Pipe Size For Cooling Water System

CLIENT : DHARANI SUGARS CHEMICALS LTD.
PROJECT : DISTILLERY IBR/NIBR PIPING
DATE : 31.07.2010
REV : 01
BENDING TOLERANCE OR MARGIN
32000
SA 106 Gr.B
0.08837
168.3 7.11
150
40
40-50 42.127 13.5
949.14 1.5
4.85
6.22
28.27
P01
Main Steam line to Turbine(3MW)
32TPH Boiler
3MW Turbine
380
390
32
44
32000
32000
SA 106 Gr.B
0.08837
219.1 8.18
200
40
40-50 24.332 13.5
949.14 1.5
6.49
7.16
10.35
P01
32TPH Boiler
3MW Turbine
380
390
32
44
32000
32000
SA 106 Gr.B
0.08837
168.3 7.11
150
40
40-50 42.127 13.5
949.14 1.5
5.33
6.22
16.72
P01
32TPH Boiler
3MW Turbine
380
390
32
44
32000
32000
SA 106 Gr.B
0.08837
33.4
3.68
25
40
40-50 1474.9 13.5
949.14 1.5
2.26
3.22
42.47
P01
32TPH Boiler
3MW Turbine
380
390
32
44
32000
32000
SA 106 Gr.B
0.08837
21.3
2.77
15
40
40-50 4026.6 13.5
949.14 1.5
1.98
2.42
22.12
P01A
Main steam line to Atmosphere(Start

up vent).
Tapping from Main

Steam Line
Atmosphere
380
390
10
12
515
515
SA 106 Gr.B
0.29306
60.3
5.54
50
80
20-30 22.034 13.5
949.14 1.5
1.88
4.85
157.95
P01A
Main steam line to Atmosphere(Start

up vent).
Tapping from Main

Steam Line
Atmosphere
380
390
32
44
515
515
SA 106 Gr.B
0.08837
60.3
5.54
50
80
20-30 6.6439 13.5
949.14 1.5
2.87
4.85
68.77
Silencer
380
390
10.8
10667
10667
SA 106 Gr.B
0.297
219.9 6.35
200
20
20-30 26.099 13.5
949.14 1.5
2.75
5.56
102.38
PRDS-3
380
390
32
38.4
32000
32000
SA 106 Gr.B
0.08837
168.3 7.11
150
40
40-50 42.127 13.5
949.14 1.5
4.85
6.22
28.27
5.0ATA Header.
160
170
4.2
5.04
32000
32000
SA 106 Gr.B
0.37841
406.4 7.92
400
20
20-30 28.077 15
1054.6 1.5
2.47
6.93
180.65
PRDS-1
317
327
15
18
16000
16000
SA 106 Gr.B
0.16197
168.3 7.11
150
40
30-40 38.607 15
1054.6 1.5
2.93
6.22
112.58
PRDS-1
317
327
15
18
16000
16000
SA 106 Gr.B
0.16197
33.4
3.38
25
40
30-40 1291.5 15
1054.6 1.5
1.78
2.96
65.86
PRDS-1
317
327
15
18
16000
16000
SA 106 Gr.B
0.16197
21.3
2.77
15
80
30-40 3690.2 15
1054.6 1.5
1.68
2.42
44.22
5.0ATA Header.
160
170
4.2
5.04
17243
17243
SA 106 Gr.B
0.37841
323.9 6.35
300
20
20-30 23.837 15
1054.6 1.5
2.27
5.56
144.51
5.0ATA Header.
160
170
4.2
5.04
17243
17243
IS 3589
0.37841
323.9 5.6
300
5.6Thk. 20-30 23.609 12.8
899.93 1.5
2.40
4.90
103.76
Main Steam from Control valve to

PCV
Silencer(Start up vent).
By-Pass from Main steam line to PRDS- Tapping from Main
3.
Steam Line
Steam from PRDS-3 to 5.0ATA
PRDS-3
header.
22MW 2nd
22MW 2nd Extraction line to PRDS-1.
Extraction
22MW 2nd
Extraction
22MW 2nd
Extraction
PRDS-1
header.
PRDS-1
header.
3MW Turbine Extraction to DeTurbine Extraction
Superheater.
P01B
P01C
P01D
P02
P02
P02
P02A
P02A
P03
P03
3MW Turbine Extraction to DeSuperheater.
P03A
Steam from 5.0ATA header to Distillery

5.0ATA Header.
Analyser.
MATRIX SOLUTION
BANGALORE
Turbine Extraction
PIPE SIZE IN MM (OD)
DESIGNED
OPERATING
DESIGNED
OPERATING
TO
MINIMUM THICKNESS REQUIRED IN MM
32000
ALLOWABLE STRESS IN KG/CM2
38.4
ALLOWABLE STRESS IN KSI
32
ACTUAL VELOCITY
390
VELOCITY AS PER STANDARD
380
SCHEDULE
3MW Turbine
PIPE THICKNESS AVAILABLE IN MM
MINIMUM THICKNESS AVAILABLE IN MM
CORROSION ALLOWANCE CONSIDERED
PIPE SIZE NB CONSIDERED AS PER PROCESS

(NB)
SPECIFIC VOLUME IN M3/Kg AT OPERATING

CONDITION.
32TPH Boiler
MATERIAL SPECIFICATION
DESIGNED
FLOW KG/hr
OPERATING
P01
FROM
LINE NO
SYSTEM DESCRIPTION
SL.NO
PRESSURE KG/Cm2 (g)
TEMPERATURE IN DEG C
PIPE LINE SIZE THICKNESS CALCULATION
De-Superheater.
195
205
4.2
5.04
19000
19000
SA 106 Gr.B
0.41432
355.6 7.92
350
20
20-30 24.119 15
1054.6 1.5
2.35
6.93
195.13
De-Superheater.
195
205
4.2
5.04
19000
19000
IS 3589
0.41432
355.6 8
350
8Thk.
20-30 24.142 12.8
899.93 1.5
2.49
7.00
180.73
Distillery Analyser.
160
170
4.2
5.04
19500
19500
SA 106 Gr.B
0.37841
355.6 7.92
350
20
20-30 22.608 15
1054.6 1.5
2.35
6.93
195.13

Steam from 5.0ATA header to Distillery

5.0ATA Header.
Analyser.
P03A
10
Steam from Down-stream of Turbine

P03B Extraction De-Super heater to 5.0ATA
header.
10

P03B Extraction De-Super heater to 5.0ATA
header.
11
P04
11
DATE : 31.07.2010
REV : 01
Distillery Analyser.
160
170
4.2
5.04
19500
19500
IS 3589
0.37841
355.6 8
350
8Thk.
20-30 22.629 12.8
899.93 1.5
2.49
7.00
180.73
Down-Stream of
Turbine Extraction
De-superheater.
5.0 ATA header.
160
170
4.2
5.04
20500
20500
SA 106 Gr.B
0.37841
355.6 7.92
350
20
20-30 23.768 15
1054.6 1.5
2.35
6.93
195.13
Down-Stream of
Turbine Extraction
De-superheater.
5.0 ATA header.
160
170
4.2
5.04
20500
20500
IS 3589
0.37841
355.6 8
350
8Thk.
20-30 23.79
12.8
899.93 1.5
2.49
7.00
180.73
3mw Turbine Exhaust to DeSuperheater.
Turbine Exhaust.
De-Superheater.
153
163
1.6
1.92
13000
13000
SA 106 Gr.B
0.76006
406.4 7.92
400
20
20-30 22.91
15
1054.6 1.5
1.87
6.93
270.65
P04
3mw Turbine Exhaust to DeSuperheater.
Turbine Exhaust.
De-Superheater.
153
163
1.6
1.92
13000
13000
SA 106 Gr.B
0.76006
406.4 8.8
400
8.8Thk. 20-30 23.118 12.8
899.93 1.5
1.93
7.70
298.31
12
P04A
Steam from 2.5ATA Header to

Distillery Evaporator.
2.5ATA Header.
Distillery Evaporator
130
140
1.6
1.92
13500
13500
SA 106 Gr.B
0.71423
406.4 7.92
400
20
1054.6 1.5
1.87
6.93
270.65
12
P04A
Steam from 2.5ATA Header to

Distillery Evaporator.
2.5ATA Header.
Distillery Evaporator
130
140
1.6
1.92
13500
13500
SA 106 Gr.B
0.71423
406.4 8.8
400
8.8Thk. 20-30 22.559 12.8
899.93 1.5
1.93
7.70
298.31
13
P04B
Steam from turbine exhaust to

atmosphere.
Turbine Exhaust.
Valve
153
163
1.6
1.92
4333
4333
SA 106 Gr.B
0.76006
219.1 6.35
200
20
20-30 27.344 15
1054.6 1.5
1.70
5.56
226.97
14
P04C
Valve
Atmosphere
153
163
1.2
4333
4333
SA 106 Gr.B
1.278
219.1 6.35
200
20
20-30 45.974 15
1054.6 1.5
1.62
5.56
242.01
15
P04D
16
P04E
16
P04E
17
P04F
18
P04G
19
P04H
20
P04J
21
P04K
22
22
23
P04L
P04L
P04M
Steam from turbine exhaust to

atmosphere.
Steam From 5.0ATA Header to PRDS2.
Steam from PRDS-2 TO 2.5ATA
Header.
Steam from PRDS-2 TO 2.5ATA
Header.
Spray water to PRDS-1 De-Super
heater.
heater.
heater.
Spray water to Turbine Ext. De-Super
heater.
Spray water to Turbine EHS De-Super
heater.
Exhaust De-Super heater to 2.5ATA
header.
20-30 22.357 15
5.0ATA Header.
PRDS-2
160
170
4.2
5.04
8243
8243
SA 106 Gr.B
0.37841
219.1 6.35
200
20
20-30 25.899 15
1054.6 1.5
2.02
5.56
174.72
PRDS-2
2.5ATA Header.
130
140
1.6
1.92
8500
8500
SA 106 Gr.B
0.71423
323.9 6.35
300
20
20-30 22.178 15
1054.6 1.5
1.79
5.56
209.61
PRDS-2
2.5ATA Header.
130
140
1.6
1.92
8500
8500
IS 3589
0.71423
323.9 5.6
300
5.6Thk. 20-30 21.966 12.8
899.93 1.5
1.85
4.90
165.56
Booster Pump
PRDS-1
80
90
18
21.6
2244
2244
SA 312TP304
0.001
48.26 2.77
40
10S
1.5-2
0.4349 17.86
1255.7 1
1.41
2.42
71.62
Booster Pump
PRDS-2
80
90
18
21.6
380
380
SA 312TP304
0.001
48.26 2.77
40
10S
1.5-2
0.0736 17.86
1255.7 1
1.41
2.42
71.62
BFP Discharge.
PRDS-3
150
160
32
38.4
6500
6500
SA 106 Gr.B
0.0011
48.26 5.08
40
80
1.5-3
1.7422 15
1054.6 2
2.87
4.45
55.09
80
90
18
21.6
2244
2244
SA 312TP304
0.001
48.26 2.77
40
10S
1.5-3
0.4349 17.86
1255.7 1
1.41
2.42
71.62
80
90
18
21.6
380
380
SA 312TP304
0.001
48.26 2.77
40
10S
1.5-3
0.0736 17.86
1255.7 1
1.41
2.42
71.62
20-30 22.357 15
1054.6 1.5
1.87
6.93
270.65
Booster Pump
Booster Pump
Turbine Ext. DeSuper heater.

Turbine EHS DeSuper heater.
Down-Stream of
Turbine Exhaust.
2.5ATA Header.
80
90
1.6
1.92
13500
13500
SA 106 Gr.B
0.71423
406.4 7.92
400
20

Exhaust De-Super heater to 2.5ATA
header.
Down-Stream of
Turbine Exhaust.
2.5ATA Header.
130
140
1.6
1.92
13500
13500
SA 106 Gr.B
0.71423
406.4 8.8
400
8.8Thk. 20-30 22.559 12.8
899.93 1.5
1.93
7.70
298.31
3MW DM water storage tank to

Desuper heating spraying system.
3MW DM water
storage tank spray
water pump
discharge.
De-superheating
station.
80
90
18
21.6
8000
8000
SA 312TP304
0.001
60.3
50
10S
1255.7 1
1.52
2.42
59.97
MATRIX SOLUTION
BANGALORE
2.77
1-2
0.9436 17.86
REMARKS

OK. Pending till

stress analysis.
OK. Pending till
stress analysis.
OK. Pending till
stress analysis.
OK. Pending till
stress analysis.
OK. Pending till
stress analysis.
OK
OK
Deleted.
For Future
Provision.
For Future
Provision.
OK
OK
OK
OK
OK
OK
OK
OK, For 300Nb
26m/sec. as per
commitment 350
NB.
MATRIX SOLUTION
BANGALORE
DATE : 31.07.2010
REV : 01

OK, For 300Nb

26m/sec. as per
commitment 350
NB.
OK, For 300Nb
28m/sec. as per
commitment 350
NB.
OK, For 300Nb
28m/sec. as per
commitment 350
NB.
OK, For 350Nb
30m/sec. but as
per commitment
400 NB.
OK, For 350Nb
30m/sec. but as
per commitment
400 NB.
OK, For 350Nb
28m/sec. but as
per commitment
400 NB.
OK, For 350Nb
28m/sec. but as
per commitment
400 NB.
OK
OK, For 350NB vel
is 25m/sec.
OK
OK
OK
OK
OK
For Future
Provision.
OK
OK
OK
OK
OK
MATRIX SOLUTION
BANGALORE
DATE : 31.07.2010
REV : 01
OPERATING
DESIGNED
OPERATING
DESIGNED
MATERIAL SPECIFICATION
SPECIFIC VOLUME IN M3/Kg AT

OPERATING CONDITION
PIPE SIZE IN MM (OD)
PIPE THICKNESS AVAILABLE IN

MM
THICKNESS
VELOCITY AS PER STANDARD
ACTUAL VELOCITY
ALLOWABLE STRESS IN KSI
ALLOWABLE STRESS IN KG/CM2

AS PER IBR ASME B 31.1.
CORROSION ALLOWANCE
CONSIDERED
MINIMUM THICKNESS REQUIRED

IN MM
MINIMUM THICKNESS AVAILABLE

IN MM
BENDING TOLERANCE OR MARGIN
REMARKS
31
41
1.2
2700000
2700000
SA 53 Gr.B
0.00100472
914
7.92
900
SCH 10
<1
1.2
15.0
1054.6
2.52
7.13
182.88
VELOCITY IS MORE
P02
MAIN CW PUMP DISCHARGE
31
41
2.4
2700000
2700000
SA 53 Gr.B
0.00100472
762
7.92
750
SCH 10
1.5-2.0
1.7
15.0
1054.6
2.87
7.13
148.69
OK
P03
CW MAIN SUPPLY HEADER
31
41
2.4
2700000
2700000
SA 53 Gr.B
0.00100472
762
7.92
750
SCH 10
1.5-2.0
1.7
15.0
1054.6
2.87
7.13
148.69
OK
P04
CONDENSER INLET
31
41
2.4
1475000
1475000
SA 53 Gr.B
0.00100472
457
6.35
450
SCH 10
1.5-2.0
2.7
15.0
1054.6
2.52
5.72
126.83
MORE
P05
CONDENSER OUTLET
41
51
1.5
1.8
1475000
1475000
SA 53 Gr.B
0.00100828
457
6.35
450
SCH 10
1.5-2.0
2.7
15.0
1054.6
2.39
5.72
139.15
MORE
P06
CW RETURN HEADER
41
51
1.5
1.8
3075000
3075000
SA 53 Gr.B
0.00100828
813
7.92
650
SCH 10
1.5-2.0
1.7
15.0
1054.6
2.69
7.13
164.65
MORE
P07
CW RETURN HEADER-1
41
51
1.5
1.8
1350000
1350000
SA 53 Gr.B
0.00100828
559
6.35
200
SCH 20
1.5-2.0
1.6
15.0
1054.6
2.48
5.72
130.75
OK
P08
CT INLET
41
51
1.5
1.8
225000
225000
SA 53 Gr.B
0.00100828
219.1
6.35
200
SCH 20
1.5-2.0
1.9
15.0
1054.6
2.19
5.72
161.33
OK
P09
AUX. CW PUMP SUCTION.
31
41
1.2
125000
125000
SA 53 Gr.B
0.00100472
219.1
6.35
200
SCH 10
<1
1.0
15.0
1054.6
2.12
5.72
168.99
VELOCITY IS MORE
10
P10
AUX. CW PUMP DISCHARGE
31
41
6.5
7.8
125000
125000
SA 53 Gr.B
0.00100472
168.3
7.11
150
SCH 40
1.5-2.0
1.9
15.0
1054.6
2.62
6.40
144.19
OK
11
P11
AUX. CW SUPPLY HEADER
31
41
6.5
7.8
125000
125000
SA 53 Gr.B
0.00100472
168.3
7.11
150
SCH 40
1.5-2.0
1.9
15.0
1054.6
2.62
6.40
144.19
OK
12
P12
ALTERNATER INLET
31
41
6.5
7.8
68400
68400
SA 53 Gr.B
0.00100472
168.3
7.11
150
SCH 40
1.0-1.5
1.0
15.0
1054.6
2.62
6.40
144.19
OK
13
P13
OIL COOLER INLET
31
41
6.5
7.8
35000
35000
SA 53 Gr.B
0.00100472
114.3
6.02
100
SCH 40
1.0-1.5
1.2
15.0
1054.6
2.42
5.42
123.75
OK
14
P14
SAMPLE COOLER INLET
31
41
6.5
7.8
10000
10000
SA 53 Gr.B
0.00100472
60.3
3.91
40
SCH 40
1.0-1.5
1.3
15.0
1054.6
2.22
3.52
58.35
OK
15
P15
BOILER INLET
31
41
6.5
7.8
11600
11600
SA 53 Gr.B
0.00100472
60.3
3.91
40
SCH 40
1.2-2.0
1.5
15.0
1054.6
2.22
3.52
58.35
OK
16
P16
ALTERNATER OUTLET
31
41
6.5
7.8
68400
68400
SA 53 Gr.B
0.00100472
168.3
7.11
150
SCH 40
1.0-1.5
1.0
15.0
1054.6
2.62
6.40
144.19
OK
17
P17
OIL COOLER OUTLET
31
41
6.5
7.8
35000
35000
SA 53 Gr.B
0.00100472
114.3
6.02
100
SCH 40
1.0-1.5
1.2
15.0
1054.6
2.42
5.42
123.75
OK
18
P18
SAMPLE COOLER OUTLET
31
41
6.5
7.8
10000
10000
SA 53 Gr.B
0.00100472
60.3
3.91
40
SCH 40
1.0-1.5
1.3
15.0
1054.6
2.22
3.52
58.35
OK
19
P19
BOILER OUTLET
41
51
1.5
1.8
11600
11600
SA 53 Gr.B
0.00100828
60.3
3.91
40
SCH 40
1.2-2.0
1.5
15.0
1054.6
2.05
3.52
71.54
OK
PRESSURE
KG/Cm2 (g)
PIPE SIZE NB CONSIDERED AS

PER PROCESS (NB)
DESIGNED
MAIN CW PUMP SUCTION
FLOW KG/hr
OPERATING
P01
TEMPERATURE
IN DEG C
LINE NO.
SYSTEM DESCRIPTION
SL.NO
PIPE LINE SIZE AND THICKNESS CALCULATIONS FOR COOLING WATER

Pipe Size For Cooling Water System

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Pipe Size For Cooling Water System

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CLIENT : DHARANI SUGARS CHEMICALS LTD.

PROJECT : DISTILLERY IBR/NIBR PIPING

BENDING TOLERANCE OR MARGIN

40-50 42.127 13.5

Main Steam line to Turbine(3MW)

40-50 24.332 13.5

Main Steam line to Turbine(3MW)

40-50 42.127 13.5

Main Steam line to Turbine(3MW)

40-50 1474.9 13.5

Main Steam line to Turbine(3MW)

40-50 4026.6 13.5

Main steam line to Atmosphere(Start

Tapping from Main

20-30 22.034 13.5

Main steam line to Atmosphere(Start

Tapping from Main

20-30 6.6439 13.5

20-30 26.099 13.5

40-50 42.127 13.5

5.6Thk. 20-30 23.609 12.8

Main Steam from Control valve to

3MW Turbine Extraction to DeSuperheater.

Steam from 5.0ATA header to Distillery

PIPE SIZE IN MM (OD)

MINIMUM THICKNESS REQUIRED IN MM

ALLOWABLE STRESS IN KG/CM2

ALLOWABLE STRESS IN KSI

VELOCITY AS PER STANDARD

PIPE THICKNESS AVAILABLE IN MM

MINIMUM THICKNESS AVAILABLE IN MM

CORROSION ALLOWANCE CONSIDERED

PIPE SIZE NB CONSIDERED AS PER PROCESS

SPECIFIC VOLUME IN M3/Kg AT OPERATING

Main Steam line to Turbine(3MW)

PRESSURE KG/Cm2 (g)

PIPE LINE SIZE THICKNESS CALCULATION

20-30 24.142 12.8

CLIENT : DHARANI SUGARS CHEMICALS LTD.

Steam from 5.0ATA header to Distillery

Steam from Down-stream of Turbine

Steam from Down-stream of Turbine

PIPE LINE SIZE THICKNESS CALCULATION

20-30 22.629 12.8

5.0 ATA header.

5.0 ATA header.

3mw Turbine Exhaust to DeSuperheater.

3mw Turbine Exhaust to DeSuperheater.

8.8Thk. 20-30 23.118 12.8

Steam from 2.5ATA Header to

Steam from 2.5ATA Header to

8.8Thk. 20-30 22.559 12.8

Steam from turbine exhaust to

Steam from turbine exhaust to

5.6Thk. 20-30 21.966 12.8

Turbine Ext. DeSuper heater.

Steam from Down-stream of Turbine

8.8Thk. 20-30 22.559 12.8

3MW DM water storage tank to

PIPE LINE SIZE THICKNESS CALCULATION

CLIENT : DHARANI SUGARS CHEMICALS LTD.

OK. Pending till