22 of 57

Component
DN300 DN350 10 9
DN250 DN150 2 9
DN80 - 2 -
DN65 - 2 -
DN300xDN250 DN150xDN150 1 1
T-Junctions
DN80xDN65 - 1 -
DN300xDN65 DN350xDN100 1 1
Reducers
DN100xDN80 - 1 -
15-Dec-17 Page 23 of 57

Condition Condition
3
(m /hr) (m3/hr)
001 COKE OVEN PROPER On 15 On 7.5
002 CDCP On 15 On 7.5
003A BY PRODUCT PLAN On 15 On 375
64 BASE BLENDING PLANT (PUMPHOUSE 2 ) On 8 On 31
011-01B PBS-(BTPG) On 1 On 15
64 BASE BLENDING PLANT (PUMPHOUSE 1) On 25 On 40
FWPH for CO On 26 Off -
001-SE-01 On 1 On 2

Branching-10 has Drinking & Industrial water pipeline. Drinking water pipeline of
Branching-10 is supplying water to sixteen consumer package’s and Industrial water pipeline is
supplying water to fourteen consumer package’s. Pipeline view and number of components are
given below:
15-Dec-17 Page 24 of 57

Component
DN250 DN600 8 7
DN150 DN500 7 1
DN50 DN150 26 20
- DN50 - 25
15-Dec-17 Page 25 of 57
DN250xDN250 DN600xDN500 1 1
T-Junctions
DN150xDN50 DN150xDN150 1 1
DN150xDN100 DN150xDN50 1 1
Reducers DN250xDN50 DN600xDN400 1 1

Condition Condition
(m3/hr) (m3/hr)
125-01 ACVS FOR BOF & CCP On 5 On 100
49-1 REHEATING FURNACE FOR BAR & ROD MILL On 5 On 40
071-A HTSS-65 SUBSTATUION (13/18) On 1 On 4
077-1 (NAMED AS 77-02 IN PLOT PLAN) EXTERNAL
On 240 On 1200
WATER SYSTEM FOR SMS-III
077-02 EXTERNAL WATER SYSTEM FOR WTP-6 & 7
On 0 On 345
(BRM)
077-02 EXTERNAL WATER SYSTEM FOR WTP-5
On 5 On 5
(BRM)
31 HMHS DUM PIT On 5 On 10
129 BOF & CCP AREA REPAIR SHOP On 2 On 5
077-1 EXTERNAL WATER SYSTEM (BRM) WTP-2 On 10 On 5
46 (BRM) On 5 On 5
122 LAB BLDG, MILLS On 1 On 1
32 PROPANE STORAGE & HANDLING SYSTEM On 2 Off -
125-02 (BRM) ACVS FOR BRM On 5 On 50
138 FIRE STATION BUILDINGS On 2 On 2
FWPH for URM On 26 Off -

15-Dec-17 Page 26 of 57
2.2 Boundary Conditions & Material Properties
2.2.1 Material Properties

Table 2.2.1.1: Material Properties for Analysis
Type Material Value
Density = 998.2 kg/m3

Fluid Water
Viscosity=1.0016 E-03 kg/m-s
Solid Pipe Carbon Steel Roughness=0.061 mm
2.2.2 Boundary Conditions

Table 2.2.2.1: Boundary Condition of Drinking Water Pipeline
Drinking Water Pipeline

Location
Boundary Condition Value
Inlet
Pressure Inlet 70 mWc
(MARODA Plant-II)
Outlet 1509 m3/h
Mass Flow Outlet
(Packages of Branching's) (Total Consumption at package outlets)
Table 2.2.2.2: Boundary Condition of Industrial Water Pipeline
Industrial Water Pipeline

Location
Boundary Condition Value
Inlet
Pressure Inlet 80 mWc
(MARODA Plant-I)
Outlet 6036 m3/h
Mass Flow Outlet
(Packages of Branching's) (Total Consumption at package outlets)
15-Dec-17 Page 27 of 57
Fig 2.2.2.1 Boundary Conditions-Drinking Water Pipeline
Fig 2.2.2.2 Boundary Conditions- Industrial Water Pipeline

15-Dec-17 Page 28 of 57
2.3 Assumptions for simulation

1. A steady state simulation is carried out.
2. Single phase (liquid phase) simulation is carried out.
3. Isothermal simulation is carried out.
3. CFD Cases Description

Number of End Consumer Volume Flow Rate of Pump
Case Name Supply Location
Packages (m3/hr)
Drinking Water MARODA Plant-2 83 1650
Industrial Water MARODA Plant-1 69 6600
4. Pipeline Analysis Cases Observations

1. Drinking Water Pipeline: Minimum available pressure at entry of all Drinking Water (DW)
Packages within branching’s & Main Header is above 2 kgf/cm2 (20 mWc).
2. Industrial Water Pipeline: Minimum available pressure at entry of all Industrial Water
(IW) Packages within branching’s & Main Header is above 1 kgf/cm2 (10 mWc).
3. All Drinking & Industrial Water (IW) packages within branches & Main Header will get the
required specified flow rate.
Drinking Water Pipeline Industrial Water Pipeline
Minimum Available Minimum Available
Total Flow Total
Package Pressure at Package Entry Pressure at Package
Rate Flow Rate
in Branching Entry in Branching
(m3/h) (kgf/cm2) (mWc) (m3/h) (kgf/cm2) (mWc)
Main Header 71 4.80 48.05 400 5.25 52.58
Branching-1 19 4.72 47.23 850 5.71 57.10
Branching-2 58 4.72 47.23 162 5.69 56.86
Branching-3 29 4.23 42.26 45 4.98 49.84
Branching-4 28 3.64 36.38 8 5.40 54.00
Branching-5 107 4.50 45.03 275 5.11 51.15
Branching-6 42 4.86 48.62 154 5.84 58.41
Branching-7 62 2.61 26.10 445 6.40 64.05
Branching-8 671 4.70 46.99 1439 5.93 59.31
Branching-9 107 4.78 47.80 482 5.82 58.25
Branching-10 315 4.51 45.11 1776 5.13 51.31
Total Flow Rate &
Minimum Available 1509 2.61 26.10 6036 4.98 49.84
Pressure in Pipeline
15-Dec-17 Page 29 of 57
Appendix A – Pipeline Analysis Model Layout
Drinking Water & Industrial Water Pipeline Layout from FlowMaster

15-Dec-17 Page 30 of 57
Appendix B – Main Header Pipeline Package’s
Fig B.1 Location of Consumer Package in Main Header Pipeline
Fig B.2 Drinking Water Pipeline Layout for Main Header (FlowMaster)
15-Dec-17 Page 31 of 57
Fig B.3 Industrial Water Pipeline Layout for Main Header (FlowMaster)
Table B.1: Pressure Details at Consumer Package Entry for Main Header Pipeline
Flow Available Pressure at Flow Available Pressure at
Package
Rate Package Entry Rate Package Entry
3
(m /h) (kgf/cm2) (mWc) (m /h) (kgf/cm2)
3
(mWc)
071A HTSS-48
1 5.34 53.43 4 5.82 58.16
SUBSTATION (6/18)
071A HTSS-73
1 4.80 48.05 4 6.39 63.88
SUBSTATION (18/18)
FWPH for MARODA-I 26 4.73 47.32 - - -
077-02 FWPH OHP-A 26 5.69 56.99 - - -
061 OHP Part-B 17 5.60 56.07 392 5.25 52.58
Total Flow Rate &
Minimum Pressure in 71 4.80 48.05 400 5.25 52.58
Main Header
15-Dec-17 Page 32 of 57
Appendix C – Results of Branching-1 Pipeline
Fig C.1 Location of Consumer Package in Branching-1 Pipeline
Fig C.2 Drinking Water Pipeline Layout Showing Pressure for Branching-1 (FlowMaster)
15-Dec-17 Page 33 of 57
Fig C.3 Industrial Water Pipeline Layout Showing Pressure for Branching-1 (FlowMaster)
Table C.1: Pressure Details at Consumer Package Entry for Branching-1 Pipeline
Package
3
(m /h) (kgf/cm2) (mWc) (m /h) (kgf/cm2)
3
(mWc)
011-01A-PBS (STB) 5 4.80 47.97 10 5.95 59.47
011-01B PBS (STG) 2 4.80 47.97 - - -
117 Welfare building 5 4.76 47.56 - - -
116B Tap Hole Mass
5 4.72 47.23 5 5.71 57.10
Shop
011-01B PBS - CT 2 4.80 48.05 835 5.71 57.10
Total Flow Rate &
Branching-1
15-Dec-17 Page 34 of 57
Appendix D – Results of Branching-2 Pipeline
Fig D.1 Location of Consumer Package in Branching-2 Pipeline
Fig D.2 Drinking Water Pipeline Layout Showing Pressure for Branching-2 (FlowMaster)
15-Dec-17 Page 35 of 57
Fig D.3 Industrial Water Pipeline Layout Showing Pressure for Branching-2 (FlowMaster)
Table D.1: Pressure Details at Consumer Package Entry for Branching-2 Pipeline
Package
61 OHP Part-B 21 5.04 50.41 58 5.78 57.84
071-A HTSS-46
1 5.10 50.99 4 5.76 57.59
SUBSTATION (3/18)
60 ORE Handling Plant 10 5.73 57.35 100 5.69 56.86
077-02 FWPH OHP-B 26 4.72 47.23 - - -
Total Flow Rate &
Branching-2
15-Dec-17 Page 36 of 57
Appendix E – Results of Branching-3 Pipeline
Fig E.1 Location of Consumer Package in Branching-3 Pipeline
Fig E.2 Drinking Water Pipeline Layout Showing Pressure for Branching-3 (FlowMaster)
15-Dec-17 Page 37 of 57
Fig E.3 Industrial Water Pipeline Layout Showing Pressure for Branching-3 (FlowMaster)
Table E.1: Pressure Details at Consumer Package Entry for Branching-3 Pipeline
Available Pressure at Available Pressure at
Package Flow Rate Flow Rate
Package Entry Package Entry
071-A HTSS-61
1 4.83 48.29 4 5.87 58.65
SUBSTATION (10/18)
25 BOF 5 4.79 47.89 5 5.82 58.25
27 HMDS 5 4.67 46.66 15 5.51 55.15
71-A HTSS-63
1 4.30 42.99 4 5.87 58.74
SUBSTATION (11/18)
077-1 WTP-1 10 4.23 42.26 5 5.04 50.41
026-CCP 5 4.29 42.91 10 4.98 49.84
123- FERRO ALLOY
2 4.85 48.46 2 5.87 58.74
STORAGE YARD
Total Flow Rate &
Branching-3
15-Dec-17 Page 38 of 57
Appendix F – Results of Branching-4 Pipeline
Fig F.1 Location of Consumer Package in Branching-4 Pipeline
Fig F.2 Drinking Water Pipeline Layout Showing Pressure for Branching-4 (FlowMaster)
15-Dec-17 Page 39 of 57
Fig F.3 Industrial Water Pipeline Layout Showing Pressure for Branching-4 (FlowMaster)
Table F.1: Pressure Details at Consumer Package Entry for Branching-4 Pipeline
071-A HTSS-71A
1 4.76 47.56 4 5.57 55.72
SUBSTATTION (16/18)
071-A HTSS-71A
1 3.97 39.73 4 5.40 54.00
SUBSTATION (17/18)
077-02 FWPH for
26 3.64 36.38 - - -
MARODA-II
Total Flow Rate &
Branching-4
15-Dec-17 Page 40 of 57
Appendix G – Results of Branching-5 Pipeline
Fig G.1 Location of Consumer Package in Branching-5 Pipeline
Fig G.2 Drinking Water Pipeline Layout Showing Pressure for Branching-5 (FlowMaster)
15-Dec-17 Page 41 of 57
Fig G.3 Industrial Water Pipeline Layout Showing Pressure for Branching-5 (FlowMaster)
Table G.1: Pressure Details at Consumer Package Entry for Branching-5 Pipeline
071-A HTSS-68
1 4.64 46.42 4 5.93 59.31
SUBSTATION (14/18)
77-02 EXTERNAL WATER
18.3333 4.64 46.42 50 5.93 59.31
SYSTEM for WTP-1 (URM)
SYSTEM FOR WTP-3 & 4 18.3333 4.50 45.03 50 5.92 59.23
(URM)
SYSTEM FOR WTP-2 18.3333 4.50 45.03 50 5.87 58.65
(URM)
117 PROJECT BUILDING
5 4.50 45.03 0 5.87 58.65
WELFARE
47 (URM) C-35
7 4.50 45.03 7 5.87 58.65
SUBSTATION
15-Dec-17 Page 42 of 57
70 AUGMENTATION OF
2 4.75 47.48 10 5.97 59.71
EXISTING MSDS
49-03 REHEATING
FURNACES FOR 5 4.74 47.40 50 5.25 52.45
UNIVERSAL RAIL MILL
125-02 (URM) ACVS FOR
URM & RAIL WELDING, 5 4.74 47.40 50 5.11 51.15
RAIL MILL
071-A HTSS-70
1 4.69 46.91 4 5.11 51.15
SUBSTATION (15/18)
077-02 FWPH for URM
26 4.50 45.03 - - -
AREA
Total Flow Rate &
Branching-5
Appendix H – Results of Branching-6 Pipeline
Fig G.1 Location of Consumer Package in Branching-6 Pipeline

15-Dec-17 Page 43 of 57
Fig H.2 Drinking Water Pipeline Layout Showing Pressure for Branching-6 (FlowMaster)
Fig H.3 Industrial Water Pipeline Layout Showing Pressure for Branching-6 (FlowMaster)
Table H.1: Pressure Details at Consumer Package Entry for Branching-6 Pipeline
Flow Available Pressure at Available Pressure at
Package Flow Rate
Rate Package Entry Package Entry
20 SINTER PLANT 15 4.89 48.86 150 58.41 5.84
071-A HTSS-43
1 4.87 48.70 4 58.41 5.84
SUBSTATION (1/18)
077-02 FWPH for SINTER
26 4.86 48.62 - - -
PLANT-III
Total Flow Rate &
Branching-6
15-Dec-17 Page 44 of 57
Appendix I – Results of Branching-7 Pipeline
Fig I.1 Location of Consumer Package in Branching-7 Pipeline
Fig I.2 Drinking Water Pipeline Layout Showing Pressure for Branching-7 (FlowMaster)
15-Dec-17 Page 45 of 57
Fig I.3 Industrial Water Pipeline Layout Showing Pressure for Branching-7 (FlowMaster)
Table I.1: Pressure Details at Consumer Package Entry for Branching-7 Pipeline
3 2 3
(m /h) (kgf/cm ) (mWc) (m /h) (kgf/cm2) (mWc)
Pump House-3 BASE
8 4.92 49.19 31 6.54 65.43
BLENDING PACKAGE
071-A HTSS-47 SUBSTATION
1 4.88 48.78 4 6.40 64.05
(4/18)
1 4.90 49.03 4 6.52 65.25
(2/18)
62 NEW COAL HANDLING
20 2.66 26.59 380 6.54 65.43
PLANT
1 2.62 26.19 4 6.50 64.97
(9/18)
122 LAB RMP-III 1 2.62 26.19 1 6.50 64.97
28 LDP 2 2.62 26.19 15 6.48 64.88
140 PIPE CONVEYOR 2 2.61 26.10 6 6.45 64.51
077-02 FWPH for REMP-III 26 2.65 26.51 - - -
Total Flow Rate & Minimum
62 2.61 26.10 445 6.40 64.05
Pressure in Branching-7
15-Dec-17 Page 46 of 57
Appendix J – Results of Branching-8 Pipeline
Fig J.1 Location of Consumer Package in Branching-8 Pipeline
Fig J.2 Drinking Water Pipeline Layout Showing Pressure for Branching-8 (FlowMaster)
15-Dec-17 Page 47 of 57
Fig J.3 Industrial Water Pipeline Layout Showing Pressure for Branching-8 (FlowMaster)
Table J.1: Pressure Details at Consumer Package Entry for Branching-8 Pipeline
114 COMPRESSED AIR
5 4.80 48.05 130 5.96 59.55
STATION-4
071A HTSS-56 SUBSTATION
1 4.80 47.97 4 5.96 59.55
(7/18)
071A HTSS-57 SUBSTATION
1 4.80 47.97 4 5.96 59.55
(8/18)
117 PROJECT WELFARE
5 4.70 46.99 - - -
BUILDING
117 PROJECT BUILDING DNW 5 4.73 47.32 - - -
077-02 FWPH for BLAST
26 4.80 47.97 - - -
FURNACE
090A-LAB BLDG 1 4.70 46.99 1 5.96 59.55
076-GAS BOOSTING STATION 2 4.81 48.13 40 5.99 59.88
011-01C PBS DM PLANT 500 4.82 48.21 15 5.96 59.55
031-HMHS (TLRS) 5 4.82 48.21 15 5.95 59.47
010-BLAST FURNACE-8 120 4.83 48.29 1230 5.93 59.31
671 4.70 46.99 1439 5.93 59.31
15-Dec-17 Page 48 of 57
Appendix K – Results of Branching-9 Pipeline
Fig K.1 Location of Consumer Package in Branching-9 Pipeline
Fig K.2 Drinking Water Pipeline Layout Showing Pressure for Branching-9 (FlowMaster)
Fig K.3 Industrial Water Pipeline Layout Showing Pressure for Branching-9 (FlowMaster)
15-Dec-17 Page 49 of 57
Table K.1: Pressure Details at Consumer Package Entry for Branching-9 Pipeline
001 COKE OVEN
15 4.89 48.86 7.5 5.82 58.25
PROPER
002 CDCP 15 4.89 48.86 7.5 5.82 58.25
003A BY PRODUCT
15 4.89 48.86 375 5.82 58.25
PLAN
071A HTSS-48
1 4.89 48.86 4 5.82 58.25
SUBSTATION (5/18)
64 BASE BLENDING
8 4.89 48.86 31 5.82 58.25
PLANT (PUMPHOUSE 2 )
011-01B PBS-(BTPG) 1 4.78 47.80 15 5.87 58.65
64 BASE BLENDING
25 4.78 47.80 40 5.87 58.65
PLANT (PUMPHOUSE 1)
FWPH for CO 26 4.89 48.86 - - -
001-SE-01 1 4.82 48.21 2 5.87 58.65
Total Flow Rate &
Branching-9
15-Dec-17 Page 50 of 57
Appendix L – Results of Branching-10 Pipeline
Fig L.1 Location of Consumer Package in Branching-10 Pipeline
Fig L.2 Drinking Water Pipeline Layout Showing Pressure for Branching-10 (FlowMaster)
15-Dec-17 Page 51 of 57
Fig L.3 Industrial Water Pipeline Layout Showing Pressure for Branching-10 (FlowMaster)
Table L.1: Pressure Details at Consumer Package Entry for Branching-10 Pipeline
125-01 ACVS FOR BOF &
5 4.70 46.99 100 5.13 51.31
CCP
49-1 REHEATING FURNACE
5 4.69 46.91 40 5.73 57.27
FOR BAR & ROD MILL
071-A HTSS-65
1 4.69 46.91 4 5.73 57.27
SUBSTATUION (13/18)
077-1 (NAMED AS 77-02 IN
PLOT PLAN) EXTERNAL 240 4.67 46.74 1200 5.73 57.35
WATER SYSTEM FOR SMS-III
SYSTEM FOR WTP-6 & 7 0 4.69 46.91 345 5.73 57.27
(BRM)
5 4.65 46.50 5 5.63 56.29
SYSTEM FOR WTP-5 (BRM)
15-Dec-17 Page 52 of 57
31 HMHS DUM PIT 5 4.67 46.66 10 5.62 56.21

129 BOF & CCP AREA
2 4.68 46.83 5 5.67 56.70
REPAIR SHOP
10 4.65 46.50 5 5.63 56.29
SYSTEM (BRM) WTP-2
46 (BRM) 5 4.65 46.50 5 5.63 56.29
122 LAB BLDG, MILLS 1 4.64 46.42 1 5.62 56.21
32 PROPANE STORAGE &
2 4.51 45.11 - - -
HANDLING SYSTEM
125-02 (BRM) ACVS FOR
5 4.52 45.19 50 5.58 55.80
BRM
1 4.52 45.19 4 5.58 55.80
(12/18)
138 FIRE STATION
2 4.67 46.74 2 5.68 56.78
BUILDINGS
FWPH for URM 26 4.51 45.11 - - -
315 4.51 45.11 1776 5.13 51.31
15-Dec-17 Page 53 of 57
Annexure-A – Result Verification

A simple straight pipe flow case is checked for pressure drop verification between
analytical calculation and 1D CFD simulation in Flowmaster. It is observed that, pressure drop
obtained from 1D CFD simulation is close to analytically calculated value. Case study of straight
pipe pressure drop result verification is given below:
A.1 1D CFD Simulation in FlowMaster

A straight pipe of diameter DN50 is considered for 1D CFD simulation in FlowMaster.
Length of pipe is 45983mm. Flow rate & material property details are as given below:
 Volume Flow Rate – 5 m3/hr

 Density of Water – 998.207 kg/m3
 Dynamic Viscosity – 1.0016 E-03 kg/m-s
 Roughness of Pipe – 0.061 mm (Carbon Steel)
Case Setup:
Fig 1 Case Setup in FlowMaster (Pipe Details)

15-Dec-17 Page 54 of 57
Fig 2 Case Setup in FlowMaster (Friction Values)
Fig 3 Straight Pipe Boundary Condition (FlowMaster)

15-Dec-17 Page 55 of 57
Results of Simulation:
Fig 4 Straight Pipe showing Pressure Value at Inlet & Outlet (FlowMaster)
Fig 5 Results obtained in 1D CFD Simulation (FlowMaster)

15-Dec-17 Page 56 of 57
A.2 Analytical Pressure Drop Evaluation

Pressure Drop Formulae’s:
Same case of simple straight pipe with diameter DN50 & length 45983 mm is considered
for pressure drop evaluation analytically. Simplified form of Darcy’s equation is used to evaluate
pressure drop. Darcy’s equation for pressure drop calculation is given below,
.........................(1)
Where, P2 = Pressure at outlet of pipe (node 2), Pa

P1 = Pressure at inlet of pipe (node 1), Pa
f = Darcy’s friction factor
L = Length of straight pipe, m
M1 = Mass flow rate in pipe, kg/s
A = Cross sectional area of pipe, m2
ρ = Density of fluid, kg/m3
d = diameter of straight pipe, m
Friction factor, f is calculated based on Colebrook-White and Hazen Williams equations as given
below,
If Reynold’s number, Re < 2000
.........................(2)
If Reynold’s number, Re > 4000
.........................(3)
Where, f= fl = Darcy’s friction factor for laminar flow

ft = Darcy’s friction factor for turbulent flow
Re= Reynolds number
k= wall roughness, mm
D= Pipe diameter, mm
15-Dec-17 Page 57 of 57
Input Data for Calculation:

Volume Flow Rate = 5 m3/hr.
Density of Water = 998.207 kg/m3
Dynamic Viscosity = 1.0016 E-03 kg/m-s
Roughness of Pipe = 0.061 mm (Carbon Steel)
Diameter of Pipe for DN50 = 49.33 mm = 0.04933 m
Length of Pipe = 45983 mm = 45.983 m
Cross Sectional Area of pipe for DN50 = 0.001911 m2
Velocity of Fluid = 0.7267 m/s
Reynolds number, Re for straight pipe case is calculated below,

𝜌𝑣𝑑
Re =
µ
Where,
ρ= Density of fluid, kg/m3
v = Velocity of fluid, m/s
d= diameter of pipe, m
µ = Dynamic viscosity of fluid, kg/m-s
𝟗𝟗𝟖.𝟐𝟎𝟔 𝑿 𝟎.𝟕𝟐𝟔𝟕 𝑿 𝟎.𝟎𝟒𝟗𝟑𝟑

Re = = 35726.4243
𝟏.𝟎𝟎𝟏𝐄−𝟎𝟑
For Re > 4000, friction factor is calculated below based on equation (3),
𝟎.𝟐𝟓
f= = 0.02599
[𝒍𝒐𝒈((𝟎.𝟎𝟔𝟏/(𝟑.𝟕 𝑿 𝟒𝟗.𝟑𝟑)) + (𝟓.𝟕𝟒 / 𝟑𝟓𝟕𝟐𝟔.𝟒𝟐𝟒𝟑^𝟎.𝟗))]^𝟐
Therefore, pressure drop in straight pipe of DN50 is calculated based on simplified Darcy’s
equation (1) given below,
(𝟎.𝟎𝟐𝟓𝟗𝟗 𝐱 𝟒𝟓.𝟗𝟖𝟑) 𝐱 (𝟏.𝟑𝟖𝟔𝟒 𝐱 𝟏.𝟑𝟖𝟔𝟒)

P2-P1 = = 6387.6174 Pa = 0.06387 bar
𝟎.𝟎𝟒𝟗𝟑𝟑 𝒙 𝟐 𝒙 𝟗𝟗𝟖.𝟐𝟎𝟔 𝒙 𝟎.𝟎𝟎𝟏𝟗𝟏𝟏𝟐𝟐𝟔^𝟐
A.3 Comparison of 1D CFD & Theoretical Results

1. Pressure drop calculated based on 1D CFD simulation in flowmaster software is
0.06388 bar as shown in section A.1.
2. Pressure drop calculated based Analytical formulations is 0.06387 bar as shown
in section A.2.
3. Therefore, Pressure drop values for both cases are close and hence results of 1D
CFD simulation are verified.

DI PipeRoutingDP 01 X CFD Simulation Report R1

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VOLTAS LIMITED PREP N.S NO.

DOMESTIC PROJECT GROUP DWMW/BSP/02/BE/07014

VOLTAS PRESSURE DROP APVD A.K.R BSP/VL/10/078A/15/005/02/BE/07014

PROJECT NO : Pkg No. 078A

CLIENT : BHILAI STEEL PLANT

CONSULTANT : MECON RANCHI

1 ISSUED FOR REFERENCE N.S A.K.R 15.12.2017

Annexure-A – Result Verification .................................................................................. 53

2.1 Geometry Details

Fig 2.1.1 Geometry Details-Overall Pipeline System

2.1.1 Main Header Pipeline

Fig 2.1.1.1 Plot View of Main Header Pipeline

Table 2.1.1.1: Components of Main Header Pipeline

Table 2.1.1.2: Packages of Main Header Pipeline

071A HTSS-73 SUBSTATION (18/18) On 1 On 4

FWPH for MARODA-I On 26 Off -

077-02 FWPH OHP-A On 26 Off -

061 OHP Part-B On 17 On 392

2.1.2 Branching-1 Pipeline

Fig 2.1.2.1 Isometric View of Branching-1 Pipeline

Table 2.1.2.1: Components of Branching-1 Pipeline

Table 2.1.2.2: Packages of Branching-1 Pipeline

011-01B PBS (STG) On 2 Off -

117 Welfare building On 5 Off -

116B Tap Hole Mass Shop On 5 On 5

011-01B PBS - CT On 2 On 835

2.1.3 Branching-2 Pipeline

Fig 2.1.3.1 Isometric View of Branching-2 Pipeline

Table 2.1.3.2: Packages of Branching-2 Pipeline

071-A HTSS-46 SUBSTATION (3/18) On 1 On 4

60 ORE Handling Plant On 10 On 100

077-02 FWPH OHP-B On 26 Off -

2.1.4 Branching-3 Pipeline

Fig 2.1.4.1 Isometric View of BRANCHING-3 Branching

Table 2.1.4.1: Components of Branching-3 Pipeline

Table 2.1.4.2: Packages of Branching-3 Pipeline

71-A HTSS-63 SUBSTATION (11/18) On 1 On 4

123- FERRO ALLOY STORAGE YARD On 2 On 2

2.1.5 Branching-4 Pipeline

Fig 2.1.5.1 Isometric View of Branching-4 Pipeline

Table 2.1.5.2: Packages of Branching-4 Pipeline

071-A HTSS-71A SUBSTATION (17/18) On 1 On 4

077-02 FWPH for MARODA-II On 26 Off -

2.1.6 Branching-5 Pipeline

Fig 2.1.6.1 Isometric View of Branching-5 Pipeline

Table 2.1.6.2: Packages of Branching-5 Pipeline

77-02 EXTERNAL WATER SYSTEM for

47 (URM) C-35 SUBSTATION On 7 On 7

70 AUGMENTATION OF EXISTING MSDS On 2 On 10

49-03 REHEATING FURNACES FOR

077-02 FWPH for URM AREA On 26 Off -

2.1.7 Branching-6 Pipeline

Fig 2.1.7.1 Isometric View of Branching-6 Pipeline

Table 2.1.7.2: Packages of Branching-6 Pipeline

071-A HTSS-43 SUBSTATION (1/18) On 1 On 4

077-02 FWPH for SINTER PLANT-III On 26 Off -

2.1.8 Branching-7 Pipeline

Fig 2.1.8.1 Isometric View of Branching-7 Pipeline

Table 2.1.8.1: Components of Branching-7 Pipeline

Table 2.1.8.2: Packages of Branching-7 Pipeline

071-A HTSS-45 SUBSTATION (2/18) On 1 On 4

62 NEW COAL HANDLING PLANT On 20 On 380

071-A HTSS-60 SUBSTATION (9/18) On 1 On 4