PROCESS DESIGN CALCULATIONS FOR TUBE SETTLER IN WATER TREATMENT PLANT

Raw water Flow = 100 MldRecycle Flow = 5 MldDesign Flow = 100+5

= 105 MldNumber of units provided = 4 nos.So, Design flow per Tube Settler = 105/4

= 26.250 Mld= 26250.000 m³/d= 1093.750 m³/h

Shape of unit = SquareLength/ Breadth of Tube Settler provided = 11.40 m

Tube Pack Data:Shape = Hexagonal - Chevron Cross sectional area = 120 x 44 mm x mmHydraulic radius

= 0.015 mSettling area : 60° Slope = 11 m²/m³Settling area : 55° Slope = 13 m²/m³Vertical Space between

Tubes = 0.044 mAngle of inclination = 55 °

Select, Settling rate on the horizontal projected a rea of Tube Pack = 1.00 m³/m²/hApply the probability

factor,as recommended by theT ube Pack Vendor = 0.70Revised Settling rate on the horizontal projected a

rea of Tube Pack = 1* 0.7

= 0.70 m³/m²/hKinematic viscosity of water at 30°C = 0.00000080 m²/sDesign temperature of water =

20.00 °CKinematic viscosity of water at 20°C = 0.000001003 m²/sCorrection Factor for Settling rate, w.r.t.

Kinematic viscosity = 0.0000008/0.000001003

= 0.798Corrected Settling rate = 0.7*0.798

= 0.558 m³/m²/hSelected Settling rate on the horizontal projected area of Tube Pack = 0.700

m³/m²/hSelected vertical depth of Tube Pack = 1.000Plan area of the Tube Settler = 11.4*11.4

= 129.960 m²Volume of Tube Pack provided = 129.96*1

= 129.960 m³Loss of volume of Tube Pack, on account of inclination = 11.4*1 *(1/TAN55°)

= 7.982 m³Effective volume of Tube Pack = 129.96-7.982

= 121.978 m³Settling area of Tube Pack, corresponding to the inclination, = 121.978*13 based on the

effective volume of Tube Pack = 1585.709 m²

Actual Settling rate on the horizontal projected a rea of Tube Pack = 1093.75 / 1585.7090.690 m³/m²/h

< 0.70 m³/m²/hHence O.K.

Check for the performance of the Tube Settler: Sedimentation takes place in the length following the

transition length and it will retain all partic leswith a settling velocity less than V s.

Vs = V. k / { [sin θ + (Ls/d)cos θ ] }Where,Vs = Settling velocity, m³/m²/h

5.0 (C) TUBE SETTLER

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Ls = Settling length of Tube

d = depth of water in a Tube at right angle to the direction of flow, mθ = angle of inclination of Tube Pack

to the horizontalk = a coefficient = 1.33 for Hexagonal Tubes

Schiller formula to calculate transition length:

Lt = 0.0288 NR .DWhere,Lt = Transition length V = Average velocity of flow in the Tubes, m³/h.m² = U /

sin θ U = Average upward velocity, m³/h.m² = Surface loading rate of the Settling Tank = Rate of flow /

Tube entrance areaν = Kinematic viscosity of water, m²/s = 0.00000086 m²/sNR = Reynolds Number

Ls = L - LtWhere,L = Length of TubeLs = Settling length of Tube

Plan area of the Tube Settler = 11.4*11.4= 129.96 m²

The tube entrance area is reduced due to the thick ness of the tube pack and also due to the supportin g

structure provided.The support width of minimum 60 mm is recommended a t a centre-to-centre distance

of 1000 mm, in a square grid.No. of supporting angles, lengthwise @ 1m c-c spacing = (11.4/1)+1

= 12.40 nos.Say = 13.00 nos.No. of supporting angles, breadthwise @ 1m c-c spacing = (11.4/1)+1

= 12.40 nos.Say = 13.00 nos.Width of supporting angle of standard size, provided = 65.000 mm

= 0.065 mPlan area lost by the supporting angles of width 65 mm = (11.4*13*0.065)+(11.4*13*0.065

-(13*13*0.065*0.065)= 0.768 m²

Plan area lost by the thickness of the Tube Pack = 3.00 % of plan area= 3%*129.96= 3.899 m²

Total area of obstruction for flow through Tube Pack = 0.768+3.899= 4.667 m²

Tube entrance area = 129.96-4.667= 125.293 m²

Average upward velocity, U = 1093.75/125.293= 8.730 m/h

Average velocity of flow in the Tubes, V = U / sin θ = 8.73 / sin 55°= 10.657 m/h= 0.003 m/s

Hydraulic radius, R ( = CSA / Wetted perimeter) = 0.01500 mEquivalent diameter, D ( = 4 R) = 4*0.015

= 0.060 mReynolds Number, NR = V R

ν = 0.003*0.015/0.00000086= 51.632
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Transition length of Tube = 0.0288*NR*D

= 0.0288*51.632*0.06= 0.089 m

Settling length of Tube, Ls = L - Lt

= 1-0.089= 0.911 m

Relative settling length of tube = Ls/d = 0.911/0.044= 20.700

Coefficient k for Hexagonal shaped Tubes = 1.33

Vs = V. k / { [sin θ + (Ls/d)cos θ ] }

= 10.657*1.33/((sin55°+20.7*cos55°))= 1.117 m³/m²/h> 0.690

Hence O.K.

Unit SizeLength / Breadth of Tube Settler provided = 11.40 mFlow per Tube Settler = 1093.75 m³/h

= 0.3038 m³/sApprox.liquid height above the top of the tube pack = 0.65 mVertical Height of Plates = 1.00

mHorizontal velocity in the clarification shall be 0 .02 to 0.03 m/s.Horizontal Velocity in the clarification

zone selected = 0.025 m/sC/S area of clarification zone required below Tube Pack = 1093.75 / 3600 / 0.025

= 12.15 m²Height of the Clarification zone required = 12.15 / 11.4

= 1.066 mDepth of the sludge compression zone provided = 1.00 mSpace provided for sludge scrapper =

0.30 mSide water depth of unit required = 0.65 + 1 + 1.066 + 1 + 0.3

= 4.016 mSWD provided = 4.05 m

Hence O.K.

Provide V-Notch weir plates on the inner side of overflow launders.Recommended weir loading for Tube

Settler = 250 m³/m/dLength of weir to be provided = 26250/250

= 105.000 mNo.of overflow launders to be provided = 105/(2*(11.4-(1/TAN 55°)

= 4.907Say = 6.000 nos.Approx.length of weir provided in each Tube Settler = 6*2*((11.4)-(1/TAN55°))

= 128.398 mDischarge rate at design flow over the weir = 1093.75 / 128.398
= 8.52 m³/m/h= 204.44 m³/m/d< 250.00 m³/m/d

Hence O.K.Design Hydraulic flow per Tube Settler = 30.000 Mld

= 30000.000 m³/dDischarge rate at design Hydraulic flow over the weir = 30000 / 128.398

= 233.65 m³/m/d

Size: 4 Nos. Tube Settlers, each of 11.4 m x 11.4 m x 4.05 m SWD