CALCULATION

HFO / DO DRAIN PUMP SIZING

A 15/06/07 PRELIMINARY ISSUE PMK TAI KN
INL SIGN INL SIGN INL SIGN
REV DATE DESCRIPTION OF REVISION
PRED CHKD PM
OWNER






WEST COAST POWER PRIVATE LIMITED
PROJECT
300 MW CCPP, KERAWALAPITIYA
SRILANKA
EPC CONTRACTOR






LAKDHANAVI LIMITED
CIVIL CONTRACTOR







LTL PROJECTS (PVT) LTD
ENGINEERS FOR
EPC CONTRACTOR
FICHTNER
CONSULTING ENGINEERS (INDIA) PVT LIMITED
CHENNAI, INDIA
PROJECT NUMBER DOCUMENT NUMBER DOCUMENT TYPE REVISION
7856 7856-ME-DSN-131-004 - A
WCPPL
300 MW Combined Cycle Power Plant
Calculation
HFO / DO Drain Pump Sizing


Doc. No. 7856-ME-DSN-131-004, Rev. A FICHTNER India Page : 2 of 11
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TABLE OF CONTENTS


1.0 GENERAL ...................................................................................................... 3

2.0 REFERENCE DOCUMENTS.......................................................................... 3

3.0 DESIGN INPUTS............................................................................................ 3

4.0 ASSUMPTIONS.............................................................................................. 3

5.0 DESIGN CODES............................................................................................ 4

6.0 DESIGN CALCULATIONS ............................................................................. 4

7.0 RESULTS....................................................................................................... 6

ANNEX - I : PIPE SIZING CALCULATIONS.......................................................................... 7

ANNEX II : PIPE THICKNESS CALCULATIONS................................................................. 8

ANNEX III : PRESSURE DROP SUMMARY........................................................................ 9

ANNEX IV : UNLOADING AREA HFO/DO DRAIN PUMP SIZING CALCULATIONS........ 10

ANNEX V : FORWARDING AREA HFO/DO DRAIN PUMP SIZING CALCULATIONS ..... 11























WCPPL
300 MW Combined Cycle Power Plant
Calculation
HFO / DO Drain Pump Sizing


Doc. No. 7856-ME-DSN-131-004, Rev. A FICHTNER India Page : 3 of 11
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1.0 GENERAL

This document provides the HFO/DO Drain Pump sizing calculations.

2.0 REFERENCE DOCUMENTS

The following documents have been referred in carrying out this calculation.

i) Plot Plan : 00-7856-G-001
ii) DBR - Fuel Oil System : 7856-ME-DBR-131-001
iii) Flow diagram - Fuel oil system : 10-7856-M-026
iv) GA of Untreated HFO storage tank : 10-7856-M-108

3.0 DESIGN INPUTS

3.1 General

Maximum allowable stress (S) for Carbon steel (A 106 Gr. B) is considered as 17.1 ksi
(1202.26 kg/cm) for seamless pipes. (Refer Table A1 - Appendix A of ASME B31.1a)

Weld joint efficiency (E) for Carbon steel (A 106 Gr. B) is considered as 1.0 for seamless
pipes. (Refer Table A1 - Appendix A of ASME B31.1a)

Material coefficient (y) is considered as 0.4. (Refer Table 104.1.2(A) of ASME B31.1a)

Corrosion allowance (A) is considered as 1.5 mm.

Manufacturing tolerance (tol) is considered as 12.5%.

The design pressure (P) is the maximum sustained pressure, which is the shut-off
pressure of the system. Design pressure of 15 bar (a) [15.30kg/cm
2
(a)] is considered
adequate.

The design temperature for the piping is considered as 60C.


3.2 Drain Pump Sizing Criteria

The design velocity is limited to 0.9 m/s at suction side and 1.5 m/s at the discharge side
of the Drain oil pump.

Specific gravity of Drain oil at operating temperature is considered as 0.97.

Kinematic viscosity of Drain oil at operating temperature is considered as 1000cSt.

Vapour pressure of Drain oil at operating temperature is considered as 0.2mlc
(Preliminary data).


4.0 ASSUMPTIONS

Pressure drop across suction strainer is considered as 0.45mlc.

The pipe routing considered for pressure drop calculations is preliminary and is subject to
changes based on finalised piping layout

Roughness of the pipe is considered as 0.05mm.

WCPPL
300 MW Combined Cycle Power Plant
Calculation
HFO / DO Drain Pump Sizing


Doc. No. 7856-ME-DSN-131-004, Rev. A FICHTNER India Page : 4 of 11
Calculation_drain pump_A

5.0 DESIGN CODES

The following codes, standards and publications have been referred

ASME B31.1 Addenda-2005 : Power Piping

ASME B36.10 : Welded & Seamless wrought steel pipe

Flow of fluids Crane hand book.


6.0 DESIGN CALCULATIONS

6.1 Line Sizing Calculation

The pipe inner diameter is calculated based on design flow rate and allowable velocity





Where,

ID = Inside diameter of pipe (m)
Q = Design Flow rate (m
3
/ h)
V = Velocity of flow (m / s)

Based on the calculated inner diameter of the steel pipe, a standard pipe is selected.

6.2 Pipe Wall Thickness Calculation

Using the internal fluid pressure, outer diameter and allowable stress of the material, the
minimum pipe wall thickness is calculated as per ASME B 31.1a, clause 104.1.2 by,



t
m+ t
= t
m

(

tol 100
100



Where,

t
m
= Minimum required wall thickness (mm)
t
m+ t
= Minimum required wall thickness with manufacturing tolerance (mm)
P = Internal design pressure (kg/cm
2
)
OD = Outside diameter of pipe (mm)
S = Maximum allowable stress in material due to internal pressure (kg/cm
2
)
E = Weld joint efficiency
y = Material coefficient
A = Corrosion allowance (mm)
tol = Manufacturing tolerance (%)


( )
(

+
+

= A
Py SE
OD P
t
m
2
V
Q
ID

3600) / ( 4
WCPPL
300 MW Combined Cycle Power Plant
Calculation
HFO / DO Drain Pump Sizing


Doc. No. 7856-ME-DSN-131-004, Rev. A FICHTNER India Page : 5 of 11
Calculation_drain pump_A

Based on calculated minimum wall thickness a standard pipe thickness is selected. For the
selected pipe thickness, the maximum pressure that can be withstood by the pipe is
calculated as follows:






t
s
= Selected pipe thickness (mm)

For detailed calculations refer ANNEX I & II

6.3 Pressure Drop Calculation

6.3.1 Criteria for Pressure Drop Calculation

A) Pressure drop in the fuel oil piping is calculated using Darcy's equation









Where,

H
f
= Pressure drop in the piping (mlc)
f = Darcy's friction factor for pipe (which is 4 times the Chen's friction
factor)
f ' = Chen's friction factor
L = length of pipe (m)
V = Velocity of the fluid (m/s)
d = Internal diameter of the pipe (m)
g = Acceleration due to gravity (9.81 m/s
2
)

Reynolds number (Re) is calculated by following equation





Where,

= Density (kg/m
3
)
= Viscosity (kg/m sec)

Chen's Friction factor (f ') for piping is calculated by following equation









( )
(

=
) ( 2
2
max
A t y OD
A t E S
P
s
s
2gd
LV f
H
2
f
=
(
(
(
(

|
.
|

\
|
= A4 log
Re
5.0452
-
3.7065
d
k
log 4 -
'
1
f

Vd
Re =
2gd
LV 4f
H
2 '
f
=
WCPPL
300 MW Combined Cycle Power Plant
Calculation
HFO / DO Drain Pump Sizing


Doc. No. 7856-ME-DSN-131-004, Rev. A FICHTNER India Page : 6 of 11
Calculation_drain pump_A

Where,







k = Roughness of the pipe (mm)


B) For valves and fittings the pressure drop is calculated as follows:


Where,

H
f t
= Pressure drop in valves and fitting in mlc.

K = Resistance co-efficient of fitting as per Flow of Fluids by
Crane.

For pressure drop summary refer ANNEX - III


6.4 HFO/DO Drain Pump Sizing Calculations

The detailed Drain pump sizing calculations are carried out for the HFO/DO Unloading area
and HFO/DO Forwarding area to determine the Total Developed Head (TDH), Available
NPSH and Estimated Shaft power. The detailed calculations are furnished in
ANNEX IV & V.

7.0 RESULTS

The results of calculation and final selected parameters for the Unloading and Forwarding
area HFO/DO Drain pump are tabulated below

7.1 Unloading area HFO/DO Drain Pump

Number of working pumps : 1
Pump type : Positive displacement, Single screw,
Vertical tank mounted type.
Rated capacity of the pump : 5 m
3
/hr
Pump design TDH : 50 mlc
Available NPSH : 10.20 mlc
Estimated shaft power : 1.65 kW

7.2 Forwarding area HFO/DO Drain Pump

Number of working pumps : 1
Pump type : Positive displacement, Single screw,
Vertical tank mounted type.
Rated capacity of the pump : 5 m
3
/hr
Pump design TDH : 50 mlc
Available NPSH : 10.20 mlc
Estimated shaft power : 1.65 kW

Re
7.149

2.8257
d
k
A4
0.8981
1098 . 1
|
.
|

\
|
+
|
.
|

\
|
=
g
V
K H
ft
2
2
=
WCPPL
300 MW Combined Cycle Power Plant
Calculation
HFO / DO Drain Pump Sizing


Doc. No. 7856-ME-DSN-131-004, Rev. A FICHTNER India Page : 7 of 11
Calculation_drain pump_A


ANNEX - I : PIPE SIZING CALCULATIONS




NB
OD of the
pipe
Available ID
of the pipe
m
3
/ h m / s mm - mm SCH mm mm m / s
HFO/DO Unloading area
1
Pipe line from Drain oil pump outlet to
Untreated HFO tank recirculation nozzle
inlet
5 1.5 34.34 50 60.3 80 5.54 49.22 0.73
HFO/DO Forwarding area
2
Pipe line from Drain oil pump outlet to
Untreated HFO tank recirculation nozzle
inlet
5 1.5 34.34 50 60.3 80 5.54 49.22 0.73
Selected pipe details
Calculated
velocity
Location Sl. No.
Flow rate
Limiting
Velocity
Required
ID of the
pipe
Thickness
WCPPL
300 MW Combined Cycle Power Plant
Calculation
HFO / DO Drain Pump Sizing


Doc. No. 7856-ME-DSN-131-004, Rev. A FICHTNER India Page : 8 of 11
Calculation_drain pump_A



ANNEX II : PIPE THICKNESS CALCULATIONS


UNIT
-
HFO/DO Unloading area
Pipe line from Drain oil pump 1 outlet
to Untreated HFO tank recirculation
nozzle inlet
HFO/DO Forwarding area
Pipe line from Drain oil pump 2 outlet
to Untreated HFO tank recirulation
nozzle inlet
SELECTED PIPE SIZE NB 50 50
mm 60.30 60.30
- SA 106 Gr B SA 106 Gr B
kg / cm(a) 15.30 15.30
C 60 60
kg / cm 1202.26 1202.26
mm 1.50 1.50
- 1 1
- 0.4 0.4
MANUFACTURING TOLERANCE % 12.5 12.5
MINIMUM REQUIRED THICKNESS mm 1.88 1.88
mm 2.15 2.15
SCH 80 80
mm 5.54 5.54
kg / cm 170.22 170.22 MAXIMUM WITH STANDING PRESSURE
PROVIDED THICKNESS
VARIABLE COEFFICIENT
SELECTED PIPE SCHEDULE
MINIMUM REQUIRED THICKNESS
WITH MANUFACTURING
TOLERANCE
MATERIAL
OUTER DIAMETER OF THE PIPE
DESIGN PRESSURE
EFFICIENCY FACTOR
CORROSION ALLOWANCE
DESIGN TEMPERATURE
ALLOWABLE STRESS
PARTICULARS DATA
DESCRIPTION
WCPPL
300 MW Combined Cycle Power Plant
Calculation
HFO / DO Drain Pump Sizing


Doc. No. 7856-ME-DSN-131-004, Rev. A FICHTNER India Page : 9 of 11
Calculation_drain pump_A



ANNEX III : PRESSURE DROP SUMMARY



bar mlc
1 1.9626 20.625
HFO / DO Forwarding area
2 3.5274 37.069
Pressure drop
Pressure Drop Calculation
HFO / DO Unloading area
Pressure drop in piping from Drain oil pump outlet to
Untreated HFO tank recirculation nozzle inlet
Location S. No
Pressure drop in piping from Drain oil pump outlet to
Untreated HFO tank recirculation nozzle inlet
WCPPL
300 MW Combined Cycle Power Plant
Calculation
HFO / DO Drain Pump Sizing


Doc. No. 7856-ME-DSN-131-004, Rev. A FICHTNER India Page : 10 of 11
Calculation_drain pump_A


ANNEX IV : UNLOADING AREA HFO/DO DRAIN PUMP SIZING CALCULATIONS





1 Total Number of pumps 1
2 Number of operating pumps 1
3 Total flow per pump (m / h) 5
4 (kg / m
3
) 970
5 Capacity of the drain oil tank m
3
2
I
I. SUCTION SIDE :
1 (mlc) 10.65 (Atmospheric Pressure : 1.01325 bar a )
2 Static Head (mlc) 0.20 (Assumed min.submergence in
the tank)
3 (mlc) 0.00 (Not applicable)
4 Pressure drop in suction strainer (mlc) 0.45 (Preliminary data)
5 Available Suction Head [ Atmospheric pressure + Static head in the tank - (mlc) 10.40
Pressure drop in suction strainer ]
II. DISCHARGE SIDE :
1 Pressure required at destination (mlc) 10.65 (Atmospheric Pressure : 1.01325 bar a )
2 Static head required (mlc) 11.635 (From GA of untreated Heavy fuel
oil storage tank)
3 Friction loss in the piping (mlc) 20.62 (Refer ANNEX - III)
4 Required Discharge Head [ Pressure required at destination + Static head (mlc) 42.91
required + Friction loss in piping ]
III. TOTAL DEVELOPED HEAD :
1 Total Developed Head (mlc) 32.51
[ Required Discharge head - Available Suction head ]
2 Selected Total Develoed Head (mlc) 50.00
II
1 Available pressure (mlc) 10.65 (Atmospheric Pressure : 1.01325 bar a )
2 Static Head (mlc) 0.20 (Assumed min. submergence in the
tank)
3 Piping friction loss in suction line (mlc) 0.00 (Not applicable)
4 Vapour pressure of fuel oil at operating temperature (mlc) 0.20 (Preliminary data)
5 Pressure drop in suction strainer (mlc) 0.45 (Preliminary data)
6 Available NPSH [ Atmospheric pressure + Static head in the tank - (mlc) 10.20
Vapour pressure of fuel oil at operating temperature - Pressure drop in
Suction Strainer)
III
1 Pump type
2 Rated Capacity per pump (m / h) 5
3 Selected Total Developed Head for pump (mlc) 50.00
4 Available NPSH (mlc) 10.20
5 Pump efficiency % 40 (Vendor to confirm)
6 Estimated Shaft power kW 1.65
Vertical tank mounted type
Positive displacement, Singl Screw,
Density of drain oil
PUMP DESIGN PARAMETERS
HEAD CALCULATION
AVAILABLE NPSH CALCULATION
Available pressure
Friction loss in the piping
WCPPL
300 MW Combined Cycle Power Plant
Calculation
HFO / DO Drain Pump Sizing


Doc. No. 7856-ME-DSN-131-004, Rev. A FICHTNER India Page : 11 of 11
Calculation_drain pump_A

ANNEX V : FORWARDING AREA HFO/DO DRAIN PUMP SIZING CALCULATIONS


1 Total Number of pumps 1
2 Number of operating pumps 1
3 Total flow per pump (m / h) 5
4 (kg / m
3
) 970
5 Capacity of the drain oil tank m
3
2
I
I. SUCTION SIDE :
1 (mlc) 10.65 (Atmospheric Pressure : 1.01325 bar a )
2 Static Head (mlc) 0.20 (Assumed min.submergence in
the tank)
3 (mlc) 0.00 (Not applicable)
4 Pressure drop in suction strainer (mlc) 0.45 (Preliminary data)
5 Available Suction Head [ Atmospheric pressure + Static head in the tank - (mlc) 10.40
Pressure drop in suction strainer ]
II. DISCHARGE SIDE :
1 Pressure required at destination (mlc) 10.65 (Atmospheric Pressure : 1.01325 bar a )
2 Static head required (mlc) 11.635 (From GA of untreated Heavy fuel
oil storage tank)
3 Friction loss in the piping (mlc) 37.07 (Refer ANNEX - III)
4 Required Discharge Head [ Pressure required at destination + Static head (mlc) 59.35
required + Friction loss in piping ]
III. TOTAL DEVELOPED HEAD :
1 Total Developed Head (mlc) 48.95
[ Required Discharge head - Available Suction head ]
2 Selected Total Developed Head (mlc) 50.00
II
1 Available pressure (mlc) 10.65 (Atmospheric Pressure : 1.01325 bar a )
2 Static Head (mlc) 0.20 (Assumed min. submergence in the
tank)
3 Piping friction loss in suction line (mlc) 0.00 (Not applicable)
4 Vapour pressure of fuel oil at operating temperature (mlc) 0.20 (Preliminary data)
5 Pressure drop in suction strainer (mlc) 0.45 (Preliminary data)
6 Available NPSH [ Atmospheric pressure + Static head in the tank - (mlc) 10.20
Vapour pressure of fuel oil at operating temperature - Pressure drop in ]
Suction Strainer)
III
1 Pump type
2 Rated Capacity per pump (m / h) 5
3 Selected Total Developed Head for pump (mlc) 50.00
4 Available NPSH (mlc) 10.20
5 Pump efficiency % 40 (Vendor to confirm)
6 Estimated Shaft power kW 1.65
Vertical tank mounted type
Positive displacement, Singl Screw,
Density of drain oil
PUMP DESIGN PARAMETERS
HEAD CALCULATION
AVAILABLE NPSH CALCULATION
Available pressure
Friction loss in the piping