TOPIC

• NPSH CALCULATION
• DYKE WALL HEIGHT AND WIDTH CALCULATION
• MITER BEND CALCULATION
• P-T RATING
• LINE SIZING CALCULATION
• PIPE ELBOW CENTRE CALCULATION
• INSULATION THICKNESS FOR PIPES
• ESTIMATION OF PIPE PAINT QUANTITY
- निखिल चौंडकर
What is NPSH ?
Example 1
Example 2
Example 3
DYKE WALL CALCULATION

❑ Exercise-
➢ Calculate dyke wall height and width for below
mentioned tanks :
• Tanks Vol (m3)
• A 350
• B 270
• C 750
• D 995
• E 200
• F 500
Dyke wall Ht (M) Dyke wall thickness (M) ➢ Aggregate capacity in one dyke enclosure:
o Group of Fixed roof tanks: Upto 60,000 m3
Up to 1 0.6 o Group of Floating roof tanks: Upto 120,000 m3
1 to 2 1 o Fixed cum floating roof tanks shall be treated as
fixed roof tanks.

✓ Class – A and / or Class – B petroleum products :- Same

dyked enclosure
✓ Class – C: – Preferably separate dyked enclosures.
✓ Tanks shall be arranged in maximum two rows. Tanks
having 50,000 m3 capacities and above shall be laid in
single row.
✓ The tank height shall not exceed one and half times the
diameter of the tank or 20 m whichever is less.
✓ The minimum distance between a tank shell and the
inside toe of the dyke wall shall not be less than half the
height of the tank.
✓ Dyked enclosure for petroleum class shall be able to
If tank vol > 30m (Fire wall is req. of 150 x 60mm) contain the complete contents of the largest tank in the
If tank vol > 20,000m3 (Fire wall 150 x 60mm req) dyke in case of any emergency.
 Miter Bend

• Fabricated bend using straight pipe piece.

• No thinning.
• Used in low pressure service.
• Pressure holding capacity check as per ASME B 31.3
• Max MITRE bend allowed in one MITRE bend= 5 nos as per ASME B 31.3
• Not suitable for Pigging.

Total angle
• Angle of cut = No of miters

1.L2 : Distance of first and last reference line from pipe ends.
2.L1 : Distance between reference lines.
3.Cut Back : Offset distance of cut lines from reference lines at the top and bottom of pipe.
Exercise-
Consider we want to create 90 degree elbow of 10″ size with elbow center radius same as standard elbow
 150LB - 150LBS - 150# - CLASS 150

What is pressure-temperature rating?

Pressure- temperature rating is the maximum allowable non-shock gauge pressure at the specific temperature for given material.

➢ Step To Find Out P-T Rating

Step:1 Find the Material Group no in ASME 16.5 table 1A

Step:2 Determine required Flange Rating based on Pressure Temperature rating = table 2-1.1

Ex. Pipe Material ASTM A 106 GR B

Design Temperature 2700 C
Design Pressure 13.8 bar

Exercise-

1) we want to use ASTM A105 flange for our service that has a pressure rating 1,200 psig and at 500 °F.

2)What is the P-T rating of C.S. material at 15 kg/cm2 design pressure & 2000 C design temperature ?

2) What is the P-T rating of S.S316 material at 21 kg/cm2 design pressure & 2250 C design temperature ?
Why Line Sizing is so important? Velocity Consideration
Fluid Recom. Velo. in m/s
Steam
➢ Continuity Equation Superheated steam 40 to 75
Saturated steam 20 to 40
➢ Selection of velocity depends on : Wet steam 20 to 30
• Pressure Drop Water
• NPSH Pump Suction 0.5 to 1.5
• Noise Pump Delivery 1 to 3
• Pipe Erosion Boiler feed discharge 3 to 6
• Water Hammer & Surge Pressure City water 0.5 to 1.5
OIL
EXERCISE-
Heavy oil 1 to 2
Light oil 1 to 2
The water flowing through CS pipe at 300 m3/hr, having viscosity 1cp. Pipe Gases
Sch is 40. find out pressure drop for 100 M length and line size. Ccompressed Air 5 to 15
Fuel gas 10 to 30
Vaccum 100 to 200
Procedure for line sizing
1. Select prelim size.
2. Assume velocity ( as per chart )
3. Examine the suitability of the selected size.
Available pressure drop > calculated pressure drop

Calculation of pressure drop we need,

❑ Reynolds Number (Re)
❑ Friction Factor
 Pipe Elbow Centre Calculation

Elbow length in mm = Tan(Elbow Angle/2) X Elbow Radius in mm

Example 1:
Calculate elbow center to end dimension for 4 inch nominal
pipe diameter elbow at 60 degree angle,
cut from 90 degree LR elbow.

Example 2:
Calculate elbow center to end dimension for 2 inch nominal
pipe diameter elbow at 30 degree angle, cut from 45 degree
LR elbow.
 Estimation of Pipe Paint Quantity

Required paint quantity for painting of a pipe depends on following factors :

• Pipe Diameter.
• Length of Pipe.
• Required Dry Film Thickness (DFT).
• Percentage of Solids content in a given paint.
• Wastage of paint during painting which is based on type of painting method used.

Wet Film Thickness (WFT) = DFT/Fraction of Solids.

Theoretical Paint Quantity = Surface Area X WFT

Wastage
During painting process, some amount of paint gets wasted which depends on method of paint application.
Typical wastage percentages are :
➢ Brush or Roller Painting : 10%.
➢ Airless Spray Painting : 20%.
➢ Conventional Spray Painting : 30%
So, we have to add wastage to calculated paint quantity to get actual paint quantity.
Actual Paint Quantity = Theoretical Paint Quantity / Fraction Actual Paint Usage.
EXAMPLE CALCULATION

PIPE OF NOMINAL PIPE DIAMETER 10″ TO BE PAINTED WITH INORGANIC ZINC SILICATE COATING WITH SOLIDS
PERCENTAGE OF 60%. REQUIRED DRY FILM THICKNESS IS 70 MICRONS. METHOD OF APPLICATION IS CONVENTIONAL
SPRAY PAINTING. CALCULATE AMOUNT OF PAINT REQUIRED FOR LENGTH OF 100 METERS.

1. Pipe Dia in mm (D) = 10″ X 25.4 = 254mm.

2. Length of Pipe (L) = 100 meters = 100000 mm.

3. Surface area of pipe for one meter (A) = Pi X D = 3.141 X 254 = 0.797814 Sq. MM. (It is not necessary to take actual pipe
outside diameter from pipe data tables. Difference is negligible.)

4. Total Surface Area = A X L = 797.814 X 10000 0= 79781400 Sq.MM.

5. Required Dry Film Thickness (DFT) = 70 microns = 0.07 mm.

6. Fraction of Solids in Paint (S) = Solids Percent/100 = 60/100 = 0.6

7. Welt Film Thickness (WFT) = (DFT/S) = 0.07/0.6 = 0.1167 mm.

8. Theoretical volume of paint required = Total Surface Area X WFT = 79781400 X 0.1167 = 9310489 Cubic MM. =
9.310489 Liters.

9. For conventional spray painting method, estimated wasted is around 30%. So only 70% paint gets used for actual
painting. So amount of actual paint required is theoretical paint quantity divided by fraction of actual paint usage.

10. Actual Paint Volume = Theoretical Paint Volume/0.7 = 9.310489/0.7 = 13.3 Liters.
 Ca e s
lculatio
n of Insulation Thickness for Pip

Formula for Steady state heat transfer through insulating material

wrapped around a pipe is as follows :

Total heat transferred (Q) from pipe through such insulating material depends on following factors :
N : Length of Pipe.
Tp : Operating temperature of fluid inside pipe.
Ti : Maximum temperature allowed on the outside surface of insulation. Typically 50°C.
Rp : Radius of Pipe.
Ri : Radius of Insulation.
k : Thermal conductivity of insulating material.
Example Calculation
Suppose we have a pipe of Diameter 12″ with hot oil at a temperature of 200°C flowing through it.
Maximum allowed insulation temperature at the outer wall is 50°C. Allowed heat loss per meter
of pipe is 80 W/m. Insulation used is Glass Mineral Wool with thermal conductivity for that
temperature range of 0.035W/m.K. Now we have to find out required insulation thickness.

Thermal conductivity is expressed in Watts per meter per Kelvin (W/m.K) which is essentially same
as Watts per meter per degree celsius (W/m.C) (There is no multiplier in conversion from Kelvin to
degrees. So incremental change in Kelvin is same as incremental change in Celsius.)

In above formula, Q is total heat loss and N is length of pipe. So Q/N becomes our allowed heat loss
per meter of pipe which is 80W/m.
A thick walled tube of S.S having a k = 21.63 W/m k with dimensions of 0.0254m ID & 0.0508m OD is covered
With a 0.0254m layer of Asbestos insulation k = 0.2453 W/m k. The inside wall temperature of the pipe is
811K and the outside surface of the insulation is at 310.8 K. For a 0.305m length of pipe, calculate the heat
Loss and also the temperature at the interface between the metal and also the interface between the metal
And the insulation.

Q = delta T R = delta r Alm = Ao –Ai

R K Alm Ln (Ao/Ai)