Design Guide-Fichtner PDF

FICHTNER India
DESIGN GUIDES
CONTENTS

APPROVED BY : DEPARTMENT : MECHANICAL DATE : 02/06/99 PAGE : 1 of 2

C:\Siva\REFERENCES\USEFUL BOOKS\DESIGN GUIDE-FICHTNER\DESIGN GUIDE CONTENT.doc
Sl.
No.
W.I. No. Rev. Description Date of
Issue
1. WI-ME-DSN-100-001 R-1 LHV, HHV Calculations Fuel Oil 11/04/98
2. WI-ME-DSN-100-002 R-1 Flue Gas Dew Point Calculations 11/04/98
3. WI-ME-DSN-100-003 R-1 Fan Power Calculations 11/04/98
4. WI-ME-DSN-100-004 R-1 Oil Heater Steam Requirement
Calculations
11/04/98
5. WI-ME-DSN-100-005 R-1 LHV, HHV Calculations Coal 11/04/98
6. WI-ME-DSN-100-006 R-1 LHV, HHV Calculations Gaseous fuel
(Natural Gas)
11/04/98
7. WI-ME-DSN-100-007 R-1 Stoichometric Air Reqt. Solid and
Liquid Fuels
11/04/98
8. WI-ME-DSN-100-008 R-1 Recommended feed water & boiler
water quality for power plant
application
11/04/98
9. WI-ME-DSN-100-009 R-1 Boiler Blow Down Calculations 11/04/98
10. WI-ME-DSN-100-010 R-1 Chimney Sizing 11/04/98
11. WI-ME-DSN-100-011 R-1 Emission / Ambient air quality
calculations
11/04/98
12. WI-ME-DSN-103-001 R-1 Ash handling system Typical write up 11/04/98
13. WI-ME-DSN-108-001 R-1 Raw Water Analysis Conversion
factors for Ionic loads
11/04/98
14. WI-ME-DSN-108-002 R-1 Raw Water Analysis Format 11/04/98
15. WI-ME-DSN-122-001 R-1 Cooling Tower Blow Down Evaporation
& Drift Loss Calculations
11/04/98
16. WI-ME-DSN-123-001 R-1 Horizontal pump Vs Typical write up
vertical pump
11/04/98
17. WI-ME-DSN-124-001 R-1 Merits / Demerits of Plate Type Heat
Exchanger
11/04/98
18. WI-ME-DSN-126-001 R-1 Water Cooled Condenser Sizing 11/04/98
19. WI-ME-DSN-126-002 R-1 Air Cooled Heat Exchanger /
condenser
11/04/98
20 WI-ME-DSN-166-001 R-0 Guidelines on Basic Aspects for Fire
Protection System
02/06/99
21. WI-ME-DSN-180-001 R-0 Standard tank size and weight chart 13/04/98
22. WI-ME-DSN-180-002 R-0 Tank cost estimates 13/04/98
23. WI-ME-DSN-180-003 R-0 Heating coil size calculation for storage
tanks
13/04/98
24. WI-ME-DSN-180-004 R-0 Heat loss calculation for vertical
cylindrical storage tank
13/04/98
25. WI-ME-DSN-196-001 R-1 Insulation Thickness Calculations 11/04/98
26. WI-ME-DSN-196-002 R-1 Steam Trap Selection 11/04/98
27. WI-ME-DSN-196-003 R-1 Pressure Temperature Rating 11/04/98
28. WI-ME-DSN-196-004 R-0 Standard flange dimension data 13/04/98
29. WI-ME-DSN-196-005 R-1 Weld J oint Quantity Calculation 11/04/98
FICHTNER India

DESIGN GUIDES
CONTENTS

APPROVED BY : DEPARTMENT : MECHANICAL DATE : 02/06/99 PAGE : 2 of 2

C:\Siva\REFERENCES\USEFUL BOOKS\DESIGN GUIDE-FICHTNER\DESIGN GUIDE CONTENT.doc

Sl.
No.
W.I. No. Rev. Description Date of
Issue
30. WI-ME-DSN-196-006 R-1 LPT Quantity Calculations 11/04/98
31. WI-ME-DSN-196-007 R-1 Allowable Pipe Span 11/04/98
32. WI-ME-DSN-196-008 R-1 Scope of IBR Documentation-A Guide
Line
11/04/98
33. WI-ME-DSN-196-009 R-1 Mild Steel Pipe - Size Dimension &
Weight
11/04/98
34. WI-ME-DSN-196-010 R-1 Seamless or Electrically Welded Steel
Tubes / Pipes IS 3589
11/04/98
35. WI-ME-DSN-196-011 R-1 Pipe Thickness Calculation (IBR
Ready Reckoner)
11/04/98
36. WI-ME-DSN-196-012 R-0 Pipe sizing calculation Steam service 13/04/98
37. WI-ME-DSN-196-013 R-0 Pipe sizing calculation Water service 13/04/98
38. WI-ME-DSN-196-014 R-0 Piping sizing calculation Air service 13/04/98
39. WI-ME-DSN-196-015 R-0 Allowable velocities in pipes 13/04/98
40. WI-ME-DSN-700-015 R-0 List of Calculation in EXCEL
available in Mechanical department
02/06/99

FICHTNER India

DOC. NO. WI-ME-DSN-100-001 REV. NO. R-A PAGE 1 OF 1
C:\Siva\REFERENCES\USEFUL BOOKS\DESIGN
GUIDE-FICHTNER\WI-ME-DSN-100-001.doc
FORM T10 REV - A

LHV, HHV CALCULATIONS - FUEL OIL

Qv = 12,400 - 2100 d
2

% H = 26 - 15d

Qp = Qv - 50.45 X %H

Where,

Qv = Higher heating value at constant volume in kcal/kg of oil, free of
water, ash and sulphur, final products being Co
2
gas +water.

Qp = Net Heat of combustion (LHV) at constant pressure (atm) in kcal/kg -
free of water, ash and sulphur, final products being Co
2
gas +H
2
O
(vapour)

%H = Percentage of Hydrogen in the Hydrocarbon fuel.

d = Specific gravity of the fuel at 60F.

CORRECTION VALUES FOR WATER, ASH AND SULPHUR CONTENT IN FUEL

Qv =Qv - 0.01 Qv (%H
2
O +% ASH +%S) +X(%S)

Qp =Qp - 0.01 Qp (%H
2
O +% ASH +%S) +X(%S) - Y (%H
2
O)

Where Qv = Higher Heating Value at constant volume per unit quantity of fuel oil
containing water, ash, sulphur. Final products being ash, gaseous
Co
2
, So
2
and liquid water.

Qp = Net heat of combustion (LHV) at constant pressure per unit quantity
of fuel oil containing water, ash and sulphur. Final products being
ash, gaseous Co
2
, So
2
and H
2
O.

% Ash = percentage of ash determined by ASTM D-482.

% H
2
O = percentage of water determined by ASTM D-95.

% S = percentage of sulphur determined by ASTM D-129.

X & Y are constants which vary in value depending upon the units in which heating
value is reported.

UNIT X Y
kcal/kg 22.5 5.85

FICHTNER India

C:\Siva\REFERENCES\USEFUL BOOKS\DESIGN GUIDE-FICHTNER\WI-ME-DSN-100-002.doc FORM T10 REV - A

FLUE GAS DEW POINT CALCULATIONS

Flue gas Dew point temperature is determined from the following correlation :

1000
------- = 1.7842 +0.0269 * log(Pw) - 0.1031 * log(PS03) +
Tdp
0.0329 * log (Pw) * log (PSo3)

Tdp = Flue gas dew point temperature in k.

Pw = Partial pressure of water vapour.

PS03 = Partial pressure of sulphur tri-oxide.

DEW POINT :

Dew point is the temperature at which an un-saturated gas vapour mixture becomes
saturated as a result of iso-baric cooling at constant absolute humidity. The dew point
is also the saturation temperature corresponding to the initial partial pressure of the
vapour. If the cooling proceeds further, both temperature and the absolute humidity
decrease and rapid condensation of water vapour takes place.

EFFECT OF SULPHUR IN FUEL ON DEW POINT OF COMBUSTION GASES

Sulphur forms sulphur-di-oxide and a small but significant amount of sulphur-tri-oxide,
when burnt. The sulphur tri-oxide that is formed can combine with water vapour to
form sulphuric acid. The sulphuric acid will remain in the vapour state as long as the
temperature of the exhaust gas is above dew point of the gas. When in the vapour
state i.e above dew point it causes no corrosion.

If however, the temperature of stack gases is lowered below the dew point, sulphuric
acid will condense out and cause corrosion of metal.

FICHTNER India

FORM T10 REV - A

FAN POWER CALCULATIONS

The Input Required for fan power calculations are :

(i) Density of the fluid (kg/m
3
),

(ii) Flow rate of the fluid (m
3
/sec), Q

(iii) Head to be developed (mWC), H

(iv) Fan efficiency ()

(v) Accelaration due to gravity (m/sec
2
), g

Power of the fan drive motor N
mot
, KW : m Q H g
------------
1000 tr

where m = 1.05 to 1.2 is the power reserve factor

If the fan is directly connected to
the motor, the transmission
efficiency tr = 1

for V - belt transmission tr = 0.92

The fan power consumption depends on the gas quantity and the resistance through
the boiler gas passes which will be dependant on the particular boiler design and the
range of fuels to be burned.

FAN SELECTION CRITERIA

a) Capacity and Head

In selecting a fan, one is guided by the maximum capacity Q and head H required of
the fan as applied to a given air or gas duct work. A margin in pressure and volume
over normal requirements is necessary to compensate for boiler fouling, adverse
combustion conditions, poor fuel and to provide cover for possible slight errors in the
estimates of draught system requirements. The margin is usually about 20% for
volume and about 50% for system resistance. The cost of

providing margins in fan duty, is higher than for most other items of plant owing to the
square law relating volume to pressure and to the cube law relating volume to
FICHTNER India

FORM T10 REV - A

horsepower. If a 20% margin of volume capacity is required, the pressure needed
would be about 1.5 times and the horsepower about 1.75 times the requirements for
the net capacity. The penalty paid for excessive fan capacity is therefore, severe both
in capital and operating costs.

b) Fan Speed

The following is an illustration of the magnitude of i-d fan power consumption
for one 500 MW boiler provided with two-speed i.d fans. To handle the boiler
C.M.R gas flow at the lower speed of 490 rev/min each fan would require
1320 b.h.p. Changing to high speed at this point closes the inlet vane gear
and results in a reduction in fan efficiency which would require an additional
200 b.h.p per fan. With both i.d fans running at top speed at boiler C.M.R, an
additional 400 b.h.p is required and it can, therefore, be appreciated that low
speed operation should be used on all possible occasions. In this instance,
the rated i.e fan motor horse power to cater for the fan design margins
was 2290 b.h.p at 590 rev/min.

c) Density of the Fluid

The capacity of the forced draft fans is to be determined at the lowest density
condition prevailing at the site.

For the same heat input to boilers, the air quantity required in mass flow units
(kg/hr) remains the same irrespective of the ambient conditions.

W =60 q

where
w =mass flow, kg/hr
=density, kg/m
3

q =Volumetric flow, m
3
/hr

Fans discharge constant volumetric flow at any density. Hence if the fan is
sized to give a particular volumetric flow at the high density condition, the
mass flow would decrease when density decreases as can be seen in the
equation above. Hence the fan must be sized to deliver the volumetric flow at
the lowest density condition, in which case the output will be higher at the
higher density condition, which can be then controlled.

Also, the gas pressure drop p in mmwc across the wind box is proportional
to w
2
/l. If the air density decreases as at high-temperature conditions, the
pressure drop increases, because W remains unchanged for a given heat
input. Considering the fact that H/ is a constant for a given fan, where H is
the static head in mmwc, using the lowest ensures that the head available at
higher density will be larger.

FICHTNER India

FORM T10 REV - A

OIL HEATER STEAM REQUIREMENT CALCULATIONS

a) Continuous steam requirement for Fuel Oil Tank Floor Heaters

1. Minimum temperature = t
min
C

2. Temperature of oil which is to
be maintained in the fuel oil tank = t C

3. Heat transfer coefficient between
the tank surface and atmosphere = h kcal/hr/m
2
C

4. Fuel oil tank dimensions

Diameter = `D m.

Height = `H m.

5. Surface area of the tank = DH m
2

6. Heat loss from the tank surface
to the atmosphere taking 10%
margin (H
l
) = h x A (t - t
min
) x 1.1

7. Auxiliary steam parameters
available are:

Pressure = `p ata

Temperature = T C

Enthalpy = Hs kcal/kg

8. Enthalpy of condensate at outlet = Hc kcal/kg

9. Steam required for floor heater
for heating the tank =
H
Hs Hc
kg hr
l
( )
/

b. Steam requirement for storage tank out flow Heater

1. Number of heaters working at a time
(Assumed one tank working at a time) = one (1)

2. Fuel oil flow through heater = mfo

FICHTNER India

FORM T10 REV - A

3. Average temperature of fuel oil at
the inlet to outflow heater = t
1
C

4. Temperature of the fuel at the outlet
of outflow heater = t
2
C

5. Steam parameters available are

Pressure = p kg/cm
2

Temperature = T C

Enthalpy = Hs kcal/kg.

6. Condensate enthalpy at the
outlet of the heater = Hc kcal/kg.

7. Specific heat of the fuel oil = Cp kcal/kg C

8. Heat energy required for
raising the temperature of the oil = mfo * Cp * (t
2
- t
1
)

9. Steam required for the outflow
heater taking 10% margin =
mfo Cp t t
Hs Hc
x
* * ( )
( )
.
2 1
11

C. Steam requirement for the steam coil air preheater

1. Heat input to SG at BMCR = Q kcal/hr.

2. Coal required to give this
heat energy (mc) =
Q
C V of coal
kg hr
. .
/

3. Coal required at 30% MCR (mc30) = m
c
* 0.3 kg/hr

4. The theoretical air required for
burning the coal (kg/kg of coal = ma

5. Actual air required
(with 20% excess air) (mact) = 1.2 * ma (kg/kg of coal)

6. Air required at 30% MCR (Ma) = mact x mc30 kg/hr

FICHTNER India

FORM T10 REV - A

7. Aux. Steam parameters

Pressure = pata

Temperature = T C

Enthalpy = Hs kcal/kg

8. Enthalpy of condensate at the
outlet of SCAPH = Hc kcal/kg

9. Minimum ambient air temperature
(for the design of SCAPH) = t
1
C

10. Temperature to which the air is
to be raised = t
2
C

11. Specific heat of air = Cpa kcal/kg C

12. Heat energy required to raise
air temperature to t
2
C = Ma * Cpa * (t
2
- t
1
) kcal/hr.

13. Steam required to give this heat
energy at 30% MCR =
Ma Cpa t t
Hs Hc
* * ( )
( )
2 1
kg/hr

FICHTNER India

FORM T10 REV - A

LHV, HHV CALCULATIONS - COAL

( ) { }
14500 62000 4000
2
8
C H S + +
2 o

Higher Heating Value (HHV) = -------------------------------------------------------------
1.8

HHV in kcal/kg

{ } HHV Btu lb x H W * . ( / ) 18 9720 1110
2

Lower heating value (LHV) = ---------------------------------------------------
1.8

LHV in kcal/kg

Where,

W is the fraction by weight of moisture in fuel and C, H
2
, O
2
and S are fractions by
weight of carbon, hydrogen, oxygen and sulfur in the fuel.

FICHTNER India

FORM T10 REV - A

LHV, HHV CALCULATIONS FOR GASEOUS FUEL - (NATURAL GAS)

% WT

NOTA-
TION

COMPOSITION %
VOL
MOL.
WT
xiMi
xnMn /100
|
\
|
.
|
|

n=CH
4
, C
2
H6 etc
i =cons for which % wt conversion to be
done

HHV
(KCAL/KG)
LHV
(KCAL/KG)
METHANE
(CH
4
)
X
CH4
16.043
X
xnMn
CH4
16043
100
.
/
|
\
|
.
|
|

n =CH4, C2H6 etc.

X
1
13269.23077 11944.57716
ETHANE (C
2
H6) X
C2H6
30.07
X
xnMn
C H 2 6
3007
100
.
/
|
\
|
.
|
|

n =CH4, C2H6 etc.

X
2
12403.24892 11353.32059
PROPANE
(C3H8)
X
C3H8
44.097
X
xnMn
C H 3 8
44097
100
.
/
|
\
|
.
|
|

n =CH4, C2H6 etc.

X
3
12036.55041 11082.17869
I - BUTANE
(C4H10)
X
C4H10
58.124
X
xnMn
C H 4 10
58124
100
.
/
|
\
|
.
|
|

n =CH4, C2H6 etc.

X
4
11811.99236 10907.78786
N-BUTANE
(C4H10)
X
C4H10
58.124
X
xnMn
C H 4 10
58124
100
.
/
|
\
|
.
|
|

n =CH4, C2H6 etc.

X
5
11840.65934 10935.26039
I-PENTANE
(C5H12)
X
C5H12
72.151
X
xnMn
C H 5 12
72151
100
.
/
|
\
|
.
|
|

n =CH4, C5H12 etc.

X
6
11698,51887 10822,98137
N - PENTANE
(C5H12)
X
C5H12
72.151
X
xnMn
C H 5 12
72151
100
.
/
|
\
|
.
|
|

n =CH4, C5H12 etc.

X
7
11720.01911 10845.67606
FICHTNER India

FORM T10 REV - A

NITROGEN (N
2
) X
N2
28.013
X
xnMn
N2
28013
100
.
/
|
\
|
.
|
|

n =CH4,C5H12 etc.

X
8

HEXANE PLUS X
HEX
86.169
X
xnMn
HEX
86169
100
.
/
|
\
|
.
|
|

n =CH4,C5H12 etc.

X
9
11636.40767 10781.17535
Molecular weight of the gas mixture(MW)= ( ) MWi Yi X

where, Yi = Volume fraction of gas i.
MWi = Molecular weight of gas i.
Density of the gas g(lb/cu.ft) = 492 x MW x
P
t 359 460 147 ( ) . +

g(kg/M
3
) = fg(lb/cu.ft) * 16.033

where, P = gas pressure, psia
t = gas temperature, F
MW = gas molecular weight
g = gas density, lb/cu. Ft.

Higher Heating Value
of the gas (HHV) =
x
HHV
x
HHV
x
HHV
CH C H C H
1
100
2
100
3
100
4 2 6 3 8
*( ) *( ) *( )
(
+

(
+

(

+
x
HHV
x
HHV
x
HHV
C H C H C H
4
100
5
100
6
100
4 10 4 10 5 12
*( ) *( ) *( )
(
+

(
+

(

+
x
HHV
x
HHV
C H Hexane
7
100
9
100
5 12
*( ) *( )
(
+

(
plus

HHV is in kcal/kg. HHV in kcal/Nm
3
= HHV(kcal/kg) x gas density (kg/m
3
).

Lower Heating Value
of the gas (LHV) =
x
LHV
x
LHV
x
LHV C H
CH C H
1
100
2
100
3
100
3 8
4 2 6
*( ) *( ) *( )
(
+

(
+

(

+
x
LHV
x
LHV
x
LHV
C H C H C H
4
100
5
100
6
100
4 10 4 10 5 12
*( ) *( ) *( )
(
+

(
+

(

+
x
LHV
x
LHV
C H
7
100
9
100
5 12
*( ) *( )
(
+

(
Hexane Plus

LHV is in kcal/kg. LHV in kcal/Nm
3
= LHV (kcal/kg) x gas density (kg/m
3
).

FICHTNER India

FORM T10 REV - A

STOICHIOMETRIC AIR REQUIREMENT - SOLID AND LIQUIDFUELS

CONSTI-
TUENT

FRACTION
O
2

REQUIRED
PER KG OF
CONSTITUENT

O
2

REQUIRED
PER KG
OF FUEL
Carbon Xc 2.664 Xc x 2.664

Hydrogen XH2 7.937 XH2 x 7.937

Oxygen

- - -
Sulphur Xs 0.998 Xs x 0.998

Nitrogen

- - -
Moisture

- - -
Total *T

* Total O
2
required per kg of fuel shall be obtained by deducting the oxygen
present in the fuel.

Stoichiometric dry air = O
2
kg/kg of fuel (T) x 4.3196
(kg/kg of fuel fired)
FICHTNER India

FORM T10 REV - A

STOICHIOMETRIC AIR REQUIREMENT - GASEOUS FUEL

Description

% by Vol.

Mol. Wt of
comp.

% by wt (c)
XiMi
XnMn /100

Dry Air

A

B
kg/kg of
comp.
D
kg/kg of gas
(C/100xD)
Hydrogen (H
2
) 2.02 34.21

Carbon
monoxide
(CO)

28.01 2.46
Methane
(CH
4
)
16.04 17.20

Ethane (C
2
H
6
) 30.07 16.06

Propane
(C
3
H
8
)
44.09 15.64

I-Butane
(C
4
H
10
)
58.12 15.43

N-Butane
(C
4
H
10
)
58.12 15.43

I-Pentane
(C
5
H
12
)
72.15 15.30

N-Pentane
(C
5
H
12
)
72.15 15.30

Hexanes
(C
6
H
14
)
86.17 15.21

Ethylene
(C
2
H
4
)

28.05 14.75
Propylene
(C
3
H
6
)

42.08 14.75

Air required / kg of gas =
( ) ( ) % by wt of constituent (xi) x Dry Air kg/ kg of comp.(xi)
i
N
=
1

Where N is the N
th
number of constituent in the gas.

FICHTNER India

FORM T10 REV - A

RECOMMENDED FEEDWATER & BOILERWATER QUALITY FOR

POWER PLANT APPLICATION

(USING DEMINERALISED WATER)

DRUM OPERATING PRESSURE OF
SL.NO. DESCRIPTION UPTO 20 BAR(g)
FEED WATER BOILER WATER

1 HARDNESS 1 -

2 pH@25 C 8.8-9.2 10.0-10.5

3 IRON,TOTAL ppm 0.05 -

4 SILICA, SiO
2
ppm 1 25

5 CONDUCTIVITY
micro s/cm

10

1000

6 HYDRAZINE
RESIDUAL ppm
- -

7 PHOSPHATE
RESIDUAL ppm
-
20.0-40.0

8

OXYGEN max,ppm

0.02

-

9

TDS max, ppm

-

500

10

COPPER,TOTAL,ppm

0.01

-
11 SODIUM SULPHATE
AS Na
2
SO
3
ppm
- 20-40

FICHTNER India

FORM T10 REV - A




SL.NO. DESCRIPTION 21-40 BAR(g)

1

HARDNESS

0.5

-

2

pH@25 C

8.8-9.2

10.0-10.5

3

IRON ,TOTAL ppm

0.02

-

4

SILICA, SiO
2
ppm

0.3

15

5

CONDUCTIVITY
micro s/cm

5

400

6

HYDRAZINE
RESIDUAL ppm

-

-

7

PHOSPHATE
RESIDUAL ppm

-

20.0-40.0

8

OXYGEN max,ppm

0.02

-

9

TDS max, ppm

-

200

10

COPPER,TOTAL,ppm

0.01

-

11

SODIUM SULPHATE
AS Na
2
SO
3
ppm

-

5-10

FICHTNER India

FORM T10 REV - A





1

HARDNESS

NIL

-

2

pH@25 C

8.8-9.2

9.8-10.2

3

IRON ,TOTAL ppm

0.01

-

4

SILICA, SiO
2
ppm

0.1

10

5

CONDUCTIVITY
micro s/cm

2

300

6

HYDRAZINE
RESIDUAL ppm

0.02-0.04

-

7

PHOSPHATE
RESIDUAL ppm

-

15.0-25.0

8

OXYGEN max,ppm

0.01

-

9

TDS max, ppm

-

150

10

COPPER,TOTAL,ppm

0.01

-

11

SODIUM SULPHATE
AS Na
2
SO
3
PPM

-

-

FICHTNER India

FORM T10 REV - A





1

HARDNESS

NIL

-

2

pH@25 C

8.8-9.2

9.8-10.2

3

IRON ,TOTAL ppm

0.01

-

4

SILICA, SiO
2
ppm

0.02

10

5

CONDUCTIVITY
micro s/cm

0.5

200

6

HYDRAZINE
RESIDUAL ppm

0.01-0.02

-

7

PHOSPHATE
RESIDUAL ppm

-

15.0-25.0

8

OXYGEN max,ppm

0.007

-

9

TDS max, ppm

-

150

10

COPPER,TOTAL,ppm

0.01

-

11

SODIUM SULPHATE
AS Na
2
SO
3
PPM

-

-

FICHTNER India

FORM T10 REV - A




SL.NO. DESCRIPTION 100&ABOVE BAR(g)

1

HARDNESS

NIL

-

2

pH@25 C

8.8-9.2

9.4-9.7

3

IRON ,TOTAL ppm

0.01

-

4

SILICA, SiO
2
ppm

0.02

*

5

CONDUCTIVITY
micro s/cm

0.3

<100

6

HYDRAZINE
RESIDUAL ppm

0.01-0.02

-

7

PHOSPHATE
RESIDUAL ppm

-

5.0-10.0

8

OXYGEN max,ppm

0.007

-

9

TDS max ppm

-

<100

10

COPPER,TOTAL,ppm

0.005

-

11

SODIUM SULPHATE
AS Na
2
SO
3
ppm

-

-

* AS SUITABLE FOR 0.02 ppm SiO
2
IN
STEAM LEAVING THE DRUM
FICHTNER India

FORM T10 REV - A

FEEDWATER & BOILERWATER QUALITY FOR


(USING SOFTENED WATER)

SL.NO. DESCRIPTION UP TO 20 BAR(g)

1 Iron as Fe ppm 0.100 -

2 Copper as Cu ppm 0.05 -

3 Total hardness as
CaCO
3
ppm

0.300

-

4 Silica, SiO
2
ppm - 150

5 Total alkalinity as CaCO
3
- 700

6

Specific conductance
micro s/cm

-

7000

FICHTNER India

FORM T10 REV - A




SL.NO. DESCRIPTION 21 - 40 BAR(g)



3 Total hardness as
CaCO
3
ppm

0.200

-

4 Silica, SiO
2
ppm - 40

3
- 500

6 Specific conductance
micro s/cm

-

5000

FICHTNER India

FORM T10 REV - A







3 Total hardness as
CaCO
3
ppm

0.100

-

4 Silica, SiO
2
ppm - 20

3
- 300

micro s/cm

-

3000

FICHTNER India

FORM T10 REV - A







3 Total hardness as
CaCO
3
ppm

0.050

-

4 Silica, SiO
2
ppm - 8

3
- 200

micro s/cm

-

2000

FICHTNER India

FORM T10 REV - A

BOILER BLOW DOWN CALCULATIONS

DEFINITION

Boiler Blowdown is defined as the process of removal of a fraction of water from boiler
unit and its replacement by feed water. This is done to prevent build up of excessive
concentration of undesirable substances in Boiler Water.
Continuous Blowdown is carried out to maintain dissolved solid concentration within
prescribed limits in the Boiler Water.

Intermediate Blowdown is carried out to reduce the sludge level in the Boiler Water
and also to accelerate the Continuous Blow down process.
E - Evaporation rate (TPH)
S - Solid content of Feed Water (g/m
3
)
V - Boiler Water content (m
3
)
C - Maximum allowable concentration of solids in Boiler Water (g/m
3
)
C
1
- Concentration of solids in Boiler Water on completion of Intermittent
Blowdown (g/m
3
).
B - Actual Intermittent or Continuous Blowdown rate as percentage of Evaporation
rate.
B
A
- Average Intermittent Blowdown as percentage of Evaporation rate.
d - Duration of Intermittent Blowdown operation (h).
t - Interval between completion of one Blowdown operation and completion of the
next (h).
Q - Quantity of Boiler Water discharge during each Intermittent Blowdown
operation (m
3
).
FICHTNER India

FORM T10 REV - A

Continuous Blowdown
C
1
=C
B
A
=B
d =t
B =100 x [S/(C-S)]
The above relationship is valid for various constituents of water like Alkalinity, salt
content, silica etc., Check for the Blowdown rate for each constituent separately and
the minimum value of Blowdown rate shall be considered and the corresponding
constituent shall be the governing factor. Refer document no. 100/11 for Boiler Water
limits for various drum pressure levels.
Intermittent Blowdown

B =tsv x 100/[d(CV-0.5SE(t-d)-VS)]

Q =EtSV/[CV-0.5SE(t-d)-VS]

C
1
=C - [(t-d) SE/V]
B
A
=Q x 100/tE

FICHTNER India

FORM T10 REV - A

CHIMNEY SIZING

Introduction

Chimneys, as we know them today, are tall slender structures which fulfill an
important function. They had a humble beginning as house hold vents and over the
years, as vents grew larger and taller, they came to be known as chimneys. A cluster
of them is a stack.

Function

A chimney is a means by which flue gases are discharged at a high elevation so that
after dilution due to atmospheric turbulence, their concentration and that of their
entrained solid particulates is with in acceptable limits on reaching the ground. A
chimney achieves simultaneous reduction in concentration of a number of pollutants
(such as SO
2 ,
NO
x
, CO, Suspended\Particulate Matter (SPM), Respirable Particulate
Matter

(RPM). Size less than 10 m, lead etc) and being highly reliable it does not
require a stand by, while these are its merits, it is well to remember that a chimney is
not the complete solution to the problem of pollution control.

Chimney classification

Chimney are classified based on their height (tall or short), number of flues (single or
multi), material of construction (Brick, RCC, steel, FRP), structural support (Guyed or
self supporting), lining (Lined or unlined). When Multiflue chimney is selected ?
often, a single chimney serves more than one boiler. In such a case when one of the
gas sources is shut down for maintenance the gas exit velocity will reduce because of
a reduction in the total volume of gases to be handled. This can lead to heavy
pollution and in order to overcome this problem, a chimney serving more than one
boiler can be provided with a separate flue for each gas source with such flues
housed in a common enclosing concrete wind shield. These are called as Multi-flue
chimneys.

Exit Velocity

Flue gases emerging from a chimney experience a field of increasing wind speed,
soon a speed will be reached (termed critical wind speed) when the wind will shear off
the emerging gas plume and this can lead to excessive pollutant deposition. If the exit
velocity is low, it can permit cold air to flow down a part of the chimney causing acids
contained in flue gases to condense on the walls and cause damage. In order to
avoid this, the flue gas velocity (ie. when chimney is operating in part load) should be
such that 1.5 times the wind velocity.

A part from this, a larger exit velocity will result in higher plume rise which in turn will
lead to a diminished GLC of pollutants. For the above reasons, a high exit velocity is
preferred but this can damage the lining due to erosion. With steel liners, velocities
upto 45 m/s can be used and with brick liners velocities higher than 30 m/s is not
recommended.

For power plant chimneys handling more than 2000 M
3
/min of flue gases, exit
velocities will be in the range of 20-25 m/s.

In general for our calculations purpose we use flue gas velocity as 1.5 times the
wind velocity, which is recommended in IS 4998 and Tall chimneys by S.N
Manohar.
FICHTNER India

FORM T10 REV - A

Physical Dimensions

Shape

Any shape for the chimney, other than circular, offers greater resistance to wind
currents and is more prone to oscillation. Hence circular shape is recommended.

Exit size

The top dimensions of a flue are fixed such that a given volume of gases can be
discharged at the design exit velocity. A 20% increase in the cross sectional area
shall be provided for the effect of reduced velocity near the inner surface of the
chimney due to friction. If a chimney has to handle a range of gas volumes, then the
exit velocity should be high at minimum load and at the same time should not exceed
the limiting values when operating at full load.

Physical height

The following two consideration dictate the physical height of a chimney.

1. To generate a draft which will cause gases to flow out with the desired exit velocity.

2. To satisfy local regulations in respect of permissible GLC of Pollutants.

CHIMNEY SIZING CRITERIA

Step : 1

Chimney height based on IS: 4998 (Part-I) 1975.

Height of the chimney `H =
AQFK
C
n
V T P
|
\
|
.
|
|
\
|
.
|
1 2 1 6 /
*
/

where

A = a coefficient depending upon the atmospheric vertical temperature distribution
which determines the condition for vertical and horizontal dispersion of the
substances in air. these value for Indian condition may be taken as 200.

Q = total emission of impurities from all chimneys (mg/s)

F = a coefficient to account for the substances settling velocity in the atmosphere.
This value may be taken as 1 for SO
2
, since the settling velocity of SO
2
is
nearly zero ; and 2 for dust if the average practical dust collecting efficiency is
not less then 90 percent and 2.5 if the efficiency is less then 90% percent.

K = a coefficient accounting for the effect of flue gas exit velocity for the chimney
V
o
. The values are given below.

Flue gas Exit Velocity
V
o
m/s
Value of K

10-15

1

FICHTNER India

FORM T10 REV - A

20-25 0.9

30-35

0.8

C
p
=Maximum expected concentration of the pollutant at grade level (mg/M
3
)

n =Number of chimneys

V = Total volume of flue gases discharged from chimneys (M
3
/s

)

T = Temperature difference between flue gas Tg and ambient air temperature Ta (C)

= T
g
- T
a

Step - 2

If background pollution is already in existence in the area under consideration, the
chimney height calculated shall be modified as follows.

H
c
= H
C
C C
p
p e
|
\
|
.
|
1 2 /

Where

H
c
= corrected chimney height in (m)

C
e
= existing background concentration in (Mg/m
3
)

Step - 3

CHIMNEY HEIGHT AS PER POLLUTION CONTROL BOARD NORMS.

However, as per pollution control norms the stack height requirement for sulphur di-
oxide control shall be as follows.

H = 14 (Q)
0.3

Where

H = Chimney height (m)

Q = SO
2
emission rate (kg/hr)

Chimney height calculated based on the above two methods has to be compared, and
the tallest one shall be selected.

Stack height requirement as per pollution control norms for larger capacity power
plants is as follows. For Boiler size less than 200 MW above steps shall be followed, if
Boiler size is above 200 MW & less then 500 MW then 220 M height chimney shall be
selected if the Boiler size is more than 500 MW then 275 M height chimney shall be
selected.

Step - 4

FICHTNER India

FORM T10 REV - A

CHIMNEY DIAMETER

Chimney diameter at the exit shall be calculated as given below

D
e
=
4
0
V
V

Where

D
e
= diameter at exit (m)

V = total volume of flue gas (M
3
/sec)

V
0
= allowable velocity at the exit (M/Sec.) ie. 1.5 x wind speed.

As explained earlier the calculated diameter has to be increased by 20%

De
c
= 1.2 x De

Where

De
c
= corrected diameter at the exit.

Stack Draft Calculations :-

After finishing the above calculation, stack draft calculation shall be done and draft
available shall be checked. The following are the procedure to calculate the net draft
available.

Net draft available is nothing but theoretical draft calculated less the dynamic head
loss due to kinetic energy of gases leaving a chimney and the head lost in overcoming
friction along the internal surface of a flue.

Net draft =theoretical draft - (Dynamic loss +Friction loss).

Net draft = 13.6 * 0.029 BH
d

1 1
T V T V a a g g

`
)

15.4x10
-9
x Q
2
g
x V
g
H f
T
B D
T
B D
T
BeD
d
gm
m m
gt
E t
ge
e
5 4 4
+

`
)
MM of H
2
O
where

B = Barometer pressure (mm of Hg)

H
d
=height of chimney above breeching (m)

T
a
=air temperature ( K)

V
a
=Sp. volume of air at STP =0.775 (m
3
/kg)

T
g
= Temperature of flue gas ( K)

V
g
= Sp. volume of flue gas at STP (m
3
/kg)

Q
g
= Mass emission rate of flue gas (g/sec)
FICHTNER India

FORM T10 REV - A

f = friction factor (refer enclosed chart)

T
gm
= Temp of flue gas at mean height (k)

B
m
= Barometric pressure at Mean height (mm of Hg)

D
m
= Diameter of chimney at mean height (m)

T
gt
=Temperature of flue gas at top of chimney ( K)

B
t
=Barometric pressure at top (mm of Hg)

D
t
= Diameter of chimney at top (m)

T
ge
= Temperature of flue gas at breeching level (m)

B
e
= Barometric pressure at breeching level (mm of Hg)

D
e
= Diameter of chimney at breeching level (m)

Clearances

The following clearances has to be obtained for installing a chimney

1. Stack height clearance from National Air port Authority

2. Environmental clearance from state pollution control board and from Ministry of
Environment & Forest, Government of India.

FICHTNER India

FORM T10 REV - A

EMISSION/AMBIENT AIR QUALITY CALCULATIONS

PARTICULATE EMISSION LEVELS

Particulate emission data are needed to size dust collectors for coal-fired boilers. In
coal-fired boilers, about 75% of the ash is carried away by the flue gases and 25%
drops into the ash pit. The following expression may be used for determining the Ash
concentration in the flue gas.

C
a
= 2,40,000 x (% ash/100)
------------------------------------------------------------------
T x [7.6 x 10
-6
x HHV x (100+E) +1 - (% ash/100)]

Where

C
a
= ash concentration, grains / cu.ft

E = excess air %

T = gas temperature,
O
R

HHV = Higher Heating value, Btu/lb

To convert ash concentration in grains/cu.ft to kg/m
3

C
a
= 0.01 x A x 7000 x

Ash concentration in lb/ft
3
= C
a

----
70

Ash concentration (kg/m
3
) = C
a

---- * 16.033
70

= gas density, lb/Cu.ft = 39.5 / (460+t)

t = gas temperature , F

C
a
= ash content, grains/acf or grains/scf depending on whether
density is
computed at actual temperature or at 60F

A = ash content, % by weight

The expression for density is based on atmospheric flue gases having molecular
weight of 28.8

The ESP is sized to achieve an outlet dust concentration of 150 mg/Nm
3

FICHTNER India

FORM T10 REV - A

SO
2
Emission LEVEL

Emission of S0
2
in lb/mmBtu (e) = 2 x 10
4
S
-------
HHV

Where S is the % sulfur in the fuel.

HHV = Higher Heating value of the fuel Btu/lb

Conversion S0
2
Emission rate in lb/mmBtu to PPM

Weight flow rate of flue gas produced / MMBtu Wg = 10
6
+(1+%E)*A

HHV 100

Air/MMBtu of fuel (A) = 760 for Bituminous coals

= 745-750 for furnace oil and lignite

= 780 for Anthracite

= 800 for coke

Moles of flue gas = Wg ; Mf : Molecular weight of flue gas
(mf) Mf
Moles of SO
2
= e MSO
2
: Molecular weight of SO
2

---
(MSO
2
) = MSO
2

(SO
2
) in ppm = M SO
2
x 10
6

---------
Mf

NO
X
in Volumetric Units on dry Basis

100 * (w/46) (W/Mw)
Vn(ppmvd) =
100-%H
2
O --------- (1)
where
%H
2
O =Volume of water vapour
MW =Molecular weight of the Exhaust Gases
M =Flow rate of NO
2
, lb/hr
W =Turbine Exhaust Gas Flow, lb/hr

The value of V obtained with Eq-1 must be converted to 15% Oxygen on dry basis to
give ppmvd of No
x
at 15% O
2
.

V * (21-15) * 16
6

Vn(ppmvd 15% 02) =
21 - 100%02/(100-%H
2
O) ------- (2)

=V * F

where %O
2
=Oxygen present in the wet exhaust gases. Factor F converts V to 15%
Oxygen basis, which is the usual basis for reporting emissions.

FICHTNER India

FORM T10 REV - A

Co-Emission in ppmvd

Vc =1.642 * Vn (for the same Wlb/hr rate)
Because the ratio of Molecular weights of NO
2
and Co is 1.642.

NOISE EMISSION LEVELS

NOISE LEVEL LIMITATIONS

1. NOISE LEVEL LIMITATIONS AROUND EQUIPMENTS

During normal operating conditions (70% load to 100% load), the noise level
around the equipments shall not exceed 90 db (A) measured at a distance of
1 m from the nearest surface of the machine and at a height of 1.2 m from the
floor level.

2. NOISE LEVEL LIMITATIONS AT THE CONTROL PROPERTY BOUNDARY

The noise level at the Control property boundary shall be limited to the values
as given in the table below:-

Ambient Air quality standards in respect of Noise

AREA
CODE
CATEGORY OF
AREA
LIMITS IN DB(A)
DAY-
TIME
NIGHT
TIME
A. Industrial area 75 70
B. Commercial area 65 55
C. Residential area 55 45
D. Silence area 50 40

Day time is between 6 a.m to 9 p.m

Night time is between 9 p.m to 6 a.m

The noise levels at the property boundary line shall be specified as per the above
table which should remain within the prescribed limits throughout the plant operating
range (i.e) 70% load to 100% load. It is to be noted that the noise limit is for total
noise (background noise +plant noise)
FICHTNER India

FORM T10 REV - A

NOISE LEVEL MEASUREMENT AROUND EQUIPMENTS

The noise level limitations as stipulated in the above table shall be demonstrated
around the following equipments:

1. Gas Turbine

2. Steam Turbine

3. Circulating Water Pumps

4. Boiler Feed pumps

5. Condensate Extraction pumps

6. Steam J et air Ejectors

7. Pulverising Mills

8. F.D fans, I.D fans & P.A. fans

For equipments inside the building, the noise monitoring should be done for 8 hours
continuously as the worker is exposed to the noise of 8 hours during a shift. The
noise limits for industrial workers has been prescribed as 90dB(A)

Noise measurements should be done on the prescribed paths. After carrying out the
pilot survey, detailed baseline noise data should be collected. These should be
atleast four key measuring points which depend upon the size of the machine and the
symmetry of the acoustic radiation. The noize measurement should be done at 4 key
measuring points and successive measuring locations. The successive measuring
locations should be on the prescribed path at intervals of not more than 1 meter
commencing from the 4 key measuring points.

EXCLUSIONS

Noise levels during plant transients, upset conditions and noise levels resulting from
the actuation of safety devices may exceed the limits specified for a short period of
time.
FICHTNER India

FORM T10 REV - A

MONITORING OF NOISE

The monitoring of noise shall be done inaccordance with the following IS standards.

IS 4758 : 1968 Methods of Measurement of noise emitted by
machines

IS 6098 : 1971 Methods of Measurement of air borne noise
emitted by rotating electrical machinery

IS 7194 : 1973 Assessment of noise exposure during work for
hearing conservation purposes

IS 9779 : 1981 Sound level meters (superseding IS:3931 - 1966)
and (IS 3932 - 1966)

IS 9989 : 1981 Assessment of noise with respect to community
response

IS 10423 : 1982 Personal sound exposure meter.

IS 10534 : 1983 Methods of measurement of airborne noise
emitted by gas turbine installations

IS 9876 : 1981 Guide to measurement of airborne acoustical
noise and evaluation of its effect on man.

FICHTNER India

DOC. NO. WI-ME-DSN-103-001 REV. NO. R-1 PAGE 1 OF 8
FORM T10 REV - A

ASH HANDLING SYSTEM

1.0.0 Introduction

This document is a guide line applied to ash handling facilities for solid fuel fired
steam generators, extending from ash collection points of the combustion residues
upto the places of dispatch from the power station area.

1.1.0 Fuel Used & Ash Content

The fuels normally considered are solid fuels like coal/lignite/washery middlings etc.
When other fuels are used appropriate considerations are to be made. A decisive
influence on the properties of ash is exerted by the physical, chemical and
technological conditions of combustion. Generally either fluidized bed furnaces or
pulverised coal fired furnaces are adopted depending on the generating capacity of
the plant. Normally it is considered that for coal the total ash percentage will be about
45% and for lignite about .....% for designing the ash handling system. The correct
data shall be obtained from the design spec for fuel.

2.0.0 Type of ash generation

The type of ash produced due to burning of solid fuel such as coal/lignite is Bed ash /
Bottom ash, Cyclone ash and fly ash. The bed / bottom ash is a coarse ash
discharged from the boiler bed area or furnace hopper. Normally the quantity of bed
ash is about 20% of total ash content of the fuel. The density of bed ash is about 800
to 1100 kg/m
3
. The average particle size range is 1.0 to 10mm and maximum is
30mm. The fly ash is entrained in the flue gas and collected in the Economiser / Air
preheater hoppers, downstream electrostatic precipitator hoppers and in the chimney
ash hopper. Normally the quantity of fly ash is about 80% of total ash content of the
fuel. The density of fly ash is about 500 to 900 kg/m
3
. The average particle size
range is 0.1 to 3.0 mm. Maximum is 10 mm.

The ash handling system is distinguished according to the type of ash such as.

- Coarse ash or granulate
- fly ash.

3.0.0 Ash handling systems
FICHTNER India

FORM T10 REV - A

The ash handling systems are classified as

- Mechanical conveying systems

- Hydraulic conveying systems

- Pneumatic conveying systems

The mechanical conveying systems generally consists of

- Submerged scrapper conveyors

- Belt conveyors

Hydraulic conveying system uses water as a conveying medium. The system
consists of pumps, ejectors, sluiceways and conveying pipelines.

Pneumatic conveying systems are specifically used for collection points where dust is
obtained. The system uses air as the conveying medium.

3.1.0 Mechanical Conveying Systems

Submerged scrapper conveyors are provided below the combustion chambers of
boilers and are used for the quenching and discharge of the bed ash discharged. The
scrappers are generally spaced at 0.5 to 1.0m between two endless chains at the
bottom of a water filled through and operate at low speed at about 0.3 to 1m/min
before discharge.

The boiler outlet is sealed off by means of a submerged chute immersing in the water
bath. Boiler downward expansion must be considered in the immersion depth. The
maximum cooling water outlet temperature shall not exceed 50C. Depending on the
water temperature difference the required amount of water is about 6 to 20 times of
the amount of ash generated. The drainage water is polluted with fine ash and hence
the overflow / drain pipe shall be adequately sized and necessary down stream
classifying equipment is installed.

Belt conveyors are provided when longer distance conveying is required. Care must
be taken to ensure that sufficiently cool bed ash is conveyed. Maximum inclinet of
belt conveyor is limited to 16.

3.2.0 Hydraulic conveying systems
FICHTNER India

FORM T10 REV - A

3.2.1 The hydraulic handling system of ash consists of slurry pumps. Ejectors, sluiceways,
sump etc. The bottom ash collected is normally stored in a water impounded ash
hopper for 8hrs. Then the ash is crushed to a handling particle size of maximum
50mm and pumped to disposal site by slurry pumps. Because of high heat dissipation
rate water must be fed in continuously as the water temperature is limited to 60C.
The water impounded hopper is a steel shell with a temperature resistant lining on the
inside.

3.2.2 The slurry pumps used for conveying are normally of single stage non-clog centrifugal
pumps having a maximum speed of 1000 rpm for transport distance upto 3 km.
(horizontal). When the distance is more 2 to 3 pumps are connected in series or
intermediate pump stations are provided.

3.2.3 Ejectors

When Ejectors are used ash to water ratio is 1:4 to 1:10 depending on the ash size,
feeding configuration. The necessary water pressure upstream is about 6 to 8 times
the pressure in the delivery piping after the ejector. This pressure level depends on
ejector efficiency, delivery length, delivery head and piping resistance. Ejectors are
simple in design, replacement is easy and less maintenance compared to slurry
pumps. Ejector system is normally adapted for fly ash conveying.

Sluiceways conveyance is adapted for bed ash / coarse ash. Sluiceways are suitable
only for short distance up to the slurry sump from where the ash slurry is conveyed by
pumps. The slope of sluiceway is about 2 to 3% and water requirement is about 20
times the ash handled.

3.3.0 Pneumatic Conveying Systems

In Pneumatic conveying systems the ash is discharged by means of compressed air
either directly from the hoppers or from a collecting vessel and conveyed to the silos
through piping. The piping resistance is over come by conveying air pressure. Two
types of pneumatic conveying systems are

- dilute phase conveying and

- dense phase conveying

Advantages of pneumatic systems are

FICHTNER India

FORM T10 REV - A

a) Long distance conveying so that storage can be located for off from the plant.

b) Ash can be conveyed directly from multiple hoppers to the disposal point.

c) Higher conveying capacity over longer distances.

Hence medium capacity powerstations normally select pneumatic systems.

The system components are

1) Conveying pipe line with required fittings.

2) Positive displacement air supply blower or compressor.

3) Pressure feeders attached to the collection hoppers to feed into the conveying
pipe.

4) Storage bin.

5) Silo unloading systems.

3.3.1 Lean Phase Conveying

In Dilute phase / lean phase conveying system the gas velocities are much greater
than the settling velocity of the individual grain.

The velocity of conveying air in lean phase is about 15 m/sec to 20 m/sec at a mass
flow ratio about 10 and pressure loss is about 0.1 to 1 bar/100m. The particle velocity
is about 0.9-1 m/sec.

3.3.2 Dense Phase Conveying

In dense phase conveying the velocity of conveying is low but higher pressure is used
where the material to be transported completely fills the pipe and transported in
separate plugs.

The velocity of coveying air in dense phase is 1 to 10m/s with mass flow ratio 20 to
150 and the pressure loss is about 0.5 to 1 bar/100m. The particle velocity is 0.5 to
0.9 m/sec.

3.3.3 System description

3.3.1 Dense phase conveying system

FICHTNER India

FORM T10 REV - A

The system envisages removal of fly ash/bedash pneumatically by means of pressure
conveying system. Fly ash would be collected in various hoppers located in flue gas
path viz. economiser, air preheater, ESP and the chimney hopper which amount to a
maximum of 80% of total ash produced in the furnace. Bed ash will be collected from
the bed ash discharge points after necessary cooling by the bed ash coolers or water
cooled hoppers which amount to 20% of total ash generated.

The bedash / flyash collected would be fed into the individual transmitter vessel
located below the hoppers. At each hopper level probe shall be provided for initiating
the conveying cycle. The system can operated both in level / timer mode. The ash
collecting surge hopper shall be provided with water cooling arrangement whenever
hotash (generally for / bedash / cycloneash) is handled. The isolation seal valves are
also water cooled.

The operation of the system is fully automatic. When the system is operated in auto -
timer mode the system shall have continuous cycle after a preset interval of time. In
level mode level prope provided in the surge hopper shall initiate the conveying cycle.
The isolation valve shall open and allow ash by gravity into the transmitter vessel by
gravity till it is closed automatically by the timer preset as per process parameters. On
closure of the isolation valve. The valve seal gets inflated and the conveying air is
injected into the vessel. The vessel is pressurised and the material resistance helps
pressure build up which conveys the material to the destination silo. When conveying
is complete the pressure drop down to nearly atmospheric pressure and is sensed by
the control system, the air supply to the system is stopped. The transmitter vessel is
ready for the next cycle.

Ash is conveyed by M.S ERW pipes conforming to is............ heavy grade with long
radius allow CI bends upto the terminal box located on top of the silo. The terminal
box help the ash to be discharged into the silo. The conveying air escapes by the
vent provided on top of the silo. The vent is provided with reverse pulsejet type bag
filter to filter the vent air. The size of the ash silo is depending upon the quantity of
ash generated and the silo discharging operation cycle.

The ash conveying pipe line should have minimum number of bends as far as
possible to avoid choking of the line and reduce maintenance problems. The bends
should have long radius about 10 D of the pipe dia.

Incase two or more silos are to be used for collecting the ash from single line
pneumaticaly operated divertor valves are used to divert the ash to the required silo.
FICHTNER India

FORM T10 REV - A

3.3.2 The lean phase conveying system also functions similar to the dense phase system
only with the difference of high volume air supply source at low pressure.

The general system configurations are enclosed in the Annexure -1.
FICHTNER India

FORM T10 REV - A

FICHTNER India

FORM T10 REV - A

FICHTNER India

FORM T10 REV - A

RAW WATER ANALYSIS CONVERSION FACTORS FOR IONIC LOADS

Raw Water contains impurities which can be classified as Suspended Solids and
Dissolved Solids. Suspended solids can be removed by Filtration. The Dissolved
Solids can be removed only by Distillation, Reverse osmosis and Ion Exchange
process.

The constituents of Dissolved solids are salts of Calcium, Magnesium, Sodium and
Potassium existing in the form of CaCO
3
, MgCO
3
, CaSO
4
, Na
2
, SO
4
, etc.

The most popularly used scale for measurement of Ionic load is mg/l or Parts Per
Million (PPM). The constituents are measured on the basis of As CaCO
3
or As
such. The actual load of constituent Ion measured on As such basis are converted
to As CaCO3 basis by multiplying the PPM As such by the factor Atomic weight of
constituent / Atomic weight of CaCO
3
. Atomic weight of CaCO
3
is 100.

It is imperative to convert all Ionic loads to As CaCO
3
. Basis in order to check for
Ionic balance. Ionic balance is achieved if total Cation load is equal to total Anion load.

Another scale for measurement of Ionic load is Equivalent Mass/I (Eq.m/l). The
Equivalent Mass of given substance is the quantity of the substance that will combine
with or replace in a given reaction one atom of Hydrogen (or another monovalent
element as the amount of the substance corresponding to the transition of one
electron (in oxidising reducing reactions).

Eq =M/n.

But this scale is not used extensively because the equivalent of many chemical
compositions is not constant as it depends on the type of reaction involved.

The multiplication factors for conversion of Ionic load from AS SUCH to AS CaCO
3

are as follows:

FICHTNER India

FORM T10 REV - A

SL.NO. IONS MULTIPLICATION FACTOR
1. Calcium (Ca
++
) 2.50

2. Magnesium (Mg
++
) 4.10

3. Sodium (Na
+
) 2.18

4. Potassium (K
+
) 1.28

5. Sulphur (S
++
) 3.13

6. Aluminium (Al
+
) 5.58

7. Fluorine (F
+
) 2.56

8. Bicarbonates (HCO
3
) 0.82

9. Sulphates (SO
4
) 1.04

10. Chloride (CI) 1.41

11. Nitrate (NO
2
) 0.81

12. Iron (Fe) 0.79

13. Silica (Si) 0.83

Sl.No.1 to 7 gives the Cation part and Sl.No.8 to Sl.No.11 indicates the Anion part.
Total cationic load shall be equal to Total anionic load which is called ionic balance.

Add the Cation load, Anion load, Iron and Silica in AS SUCH basis to obtain Total
Dissolved Solids (TDS).

FICHTNER India

FORM T10 REV - A

RAW WATER ANALYSIS

Raw water available at the site shall be analysed in a laboratory and its physical,
chemical and Bacteriological Characteristics shall be furnished as per the format
given below. These data shall be obtained for four seasons over one year. To work
out the seasonal average water analysis over a period of atleast 3 years shall be
made available.

These details are important to decide the treatment scheme for the raw water to make
it suitable for the end user.

Source of water

1. Bore Well

2. Open Well

3. River

4. Sea

5. Others

Physical Characteristics

1. Colour

2. Taste

3. Odour

4. Temperature (C)

Chemical characteristics

1. Ph
2. Specific conductance (micro siemens / cm)
3. Turbidity (NTU)
4. Total Dissolved solids in ppm
5. Total Suspended Solids in ppm
6. Total Alkalinity as CaCO
3
in ppm
7. Bicarbonates as HCO
3
in ppm
8. Calcium as CaCO
3
in ppm
9. Magnesium as CaCO
3
in ppm
11. Sodium as CaCO
3
in ppm
FICHTNER India

FORM T10 REV - A

12. Potassium as CaCO
3
in ppm
13. Chlorides as CaCO
3
in ppm
14. Sulphates as CaCO
3
in ppm
15. Fluorides as CaCO
3
in ppm
16. Total Phosphorus As P in ppm
17. Nitrates as CaCO
3
in ppm
18. Nitrites as CaCO
3
in ppm
19. Ammonical Nitrogen As NH
3
-N
20. Total Chlorine As Cl
2
in ppm
21. Bromides As Br in ppm
22. Oil & Grease in ppm
23. Total Cyanides As CN in ppm
24. Phosphates as CaCO
3
in ppm
25. Dissolved Oxygen in ppm
26. Chemical Oxygen Demand in ppm
27. Biochemical Oxygen Demand (for 5
days at 20C)
in ppm
28. Total Organic Carbon in ppm
29. Total Silica as SiO
2
in ppm
30. Reactive Silica as SiO
2
in ppm
31. Colloidal Silica as SiO
2
in ppm
32. Total Iron as Fe in ppm
33. Dissolved Iron as Fe in ppm
34. Total Manganese as Min in ppm
35. Dissolved Manganese as Min in ppm
36. Total Lead as Pb in ppm
37. Total Cadmium as Cd in ppm
38. Total Copper as Cu in ppm
39. Total Strontium as Sr in ppm
40. Total Barium as Ba in ppm
41. Total Aluminium as Al in ppm
42. Total Lithium as Li in ppm
43. Total Zinc as Zn in ppm
44. Total Nickel as Ni in ppm
45. Total Selenium as Se in ppm
46. Total Tin as Sn in ppm
47. Total Mercury as Hg in ppm
FICHTNER India

FORM T10 REV - A

48. Total Cobalt as Co in ppm
49. Total Arsenic as As in ppm
50. Total Chromium as Cr in ppm
51. Silt Density Index

Bacteriological Characteristics

1. Aerobic bacterial plate count at 37C
(72 hrs)
as CFU per ml
2. Total Faecal Coliform count, as Most
Propable Number (MPN) per 100 ml
as CFU per ml
3. Total E. Coli bacteria in
100 ml

FICHTNER India

FORM T10 REV - A

COOLING TOWER
BLOW DOWN, EVAPORATION & DRIFT LOSS CALCULATIONS

DEFINITION

The Circulating Water of the Cooling Water System gains heat in the Condenser &
other Auxiliaries and rejects the same in the Cooling Tower. In the Cooling Tower the
spray of water comes in contact with air. A part of the Water is evaporated and the
remaining water is cooled. The latent heat for evaporating a part of Water is obtained
from the balance water which is getting cooled.

In the Cooling Water System Water loss takes place in three different ways.
1. Evaporation loss
2. Blowdown loss
3. Drift loss

Evaporation loss
A part of Water evaporated in order to cool the remaining Water is Evaporation loss.
Evaporation loss is calculated by the relation
E =T/6.11
E - Evaporation loss in %
T - Temperature of Cooling in the tower. (Difference between Inlet & Outlet Temp.)

Drift Loss
Drift loss is the loss of Water in the Cooling Tower by entertainment of Water particles
along with the Water vapour. Drift eliminators are installed in the Cooling Tower to
minimise the Drift loss. Normally Drift loss is in the range of 0.1% to 0.2% of System
flowrate.
FICHTNER India

FORM T10 REV - A

Blowdown loss
The Water which is evaporated does not carry any dissolved solids with it. The
dissolved solids are getting concentrated in the Bulk Water. Over a period of time, the
Concentration levels reaches a limit above which the solids tend to precipitate and
form scales on the pipes and heat transfer surfaces. The process of removing
calculated quantity of Water and adding fresh Water in order to maintain the
concentration levels of dissolved solids below prescribed limits to avoid Scaling is
called as Blowdown. Blowdown is calculated as

B =[E/(C-1)] - D
Where B - Blowdown loss %
D - Drift loss %
C - Cycle of concentration

Cycle of concentration (COC) is determined based on the Scaling/Corrosion
behaviour of circulating water. Refer Document No.108/2 for calculation of Scaling
Index and Cycle Of Concentration.

Make up of Losses
The losses in the Cooling Water System due to Evaporation, Drift and Blowdown has
to be made up using fresh Water. The quantity of fresh Water make up is addition of
all the losses put together.
M =E +B +D
=E +{[E/(C-1)] - D}+D
=E +E/(C-1)
M =EC/(C-1)
M - Makeup quantity % of total flow
E - Evaporation loss % of total flow
C - Cycle of concentration.
FICHTNER India

C:\Siva\REFERENCES\USEFUL BOOKS\DESIGN GUIDE-
FICHTNER\WI-ME-DSN-123-001.doc
FORM T10 REV - A

DIFFERENCE BETWEEN HORIZONTAL PUMPS & VERTICAL PUMPS

Introduction

A pump is defined as a device which raises or transfers fluids.

Pumps may be classified on the basis of the applications they serve, the materials from
which they are constructed, the liquid they handle, and even their orientation in space.
All such classifications, however, are limited in scope and tend to substantially overlap
each offer.

All pumps may be divided into two major categories.

1. Dynamic.

2. Displacement.
Dynamic : In which energy is continuously added to increase the fluid velocities within the
machine to values in excess of those occurring at the discharge such that
subsequent velocity reduction within or beyond the pump produces a pressure
increase.

Displacement : In which energy is periodically added by application of force to one or more
movable boundaries of any desired number of enclosed, fluid- containing
volumes, resulting in direct increase in pressure upto the value required to move
the fluid through valves or parts into the discharge line.

FICHTNER India

FORM T10 REV - A

PUMPS
DISPLACEMENT
DYNAMIC
CENTRIFUGAL
AXIAL FLOW

SINGLE FLOW

MULTISTAGE
CLOSED IMPELLER
OPEN IMPELLER
MIXED FLOW
RADIAL FLOW
SINGLE SUCTION
DOUBLE SUCTION
SELF PRIMING
NON PRIMING
SINGLE STAGE
MULTI STAGE
OPEN IMPELLER
SEMI-OPEN IMPELLER
CLOSED IMPELLER
PERIPHERAL
SINGLE STAGE
MULTI STAGE
SELF - PRIMING
NON - PRIMING
SPECIAL TYPE
J ET REDUCTOR
GAS LIFT
HYDRAULIC RAM
ELECTROMAGNETIC
FICHTNER India

FORM T10 REV - A

PUMPS PUMPS
DYNAMIC DISPLACEMENT DISPLACEMENT
RECIPROCATING RECIPROCATING
PISTON PLUNGER

PISTON PLUNGER

STEAM-DOUBLE ACTING
SIMPLEX
DUPLEX
POWER
SINGLE ACTING
DOUBLE ACTING
SIMPLEX
DUPLEX
TRIPLEX
MULTIPLEX
DIAPHRAGM
SIMPLEX
MULTIPLE

FLUID OPERATED
MECHANICALLY OPERATED
ROTARY
SINGLE ROTOR
VANE
PISTON
FLEXIBLE MEMBER
SCREW
PERISTALTIC
MULTIPLE ROTOR
GEAR
LOBE
CIRCUMFERENTIAL PISTON
SCREW
FICHTNER India

FORM T10 REV - A

Some of the factors that influence the selection of a pump follow.

1. Liquid to be handled.

a. Quantity and pressure.
b. Viscosity of the liquid at the pumping temperature.
c. Relation of the suction pressure at the pumping temperature to the
vapour pressure.
d. Is the liquid corrosive.
e. Is the liquid abrasive (does it contain solids).
f. Are undissolved gases present.

2. Requirements.

a. Must the pump meter as well as raise or transfer.
b. Must the pump supply a variable quantity in response to process needs.
c. Will there always be liquid for the pump to handle.
d. Is filterability a problem.

3. Sealing

a. Solvents (leaching of lubricant).
b. Solids (abrasion of packing or seals .
c. Toxicity.
d. Flammable vapors.
e. In compatibility with ambient condition.
f. Loss of expensive fluids.

4. Safety

a. Material of construction to avoid fire hazard.
b. Pressure protection (particularly solids)

5. Size and position.

a. How much space is available.
b. Where must the pump be located.

6. Scale - up problems.

7. Standardisation (with other types and makes already installed)

GENERAL FEATURES OF CENTRIFUGAL PUMPS

Centrifugal pumps accomplish the generation of pressure by the conversion of velocity
head in to static head. The rotary motion of impellers adds energy to the service fluid in
the form of a velocity increase. This velocity increase is converted into static head in the
volute diffusing section of the casing. A pump operating at a fixed speed will develop
the same theoretical head in metre of flowing fluid, regardless of density. However, the
pressure corresponding to the developed head (in bar) depends on the fluid density.

The parameters that establish the maximum head (in metre of fluid) that a centrifugal
pump can develop are the pump speed (rpm), impeller diameter, and the number of
FICHTNER India

FORM T10 REV - A

impellers in series combination. Impeller design and blade angle mainly affect the slope
and shape of the head - capacity curve and normally have no or little effects on the
developed head.

Normal and maximum viscosity ranges are a major consideration in pump selection
because of possible deterioration in performance with increasing viscosity. Deterioration
can be both continuous and gradual. The table can serve as a guide in selecting the
proper centrifugal pump type for an application.

VISCOSITY SENSITIVITY OF DIFFERENT PUMP TYPES

KINEMATIC VISCOSITY GUIDELINES
TYPE PUMP U =/P
(mm
2
/sec)

Rotary 7 Nominal minimum viscosity for rotory
pumps. Efficiency begins to decrease
as viscosity increases viscosity should
be specified for services when it
exceeds this level.

Centrifugal <30 Centrifugal pumps preferred over
rotary when conditions allow
application of either type.

Centrifugal 30 The head - capacity capability of a
centrifugal pump begins to deteriorate.

Centrifugal 30-110 Centrifugal pump preferred over rotary
despite some efficiency drop.

Positive Displacement 110-220 These are almost always used if the
expected viscosity exceeds this level.

Rotary 110-650 Rotary preferred if viscosity falls in this
range.

Most centrifugal pump types are not self-priming, meaning that they are not capable of
evacuating vapour from the suction line so that liquid can flow into the line and into the
pump casing without external assistance. The impellers on centrifugal pumps are
designed specifically for efficient liquid pumping and are not operated at high enough tip
speeds to convert them into vapour compressors. The differential head that the pump
impeller can deliver in the same on vapour as on liquid. However, the equivalent
differential pressure rise capability in much lower with vapour. Thus, centrifugal pump
impellers are not capable of generating a significant reduction in the pressure exerted by
the vapour in the suction line to permit liquid flow.

To prime a centrifugal pump before starting, the suction line and pump casing must be
filled with liquid. When the suction source is at positive pressure or is positioned above
the pump, priming is done by opening the suction valve and releasing (venting) the
trapped vapour from a valued connection on the pump casing or discharge line (located
inside the discharge block valve). Liquid then will flow into the suction line and pump
casing to displace the venting vapour.

FICHTNER India

FORM T10 REV - A

Specially designed centrifugal pumps are self-priming. One type accomplishes
evacuation of the suction line vapour by entertainment of vapour bubbles from the
suction side of the impeller in a charge of liquid held in the pump casing. The liquid
charge in recirculated to the suction side after separating the entrained vapour.

Most centrifugal pumps have a self-venting feature small amounts of vapour trapped
within the casing at start-up (after suction, priming in complete) are swept out into the
discharge line when the pump is started. Horizontally split casings are not arranged to
be self-venting, however, and are equipped with specially designed valved vent
connections requiring manual operation. single-stage centrifugal pumps with top
discharge connections have good self-venting performance eventhough the casing
shape places a small high - point vapour pocket in the top of the discharge volute.

CONSTRUCTION FEATURES OF CENTRIFUGAL PUMPS

There are a variety of design features applied to the different construction styles of
centrifugal pumps. A summary of the main features follows.

Volutes and Diffusers

Pump have diverging channels called volutes which are cast into the discharge zone of
the casing. This casing section collects the liquid discharged by the impeller and
converts velocity energy into the pressure energy. A centrifugal pump volute increases
in area from its initial point until it encompasses the full 360 around the impeller and
then flares out to the final discharge opening. Single-valves passages are simple type
of design causes an unbalanced load on the impeller because of the variation in
pressure around the periphery when the pump is operated at capacities other than
design condition. Double - volute configurations are employed when the unbalanced
force level threaten to cause significant shaft deflection. Twin/Double Volute design
consists of two 180 volutes a passage external to the second joins the two into a
common discharge.

Vaned diffusers for pressure conversion offer the advantages of balanced radial force,
compact size, and peak efficiency at high head and low flow. But they are more difficult
to fabricate and repair than volute pumps.

IMPELLER

Common impellers are enclosed with full discs and shrouds

Semi open impellers have a full back disc but no front shrouds

Fully open impellers have vanes but little or no disc material. They are employed
accordingly in low - head, solids - handling service.

Impeller can be clasified by the shape, and form of their vanes.

1. Straight vane impeller :

The vane surfaces are generated by straight lines parallel to the axis of rotation.
These are also called single curvature vane.

2. Francis - vane impeller :

The vane surfaces of francis - vane impeller have double curvature lower
specific speeds less than 4200 are called francis vane impeller.

FICHTNER India

FORM T10 REV - A

3. Mixed flow impeller :

An impeller design that has both a radial and axial flow components is called a
mixed-flow impeller. It is generally resticated to single - suction design with a
specific speed above 4200.

4. Propeller or axial flow impeller :

Mixed flow impellers with a very small radial flow components are usually
referred to as propellers. In a true propeller or axial-flow impeller the flow strictly
parallels to the axis of rotation.

Further the impeller can be clasified into (a) Single - suction impeller (b) Double suction
impeller

In a single-suction impeller, the liquid enters the suction eye on one side only. As a
double-suction impeller, the liquid enters the impeller simultaneously from both sides.

Wearing Rings

Wearings are generally fitted at the close - clearance position in the pump casing and at
an apposing position on the impeller, which allows easy restoration of the design
clearnace to separate the discharge pressure zone of the pump from the suction
pressure areas and to minimise back leakage. Many high - pressure centrifugal pumps
are fitted with wearing rings at the back sides (disc) of the impeller. This reduces the
thrust force on the impeller, at the same time minimizing the stiffing box pressure.

Nozzles

Many horizantal pumps all provided with suction and discharge nozzles on the top of the
casings. In some horizontal pumps, suction nozzles are located at the end of the pump
co-axial with the shaft centre line. In horizontally split pumps positioning of the nozzles in
the bottom half of the casing so that the bottom half does not have to be disturbed
during maintenance.

Stuffing boxes

Stuffing boxes have the primary function of protecting the pump against leakage at the
point where the shaft passes out through the pump casing. If the pump handles a
suction lift and the pressure at the interior stuffing box end is below atmospheric, the
stuffing box function is to prevent air leakage in to the pump. If this pressure above
atmospheric, the function is to prevent liquid leakage out of the pump. Conventional
stuffing boxes are filled with either packing material, such as braided rope or with a
mechanical shaft seal.

Bearings

The function of bearings in the centrifugal pumps is to keep the shaft or rotor in correct
alignment with the stationary parts under the action of radial and transverse loads.
Those that give radial positioning to the rotor are known as line bearings, where as
those that locate the rotor axially are called thrust bearings. All types of bearings have
been used in centrifugal pumps.

DIFFERENCE BETWEEN HORIZONTAL PUMPS & VERTICAL PUMPS

FICHTNER India

FORM T10 REV - A

HORIZONTAL VERTICAL

1 Shaft orientation is horizontal (ex.) End
suction, Horizontal split
Shaft orientation is vertical (ex.)
vertical turbine pump, vertical
condensate pump etc.

2 Pump supported by casing & foot
support
Pump supported by suspended
column

3 Location of suction nozzle can be end,
side, bottom or top suction
Only bottom suction is possible.

4 Occupies more floor space

Less floor space is requried
5 Mechanical cost :

Cost of pump-motor set is low Cost of pump-motor set is high (2 to 3
times)

Installation cost is low Installation cost is high

cost of piping & valves is higher for all
application due to additional shut off
valve and expansion bellow in the
suction line.

The same is not required.

6 Civil cost : (2 to 6 times more)

For all application horizontal pumps
have to be located below the minimum
water level of respective reservoir to
facilitate flooded suction of pump and
this requires excavation (Dry pit) of
soil adjacent to respective reservoir
sump.

Vertical pumps can be directly located
inside the respective reservoir sumps
and requires excavation (sum pit) for
submergence of pump below
minimum water level within the
reservoir sump, which is nominal
compared to excavation required for
horizontal pump dry pit.

Cost of substruction like dry pit for
horizontal pump is high
Cost of substruction like pump resting
slab and sump pit is low.

FICHTNER India

FORM T10 REV - A

HORIZONTAL VERTICAL

Horizantal pumps will have to be
located indoor due to the requirement
of a dry pit and so cost of super
structure is an additional cost. For fire
water pumps cost of super structure is
higher in case of horizantal pumps due
to higher floor space requirements.
Cost of super structure is low
since vertical pump can be located in
outdoor.

7 Other cost :

Other cost like crane rails, electrical
cables, lighting, ventilation etc. will be
higher with horizantal type pump
because of greater length of pump
house.

8 maintenance cost is low Maintenance cost is very high

9 Efficiency is high Efficiency is low due to transmission
loss.

FICHTNER India

FORM T10 REV - A

MERITS/DEMERITS OF PLATE TYPE HEAT EXCHANGERS BLOW DOWN,

General :-
The plate type heat exchanger is an assembly of corrugated plates held between the
stationary and follower plate with the help of long tie bolds.

Classifications of plate heat exchanger
a. Gasketted plate heat exchanger
b. Semi-welded plate heat exchanger
c. Double wall plate heat exchanger
d. Wide gap plate heat exchanger
e. Flow flex, the tubular plate heat exchanger
f. Graphite, plate heat exchanger
g. Plate evaporator
h Brazed plate heat exchanger
i. Fully - welded plate heat exchanger
Merits of plate heat exchanger
Low investment cost : High efficiency and their sheet Materials result in
economical units, practically when expensive
Materials are required.

Easy Maintenance : A PHE can generally be cleaned by operating the unit
with chemical detergents for a short period. Should a
heat exchanger need to be opened for inspection or
cleaning, the heating surface is 100% accessible
simply by removing the tightening bolts.

Small space requirement : The PHE is extremely compact in design, relation to
its capacity and it does not require any extra space
for service or Maintenance.
Great Thermal Efficiency
/close : Plate pattern are designed to induce a high degree of
Temperature Approach turbulence which reduces
fouling and improves heat transfer. This high
turbulence in full counter current flow makes it
economically feasible to use temperature
approaches down to 1C

Flexibility : With in a couple of hours, the PHE can be
redesigned simply by adding, removing or
rearranging plates within the length of the frame.
Extended frame capacity can be supplied if the
original capacity is expected to increase radically.
Lower Cooling Water
FICHTNER India

FORM T10 REV - A

Flow Rate : Owing to identical channel geomentries as well as
high thermal efficiency for both fluids, the PHE
greatly reduces the cooling water flow rate. This in
turn means lower installation costs for piping, valves
and pumps.

Low hold up volume : The thin channels mean that the liquid volume is low
in comparison to other types of heat exchangers.
This ensure quick process control and reduces total
installation weight.

Low weight : The compact design and their plate materials
contribute to a low weight heat exchanger. A higher
weight heat Exchanger in turn requires smaller
foundations.

No vibrations : The Metal to Metal contact between plates means a
rigid plate free from vibrations.

No welds : The absence of welds considerably reduces
expensive non-destructive test procedures.

Demerits of Plate heat Exchangers

Pressure drop : Pressure drop across the fluid is high when
compared to shell & tube type.

Cost : Slightly higher when lower grade material are used
(such as carbon steel).

Pressure : Not suitable for high pressure service

Application : PHE is not used in condensing plant, vapourising,
super heating system.

: Gaseous fluids not recommend to use in PHE
FICHTNER India

FORM T10 REV - A

Gasket Material Selection with respect to Temperature & Application :-

Gasket Material Max. Temp. C Application

Nitrite rubber 135 Fatty Materials
Butyl rubber 150 Aldehydes, Ketones &
esters.
Ethylene propylene
rubber
150 High temp resistance
to a variety of
chemicals
Viton 175 Minerals, vegetable &
animal oils, fuels
Compressed asbestos 260 Organic solvents
eg. chlorinated
hydrocarbons.

FICHTNER India


WATER COOLED SURFACE CONDENSER SIZING

Introduction

Power plant condenser receives exhaust steam from the low pressure turbine and
condenses it to liquid for reuse. The surface condenser serves three important
functions :

# Provides a low back pressure at the turbine exhaust to maximise plant
thermal efficiency and reduce the heat rate.

# Conserves the high purity water for reuse in the boiler-turbine system to
minimise water treatment costs.

# Deareates the condensate to minimise corrosion potential in the balance of
the power system components, and

# Serve as a collection point for all condensate drains.

Design consideration

The base thermal load to be handled by condenser is set by the turbine heat balance
at maximum load conditions. Unless otherwise specified, the condenser duty for
turbine service is assumed to be the product of the steam flow in kg/sr and 527
kcal/kg.

Condenser back pressure usually range from 0.034 to 0.152 bar with higher
pressures possible where the cooling water temperature is elevated.

Condensers are also sized to handle transient thermal load conditions which can
exceed the maximum load conditions which would be part load or full load turbine
steam bypass to the condenser from the boiler.

Cooling water velocity can be in the range of 2 to 2.4 m/s taking into consideration
fouling, water quality, erosion potential and tube material. Velocity below 0.9 m/s are
not recommended because of the potential for poor tube side flow distribution.

The cooling water temperature increase is frequently between 8 and 14C. It is very
important to take care in the design of condenser, is the minimum terminal
temperature difference. The minimum terminal temperature difference shall not be
less than 3C.

Bifouling resistance and high thermal conductivity as well as resistance to erosion-
corrosion, pitting, crevice corrosion are all considerations in the material selection.
Material with copper alloys present problems in high pressure boiler because of the
potential for copper transport into the boiler and turbine where deposition can occur.

Thermal and hydraulic performance of surface condensers can be obtained from
detailed information provided in standards for steam surface condensers, HEI.

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Q =UA LMTD

T1 - T2
LMTD =
l n (T1 - T2)

A = Do nNL

Where,

A - Surface area - m
2

Do - Outside diameter of tube - m

n - Number of passes

N - Number of tubes - nos.

L - Tube length - m

U - Overall heat transfer coefficient - w/m
2
K

Q - Heat duty - w

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AIR COOLED HEAT EXCHANGER/CONDENSER

C O N T E N T S

SL. NO. DESCRIPTION PAGE NO.

1.0.0 INTRODUCTION 2

2.0.0 GENERAL SYSTEM DESCRIPTION 2

3.0.0 TECHNICAL CONSIDERATIONS 3

4.0.0 DESIGN CONSIDERATIONS 4

5.0.0 INPUT DATA TO DESIGN THE COOLING SYSTEM 6

6.0.0 CODES & STANDARDS 7

7.0.0 TUBE BUNDLE 7

8.0.0 FORCED AND INDUCED DRAFT 10

9.0.0 AIR FLOW CONTROL 12

10.0.0 AIR COOLED HEAT EXCHANGER COST 13
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AIR COOLED HEAT EXCHANGER/CONDENSER

1.0.0 Introduction

A large quantity of heat is generated in various industrial processes including those in
power generation industries. This heat must be disposed off continuously,resulting in
a heavy demand for heat exchangers. If large quantity of good quality fresh water is
available from a cheap source, the same can be fed once through the heat
exchangers and can take away the heat from the processes and equipments.

Due to the increasing cost of good quality fresh water and also the decreased
availability in sufficient quantities at various plant locations ,continuous supply of fresh
cooling water to the industrial plants and processes becomes more and more an
acute problem, and hence the available fresh water can rarely be wasted. Thus it is
necessary to use an internal circuit of fresh cooling water as the heat transfer
medium which picks up the heat from the processes and equipments in the plant and
consequently has to be cooled again for recirculation.

Therefore the best solution for fresh water cooling is by an Air Cooled Heat
Exchanger.

Definition of Air cooled heat exchanger

The circulating fresh water is cooled indirectly by air in a heat exchanger in which the
water passes inside tubes which are finned on the outside in order to obtain surface
extension. The water is indirectly cooled by means of air which is forced through the
heat exchanger by fans.

2.0.0 General System Description
Air cooled Heat Exchanger includes a tube bundle, which generally has fins over the
tubes, and a fan, which moves air across the tubes and is provided with a driver.
Electric Motors are the most commonly used drives; typical drive arrangements
require a V-belt or a direct coupled. A plenum and structural supports are basic
components. Louvers are often used.

The system also includes a vacuum equipment system, a condensate receiver,
pumps and a control system. Designing an Air cooled exchanger/condenser considers
a lot of optimisation which includes sizing and layout of the main steam duct.

The system works as follows:
At vacuum condition, the steam flows from the turbine exhaust, through large
diameter ducts to the air cooled heat exchangers. The steam distribution manifolds
will guide the steam to the individual steam condenser bundles, where the steam is
condensed against air, forced across the finned tube by large axial fans. Condensate
flows by gravity into the condensate receiver from where it is pumped back to the
boiler feed water system. Air, leaking into the system via turbine glands, etc., is cooled
to the maximum extent and then removed by the vacuum system. The system
consumes no water and require no plenum.

The system shall be designed for automatic control of the turbine back pressure for
the entire range of steam flows and various ambient temperature. The system is
equipped with a number of fans driven by electric motors. The control is achieved by
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switching fan individually or in groups from full to off. With the pressure control system
in operation, a satisfactory variability is obtainable for continuous and stable operation.
Especially in case of minor temperature fluctuation.

As far as performance guarantee test, the extrapolation from the design condition
shall not differ by more than plus or minus ten (10) percent on steam flow quantity and
plus or minus (5) degrees Celsius on air ambient temperature when all fans are
operating at full speed.

The auxiliary power consumption of the direct system being about 1.5% of the unit
power and is approximately 3 times higher than for the indirect system.

With the indirect system the turbine is condensed in a conventional, water cooled
surface condenser and the required cooling water flow is recooled in the closed circuit
via a natural draft dry cooling tower. The condensation heat transported with the
cooling water flow is transferred to the air in the cooling tower. This air heats up and
as a result of the chimney effect of the tower, generates the required cooling air flow.

To quote an example, an article from MPS (Modern power systems,J anuary 1996)
about J andar project.The only water resources in J andar are three wells equipped
with well water pumps.To save this valuable water, an air cooled condenser has been
chosen to condense the turbine exhaust steam or steam from the turbine by-pass.
Condenser is manufactured by ABB-Lummus Heat transfer in the Netherlands.

Exhaust steam from the steam turbine flows through large diameter ducts to the air
cooled condenser. The steam distributed by manifolds is guided to the condenser
heat exchanger bundles consisting of finned tubes. The steam is condensed by
ambient air blown across the finned tubes by forced axial fans. The design value of
the condenser is 65 mm Hg.

The condenser is by far the biggest piece of requirement at site. The size of the
condenser (2 units) is about 100 m x 65 m and the height is 30 m. Its external
surface area is more than 1,000,000 m. There are a total of 40 fans each run by a
200 KW motor and equipped with two speed systems. In normal operation, there is no
need for water, as the heat is rejected to the ambient air One condenser consists of
four roof-type streets of finned tube elements. Twenty large axial flow fans, located
under the roofs force the cooling air through the fins.

3.0.0 Technical considerations

Adequate optimisation of system does not merely compare different cooling systems
concerning the investment,operating and maintenance cost, but must also consider
the turbine design and differences in turbine investment too.

A Steam Turbine which is linked to a wet cooling system is subject to a relatively low
backpressure variations, whereas a steam turbine which operates together with a dry
cooling system has to cope with considerable backpressure differences depending on
the higher fluctuation of the air temperature. Thus, the design of turbine, particularly
the design of the LP section has to match the selected cooling system.

Higher back pressure levels result in smaller dimensions of the end blades and vanes
of the LP turbine and entail lower turbine investment cost. The difference in cost
between a dry cooling turbine and wet cooling turbine is an input of the
optimisation program.

Further to the turbine characteristic, the ambient air temperature range through a year
is an important input for the evaluation of dry cooling against wet cooling or the
evaluation within different dry cooling system. The consideration of merely the
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average annual air temperature for dry cooling optimization and design is completely
inadequate, as far as large power plants are concerned.

To find the best suitable size of an air cooled condenser or indirect system with dry
cooling tower the duration of the different prevailing air temperature has to be taken
into account together with the turbine characteristic and the planned number of
operating hours.

Hence an optimisation study shall be performed in co-operation with the turbine and
ACC supplier, looking at temperature frequency curves for the area, load
characteristics and turbine back pressure. This will result in a set of design parameter
that will form the basis of design.

4.0.0 Design Considerations

4.1.0 Design Dry Bulb Temperature :

The typically selected value is the temperature which is equaled or exceeded 2
percent of the time during the warmest consecutive 4 months. Since air temperatures
at industrial sites are frequently higher than those used for these weather-data
reports, it is good practice to add 1 to 3 C to the tabulated value.

4.2.0 Air Recirculation

Prevailing winds and the locations and elevations of buildings, equipment, fired
heaters, etc., require consideration. All air-cooled heat exchangers in a bank are of
one type, i.e, all forced-draft or all induced-draft. Banks of air cooled exchangers must
be placed far enough apart to minimise air recirculation.

4.3.0 Wintertime Operations

For winterization problems, provision must be made for heavy rain, strong winds,
freezing of moisture upon the fins, etc.,

4.4.0 Noise

Two identical fans have a noise level 3 dBa higher than one fan, while eight identical
fans have a noise level 9 dB(a) higher than a single fan. Noise level at the plant site is
affected by the exchanger position, the reflective surfaces near the fan, the hardness
of these surfaces, and noise from adjacent equipment. The extensive use of air
cooled heat exchangers contributes significantly to plant noise level.

4.5.0 Ground Area and Space Requirements

Comparisons of the overall space requirements for plants using air cooling versus
water cooling are not consistent. Some air-cooled units are installed above other
equipment - pipe racks, shell and tube exchangers etc. Some plants avoid such
installation because of safety considerations.
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4.6.0 Safety

Leaks in air cooled units are directly to the atmosphere and can cause fire hazards or
toxic-fume hazards. However, the large air flow through an air cooled exchanger
greatly reduces any concentration of toxic fluids.

Segal [pet. refiner, 38, 106 (April 1959)] reports that air-fin coolers are not located
over pumps, compressors, electrical switchgear, control houses and, in general, the
amount of equipment such as drums, shell and tube exchangers located beneath
them are maximized.

Pipe rack mounted Air Cooled Heat Exchangers with flammable fluids generally have
concrete fire decks which isolate the exchangers from the piping.

4.7.0 Atmospheric Corrosions

Air cooled heat exchangers should not be located where corrosive vapours and fumes
from vent stacks will pass through them.

4.8.0 Air Side Fouling

Air-side fouling is generally negligible.

4.9.0 Process-side Cleaning

Either Chemical or Mechanical cleaning on the inside of the tubes can readily be
accomplished.

4.10.0 Process-side Design Pressure

The high pressure process fluid is always in the tubes. Tube side headers are
relatively small as compared with water cooled units when the high pressure is
generally on the shell side. High pressure design of rectangular headers is
complicated.

The plug type Header is normally used for design gauge pressures to 13790 Kpa
(2000 lb/in
2
) and has been used to 62000 Kpa (9000 lb/in
2
). The use of threaded
plugs at these pressures creates problems. Removable cover plate Headers are
generally limited to gauge pressures of 2068 Kpa (3000 lb/in
2
). The expensive billet
type header is used for high pressure service.

4.11.0 Bond Resistance

Vibration and thermal cycling affect the bond resistance of the various types of tubes
in different manners and thus affect the amount of heat transfer through the fin tube.

4.12.0 Approach Temperature

The approach temperature, which is the difference between the process-fluid outlet
temperature and the design dry-bulb air temperature, has a practical minimum value
of 8 to 14 C. When a lower process-fluid outlet temperature is required, an air-
humidification chamber can be provided to reduce the inlet air temperature toward the
wet bulb temperature. A 5.6 C approach is feasible. Since typical summer wet bulb
design temperatures in the United States are 8.3 C lower than dry bulb temperatures,
the outlet process-fluid temperature can be 3 C below the dry bulb temperature.

4.13.0 Mean-temperature-difference (MTD) Correction Factor

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When the outlet temperatures of both fluids are identical, the MTD Correction factor
for a 1:2 shell and tube exchanger (one pass shell side, two or more passes tube
side) is approximately 0.8. For a single pass air cooled heat exchanger the factor is
0.91. A two pass exchanger has a factor of 0.96, while a three pass exchanger has a
factor of 0.99 when passes are arranged for counterflow.

4.14.0 Maintenance Cost

Maintenance for air cooled equipment as compared with shell and tube coolers
(complete with cooling towers costs) indicates that air-cooling maintenance costs are
approximately 0.3 to 0.5 those for water cooled equipment.

4.15.0 Operating Costs

Power requirements for air cooled heat exchangers can be lower than at the summer
design condition provided that an adequate means of air-flow control is used. The
annual power requirement for an exchanger is a function of the means of air flow
control, the exchanger service, the air temperature rise, and the approach
temperature.

When the mean annual temperature is 16.7C lower than the design dry-bulb
temperature and when both fans in a bay have automatically controllable pitch of fan
blades, annual power required has been found to be 22, 36 and 54 percent
respectively of that needed at the design condition for three process services.

Alternatively, when fans have two speed motors, these deliver one half of the design
flow of air at half speed and use only one-eighth of the power of the full-speed
condition.

5.0.0 Input data to design the cooling system

i) Generated power

ii) Steam flow

iii) Condensing pressure & Temperature

iv) Rejected heat (total)

v) Design dry bulb temperature

vi) Design wet bulb temperature

vii) Relative humidity

viii) Design Steam Pressure & Temperature.

ix) ITD : Initial temperature difference is the main design parameters of the dry
cooling system.

x) Space Limitations

xi) Tube Details

a) Tube Diameter
b) Tube Material

xii) Fin Details
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a) Fin Type
b) Fin Height
c) Fin Thickness
d) Fin Material

xiii) Forced Draft/Induced Draft

xiv) Noise Level

6.0.0 Codes & Standards

API 661.

7.0.0 Design Description

7.1.0 Tube Bundle

The principal parts of the tube bundle are the finned tubes and the header.

Most commonly used is the plug header which is a welded box. The second most
commonly used header is a cover plate header. The cover plate is bolted to the top,
bottom and end plates of the header. Removing the cover plate provides direct
access to the tubes without the necessity of removing individual threaded plugs.

Other types of headers include the bonnet type header, which is constructed similarly
to the bonnet construction of shell and tube heat exchangers ; manifold type headers,
which are made from pipe and have tubes welded into the manifold; and billet type
headers, made from a solid piece of material machined channels for distributing the
fluid. Serpentine type tube bundles are some times

used for very viscous fluids. A single continuous flow path through pipe is provided.
Tube bundles are designed to be rigid and self contained and are mounted so that
they expand independently of the supporting structure.

The face area of the tube bundle is its length times width. The net free area for air
flow through the bundle is about 50% of the face area of the bundle. The standard air
face velocity (FV) is the velocity of standard air passing through the tube bundle and
generally ranges from 1.5 to 3.6 m/s.

7.2.0 Tube Bundle Design Temperature

The maximum and minimum design temperature and minimum design metal
temperature for pressure parts shall be specified by the purchaser.

1. #For pressure parts that are not tubes and that are constructed of carbon and low
alloy steel as indicated in Section-VIII, Division.1, Part UCS of the ASME code, the
maximum design temperature shall be atleast 343C ; if otherwise dictated by
flange ratings, the maximum design temperature shall be atleast the specified
process fluid inlet temperature plus 28C.

For pressure parts that are not tubes and that are constructed of materials other
than those indicated in (1) #, the maximum design temperature shall be the
specified process fluid inlet temperature plus 28C.

The design temperature for pressure parts, as listed on the air cooled heat
exchanger specification sheet, are intended to govern fin type selection or to apply
in determining exposure temperatures of mechanical and instrumentation
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components. The purchaser, shall separately specify the maximum operating
temperature to be applied for fin type selection (the fin design temperature).

7.3.0 Tube Bundle Design Pressure

# The design pressure shall be specified by the purchaser

# If the design pressure is not specified, it shall be the greater of the following

a) The inlet pressure plus 10 per cent

b) The inlet pressure plus 25 pounds per sq.inch (172 kilo pascals).

The diameter of the plug holes shall be equal to the nominal outside diameter of the
tube plus atleast 0.8 mm.

7.4.0 Tubes

The recommended minimum tube outside diameter is 25.4 mm. Fin heights vary
from 12.7 mm to 15.9 mm, fin spacing from 3.6 mm to 2.3 mm (7 to 11 per linear
inch) and tube triangular pitch from 50.8 to 63.5 mm. Ratio of extended surface to
bare tube outside surface varies from about 7 to 20. The 38 mm (1) tube has been
used for flue gas and viscous oil service. Tube size, fin heights and fin spacing can
be further varied.

Tube lengths vary and may be as great as 18.3 m (60 ft). when tube length exceeds
12.2 m (40 ft), three fans are generally installed in each bay. Frequently used tube
lengths vary from 6.1 to 12.2 m (20 to 40 ft).

The total unfinned length of a finned tube between tube sheets after assembly shall
not exceed 1.5 times the thickness of one tube sheet.

The wall thickness for tubes with an outside diameter of 1-1 (25.4 - 38.1 mm) shall
not be less than the following.

For embedded fin tubes, the thickness furnished below shall be measured from the
bottom of the groove.

A) For carbon steel or ferritic low alloy steel (maximum 9 percent chrome),
2.11 mm

b) For high alloy (Austenitic and ferritic steel), 1.65 mm

c) For non ferrous material, 1.65 mm

d) For titanium, 1.24 mm

Greater wall thickness may be appropriate for severe services or certain tube
configurations.

The type of construction furnished shall be demonstrated by the vendor to be suitable
for the intended service conditions as defined by such factors as metal temperature,
cycling, loss of cooling, effect of environment, and any specified abnormal operating
conditions.

Finned Tube Construction
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The following are several types of commonly used finned tube construction.

a) Embedded construction in which aluminium fin with a rectangular cross
section is wrapped under tension and mechanically embedded in a groove
0.25 0.05 mm in depth, spirally cut into the outside surface of the tube.
Tube wall thickness is measured from the bottom of the groove to the inside
diameter of the tube.

b) Integral construction, in which fins are formed by extrusion from an,
aluminium outer tube that is mechanically bonded to an inner tube or liner.

c) Overlapped, footed construction, in which an L-shaped aluminum fin is
wrapped under tension over the outside surface of a tube, with the tube fully
covered by the overlapped feet under and between the fins. The fin end at
each end of the tube shall be secured to prevent loosening or unravelling of
the fins by a cast zinc collar 12.5 mm in width.

d) Footed construction, in which an L-shaped aluminum fin is wrapped under
tension over the outside surface of a tube, with the tube fully covered by the
feet between the fins. The fin end at each end of the tube
shall be secured to prevent loosening on unravelling of the fins by a cast zinc
collar 13 mm in width.

e) Externally bonded construction, in which fins are bonded to the outside
surface of tubes by hot-dip galvanising, brazing or welding.

For fins that are wrapped under tension or embedded and that have fin heights not
exceeding 12 mm, the minimum stock thickness shall be 0.35 mm. For those that
have fin heights exceeding 12 mm the minimum stock thickness shall be 0.40 mm.

7.5.0 Constructional Aspects

#Flattening in the bend of U tubes shall not exceed 10% of the tubes nominal
outside diameter.

#When U bends formed from tube materials with low ductility or materials that are
susceptible to work hardening may require special consideration. If cold working
induces embrittlement or susceptibility to stress corrosion in some materials or
environments, then heat treatment should be considered.

Typical metal design temperatures for these finned tube constructions are 399C
embedded, 288C integral, 232 C overlapped footed and 177 C footed. Tube ends
are left bare to permit insertion of the tubes into appropriate holes in the header or
tube sheets. Tube ends are usually roller expanded into these tube holes.
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7.6.0 AIR SIDE DESIGN

Environmental factors such as weather, terrain, mounting, and adjacent buildings and
equipment influence the air side performance of an air cooled heat exchanger. These
factors shall be notified to the Vendor/Bidder for consideration in the air side design.

Fan selection at design condition shall ensure that at constant speed the fan can
provide by an increase in blade angle, a 10% increase in air flow and a corresponding
pressure increase. Since this requirement is to prevent stall and in
efficient operation of the fan, the resulting increased power requirement need not
govern the drive rating.

The vendor may estimate the design exposure temperature for mechanical
components by conventional heat transfer analyses and submit the same for approval
from consultant. As an alternative, these temperatures may be estimated by the
following and furnished to the Bidder/Vendor.

a) The minimum design exposure temperature for mechanical and
instrumentation components located above the tube bundle shall be equal to
or greater than the following values :

1. The maximum process inlet temperature less 56C. (The maximum
process inlet temperature is not the mechanical design temperature).

2. The heating coil inlet temperature less 56C. (The heating coil inlet
temperature is not the heating coil mechanical design temperature).

3. For units with exhaust air louvers, automatically controlled pitch fans,
or two speed fan motors, the inlet temperature stated above less
28 C.

In no case shall the minimum design exposure temperature be less than the design
dry bulb temperature.

b) The minimum design exposure temperature for mechanical and
instrumentation components located below the tube bundle shall be equal to
or greater than the following values.

1. The maximum process inlet temperature less 200F (111C) (The
maximum process inlet temperature is not the mechanical design
temperature).
2. The heating coil inlet temperature less 200F (111C) (The heating
coil inlet temperature is not the heating coil mechanical design
temperature).

3. For units exhaust air louvers, automatically controlled pitch fans, or
two speed fan motors, the inlet temperatures stated above less 100F
(56C).

8.0.0 Forced and induced draft

The forced draft unit, pushes air across the finned tube surface. The fans are located
below the tube bundles. The induced draft design has the fan above the bundle, and
the air is pulled across the finned tube surface. In theory, a primary advantage of the
forced draft unit is that less power is required. This is true when the air temperature
rise exceeds 30C.

Air cooled heat exchangers are generally arranged in banks with several exchangers
installed side by side. The height of the bundle above ground must be one half of the
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tube length to produce an inlet velocity equal to the face velocity. This requirements
applies both to ground mounted exchangers and to those pipe rack installed
exchangers which have a fire deck above the pipe rack.

The forced draft design offers better accessibility to the fan for on stream
maintenance and fan blade adjustment. The design also provides a fan and V belt
assembly, which are not exposed to the hot air stream that exits from the unit.
Structural costs are less and mechanical life is longer.

Induced draft design provides more even distribution of air across the bundle, since
air velocity approaching the bundle is relatively low. This design is better suited for
exchangers designed for a close approach of product outlet temperature and ambient
air temperature.

Induced draft units are less likely to recirculate the hot exhaust air since the exit air
velocity is several times that of the forced draft unit. Induced draft design more readily
permits the installation of the air cooled equipment above other mechanical
equipment, such as pipe racks or shell and tube exchangers.

8.1.0 FANS

Two or more fans aligned in the direction of tube length shall be provided for each
bay. Single fan arrangements are acceptable when agreed on by the
Consultant/Purchaser and vendor.

#Fans shall be of the axial flow type, Axial flow types fans are large volume, low
pressure devices. Each fan shall be sized so that the area occupied by the fan is
atleast 40 percent of the bundle face area served by that fan.

#Fan diameters are selected to give velocity pressures of approximately 2.5 mm of
water. Total fan efficiency (fan, driver and transmission device) is about 75 percent
and fan drives usually have a minimum of 95 percent mechanical efficiency.

#Usually fans are provided with four or six blades. Larger fans may have more
blades. Fan diameter is generally slightly less than the width of the bay.

#The axial flow fan is inherently a device for moving a consistent volume of air when
blade setting and speed of rotation are constant. The variation in the amount of air
flow can be obtained by adjusting the blade angle of the fan and speed of rotation.
The blade angle can be either a) permanently fixed b) hand adjustable or c)
automatically adjusted. Air delivery and fan power are a direct function of blade pitch
angle.

# Fan mounting should provide a minimum of one-half to three-fourths diameter
between fan and ground on a forced draft heat exchanger and one half diameter
between tubes and fan on an induced draft cooler.

#Fan blades can be made of aluminum, molded plastic, laminated plastic, carbon
steel, stainless steel, and monel.

#Fan noise level shall be in accordance with API recommended practice 631 M.

At the fan tip speed required for economical performance, a large amount of noise is
produced. The predominant source of noise is vortex shedding at the trailing edge of
the fan blade. Noise control of air-cooled exchangers is required by the Occupational
Safety and Health Act (OSHA) API 661 has the purchaser specifying sound pressure
level (SPL) values per fan at a location designated by the purchaser and also
specifying sound power level (PWL) values per fan. These are designated at the
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following octave band center frequency 31, 63, 125, 250, 500, 1000, 2000, 4000 &
8000 and also the dB (A) value (the dB(a) is the weighted single value sound
pressure level).

Reducing the fan tip speed results in a straight-line reduction in air flow while the
noise level decreases. The API Std 661 limits fan tip speed to 61 m/s for typical
construction. Fan design changes which reduce noise include increasing the number
of fan blades, increasing the width of the fan blades and reducing the clearance
between fan tip and fan ring. In no case shall fan tip speed exceed 81 m/s.

8.2.0 Fan Ring and Plenum Chambers

The air must be distributed from the circular fan to the rectangular face of the tube
bundle. The air velocity at the fan is between 3.8 and 10.2 m/s. The plenum chamber
depth (from fan to tube bundle) is dependent upon the fan dispersion angle which
should have a maximum value of 45.

Fan performance is directly affected by the increased clearance between fan ring and
blade tip and adequate provision in design must be made for the reduction in air flow.

API 661 requires that fan tip clearance be a maximum of 0.5 percent of the fan
diameter (for diameters between 1.9 and 3.8 ) max. clearance in 9.5 mm for smaller
fans and 19 mm for larger fans.

The depth of the fan ring is critical. Worsham (ASME, Pap 59-PET-27 Petroleum
Mechanical Engineering Conference, Houston, 1959) reports an increase in flow
varying from 5 to 15 percent with the same power consumption when the depth of a
fan ring was doubled. The percentage increase was proportional to the volume of air
and static pressure against which the fan was operating. When making a selection,
the stall out condition, which develops when the fan cannot produce any more air
regardless of power input, should be considered.

9.0.0 Air Flow Control

Process operating requirements and weather conditions are considered in
determining the method of controlling air flow. The most common methods include
simple On-Off control, On-Off step control (in the case of multiple-driver units), two
speed motor control, variable speed drivers, controllable fan pitch, manually or
automatically adjustable louvers, and air recirculation.

Winterization is the provision of design features, procedures, or systems for air cooled
heat exchangers to avoid process fluid operating problems resulting from low-
temperature inlet air. These include fluid freezing, pour point, wax formation, hydrate
formation, laminar flow and condensation at the dew point (which may initiate
corrosion).

10.0.0 Air cooled heat exchanger cost

Table

Sl.
No.
Description Value 1 Value 2 Value 3 Value 4 Value 5
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1 Surface (bare tube),
Sq.Ft

500

1000

2000

3000

5000
2 Cost of 12 row deep
bundle, dollars/sq.ft

9.0

7.6

6.8

5.7

5.3
3 Factor for bundle
depth

6 rows
4 rows
3 rows

1.07
1.2
1.25

1.07
1.2
1.25

1.07
1.2
1.25

1.12
1.3
1.5

1.12
1.3
1.5

Base : Bare-Tube external surface 1 in O.D by 12 BWG by 24 ft Steel tube with 8
aluminium fins per inch 5/8 in high, steel headers 150 lb/sq in design
pressure. V-belt drive and explosive-proof motor. Bare tube surface 0.262
sq.ft/ft. Fin tube surface bare tube surface ratio is 16.9.

Factor : 20 ft tube length 1.05
30 ft tube length 0.95
18 BWG admiralty tube 1.04
16 BWG admiralty tube 1.12

Note : To convert feet to metres, multiply by 0.3048
To convert sq.ft to sq.m, multiply by 0.0929

The cost data that appear in table are unchanged from those published in the 1963
edition of perrys handbook. In 1969 Guthrie [Chem Eng., 75, 114 (Mar, 24, 1969)]
presented cost data for field-erected air cooled exchangers. These costs are only
25% greater than those of table and include the costs of steel stairways, indirect sub-
contractor charges, and field-erection charges. Since minimal field costs would be
this high (i.e 25% of purchase price), the basic costs appear to be unchanged.
(Guthrie indicated a cost band of plus or minus 25%).

Book Reference :
1) Perrys Chemical Engineers Handbook.
2) API 661
3) Technical Papers.

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F
O
R
M
T
1
0

R
E
V
-
B

GUIDE LINES ON BASIC DESIGN ASPECTS FOR FIRE PROTECTION SYSTEM

1.0.0 INTRODUCTION

1.1.0 Fire protection systems are installed in various industries like power plants, petrochemical
complexes, chemical manufacturing units, textile plants, pulp-paper mills, automobile industry
etc. and commercial / housing complex to protect high and low value assets, costly chemicals,
raw materials, processed goods etc. from fire hazards occurring due to

a. Ignition of flammable liquids, grease, solvents and the like.
b. Fault or short circuit in electrical equipment.
c. Burning of ordinary combustibles like wood, cloth, paper and the like.
d. Fire in gaseous substances under pressure.
e. Fire in reactive chemicals, active metals and the like.
f. Fire in electrical equipment like transformers, oil switches, motors, cable trays and cable
runs.

1.2.0 The fire protection system is generally designed to fight two fires simultaneously.

1.3.0 The fire protection system has two main functions :

a. To detect fire and create an alarm through fire detection and alarm system
b. To control and extinguish fire by fire fighting equipment / system

1.4.0 Though fire protection system are installed in various industries and commercial / residential
complex, this design basis covers the fire protection system only for power and chemical
plants.

2.0.0 FIRE FIGHTING SYSTEM

2.1.0 Following fire fighting systems are used in industries either individually or in combinations
depending on the type and intensity of hazards.

a. Fire water system
- Fire hydrants system
- Sprinkler system
- Water spray system

b. Foam system

c. Gas based fire extinguishing system

- CO
2
flooding system
- Halon alternate system
- FM200 system

d. First aid fire fighting equipment

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2.2.0 Fire Water System

2.2.1 Fire water system uses water for fire extinguishing, fire control, cooling of equipment and
protection of equipment and personnel from heat radiation. For these purposes water is used
in various forms such as straight jet, water fog, water curtain, water spray, deluge/sprinkler,
foam etc. The main components of the Fire water system are fire water storage tank, fire
water pumps and distribution piping network.

2.2.2 Hydrant System

Fire hydrant system is provided for entire plant protection and is complete with fire hydrants,
hoses, branch pipes and nozzles. The design of the hydrant piping network shall be as per
the stipulations of Tariff Advisory Committee (TAC). Hydrant points in case of light &
ordinary hazard are generally single headed. Incase of tank farm storing inflammable
chemicals/fuels in a plant classified as ordinary hazard the tank farm area alone shall be
provided with water monitors/double hydrants based on the layout. Based on the equipment
height and provision of staircase for approach etc. monitor/landing valves (single hydrant)
shall be provided.

2.2.3 Water Sprinkler System

Fixed water sprinkler system is generally provided inside buildings for fire extinguishing and
cooling a particular area in case of fire. Some of the area & where sprinkler system are used
are buildings/ sheds storing combustible and flammable materials. The water spray density
and the design of piping system shall be as per TAC regulations. Fixed water sprinkler in most
cases is provided as detection system for medium/high velocity water spray system.

2.2.4 Water Spray System

Water spray system are categorized into High Velocity and Medium Velocity water spray
systems.

The medium velocity water spray system is generally provided for surface cooling to prevent
heat build up. However in case of cable trays it is used for fire extinguishing. Generally
medium velocity water spray system is provided for the following facilities in a power/chemical
plant.

i. Fuel oil/inflammable liquid storage tanks
ii. Cable spreader room
iii. Coal conveyors and handling systems
iv. Fuel/inflammable liquid loading/unloading area.

The high velocity water spray is used for fire extinguishing by formation of inflammable mist
due to emulsion of water droplets and smoke.

High velocity water spray system is provided for the following facilities in a power/chemical
plant.

i. Transformers

ii. Lubrication oil tanks of turbines.

The water spray density and piping design shall be as per relevant TAC regulations. Generally
the medium velocity water spray is tapped off from the hydrant network and the high velocity
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water spray system is independent. However based on the size of the equipment and the
water requirement for various systems, medium velocity water spray may be tapped from high
velocity water spray system.

2.3.0 Gas Based Fire Extinguishing System

Gas based fire extinguishing system is used to protect those equipment on which water based
fire fighting system cannot be used.

Following are the areas where gas based system are widely used.

i) Turbogenerators, switch gear rooms, cable ducts, false ceiling voids, false flooring voids,
control room etc.

ii) Record rooms.

Following system are generally used.

i) Carbon di-oxide system

ii) FM 200 system

iii) NAF SIII system

iv) IGOI system

v) IG 55 system

Carbon-di-oxide systems and FM 200 systems are presently used widely. The other systems
are also being used as alternate systems. However carbon-di-oxide system is not preferred
for areas involving human presence. Relevant NFPA codes shall be followed for design of the
above system. Where codes are not available manufacturers recommendation has to be
followed.

2.4.0 Foam System

Foam system is provided for fighting fuel / inflammable liquid fires. The fire is suppressed by
formation of stable foam on the surface of the burning liquid which cuts off oxygen supply
there by extinguishing the fire.

There are various types of foams available. Broadly they are classified into protein foam and
synthetic foam. Synthetic foams are generally preferable than protein foam.

2.5.0 First Aid Fire Fighting Equipment

First aid fire fighting equipment are provided at convenient locations and shall at all times be
readily accessible and clearly visible. The equipment are.

i. Portable fire extinguishers Dry chemical powder fire extinguishers / carbon dioxide
extinguishers / Soda acid extinguishers.

ii. Wheeled fire fighting equipment wheeled portable water or foam monitor / Foam
compound trolley / Dry chemical power trolley.

iii. Hose reels and accessories.
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3.0 FIRE DETECTION & ALARM SYSTEM

3.1 Fire detection & alarm system is provided for actuation of fire fighting system, warning and
evacuation of plant personnel. The fire detection system responds to four indications of fire
viz. Temperature rise, smoke, flame and gases. However the fire should always be detected
in the incipient stages for effective fire fighting. The fire detection & alarm system should
preferably be addressable analog type on the conventional detection system have proven to
be in effective in Indian conditions.

3.2 Basically there are four types of detectors viz, temperature, smoke, flame and gas detector.
Each type of detector operates on different principle for detecting fire.

In each type of detector there are varieties of detectors categorized based on the principle of
detection.

3.2.1 Heat Detector

The type of heat detectors that are generally available are :

a. Fixed temperature detector.
b. Rate of rise detector.
c. Rate compensation detector.
d. Linear heat serving cable.

The fixed temperature detector are installed where the anticipated rate of rise is not drastic.

The rate of rise detectors are used where the rate of rise is temperature is drastic.

The rate compensation detectors are also used where the rate of rise of temperature is drastic
but it is more reliable than rate of rise detector.

The linear heat sensing cable are basically fixed temperature detectors and are widely used in
places like cable gallery / coal conveyors etc.

3.2.2 Smoke Detector

a. Ionization smoke detector

b. Photoelectric smoke detector

c. Dual chamber smoke detector

The ionization smoke detector is usually effective for invisible particles produced by most fires
and hence are suitable for detection of incipient fires.

Other types are detectors are effective for detection of smoldering fires.

3.2.3 Flame Detector

Following are the types of flame detectors available.

a. Flame flicker detector.

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b. Infra red detector.

c. Photo electric flame detector.

d. Ultra violet detector.

The infra red and ultra violet detectors are the widely used flame detectors which are suitable
for detecting smoldering, static and moving fires.

The comparison chart of UV & IR detector is as follows based on which the detectors can be
selected.

UV IR

Fast Slow, Takes time to discriminate between false
and real fires.

Sensitive Sensitive

Responds to welding Responds to black body

Affected by oil & smoke Not affected by oil & smoke

Better for open flame Bidder for smoldering fires

Affected by gamma / X-ray Affected by CO
2
, C
6
H
6
& Halon

Affected by lightning

Not affected by lightning

3.2.4 Gas Detectors

The types of gas detectors are as follows.

a. Semi conductor gas detector.

b. Catalytic element gas detector.

The gas detectors are provided for detecting inflammable and toxic gases. The selection of
type & detector is generally based on the type of gas prevailing in the area of hazard and as
per manufacturers recommendation.

3.3.0 Fire Detector Selection Guide Given Below Compare the Various Detectors

Type Application Response Limits/Advantages Cost
Photo-
Electric
Office/Control/
Computer rooms
Early warning to
fires (secs)
Must be used indoors where
smoke can be contained. Not
adversely affected by wind.
Moderate
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Ionization Offices/Control/
computer room
combustibles
Early warning to
fast flaming fires
Adversely affected by wind. To
be used indoors.
Moderate
Fixed
tempe-
rature
Large areas
where life safety
is not paramount
Responds when
predetermined
temperature is
reached (min).
Very low false alarm rate.
Simple reliable device.
Low
Rate of
rise
Large areas
where life safety
is not paramount
Responds to a
Specified temp.
Usually faster
than fixed
temperature
type.
Used indoors. Low false alarm
rates. Can be used in
corrosive environments.
Low
Infrared Hazardous
areas ducts / or
dark enclosed
areas
Rapid response
(millisecs)
Indoor use. Affected by other
IR sources.
High
Ultraviolet Hazardous area
fuel loading /
explosion
suppression
Rapid response
(millisecs).
May be blinded by oil film/thick
smoke/arc welding.
High
Gas
detector
Hazardous fuel
oil area
Rapid response
(millisecs).
Indoor use High

4.0 DESIGN STANDARDS FOLLOWED FOR STATUTORY CLEARANCE / APPROVAL OF
VARIOUS FIRE PROTECTION SYSTEMS

Hydrant System - TAC Manual / NFPA 14 / OISD 116/117

Sprinkler System - TAC Manual / NFPA 13 / OISD 116/117

Spray System - TAC Manual / NFPA 15 / OISD 116/117

Foam System - IS 12835 NFPA 11 / NFPA 11A / OISD 116/117

CO
2
Flooding System - IS 6382 / NFPA 12

Halocarbon & Inert - NFPA 2001
Gas Flooding System
(Clean Agent System)

Fire Alarm & Detection System - IS 2189 / NFPA 72 E

Abbreviations

TAC - Tariff Advisory Committee

NFPA - National Fire Protection Association

OISD - Oil Industries Safety Directorate

List of Standards for Reference
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NFPA 11 - Standard for Low Expansion Foam and Combined Agent Systems.

NFPA 11A - Standard for Medium and High Expansion Foam Systems.

NFPA 12 - Standard for Mobile Foam Apparatus.

NFPA 13 - Standard for Installation of sprinkler systems.

NFPA 14 - Standard for the installation of Standpipe & Hose systems.

NFPA 15 - Standard for installation of Water Spray Fixed Systems.

NFPA 16 - Standard for Deluge Foam water Sprinkler and Foam water Spray
systems.

NFPA 16A - Recommended practice for the Installation of closed-head Foam-
Water Sprinkler Systems.

NFPA 18 - Standard on Wetting Agents.

NFPA20 - Standard for the Installation of Centrifugal Fire Pumps.

NFPA71 - Central Station Signaling Systems.

NFPA72A - Local Protective Signaling Systems.

NFPA72B - Auxiliary Protective Signaling Systems.

NFPA72C - Remote Station Protective Signaling Systems.

NFPA72D - Proprietary Protective Signaling Systems.

NFPA72E - Standard on Automatic Fire Detectors.

TAC

Fire Protection Manual - Part I

Fire Protection Manual - Part II

TAC Building Regulations

TAC Regulations for Electrical equipment of Buildings.

OISD

OISD 116 - Fire Protection Facilities for Petroleum Refineries / Process Plants

OISD 117 - Fire Protection Facilities for Petroleum Depots and Terminals.

OISD 156 - Fire Protection Facilities for Port Terminals.

Miscellaneous

API 2001 - Fire Protection in Refineries
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IS 3844 - Code of practice for Installation of Internal Fire Hydrants in Multistory
Building.

FICHTNER India

FORM T10 REV - A

STANDARD TANK SIZE CHART
FLOATING ROOF TANK

Nominal in Height in Nominal J oing Efficiency J oing Efficiency J oing
Efficiency
Diameter Metres Capacity Factor 0.7/0.85 Factor 0.7 Factor 0.85
Metres In m Without corrosion
allowance
Without
corrosion
allowance
Structural steel
Requrement in
Tonns.
Steel plate
requirement in Tonns.
Steel plate
requirement in
Tonns.
8 7.0 302 4.875 19.080 19.080

10 7.5 510 5.555 26.200 26.615
9.0 628 6.605 28.100 28.900

12 7.5 736 6.580 34.100 35.055
9.0 905 7.100 36.800 37.790

16 8.0 1407 8.080 58.460 60.475
10.0 1810 8.675 64.560 68.210
12.0 2212 8.920 70.640 76.575
14.0 2614 9.525 80.380 84.830

20 8.5 2356 7.025 80.515 84.550
10.5 2984 7.680 91.125 97.065
12.5 3612 8.335 101.825 108.910
14.5 4241 8.935 115.535 122.615
16.5 4869 11.570 134.390 144.850

24 8.5 3393 7.855 108.565 133.410
10.5 4298 8.515 121.460 128.125
12.5 5203 9.170 137.895 146.790
14.5 6107 9.845 156.175 166.500
16.5 7012 10.505 176.280 190.265
18.5 7917 11.260 200.135 216.345
20.0 8595 14.760 229.505 245.715

28 9.0 4926 9.110 145.450 153.680
11.0 6158 9.770 162.495 174.540
13.0 7389 10.425 183.820 195.865
15.0 8620 11.080 211.645 226.285
17.0 9852 11.895 241.490 258.045
19.0 11084 12.565 274.670 291.350
20.0 11699 12.895 281.830 311.830

32 9.0 6434 10.365 179.050 188.750
11.0 8043 11.025 209.035 215.545
13.0 9651 11.680 233.665 251.010
15.0 11260 12.335 263.240 282.245
17.0 12868 13.080 313.520 329.060
20.0 15280 13.735 378.685 402.795

Efficiency
FICHTNER India

FORM T10 REV - A

allowance
Without
corrosion
allowance
Structural steel
Requrement in
Tonns.
Steel plate
Steel plate
requirement in
Tonns.

36 9.0 8143 11.540 223.390 233.390
11.0 10178 12.200 253.535 264.970
13.0 12214 12.853 292.795 309.075
15.0 14250 13.510 335.550 351.655
17.0 16296 14.270 385.365 403.820
20.0 19340 14.925 468.450 492.420

40 10.0 11310 13.460 296.925 306.070
12.0 13823 14.120 337.545 353.010
14.0 16336 14.775 389.260 405.720
16.0 18850 15.430 442.850 470.610
18.0 21362 16.290 507.115 533.250
20.0 23876 16.945 586.465 609.785

44 10.0 13685 14.975 352.705 366.365
12.0 16726 15.630 401.480 420.170
14.0 19767 16.290 468.675 478.985
16.0 22808 16.945 534.525 564.200
18.0 25850 17.705 606.780 637.455
20.0 28890 18.460 705.835 723.105

48 10.0 16286 16.242 409.91 428.490
12.0 19905 16.900 472.535 498.415
14.0 23524 17.555 536.695 573.520
16.0 27143 18.210 634.080 652.645
18.0 30762 19.070 724.180 757.650
18.5 31667 19.225 737.335 781.780

50 10.0 17671 17.280 444.935 462.645
12.0 21598 17.935 510.455 529.790
14.0 25525 18.595 592.580 608.380
16.0 29452 19.250 678.930 709.980
18.0 33380 20.110 780.735 807.335
18.5 34361 20.765 809.115 N.A.,

FICHTNER India

FORM T10 REV - A

FIXED ROOF TANK

Efficiency
allowance
Without
corrosion
allowance
Structural steel
Requrement in
Tonns.
Steel plate
Steel plate
requirement in
Tonns.
6 6.0 168 1.440 9.825 9.825
7.5 210 1.950 10.965 10.965
9.0 253 2.155 12.105 12.105

7 6.0 229 1.990 11.735 11.735
7.5 286 2.190 13.065 13.065
9.0 344 2.400 14.395 14.395
10.5 402 2.600 15.725 15.725

8 7.5 374 2.420 15.350 15.950
9.0 450 2.630 16.870 17.470
10.5 525 2.830 18.390 18.990
12.0 600 3.030 19.910 20.510

9 9.0 569 2.890 19.515 19.515
10.5 665 3.090 21.225 21.225
12.0 760 3.300 22.935 22.935
13.5 855 3.495 25.365 25.025

12 9.0 1012 4.875 29.140 29.140
10.5 1182 5.080 31.920 31.460
12.0 1351 5.280 34.745 33.825
14.0 1578 5.545 40.110 37.825
16.0 1804 5.645 45.440 42.240
18.0 2030 6.085 51.275 47.615

14 9.0 1378 6.685 37.740 37.245
11.0 1685 6.950 42.975 41.375
13.0 1993 7.270 48.175 46.575
15.0 2301 7.540 56.040 51.775
17.0 2609 7.810 63.425 58.615
20.0 3071 8.265 76.295 69.355

16 9.0 1800 8.030 48.915 48.915
11.0 2200 8.345 56.285 53.850
13.0 2604 8.615 63.730 61.290
15.0 3006 8.935 71.105 68.665
17.0 3408 9.205 83.515 76.040
20.0 4011 9.600 100.720 90.825
FICHTNER India

FORM T10 REV - A

Efficiency
allowance
Without
corrosion
allowance
Structural steel
Requrement in
Tonns.
Steel plate
Steel plate
requirement in
Tonns.

18 9.5 2405 9.875 61.876 59.506
11.5 2914 10.145 70.556 67.811
13.5 3422 10.415 80.306 76.106
15.5 3932 10.685 91.351 84.486
17.5 4440 11.020 105.226 96.981
20.0 5076 11.340 121.835 110.850

20 10.0 3126 11.590 75.720 72.67
12.0 3754 12.205 86.555 83.505
14.0 4382 12.475 98.940 92.805
16.0 5.10 12.790 114.235 103.555
18.0 5639 13.115 129.655 120.500
20.0 6267 13.385 148.575 134.875

22 10.0 3782 13.690 90.050 87.960
12.0 4542 13.955 103.445 98.10
14.0 5303 14.225 118.625 111.605
16.0 6063 14.545 135.270 127.030
18.0 6823 14.815 155.380 141.650
20.0 7584 15.085 177.155 160.070

24 10.0 4501 14.250 104.095 101.915
12.0 5406 15.920 118.715 115.200
14.0 6310 17.360 136.980 129.675
16.0 7215 19.525 158.920 145.765
18.0 8120 21.980 180.850 166.375
20.0 9025 24.605 206.435 188.155

26 8.5 4486 14.610 107.240 106.755
10.5 5548 15.995 123.075 118.735
12.5 6610 18.610 142.865 134.560
14.5 7672 19.910 164.650 154.900
16.5 2734 22.815 188.410 174.555
20.0 10592 29.065 240.330 212.560

28 8.5 5203 16.855 121.050 120.650
10.5 6435 18.415 142.375 133.430
12.5 7666 20.775 161.550 153.340
14.5 8898 22.740 185.010 174.510
16.5 10129 25.915 214.870 195.857
20.0 12284 33.100 274.360 243.380
FICHTNER India

FORM T10 REV - A

Efficiency
allowance
Without
corrosion
allowance
Structural steel
Requrement in
Tonns.
Steel plate
Steel plate
requirement in
Tonns.

30 8.5 5973 20.150 139.885 133.030
10.5 7387 22.465 158.640 151.960
12.5 8800 25.555 179.480 172.620
14.5 10214 28.675 218.715 195.850
16.5 11628 34.950 246.525 223.840
20.0 14102 41.685 310.000 279.110

32 8.5 6796 24.540 154.865 149.380
10.5 8404 26.850 174.765 169.890
12.5 10013 29.930 211.861 192.355
14.5 11621 33.095 238.755 221.870
16.5 13230 37.090 272.410 254.118
20.0 16045 47.335 359.785 317.065

34 9.0 8126 26.370 103.800 173.515
11.0 9942 29.010 207.750 197.775
13.0 11758 31.840 241.855 225.320
15.0 13573 36.105 283.880 255.380
17.0 15389 41.220 319.265 295.040
20.0 18113 48.610 397.735 356.615

36 9.0 9110 29.570 201.345 193.520
11.0 11146 33.060 232.105 215.115
13.0 13181 36.655 268.370 254.655
15.0 15217 41.640 314.085 288.430
17.0 17253 47.865 364.055 321.005
20.0 20307 56.845 447.150 390.320

38 10.0 11284 330035 218.800 236.605
12.0 13553 36.980 288.875 264.336
14.0 15821 40.130 334.170 312.450
16.0 18089 45.453 388.405 348.795
18.0 20357 51.405 445.255 389.265
20.0 22625 58.665 505.220 458.890

40 10.0 12504 37.315 272.220 256.510
12.0 15017 41.970 313.050 297.805
14.0 17530 45.625 365.220 336.265
16.0 20043 52.010 419.455 374.515
18.0 22557 59.000 482.880 440.205
20.0 25070 67.695 562.270 495.210
FICHTNER India

FORM T10 REV - A

Efficiency
allowance
Without
corrosion
allowance
Structural steel
Requrement in
Tonns.
Steel plate
Steel plate
requirement in
Tonns.

42 10.0 13785 41.355 296.900 283.405
12.0 13556 46.375 346.290 323.805
14.0 19327 49.825 398.350 364.025
16.0 22098 61.275 467.500 422.040
18.0 24867 64.950 535.820 478.210
20.0 27640 71.675 612.180 542.365

44 10.0 15129 46.675 325.133 311.722
12.0 18170 53.710 374.165 350.695
14.0 21211 59.995 442.240 399.700
16.0 24252 77.480 507.165 556.870
18.0 27294 83.945 579.680 521.001
20.0 30335 94.030 679.660 598.265

46 10.0 16536 52.415 342.245 334.405
12.0 19860 59.855 412.810 382.160
14.0 23184 66.135 474.488 435.150
16.0 26507 83.515 546.005 503.940
18.0 29831 90.170 640.307 572.480
20.0 33155 100.050 730.040 643.005

48 10.0 18005 56.830 379.545 36.255
12.0 21624 64.165 443.205 411.090
14.0 25243 70.455 506.620 470.040
16.0 28862 87.925 604.005 530.165
18.0 32482 94.390 695.225 615.445

50 10.0 19537 60.295 411.895 158.950
12.0 23464 69.060 478.625 441.220
14.0 27391 77.515 560.065 510.530
16.0 31318 97.250 646.275 579.565
18.0 35245 104.890 749.125 667.715

FICHTNER India

FORM T10 REV - A

FLOATING ROOF TANK COSTING

FICHTNER India

FORM T10 REV - A

TANK COST ESTIMATE

Basis for Costing

Plate cost per Ton of steel plate 30000.00

Stru. Steel cost per Ton of pltate 26000.00

Fabr. Design cost per Ton of plt. 8090.00

Internal area (painting )m 1539.38

External area (painting )m 1225.22

Internal painting cost per m 225.00

External painting cost per m 215.00

Anti-coro. Painting area m 314.16

Anti-coro. Painting area m 314.16

Structrual painting cost per Ton 4500.00

Foam seal length in m 62.83

Foam seal cost per m length 3030.00

FICHTNER India

FORM T10 REV - A

PROJECT

TANK SIZE

Diameter in m 20
Height in m 14.5
Capacity in m 4241.0

SL.
NO.
DESCRIPTION COST IN RS.

1 Plate requirement in Tonnes 116.52

2 Structural steel requirement in Tonnes 8.995

3 Plate cost for 116.52 Tonnes (@ Rs. 30000 / Ton) 3495600.00

4 Structural steel cost for 8.995 Tonnes
(@Rs. 26000 / Ton) 233870.00

5 Design, Transportation, Fabrication & testing 942646.80
(@ Rs. 8090 / Ton)

6 Structural steel fabrication cost for 8.995 Tonnes
(@ Rs. 3000 / Ton) 26985.00

7 Design, Engineering, Manufacturing, Supply,
Erection and commissioning of emergency drain,
Roof drain, Flame arrester, Consrevation vent, Rim
vents, Bleeder vent, Gauge hatch, Approval from
CCE sheel appurtanenances etc.

8 Painting
Inernal (1539.38 cm Rs. 215 / m) 330966.70
External (1225.22 m Rs. 215 / m) 263422.30
Anti corosive (314.16m Rs. 95/m) 29845.20
Surface preparation & painting strt. 40477.50
(Rs. 4500 / Ton for tons)

9 Foam seal (62.83 m @ Rs. 3030 / m) 190374.90

10 Calibration (Including supply of strapping tapes &
assemblies, labour etc.)
15000.00

11 Erection of Fire fighting arrangement

Foam system 40000.00

Fixed spray water system 150000.00

Total cost in Rs. 6059188.40
FICHTNER India

FORM T10 REV - A

PROJECT

TANK SIZE

Diameter in m 20
Height in m 14.5
Capacity in m 4241.0

SL.
NO.
DESCRIPTION COST IN RS.

1 Plate requirement in Tonnes 116.52

2 Structural steel requirement in Tonnes 8.995

3 Plate cost for 116.52 tonnes 3495600.00
(@ Rs. 30000 / Ton)

4 Structural steel cost for 8.995 Tonnes
(@Rs. 26000 / Ton) 233870.00

5 Design, Transportation, Fabrication & testing 942646.80
(@ Rs. 8090 / Ton)

6 Structural steel fabrication cost for 8.995 Tonnes
(@ Rs. 3000 / Ton) 26985.00

7 Design, Engineering, Manufacturing, Supply,
Erection and commissioning of emergency drain,
Roof drain, Flame arrester, Consrevation vent, Rim
vents, Bleeder vent, Gauge hatch, Approval from
CCE sheel appurtanenances etc.

8 Painting
Inernal (1539.38 cm Rs. 215 / m) 330966.70
External (1225.22 m Rs. 215 / m) 263422.30
Anti corosive (314.16m Rs. 95/m) 29845.20
Surface preparation & painting strt. 40477.50
(Rs. 4500 / Ton for tons)

9 Foam seal (62.83 m @ Rs. 3030 / m) 190374.90

10 Calibration (Including supply of strapping tapes &
assemblies, labour etc.)
15000.00

11 Erection of Fire fighting arrangement

Foam system 40000.00

Fixed spray water system 150000.00

Total cost in Rs. 6059188.40

FICHTNER India

FORM T10 REV A

HEATING COIL SIZE CALCULATION FOR STORAGE TANKS

C O N T E N T S

SL. NO. DESCRIPTION PAGE NO

1. DESIGN PROCEDURE 3

2. TABLES AND FIGURES 8

3. COMPUTER PROGRAM 11

4. MANUAL SAMPLE CALCULATION 14

5. COMPUTER PROGRAM OUTPUT 18

6. THE SOURCE ARTICLE 21

FICHTNER India

FORM T10 REV A


DESIGN PROCEDURE

FICHTNER India

FORM T10 REV A

INTRODUCTION

This calculation is a continuation of the calculation (Heat Loss Calculation for Storage Tanks)
given in document WI-ME-DSN-180-004. Here, the size (Length & diameter) of the coil required
for the compensating the heat loss which is calculated in WI-ME-DSN-180-004 is calculated.

ASSUMPTIONS

1. The coil is fully immersed in the fluid.

2. The fluid inside the coil (fluid in coil) is flowing and the outside fluid is stationary.

NOMENCLATURE USED IN CALCULATIONS

F
tank
- Fluid Inside the Tank.

F
coil
- Fluid Inside the Coil.

Q - Total Heat Loss from storage tank, KW

tF
tank
- Temperature of the fluid in tank, F

tF
coil
- Temperature of the fluid in coil, F

h
fg
- Latent heat of fluid in coil at given pressure & temperature, KJ /kg

V
sp
- Specific volume of fluid in coil at given pressure & temperature m
3
/kg.

T
f
- Film temperature, F.

K
f
- Thermal conductivity of liquid, Btu/hr. ft
2
F

r
- Density of liquid, lb/ft
3

C
pf
- Specific heat of the liquid, Btu/lb F

f
- Dynamic viscosity of the liquid, cP

- Coefficient of thermal expansion, F
-1

m
Fcoil
- Mass flow rate of fluid in coil, m
3
/sec.

V
s
- Velocity of fluid in coil, m/sec.

A
s
- Area required for flow of fluid in coil, m
2

di - Inside diameter of the selected pipe, inch. (From Table-1)
1. DESIGN PROCEDURE
FICHTNER India

FORM T10 REV A

do - Outside diameter of the selected pipe, inch (From Table-1)

h
c
- Heat transfer coefficient for free convection, Btu/hr ft
2
F.

h
io
- Heat transfer coefficient for condensation of fluid in coil,
Btu/hr ft
2
F (Assumed 1500)

V
c
- Clean overall coefficient Btu/hr ft
2
F.

R
d
- Assumed dirt factor, hr.ft
2
F/Btu (From Table-2)

U
D
- Design overall coefficient, Btu/hr ft
2
F.

S - Total Heat transfer area, ft
2
.

- Surface area per linear feet, ft
2
/ft. (From Table-1)

L - Length of the pipe required, ft.

INPUT REQUIREMENTS

The input required are as follows.

1. Heat loss from liquid storage KW.
tank (Q)

2. Fluid F
tank
s Temperature (tF
tank
) F

3. Fluid F
coil
s Temperature (tF
coil
) F

4. Latent heat of fluid in coil (h
fg
) KJ /kg.

5. Specific volume of fluid in coil (V
sp
) m
3
/kg.

T
f
can be calculated as

t
Ftank
+t
Fcoil
F
T
f
= -----------------
2

t
= t
Fcoil
- t
Ftank
F

Physical properties of F
tank
at film temperature T
f
F.

(Refer Ref-1, Ref-2 for properties of different fluids)

6. Thermal conductivity of fluid (K
f
) Btu/hr ft F

7. Density of fluid (
f
) lb/ft
3
.

8. Specific heat of fluid (C
pf
) Btu/lb F

9. Dynamic viscosity of fluid (
f
) cP.

10. Co-efficient of thermal

FICHTNER India

FORM T10 REV A

expansion () F
-1

PIPE SIZE CALCULATION

The mass flow rate of the F
coil
can be calculated as

Q x V
SP

m
Fcoil
= ------------ m
3
/sec
hfg

11. Assumed velocity Vs m/sec.

The area required based on the Assumed velocity (Vs) and mass flow rate (m
Fcoil
) can be
calculated as

A
s
=m
Fcoil
/ V
s
inch
2

Now match this value (As) in the Table-1 and select the nearest flow area available and
corresponding OD, ID and value.

12. Flow area from chart (As) inch
2
.

13. Outside diameter from chart (do) inch.

14. Inside diameter from chart (di ) inch.

15. Heat transfer coefficient
for condensation of fluid in coil () Btu/hr. ft
2
F

The actual velocity has to be calculated for the selected size and has to be verified with
allowable velocity listed in document WI-ME-196-1 for different services.

m
Fcoil
V
A
= -----------
(/4) (di)
2

If V
A
is not with in permissible limits then select a different size and recalculate until a
acceptable value reached.

Heat Transfer Coefficients and Length Calculation :-

Since the coil is immersed in the fluid, and metal wall temperature is almost equal to fluid
temperature. The conductive and radiative heat transfer coefficients are neglected. Only the
convective heat transfer coefficient is calculated.

The dimensional calculation for free convective coefficient h
c
for gasses and liquids is

h
K c
f
t
d
c
f f f
o
=
|
\
|
.
|
|
|
\
|
.
|
(
(
116
3 2
025

'
.
from ref (1)

FICHTNER India

FORM T10 REV A

Where all properties involved in the formula is at film temperature T
f
.

Calculation of the clean overall coefficient U
C

U
h h
h h
c
io c
io c
=

+
Btu/hr. ft
2
F, from Ref (1)

Where h
io
= Heat transfer coefficient for condensation of steam assumed
1500 Btu/hr ft
2
F. For detail discussion refer (Ref 1). Page (301-303).

Calculation of the design overall coefficient U
D

U
U Rd
U Rd
D
C
C
=

+
( / )
( / )
1
1
But/hr. ft
2
f, from Ref (1).

Where Rd is the dirt factor which has to be selected from Table 2.

Calculation of the total surface, S

S
Q
U t
ft
D
=
2
From Ref (1)

Calculation of the length of the pipe, L

L
S
ft =

References :

i. Donald Q Kern, Process Heat Transfer. Mcgraw Hill Book Company, 1965.

ii. C.P. Kothandaraman, Heat and Mass Transfer Data Book

FICHTNER India

FORM T10 REV A

Connected Calculation & Documents :

Sl.
No.
Description

Document No.
1 Heat loss calculation for vertical storage
tanks

: WI-ME-DSN-180-004
2. Allowable velocities in pipes

: WI-ME-DSN-196-014

FICHTNER India

FORM T10 REV A


TABLES AND FIGURES
FICHTNER India

FORM T10 REV A

TABLE -1

Nominal
pipe
size, IPS,
in

OD,
in

Schedule
No.

ID, in
Flow
area per
pipe, in
2

Surface per lin ft,ft
2
/ ft Weight
per lin ft,
lb steel
Outside Inside

1/8 0.405 40*
80+
0.269
0.215
0.058
0.036
0.106 0.070
0.056
0.25
0.32
0.540 40*
80+
0.364
0.302
0.104
0.072
0.141 0.095
0.079
0.43
0.54
3/8 0.675 40*
80+
0.493
0.423
0.192
0.141
0.177 0.129
0.111
0.57
0.74
0.840 40*
80+
0.622
0.546
0.304
0.235
0.220 0.163
0.143
0.85
1.09
3/4 1.050 40*
80+
0.824
0.742
0.534
0.432
0.275 0.216
0.194
1.13
1.48
1 1.32 40*
80+
1.049
0.957
0.864
0.718
0.344 0.274
0.250
1.68
2.17
1 1.66 40*
80+
1.380
1.278
1.50
1.28
0.435 0.362
0.335
2.28
3.00
1 1.90 40*
80+
1.610
1.500
2.04
1.76
0.498 0.422
0.393
2.72
3.64
2 2.38 40*
80+
2.067
1.939
3.35
2.95
0.622 0.542
0.508
3.66
5.03
2 2.88 40*
80+
2.469
2.323
4.79
4.23
0.753 0.647
0.609
5.80
7.67
3 3.50 40*
80+
3.068
2.900
7.38
6.61
0.917 0.804
0.760
7.58
10.3
4 4.50 40*
80+
4.026
3.826
12.7
11.5
1.178 1.055
1.002
10.8
15.0
6 6.625 40*
80+
6.065
5.761
28.9
26.1
1.734 1.590
1.510
19.0
28.6
8 8.625 40*
80+
7.981
7.625
50.0
45.7
2.258 2.090
2.000
28.6
43.4
10 10.75 40*
60
10.02
9.75
78.8
74.6
2.814 2.62
2.55
40.5
54.8
12 12.75 30 12.09 115 3.338 3.17 43.8
14 14.0 30 13.25 138 3.665 3.47 54.6
16 16.0 30 15.25 183 4.189 4.00 62.6
18 18.0 20++ 17.25 234 4.712 4.52 72.7
20 20.0 20 19.25 291 5.236 5.05 78.6
22 22.0 20++ 21.25 355 5.747 5.56 84.0
24 24.0 20 23.25 425 6.283 6.09 94.7

* - Commonly known as standard
+ - Commonly known as extra heavy
++- Approximate
Taken from Ref (1) given in the references section.

2. TABLES AND FIGURES
FICHTNER India

FORM T10 REV A

TABLE - 2

Temperature of heating medium Up to 240F 240-400F+
Temperature of water ............... 125F or less Over 125F
Water velocity
fps
Water velocity
fps
Water 3 ft and
less
Over 3 ft 3 ft and
less
Over 3 ft
Sea water 0.0005 0.0005 0.001 0.001
Brackish water 0.002 0.001 0.003 0.002
Cooling tower and artificial spray pond

Treated make-up 0.001 0.001 0.002 0.002
Untreated 0.003 0.003 0.005 0.004
City or well water (such as Great Lakes) 0.001 0.001 0.002 0.002
Great Lakes 0.001 0.001 0.002 0.002
River water
Minimum 0.002 0.001 0.003 0.022
Mississippi 0.003 0.002 0.004 0.003
Delaware, Schuylkill 0.003 0.002 0.004 0.003
East River and New York Bay 0.003 0.002 0.004 0.003
Chicago sanitary canal 0.008 0.006 0.010 0.008
Muddy or silty 0.003 0.002 0.004 0.003
Hard (over 15 grains / gal) 0.003 0.003 0.005 0.005
Engine jacket 0.001 0.001 0.001 0.001
Distilled 0.0005 0.0005 0.0005 0.0005
Treated boiler feed water 0.001 0.0005 0.001 0.001
Boiler blowdown 0.002 0.002 0.002 0.002

++Ratings in the last two columns are based on a temperature of the heating medium of 240 to 400F. If
the heating medium temperature is over 400F, and the cooling medium is known to scale these ratings
should be modified accordingly.
Petroleum Fractions

Oils (industrial) : Liquids (industrial) :

Fuel oil 0.005 Organic 0.001
Clean recirculating oil 0.001 Refrigerating liquids, heating
Machinery and transformer oils 0.001 cooling, or evaporating 0.001
Quenching oil 0.004 Brine (cooling) 0.001
Vegetable oils 0.003 Atmospheric distillation units:
Gases, vapors (industrial) : Residual bottoms, less than
Coke-oven gas, manufactured 25API 0.005
gas 0.01 Distillate bottoms, 25API or
Diesel-engine exhaust gas 0.01 above 0.002
Organic vapors 0.0005 Atmospheric distillation units :
Fluid in coil (non-oil bearing) 0.0 Overhead untreated vapors 0.0013
Alcohol vapors 0.0 Overhead treated vapors 0.003
Fluid in coil, exhaust (oil bearing Side-stream cuts 0.0013
from reciprocating engines) 0.001 Vacuum distillation units:
Refrigerating vapors (condensing Overhead vapors to oil :
from reciprocating compressors) 0.002 From bubble tower (partial
Air condenser) 0.001
0.002 From flash pot (no appreciable
reflux) 0.003
Taken from Ref (1) given in references section.
FICHTNER India

FORM T10 REV A


COMPUTER PROGRAM
FICHTNER India

FORM T10 REV A

This program is available in the following location

F:\MECH\ISO\TANK\COILSIZE.XLS

1. Capabilities of Program

1. Has a unit conversion facility.

2. Section wise printouts can be taken.

3. Saves the data separately in a file specified by the user.

2. Limitation & Warnings

1. Uses American Unit Systems. Hence check the units of inputs before inputing
the value.

2. Do not enter invalid data or O in the cells. It may lead to fatal errors.

3. This program can not be used for

Features

3. Interface and features of the program

i. Save as Button

Since space is limited in the computers, you can not save this Excel worksheet. This
is only a template but you can save your entered data.

Press `SAVE AS Button. A dialog appears, give the path and filename with
. dat extension depending upon where you want to save.

Ex - F:\MECH\GACL\TANK1.DAT

ii. Open Button

With this OPEN button you can (open) retrieve the saved data.

Press `open button. Open dialog appears. Give the name of the file with path.


iii. Exit Button

3. COMPUTER PROGRAM
FICHTNER India

FORM T10 REV A

Pressing this button will close the work book with out saving, hence ensure that the
datas entered are saved before pressing this button.

iv. Coilsizing Button (Main sheet)

The pressing this button will lead you to the actual calculating.

v. Main Sheet Button (Coil sizing sheet)

Returns to the main sheet.

vi. Print Button (Coil sizing sheet)

Will lead you to the print preview mode press`Print there to take the printout.

vii. Help Button (Coil sizing sheet)

Leads to the help sheet, where you can get technical help and tables refered in the
program.

FICHTNER India

FORM T10 REV A


MANUAL SAMPLE CALCULATION
FICHTNER India

FORM T10 REV A

Heating Coil Size Calculation for Storage Tanks

Fluid inside the tank = Fuel oil

Fluid inside the coil = Steam

Input:

* Heat loss from liquid storage Q =160 kW
Tank =545942.4 Btu/hr

* Fuel oil temperature t oil =122F

* Steam temperature t steam =329F

* Latent heat of steam h
fg
=2064.9 KJ /kg
t 6 bar (g)

* Specific volume of steam Vsp =0.2766 m
3
/kg

Finding the film temperature

toil +tsteam 122 +329
t
f
= ---------------- = --------------
2 2
=225.5 F

Finding AMTD (t)

t = tsteam toil =329-122 =207F

Physical properties at film temperature (tf)

(I) Thermal conductivity of liquid (K
f
) = 0.085 Btu/hr ftF

(ii) Density of the liquid (
f
) = 53.68 lb/ft
3

(iii) Specific heat of the liquid C
pf
= 0.51 Btu/lbF

(iv) Dynamic viscocity of the liquid
f
= 83.22 lb/fthr

= 34.39 CP

Coefficient of thermal expansion = 1.396 F
-1

Finding mass flow rate of steam

m
steam
= QxVsp / h
fg

160 x 0.2766
= ----------------- = 0.02143 m
3
/sec
2064.9

Assumed velocity (Vs) =20 m/sec
4. MANUAL SAMPLE CALCULATION
FICHTNER India

FORM T10 REV A

Finding area required for steam flow

A
S
= m
steam
/ Vs

= 0.02143 / 20

= 0.0010715 m
2

= 1.6610 inch
2

Pipe size selection from Table 1

Matching the area A
S
with table 1 we get immediate higher value as

= 1.76

The corresponding pipe size (at SCH 80)

OD = 1.90 inch
ID = 1.5 inch
= 0.498 ft
2
/ ft

Finding Actual Velocity :-

0.02143
V = ------------
(/4) (1.5x0.0254)
2

= 18.79 m/sec.

The actual velocity value lies with in the allowable range. Hence size is OK.

Finding free convection coefficient

h
c
= 116 [(K
f
3

f
2
C
Pr
/
f
) (t / d
O
)]
0.25

= 116 [ (0.085
3
x 53.68
2
x 0.51 x 1.39 x 10-
6
/ 34.39) x (207/1.9) ]
0.25

= 5.185 Btu/hr ft
2
F

Finding clean overall coefficient

Heat transfer coefficient for
Condensation of steam h
io
= 1500 Btu / hr ft
2
F

h
io
x h
c

Uc = -----------
h
io
+h
c

1500 x 5.185
= ------------------- = 5.167 Btu / hr ft
2
F
(1500 +5.185)

FICHTNER India

FORM T10 REV A

Finding Design Overall Coefficient:

* Dirt factor Rd from Table 2 for Fuel Oil

Rd =0.005 hr ft
2
F/Btu

Uc x 1/Rd
UD = ---------------
Uc +1/Rd

5.167 x (1/0.005)
= ------------------------
(5.167 +(1/0.005)

= 5.0368 Btu/hr ft
2
F

Finding Total Heat Transfer Area: -

Q
S = -----------
Up x T

545942.4
= ------------------
5.0368 x 207

= 523.6 ft
2

Finding length of the pipe required: -

L = S /

= 523.6 / 0.498

= 1051.4 ft.

= 320.3 m

FICHTNER India

FORM T10 REV A


COMPUTER PROGRAM - OUTPUT
FICHTNER India

FORM T10 REV A

H E A T I N G C O I L S I Z E C A L C U L A T I O N F O R S T O R A G E T A N K S
Client xxx Project xxx
PpdBy xxx ChkdBy xxx AppBy xxx Document No xxx

Description Symbols Values Units
Input
Fluid Inside the Tank F
tank
FuelOil
Fluid Inside the Coil F
coil
Steam

Heat Loss from Liquid Storage Tank Q 160 KW
Fluid F
tank
's Temperature t
Ftank
122 F
Fluid F
Coil
's Temperature t
FColi
329 F
Latent Heat of F
coil
h
fg
2064.9 KJ / Kg
Specific Volume of F
coil
V
sp
0.2766 m / Kg

Film Temperature t
f
225.5 F
Arithmatic Mean Temperature Difference t 207 F

Physical properties of F
tank
at Film Temperature t
f
ie 225.5 F

Thermal Conductivity K
f
0.085 Btu / hr ft F
Density
f
53.68 lb / ft
Specific Heat C
pf
0.51 Btu / lb F
Dynamic Viscosity '
f
34.39 cP
Coefficient of Thermal Expansion 1.396E-06 F
-1

Mass flow rate of F
coil
m
Fcoil
0.021433 m /sec

Assumed Velocity V
s
20 m / sec

Area Required for F
coil
Flow A
s
0.001072 m
A
s
1.66092 inch

The following Values are tobe selected from Table1 Given in Help

Flow Area As 1.76 inch
OD of the Pipe d
O
1.9 inch
ID of the Pipe d
I
1.5 inch
Surface Area per linear feet 0.498 ft / ft

Actual Velocity V
A
18.79894 m / sec

5. COMPUTER PROGRAM - OUTPUT
FICHTNER India

FORM T10 REV A

Description Symbols Values Units

Heat Transfer coefficient & Area
Calculation

Heat transfer coef. for condensation of steam h
IO
1500 Btu / hr ft F
Dirt Factor ( From Table 2 in Help) R
d
0.005 hr ft F / Btu

Free Convection Coefficient h
C
5.185 Btu / hr ft F
Clean Overall Coefficient U
C
5.167 Btu / hr ft F
Design Overall Coefficient U
D
5.037 Btu / hr ft F

Total Heat Transfer Area S 523.749 ft
Length of the pipe Required L 1051.706 ft
L 320.560 m

FICHTNER India

FORM T10 REV A


THE SOURCE ARTICLE

FICHTNER India

FORM T10 REV A

FICHTNER India

FORM T10 REV A

FICHTNER India

FORM T10 REV A

FICHTNER India

FORM T10 REV - A

HEAT LOSS CALCULATION FOR VERTICAL CYLINDRICAL STORAGE TANKS

C O N T E N T S

SL. NO. DESCRIPTION PAGE
NO.



3. COMPUTER PROGRAM 13


5. THE SOURCE ARTICLE 31

This procedure has been verified with sample datas (i) manually as described in section (4) and
(ii) through program as described in section (5) and it is noted that the results are matching in
both cases. Though the procedure is checked for errors, users are requested to check the input
before calculation. Read section (3) Computer Program thoroughly before performing the
calculation in computer.

FICHTNER India

FORM T10 REV - A

INTRODUCTION

Heating or cooling storage tanks in power or process plants can be a major energy expense.
Hence a detailed study of heat transfer involved in tanks is required to bring down the costs.

This design procedure determines the heat transfer to or from a vertical cylindrical storage tank
seated on the ground. It includes the effects of tank configuration, physical properties of liquid &
vapour in the tank, liquid level, ambient temperature, outside air, wind speed as well as
temperature variations within the tank between air and ground.

ASSUMPTIONS

1. This procedure assumes a tank with configuration shown in fig. 1 [Section (2) Fig1]. The
surfaces from which heat can be transferred are as follows.

i. Wet side of tank wall.

ii. Dry side of tank wall.

iii. Tank bottom

iv. Tank roof.

2. The temperature of vapour above liquid level is 5F less than the liquid temperature
and the temperature of ground is 5F greater than the ambient temperature.


A = Area of heat transfer surface, ft
2

A
b
for bottom
A
d
for dry wall
A
w
for wet wall
A
r
for roof

C
p
Specific heat at constant pressure, Btu/lbF
D Diameter of tank, ft
d Height of conical roof at centre, ft
g Acceleration due to gravity, 4.17x10
8
ft/hr
2

h Individual film coefficient of heat transfer, Btu/ft
2
hF
- h
Aw
for air outside walls.
- h
Ar
for air outside roof.
- h
Aw
and h
Ar
for still air
- h
Lw
for liquid between walls.
- h
Lb
for liquid near bottom.
- h
Vw
for vapour near the wall.
- h
Vr
for vapour near the roof.

NOMENCLATURE USED IN CALCULATIONS (continued)
1. DESIGN PROCEDURE
FICHTNER India

FORM T10 REV - A

h
F
Fouling coefficient, Btu/ft
2
-h F
h
Fw
for liquid at the walls, Btu/ft
2
-h F
h
Fb
for liquid at the bottom, Btu/ft
2
-h F
h
Fv
for vapour at the wall, Btu/ft
2
-h F
h
Fr
for vapour at the roof, Btu/ft
2
-h F
h
G
heat transfer coefficient for ground, Btu/ft
2
-h F
h
I
heat transfer coefficient for insulation, Btu/ft
2
-h F
h
M
heat transfer coefficient for metal, Btu/ft
2
-h F
h
R
- heat transfer coefficient for radiation, Btu/ft
2
-h F
h
Rb
for bottom
h
Rd
for dry wall
h
Rw
for wet wall
h
Rr
for roof
K - Thermal conductivity, Btu/ft
2
-h F
K
G
for ground
K
I
for insulation
K
M
for metal wall
L - Total length for heat transfer surface, ft
L
w
- Total length for wetted surface, ft
N
Gr
- Grashof number, L
3
2
g T/
2

N
NU
- Nusselt number = hD/k or hL/k

N
Pr
- Prandtl number = C
p
/k
Q - Rate of heat transfer, Btu/h
q - Individual rate of heat transfer Btu/h
q
b
for bottom
q
r
for roof
q
w
for wet wall
q
d
for dry wall
T Temperature F
T
A
for ambient air
T
V
for vapour
T
G
for ground
T
L
for bulk liquid
T Temperature difference, F
t Surface thickness, ft
t
I
for insulation
t
M
for metal
U Overall heat transfer coefficient Btu/ft
2
hF
U
b
for bottom
U
d
for dry wall
U
w
for wet wall
U
r
for roof
W
f
Wind enhancement factor
Volumetric co-efficient for thermal expansion, F
-1

Viscosity of fluid, lb/ft-h
Density of fluid, lb/ft
3

Emmissivity

INPUT REQUIREMENTS

The inputs required are as follows :

FICHTNER India

FORM T10 REV - A

Tank Details

Tank Diameter D ft.

Height of the roof from centre d ft.

Tank Total Height L ft.

Liquid Level L
w
ft.

Tank wall thickness t
M
ft.

Insulation thickness t
I
ft.

Temperature

Bult Liquid T
L
F

Vapour T
V
F

Ground T
G
F

Ambient T
A
F

Thermal Conductivities

Metal wall K
M
Btu/ft h-F

Insulation K
I
Btu/ft h-F

Ground K
G
Btu/ft h-F

Surface Emmisivity

Roof
R

Wall
R

Fouling Coefficients

Dry wall h
Fd
Btu/ft
2
h-F

Wet wall h
Fw
Btu/ft
2
h-F

Roof h
Fr
Btu/ft
2
h-F

Ground h
FG
Btu/ft
2
h-F

Miscellaneous Data

Acceleration due to gravity g ft/hr
2

Wind enhancement factor W
f

FICHTNER India

FORM T10 REV - A

Latent heat of steam h
fg
kcal/kg

Physical Properties

Property Liquid Air Vapour

Density (lb/ft
3
) :

Specific heat (Btu/lb-F) : C
p

Viscosity lb/ft-h :

Thermal conductivity (Btu/ft-hF) : k

Coefficient of volumetric
expansion of air, F
-1
:

The basic approach is to calculate the heat loss from each of the four categories of surfaces,
and then add the individual heat losses to get the total heat loss. Thus :

For dry sidewall q
d
= U
d
A
d
(T
V
- T
A
) ---------- (1)
For wet sidewall q
w
= U
w
A
w
(T
L
- T
A
) ---------- (2)
For tank bottom q
b
= U
b
A
b
(T
L
- T
G
) ---------- (3)
For tank roof q
r
= U
r
A
r
(T
V
- T
A
) ---------- (4)
Total Q = q
d
+q
w
+q
b
- q
r
---------- (5)

When using these equations in design or rating problems, the various temperatures are
assumed for typical conditions or determined by measurement. The area values are also easily
obtained :

A
d
= D (L - L
w
) ---------- (6)
A
w
= DL
w
---------- (7)
A
b
= D
2
/4 ---------- (8)
A
r
= (D/2) (D
2
/ 4 +d
2
)

---------- (9)

The overall coefficients

The overall heat-transfer coefficient for the dry sidewall of the tank (U
d
) is calculated as the sum
of the resistances of vapor film, fouling, metal wall, insulation (if any), and outside air
(convection plus radiation).

The outside air heat-transfer coefficient (h
AW
) is a function of wind velocity as well as
temperature gradient. Data on the effect wind velocity and T have been presented by
FICHTNER India

FORM T10 REV - A

stuhlbarg and Boyen. With a little bit of manipulation, their data were replotted yielding the wind
enhancement factor (W
f
). By definition.

W
f
= h
AW
/ h
AW
= h
Ar
/h
Ar
- - - - - - - - (10)

The wind enhancement factors are given in Section (2) Table 1.

Therefore, once the outside-air coefficient for still air (h
AW
) is known, the overall dry-sidewall
coefficient at various wind velocities can be computed as :

1/U
d
=1/h
VW
+ t
M
/ k
M
+ t
I
/ k
I
+ 1/(W
f
h
AW
+ h
Rd
) + 1/h
Fd
- - - - - - - - (11)

Similarly, the overall coefficients for the wet sidewall, bottom and roof surfaces are :

1/U
W
= 1/h
LW
+ t
M
/ k
M
+ t
I
/ k
I
+ 1(W
f
h
AW
+ h
RW
) + 1/h
FW
- - - - - - - - - (12)

1/U
b
= 1/h
Lb
+ t
M
/ k
M
+ 1/h
G
+ 1/h
Fb
- - - - - - - - - (13)

1/U
r
= 1/h
Vr
+ t
M
/ k
M
+ 1(W
f
h
Ar
+ h
Rr
) + 1/h
Fr
- - - - - - - - - (14)

Eq. 13 and 14 assume that the roof and bottom are uninsulated, which is generally the case in
temperature estimates.

Individual film heat-transfer coefficients

The film heat-transfer coefficients may be divided into four categories :

(i) convection from vertical wall
(ii) convection from horizontal surfaces
(iii) pure conduction and
(iv) radiative heat transfer. Within each category relations are presented for
several flow regimes.

Vertical-wall film coefficients.

These apply to the inside wall (wet or dry) and the outside wall (still air). For vertical plates and
cylinders, Kato et al have recommended the following for liquids and vapors :

N N N
Nu Gr
= 0138 055
036 0175
. ( . )
.
Pr
.
- - - - - - - - - - (15)

Where 0.1 <N
Pr
<40 and N
Gr
> 10
9
.

For isothermal vertical plates, Ede reported the following for liquids :

N
Nu
= 0.495 (N
Gr
N
Pr
)
0.25
- - - - - - - - - - (16)

Where N
Pr
> 100 and 10
4
<(N
Gr
N
pr
) < 10
9
, and for gases :
FICHTNER India

FORM T10 REV - A

N N N N
Nu Gr
= +

00295 1 05
040 047 067 040
. ( . )
.
Pr
.
Pr
. .
- - - - - - - - - - (17)

Where N
Pr
5 and (N
Gr
N
Pr
) > 10
9
.

For vertical plates taller than 3 ft. stuhlbarg recommends :

h = 0.45 kL
-0.75
(N
Gr
N
Pr
)
0.25
- - - - - - - - - - (18)

Where 10
4
<(N
Gr
N
Pr
) <10
9
.

Horizontal-surface heat-transfer coefficients.

These coefficients apply to the roof and inside-bottom surface of the tank. The bottom is
assumed to be flat. For surfaces facing up :

N
Nu
= 0.14 (N
Gr
N
Pr
)
0.33
- - - - - - - - - - (19)

For surfaces facing down :

N
Nu
= (0.27 k/D) (N
Gr
N
Pr
)
0.25
- - - - - - - - - - (20)

Both equations apply in the range 2 X 10
7
<(N
Gr
N
Pr
) <3 X 10
10
.

Equivalent coefficients for conductive heat transfer.

The wall and insulation coefficients are derived from the thermal Conductivities :

h
M
= k
M
/ t
M
- - - - - - - (21)

h
I
= k
I
/ t
I
- - - - - - - - (22)

The coefficient for heat transfer to and from the ground is the coefficient for heat conduction
from a semi-infinite solid :

H
g
= 8 k
G
/ D - - - - - - - - (23)

Fouling coefficients

The coefficients h
Fd
, h
Fw
and h
Fb
apply to the vapor and liquid at the wall, and the liquid at the
bottom of the tank, respectively. These are empirical, and depend on the type of fluid and other
factors such as tank cleaning. Generally, h
Fd
is the greatest, of the three, and h
Fb
the least,
indicating that the greatest fouling resistance is at the bottom of the tank.

Fouling coefficient are given in Section (2) Table 2.

Equivalent coefficient for radiative heat transfer.

FICHTNER India

FORM T10 REV - A

The coefficient for sidewalls and roof depends on the emmisivity of these surfaces and is given
by :

h
T T
T T
R
ws A
Ws A
=
+
|
\
|
.
|

+
|
\
|
.
|
(
(
01713
460
100
460
100
4 4
.
- - - - - - - - - - - (24)

With these relationships, heat transfer to or from the tank can be calculated.

To begin the calculation, it is assumed that the outside wall temperatures are related to the bulk-
fluid temperatures by.

T
w
= T
A
+0.5 (T
v
- T
A
) for uninsulated surfaces
T
ws
= T
A
+0.25 (T
bulk
- T
A
) for insulated surfaces

In order to calculate accurate coefficients for heat transfer, better estimates of these wall
temperatures must be obtained. This requires an iterative procedure that can be programmed
and run on a computer.

For dry wall, the rate of heat loss is given by all three of the following :

q
d
= U
d
A
d
(T
V
- T
A
)

- - - - - - - - - - (25)
= h
vw
A
d
(T
V
- T
W
) - - - - - - - - - - (26)
= (h
Rd
+h
Aw
) A
d
(T
ws
- T
A
) - - - - - - - - - - (27)

Solving Eq. 25 and 27 for T
ws
yields :

T
ws
={U
d
/ (h
Rd
+h
Aw
)}(T
V
- T
A
) +T
A
- - - - - - - - - - (28)

Similarly, solving Eq. 25 and 26 for T
w
yields :

T
w
=T
v
- (U
d
/ h
vw
) (T
V
- T
A
) - - - - - - - - - - (29)

Using the same approach, T
w
and T
ws
can be calculated for the wet wall, and Tw for the roof
and bottom of the tank.

To find the correct wall temperatures, initial estimates of U and h values are used in Eq. 28 and
29 (and in the parallel equations for the other surfaces) to get new T
w
and T
ws
values. Using
these new temperatures, Grashof numbers, individual heat-transfer coefficients and overall
coefficients, are recomputed and then iterated again to get a new set of T
w
and T
ws
values.
When the current and previous iterations temperature estimates are the same (within a
specified tolerance =0.0001), the iteration is completed.

References :

i. J immy D. Kumana and Samir P. Kothari, Henningson & Durham and Richardson, Inc.
Predict storage-tank heat transfer precisely. Chemical Engineering J ournal. March
22, 1982, PP : 127 - 132.
FICHTNER India

FORM T10 REV - A

ii. Perry, R.H, and Chitton, C.H, Chemical Engineers Handbook Mcgraw-Hill Newyork,
1973.

iii. Kern, D.Q, Process Heat Transfer. Mcgraw-Hill, Newyork, 1950.

FICHTNER India

FORM T10 REV - A


TABLES AND FIGURES
FICHTNER India

FORM T10 REV - A

TABLE - 1

Table for Wind Enhancement factor *

Temp Diff (F)
WindSpeed (mph)
15 25 50 100 200
5 2.20 2.05 1.90 1.75 1.65
10 3.30 3.
00
2.75 2.50 2.20
15 4.50 4.00 3.70 3.30 2.80
20 5.70 5.00 4.40 4.00 3.45
25 6.80 6.00 5.30 4.80 4.00
30 --- --- 6.20 5.50 4.70
*Consolidated from the Article Predict Storage Tank Heat Transfer precisely published in Chemical Engineering March-22
1982 by J immy D Kumana & Samir P. Kothari
TABLE - 2

Selection Of Fouling Coefficients*
Water

Temperature of Heating Medium Up to 240F 240 - 400
Temperature of Water 125F or Less Above 125F
Water velocity ft / sec 3 >3 3 >3
Distilled 2000 2000 2000 2000
Sea Water 2000 2000 1000 1000
Treated Boiler feed water 1000 2000 1000 1000
Treated makeup for cooling tower 1000 1000 500 500
City, well, Great Lakes 1000 1000 500 500
Brackish, clean river water 500 1000 330 500
River water, muddy, silty 330 500 250 330
Hard (over 15 g /gal) 330 330 200 200
Chicago Sanitary Canal 125 170 100 125

Chemicals

Inorganic
Gases ( oil - bearing or dirty) 500
Liquids (heating or vaporization) 500
Refrigerant brines 1000
Organic
Gases
Process 1000
Utility (Oil - bearing , refrigerant, etc ) 500
Condensing vapors (condensers) 1000
Liquids
Process 1000
Vaporizing Liquids(reboilers) 500
Heat transfer media 1000
Refrigerant Liquids 1000
Polymer forming Liquids 200
Oils ( vegetable and heavy Gas Oil) 330
Asphalt and residuum 100

* Taken from Perrys Chemical Engineers hand book by Robert H. Perry - (Table 10-9 , Page 10-43)
2. TABLES AND FIGURE
FICHTNER India

FORM T10 REV - A

L
L
w
D
d
Vapour
Air q
r

q
d
q
w
FIG:1
q
b
Liquid
FICHTNER India

FORM T10 REV - A


COMPUTER PROGRAM
FICHTNER India

FORM T10 REV - A

This design procedure has been computerised using Microsoft Excel. The following sections
are briefly describing the interface of the program.

1.1 Capabilities of program

- This program automatically does the iteration procedure once the required
inputs are entered.

- Has a unit conversion section for converting units from SI to American unit
system.

- Has a explanatory figure.

- Has a `Print utility through which print outs can be taken section wise, ie.
Input, Calculation and Output.

- Has facility to save the datas separately.

1.2 Limitations

1. This program is divided into two parts Insulated and Uninsulated use
specific sections as required.

2. This program uses American unit system (For this conversion utility has been
provided).

3. Do not enter invalid data into the cells. It may lead to fatal errors.

4. This program cannot be used for horizontal type storage tanks.

5. Do not use this program for storage of cryogenic liquids.

Features

1. Save as Button

Since space is limited in the computers, you can not save this Excel worksheet. This
is only a template but you can save your entered data.

Press `SAVE AS Button. A dialog appears, give the path and filename with
. dat extension depending upon where you want to save.


2. Open Button

With this OPEN button you can (open) retrieve the saved data.
Press `open button. Open dialog appears. Give the name of the file with path.

All datas stored will be retrieved and put in appropriate cells.

3. COMPUTER PROGRAM
FICHTNER India

FORM T10 REV - A

3. Calculate Button

After entering the required input datas press this button to perform the calculation with
iteration.

4. Show Picture or Hide Picture Button

Press this button when you want to see a descriptive fig. of tank. Now the caption of
button is Hide Picture. Press the same button again, the picture will be hidden.

5. Convert Button

Pressing this button will lead you to a unit conversion table where you can perform
unit conversion calculations from SI units to American unit system.

6. Print Button

To take section wise print out

(i) Input
(ii) Calculation
(iii) Output

Press this Button. It will lead you to preview mode press PRINT to take the print
outs.

7. Exit Button

Pressing this button will close the work book with out saving so, ensure that the datas
entered are saved before pressing this button.

8. Help Button

Press help button to get a on line help on different topics.

Note : 1. This program has been developed according to the design procedure given in
section - 1. The results can be verified with the manual calculation provided in
section-4 and computer outputs provided in section - 5.

2. This program is located in the following network directory.

F:\MECH\SOFTWARE\HEATLOSS.XLS

FICHTNER India

FORM T10 REV - A



FICHTNER India

FORM T10 REV - A

Input Details

Tank Details :

Tank diameter D - 20 ft

Tank total hight L - 48 ft

Liquid level (hight) Lw - 24 ft

Tank wall thickness tw - 0.0156 ft

Tank insulation thick ti - 0.125 ft

Temperatures

Liquid side Tw - 55F

Vapour side Tv - 50F

Ground (Bottom) T
G
- 40F

Ambient T
A
- 35F

Thermal Conductivities

Metal walls K
M
- 10 Btu / ft h-f

Insulation K
L
- 0.028 Btu / ft h-f

Ground K
G
- 0.8 Btu / ft h-f

Surface Emmissivity

Roof side
R
- 0.9

Wall side
W
- 0.9

Assumed Fouling Co-efficients

Dry wall h
Fd
- 1000 Btu / ft h-f

Wet wall h
Fw
- 800 Btu / ft h-f

Roof side h
Fr
- 1000 Btu / ft h-f

Bottom side h
Fb
- 1000 Btu / ft h-f

FICHTNER India

FORM T10 REV - A

Physical Properties : Form document Annexure-1 (Section-2)

Property Liquid Air Vapour
Density (lb/ft) 4.68 0.08 0.08

Specific heat (Btu/lbf) Cp 0.6 0.25 0.25

Viscosity (lbm/h-ft) 96.8 0.01693 0.01693

Thermal conductivity (Btu/Fth-F) K 0.12 0.0151 0.0151

Co-eff. of volumetric of expansion 1 x 10
-6
0.002 0.002

Miscellaneous Data

Acceleration due to gravity g - 4.17 x 10
8
ft/hr

Wind enhancement factor W
f
- 3.3

Latent heat of steam - 566.3 Kcal / Kg from steam table.

Note :

Wind enhacement factor taken from document Annexure-I (section-1).

CALCULATION OF GRASHUF NO AND PRANDTL NO FOR LIQUID AND VAPOUR

1. Grashof No for Liquid

NGr - L
3
g T /

- L
3
x (4.68) x 4.17 x 10
8
x 1 x 10
-6
x T
96.8

- 0.9747 L
3
T

2. Prandtl No for liquid

Npr - C
P
/ k

- 0.6 x 96.8
0.12

FICHTNER India

FORM T10 REV - A

3. Gashof No for Vapour

N
Gr
- L
3
x (0.08) x 4.17 x 10
8
x 0.002 x T
(0.01693)

- 1.862 x 10
7
L
3
T

4. Prand No for Vapour

N
pr
- 0.25 x 0.01693
0.011

- 0.28

Finding Individual Heat Transfer Coeffs

1) COEFF. FOR VAPOUR AT WALL (h
vw
)

i) Assumed wall temperature

Tw - T
V
+T
A
= 50 +35 =42.5F
2 2

ii) Grashut no.

NGR - 1.9 x 10
7
x L
3
x T

= 1.9 x 10
7
x (24) x (50-42.5)

= 1.97 x 10
12

iii) Nusselt no.

= 0.138 (N
Gr
)
0.36
(N
Pr

0.175
0.55)

= 0.138 x (1.97 x 10
12
)
0.36
x (0.28
0.175
0.55)

= 921.1

iv) Heat transfer coeff.

Na = h.L/K

Therefore, h
VW
= KN
u
/ L

= 0.0151 x 921.1
24

= 0.581 Btu / ft h.f

FICHTNER India

FORM T10 REV - A

2) CO.EFF FOR LIQUID AT WALL (h
LW
)

i) Assumed Wall Temperature

Tw = T
L
+T
A
/ 2

= 45F

ii) Grashof No.

= 0.9747 L T

= 0.9747 x 24 x (55-45)

= 1.34 x 10
5

iii) Heat transfer Co-eff.

= (0.45 K/L
w

0.75
) x (N
Gr
P
r
)
0.25

= (0.45 x 0.12 / (24)
0.75
) x (1.34 x 10
5
x 484)
0.25

h
LW
= 0.4469 Btu / Ft h : f

3) COEFF FOR VAPOUR AT ROOF (h
Vr
)


Tw = T
V
+T
A
/ 2

= 50 +35 / 2

= 42.5

ii) Grashof No.

N
Gr
= 1.9 x 10
7
x D
3
x (T
V
T
W
)

= 1.9 x 10
7
x 20
3
x (50-42.5)

= 1.14 x 10
12

iii) Heat Transfer coeff.

= (0.27 K/D) x (N
Gr
N
Pr
)
0.25

= (0.27 x 0.0151/20) x (1.14 x 10
12
x 0.28)
0.25

h
Vr
= 0.154 Btu / ft h - F

FICHTNER India

FORM T10 REV - A

4) COEFF. FOR LIQUID AT BOTTOM (h
lb
)


T
w
= T
L
+T
G
/ 2

= 55 +40 / 2

= 47.5F

ii) Grashof No.

N
Gr
= 0.9747 x L
3
x T

= 0.9747 x (20) x (55-47.5)

= 58482

iii) Nusselt No.

= 0.14 (N
Gr
N
Pr
)
0.33

= 0.14 (58482 x 484)
0.33

Na = 40.29

iv) Co-efficient h
Lb
= K
Nu
/ L = 0.12 x 40.29 / 20 = 0.241 Btu / ft hF

5) COEFF. FOR OUTSIDE AIR AT ROOF (h
Ar
)

i) Assumed wall temperture

Since roof is uninsulated

T
w
T
ws
= 50 +35 / 2

= 42.5

ii) Grashof No.

N
Gr
= 1.9 x 10
7
x L T

= 1.9 x 10
7
x 20
3
x (42.5 35)

= 1.14 x 10
12

iii) Nusselt No.

N
u
= 0.14 (N
Gr
N
pr
) 0.33

= 0.14 (1.14 x 10
12
x 0.28)
0.33

= 875.92

FICHTNER India

FORM T10 REV - A

iv) Heat transfer coeff.

H

Ar
=KN
u
/D = 0.015 x 875.92 / 20

= 0.6613 Btu/ft h F

6) COEFF. FOR OUTSIDE AIR AT WALL (h
1
AW)


Note : Here both liquid and vapour included. Hence it is assumed that, Temperature drop
across the film is of the temp. drop from inside fluid to outside Air (Averaged for
both)

T
1
= T
L
-T
A
=55-35=20F; T
2
=T
V
-T
A
=50-35=15F

T
= T
1
+T
2
/ 2x 4

T
= 20 +15 / 4 x 2

= 4.375 F

ii) Grashof No.

N
Gr
= 1.9 x 10
7
x L T

= 1.9 x 10
7
x 48 x 4.375

= 9.19 x 10
12

iii) Nusselt No.

N
u
= 0.138 N
Gr

0.36
(N
pr

0.175
0.55)

= 0.138 x (9.19 x 10
12
)
0.36
x (0.28
0.175
0.55)

= 1603.73

iv) Heat transfer Coeff.

h
AW
= K.N
u
/ L

= 0.0151 x 1603.73 / 48

= 0.51 Btu / ft h. F

7) CALCULATING CONDUCTION COEFFICIENTS

i) For ground (h
G
)

h
G
= 8 K
G
/ D

= 8 x 0.8 / x 20

= 0.102 Btu/ft h F

FICHTNER India

FORM T10 REV - A

ii) For metal (h
M
)

h
M
= K
M
/ t
M

= 10 / 0.0156

= 640 Btu / ft h F

iii) For insulation (h
I
)

h
I
= K
I
/ t
I

= 0.028 / 0.125

= 0.224 Btu / ft h F

8) CALCULATING RADIATION COEFFS :

i) For dry side wall (h
RD
)

For insulated surfaces assuming

T
ws
= T
A
+0.25 (T bulk T
A
)

Where T bulk is the temperature of the liquid & vapour inside

= 35 +0.25 (50-35)

T
WS
= 38.75

h
RD
= 0.1713 / (T
WS
T
A
) x [(Tws+460)
4
(TA+460)
4
]
100 100

= 0.1713 x 0.9 / (38.75 35) x [(38.75+460)
4
(35+46)
4
]
100 100

= 0.757 Btu / ft h F

ii) For wet side wall (h
RW
)

T
WS
= T
A
+0.25 (T bulk T
A
)

= 35 +0.25 (55-35)

= 40F

h
RW
= 0.1713 x 0.9 / (40-35) x [(40+460)
4
(35-460)
4

100 100
= 0.759 Btu / ft h F

FICHTNER India

FORM T10 REV - A

iii) For roof side (h
Rr
)

Roof is uninsulated

Hence assuming

T
WS
= TA +0.5 (T
V
T
A
)

= 35 +0.5 (50 35)

= 42.5 F

h
Rr
= 0.1713 x 0.9 / 42.5 35) x [(42.5+460)
4
35+360)
4
]
100 100

= 0.765 Btu / Ft h.f

FINDING OVERALL COEFF. FOR EACH SIDE

I. Dry Area

1/
Ud
= 1/h
VW
+t
M
/K
M
+tI / kI +1/(W
f
h
Aw
) +h
RW
)+1/h
Fd

= 1/0.581 +1/640 +1/0.224 +1/(3.3 x 0.51 +0.759) +1/1000

= 6.597

U
d
= 0.1516

II. Wet Area

1/
UW
= 1/h
Lw
+t
M
/K
M
+ti/Ki +1/(W
f
h
1
Aw
) +h
RW
+1/h
Fw

= 1/0.4469+1/640+1/0.224+1/(3.3 x 0.51 +0.759) +1/800

= 7.114

U
W
= 0.140

III. Roof Area

1/Ur = 1/h
vr
+t
M
/K
M
+1/(Wfh
AR
+h
Rr
) +1/h
Fr

= 1/0.154 +1/640 +1/(3.3 x 0.6613 +0.765) +1/100

= 6.835

U
r
= 0.1463

FICHTNER India

FORM T10 REV - A

IV. Bottom Area

1/
Ub
= 1/h
Lb
+t
M
/K
M
+1/
ha
+1/h
Fb

= 1/0.241 +1/640 +1/0.102 +1/500

1/U
b
= 13.99

U
b
= 0.0716

RECALCULATION OF T
W
AND T
WS

Since the wall temperatures are assumed initially. It has to be recalculated to obtain a closer heat
transfer co-efficient based on the following formula :

T
ws
= (Ud / (h
Rd
+h
AW
) x (T
V
T
A
) +T
A

T
w
= T
V
(Ud/h
VW
) (T
V
-T
A
)

i) For Dry Area

T
WS
= (0.1504/(0.757+051)) x (50-35) +35

= 36.78 F

T
W
= 50-(0.1504 / 0.581) x (50-35)

= 46.12 F

ii) For Wet Area

T
WS
= (U
w
/ (h
RW
+h
AW
) x (T
L
-T
A
) +T
A

= (0.1396 / (0.759 +0.51) x (55-35) +35

= 37.21 F

T
W
= T
L
(U
W
/ h
LW
) (T
L
-T
A
)

= 55-(0.1396 / 0.4469) (55-35)
= 48.75F

iii) For Roof

T
W
= T
V
(U
r
/ h
Vr
) (T
V
-T
A
)

= 50 (0.1453/0.154) (50-35)

= 35.84 F

FICHTNER India

FORM T10 REV - A

iv) For Bottom

TW = TL (Ub / h
Lb
) (T
L
T
G
)

= 55 (0.0716 / 0.241) (55-40)

= 50.54 F

Based on the above Recalculated temperatures . The overall coeffs should be calculated
again through alteration. When the difference is within a limit , iteration can be stopped. The
iterated value and final results are tabulated as below.

Description Symbol Actual It-1 It-2 It-3 It-4 It-5
Coeff. For
vapour at wall
h
VW

Assumed wall
temp.
T
W
42.5 46.0916 45.3265 45.5316 45.4807 45.4936

Grashof
No.
N
Gr
1.93x10
12
1.01x10
12
1.2x10
12
1.15x10
12
1.16x10
12
1.16x10
12

Busslet
No.
N
Nu
915.08 723.69 771.80 759.44 462.54 761.76

Heat transfer
coeff
H
VW
0.58 0.46 0.49 0.48 0.48 0.48

Coeff for
liquidat wall
H
LW

Assumed wall
temp
T
w
45.0 48.7619 48.1746 48.2761 48.2593 48.2621

Grashoff no. N
Gr
134744.41 84055.26 91968.75 90600.33 90826.77 90789.01

Heat transfer
coeff
h
LW
0.45 0.3977 0.4068 0.4053 0.4055 0.4055

Coeff. For
vapour at Roof
h
Vr

Assumed wall
temp.
T
W
42.5 46.09 45.33 45.53 45.48 45.49

Grashoff no. N
Gr
1.12x10
12
5.82x10
11
6.96x10
11
6.66x10
11
6.73x10
11
6.71x10
11

Heat transfer
coeff
h
Vr
0.152 0.1296 0.1355 0.1340 0.1344 0.1343

Coeff.for liquid
bottom
h
Lb

Assumed wall
temp.
T
W
47.5 49.07 53.44 52.93 53.04 53.02
FICHTNER India

FORM T10 REV - A


Grashof
No
N
Gr
58482.82 46216.78 12195.56 16141.59 15274.09 15443.78

Nusslet
No.
N
Nu
40.29 37.28 24.02 26.35 25.87 25.97

Heat transfer
coeff.
h
Lb
0.24 0.22 0.14 0.16 0.16 0.16

Coeff for
outside air at
roof
h
Ar

Assumed wall
temp
T
WS
42.5 36.79 36.51 36.54 36.54 36.54

Grashof
No.
N
Gr
1.117x 10
12
2.67x10
11
2.25x10
11
2.30x10
11
2.29x10
11
2.29x10
11

Nusslet
No.
N
Nu
870.45 542.43 513.01 516.62 515.77 515.98

Heat transfer
co-eff
h
Ar
0.66 0.41 0.39 0.39 0.39 0.39

Coeff for
outside air at
wall
h
1
Ar

Assumed wall
temp
T
WS
4.38 9.25 9.18 9.19 9.18 9.18

Grashof
No.
N
Gr
9.01x10
12
1.91x10
13
1.89x10
13
1.89x10
13
1.89x10
13
1.89x10
13

Nusslet
No.
N
Nu
1593.32 2086.26 2080.50 2081.01 2080.91 2080.93

Heat transfer
co-eff
h

Ar
0.5 0.66 0.65 0.65 0.65 0.65

Conduction
coefficients

For ground h
G
0.10 0.10 0.10 0.10 0.10 0.10
For metal h
M
641.03 641.03 641.03 641.03 641.03 641.03
For Insulation h
I
0.22 0.22 0.22 0.22 0.22 0.22

Radiation
coefficients

FICHTNER India

FORM T10 REV - A

For dry side
wall
h
RD

Wall temp. T
WS
38.75 36.79 36.51 36.54 36.54 36.54

Heat transfer
coeff.
H
RD
0.76 0.75 0.75 0.75 0.75 0.75
For wet side
wall
h
RW

Wall temp. T
WS
40.00 37.21 36.93 36.94 36.94 36.94

Heat transfer
coeff.
h
RW
0.76 0.75 0.75 0.75 0.75 0.75

For roof side h
Rr

Wall temp. T
WS
42.50 36.79 36.51 36.54 36.54 36.54

Heat transfer
coeff.
h
Rr
0.77 0.75 0.75 0.75 0.75 0.75
Overall coeff.
For each side

For Dry area
Overall heat
Transfer
Coeff.
1/Ud 6.67 7.05 6.91 6.95 6.94 6.94
Ud 0.1500 0.1419 0.1447 0.1440 0.1441 0.1441

For wet area

Overall heat 1/Ud 7.16 7.37 7.31 7.32 7.32 7.32
Transfer
coeff.
Uw 0.1396 0.1357 0.1368 0.1366 0.1366 0.1366

Ud 0.1500 0.1419 0.1447 0.1440 0.1441 0.1441

For roof area

Over all heat
Transfer
Coeff.
1/Ur 6.94 8.25 7.93 8.01 7.99 7.99
Ur 0.1440 0.1213 0.1261 0.1249 0.1252 0.1251
For bottom
area

Overall heat
Transfer
coeff.
1/Ub 13.96 14.29 16.76 16.15 16.26 16.24
Ub 0.07 0.07 0.06 0.06 0.06 0.06

FICHTNER India

FORM T10 REV - A

AREA CALCULATION FOR EACH SIDE

i) Dry side

Ad = D (L-Lw)

= x 20 x (48.24)

= 1507.96 ft

ii) Wet side

Aw = DL
W

= x 20 x 24

= 1507.96 ft

iii) Roof side

At = ( D/2) (D / 4+d)

= ( x 20/2) ((20) / 4)

= 314.16 ft

iv) Bottom side

Ab = D / 4
= x (20) / 4
= 314.16 ft

HEAT LOSS CALCULATION FOR EACH SIDE

i) For dry side

q
d
= U
d
A
d
(T
V
-T
A
)

= 0.1441 x 1507.96 x (50-35)

= 3529.45 Btu/hr.

ii) For wet side

q = U
w
A
w
(T
L
T
A
)

= 0.1366 x 1507.96 x (55-35)

= 4119.74 Btu/hr

FICHTNER India

FORM T10 REV - A

iii) For roof side

q
r
= U
r
A
r
(T
V
-T
A
)

= 0.1251 x 314.16 (50-35)

= 589.52 Btu / hr.

iv) For bottom side

q
b
= U
b
A
b
(T
L
T
A
)

= 0.06 x 314.16 x (55-40)

= 282.74 Btu/hr.

Total Heat Loss

Q = q
d
+q
w
+q
r
+q
b

= 3259.45 +4119.74 +589.52 +282.74

= 8251.45 Btu/hr

= 2082.96 Kcal / hr.

Required Steam Flow Rate

= 2082.96 / 566.3

= 3.68 Kg/hr.

FICHTNER India

FORM T10 REV - A


THE SOURCE ARTICLE
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FORM T10 REV - A

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FORM T10 REV - A

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FORM T10 REV - A

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FORM T10 REV - A

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FORM T10 REV - A

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FORM T10 REV - A

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THERMAL INSULATION

1.0.0 Introduction

Heat is transfered by radiation, conduction, and convection, Radiation is the primary mode
and can occur even in vacuum. The amount of heat transferred for a given area is relative to
the temperature differential and emissivity from the radiating to the absorbing surface. The
prime purpose of a thermal insulation system is to minimise the amount of heat transferred
and for personnel protection.

2.0.0 Codes and Standards

IS 8183
IS 9842

3.0.0 Selection of Insulating Materials

The properties of insulation is necessary for selection of the proper insulation for specific use.
Many times in a given installation, a certain property may be of little importance whereas the
same property may be of utmost importance in a different application. The important
properties and their significance are as under.

1. Suitability of Service Temperature

The insulating material should not fail mechanically, chemically, or thermally within the
limits of temperature provided. It is necessary to consider the following items.

a) Linear Shrinkage
b) Loss of Compressive Strength
c) Internal self heating for deciding on the limiting temperature of the product.

2. Thermal Resistance
3. Thermal Diffusivity
4. Mechanical properties
5. Chemical properties
6. Economics.

4.0.0 Insulation in available in three forms

# Rigid pipe section
# Resin Bonded mattresses
# Resin Bonded slabs.

4.1.0 Rigid pipe section :

Materials conform to IS 9842, ASTM C 547 and BS 3958 Part 4 and density equal to 144
kg/m
3
. The temperature limit is between - 100 C to 750 C. Material totally incombustible.

For thermal conductivity, refer IS. The rigid pipe sections is chemically neutral and neither
causes nor accelerates corrosion. The pipe sections are water repellant and non
hygroscopic.

Application

FICHTNER India


They are suitable for steam and process pipe insulation operating at temperature upto 750 C
with a maximum diameter of pipe of 400 NB Due to high rigidity and compressive strength,
lightly bonded rigid pipe section can be used where high temperature and vibration is
encountered.

4.2.0 Resin Bonded Mattresses

Resin Bonded Mattresses conform to IS 8183. These are available in standard densities as
50, 80, 100, 125, 150 kg/m
3
and temperature limit is between - 100C to 750C and material
is totally in combustible when tested as per BS 476 part 4. The resin bonded mattresses are
water repellant and non hygroscopic. It is also chemically netural and neither causes nor
accelerates corrosion. For thermal conductivity, refer IS values.

Application

Due to wide range of densities available they are the preferred choice for various applications
like ESPs, Chimneys, Air Preheaters, Boiler Walls, Ducts, Steam Turbines, Columns etc.,

4.3.0 Resin Bonded Slabs

Resin Bonded Slabs conforms to IS 8183 and BS 3958 part 5. It is manufactured by using
select Basalt rocks. The precise control at every stage of manufacturing ensures that the
slabs offer maximum resistance to heat transfer. The insulation material thus manufactured
has built-in characteristics for superior thermal performance. The density ranges from 50 to
200 kg/m
3
to suit various application requirements and the temperature range is - 100C to
750C. The material is totally incombustible.

Application

They are suitable for a wide range of applications for thermal and Acoustical insulations.

5.0.0 Formula

The formula given below is used to determine the heat loss from the surface for a specified
insulation thickness. Loss due to radiation is not considered as the same may be negligible.

T overall
Heat Flow Q =
R

T = Overall difference in temperature C, T
i
- T
o

R = Thermal resistance, hr k/kcal or k/w
Q = Heat flow kcal/or W

(i) Cylindrical Body

R ={(1/(2**l)) * [(1/h
i
r
l
)+(1/k
1
)* ln (r
2
/ r
1
) +(1/k
2
) * ln (r
3
/ r
2
) +(1/h
0
r
3
)]}

k
1
, k
2
=Thermal conductivity, w/mk

hi, ho = Convective heat transfer co-efficient, w/m
2
k. (Refer heat transfer data book,
Kothandaraman).

l =length, m
FICHTNER India


r
1
, r
2
, r
3
=radius, m

(ii) Flat Body R =L/(K*A)

6.0.0 Recommended Insulation Thickness

Refer Annexure -1 for insulation thickness for indoor and out door installation.

FICHTNER India


RECOMMENDED INSULATION THICKNESS AT DIFFERENT TEMPERATURES FOR PIPING

A. INDOOR INSTALLATION

Insulation thickness in mm for various temperature ranges
Pipe
SL. Size 100C 100C 125C 150C 175C 200C 225C 250C 275C 300C 325C 350C 375C 400C 425C 450C 475C 500C 525C
NO. NB & upto upto upto upto upto upto upto upto upto upto upto upto upto upto upto upto upto upto
below 125C 150C 175C 200C 225C 250C 275C 300C 325C 350C 375C 400C 425C 450C 475C 500C 525C 550C

1 25 &
below
25 50 50 50 50 50 75 75 75 75 75 100 100 100 100 125 125 125 125
2 32 25 50 50 50 50 50 75 75 75 75 100 100 100 100 125 125 125 125 150
3 40 25 50 50 50 50 50 75 75 75 75 100 100 100 100 125 125 125 125 150
4 50 25 50 50 50 50 50 75 75 75 100 100 100 100 125 125 125 150 150 150
5 65 25 50 50 50 50 75 75 75 75 100 100 100 100 125 125 150 150 150 150
6 80 25 50 50 50 50 75 75 75 75 100 100 100 125 125 125 150 150 150 175
7 100 25 50 50 50 50 75 75 75 100 100 100 125 125 125 150 150 150 150 175
8 150 50 50 50 50 75 75 75 100 100 100 125 125 125 150 150 175 175 175 175
9 200 50 50 50 50 75 75 75 100 100 100 125 125 150 150 150 175 175 175 200
10 250 50 50 50 50 75 75 75 100 100 125 125 125 150 150 175 175 200 200 200
11 300 50 50 50 50 75 75 75 100 100 125 125 125 150 150 175 175 200 200 200
12 350 50 50 50 50 75 75 75 100 100 125 125 125 150 150 175 175 200 200 225
13 400 50 50 50 50 75 75 100 100 100 125 125 150 150 175 175 200 200 200 225
14 450 50 50 50 50 75 75 100 100 100 125 125 150 150 175 175 200 200 200 225
15 500 50 50 50 50 75 75 100 100 100 125 150 150 150 175 175 200 200 225 225
16 600 50 50 50 50 75 75 100 100 125 125 150 150 150 175 175 200 225 225 225

FICHTNER India


A. INDOOR INSTALLATION
Pipe
17 700 50 50 75 75 75 75 100 100 125 125 150 150 175 175 200 200 225 225 250
18 800 50 50 75 75 75 75 100 100 125 125 150 150 175 175 200 200 225 225 250
19 900 50 50 75 75 75 75 100 100 125 125 150 150 175 175 200 200 225 225 250
20 1000 50 50 75 75 75 75 100 100 125 125 150 150 175 200 200 225 225 225 250

Notes : 1. Insulating Material : Bonded Mineral Wool as per IS : 8183, Group 2 for temp. upto 350C, Group 3 for temp. between 350C & 500C, Group 4 for
temp. between 500C & 550C.

2. Minimum wind velocity considered for indoor installations : 100 M/min

3. Insulation surface temperature restricted within 60-62C for ambient temp. of 45C, and heat loss through insulation restricted within 140 Kcal/hr. at a
minimum ambient temperature of
(-) 2C and maximum wind velocity of 3000 M/min.

4. Insulated pipes will be jacketted by aluminium sheets conforming to IS : 737 or approved equivalent. The recommended thickness of aluminium
sheets is as follows :-

O. D of Insulation Thickness of Jacketting Sheet

a. Upto 325 mm 24 SWG
b. 325 to 900 mm, both sizes exclusive 22 SWG
c. 900 mm and above 20 SWG
RECOMMENDED INSULATION THICKNESS AT DIFFERENT TEMPERATURES FOR PIPING
FICHTNER India


B. OUTDOOR INSTALLATION

Pipe

1 25 &
below
25 50 50 50 50 50 50 50 50 50 75 75 75 75 75 75 100 100 100
2 32 25 50 50 50 50 50 50 50 50 50 75 75 75 75 75 100 100 100 100
3 40 25 50 50 50 50 50 50 50 50 75 75 75 75 75 75 100 100 100 100
4 50 25 50 50 50 50 50 50 50 50 75 75 75 75 75 100 100 100 100 100
5 65 25 50 50 50 50 50 50 50 50 75 75 75 75 100 100 100 100 100 125
6 80 25 50 50 50 50 50 50 50 75 75 75 75 75 100 100 100 100 100 125
7 100 25 50 50 50 50 50 50 50 75 75 75 75 100 100 100 100 125 125 125
8 150 50 50 50 50 50 50 50 50 75 75 75 100 100 100 100 125 125 125 125
9 200 50 50 50 50 50 50 50 75 75 75 100 100 100 100 125 125 125 125 150
10 250 50 50 50 50 50 50 50 75 75 75 100 100 100 100 125 125 125 125 150
11 300 50 50 50 50 50 50 50 75 75 75 100 100 100 100 125 125 125 150 150
12 350 50 50 50 50 50 50 50 75 75 75 100 100 100 125 125 125 150 150 150
13 400 50 50 50 50 50 50 50 75 75 75 100 100 100 125 125 125 150 150 150
14 450 50 50 50 50 50 50 50 75 75 75 100 100 100 125 125 125 150 150 150
15 500 50 50 50 50 50 50 50 75 75 75 100 100 100 125 125 125 150 150 150
16 600 50 50 50 50 50 50 50 75 75 100 100 100 100 125 125 150 150 150 175

FICHTNER India


B. OUTDOOR INSTALLATION
Pipe
17 700 50 50 75 75 75 75 75 75 75 100 100 100 125 125 125 150 150 150 175
18 800 50 50 75 75 75 75 75 75 75 100 100 100 125 125 125 150 150 150 175
19 900 50 50 75 75 75 75 75 75 75 100 100 100 125 125 125 150 150 150 175
20 1000 50 50 75 75 75 75 75 75 75 100 100 100 125 125 125 150 150 150 175

Notes : 1. Insulating Material : Bonded Mineral Wool as per IS : 8183, Group 2 for temp. upto 350C, Group 3 for temp. between 350C & 500C, Group 4 for
temp. between 500C & 550C.
2. Minimum wind velocity considered for indoor installations : 300 M/min
3. Insulation surface temperature restricted within 60-62C for ambient temp. of 46C, and heat loss through insulation restricted within 220 Kcal/hr. at a
minimum ambient temperature of
(-) 2C and maximum wind velocity of 3000 M/min.
4. For temperature upto 175C, same insulation thickness as for Indoor installations retained.
5. Insulated pipes will be jacketted by aluminium sheets conforming to IS : 737 or approved equivalent. The recommended thickness of aluminium
sheets is as follows :-

O. D of Insulation Thickness of Jacketting Sheet

a. Upto 325 mm 24 SWG
b. 325 to 900 mm, both sizes exclusive 22 SWG
c. 900 mm and above 20 SWG

FICHTNER India

FORM T10 REV - A

STEAM TRAP SELECTION

C O N T E N T S


1.0.0 INTRODUCTION 2

2.0.0 DESIGN CONCEPT 2

3.0.0 BASIC PRINCIPLES OF STEAM TRAP OPERATION 3

4.0.0 SIZING STEAM TRAPS 3

5.0.0 ADVANTAGES AND LIMITATIONS 3

6.0.0 QUICK REFERENCE STEAM TRAP SELECTION GUIDE 7

7.0.0 REFERENCE 7

8.0.0 FORMULA 7

FICHTNER India

FORM T10 REV - A

STEAM TRAP SELECTION

1.0.0 Introduction

Steam Generated in a Steam Generator loses its heat in heating, process application,
pipe radiation loss and in doing so, the steam returns to its condensate (i.e., liquid
state). If condensate is not drained immediately or trapped from the system, it
reduces the operating efficiency by slowing the heat transfer process and cause
physical damage through the phenomenon known as Water Hammer. Water Hammer
is caused due to accumulation of condensate in the pipe which is swept by the
velocity of steam when suddenly stopped by a pipe bend, fitting or valve. To avoid
water pockets, piping must be designed to drain properly. A trap is therefore required
at all locations when condensate is formed and collected.

Identified locations are as follows :

a) Steam Distribution Mains

i) At elevation changes such as risers and expansion loops.
ii) At all low points and at intervals of 60 to 150 m on long horizontal runs.
iii) Ahead of all possible Dead-ended areas such as shutoff valves, pressure and
temperature control valves and at ends of mains.

b) Steam Tracing Service

i) On traced and jacketed piping and valves
ii) For freeze protection of instruments and equipment

c) Steam Operated Equipment

i) Ahead of humidifiers, pumps, turbines etc.,
ii) Draining directly below heat exchangers, coils, unit heaters, driers etc.,

2.0.0 Design Concept

i) Air Venting

The air and other non condensible gases such as CO
2
etc present in the system
shall also be purged by the trap or alternatively by an auxiliary air vent.

The Steam Trap is an automatic drain valve which shall sense the difference
between the steam and condensate, operate under varying inlet and back
pressures, changing condensate loads and shall also release non condensible
gases while not wasting any steam.

ii) Trap Discharge Temperature

The temperature at which the condensate is discharged by the trap is important in
maintaining energy efficiency. While most applications require that the condensate
be discharged at close to steam temperature utilising the steam latent heat, some
may tolerate some degree of water logging and thereby also use the sensible heat
contained in the condensate as it cools down to 100 C. The type of trap selected
must therefore be matched to its intended use if the most effective energy use of
the steam system is to be realised.

3.0.0 Basic Principles of Steam Trap Operation

FICHTNER India

FORM T10 REV - A

The different types of steam traps operate by sensing the difference between steam
and condensate using one or more of three basic physical properties. When classified
according to these operating principles, each design has advantages and limitations
which must be considered when selecting a steam trap.

Density Operated-Mechanical Traps

i) Float
ii) Inverted Bucket

Temperature Operated - Thermostatic Traps

i) Balanced - Pressure Thermostatic
ii) Thermostatic

a) Liquid Expansion
b) Bimetal Expansion

Kinetic Energy Operated - Disc and Orifice Traps

i) Thermo Dynamic Traps
ii) Impulse or Orifice.

4.0.0 Sizing Steam Traps

4.1 Calculate or estimate the maximum condensate load in kg/hr.

4.2 Pressure at inlet of trap. This may be significantly less than the pressure in the steam
supply main. Select a trap with pressure rating equal to or greater than the steam line
pressure, but with a capacity based on the estimated pressure at the trap inlet. For
example, in a heat exchanger, if all the steam is condensed in the coil, the trap will
only be pressurised by the hydraulic leg of water ahead of it. This is 0.1 kg/cm
2

for each 1 metre drop from the coil to the trap inlet.

4.3 Back pressure against which the trap must operate. In many installations the piping
from the outlet of the trap is connected into a common return system which may
contain some pressure. The trap will have to operate against this pressure plus any
static head created if the trap is required to lift the condensate to an overhead return.

5.0.0 Advantages and Limitations

1. Density Operated Traps

Float and Thermostatic Traps:

Advantages :

Discharges condensate continuously as rapidly as it forms.
High air venting capacity through auxiliary balanced pressure air vent, which is
self- adjusting for varying steam pressures.
High thermal efficiency at both light and heavy loads.
Continuous modulating discharge does not create pressure disturbances,
which may cause erratic control in air heating coils, shell and tube exchangers,
etc.,
Steam lock release (S.L.R) facility available.
Inline inlet and outlet facility, easy installation at low cost.
Robust, fair resistance to water hammer.
FICHTNER India

FORM T10 REV - A

Unaffected by changes in line pressure.

Limitations

Cannot be used where trap is fitted with air vent bellows & degree of
superheat >100 C.
Applications subjected to freezing must be protected with insulation & SLR.
Water hammer can damage float.

Applications

Air unit heaters, Hot water heaters, Heat exchangers, Reboilers, etc.,

2. Inverted Bucket Traps

Advantages :

Fair resistance to water hammer.
Can be made for very high pressures.

Limitations

Low thermal efficiency under varying loads and pressures, some steam loss
for operation.
Must maintain water seal to avoid continuous discharge of steam.
Must be protected from freezing.
Cannot discharge condensate continuously as rapidly as it forms.
Bleed hole in bucket has very limited air venting capacity.
Bimetal auxiliary air vent must be factory set at low temperature not self
adjusting.

Applications

High pressure indoor steam main drops and submerged heating coils.

3. Temperature Operated Traps

Balanced - Pressure Thermostatic Traps

Advantages

High air venting capacity for fast start-up.
Large capacity in small size.
Self-adjusting; will operate without adjustments at all pressures within its
range.
Will not freeze if given free discharge.
Uses small valve sizes for all pressures within its operating range.
Minimum parts.
Operates in vacuum system.
Can withstand superheat of 100 C.

Limitations

Most are not suitable for highly superheated steam.
FICHTNER India

FORM T10 REV - A

Limited resistance to water hammer and corrosion depending on bellow
construction.
Not suitable for application in which condensate must be discharged as fast as
it is formed. Condensate must cool before it can be discharged.
Blast discharge at higher pressure with most models.

Applications

Low and medium pressure submerged heating coils, steam tracer, steam
radiators.

4. Liquid Expansion Thermostatic Traps

Advantages

Withstands hammer.
Very high thermal efficiency
Low temperature discharge eliminates flash steam around operating stations.
Will not freeze when given free discharge.
Generally fails in an open position.

Limitations

Limited to applications such as storage tanks and some tracer lines where
condensate can be held back and subcooled before discharge.
Corrosive condensage can attack bronze bellows in thermostatic element.
Not self-adjusting to pressure changes.
Must have an open discharge outlet.

Applications

Steam tracing lines, storage tank coils, open tank heating coils.

5. Bimetallic Thermostatic Traps

Advantages

Withstand water hammer.
Very high thermal efficiency when set to discharge at low temperature.
Low temperature discharge eliminates flash steam around operating stations.
Some designs will not freeze when given free discharge.
Performs well on superheated steam application.

Limitations

Inconsistent operation and slower response.
Limited to applications in which condensate can be held back and subcooled
before being discharged.
Bimetal characteristics may change after being in use repairing service.
Not self-adjusting to inlet pressure changes.

Applications

Steam tracing lines which can tolerate partial flooding, storage tank coils.
FICHTNER India

FORM T10 REV - A

6. Kinetic Operated Traps

Thermo Dynamic Disc Traps

Advantages

Compact, light weight
All stainless steel construction for good corrosion resistance.
High resistance to water hammer.
Long life due to hardened seat and disc.
Only one moving part.
One trap for all pressures from 0.25 bar to 120 bar.
Efficient operation under varying loads and pressures.
Fast response to changing loads.
Discharges condensate at steam temperature to prevent water logging.

Limitations

Not suitable for pressures below 0.25 bar.
Some models limited to 50% back pressures, others suitable for 80% back
pressures.
Not recommended for low pressure applications with temperature control
valves.

Applications

Steam main drips, High pressure and superheat, steam tracer lines, unit heaters.

Impulse Traps

Advantages

Small, light-weight.
All stainless steel construction.
Good resistance to superheat and water hammer.

Limitations

Continuous bleed orifices will waste steam on light loads.
Close-fitting valve parts are subject to sticking.
Condensate held back can cause water logging.
Condensate held back may contribute to corrosion and water hammer.
Should not be used where back pressure will exceed 30% of inlet pressure.

Applications

Not recommended.

6.0.0 Quick Reference Steam Trap Selection Guide

FICHTNER India

FORM T10 REV - A

Sl.No. Application First Choice Second Choice

1. Air Heating Coils
Low and Medium Pressure
High Pressure

Float
Float

Bucket
Bucket
2. Hot Water Heaters
(Instantaneous)

Float

-------
3. Hot Water Heaters (Storage) Float Bucket
4. Shell and Tube Exchangers
Small-High Pressure
Large-Low Pressure
Reboilers

Float
Float
Float

Thermodynamic/Bucket
Bucket
Bucket
5. Steam Humidifiers Float Bucket
6. Steam Tracer Lines Balanced-Pressure
Thermostatic
Thermodynamic/
Bimetallic
7. Storage Tank Coils Float Thermodynamic/Bucket
8. Submerged Heating Coils
High Pressure

Low and Medium Pressure

Float
Thermodynamic

Float

Bucket
Balanced Pressure
Thermostatic
Balanced Pressure
Thermostatic
9. Unit Heaters Float Thermodynamic
10. Steam Pipe Coils (Air Heating) Balanced Pressure
Thermostatic
Thermodynamic
11. Steam Line Drip Traps
0 -1 bar
1 - 120 bar
High Pressure Superheat

Float
Thermodynamic
Thermodynamic

Bucket
Bucket
Bimetallic
12. Steam J acketed Vessels
High Pressure
Low Pressure

Thermodynamic
Float

Bucket
Thermodynamic
13. Steam Separators
0 - 1 bar
1 - 120 bar

Float
Thermodynamic

Bucket
Bucket

7.0.0 Reference :

Steam trap Selection & Application Guide - Spirax.

8.0.0 Formula

Calculating Condensate Loads, General Applications

litres/hr
Heating water : kgs. condensate/hr = ---------- x rise in C
500

litres/hr
Heating fuel oil : kgs. condensate/hr = ---------- x rise in C
1000

NM
3
/min.
FICHTNER India

FORM T10 REV - A

Heating air : kgs. condensate/hr = ----------- x rise in C
27

Condensate (kg/hr) per 30m of Insulated Steam Main at 21 C Ambient :

Steam Main Size (mm NB)

50 80 100 150 200 250
0.7 3 4 5 8 10 12
4 5 7 9 14 17 21
7 6 9 11 16 20 25
20 10 15 19 28 35 44
42 15 22 28 41 52 64

Note : approximate load per 30m

Steam Tracing Line is 30 kg/hr.

Calculating Condensate Load for Specialised Applications

Heating Liquid in J acketed Vessels. Steam J acketed Dryers.

W x Cp X T
kg. Cond./hr =----------------------
L x t

W =weight of liquid (kg.)
Cp =spec. heat of liquid (K Cal./kg. C)
T =temp. rise of liquid C
L =latent heat of steam (K Cal./kg.)
t =time in hours

Heating Air:

Pipe Coils & Radiation

A x U x T
kg. Cond./hr =-------------------
L

A =heating surface area (m
2
)
U =heat transfer coefficient (K Cal./m
2
C)
(2 for free convection)
T =temp. rise of material in C
L =latent heat of steam (K Cal./kg.)

FICHTNER India


PRESSURE - TEMPERATURE RATINGS
TABLE 1 - LIST OF MATERIAL SPECIFICATIONS/GROUPS

REF: ASME B16.5-1996 PIPE FLANGES/ FLANGED FITTINGS

Pressure Applicable ASTM Specifications
Matl Nominal Temperature Matl
Group Designation Rating Table Forgings Castings Plates Group
1.1 C-Si 2-1.1 A 105 A 216 Gr.WCB A 515 Gr. 70 1.1
C-Mn-Si A 350 Gr.LF2 A 516 Gr. 70
A 537 Cl.1
1.2 C-Mn-Si 2-1.2 A 216 Gr.WCC 1.2
2Ni A 352 Gr.WCC
3Ni A 352 Gr.LC2 A 203 Gr. B
A 350 Gr.LF3 A 352 Gr.LC3 A 203 Gr. E
1.3 C-Si 2-1.3 A 352 Gr.LCB A 515 Gr. 65 1.3
C-Mn-Si A 516 Gr. 65
2Ni A 203 Gr. A
3Ni A 203 Gr. D
1.4 C-Si 2-1.4 A 515 Gr. 60 1.4
C-Mn-Si A 350 Gr.LF1 Cl.1 A 516 Gr. 60
1.5 C-Mo 2-1.5 A 182 Gr. F1 A 217 Gr. WC1 A 204 Gr.A 1.5
A 352 Gr.LC1 A 204 Gr.B
1.7 C-Mo 2-1.7 A 204 Gr.C 1.7
Cr-Mo A 182 Gr. F2
Ni-Cr-Mo A 217 Gr. WC4
Ni-Cr-1Mo A 217 Gr. WC5
1.9 1Cr-Mo 2-1.9 A 182 Gr. F12 Cl.2 1.9
1Cr-Mo A 217 Gr. WC6
1Cr-Mo-Si A 182 Gr. F11 Cl.2 A 387 Gr. 11 Cl.2
1.10 2Cr-1Mo 2-1.10 A 182 Gr. F22 Cl.3 A 217 Gr. WC9 A 387 Gr. 22 Cl.2 1.10
1.13 5Cr-Mo 2-1.13 A 182 Gr. F5 1.13
A 182 Gr. F5a A 217 Gr. C5
1.14 9Cr-1Mo 2-1.14 A 182 Gr. F9 A 217 Gr. C12 1.14
2.1 18Cr-8Ni 2-2.1 A 182 Gr. F304 A 351 Gr. CF3 A 240 Gr. 304 2.1
A 182 Gr. F304H A 351 Gr. CF8 A 240 Gr. 304H
FICHTNER India


2.2 16Cr-12Ni-2Mo 2-2.2 A 182 Gr. F316 A 351 Gr. CF3M A 240 Gr. 316 2.2
A 182 Gr. F316H A 351 Gr. CF8M A 240 Gr. 316H
18Cr-13Ni-3Mo A 240 Gr. 317
19Cr-10Ni-3Mo A 351 Gr. CG8M
2.3 18Cr-8Ni 2-2.3 A 182 Gr. F304L A 240 Gr. 304L 2.3
16Cr-12Ni-2Mo A 182 Gr. F316L A 240 Gr. 316L
2.4 18Cr-10Ni-Ti 2-2.4 A 182 Gr. F321 A 240 Gr. 321 2.4
A 182 Gr. F321H A 240 Gr. 321H
2.5 18Cr-10Ni-Cb 2-2.5 A 182 Gr. F347 A 351 Gr. CF8C A 240 Gr. 347 2.5
A 182 Gr. F347H A 240 Gr. 347H
A 182 Gr. F348 A 240 Gr. F348
A 182 Gr. F348H A 240 Gr. F348H
2.6 25Cr-12Ni 2-2.6 A 351 Gr. CH8 2.6
A 351 Gr. CH20
A 240 Gr. 310S
A 240 Gr. 310H
2.7 25Cr-20Ni 2-2.7 A 182 Gr. F310 A 351 Gr. CK20 A 240 Gr. 310S 2.7
A 240 Gr. 310H
2.8 20Cr-18Ni-6Mo 2-2.8 A 182 Gr. F44 A 351 Gr.
CK3MCuN
A 240 Gr. S31254 2.8
22Cr-5Ni-3Mo-N A 182 Gr. F51 A 240 Gr. S31803
25Cr-7Ni-4Mo-N A 182 Gr. F53 A 240 Gr. S32750
3.1 35Ni-35Fe-20Cr-Cb 2-3.1 B 462 Gr. N08020 B 463 Gr. N08020 3.1
28Ni-19Cr-Cu-Mo A 351 Gr. CN7M
3.2 99.0Ni 2-3.2 B 160 Gr. N02200 B 162 Gr. N02200 3.2
3.3 99.0Ni-Low c 2-3.3 B 160 Gr. N02201 B 162 Gr. N02201 3.3
3.4 67Ni-30Cu 2-3.4 B 564 Gr.N04400 B 127 Gr. N04400 3.4
67Ni-30Cu-S B 164 Gr.N04405
3.5 72Ni-15Cr-8Fe 2-3.5 B 564 Gr.N06600 B 168 Gr. N06600 3.5
3.6 33Ni-42Fe-21 Cr 2-3.6 B 564 Gr.N08800 B 409 Gr. N08800 3.6
3.7 65Ni-28Mo-2Fe 2-3.7 B 335 Gr. N10665 B 333 Gr. N10665 3.7
3.8 54Ni-16Mo-15Cr 2-3.8 B 564 Gr. N10276 B 575 Gr. N10276 3.8
60Ni-22Cr-9Mo-3.5Cb B 564 Gr. N06625 B 443 Gr. N06625
62Ni-28Mo-5Fe B 335 Gr. N100001 B 333 Gr. N10001
70Ni-16Mo-7Cr-5Fe B 573 Gr. N100003 B 434 Gr. N10003
61Ni-16Mo-16Cr B 574 Gr. N06455 B 575 Gr. N06455
42Ni-21.5Cr-3Mo-2.3Cu B 564 Gr. N08825 B 424 Gr. N08825
FICHTNER India


3.9 47Ni-22Cr-9Mo-18Fe 2-3.9 B 572 Gr. N06002 B 435 Gr. N06002 3.9
3.10 25Ni-46Fe-21Cr-5Mo 2-3.10 B 672 Gr. N08700 B 599 Gr. N08700 3.10
3.11 44Fe-25Ni-21Cr-Mo 2-3.11 B 649 Gr. N08904 B 625 Gr. N08904 3.11
3.12 26Ni-43Fe-22Cr-5Mo 2-3.12 B 621 Gr. N08320 B 620 Gr. N08320 3.12
47Ni-22Cr-20Fe-7Mo B 581 Gr. N06985 B 582 Gr. N06985
3.13 49Ni-25Cr-18Fe-6Mo 2-3.13 B 581 Gr. N06975 B 582 Gr. N06975 3.13
Ni-Fe-Cr-Mo-Low Cu B 564 Gr. N08031 B 625 Gr. N08031
3.14 47Ni-22Cr-19Fe-6Mo 2-3.14 B 581 Gr. N06007 B 582 Gr. N06007 3.14
3.15 33Ni-42Fe-21Cr 2-3.15 B 564 Gr. N08810 B 409 Gr. N08810 3.15
3.16 35Ni-19Cr-1Si 2-3.16 B 511 Gr. N08330 B 536 Gr. N08330 3.16

NOTE :

(1) ASME Boiler and Pressure Vessel Code, Section II materials, which also meet the
requirements of the listed ASTM specifications, may also be used.
FICHTNER India

REFERENCE: ANSI B16.5, PIPE FLANGES AND FLANGED FITTINGS
GROUPS INDICATED: ONLY POWER PLANT APPLICABLE AREA

WORKING PRESSURES BY CLASSES,psig (150)

GROUP
CLASS 150#
TEMP.F 1.1 1.2 1.3 1.4 1.5 1.7 1.9 1.10 1.13 1.14 2.1 2.2 2.3 2.4 2.5 2.6 2.7

(-)20to100 285 290 265 235 265 290 290 290 290 290 275 275 230 275 275 260 260
200 260 260 250 215 260 260 260 260 260 260 230 235 195 245 255 230 235
300 230 230 230 210 230 230 230 230 230 230 205 215 175 230 230 220 220
400 200 200 200 200 200 200 200 200 200 200 190 195 160 200 200 200 200
500 170 170 170 170 170 170 170 170 170 170 170 170 145 170 170 170 170
600 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140
650 125 125 125 125 125 125 125 125 125 125 125 125 125 125 125 125 125
700 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110
750 95 95 95 95 95 95 95 95 95 95 95 95 95 95 95 95 95
800 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80
850 65 65 65 65 65 65 65 65 65 65 65 65 65 65 65 65 65
900 50 50 50 50 50 50 50 50 50 50 50 50 _ 50 50 50 50
950 35 35 35 35 35 35 35 35 35 35 35 35 _ 35 35 35 35
1000 20 20 20 20 20 20 20 20 20 20 20 20 _ 20 20 20 20
1050
1100
1150
1200
1250
1300

FICHTNER India



GROUP
CLASS 300#
TEMP.F 1.1 1.2 1.3 1.4 1.5 1.7 1.9 1.10 1.13 1.14 2.1 2.2 2.3 2.4 2.5 2.6 2.7

(-)20to100 740 750 695 620 695 750 750 750 750 750 720 720 600 720 720 670 670
200 675 750 655 560 680 750 750 750 745 750 600 620 505 645 660 605 605
300 655 730 640 550 655 720 720 730 715 730 540 560 455 595 615 570 570
400 635 705 620 530 640 695 695 705 705 705 495 515 415 550 575 535 535
500 600 665 585 500 620 665 665 665 665 665 465 480 380 515 540 505 505
600 550 605 535 455 605 605 605 605 605 605 435 450 360 485 515 480 480
650 535 590 525 450 590 590 590 590 590 590 430 445 350 480 505 465 470
700 535 570 520 450 570 570 570 570 570 570 425 430 345 465 495 455 455
750 505 505 475 445 530 530 530 530 530 530 415 425 335 460 490 445 450
800 410 410 390 370 510 510 510 510 510 510 405 420 330 450 485 435 435
850 270 270 270 270 485 485 485 485 485 485 395 420 320 445 485 425 425
900 170 170 170 170 450 450 450 450 370 450 390 415 440 450 415 420
950 105 105 105 105 280 315 320 375 275 375 380 385 385 385 385 385
1000 50 50 50 50 165 200 215 260 200 255 320 350 355 365 335 345
1050 160 145 175 145 170 310 345 315 360 290 335
1100 95 110 100 115 255 305 270 325 225 260
1150 60 70 60 75 200 235 235 275 170 190
1200 40 40 35 50 155 185 185 170 130 135
1250 115 145 140 125 100 105
1300 85 115 110 95 80 75
1350 60 95 85 70 60 60
1400 50 75 65 55 45 45
1450 35 60 50 40 30 35
1500 25 40 40 35 25 25

FICHTNER India



GROUP
CLASS 400#
TEMP.F 1.1 1.2 1.3 1.4 1.5 1.7 1.9 1.10 1.13 1.14 2.1 2.2 2.3 2.4 2.5 2.6 2.7

(-)20to100 990 1000 925 825 925 1000 1000 1000 1000 1000 960 960 800 960 960 895 895
200 900 1000 875 750 905 1000 1000 1000 995 1000 800 825 675 880 880 805 810
300 875 970 850 730 870 965 965 970 955 970 720 745 605 795 820 760 760
400 845 940 825 705 855 925 925 940 940 940 660 685 550 735 765 710 715
500 800 885 775 665 830 885 885 885 885 885 620 635 510 685 720 670 675
600 730 805 710 610 805 805 805 805 805 805 580 600 480 650 685 635 640
650 715 785 695 600 785 785 785 785 785 785 575 590 470 635 670 620 625
700 710 755 690 600 755 710 755 755 755 755 565 580 460 620 660 610 610
750 670 670 630 590 710 675 710 710 705 710 555 570 450 610 655 595 600
800 550 550 520 495 675 650 675 675 675 675 540 565 440 600 650 580 580
850 355 355 355 355 650 600 650 650 645 650 530 555 430 595 645 565 575
900 230 230 230 230 600 420 600 600 495 600 520 555 590 600 555 555
950 140 140 140 140 375 270 425 505 365 505 510 515 515 515 515 515
1000 70 70 70 70 220 210 290 345 265 340 430 465 475 485 450 460
1050 190 235 190 230 410 460 415 480 390 450
1100 130 145 135 150 345 405 360 430 300 345
1150 80 90 80 100 265 315 315 365 230 250
1200 50 55 45 70 205 245 245 230 175 185
1250 150 195 185 165 135 135
1300 115 155 145 125 105 100
1350 80 130 115 90 80 80
1400 65 100 85 75 60 60
1450 45 80 70 55 40 45
1500 35 55 50 45 30 35

FICHTNER India


GROUP
CLASS 600#
TEMP.F 1.1 1.2 1.3 1.4 1.5 1.7 1.9 1.10 1.13 1.14 2.1 2.2 2.3 2.4 2.5 2.6 2.7

(-)20to100 1480 1500 1390 1235 1390 1500 1500 1500 1500 1500 1440 1440 1200 1440 1440 1345 1345
200 1350 1500 1315 1125 1360 1500 1500 1500 1490 1500 1200 1240 1015 1290 1320 1210 1215
300 1315 1455 1275 1095 1305 1445 1445 1455 1430 1455 1080 1120 910 1190 1230 1140 1140
400 1270 1410 1235 1060 1280 1385 1385 1410 1410 1410 995 1025 825 1105 1145 1065 1070
500 1200 1330 1165 995 1245 1330 1330 1330 1330 1330 930 955 765 1030 1080 1010 1015
600 1095 1210 1065 915 1210 1210 1210 1210 1210 1210 875 900 720 975 1025 955 960
650 1075 1175 1045 895 1175 1175 1175 1175 1175 1175 960 890 700 955 1010 930 935
700 1065 1135 1035 895 1135 1135 1135 1135 1135 1135 850 870 685 930 990 910 910
750 1010 1010 945 885 1065 1065 1065 1065 1055 1065 830 855 670 915 985 895 900
800 825 825 780 740 1015 1015 1015 1015 1015 1015 805 845 660 900 975 870 875
850 535 535 535 535 975 975 975 975 965 975 790 835 645 895 970 850 855
900 345 345 345 345 900 900 900 900 740 900 780 830 885 900 830 835
950 205 205 205 205 560 630 640 755 550 755 765 775 775 775 775 775
1000 105 105 105 105 330 405 430 520 400 505 640 700 715 725 670 685
1050 315 290 350 290 345 615 685 625 720 585 670
1100 190 220 200 225 515 610 545 645 445 520
1150 125 135 125 150 400 475 465 550 345 375
1200 75 80 70 105 310 370 370 345 260 275
1250 225 295 280 245 200 205
1300 170 235 220 185 160 150
1350 125 190 170 135 115 115
1400 95 150 130 110 90 90
1450 70 115 105 80 60 65
1500 55 85 75 70 50 50

FICHTNER India


GROUP
CLASS 900#
TEMP.F 1.1 1.2 1.3 1.4 1.5 1.7 1.9 1.10 1.13 1.14 2.1 2.2 2.3 2.4 2.5 2.6 2.7

(-)20to100 2220 2250 2085 1850 2085 2250 2250 2250 2250 2250 2160 2160 1800 2160 2160 2015 2015
200 2025 2250 1970 1685 2035 2250 2250 2250 2235 2250 1800 1860 1520 1935 1980 1815 1820
300 1970 2185 1915 1640 1955 2165 2165 2185 2150 2185 1620 1680 1360 1785 1845 1705 1705
400 1900 2115 1850 1585 1920 2080 2080 2115 2115 2115 1490 1540 1240 1655 1720 1600 1605
500 1795 1995 1745 1495 1865 1995 1995 1995 1995 1995 1395 1435 1145 1545 1620 1510 1520
600 1640 1815 1600 1370 1815 1815 1815 1815 1815 1815 1310 1355 1080 1460 1540 1435 1440
650 1610 1765 1570 1345 1765 1765 1765 1765 1765 1765 1290 1330 1050 1435 1510 1395 1405
700 1600 1705 1555 1345 1705 1705 1705 1705 1705 1705 1275 1305 1030 1395 1485 1370 1370
750 151 1510 1420 1325 1595 1595 1595 1595 1585 1595 1245 1280 1010 1375 1475 1340 1345
800 1235 1235 1175 1110 1525 1525 1525 1525 1525 1525 1210 1265 985 1355 1460 1305 1310
850 805 805 805 805 1460 1460 1460 1460 1450 1460 1190 1255 965 1340 1455 1275 1280
900 515 515 515 515 1350 1350 1350 1350 1110 1350 1165 1245 1325 1350 1245 1255
950 310 310 310 310 845 945 955 1130 825 1130 1145 1160 1160 1160 1160 1160
1000 155 155 155 155 495 605 650 780 595 760 965 1050 1070 1090 1010 1030
1050 475 430 525 430 515 925 1030 940 1080 875 1010
1100 290 330 300 340 770 915 815 965 670 780
1150 185 205 185 225 595 710 710 825 515 565
1200 115 125 105 155 465 555 555 515 390 410
1250 340 440 420 370 300 310
1300 255 350 330 280 235 225
1350 185 290 255 205 175 175
1400 145 225 195 165 135 135
1450 105 175 155 125 95 100
1500 80 125 115 105 70 75

FICHTNER India

GROUP
CLASS 1500#
TEMP.F 1.1 1.2 1.3 1.4 1.5 1.7 1.9 1.10 1.13 1.14 2.1 2.2 2.3 2.4 2.5 2.6 2.7

(-)20to100 3705 3750 3470 3085 3470 3750 3750 3750 3750 3750 3600 3600 3000 3600 3600 3360 3360
200 3375 3750 3280 2810 3395 3750 3750 3750 3725 3750 3000 3095 2530 3230 3300 3025 3035
300 3280 3640 3190 2735 3260 3610 3610 3640 3580 3640 2700 2795 2270 2975 3070 2845 2845
400 3170 3530 3085 2645 3200 3465 3465 3530 3530 3530 2485 2570 2065 2760 2870 2665 2675
500 2995 3325 2910 2490 3105 3325 3325 3325 3325 3325 2330 2390 1910 2570 2700 2520 2530
600 2735 3025 2665 2285 3025 3025 3025 3025 3025 3025 2185 2255 1800 2435 2570 2390 2400
650 2685 2940 2615 2245 1940 2940 2940 2940 2940 2940 2150 2220 1750 2390 2520 2330 2340
700 2665 2840 2590 2245 2840 2840 2840 2840 2840 2840 2125 2170 1715 2330 2470 2280 2280
750 2520 2520 2365 2210 2660 2660 2660 2660 2640 2660 2075 2135 1680 2290 2460 2230 2245
800 2060 2060 1955 1850 2540 2540 2540 2540 2540 2540 2015 2110 1645 2255 2435 2170 2185
850 1340 1340 1340 1340 2435 2435 2435 2435 2415 2435 1980 2090 1610 2230 2425 2125 2135
900 860 860 860 860 2245 2245 2245 2245 1850 2245 1945 2075 2210 2245 2075 2090
950 515 515 515 515 1405 1575 1595 1885 1370 1885 1910 1930 1930 1930 1930 1930
1000 260 260 260 260 825 1010 1080 1305 995 1270 1605 1750 1785 1820 1680 1720
1050 790 720 875 720 855 1545 1720 1565 1800 1460 1680
1100 480 550 495 565 1285 1525 1360 1610 1115 1305
1150 310 345 310 375 995 1185 1185 1370 860 945
1200 190 205 170 255 770 925 925 855 650 685
1250 565 735 705 615 495 515
1300 430 585 550 465 395 375
1350 310 480 430 345 290 290
1400 240 380 325 275 225 225
1450 170 290 255 205 155 165
1500 135 205 190 170 120 130



FICHTNER India

GROUP
CLASS 2500#
TEMP.F 1.1 1.2 1.3 1.4 1.5 1.7 1.9 1.10 1.13 1.14 2.1 2.2 2.3 2.4 2.5 2.6 2.7

(-)20to100 6170 6250 5785 5145 5785 6250 6250 6250 6250 6250 6000 6000 5000 6000 6000 5600 5600
200 5625 6250 5470 4680 5660 6250 6250 6250 6250 6250 5000 5160 4220 5380 5500 5040 5060
300 5470 6070 5315 4560 5435 6015 6015 6070 5965 6070 4500 4660 3780 4960 5120 4740 4740
400 5280 5880 5145 4405 5330 5775 5775 5880 5880 5880 4140 4280 3440 4600 4780 4440 4260
500 4990 5540 4850 4150 5180 5540 5540 5540 5540 5540 3880 3980 3180 4285 4500 4200 4220
600 4560 5040 4440 3805 5040 5040 5040 5040 5040 5040 3640 3760 3000 4060 4280 3980 4000
650 4475 4905 4355 3740 4905 4905 4905 4905 4905 4905 3580 3700 2920 3980 4200 3880 3900
700 4440 4730 4320 3740 4730 4730 4730 4730 4730 4730 3540 3620 2860 3880 4120 3800 3800
750 4200 4200 3945 3685 4430 4430 4430 4430 4430 4430 3460 3560 2800 3820 4100 3720 3740
800 3430 3430 3260 3085 4230 4230 4230 4230 4230 4230 3360 3520 2740 3760 4060 3620 3640
850 2230 2230 2230 2230 4060 4060 4060 4060 4030 4060 3300 3480 2680 3720 4040 3540 3560
900 1430 1430 1430 1430 3745 3745 3745 3745 3085 3745 3240 3460 3680 3745 3460 3480
950 860 860 860 860 2345 2630 2655 3145 2285 3145 3180 3220 3220 3220 3220 3220
1000 430 430 430 430 1370 1685 1800 2170 1655 2115 2675 2915 2970 3030 2800 2865
1050 1315 1200 1455 1200 1430 2570 2865 2605 3000 2430 2800
1100 800 915 830 945 2145 2545 2265 2685 1860 2170
1150 515 570 515 630 1655 1970 1970 2285 1430 1570
1200 315 345 285 430 1285 1545 1545 1430 1085 1145
1250 945 1230 1170 1030 830 855
1300 715 970 915 770 660 630
1350 515 800 715 570 485 485
1400 400 630 545 455 370 370
1450 285 485 430 345 260 275
1500 230 345 315 285 200 215

FICHTNER India

FORM T10 REV - A

STANDARD FLANGE DIMENSION DATA

FICHTNER India

FORM T10 REV - A

WELD JOINT QUANTITY CALCULATION

OBJECTIVE

This procedure is to find out total inch weld length

PROCEDURE

Procedure for calculating the total inch length welded by calculating no. of joints shall
be as per the following steps.

1. Classification based on type of material
2. Size of pipe welded in inches
3. Calculate no. of joints

CLASSIFICATION

Carbon steel
Alloy steel
Stainless steel

PIPE SIZES

In each class of above material note the pipe sizes and no. of joints.

WELD LENGTH

Total weld length shall be calculated as per the following table.

Sl.
No.
Material Pipe Size
Inch (D)
No. of Joints
N
Inch Weld
Length
1. Carbon
Steel
...D1
...D2
..
..
....N1
....N2
...
....
D1 *N1
D2 *N2
...
..
TOTAL
2. Alloy
Steel
...D1
...D2
..
..
..
...N1
...N2
...
...
....
D1 *N1
D2 *N2
...
...
..
TOTAL
3. Stainless
Steel
...D1
...D2
..
..
..
...N1
...N2
...
...
....
D1 *N1
D2 *N2
...
...
..
TOTAL

FICHTNER India

FORM T10 REV - A

LPT QUANTITY CALCULATIONS

OBJECTIVE

This procedure is to find out total Liquid Penetrat Test quantity calculation

PROCEDURE

LPT shall be carried out for atleast 10% of the total pipe welding joints based on
services. For the additional liquid penetrant tests following procedure shall be carried
out to calculate its total quantity.

1. Size of pipe joints tested.
2. Calculate no. of joints.

PIPE SIZES

Note the pipe sizes and no. of joints

WELD LENGTH

Total LPT quantity shall be calculated as per the following table

Sl. No. Pipe Size
Inch (D)
No. of Joints
N
LPT Quantity
Nos
1. ...D1 ...N1 D1 *N1
2. ...D2 ...N2 D2 *N2
3. .. ... ...
. .. ... ...

TOTAL

FICHTNER India


BASIS: ANSI B31.1
ALLOWABLE PIPE SPANS

L= [(384*d*E*I/5*w)]
1/4

L= Length of span

d=2.5mm,deflect
ion
0.25 cm

w=weight in kg/cm

E=Modulus Of Elasticity kg/cm 1947000 191300
0
1855000 1843000 1795000 1732000 1633000
I= Moment of Inertia Temperature C 21-93 94-149 150-204 205-260 261-316 317-371 371-427
NOM
PIPE
OD SCH PIPE
WT
PIPE
WT
PIPE
WT
PIPEW
T
PIPEWT WIND WIND MOM
OF
SECTIO
N
MAXIMUM ALLOWABLE SPAN BARE PIPE
+ INSUL +WAT
ER
+WAT+I
NS
FORCE FORCE INERTI
A
MODUL
US
21-93c 94-
149c
150-
204c
205-
260c
261-
316c
317-
371c
371-
427c
SIZE, IN MM N/M KG/M KG/M KG/M KG/M N/M KG/M 'I
CM
4
Z CM
3
CM CM CM CM CM CM CM
10S 39.3 3.93 6.55 6.28 8.9 37.3 3.73 20.77 6.883 375 373 370 370 367 364 359
2 60.3 40 54.4 5.44 8.07 7.6 10.23 37.3 3.73 27.72 9.193 372 370 367 366 364 361 356
80 74.7 7.47 10.1 9.38 12.01 37.3 3.73 36.13 11.979 367 365 362 362 359 356 351
10S 64.4 6.44 9.61 11.81 14.98 50 5 75.84 17.06 458 456 453 452 449 445 438
3 88.9 40 112.8 11.28 14.45 16.04 19.21 50 5 125.7 28.25 452 450 446 446 443 439 432
80 152.5 15.25 18.42 19.04 22.68 50 5 162.33 36.49 447 445 441 441 438 434 427
10S 83.5 8.35 13.02 17.53 22.2 61 6.1 164.83 28.87 521 519 515 514 511 506 499
4 114.3 40 160.6 16.06 20.73 24.26 28.93 61 6.1 300.93 52.6 514 512 508 507 504 500 492
80 222.9 22.29 26.98 29.7 34.37 61 6.1 400.02 69.97 509 507 503 502 499 494 487
10S 112.7 11.27 16.96 25.77 31.16 72.9 7.29 350.7 49.64 584 581 577 576 572 567 559
5 141.3 40 217.5 21.75 27.14 34.65 40.04 72.9 7.29 632.35 89.25 574 572 567 566 563 558 549
80 309.9 30.99 36.38 42.73 48.12 72.9 7.29 861.16 121.72 568 565 561 560 556 551 543
10S 136.2 13.62 19.92 34.27 40.37 84.7 8.47 599 71.28 637 634 629 628 624 618 609
6 168.3 40 282.3 28.23 34.33 46.84 52.94 84.7 8.47 1171 139.29 628 625 620 619 615 609 601
80 425.1 42.51 48.61 59.31 64.51 84.7 8.47 1686 200.41 621 618 613 612 608 603 594
10S 199.4 19.94 28.8 55.04 63.9 107.1 10.71 1473 134.54 725 722 716 715 710 704 694
8 219.1 20 332.7 33.27 42.21 66.72 75.66 107.1 10.71 2402 519.42 721 718 712 711 706 700 690
30 367.5 36.75 45.69 69.75 78.69 107.1 10.71 2639 240.73 720 717 711 710 705 699 689
40 424.8 42.48 51.42 74.75 83.69 107.1 10.71 3018 275.47 718 715 709 708 703 697 687
80 645.8 64.58 73.5 94.02 102.96 107.1 10.71 4400 401.81 710 707 702 701 696 690 680
10S 278.3 27.83 38.34 83 93.51 141.8 14.18 3201 234 810 806 800 799 793 786 775
10 273.1 20 417.2 41.72 52.23 95 105.51 141.8 14.18 4735 347.02 807 804 797 796 791 784 772
30 509.5 50.95 61.46 103 113.51 141.8 14.18 5723 419.02 805 801 795 794 789 782 770
40 602.3 60.23 70.74 111 121.51 141.8 14.18 6693 490 803 799 793 792 787 780 768
80 957.2 95.72 106.23 142 152.51 141.8 14.18 10193 747 794 791 785 783 778 771 760
FICHTNER India


NOM
PIPE
OD SCH PIPE
WT
PIPE
WT
PIPE
WT
PIPEW
T
OF
SECTIO
N
+ INSUL +WAT
ER
+WAT+I
NS
FORCE FORCE INERTI
A
MODUL
US
21-93c 94-
149c
150-
204c
205-
260c
261-
316c
317-
371c
371-
427c
CM
4
Z CM
3
10S 360.1 36.01 49.97 114 127.95 163.8 16.38 5848 361 883 879 872 871 865 857 845
12 323.9 20 496.7 49.67 63.63 126 139.95 163.8 16.38 7987 493 881 877 870 869 863 855 843
30 651.3 65.13 79.09 139 152.95 163.8 16.38 10343 539 878 874 867 866 860 852 840
40 796.5 79.65 93.61 152 165.95 163.8 16.38 12487 772 875 871 864 863 857 850 837
80 1317 131.7 145.56 197 210.95 163.8 16.38 19771 1221 866 862 855 854 848 841 828
20 679.7 67.97 82.33 159 173.35 177.8 17.78 13070 936 921 917 910 908 902 894 881
14 355.6 30 812 81.2 95.56 170 184.35 177.8 17.78 15525 873 919 915 908 907 901 893 880
40 942.9 94.29 108.65 182 196.35 177.8 17.78 17856 1003 917 913 906 905 899 891 878
80 1579.2 157.92 172.28 237 251.36 177.8 17.78 28595 1609 907 903 896 895 889 881 868
20 779.1 77.91 93.91 198 214 200.2 20.02 19688 970 986 982 974 972 966 957 943
16 406.4 30 931.2 93.12 109.12 211 227 200.2 20.02 23392 1152 984 980 973 971 965 956 942
40 1231.6 123.16 139.6 237 253 200.2 20.02 30468 1499 981 976 969 967 961 952 938
80 2030.5 203.05 218.5 307 323 200.2 20.02 48158 2370 970 966 959 957 951 942 929
20 878.4 87.84 105.94 241 259.1 222.6 22.26 28220 1237 1047 1042 1034 1033 1026 1017 1002
18 457 30 1221.1 122.11 140.21 271 289.1 222.6 22.26 38751 1694 1044 1039 1031 1029 1023 1014 999
40 1558.7 155.87 173.97 300 318.1 222.6 22.26 48782 2134 1040 1035 1028 1026 1019 1010 995
80 2540.8 254.08 272.18 386 404.1 222.6 22.26 76337 3340 1029 1025 1017 1015 1009 1000 985
20 1169.6 116.96 134.5 304 323.54 245 24.5 46368 1826 1103 1098 1090 1088 1081 1072 1056
20 508 30 1549.5 154.95 174.48 338 357.5 245 24.5 60645 2388 1100 1095 1087 1085 1078 1068 1053
40 1828.9 182.89 202.43 362 381.54 245 24.5 70926 2792 1097 1092 1084 1082 1075 1066 1050
20 1407.9 140.79 163.88 414 437 289.8 28.98 80873 2653 1211 1205 1196 1194 1186 1176 1158
24 610 30 2095.1 209.51 232.68 475 498 289.8 28.98 118209 3884 1205 1200 1191 1189 1181 1170 1153
40 2547 254.7 277.79 514 537.89 289.8 28.98 142351 4670 1202 1197 1188 1186 1178 1168 1151
20 2344.8 234.48 262.67 550 588.27 355.5 35.55 209780 5506 1352 1346 1336 1334 1325 1313 1294
28 711 30 0 0 0 0 0
40 0 0 0 0 0
80 0 0 0 0 0

FICHTNER India


BASIS: ANSI B31.1

L= [(384*d*E*I/5*w)]
1/4

L= Length of span

d=2.5mm,deflect
ion
0.25 cm

w=weight in kg/cm

0
1855000 1843000 1795000 1732000 1633000
NOM
PIPE
OD SCH PIPE
WT
PIPE
WT
PIPE
WT
PIPEW
T
OF
SECTIO
N
MAXIMUM ALLOWABLE SPAN PIPE + WATER
+ INSUL +WAT
ER
+WAT+I
NS
FORCE FORCE INERTI
A
MODUL
US
21-93c 94-
149c
150-
204c
205-
260c
261-
316c
317-
371c
371-
427c
CM
4
Z CM
3
10S 39.3 3.93 6.55 6.28 8.9 37.3 3.73 20.77 6.883 333 332 329 329 327 324 319
2 60.3 40 54.4 5.44 8.07 7.6 10.23 37.3 3.73 27.72 9.193 342 340 338 337 335 332 327
80 74.7 7.47 10.1 9.38 12.01 37.3 3.73 36.13 11.979 346 345 342 342 339 336 332
10S 64.4 6.44 9.61 11.81 14.98 50 5 75.84 17.06 394 392 389 388 386 382 377
3 88.9 40 112.8 11.28 14.45 16.04 19.21 50 5 125.7 28.25 414 412 409 408 405 402 396
80 152.5 15.25 18.42 19.04 22.68 50 5 162.33 36.49 423 421 417 417 414 410 404
10S 83.5 8.35 13.02 17.53 22.2 61 6.1 164.83 28.87 433 431 428 427 424 421 414
4 114.3 40 160.6 16.06 20.73 24.26 28.93 61 6.1 300.93 52.6 464 462 458 458 455 451 444
80 222.9 22.29 26.98 29.7 34.37 61 6.1 400.02 69.97 474 472 468 467 464 460 453
10S 112.7 11.27 16.96 25.77 31.16 72.9 7.29 350.7 49.64 475 473 469 468 465 461 454
5 141.3 40 217.5 21.75 27.14 34.65 40.04 72.9 7.29 632.35 89.25 511 509 505 504 501 496 489
80 309.9 30.99 36.38 42.73 48.12 72.9 7.29 861.16 121.72 524 522 518 517 513 509 501
10S 136.2 13.62 19.92 34.27 40.37 84.7 8.47 599 71.28 506 503 500 499 495 491 484
6 168.3 40 282.3 28.23 34.33 46.84 52.94 84.7 8.47 1171 139.29 553 550 546 545 542 537 529
80 425.1 42.51 48.61 59.31 64.51 84.7 8.47 1686 200.41 571 568 564 563 559 554 546
10S 199.4 19.94 28.8 55.04 63.9 107.1 10.71 1473 134.54 562 560 556 555 551 546 538
8 219.1 20 332.7 33.27 42.21 66.72 75.66 107.1 10.71 2402 519.42 606 603 598 597 593 588 580
30 367.5 36.75 45.69 69.75 78.69 107.1 10.71 2639 240.73 613 611 606 605 601 596 587
40 424.8 42.48 51.42 74.75 83.69 107.1 10.71 3018 275.47 623 621 616 615 611 605 596
80 645.8 64.58 73.5 94.02 102.96 107.1 10.71 4400 401.81 647 644 639 638 634 628 619
10S 278.3 27.83 38.34 83 93.51 141.8 14.18 3201 234 616 613 609 608 604 598 590
10 273.1 20 417.2 41.72 52.23 95 105.51 141.8 14.18 4735 347.02 657 654 649 648 644 638 629
30 509.5 50.95 61.46 103 113.51 141.8 14.18 5723 419.02 675 672 667 666 662 656 646
40 602.3 60.23 70.74 111 121.51 141.8 14.18 6693 490 689 686 681 680 675 669 659
80 957.2 95.72 106.23 142 152.51 141.8 14.18 10193 747 720 717 711 710 705 699 689
FICHTNER India


NOM
PIPE
OD SCH PIPE
WT
PIPE
WT
PIPE
WT
PIPEW
T
OF
SECTIO
N
MAXIMUM ALLOWABLE SPAN PIPE + WATER
+ INSUL +WAT
ER
+WAT+I
NS
FORCE FORCE INERTI
A
MODUL
US
21-93c 94-
149c
150-
204c
205-
260c
261-
316c
317-
371c
371-
427c
CM
4
Z CM
3
10S 360.1 36.01 49.97 114 127.95 163.8 16.38 5848 361 662 659 654 653 648 643 633
12 323.9 20 496.7 49.67 63.63 126 139.95 163.8 16.38 7987 493 698 695 689 688 684 678 668
30 651.3 65.13 79.09 139 152.95 163.8 16.38 10343 539 726 723 717 716 712 705 695
40 796.5 79.65 93.61 152 165.95 163.8 16.38 12487 772 744 741 735 734 729 723 712
80 1317 131.7 145.56 197 210.95 163.8 16.38 19771 1221 783 779 773 772 767 760 749
20 679.7 67.97 82.33 159 173.35 177.8 17.78 13070 936 745 741 736 734 730 723 713
14 355.6 30 812 81.2 95.56 170 184.35 177.8 17.78 15525 873 764 761 755 754 749 742 732
40 942.9 94.29 108.65 182 196.35 177.8 17.78 17856 1003 778 775 769 768 763 756 745
80 1579.2 157.92 172.28 237 251.36 177.8 17.78 28595 1609 820 816 810 808 803 796 784
20 779.1 77.91 93.91 198 214 200.2 20.02 19688 970 781 777 771 770 765 758 747
16 406.4 30 931.2 93.12 109.12 211 227 200.2 20.02 23392 1152 802 799 793 791 786 779 768
40 1231.6 123.16 139.6 237 253 200.2 20.02 30468 1499 833 829 823 821 816 809 797
80 2030.5 203.05 218.5 307 323 200.2 20.02 48158 2370 875 871 865 863 857 850 837
20 878.4 87.84 105.94 241 259.1 222.6 22.26 28220 1237 813 810 804 802 797 790 778
18 457 30 1221.1 122.11 140.21 271 289.1 222.6 22.26 38751 1694 855 851 845 843 838 830 818
40 1558.7 155.87 173.97 300 318.1 222.6 22.26 48782 2134 883 879 872 871 865 858 845
80 2540.8 254.08 272.18 386 404.1 222.6 22.26 76337 3340 927 923 916 915 909 901 887
20 1169.6 116.96 134.5 304 323.54 245 24.5 46368 1826 869 865 859 857 851 844 832
20 508 30 1549.5 154.95 174.48 338 357.5 245 24.5 60645 2388 905 901 894 893 887 879 866
40 1828.9 182.89 202.43 362 381.54 245 24.5 70926 2792 925 921 914 912 906 898 885
20 1407.9 140.79 163.88 414 437 289.8 28.98 80873 2653 924 920 913 912 906 898 885
24 610 30 2095.1 209.51 232.68 475 498 289.8 28.98 118209 3884 982 978 970 969 962 954 940
40 2547 254.7 277.79 514 537.89 289.8 28.98 142351 4670 1009 1004 997 995 988 980 965
20 2344.8 234.48 262.67 550 588.27 355.5 35.55 209780 5506 1093 1088 1080 1078 1071 1061 1046
28 711 30 0 0 0 0 0
40 0 0 0 0 0
80 0 0 0 0 0

FICHTNER India


BASIS: ANSI B31.1

L= [(384*d*E*I/5*w)]
1/4

L= Length of span

d=2.5mm,deflect
ion
0.25 cm

w=weight in kg/cm

0
1855000 1843000 1795000 1732000 1633000
NOM OD SCH PIPE
WT
PIPE
WT
PIPE
WT
PIPEW
T
OF
SECTIO
N
MAXIMUM ALLOWABLE SPAN PIPE + WATER + INSULATION
PIPE + INSUL +WAT
ER
+WAT+I
NS
FORCE FORCE INERTI
A
MODUL
US
21-93c 94-
149c
150-
204c
205-
260c
261-
316c
317-
371c
371-
427c
CM
4
Z CM
3
10S 39.3 3.93 6.55 6.28 8.9 37.3 3.73 20.77 6.883 306 304 302 301 299 297 292
2 60.3 40 54.4 5.44 8.07 7.6 10.23 37.3 3.73 27.72 9.193 317 316 313 313 311 308 304
80 74.7 7.47 10.1 9.38 12.01 37.3 3.73 36.13 11.979 326 324 322 321 319 316 312
10S 64.4 6.44 9.61 11.81 14.98 50 5 75.84 17.06 371 369 366 366 363 360 355
3 88.9 40 112.8 11.28 14.45 16.04 19.21 50 5 125.7 28.25 395 394 391 390 388 384 378
80 152.5 15.25 18.42 19.04 22.68 50 5 162.33 36.49 404 403 400 399 396 393 387
10S 83.5 8.35 13.02 17.53 22.2 61 6.1 164.83 28.87 408 406 403 403 400 396 391
4 114.3 40 160.6 16.06 20.73 24.26 28.93 61 6.1 300.93 52.6 444 442 439 438 435 431 425
80 222.9 22.29 26.98 29.7 34.37 61 6.1 400.02 69.97 457 455 451 450 448 444 437
10S 112.7 11.27 16.96 25.77 31.16 72.9 7.29 350.7 49.64 453 451 447 447 444 440 433
5 141.3 40 217.5 21.75 27.14 34.65 40.04 72.9 7.29 632.35 89.25 493 491 487 486 483 479 472
80 309.9 30.99 36.38 42.73 48.12 72.9 7.29 861.16 121.72 509 506 502 502 498 494 487
10S 136.2 13.62 19.92 34.27 40.37 84.7 8.47 599 71.28 485 483 479 479 476 471 464
6 168.3 40 282.3 28.23 34.33 46.84 52.94 84.7 8.47 1171 139.29 536 534 530 529 525 521 513
80 425.1 42.51 48.61 59.31 64.51 84.7 8.47 1686 200.41 559 557 552 551 548 543 535
10S 199.4 19.94 28.8 55.04 63.9 107.1 10.71 1473 134.54 542 539 535 534 531 526 518
8 219.1 20 332.7 33.27 42.21 66.72 75.66 107.1 10.71 2402 519.42 587 584 580 579 575 570 562
30 367.5 36.75 45.69 69.75 78.69 107.1 10.71 2639 240.73 595 592 588 587 583 578 569
40 424.8 42.48 51.42 74.75 83.69 107.1 10.71 3018 275.47 606 603 599 598 594 588 580
80 645.8 64.58 73.5 94.02 102.96 107.1 10.71 4400 401.81 632 629 625 624 619 614 605
10S 278.3 27.83 38.34 83 93.51 141.8 14.18 3201 234 598 595 591 590 586 581 572
10 273.1 20 417.2 41.72 52.23 95 105.51 141.8 14.18 4735 347.02 640 637 632 631 627 622 612
30 509.5 50.95 61.46 103 113.51 141.8 14.18 5723 419.02 659 656 651 650 646 640 631
40 602.3 60.23 70.74 111 121.51 141.8 14.18 6693 490 674 671 666 664 660 654 645
80 957.2 95.72 106.23 142 152.51 141.8 14.18 10193 747 707 704 698 697 693 687 677
FICHTNER India


NOM OD SCH PIPE
WT
PIPE
WT
PIPE
WT
PIPEW
T
OF
SECTIO
N
MAXIMUM ALLOWABLE SPAN PIPE + WATER + INSULATION
PIPE + INSUL +WAT
ER
+WAT+I
NS
FORCE FORCE INERTI
A
MODUL
US
21-93c 94-
149c
150-
204c
205-
260c
261-
316c
317-
371c
371-
427c
CM
4
Z CM
3
10S 360.1 36.01 49.97 114 127.95 163.8 16.38 5848 361 643 640 635 634 630 624 615
12 323.9 20 496.7 49.67 63.63 126 139.95 163.8 16.38 7987 493 680 677 671 670 666 660 650
30 651.3 65.13 79.09 139 152.95 163.8 16.38 10343 539 709 706 701 699 695 689 679
40 796.5 79.65 93.61 152 165.95 163.8 16.38 12487 772 728 725 720 718 714 707 697
80 1317 131.7 145.56 197 210.95 163.8 16.38 19771 1221 769 766 760 759 754 747 736
20 679.7 67.97 82.33 159 173.35 177.8 17.78 13070 936 729 725 720 719 714 708 697
14 355.6 30 812 81.2 95.56 170 184.35 177.8 17.78 15525 873 749 746 740 739 734 727 717
40 942.9 94.29 108.65 182 196.35 177.8 17.78 17856 1003 764 760 754 753 748 742 731
80 1579.2 157.92 172.28 237 251.36 177.8 17.78 28595 1609 808 804 798 797 791 784 773
20 779.1 77.91 93.91 198 214 200.2 20.02 19688 970 766 762 757 755 750 744 733
16 406.4 30 931.2 93.12 109.12 211 227 200.2 20.02 23392 1152 788 784 778 777 772 765 754
40 1231.6 123.16 139.6 237 253 200.2 20.02 30468 1499 819 816 809 808 803 796 784
80 2030.5 203.05 218.5 307 323 200.2 20.02 48158 2370 864 860 854 852 847 839 827
20 878.4 87.84 105.94 241 259.1 222.6 22.26 28220 1237 799 795 789 788 783 776 764
18 457 30 1221.1 122.11 140.21 271 289.1 222.6 22.26 38751 1694 841 838 831 830 824 817 805
40 1558.7 155.87 173.97 300 318.1 222.6 22.26 48782 2134 870 866 860 858 853 845 833
80 2540.8 254.08 272.18 386 404.1 222.6 22.26 76337 3340 917 913 906 904 898 890 877
20 1169.6 116.96 134.5 304 323.54 245 24.5 46368 1826 856 852 845 844 838 831 819
20 508 30 1549.5 154.95 174.48 338 357.5 245 24.5 60645 2388 892 888 882 880 874 867 854
40 1828.9 182.89 202.43 362 381.54 245 24.5 70926 2792 913 909 902 901 895 887 874
20 1407.9 140.79 163.88 414 437 289.8 28.98 80873 2653 912 908 901 900 894 886 873
24 610 30 2095.1 209.51 232.68 475 498 289.8 28.98 118209 3884 971 966 959 957 951 943 929
40 2547 254.7 277.79 514 537.89 289.8 28.98 142351 4670 997 993 985 984 977 969 954
20 2344.8 234.48 262.67 550 588.27 355.5 35.55 209780 5506 1075 1070 1062 1060 1053 1044 1028
28 711 30 0 0 0 0 0
40 0 0 0 0 0
80 0 0 0 0 0

FICHTNER India


BASIS: ANSI B31.1

L= [(384*d*E*I/5*w)]
1/4


L= Length of span

d=2.5mm,deflect
ion
0.25 cm

w=weight in kg/cm

0
1855000 1843000 1795000 1732000 16330
00
I= Moment of Inertia Temperature C 21-93 94-149 150-204 205-260 261-316 317-371 371-
427
NOM
PIPE
OD SCH PIPE
WT
PIPE
WT
PIPE
WT
PIPE
WT
PIPEW
T
PIPEW
T
PIPEW
T
PIPEW
T
WIND WIND MOM
OF
SECTIO
N
+
INSUL
+
INSUL
+WAT
ER
+WAT
ER
+WAT
+INS
+WAT
+INS
FORCE FORCE INERTI
A
MODUL
US
21-93c 94-
149c
150-
204c
205-
260c
261-
316c
317-
371c
371-
427c
SIZE, IN MM N/M KG/M N/M KG/M N/M KG/M N/M KG/M N/M KG/M 'I
CM
4
Z CM
3
10S 39.3 3.93 65.5 6.55 62.8 6.28 89 8.9 37.3 3.73 20.77 6.883 348 347 344 343 341 338 333
2 60.3 40 54.4 5.44 80.7 8.07 76 7.6 102.3 10.23 37.3 3.73 27.72 9.193 378 376 373 372 370 367 361
80 74.7 7.47 101 10.1 93.8 9.38 120.1 12.01 37.3 3.73 36.13 11.979 409 407 404 403 401 397 391
10S 64.4 6.44 96.1 9.61 118.1 11.81 149.8 14.98 50 5 75.84 17.06 394 392 389 389 386 383 377
3 88.9 40 112.8 11.28 144.5 14.45 160.4 16.04 192.1 19.21 50 5 125.7 28.25 453 451 448 447 444 440 434
80 152.5 15.25 184.2 18.42 190.4 19.04 226.8 22.68 50 5 162.33 36.49 489 486 483 482 479 475 468
10S 83.5 8.35 130.2 13.02 175.3 17.53 222 22.2 61 6.1 164.83 28.87 420 418 415 415 412 408 402
4 114.3 40 160.6 16.06 207.3 20.73 242.6 24.26 289.3 28.93 61 6.1 300.93 52.6 495 493 489 488 485 481 474
80 222.9 22.29 269.8 26.98 297 29.7 343.7 34.37 61 6.1 400.02 69.97 537 535 531 530 526 522 514
10S 112.7 11.27 169.6 16.96 257.7 25.77 311.6 31.16 72.9 7.29 350.7 49.64 453 451 448 447 444 440 434
5 141.3 40 217.5 21.75 271.4 27.14 346.5 34.65 400.4 40.04 72.9 7.29 632.35 89.25 534 532 528 527 523 519 511
80 309.9 30.99 363.8 36.38 427.3 42.73 481.2 48.12 72.9 7.29 861.16 121.72 583 581 576 575 572 567 558
10S 136.2 13.62 199.2 19.92 342.7 34.27 403.7 40.37 84.7 8.47 599 71.28 475 473 469 469 465 461 455
6 168.3 40 282.3 28.23 343.3 34.33 468.4 46.84 529.4 52.94 84.7 8.47 1171 139.29 570 567 563 562 558 554 545
80 425.1 42.51 486.1 48.61 593.1 59.31 645.1 64.51 84.7 8.47 1686 200.41 631 629 624 623 619 613 604
10S 199.4 19.94 288 28.8 550.4 55.04 639 63.9 107.1 10.71 1473 134.54 523 520 516 515 512 507 500
8 219.1 20 332.7 33.27 422.1 42.21 667.2 66.72 756.6 75.66 107.1 10.71 2402 519.42 594 591 587 586 582 577 568
30 367.5 36.75 456.9 45.69 697.5 69.75 786.9 78.69 107.1 10.71 2639 240.73 609 606 601 601 597 591 583
40 424.8 42.48 514.2 51.42 747.5 74.75 836.9 83.69 107.1 10.71 3018 275.47 631 628 624 623 619 613 604
80 645.8 64.58 735 73.5 940.2 94.02 1029.6 102.96 107.1 10.71 4400 401.81 701 698 693 691 687 681 671
10S 278.3 27.83 383.4 38.34 830 83 935.1 93.51 141.8 14.18 3201 234 568 565 561 560 557 552 544
10 273.1 20 417.2 41.72 522.3 52.23 950 95 1055.1 105.51 141.8 14.18 4735 347.02 628 626 621 620 616 610 601
30 509.5 50.95 614.6 61.46 1030 103 1135.1 113.51 141.8 14.18 5723 419.02 661 658 653 652 647 642 632
40 602.3 60.23 707.4 70.74 1110 111 1215.1 121.51 141.8 14.18 6693 490 689 686 681 679 675 669 659
80 957.2 95.72 1062.3 106.23 1420 142 1525.1 152.51 141.8 14.18 10193 747 773 770 764 763 758 751 740
FICHTNER India


NOM
PIPE
OD SCH PIPE
WT
PIPE
WT
PIPE
WT
PIPE
WT
PIPEW
T
PIPEW
T
PIPEW
T
PIPEW
T
WIND WIND MOM
OF
SECTIO
N
+
INSUL
+
INSUL
+WAT
ER
+WAT
ER
+WAT
+INS
+WAT
+INS
FORCE FORCE INERTI
A
MODUL
US
21-93c 94-
149c
150-
204c
205-
260c
261-
316c
317-
371c
371-
427c
SIZE, IN MM N/M KG/M N/M KG/M N/M KG/M N/M KG/M N/M KG/M 'I
CM
4
Z CM
3
10S 360.1 36.01 499.7 49.97 1140 114 1279.5 127.95 163.8 16.38 5848 361 606 603 598 597 594 588 580
12 323.9 20 496.7 49.67 636.3 63.63 1260 126 1399.5 139.95 163.8 16.38 7987 493 656 654 649 647 643 638 628
30 651.3 65.13 790.9 79.09 1390 139 1529.5 152.95 163.8 16.38 10343 539 702 699 694 693 688 682 672
40 796.5 79.65 936.1 93.61 1520 152 1659.5 165.95 163.8 16.38 12487 772 739 735 730 729 724 717 707
80 1317 131.7 1455.6 145.56 1970 197 2109.5 210.95 163.8 16.38 19771 1221 838 834 828 826 821 814 802
20 679.7 67.97 823.3 82.33 1590 159 1733.5 173.35 177.8 17.78 13070 936 710 707 701 700 696 690 679
14 355.6 30 812 81.2 955.6 95.56 1700 170 1843.5 184.35 177.8 17.78 15525 873 742 739 733 732 727 721 710
40 942.9 94.29 1086.5 108.65 1820 182 1963.5 196.35 177.8 17.78 17856 1003 771 767 761 760 755 748 737
80 1579.2 157.92 1722.8 172.28 2370 237 2513.6 251.36 177.8 17.78 28595 1609 877 873 866 865 859 851 839
20 779.1 77.91 939.1 93.91 1980 198 2140 214 200.2 20.02 19688 970 735 731 726 725 720 713 703
16 406.4 30 931.2 93.12 1091.2 109.12 2110 211 2270 227 200.2 20.02 23392 1152 768 765 759 758 753 746 735
40 1231.6 123.16 1396 139.6 2370 237 2530 253 200.2 20.02 30468 1499 824 820 814 813 807 800 788
80 2030.5 203.05 2185 218.5 3070 307 3230 323 200.2 20.02 48158 2370 933 929 922 921 915 906 893
20 878.4 87.84 1059.4 105.94 2410 241 2591 259.1 222.6 22.26 28220 1237 757 754 748 747 742 735 724
18 457 30 1221.1 122.11 1402.1 140.21 2710 271 2891 289.1 222.6 22.26 38751 1694 822 818 812 811 805 798 787
40 1558.7 155.87 1739.7 173.97 3000 300 3181 318.1 222.6 22.26 48782 2134 874 870 863 862 856 849 836
80 2540.8 254.08 2721.8 272.18 3860 386 4041 404.1 222.6 22.26 76337 3340 987 983 975 974 967 959 945
20 1169.6 116.96 1345 134.5 3040 304 3235.4 323.54 245 24.5 46368 1826 813 810 803 802 797 790 778
20 508 30 1549.5 154.95 1744.8 174.48 3380 338 3575 357.5 245 24.5 60645 2388 872 869 862 861 855 847 835
40 1828.9 182.89 2024.3 202.43 3620 362 3815.4 381.54 245 24.5 70926 2792 909 905 898 897 891 883 870
20 1407.9 140.79 1638.8 163.88 4140 414 4370 437 289.8 28.98 80873 2653 852 848 842 840 835 827 815
24 610 30 2095.1 209.51 2326.8 232.68 4750 475 4980 498 289.8 28.98 118209 3884 941 937 929 928 922 914 900
40 2547 254.7 2777.9 277.79 5140 514 5378.9 537.89 289.8 28.98 142351 4670 988 983 976 974 968 959 945
20 2344.8 234.48 2626.7 262.67 5500 550 5882.7 588.27 355.5 35.55 209780 5506 968 963 956 954 948 940 926
28 711 30 0 0 0 0 0 0 0 0 0 0 0 0
40 0 0 0 0 0 0 0 0 0 0 0 0
80 0 0 0 0 0 0 0 0 0 0 0 0

FICHTNER India


SCOPE OF IBR DOCUMENTATION A GUIDE LINE
WP > 3.5 Kg / cm(g)
From Boiler to
Primemover or
other Equipment
or both
Steam piping
None
Yes
Yes
IBR
Non IBR
Pr. Part
Yes
Treat similar
to IBR
No
Standard Procedure
No
WP<atm
Yes
ID>254
No
No
Yes
ID>254
No
Yes
Vented to
Atmosphere
Non IBR
Valve in
the Line
No
Yes
Down stream
of Valves
Up stream
of Valves
Pipe size
50 NB & below
Submit Calculations
No approval
Required
FICHTNER India

FORM T10 REV - A

MILD STEEL PIPE -SIZE,DIMENSION,WEIGHT

REF. CODE :IS 1239- PART1: 1992, BS1387:1985.
M.O.C : Mild Steel To IS 1239
NOMINAL BORE OUTSIDE DIAMETER THICKNESS PLAIN END WEIGHT
(NB) Max. Min.
INCH in. mm in. mm in. mm lb/ft Kg/ft Kg/m
LIGHT 1/8 0.396 10.1 0.387 9.8 0.072 1.83 0.243 0.110 0.362
1/4 0.532 13.5 0.518 13.2 0.072 1.83 0.347 0.157 0.516
3/8 0.671 17.0 0.656 16.7 0.072 1.83 0.453 0.205 0.674
1/2 0.841 21.4 0.825 21.0 0.08 2.03 0.64 0.290 0.952
3/4 1.059 26.9 1.041 26.4 0.092 2.34 0.944 0.428 1.405
1 1.328 33.7 1.309 33.2 0.104 2.64 1.35 0.612 2.009
1 1.67 42.4 1.65 41.9 0.104 2.64 1.73 0.785 2.575
1 1.903 48.3 1.882 47.8 0.116 2.95 2.19 0.993 3.259
2 2.3702 60.2 2.347 59.6 0.116 2.95 2.76 1.252 4.107
2 2.991 76.0 2.96 75.2 0.128 3.25 3.9 1.769 5.804
3 3.491 88.7 3.46 87.9 0.128 3.25 4.58 2.078 6.816
4 4.481 113.8 4.45 113.0 0.144 3.66 6.64 3.012 9.882

MEDIUM 1/8 0.411 10.4 0.386 9.8 0.08 2.03 0.273 0.124 0.406
1/4 0.547 13.9 0.522 13.3 0.092 2.34 0.437 0.198 0.650
3/8 0.685 17.4 0.66 16.8 0.092 2.34 0.573 0.260 0.853
1/2 0.856 21.7 0.831 21.1 0.104 2.64 0.822 0.373 1.22
3/4 1.072 27.2 1.047 26.6 0.104 2.64 1.06 0.481 1.58
1 1.346 34.2 1.316 33.4 0.128 3.25 1.64 0.744 2.44
1 1.687 42.8 1.657 42.1 0.128 3.25 2.11 0.957 3.14
1 1.919 48.7 1.889 48.0 0.128 3.25 2.43 1.10 3.62
2 2.394 60.8 2.354 59.8 0.144 3.66 3.42 1.55 5.09
2 3.014 76.6 2.969 75.4 0.144 3.66 4.38 1.99 6.52
3 3.524 89.5 3.469 88.1 0.16 4.06 5.69 2.58 8.47
4 4.524 114.9 4.459 113.3 0.176 4.47 8.14 3.69 12.11
5 5.534 140.6 5.459 138.7 0.192 4.88 10.9 4.94 16.22
6 6.539 166.1 6.459 164.1 0.192 4.88 12.9 5.85 19.20

HEAVY 1/8 0.411 10.4 0.386 9.8 0.104 2.64 0.331 0.150 0.493
1/4 0.547 13.9 0.522 13.3 0.116 2.95 0.517 0.235 0.769
3/8 0.685 17.4 0.66 16.8 0.116 2.95 0.686 0.311 1.02
1/2 0.856 21.7 0.831 21.1 0.128 3.25 0.977 0.443 1.45
3/4 1.072 27.2 1.047 26.6 0.128 3.25 1.27 0.576 1.89
1 1.346 34.2 1.316 33.4 0.16 4.06 2 0.907 2.98
1 1.687 42.8 1.657 42.1 0.16 4.06 2.58 1.170 3.84
1 1.919 48.7 1.889 48.0 0.16 4.06 2.98 1.35 4.43
2 2.394 60.8 2.354 59.8 0.176 4.5 4.14 1.88 6.16
2 3.014 76.6 2.969 75.4 0.176 4.5 5.31 2.41 7.90
3 3.524 89.5 3.469 88.1 0.192 4.88 6.76 3.07 10.06
4 4.524 114.9 4.459 113.3 0.212 5.4 9.71 4.40 14.45
5 5.534 140.6 5.459 138.7 0.212 5.4 12 5.44 17.86
6 6.539 166.1 6.459 164.1 0.212 5.4 14.3 6.49 21.28
NOTES: Maximum & Minimum OD of MS Pipe are based on mfg.tol. as per code/vendor catalogue.

FICHTNER India

FORM T10 REV - A

SEAMLESS OR ELECTRICALLY WELDED STEEL TUBES/PIPES - IS 3589
CODE REF : IS 3589- 1991
MOC : IS 3589
APPLICATION: WATER,GAS AND SEWAGE(168.3 TO2032mm OD)
SR.NO. OUTSIDE WALL WEIGHT TEST *
DIAMETER THICKNESS PRESSURE
In. mm mm Kg/m Kg/cm

AS PER SUPPLIER VENUS CATALOGUE
1 8N 219.1 5.56 29.23 77
2 6.35 33.28 84
3 7.04 36.76 91
4 7.92 41.28 105
5 8.18 42.49 112
6 8.74 45.24 120
7 9.52 49.17 127
8 10E 273.1 6.35 41.73 70
9 7.087 46.43 84
10 7.798 50.96 84
11 8.738 56.85 91
12 9.271 60.24 98
11.125 71.72 120
13 12E 323.1 6.35 49.68 56
14 7.137 55.73 67
15 7.925 61.78 70
16 8.382 65.14 84
17 8.738 67.79 84
18 9.525 73.76 84
19 10.312 79.71 91
20 11.125 85.62 98
21 14 355.6 6.35 54.63 53
22 7.137 61.33 60
23 7.925 67.98 67
24 8.738 74.62 70
25 9.525 81.21 77
26 11.125 94.31 91
27 11.913 100.87 98
28 12.7 107.28 105
29 16 406.4 6.35 62.58 46
30 7.14 70.27 53
31 7.92 77.92 56
32 8.74 85.54 63
33 9.52 93.13 70
34 11.13 108.22 77
35 11.91 115.71 84
36 12.7 123.78 91
37 18 457.2 6.35 70.53 42
38 7.137 79.2 46
39 9.925 87.85 53
40 8.738 96.47 56
41 9.525 105.05 63
42 11.125 113.61 70
43 11.913 130.62 77
44 12.7 139.07 84

FICHTNER India

FORM T10 REV - A

SEAMLESS OR ELECTRICALLY WELDED STEEL TUBES
CODE REF : IS 3589- 1991
MOC : IS 3589
APPLICATION: WATER,GAS AND SEWAGE(168.3 TO 2032mm OD)

TABLE-1 CHEMICAL COMPOSITION TABLE-2 MECHANICAL PROPERTIES
Steel Ladle Analysis Steel Tensile strength % Elong
Grade C(max) P(max) S(max) Grade MPa. 5.65*(So)
.
min min
FE 330 0.17 0.055 0.055 FE 330 330 20
FE 410 0.25 0.055 0.055 FE 410 410 18
FE 450 0.3 0.05 0.05 FE 450 450 12
In case of non availability of ladle analysis,the finished
Product may be checked to verify the chemical
Composition,if so agreed to by the producer
MANUFACTURE OF PRODUCT TOLERANCES - ON
H.F.S Hot finished seamless 1) OUTSIDE DIAMETER
E.R.W Electric Resistance / induction welded OD in welded seamless
E.F.W Electric Fusion Welded mm pipe pipe
UP to
OUTSIDE DIAMETERS 508 0.75% 1%
Further to sizes indicated in sheet 1,following finished OVER
pipe sizes in OD shall form part of the code. 508 1% 1.5%
508 711.0 914.0 1118 1422 1829
559 762.0 965.0 1168 1524 2032 2) WALL THICKNESS
610 813.0 1016.0 1219 1626 ERW 10 %
660 864.0 1067.0 1321 1727 EFW +20 %
Pipes of OD other than mentioned above shall be Seamless - 12.5 %
permissible as agreed to between the manufacturer
and the purchaser
MINIMUM SPECIFIED THICKNESS OF PIPE STRAIGHTNESS
OD OF PIPES MIN THK OF PIPE Finished pipe shall not deviate
SPECIFIED SPECIFIED from straightness by more than
168.3 to 406.6 4mm 0.2 % of total length.
Above 406.6 to 559 5mm
Above 559 to 914 6mm LINE DESIGNATION
Above 914 to 1219 7mm EFW-FE410 Means
Above 1219 to1620 8mm Electric fusion welded pipe
Above 1620 to 2032 10mm with min tensile strength of
410 MPa
HYDRAULIC PRESSURE TEST LENGTHS:
To be done before coating,wrapping&lining RANDOM LENGTH: Steel tube tobe
* Max test pressure not to exceed 5MPa,but supplied in single random length
calculate as below. frpm 4 to 7 metres or double random
P=2*S*t/D P Test pr. in MPa, length of 7 to 14 m. For order over
S Stress in MPa which shall 200m ,of any one size of tube ,it shall
Be taken as 40% of speci. be permissible to supply short random
Min tensile strength, lengths from 2 to 4m provided the total
T Specified thickness in mm, of such lengths does not exceed 7.5%
D Specified OD in mm. of total lengths
Test pr shall be applied & maintained for
sufficiently long time for proof and inspection
Normally 5 seconds are sufficient for test.

FICHTNER India


CALCULATION FOR THICKNESS OF PIPES AS PER IBR REG 350.
PROJECT SAMPLE CALCULATION ONLY
LINE DESCRIPTION

CALCULATION
1) P = 2Se*(t-c) Eqn.91 of IBR 2) P = 2Se*(t-c) .. Eqn. 91 A of IBR
D-t+c D +t-c
Hence Hence

t = PD +c t = Pd +c
2Se+P 2Se P

P Max Working Pressure TS Tensilestrength at 20C
D Outsidediameter Et Yield point (0.2% Proof stress) at temp
t Minimumthickness Sr Averagestress to producerupturein 100000hrs & in no casemorethan
c Corr. allowance=0.75 mm 1.33times thelowest stress to produceruptureat temp.
e Efficiency factor Sc Averagestress to producean elongation of 1% creep in 100000hrs (at temp)
S Allowablestress
= TS/3.5 or Et/1.6 (Which ever is less) for temp up to and incl.454C
= Sr /1.6 or Sc ( Which ever is less) for temp. above454C
R Bend radius
tb Minimumthickness beforebending
SL DIA P Temp. Material S e t in mm R tb Negative Nomimal Thickness P Remarks
NO. D in mm Kg/cm C Kg/cm calculated mm 1.1t 1.125t Thk tol.% Reqd with
tol.
selected Kg/cm
1 609.1 47.36 390 SA106GrB 1054.6 1 14.38 - - - 12.5 16.43 17.50 51.66 SAFE
2 609.1 46.36 210 SA106GrB 1054.6 1 14.10 - - - 12.5 16.11 17.50 51.66 SAFE
3 609.1 44.65 210 SA106GrB 1054.6 1 13.63 - - - 12.5 15.57 17.50 51.66 SAFE
4 609.1 42.19 210 SA106GrB 1054.6 1 12.94 - - - 12.5 14.79 17.50 51.66 SAFE
5 609.1 38.67 390 SA106GrB 1054.6 1 11.97 - - - 12.5 13.68 14.30 41.53 SAFE
6 609.1 37.62 360 SA106GrB 1054.6 1 11.67 - - - 12.5 13.34 14.30 41.53 SAFE
7 609.1 37.62 390 SA106GrB 1012 1 12.11 - - - 12.5 13.85 14.30 39.86 SAFE
8 609.1 35.35 375 SA106GrB 914 1 12.56 - - - 12.5 14.35 14.30 36.00 SAFE
9 609.1 28.83 263 SA106GrB 759.33 1 12.35 12.5 14.11 14.30 29.90 SAFE
NOTES:THE ABOVE FORMULA FORMS THE BASIS OF PIPE THICKNESS CALCULATION INDICATED IN WORK INSTRUCTION DOC.NO. WI - ME -
196-028. ALLOWABLE STRESS IS TAKEN FROM ANSI B31.1&NOT AS PER IBR WHICH IS MORE CONSERVATIVE FOR INITIAL PIPE SIZING
FICHTNER India


PIPE THICKNESS CALCULATION A READY RECKONER
CODE : IBR
MATERIAL : SA 106 Gr.B
CLASS RATING : 150 #
COROSSION ALLOWANCE :1.0
P Kg/cm 18.28 16.17 14.06 11.95 9.84 8.79 7.73 6.68 5.62
Temp. C 93.3 149 204 260 316 343 371 399 427
S Kg/cm 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
Thickness selected considering negative tolerance
OD in
NB
OD in MM
15 21.3 3.73 3.73 3.73 3.73 3.73 3.73 3.73 3.73 3.73
20 26.7 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91
25 33.4 4.55 4.55 4.55 4.55 4.55 4.55 4.55 4.55 4.55
40 48.3 5.08 5.08 5.08 5.08 5.08 5.08 5.08 5.08 5.08
50 60.3 5.54 5.54 5.54 5.54 5.54 5.54 5.54 5.54 5.54
80 88.9 5.49 5.49 5.49 5.49 5.49 5.49 5.49 5.49 5.49
100 114.3 6.02 6.02 6.02 6.02 6.02 6.02 6.02 6.02 6.02
150 168.3 7.11 7.11 7.11 7.11 7.11 7.11 7.11 7.11 7.11
200 219.1 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35
250 273.1 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35
300 323.9 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35
350 355.6 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35
400 406.4 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35
450 457 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35
500 508 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35
550 559 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35
600 608 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35 6.35

CODE : IBR
P Kg/cm 18.28 16.17 14.06 11.95 9.84 8.79 7.73 6.68 5.62
Temp. C 93.3 149 204 260 316 343 371 399 427
S Kg/cm 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
Minimum thickness calculated
OD in
NB
OD in MM
15 21.3 1.18 1.16 1.14 1.12 1.10 1.09 1.08 1.08 1.08
20 26.7 1.23 1.20 1.18 1.15 1.12 1.11 1.10 1.10 1.10
25 33.4 1.29 1.25 1.22 1.19 1.16 1.14 1.13 1.12 1.12
40 48.3 1.42 1.37 1.32 1.27 1.22 1.20 1.18 1.18 1.18
50 60.3 1.52 1.46 1.40 1.34 1.28 1.25 1.23 1.22 1.22
FICHTNER India


P Kg/cm 18.28 16.17 14.06 11.95 9.84 8.79 7.73 6.68 5.62
Temp. C 93.3 149 204 260 316 343 371 399 427
S Kg/cm 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
80 88.9 1.76 1.68 1.59 1.50 1.41 1.37 1.34 1.32 1.33
100 114.3 1.98 1.87 1.76 1.64 1.53 1.47 1.43 1.42 1.42
150 168.3 2.45 2.28 2.11 1.95 1.78 1.70 1.64 1.61 1.62
200 219.1 2.88 2.67 2.45 2.23 2.02 1.91 1.83 1.80 1.81
250 273.1 3.35 3.08 2.81 2.54 2.27 2.13 2.04 1.99 2.01
300 323.9 3.78 3.46 3.14 2.82 2.50 2.34 2.23 2.18 2.19
350 355.6 4.06 3.71 3.35 3.00 2.65 2.48 2.35 2.29 2.31
400 406.4 4.49 4.09 3.69 3.29 2.89 2.69 2.55 2.48 2.50
450 457 4.93 4.48 4.03 3.57 3.12 2.90 2.74 2.66 2.68
500 508 5.36 4.86 4.36 3.86 3.36 3.11 2.93 2.85 2.87
550 559 5.80 5.25 4.70 4.15 3.60 3.32 3.13 3.04 3.06
600 608 6.22 5.63 5.03 4.43 3.82 3.52 3.31 3.21 3.24

FICHTNER India


CODE : IBR
MATERIAL : SA 106 Gr.B UPTO 400 NB & SA672 C70 CL12 FOR 450NB &ABOVE
P Kg/cm 47.36 46.05 44.65 42.19 38.67 37.62 37.62 35.35 28.83
Temp. C 93.3 149 204 260 316 343 371 399 427
S Kg/cm 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
OD in
NB
OD in MM
15 21.3 3.73 3.73 3.73 3.73 3.73 3.73 3.73 3.73 3.73
20 26.7 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91
25 33.4 4.55 4.55 4.55 4.55 4.55 4.55 4.55 4.55 4.55
40 48.3 5.08 5.08 5.08 5.08 5.08 5.08 5.08 5.08 5.08
50 60.3 5.54 5.54 5.54 5.54 5.54 5.54 5.54 5.54 5.54
80 88.9 5.49 5.49 5.49 5.49 5.49 5.49 5.49 5.49 5.49
100 114.3 6.02 6.02 6.02 6.02 6.02 6.02 6.02 6.02 6.02
150 168.3 7.11 7.11 7.11 7.11 7.11 7.11 7.11 7.11 7.11
200 219.1 8.18 8.18 8.18 8.18 8.18 8.18 8.18 8.18 8.18
250 273.1 9.27 9.27 9.27 9.27 9.27 9.27 9.27 9.27 9.27
300 323.9 10.31 10.31 10.31 10.31 10.31 10.31 10.31 10.31 10.31
350 355.6 11.13 11.13 11.13 11.13 11.13 11.13 11.13 11.13 11.13
400 406.4 12.70 12.70 12.70 12.70 12.70 12.70 12.70 12.70 12.70
450 457 12.70 12.70 12.70 12.70 12.70 12.70 12.70 12.70 12.70
500 508 12.70 12.70 12.70 12.70 12.70 12.70 12.70 12.70 12.70
550 559 28.60 28.60 28.60 28.60 28.60 28.60 28.60 28.60 28.60
600 608 17.50 17.50 17.50 17.50 14.30 14.30 14.30 14.30 14.30

CODE : IBR
MATERIAL : SA 106 Gr.B UPTO 400 NB & SA672 C70 CL12 FOR 450NB &ABOVE
P Kg/cm 47.36 46.05 44.65 42.19 38.67 37.62 37.62 35.35 28.83
Temp. C 93.3 149 204 260 316 343 371 399 427
S Kg/cm 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
OD in
NB
OD in MM
15 21.3 1.47 1.46 1.44 1.42 1.38 1.37 1.39 1.40 1.40
20 26.7 1.59 1.57 1.55 1.52 1.48 1.47 1.49 1.51 1.50
25 33.4 1.73 1.71 1.69 1.65 1.60 1.59 1.61 1.63 1.62
40 48.3 2.06 2.03 2.00 1.95 1.87 1.85 1.88 1.92 1.90
FICHTNER India


P Kg/cm 47.36 46.05 44.65 42.19 38.67 37.62 37.62 35.35 28.83
Temp. C 93.3 149 204 260 316 343 371 399 427
S Kg/cm 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
OD in
NB
OD in MM
50 60.3 2.32 2.29 2.25 2.18 2.09 2.06 2.10 2.14 2.12
80 88.9 2.95 2.90 2.84 2.74 2.60 2.56 2.62 2.69 2.66
100 114.3 3.51 3.44 3.37 3.24 3.06 3.00 3.09 3.17 3.13
150 168.3 4.70 4.60 4.49 4.30 4.03 3.95 4.07 4.19 4.14
200 219.1 5.81 5.68 5.54 5.30 4.94 4.84 5.00 5.16 5.08
250 273.1 7.00 6.84 6.66 6.36 5.92 5.79 5.98 6.18 6.09
300 323.9 8.11 7.92 7.71 7.35 6.83 6.68 6.91 7.14 7.03
350 355.6 8.81 8.60 8.37 7.97 7.40 7.23 7.49 7.75 7.62
400 406.4 9.92 9.68 9.42 8.97 8.32 8.12 8.42 8.71 8.57
450 457 11.04 10.76 10.47 9.96 9.23 9.01 9.34 9.67 9.51
500 508 12.16 11.85 11.53 10.96 10.15 9.90 10.27 10.64 10.46
550 559 13.28 12.94 12.59 11.96 11.06 10.80 11.20 11.60 11.41
600 608 14.35 13.99 13.60 12.92 11.95 11.65 12.09 12.53 12.33

CODE : IBR
P Kg/cm 69.6 61.52 59.41 56.24 51.32 50.27 49.92 47.11 38.66
Temp. C 93.3 149 204 260 316 343 371 399 427
S Kg/cm 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
OD in
NB
OD in MM
15 21.3 3.73 3.73 3.73 3.73 3.73 3.73 3.73 3.73 3.73
20 26.7 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91
25 33.4 4.55 4.55 4.55 4.55 4.55 4.55 4.55 4.55 4.55
40 48.3 5.08 5.08 5.08 5.08 5.08 5.08 5.08 5.08 5.08
50 60.3 5.54 5.54 5.54 5.54 5.54 5.54 5.54 5.54 5.54
80 88.9 5.49 5.49 5.49 5.49 5.49 5.49 5.49 5.49 5.49
100 114.3 6.02 6.02 6.02 6.02 6.02 6.02 6.02 6.02 6.02
150 168.3 9.27 9.27 9.27 9.27 9.27 9.27 9.27 9.27 9.27
200 219.1 12.70 12.70 12.70 12.70 12.70 12.70 12.70 12.70 12.70
250 273.1 12.70 12.70 12.70 12.70 12.70 12.70 12.70 12.70 12.70
300 323.9 14.27 12.70 12.70 12.70 12.70 12.70 12.70 12.70 12.70
350 355.6 15.09 15.09 15.09 15.09 15.09 15.09 15.09 15.09 15.09
400 *406.4 19.05 19.05 19.05 19.05 19.05 19.05 19.05 19.05 19.05
450 **457 23.83 23.83 23.83 23.83 23.83 23.83 23.83 23.83 23.83
500 **508 26.20 26.20 26.20 26.20 26.20 26.20 26.20 26.20 26.20
FICHTNER India


550 559 28.60 28.60 28.60 28.60 28.60 28.60 28.60 28.60 28.60
600 608 31.00 31.00 31.00 31.00 31.00 31.00 31.00 31.00 31.00
* sch 60(16.05) can be used if
available
** sch 60 can be used if available

CODE : IBR
P Kg/cm 69.6 61.52 59.41 56.24 51.32 50.27 49.92 47.11 38.66
Temp. C 93.3 149 204 260 316 343 371 399 427
S Kg/cm 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
OD in
NB
OD in MM
15 21.3 1.68 1.60 1.58 1.55 1.51 1.50 1.51 1.54 1.53
20 26.7 1.85 1.76 1.73 1.69 1.63 1.62 1.64 1.67 1.66
25 33.4 2.07 1.95 1.92 1.87 1.79 1.78 1.80 1.84 1.83
FICHTNER India


P Kg/cm 69.6 61.52 59.41 56.24 51.32 50.27 49.92 47.11 38.66
Temp. C 93.3 149 204 260 316 343 371 399 427
S Kg/cm 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
OD in
NB
OD in MM
40 48.3 2.54 2.37 2.32 2.25 2.15 2.12 2.16 2.21 2.20
50 60.3 2.93 2.71 2.65 2.57 2.43 2.40 2.45 2.51 2.50
80 88.9 3.84 3.52 3.44 3.31 3.11 3.07 3.14 3.23 3.21
100 114.3 4.65 4.24 4.13 3.97 3.72 3.66 3.75 3.87 3.84
150 168.3 6.38 5.77 5.61 5.37 5.00 4.92 5.05 5.23 5.18
200 219.1 8.00 7.21 7.00 6.69 6.20 6.10 6.27 6.50 6.44
250 273.1 9.72 8.74 8.48 8.09 7.49 7.36 7.57 7.86 7.78
300 323.9 11.35 10.18 9.87 9.41 8.69 8.54 8.80 9.14 9.04
350 355.6 12.36 11.08 10.74 10.24 9.45 9.28 9.56 9.93 9.83
400 406.4 13.98 12.52 12.13 11.55 10.65 10.46 10.78 11.21 11.09
450 457 15.60 13.95 13.52 12.87 11.86 11.64 12.00 12.48 12.34
500 508 17.23 15.40 14.92 14.19 13.07 12.83 13.23 13.76 13.61
550 559 18.86 16.84 16.31 15.52 14.28 14.01 14.46 15.04 14.88
600 608 20.42 18.23 17.66 16.79 15.44 15.15 15.63 16.28 16.09

CODE : IBR
P Kg/cm 94.92 92.46 89.29 84.37 76.98 75.58 74.87 71.01 58
Temp. C 93.3 149 204 260 316 343 371 399 427
S Kg/cm 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
OD in
NB
OD in MM
15 21.3 3.73 3.73 3.73 3.73 3.73 3.73 3.73 3.73 3.73
20 26.7 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91
25 33.4 4.55 4.55 4.55 4.55 4.55 4.55 4.55 4.55 4.55
40 48.3 5.08 5.08 5.08 5.08 5.08 5.08 5.08 5.08 5.08
50 60.3 5.54 5.54 5.54 5.54 5.54 5.54 5.54 5.54 5.54
80 88.9 7.62 7.62 7.62 7.62 7.62 7.62 7.62 7.62 7.62
100 114.3 8.56 8.56 8.56 8.56 8.56 8.56 8.56 8.56 8.56
150 168.3 10.97 10.97 10.97 10.97 10.97 10.97 10.97 10.97 10.97
200 219.1 12.70 12.70 12.70 12.70 12.70 12.70 12.70 12.70 12.70
250 273.1 15.09 15.09 15.09 15.09 15.09 15.09 15.09 15.09 15.09
300 323.9 17.48 12.70 12.70 12.70 12.70 12.70 12.70 12.70 12.70
350 355.6 19.05 19.05 19.05 19.05 19.05 19.05 19.05 19.05 19.05
400 406.4 26.19 21.44 21.44 21.44 21.44 21.44 21.44 21.44 21.44
450 457 29.36 23.83 23.83 23.83 23.83 23.83 23.83 23.83 23.83
FICHTNER India


500 **508 32.50 32.50 32.50 26.20 26.20 26.20 26.20 26.20 26.20
550 559 34.90 34.90 34.90 28.60 28.60 28.60 28.60 28.60 28.60
600 608 38.90 38.90 38.90 31.00 31.00 31.00 31.00 31.00 31.00

CODE : IBR
P Kg/cm 94.92 92.46 89.29 84.37 76.98 75.58 74.87 71.01 58
Temp. C 93.3 149 204 260 316 343 371 399 427
S Kg/cm 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
OD in
NB
OD in MM
15 21.3 1.92 1.89 1.87 1.82 1.75 1.74 1.76 1.80 1.78
20 26.7 2.15 2.12 2.08 2.03 1.94 1.92 1.95 2.00 1.98
25 33.4 2.44 2.40 2.36 2.28 2.18 2.16 2.19 2.25 2.23
40 48.3 3.08 3.03 2.96 2.86 2.70 2.67 2.72 2.81 2.78
FICHTNER India


P Kg/cm 94.92 92.46 89.29 84.37 76.98 75.58 74.87 71.01 58
Temp. C 93.3 149 204 260 316 343 371 399 427
S Kg/cm 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
OD in
NB
OD in MM
50 60.3 3.60 3.53 3.45 3.32 3.12 3.09 3.15 3.25 3.22
80 88.9 4.83 4.73 4.61 4.42 4.13 4.08 4.17 4.32 4.27
100 114.3 5.92 5.80 5.64 5.40 5.02 4.95 5.08 5.27 5.20
150 168.3 8.25 8.07 7.84 7.47 6.93 6.82 7.00 7.29 7.19
200 219.1 10.44 10.20 9.90 9.43 8.71 8.58 8.82 9.19 9.06
250 273.1 12.76 12.47 12.09 11.50 10.62 10.45 10.74 11.21 11.05
300 323.9 14.95 14.60 14.15 13.46 12.41 12.20 12.55 13.11 12.92
350 355.6 16.31 15.93 15.44 14.68 13.52 13.30 13.68 14.30 14.08
400 406.4 18.50 18.07 17.51 16.63 15.31 15.06 15.50 16.20 15.95
450 457 20.68 20.19 19.56 18.58 17.09 16.81 17.30 18.09 17.81
500 508 22.88 22.33 21.63 20.54 18.89 18.57 19.12 20.00 19.69
550 559 25.07 24.48 23.70 22.50 20.68 20.34 20.94 21.90 21.56
600 608 27.18 26.53 25.69 24.39 22.41 22.03 22.69 23.74 23.37

CODE : IBR
CLASS RATING :900 #
P Kg/cm 142.37 138.51 133.59 126.2 115.31 113.2 112.5 106.11 86.8
Temp. C 93.3 149 204 260 316 343 371 399 427
S Kg/cm 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
OD in
NB
OD in MM
15 21.3 3.73 3.73 3.73 3.73 3.73 3.73 3.73 3.73 3.73
20 26.7 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91
25 33.4 4.55 4.55 4.55 4.55 4.55 4.55 4.55 4.55 4.55
40 48.3 5.08 5.08 5.08 5.08 5.08 5.08 5.08 5.08 5.08
50 60.3 5.54 5.54 5.54 5.54 5.54 5.54 5.54 5.54 5.54
80 88.9 7.62 7.62 7.62 7.62 7.62 7.62 7.62 7.62 7.62
100 114.3 11.13 11.13 11.13 11.13 11.13 11.13 11.13 11.13 11.13
150 168.3 14.27 14.27 14.27 14.27 14.27 14.27 14.27 14.27 14.27
200 219.1 18.26 18.26 18.26 18.26 18.26 18.26 18.26 18.26 18.26
250 273.1 21.44 21.44 21.44 21.44 21.44 21.44 21.44 21.44 21.44
300 323.9 25.40 25.40 25.40 25.40 25.40 25.40 25.40 25.40 25.40
350 355.6 27.79 27.79 27.79 26.19 26.19 26.19 26.19 26.19 26.19
400 406.4 30.96 30.96 30.96 30.96 30.96 30.96 30.96 30.96 30.96
450 457 34.93 34.93 34.93 34.93 34.93 34.93 34.93 34.93 34.93
500 508
550 559
FICHTNER India


600 608

CODE : IBR
CLASS RATING :900 #
P Kg/cm 142.37 138.51 133.59 126.2 115.31 113.2 112.5 106.11 86.8
Temp. C 93.3 149 204 260 316 343 371 399 427
S Kg/cm 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
OD in
NB
OD in MM
15 21.3 2.35 2.31 2.27 2.20 2.10 2.08 2.12 2.17 2.15
20 26.7 2.69 2.65 2.59 2.51 2.38 2.36 2.41 2.46 2.44
25 33.4 3.11 3.06 2.99 2.89 2.73 2.70 2.76 2.83 2.81
40 48.3 4.05 3.98 3.88 3.73 3.50 3.46 3.54 3.65 3.61
50 60.3 4.81 4.72 4.59 4.40 4.13 4.07 4.18 4.31 4.26
FICHTNER India


P Kg/cm 142.37 138.51 133.59 126.2 115.31 113.2 112.5 106.11 86.8
Temp. C 93.3 149 204 260 316 343 371 399 427
S Kg/cm 1054.6 1054.6 1054.6 1054.6 1054.6 1054.6 1012 914 759.33
OD in
NB
OD in MM
80 88.9 6.62 6.48 6.30 6.02 5.61 5.53 5.68 5.88 5.81
100 114.3 8.23 8.04 7.81 7.45 6.92 6.82 7.02 7.27 7.18
150 168.3 11.64 11.37 11.02 10.50 9.72 9.57 9.86 10.23 10.10
200 219.1 14.85 14.50 14.05 13.37 12.36 12.16 12.54 13.02 12.85
250 273.1 18.27 17.83 17.27 16.42 15.16 14.91 15.38 15.98 15.77
300 323.9 21.48 20.96 20.29 19.29 17.79 17.50 18.06 18.77 18.51
350 355.6 23.49 22.91 22.18 21.08 19.43 19.11 19.72 20.51 20.23
400 406.4 26.70 26.04 25.21 23.94 22.07 21.70 22.40 23.30 22.97
450 457 29.90 29.16 28.22 26.80 24.69 24.28 25.06 26.07 25.71
500 508 33.12 32.30 31.26 29.68 27.33 26.88 27.75 28.87 28.47
550 559 36.35 35.45 34.30 32.56 29.98 29.47 30.43 31.67 31.22
600 608 39.44 38.47 37.22 35.32 32.52 31.97 33.01 34.36 33.87

FICHTNER India

C:\Siva\REFERENCES\USEFUL BOOKS\DESIGN GUIDE-FICHTNER\WI-ME-
DSN-196-012.doc
FORM T10 REV - A

PIPE SIZING CALCULATIONS STEAM SERVICES

C O N T E N T S

SL. NO. DESCRIPTION

1. DESIGN PROCEDURE

2. TABLES AND FIGURES

3. MANUAL SAMPLE CALCULATION
FICHTNER India

DSN-196-012.doc
FORM T10 REV - A

DESIGN PROCEDURE
FICHTNER India

DSN-196-012.doc
FORM T10 REV - A

INTRODUCTION

The aim of this procedure is to calculate the pipe diameter and thickness for a given flow,
pressure and temperature of a steam line.


Q = Rated flow, kg/hr

d = Internal Diameter of pipe, mm

s
= Specific volume of steam at given pressure and temperature, m
3
/kg

P = Operating pressure, psi. ( 1 kg/cm =14.223 psi )

T = Operating temperature, C

Q' = Rated flow, m
3
/sec.

V = Assumed velocity, m/sec.

D = Selected outer diameter, mm

t
r
= Required thickness, mm

S
E
= Allowable stress of material , psi

A = Additional thickness (1.5), mm

Y = Co-efficient

CALCULATION :-

1. Diameter Calculation :-

(i) Convert flow from kg/hr to m
3
/sec

Select specific volume (V
s
) from the steam tables for the given Pressure and
Temperature

Q'
in (m/sec)
= Q
in (kg/hr)
x
s

3600

(ii) Calculating Diameter

d = [ 4 x Q/ x V] x 1000 mm

Assumed velocity V can be selected from Document No. WI-ME-DSN-196-014. For Quick
Reference it is attached in this document as Annexure I.
1. DESIGN PROCEDURE
FICHTNER India

DSN-196-012.doc
FORM T10 REV - A

2. Selection of Available Diameter (D)

Select a higher size than the calculated diameter from the Document No.WI-ME-DSN-196-
015. For Quick Reference it is attached in this document as Annexure II.

3. Thickness Calculation

(i) Select a Allowable Stress for the given pressure and temperature from ASME B31.1.
For Quick Reference, some of the materials frequently used are listed in Annexure III.

(ii) Select a coefficient (Y) from table 104.1.2 (A) from B31.1 for Quick Reference the
same table is reproduced in this document as Annexure IV.

(iii) Calculation of thickness

A - is usually assumed to 1.5 mm

(iv) Selection of Available thickness

From Annexure II select a higher thickness for the diameter calculated.

4. Actual Velocity Calculation

Since the above processes involves selection of available diameters and thicknesses, it is
important to recalculate the Actual Velocity of the fluid. If the Actual Velocity is not within the
limit provided in Annexure I then all the calculations has to be repeated until a suitable Velocity
Diameter and Thickness is achieved.

References

1. ASME B31.1 Power Piping Code : 1995 edition

( )
A
2
+
+
=
PY S
PD
tr
E
FICHTNER India

DSN-196-012.doc
FORM T10 REV - A

TABLES AND FIGURES

FICHTNER India

DSN-196-012.doc
FORM T10 REV - A

Annexure - 1

STANDARD ALLOWABLE VELOCITY IN PIPE LINES*

SL No Service Velocity
M/S
STEAM LINES
1 High pressure live steam lines 50 m/s
2 Low pressure steam lines above 5 bar 35 m/s
3 Low pressure steam lines below 5 bar 30 m/s
4 Saturated steam lines 25 m/s
5 Vacuum lines 60 m/s
6 Turbine bypass system (After PRDS) 200 m/s
Water and Condensate Lines
1 Feed water suction 1.25 m/s
2 Feed water discharge 4.0 m/s
3 Water / Condensate suction 1.0 m/s
4 Water / Condensate discharge 2.2 m/s
Air Lines
1 Delivery line for reciprocating compressor 30 m/s
2 Suction / delivery line for rotary compressor 25 m/s
3 Suction line for reciprocating compressor 20 m/s
Oil Lines Suction
1 Naphtha 0.8 m/s
2 HSD / LDO 0.8 m/s
3 Lube oil 0.8 m/s
Oil Lines Discharge
1 Naphtha 1.8 m/s
2 HSD / LDO 1.8 m/s
3 Lube oil 1.8 m/s
Gas Lines
1 Fuel gas / Natural gas 25 m/s

* Taken From the Document WI-ME-DSN-196-014
FICHTNER India

DSN-196-012.doc
FORM T10 REV - A

Annexure - 2

Thickness Selection
LINE PIPE DIMENSIONS*
NOM OD SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH
PIPE mm 10 20 30 STD 40 XS 60 80 100 120 140 160 XXS
SIZE
13.7 Nul Nul Nul 2.24 2.24 3.02 Nul 3.02 Nul Nul Nul Nul Nul
17.1 Nul Nul Nul 2.31 2.31 3.20 Nul 3.20 Nul Nul Nul Nul Nul
21.3 Nul Nul Nul 2.27 2.27 3.73 Nul 3.73 Nul Nul Nul 4.78 7.47
26.7 Nul Nul Nul 2.87 2.87 3.91 Nul 3.91 Nul Nul Nul 5.56 7.82
1 33.4 Nul Nul Nul 3.38 3.38 4.55 Nul 4.55 Nul Nul Nul 6.35 9.09
3 101.6 Nul Nul Nul 5.74 5.74 8.08 Nul 8.08 Nul Nul Nul Nul Nul
4 114.3 Nul Nul Nul 6.02 6.02 8.56 Nul 8.56 Nul 11.13 Nul 13.49 17.12
8 219.1 Nul 6.35 7.0 8.18 8.18 12.70 10.31 12.70 15.09 18.26 20.62 23.01 22.23
10 273.1 Nul 6.35 7.8 9.27 9.27 12.70 12.70 15.09 18.26 21.44 25.40 28.58 25.40
12 323.9 Nul 6.35 8.4 9.53 10.31 12.70 14.27 17.48 21.44 25.40 28.58 33.32 25.40
14 355.6 6.35 7.92 9.5 9.53 11.13 12.70 15.09 19.05 26.83 27.79 31.75 35.71 Nul
16 406.4 6.35 7.92 9.5 9.53 12.70 12.70 16.66 21.44 26.19 30.96 36.53 40.49 Nul
18 457 6.35 7.92 11.1 9.53 14.20 12.70 19.05 23.83 29.36 34.93 39.67 45.24 Nul
20 508 6.35 9.53 12.7 9.53 15.09 12.70 20.62 26.20 32.50 38.10 44.40 50.00 Nul
22 559 6.35 9.53 12.7 9.53 Nul 12.70 Nul 28.60 34.90 41.30 47.60 54.00 Nul
24 610 6.35 9.53 14.3 9.53 17.48 12.70 24.61 31.00 38.90 46.00 52.40 59.50 Nul
26 660 7.92 12.7 Nul 9.53 Nul 12.70 Nul Nul Nul Nul Nul Nul Nul
28 711 7.92 12.7 15.9 9.53 Nul 12.70 Nul Nul Nul Nul Nul Nul Nul

* Taken from the document WI-ME-DSN-196-015

FICHTNER India

FORM T10 REV - A

+Annexure 3

Selection of Allowable Stress from B31.1 1995 Edition in ksi for frequently used Materials

Material 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200
A 106 Gr B 15 15 15 15 15 15 15 15 15 15 15 15 15 15 14.4 13 10.8 Nul Nul Nul Nul Nul Nul Nul Nul
A 335 P 11 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 14.8 14.4 14 13.6 9.3 6.3 4.2 2.8 Nul Nul
A 335 P 22 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 14.4 13.1 11 7.8 5.8 4.2 Nul Nul
A 312 TP 304 18.8 17.8 17.8 17.8 17.8 16.6 16.6 16.2 16.2 15.9 15.9 15.9 15.9 15.9 15.9 15.6 15.2 14.9 14.7 14.4 13.8 12.2 9.8 7.7 6.1
A 312 TP 316 18.8 18.8 18.8 18.8 18.8 18.4 18.4 18.1 18.1 18 18 17 17 16.7 16.3 16.1 15.9 15.7 15.6 15.4 15.3 14.5 12.4 9.8 7.4

- Multiply these values by 1000 to convert it into psi.

- For full reference refer B31.1 1995 Edition.

- Values may be interpolated for intermediate temperatures.
FICHTNER India

FORM T10 REV - A

Annexure - 4

Selection of ' Y ' Coeffifient
Temperature
Material
900 and
Below
950 1000 1050 1100 1150 1200 1250 and
Above
Ferritic 0.4 0.5 0.7 0.7 0.7 0.7 0.7 0.7
Austinitic 0.4 0.4 0.4 0.4 0.5 0.7 0.7 0.7
Nickel Alloys 0.4 0.4 0.4 0.4 0.4 0.4 0.5 0.7

- Values may be interpolated for intermediate temperatures
- For more details refer ASME B31.1 1995 Edition Table 104.1.2(A)

FICHTNER India

FORM T10 REV - A

FICHTNER India

FORM T10 REV - A

MANUAL SAMPLE CALCULATION FOR PIPE SIZING OF STEAM LINES

Service = Main Steam Line

Material = SA 335 P 11

Pressure P = 66.1 kg/cm

Temperature T = 487 C

Flow Q = 90000 kg / hr

1.Diameter Calculation:

(i) Converting flow from kg/hr to m/sec

Specific Volume for the given Pressure and Temperature

s
= 0.05125 from steam tables

Q = (Q x
s
)/3600

= (90000 x 0.05125 ) / 3600

= 1.281 m / sec

2. Calculating Diameter:

Assumed Velocity for the line from Asnnexure I = 50 m / sec

D = 4 x Q / x V x 1000

= 4 x 1.281 / x 50 x 1000

= 180.62 mm
3. Selection of Available Diameter:
From Annexure II the next immediate available Diameter is 200 NB ( 219.1 mm OD )

4. Thickness Calculation:

(i) Allowable Stress value for the given Temperature =13385 psi from B31.1
(ii) The Coefficient Y =0.4 from B31.1
(iii) Thickness

t = [PD / (2(S
E
+PY)] +A

= [66.1 x 14.223 x 219.1 / 2 x ( 13385 +66.1 x 14.223 x 0.4 )] =
1.5

= 8.98 mm
(iv) Selection of available Thickness
From Annexure II the next immediate available thickness is 12.7 mm

FICHTNER India

FORM T10 REV - A

4. Actual Velocity Calculation:

ID =219.1 2 x 12.7
=193.7

Q = VA
V = Q/A

= 1.28 / [(/4) x (0.194)]

= 43.3 m / sec

Which is within the limit. Hence

Selected Size = 200 NB ( 219.1 mm )

Selected Thickness = 12.7 mm

FICHTNER India

FORM T10 REV - A

PIPE SIZING CALCULATIONS - WATER SERVICES

FICHTNER India

FORM T10 REV - A

PIPE SIZING CALCULATIONS - WATER SERVICES

C O N T E N T S





FICHTNER India

FORM T10 REV - A

INTRODUCTION

The water hammer problems due to pump tripping, power failure, valve opening and closing etc. in water
services, especially in cooling water services are very important in pipe thickness calculations. This
procedure calculates pipe thickness considering the above said phenomenons.

ASSUMPTIONS

1. The maximum allowable velocity for cooling water services is 2.4 m/sec.

2. For pipe sizes 150 and below use IS 1239

3. For pipe sizes above 150NB, use IS 3589


Q = Rated flow, m
3
/hr

V = Rated velocity, m/sec

D
cal
= Calculated diameter, mm

D = Selected diameter, mm

P = Operating pressure, kg/cm
2

P
S
= Shut off pressure kg/cm
2

S = Allowable stress, kg/cm
2

C = Corrosion Allowance, mm

tc1, tc2, tc3, tc4 = Calculated thickness, mm

t1, t2, t3, t4 = tc1 +C, mm

K = Bulk modules of water, lb/in
2

= Density of water, slugs / ft
3

t = Assumed pipe wall thickness,in

E = Modulus of Elasticity of pipe, lb/in
2

C1 = Constant Assumed is (1.00)

g = Acceleration due to gravity, (32.2) ft/s
2

d = Internal Diameter of Pipe, in

FICHTNER India

FORM T10 REV - A

a = Pressure wave velocity, ft/s

V = Rated flow velocity, m/sec

Q1, Q2 = Flow in water hammer condition, m
3
/hr

V1,V2 = Velocity in water hammer condition, m/sec

V = Change in velocity m/sec

H
1
, H
2
, H
3
= Surge pressure developed due to water hammer, kg/cm
2

L = Total length of the pipe, m

T
CR
= Critical time, sec

Calculation :-

1. Diameter Calculation :-

Calculated Diameter D
cal
=
4 3600 x Q
x V
( ' / )
mm

By using Table 1 select a Available Diameter (D)

2. Thickness Calculation :-

(i) Considering Shut off Head :-

Calculated thickness t
P D
S
mm c1
.
=
2

Adding Corrosion Allowance `C

mm

(ii) Considering Water Hammer Effects :-

I Calculation of Velocity of Pressure Wave (a)

The velocity of pressure wave

a
k
K E d t C
=
+
12
1 1
/
( / ) ( / )
ft/sec

t1 = tc1 + c
FICHTNER India

FORM T10 REV - A

II Calculation of critical time (T
CR
)

T
L
a
CR
=
2
Sec

if T
CR
< valve opening time then the formula

H
aV
g
= can be used to calculate surge pressure refer Piping
Hand Book page 21 - 21.

III Tripping of one pump

If is assumed that 66% of the rated flow will persist when one pump trips

Q
1
= 0.66 x Q m
3
/hr

For this condition velocity can be calculated by the formula

V
x Q
x d
m 1
4
1
2
=
/ sec

Hence surge pressure

H1 =
a v x
g
ft of H O
1
32808
2
.

=
a x v x
g
x kg m
1 2
32808
30279
.
. /

=
a x v x
g
kg cm
1 2
009934 .
/

Calculated thickness tc2 =
H x D
x S
1
2

and t
2
=tc
2
+C mm

IV Valve Opening and Closing

It is assumed that at 85% of valve closure 62.7% of the rated flow will persist.

Q
2
= 0.627 x Q

FICHTNER India

FORM T10 REV - A

For this condition velocity can be calculated by the formula

V
x Q
x d
m
2
2
2
4
=
/ sec

Hence surge pressure

H1 =
a V x
g
ft of H O
2
32808
2
.

=
a x V x
g
x kg m
2 2
32808
30279
.
. /

=
a x V x
g
kg cm
2 2
009934 .
/

Calculated thickness tc
3
=
H x D
x S
2
2

mm

V Tripping of all pumps due to power failure :

It is assumed that at this condition the surge pressure will be 1.5 times of the rated
pump pressure

H
3
= 1.5 x P

Calculated thickness tc
H x D
x S
4
2
3
=

mm

mm

t
4
= tc
4
+ C
t3 = tc3 + C
FICHTNER India

FORM T10 REV - A

(iii) Live Loads & Dead Loads (For Burried Pipes Only)

This calculation is based on the tables 2,3 & 4 (Extracted from piping Hand Book - By CROKER)

Step 1 : The Dead Load for a particular Depth can be directly selected from table 3
based on depth and Nominal Diameter of pipe.

Step 2 : Based on the wheel load applied the percentage of wheel load transmitted
can be calculated using table 4.

Adding Dead Load and Live Load (Wheel Load) we can get Total Load.

Step 3 : Matching this load with the pipe diameter, the thickness can be directly
selected from Table 5.

The maximum thickness from the above calculations should be selected as the final thickness.

References :-

1. J OHN PARMAKIAN, Water Hammer Analysis

LONGMAN, GREEN & Co, Ltd. 1955

2. J AMES CROCKER Piping Hand Book

3. American Water Works Association, Steel Pipe - A guide for design and Installation -
standard M-II

4. Burried Pipe Design
FICHTNER India

FORM T10 REV - A

Table-1

CODE REF : IS 3589 1991
MOC : IS 3589
APPLICATION : WATER , GAS AND SEWAGE 9168.3
TO 2032MM OD)
SR. NO OUTSIDE
DIAMETER

WALL THICKNESS

in. mm mm

1 8 219.1 5.56
2 6.35
3 7.04
4 7.92
5 8.18
6 8.74
7 9.52
8 10 273.1 6.35
9 7.087
10 7.798
11 8.738
12 9.271
11.125
13 12 323.1 6.35
14 7.137
15 7.925
16 8.382
17 8.738
18 9.525
19 10.312
20 11.125
21 14 355.6 6.35
22 7.137
23 7.925
24 8.738
25 9.525
26 11.125
27 11.913
28 12.7
29 16 406.4 6.35
30 7.14
31 7.92
32 8.74
33 9.52
34 11.13
35 11.91
36 12.7
FICHTNER India

FORM T10 REV - A

SR. NO OUTSIDE
DIAMETER

WALL THICKNESS

in. mm mm

37 18 457.2 6.35
38 7.137
39 9.925
40 8.738
41 9.525
42 11.125
43 11.913
44 12.7

FICHTNER India

FORM T10 REV - A

Table-2

IS 1239 - PAT1 : 1992, BS 1387 : 1985
NOMINAL BORE OUT SIDE DIAMETER THICKNESS
(NB) INCH Max. Min.
in. mm in. mm in mm
LIGHT 1/8 0.396 10.1 0.387 9.8 0.072 1.83
1/4 0.532 13.5 0.518 13.2 0.072 1.83
3/8 0.671 17.0 0.656 16.7 0.072 1.83
1/2 0.841 21.4 0.825 21.0 0.08 2.03
3/4 1.059 26.9 1.041 26.4 0.092 2.34
1 1.328 33.7 1.309 33.2 0.104 2.64
1 1.67 42.4 1.65 41.9 0.104 2.64
1 1.903 48.3 1.882 47.8 0.116 2.95
2 2.3702 60.2 2.347 59.6 0.116 2.95
2 2.991 76.0 2.96 75.2 0.128 3.25
3 3.491 88.7 3.46 87.9 0.128 3.25
4 4.481 113.8 4.45 113.0 0.144 3.66
MEDIUM 1/8 0.411 10.4 0.386 9.8 0.08 2.03
1/4 0.547 13.9 0.522 13.3 0.092 2.34
3/8 0.685 17.4 0.66 16.8 0.092 2.34
1/2 0.856 21.7 0.831 21.1 0.104 2.64
3/4 1.072 27.2 1.047 26.6 0.104 2.64
1 1.346 34.2 1.316 33.4 0.128 3.25
1 1.687 42.8 1.657 42.1 0.128 3.25
1 1.919 48.7 1.889 48.0 0.128 3.25
2 2.394 60.8 2.354 59.8 0.144 3.66
2 3.014 76.6 2.969 75.4 0.144 3.66
3 3.524 89.5 3.469 88.1 0.16 4.06
4 4.524 114.9 4.459 113.3 0.176 4.47
5 5.534 140.6 5.459 138.7 0.192 4.88
6 6.539 166.1 6.459 164.1 0.192 4.88
HEAVY 1/8 0.411 10.4 0.386 9.8 0.104 2.64
1/4 0.547 13.9 0.522 13.3 0.116 2.95
3/8 0.685 17.4 0.66 16.8 0.116 2.95
1/2 0.856 21.7 0.831 21.1 0.128 3.25
3/4 1.072 27.2 1.047 26.6 0.128 3.25
1 1.346 34.2 1.316 33.4 0.16 4.06
1 1.687 42.8 1.657 42.1 0.16 4.06
1 1.919 48.7 1.889 48.0 0.16 4.06
2 2.394 60.8 2.354 59.8 0.176 4.5
2 3.014 76.6 2.969 75.4 0.176 4.5
3 3.524 89.5 3.469 88.1 0.192 4.88
4 4.524 114.9 4.459 113.3 0.212 5.4
5 5.534 140.6 5.459 138.7 0.212 5.4
6 6.539 166.1 6.459 164.1 0.212 5.4
FICHTNER India

FORM T10 REV - A

Table-3

Dep Nominal Pipe Diameter, in.

Cov
(ft)
3 4 6 8 10 12 15 18 21 24 27 30 33 36 39 42 48 54 60
2 145 180 240 290 340 390 450 500 560 610 700 750 820 875 940 1000 1140 1280 1380
3 220 270 370 460 550 630 750 860 950 1040 1120 1200 1300 1400 1480 1580 1740 1970 2080
4 300 370 520 650 780 920 1080 1230 1400 1520 1630 1750 1850 2000 2100 2220 2500 2730 2980
5 380 470 660 830 1000 1160 1420 1610 1810 2010 2200 2340 2500 1630 2800 2950 3250 3600 3820
6 460 570 800 1000 1200 1430 1710 2000 2230 2500 2700 2950 3180 3350 3500 3650 4030 4420 4700
7 540 670 950 1180 1420 1700 2050 2400 2700 3050 3300 3570 3900 4100 4300 4440 4900 5450 5780
8 620 780 1080 1370 1620 1960 2400 2780 3200 3550 3900 4200 4500 4800 5050 5300 5900 6430 6880

Percentage of Wheel Load transmitted to Underground Pipes

(Values show percentage of Wheel load applied to one liner foot of pipe)

Table-4

Depth
of
Nominal Pipe Diameter, in.

Cover
(ft)
3 4 6 8 10 12 15 18 21 24 27 30 33 36 39 42 48 54 60
1 15.2 18.6 25.6 30.0 34.6 40.0 45.2 49.6 52.8 54.4 56.0 57.2 58.0 58.8 59.6 59.7 60.0 60.3 60.6
2 7.0 8.5 11.4 14.0 16.6 19.2 23.0 26.4 30.0 31.2 33.6 35.6 37.4 39.0 40.0 40.9 42.6 43.6 44.6
3 3.5 4.0 5.8 7.2 8.6 10.4 12.8 15.0 17.2 18.6 20.4 22.2 23.6 25.0 25.8 26.0 26.6 28.0 29.4
4 2.0 2.4 3.4 4.2 5.0 6.2 7.8 9.2 10.6 14.6 13.0 14.4 15.8 17.0 17.6 17.7 18.0 19.7 21.4
5 1.4 1.8 2.4 2.8 3.4 4.2 5.2 6.2 7.2 7.8 8.8 9.8 10.6 11.6 12.2 12.4 12.7 14.0 15.3
6 0.9 1.2 1.6 2.0 2.2 2.8 3.6 4.2 5.0 5.6 6.2 7.0 7.6 8.4 8.6 8.8 9.3 10.7 12.0
7 0.3 0.5 1.0 1.4 1.6 2.0 2.6 3.2 3.8 4.2 4.6 5.2 5.2 6.4 6.5 6.6 6.7 7.7 8.7
8 0.2 0.4 0.8 1.0 1.2 1.6 2.0 2.4 2.8 3.2 3.6 4.0 4.0 4.6 5.0 5.1 5.3 6.0 6.7
FICHTNER India

FORM T10 REV - A

Table-5

Nominal Wall thickness Allowable
Pipe Dia in. Load
in. or Schedule lb/lin ft
4 0.237 Sch 40 10000
5 0.258 Sch 40 10000
6 0.280 Sch 40 10000
8 0.250 Sch 20 8300
8 0.322 Sch 40 9900
10 0.250 Sch 20 7300
10 0.307 Std 14600
10 0.365 Sch 40 18700
12 0.250 Sch 20 5100
12 0.330 Std 13700
12 0.375 Sch 40 17500
14 0.250 Sch 10 3800
14 0.312 Sch 20 7500
14 0.375 Sch 30 13100
16 0.250 Sch 10 3000
16 0.312 Sch 20 5800
16 0.375 Sch 30 10000
18 0.250 Sch 10 2440
18 0.375 7700
18 0.437 Sch 30 12700
20 0.250 Sch 10 1900
20 0.375 Sch 20 6250
20 0.500 Sch 30 14600
24 0.250 Sch 10 1250
24 0.375 Sch 20 4250
24 0.500 10000
30 0.25 930
30 0.375 3000
30 0.500 Sch 20 6500
36 0.25 850
36 0.375 2250
36 0.500 4900
42 0.375 1750
42 0.500 3900
48 0.500 3000
48 0.625 5500
54 0.500 2800
54 0.625 4500
60 0.500 2500
60 0.625 4000

FICHTNER India

FORM T10 REV - A

PIPE SIZING - WATER SERVICE

I. Service Cooling water
II. Material IS 3589
III. Diameter calculation

Flow Q = 9000 m/hr

Assumed velocity V = 1.22 m/sec.

Calculated diameter D cal = 4 x (9000 / 3600)
x 1.22

= 1.592 m

= 1592 mm

Selected diameter = 1620 mm (OD)

IV. Thickness Calculation :

i) Considering shut-off pressure

Operating Pressure P = 1.70 kg/cm

Pump shut-off pressure Ps = 6.00 kg/cm

Allowable stress S = 1673.0 kg/cm

Corrosion allowance C = 2 mm

Calculated thickness tc1 = P
s
x D / 2 x S

= 6.00 x 1620
2 x 1673.0

= 2.91 mm

Original thickness t1 = tc1 +C

= 2.91 +2

= 4.91 mm

ii) Considering water hammer effects :

Wave velocity calculation (a)

Bulk modules of water K = 313000.00 lb/in

Density of water = 1.94 slugs / Ft

FICHTNER India

FORM T10 REV - A

Assumed pipe thickness t = 0.12 in

Modules of elasticity E = 30000000.00 lb/in
of pipe

Constant (assumed) C1 = 1.00

Acceleration due to g = 32.2 ft / s
Gravity

Internal diameter d = 63.77 2 x 0.12
Of pipe

= 63.53 in.

Wave velocity a = 12 K/P / 1 +(K/E) (d/t) C1

= 12 x 313000/1.94
1+(313000/30000000)(6.53/0.12)

= 1888.02 ft/sec.

2. Critical Time Calculation (T
cr
)

Total length of the pipe L = 100 m

= 328.1 ft

Critical time T
cr
= 2 x L / a

= 2 x 328.1 / 1888.02

= 0.34 sec.

Assumed valve opening time = 25 sec.

Since TCR <valve opening time, the surge pressure can be calculated
using the following formula

H = a V ft of water column
g

3. Tripping of one pump

It is assumed that when one pump is tripping the flow will be 66% of the rated flow

ie. Q
1
= 0.66 Q

= 0.66 x 9000

= 5940 m/hr

FICHTNER India

FORM T10 REV - A

Velocity (at 65% of flow)

V1 = Q
1
x 4
x d

= 5940/3600 x 4 / x 1.614

= 0.81 m/sec.

Surge pressure

H
1
= aV
1

g

= 1888.02 x 0.81 x 0.09934
32.2

= 4.71 kg/cm

Calculated thickness

tc
2
= H
1
x d
2 x S

= 4.71 x 1614
2 x 1673

= 2.27 mm

t2 =tc2 +c

2.27 +2 =4.27 mm

4. Valve opening and closing

At 85% of valve closure

Q
2
= 0.627 x Q

= 0.627 x 9000

= 5643 m/hr

Velocity for the same condition

V
2
= Q
2
x 4
x d

= 5643 x 4
x 1.614 x 3600

= 0.77 m/sec.

FICHTNER India

FORM T10 REV - A

Surge pressure,

H
2
= aV
g

= 1888.02 x 0.77 x 0.09934
32.2

= 4.46 kg/cm


tc3 = H
2
x d
2 x S

= 4.46 x 1614
2 x 1673

= 2.15 mm

t3 =tc3 +c
=2.15 +2
=4.15 mm

5. Tripping of all pumps due to power failure

It is assumed that during power failure, the surge pressure developed will not exceed 1.5 times
of the rated pump pressure.

H
3
= 1.5 x P

= 1.5 x 1.7

= 2.55 kg/cm


tc4 = H
3
x d
2 x S

= 2.55 x 1614
2 x 1673

= 1.23 mm
t4 =tc4 +6
=1.23 +2
=3.23 mm

FICHTNER India

FORM T10 REV - A

6. Considering live loads and dead loads

Depth of cover = 3.4 ft

Dead load from = 2044.00 lb/lin ft
Table-3

When load = 0
Applied

Total load = 2044.00 lb/lin ft.

Next higher load
In Table-5 = 3000 lb/lin ft.

Pipe thickness for = 12.00 mm
The above load

Hence selected pipe thickness =12.00 mm
FICHTNER India

FORM T10 REV - A

PIPE SIZING CALCULATIONS AIR SERVICE

C O N T E N T S

SL. NO. DESCRIPTION PAGE NO


FICHTNER India

FORM T10 REV - A

DESIGN PROCEDURE

FICHTNER India

FORM T10 REV - A

INTRODUCTION

The main of this procedure is to calculate the pipe diameter and thickness for a given flow,
pressure and temperature of a Air line.


1. The coil is fully immersed in the fluid.

2. The fluid inside the coil (fluid in coil) is flowing and the outside fluid is stationary.


Q - Rated flow, kg/hr

d - Internal diameter of pipe, mm

P
a
- Density of Air, kg/m

P - Operating pressure, Psi (1 kg / cm =14.223 psi)

T - Operating temperature, C

Q
1
- Rated flow, m/sec.

V - Assumed velocity, m/sec.

D - Selected outer diameter, mm

l
r
- Required thickness, mm

S
e
- Allowable stress of material, Psi

A - Additional thickness, mm

Y

- Co-efficient

V
A
- Actual velocity, m/sec.

P
1
- Atmospheric pressure, 1.013 bar

V
a1
- Specific volume of air at atmospheric pressure, m/kg

V
a2
- Specific volume of air at operating pressure, m/kg

a
- Density of Air at atmospheric pressure, kg/m

a
1
- Density of Air at operating pressure, kg/m
1. DESIGN PROCEDURE
FICHTNER India

FORM T10 REV - A

t
h
- Hydro test thickness, mm

CALCULATIONN

1. Diameter Calculation

i) Convert Flow from kg/hr to m/sec.

Select density of Air at required temperature from Annexure-I. Note that the values
given are for atmospheric pressure of 1.013 bar. Hence for the given pressure the
density can be calculated as follows.

Va - 1/
a

P
1
V
a1
- P V
a2

Where P
1
- Atmospheric pressure

P - Operating pressure

V
a1
- Specific volume of air at atmospheric pressure

V
a2
- Specific volume of air at operating pressure

V
a2
- P
1
V
a1
/ P

- 1.013 x V
a1
/ P

a
1

- 1/V
a2
Kg/cm

Then by dividing Q with
a
Q
1
can be calculated

Q
1

- Q /
a
1
x 3600 msec.

ii) Calculating Diameter

Using the following formula Internal diameter can be calculated.

D - (4 x Q
1
/ x V) x 1000 mm

The velocity V can be taken from the document WI-ME-DSN-196-014. For quick
reference it is attached as Annexure-II in this document.

2. SELECTION OF AVAILABLE DIAMETER (D)

FICHTNER India

FORM T10 REV - A

Select a higher size (D) than the calculated diameter from the document wI-ME-DSN-196-015.
For quick reference the same is attached as Annexure-III in this document.

3. THICKNESS CALCULATION (t
r
)

i) The material for Air line is assumed as IS 1239 or IS 3589. Hence a allowable stress
of 164 M
pa
which is 23785 Psi (S
t
)
(Refer IS 1239 or IS 3589 for more details)

ii) For IS 1239 & IS 3589 Y factor can be taken as 0.4 (Refer B31.1 for more details)

iii) Using the following formula calculate the thickness

tr -

PD / 2 (S
E
+PY ) +A mm

A is usally assumed as 1.5 mm

iv) By using Annexure-IV select a available thickness. Which is higher than t
r
.

4. CHECKING FOR HYDROTEST PRESSURE

Hydrotest pressure P
1
- 1.5 x P and

t
n
- P
1
D / 2 S
e
mm

The selected thickness should be greater than this hydrotest thickness th :

5. ACTUAL VELOCITY CALCULATION

Since a higher diameter and higher thickness is selected, it is necessary to recalculate the
actual velocity and make sure that it is within permissible limits. It values are not within limits
then a lesser thickness or a lesser diameter can be considered.

V
A
- Q
1
/ (d/1000)

References

1. ASME B31.1 power piping code : 1995 edition

2. IS 1239

3. IS 3589
FICHTNER India

FORM T10 REV - A

STANDARD ALLOWABLE VELOCITY IN PIPE LINES

--------------------------------------------------------------------------------------------------------------------------
SL SERVICE Velocity
NO. m/s
--------------------------------------------------------------------------------------------------------------------------

A) STEAM LINES

1. High pressure live steam lines 50 m/s

2. Low pressure steam lines above 5 bar 35 m/s

3. Low pressure steam lines below 5 bar 30 m/s

4. Saturated steam lines 25 m/s

5. Vacuum lines 60 m/s

6. Turbine bypass system (After PRDS) 200 m/s

B) Water and Condensate Lines

1. Feed water suction 2.0 m/s

2. Feed water discharge 4.0 m/s

3. Water / Condensate suction 1.0 m/s

4. Water / Condensate discharge 2.2 m/s

C) Air Lines

1. Delivery line for reciprocating compressor 30 m/s

2. Suction / delivery line for rotary compressor 25 m/s

3. Suction line for reciprocating compressor 20 m/s

D) Oil Lines Suction

1. Naphtha 0.8 m/s

2. HSD / LDO 0.8 m/s

3. Lube oil 0.8 m/s

FICHTNER India

FORM T10 REV - A

--------------------------------------------------------------------------------------------------------------------------
SL SERVICE Velocity
NO. M/S
--------------------------------------------------------------------------------------------------------------------------

E) Oil Lines Discharge

1. Naphtha 1.8 m/s

2. HSD / LDO 1.8 m/s

3. Lube oil 1.8 m/s

F) Gas Lines

1. Fuel gas / Natural gas 25 m/s
FICHTNER India

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LIST OF CALCULATIONS IN EXCEL AVAILABLE IN MECHANICAL DEPARTMENT

FILE PATH : F:\MECH\EXCELCAL

Sl.
No.
CATEGORY FILE NAME REMARKS

1. DM plant drainage system design 166DMPL.XLS GACL, DAHEJ

2. Condenser sizing 2135CON.XLS SEPC

3. NPSH calculation for boiler feed pump BFP-DEC1.XLS

4 Boiler feed pump sizing calculation (HP & LP) BFP-DSGN.XLS KPCL

5. Compressed air system design CAS.XLS

6 Condensate extraction pump sizing calculation CEP-DESN.XLS KPCL

7. Coal & Ash characteristics & analysis COALASH.XLS

8. Condenser sizing CONDTNEB.XLS TNEB

9 Control valve sizing for liquid services CVSIZING.XLS KPCL

10 Cooling water line pressure drop calculation CWPIPING.XLS

11 Program for cooling water treatment system CWSPROG.XLS

12 Cooling water treatment system design CWT.XLS

13 Chimney design calculation DLFCHIM.XLS

14 Determination of design pressure &
temperature calculation for various system.
DSGN-P-T.XLS KPCL

15 Sea water analysis GROUND.XLS

16 Heat loss calculations for storage tanks HEAT.XLS

17 Heat rate calculation HEATRATE.XLS

18 Heat loss calculation in heated tanks HTLOSS.XLS

19 HVAC design calculation HVACDSGN.XLS KPCL

20 IBR Document calculation IBRCAL.XLS

21 Pipe thickness calculation IBRTHK.XLS

22 Calculation of overall heat transfer co-efficient INLET.XLS

23 Measurement uncertainity analysis for heat
rate and power output
MEAS.XLS
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No.
CATEGORY FILE NAME REMARKS

24 Pipe thickness calculation PIPETHK.XLS

25 Plant design data PLSIZING.XLS

26 RA opening calculation RA.XLS

27 Reinforcement of welded branch connection REIN.XLS

28 Reinforcement of welded branch connection REIN318.XLS

29 Statistical analysis of weather data SEPC.XLS

30 Heavy fuel oil calculation for steam production SP.XLS

31 Calculation of operating torque for rubber
seated butterfly valve
TORCAL.XLS

32 Warm-up steam quantity calculation for main
steam lines.
WARM-UP.XLS

33 Pressure drop calculation for water services WATERDP.XLS

34 Steam drum popping time calculation POP-TIME.XLS

35 Flue gas analysis calculation FLUEGAS.XLS

36 Dew point temperature calculation DEWPOINT.XLS

37 Steam trace heating calculation TRACEHEATING.XLS

38 Buried pipe thickness calculation BURIEDPIPE.XLS

39 Financial analysis FINANCIALANALYSIS.
XLS

40 Insulation thickness calculation INSULTHK.XLS

Note :

For working on the above calculations, Engineers shall copy the required file(s) to his/her working
directory and do the calculation in the copy only. Calculations should not be performed on the file(s)
listed above directly.

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LIST OF SOFTWARE AVAILABLE IN MECHANICAL DEPARTMENT

Sl.
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SOFTWARE NAME VERSION APPLICATION

1 KPRO
FS
4.4/4.6 THERMODYNAMIC CYCLE
ANALYSIS

2 CAESER
TM
4.4 PIPE STRESS ANALYSIS

3 CAEPipe
TM
4.0 A PIPE STRESS ANALYSIS

3 AUTO CAD R14
TM
/ 2000/ 2002 DRAFTING

4 PRIMA VERA
TM
3.00.099.0 PROJ ECT MANAGEMENT

5 MS PROJ ECT
TM
8.0 PROJ ECT MANAGEMENT

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