PWOG-HZL-6033-PR-CAL-

Prepare : CPK
002
Cooling Water Supply and Review : CPK Rev A
Return Hydraulics and
Approve : NVR Sheet 1 of 3
Configuration
Date :22.05.2021

Cooling Water Supply and Return Hydraulics and

Configuration

OWNER
HINDUSTHAN ZINC LIMITED

PREPARED BY
M/S PWOG PLANT ENGINEERING PVT LTD

A 22.05.2021 ISSUED FOR APPROVAL CPK CPK NVR

REV REV DATE PURPOSE PREPD REVWD APPD
 Cooling Water Supply and Return Hydraulics and
Configuration A 22.05.2021 CPK ACS
REV. DATE CHD APPD Remark
DOC. NO : SERVICE : LINE SIZING CALCULATION ITEM NO. :

Following are the allowable limits for line sizing to avoid erosion, or flashing of fluid.

Allowable velocity = 4 m/s

Pressure drop per 100m = 1.5 bar/100m
Water Supply to WCD spool = 59.1 m3/hr

Individual tappling to WCD Spool = 3 inch

Common header = 6 inch

Flue Gas In

3" Return line size

Cooling Water Out

6 inch Coolong Water Return Header

6 inch Coolong Water Supply Header

3" Supply line size

Cooling Water In
3" Return line size

Flue Gas Out

3" Supply line size (Typical for 4 WCD spools/pieces)

3" Return line size

3" Supply line size

3" Return line size

3" Supply line size

 Cooling Water Supply & Return lines

REV.A

PWOG-HZL-6033-PR-CAL-002

P&ID No. (Line Origin) 1 2 3 4 5

Line No. 3" 3" 3" 3" 3"

Fluid Description Cooling Water Supply & Return lines Cooling Water Supply & Return lines Cooling Water Supply & Return lines Cooling Water Supply & Return lines Common header

From Supply HDR Supply HDR Supply HDR Supply HDR Supply HDR

To WCD Spool 1 WCD Spool 2 WCD Spool 3 WCD Spool 4 Header

INPUT DATA

Process

Case Description Cooling Water Cooling Water Cooling Water Cooling Water Cooling Water

Operating Temperature (°C) 30.0 30.0 30.0 30.0 30.0

Operating Pressure (barg) 2.0 2.0 2.0 2.0 2.0

Vapour:

Flow (kg/hr)

Flow (lb/hr)

3
Density (kg/m )

Viscosity (cP)

Molecular Weight

MMSCFD

Compressibility Factor

Liquid:

Flow (kg/hr) 59063 59063 59063 59063 236250

Flow (lb/hr) 130210 130210 130210 130210 520841

3
Density (kg/m ) 1000.00 1000.00 1000.00 1000.00 1000.00

Viscosity (cP) 1.00 1.00 1.00 1.00 1.00

3
Liquid Volumetric Flow Rate (m /hr) 59.1 59.1 59.1 59.1 236.3

Mechanical

Roughness (mm) 0.05 0.05 0.05 0.05 0.05

Pipe spec. CS CS CS CS CS

RESULTS

Line size (Nominal) 3 3 3 3 6

Pipe Schedule 40S/std 40S/std 40S/std 40S/std 40S/std

Outside Diam. (") 4 4 4 4 7

Outside Diam. (mm) 89 89 89 89 168

Inside diameter (") 3 3 3 3 6

Inside diameter (mm) 77.93 77.93 77.93 77.93 154.05

Average Fluid Velocity (m/s) 3.4 3.4 3.4 3.4 3.5

Average Fluid Velocity (ft/s) 11.29 11.29 11.29 11.29 11.55

2 2
Rho * Velocity (kg/m s ) 11833 11833 11833 11833 12397

Pressure Drop (bar/100 m) 1.45 1.45 1.45 1.45 0.66

Pressure Drop (Psi/100 ft) 6.39 6.39 6.39 6.39 2.90

Erosional Velocity (m/s) {C=100, API 14E} 3.86 3.86 3.86 3.86 3.86

Erosional Velocity > Average Fluid Velocity TRUE TRUE TRUE TRUE TRUE

Intermediate Calculations

Total mass flow (kg/hr) 59063 59063 59063 59063 236250

3
Total volumetric flow (m /hr) 59 59 59 59 236

3
Average density (kg/m ) 1000.00 1000.00 1000.00 1000.00 1000.00

Average viscosity (cP) 1.00 1.00 1.00 1.00 1.00

Inlet liquid fraction (vol%) 100.00 100.00 100.00 100.00 100.00

Reynolds No. (average) 268059 268059 268059 268059 542394

Friction Factor 0.004760 0.004760 0.004760 0.004760 0.004082

Reference Standard for Selection Criteria API 14E API 14E API 14E API 14E API 14E

Remarks Line Size is OK Line Size is OK Line Size is OK Line Size is OK Line Size is OK