POWER PLANT PIPINGS

Rajesh Kumdale Pune India

inpac@rediffmail.com
INTRODUCTION

The plant and systems are designed to achieve the best possible efficiency under the specified
operating conditions. The Power Cycle shall be designed with one low pressure feed water
heater (de-aerator). The steam requirement of the de-aerator shall be met from the bleed of the
turbine.

The cooling medium is filtered water, which is circulated through a cooling tower. The water is
supplied by owner at the terminal point (Raw Water Tank) from where it will pumped at the
required pressure to the Cooling Tower. The cooling water temperature considered is 32 Deg C
with a temperature rise of 8 Deg C across the Condenser. The Design wet bulb temperature for
the cooling tower has been considered as 27 Deg C. The efficiency of the Power plant is
deepens upon the water.

The required quantity of raw water shall be stored in the raw water tank of capacity 1500 m3.
We have considered river water of low hardness as CaCO3 and negligible Silica as SiO3
for the water treatment plant design. This is the basis for the selection of the multi-grade filter /
RO plant and DM water treatment plant. Any change in the limits of this water analysis will
impact the water treatment plant design and cost. We have not considered water softening
plant for cooling tower.

The raw water after filtration and required dosing will be taken to the cooling tower (make up)
for the condenser cooling water system. For the boiler makeup, the filtered water will be taken
through the RO/DM Water treatment plant and then stored in the DM water storage tank of 20
m3. The boiler make up water stream is designed for 2 m3 / hr capacity. In case if any other
water source is available for the power plant, the same may be indicated to us for design.
INPUT CONDITIONS
Ambient conditions and other inputs (assumed)
Temperatures :
Design temperature for performance : 35 Deg C
Design Temperature for Electrical : 45 Deg C
Relative Humidity :
Plant Design Relative Humidity : 65.0%
Design Wind Velocity : As per IS: 875
Seismic Coefficient : As per IS: 1893

Soil Bearing Capacity at 2.0 m Depth : 20 T/m2
(To be reconfirmed after site location is finalized & soil investigations
are conducted)
Cooling Water temperature : 32 Deg C
FEED WATER SYSTEM

Boiler Feed water pumps (2 Nos.) complete with
coupling, base frame and drives arrangement.
Feed regulating station for maintaining uniform level of
water in steam drum.
Stand by flow path of 100% capacity.
Feed pump re-circulation flow under low feed pump flow
conditions by automatically controlled solenoid valve
installed in between feed pump and de-aerator.
Strainers at the suction of feed water pump.
Feed line from de-aerator to feed pump suction, feed
pump discharge to economizer and from economizer to
steam drum.
DE-AERATOR CUM STORAGE TANK

De-aerator with de-aerated water storage tank.
Minimum and essential valves and fittings.
Saddle support for placement of de-aerator on
control room top.
Level control valve with required isolation.
Pressure control valve with required isolation.
Feed water piping from de-aerator outlet to feed
pump suction.
Feed water piping from the outlet of level control
station to de-aerator.
Steam piping from the outlet of pressure control
station to de-aerator.
DEAERATION TANK
SPECFICATION
Type :Horizontal spray type
Design code :As per US standards
Design pressure :22.0 Kg/cm
Design material temperature :200 Deg. C.
Storage tank capacity at NWLm316
Deaeration capacitym3/hr.60
Hydraulic test pressure :24 Kg/cm
Operating temperature :120 Deg.C.
Operating pressure : 0.35 Kg/cm2
Deaerator water inlet temp. :45 Deg.C.
Deaerator water outlet temp. :120 Deg.C.
Oxygen content in deaerator water :0.01 ppm

WATER REQUIREMENT
The raw water shall be from the day storage hold up, under ground
tank (owners scope) of 2000 m3 capacity (1500 m3 for Power Plant
and 500 m3 for fire fighting) and supplied at the inlet to the raw
water pumps and passed through multi grade filter (MGF) at 3.5
kg/cm2. One stream of the filtered water shall be taken to the
Cooling Tower. The other stream shall be taken to RO / DM Plant as
per the scheme.
The chlorine dozing system shall be provided to prevent Algae
formation and Bacteria.
The Raw Water is pumped by the Filter Feed Pump through the
Multi Grade Sand Filter (MGF) for the removal of Suspended Solids.
The unit consists of quartz sand media for the purpose. The unit
should be backwashed in a day or whenever the pressure drop
exceeds 0.8 Kg/cm2, whichever is earlier.
WATER PROPERITES
Hardness (ppm) : 0
pH @ 250C : 8.8 9.2 (after pH correction)
Conductivity @ 250C : 0.5 (microsiemen / Cm)
Total Silica (maximum) (ppm): 0.02
Residual Hydrazine (ppm) : 0.01 0.02
PIPING & PIPING MATERIALS

All piping system will be designed as per ASME B 31.1 and IBR.
Stress Analysis shall be carried out for all critical piping as per ASME B 31.1 / IBR
requirements.
Supports, Spring Supports, guides, directional anchors will be selected to satisfy all
the operating conditions.
Drains and traps will be provided as required.

The piping material selection will be based on the following recommendations
For temperature above 4240C up to 5100C - SA 335 Gr. P11 / P12 will be used
For temperature up to 4240C - SA 106 Gr. B will be used
For HP / LP chemical dosing - - SA 312 TP 304, stainless steel will
be used.
For cooling Water, Raw Water, Service Water, Safety / Relief Valve Exhaust
IS:1239 / IS:3589 ERW / EFW pipes
will be used.
For service air applications, the piping will be - IS:1239.
For instrument air applications: Galvanized pipe (Iron Pipe)
- IS:1239 Part I will be used.
PIPING
Codes, Standards & Regulations
ASME
DIN
TRD
BS
IBR
Codes and Standards:
Several groups have written codes and
standards for materials, inspection, design,
stress analysis, fabrication, heat treatment,
welding and construction of pipes and piping
components. Regulations, practices, rules and
laws are also available for use of piping. Certain
aspects are mandatory and certain aspects are
recommendatory. The commonly used
American Codes and Standards on piping

1. ASME B31.1 -Power Piping
2. ASME B31.2 -Fuel Gas Piping
3. ASME B31.3 -Process Piping
4. ASME B31.4 -Pipeline Transportation Systems for Liquid
Hydrocarbons and other Liquids.
5. ASME B31.5 -Refrigeration Piping
6. ASME B31.8 -Gas Transmission and Distribution Piping
Systems
7. ASME B31.9 - Building Services Piping
8. ASME B31.11 - Slurry Transportation Piping Systems.

Through the use of codes and standards, safety and uniform economy
are obtained. The codes and standards primarily cover the following
aspects:
1. Factors safety
2. Material property
3. Thickness calculation
4. Loads
5. Load combinations
6. Stress limits
7. Stress intensification factors
8. Flexibility factors
9. Supports
10. Flexibility analysis.



IBR 1950

ASME SEC.I

BS 1113

DIN TRD 300

REMARKS


DESIGN PRESSURE


DESIGN PRESSURE
WITH PRESSURE
DROP


DRUM DESIGN
PRESSURE


DRUM DESIGN
PERSSURE


DRUM DESIGN
PRESSURE




DESIGN
TEMPERATUE
ALLOWANCE
RADIATION


50C






ACTUAL METAL
TEMPERATURE
371C (MIN)





50C


50C





CONVECTION


39C


35C


35C





ECONOMISER


11C


25C


(15 + 2 Se) C
Max. 50C


Se - ACTUAL WALL
THICKNESS in mm.


WATER WALL


28C


50C


50C




TUBE THICKNESS
FORMULA t
min



PD
--------- + *C
2f + P



PD
--------- + 0.005D
2f + P



PD
---------
2f + P



PD
---------
2f + P


P=DESIGN PR.
D=OUTSIDE DIA
f=ALLOWABLE STRESS
CORR. TO DESIGN
METAL TEMP.


FACTOR OF SAFETY

Et R
1.5 , 2.7
SR SC
1.5

Et R
1.5 , 3.5
SR SC
1.5

Et R
1.5 , 2.7
SR
1.3

Et R
1.5 , 2.4
SR
1.0
Et = YIELD STRENGTH
R = TENSILE STRENGTH
SR = RUPTURE
STRENGTH
SC = CREEP STRENGTH


FOR ASME MATERIALS ALLOWABLE STRESS CAN BE TAKEN DIRECTLY FROM ASME SEC.II PART-D

COMPARISON OF CODES
*C = CORROSION ALLOWANCE = 0.75mm FOR P 70 bar; 0 mm FOR P > 70 bar

Sl.

Nominal

MATERIAL SPECIFICATION

Temp.

No.

Composition

ASME Section-I

DIN TRD 300

BS 1113

Limit C


01.


Carbon Steel


SA178 Gr.C, Gr.D,
SA192, SA210 Gr.A1
& Gr.C
SA106 Gr.B, Gr.C


St 35.8
St 45.8


BS3059 P2 S2 360, 440
BS3602 P1 360, 430, 500
Nb


427



02.


Mo


SA209 T1


15 Mo3 ( TUBE)


----


482


03.


1 Cr Mo


SA335 P12
SA213 T12


13 Cr Mo 44


BS3059 P2 S2 620
BS3604 P1 620 440


535


04.


1 Cr Mo


SA213 T11
SA335 P11


----


BS3604 P1, 621


552


05.


2 Cr 1 Mo


SA213 T22
SA335 P22


10 Cr Mo 910


BS3059 P2 S2 622-490
BS3604 P1, 622


577


06.


9 Cr 1 Mo V


SA213 T91
SA335 P91


X 10 Cr Mo V
Nb91


-----


635


07.


Carbon steel


ASTM A 53 Gr B


ST 32




325


08.


18 Cr 8 Ni


SA213 TP304 H


-----


BS3059 P2 304 S51
BS3605 304 S59 E


704


09.


18 Cr 10 Ni Cb


SA213 TP347 H


-----


BS3059 P2 347 S51
BS3605 347 S59 E


704

TEMPERATURE LIMITS FOR VARIOUS STEEL GRADES OF TUBES / PIPES


AREA


IBR


ASME SEC.I


BS 1113


DIN TRD 300



Tube
thickness


PD
+ C
2f + P


PD
+0.005D
2f + P


PD

2f + P


PD

2f + P



Shell
thickness


PR
+ 0.75
fE 0.5 P

PR

fE (1 Y) P

PR

fE 0.5 P

PR

fE 0.5 PE


Dished end
thickness


PDK
+ 0.75
2f

PR

2f 0.2 P

PDK

2f

2P
R 1+ 1
2f P


Flat end
thickness

CP
d + C
f



CP
d
f
P
Cd
f
P
Cd
f
DESIGN - CALCULATION OF THICKNESS REQUIRED IN VARIOUS CODES
Diameter and Thickness:
The diameter of the piping is usually decided
based on flow and heat transfer considerations.
In normal practice, the outside diameter is
specified for procurement. These are based on
the convenience and convention in manufacture.
After finalizing the diameter, the thickness of the
piping is computed based on the imposed loads.

PIPING
PIPING
Diameter
Based on flow requirements
Based on economic requirements
Based on size availability
PIPING
Thickness
Based on strength requirement
Based on process allowances
Based on thickness tolerances
Based on availability
Fluids and Pressure Drop:
The piping under present discussion may carry a single-
phase fluid or two-phase fluid. The following fluids are
commonly handled by the piping:

1. Liquid
2. Gas
3. Liquid-solid slurry
4. Gas-solid mixture
5. Liquid-vapor mixture.

PIPING
Mixture of solids, liquids and gases are rarely
used. In a maze of piping, flow distribution plays
a major role in the design of piping. To calculate
the flow in various branches of piping (in a maze
of piping), the pressure drop in various branches
are to be calculated. The following formula is
commonly used to calculate the pressure drop in
a fully developed flow in a hollow circular pipe.

PIPING
f W
2
L
AP = ----------
2gd
Where,
A P = Pressure loss in terms of head, mm of fluid column
f = Coefficient of friction
W = Velocity of fluid, mm / sec.
L = Total length of pipe, mm
g = Acceleration due to gravity = 9806.65 mm/sec
2

d = Average inside diameter of pipe, mm

PIPING
The following formula is commonly used calculate the pumping
power required:

A P p WA
HP = ---------------
75 x 10
9

Where
HP = Pumping power, HP
p = Density of fluid, gm/cc
A = Flow area = d
2
/ 4 Sq.mm

Example (Water at ambient temperature)

PIPING
Flow = 100 tonne / hr = 100 cu. m / hr = 100 / 3600 = 0.0278 cu.m / sec
d = 102.26 mm (for 4 STD pipe = 114.3 x 6.02 mm x mm)
W = 0.0278 / ( * 0.10226
2
/ 4) = 3.38 m / sec = 3.380 mm / sec
L = 100 m = 100,000 mm
f = 0.02 (approximate)
p = 1.0 gm / cc (for water at ambient temperature)
A P = 0.02 * 3380
2
* 100,000 / (2 * 9806.65 * 102.26) = 11.392 mm water column

A P p W A (11.392 mm wc) x (1.0 gm/cc) x 3.380 mm/sec) x (8.213 sq.mm)
HP = --------------- = --------------------------------------------------------------------------------------
75 x 10
9
75 x 10
9


= 4.22 HP. Considering a motor efficiency of 80%, motor rating = 4.22/08 = 5.28 HP.

Use a 6 HP Motor.

PIPING
Nominal Pipe Size (NPS):

The Nominal Pipe Size (NPS) in an ASME method of indicating the
approximate outside diameter of the connected pipe in inches. Note
that the unit (inch) is not followed after the designation.

Class of Fittings:

The class of fittings is an ASME method of indicating the pressure
carrying capacity of the fittings.

PIPING
I. Pipe sizing and Pressure drop Calculations:

Pipe Sizing:

Before proceeding beyond a preliminary / design of piping
system, it is necessary to determine the pipe inside diameter which
allow reasonable velocities and friction losses. The maximum
allowable velocities of the fluid in pipeline is that which corresponds
to the permissible pressure drop from the point of supply to the point
of consumption or is that which does not result in excessive pipe line
erosion.

PIPING
Trade Practice Steel pipes are designated by their OD or their
Nominal ID.

Due to manufacturing conditions, OD is constant.

Slight deviations from normal wall thickness, modify only the ID also
called clear width.

Why a pipe is generally not referred to by its ID.

Common Engineering practice to use nominal bore NB to indicate the
proper size of the individual parts employed in a pipeline (pipes, flanges,
fittings and valves).

Nominal bore = actual inside diameter.

PIPING
Selection of the diameter (flow rate anticipated pressure head
available).

Pressure head (provided by booster pumps, compressors, natural
head as in the case of gravity main).

Pressure head is necessary for transmission to overcome losses in
the flow rate due to internal friction in the moving fluid or to rough inside
surfaces of pipe.

Pressure drop increased through turbulence and separation of flow of
bends or in branch connections, fittings, valves and similar parts (reduce the
economy of any pipe line.




PIPING
Velocity profile in Different System:

The mean velocities of steam and water in different system
shall be as follows:

PIPING

Q = A W

t
A = --------- d
2

4

354025 x Qv
d = --------------------
w

Where A = Area, mm
2



PIPING
d = inside diameter, mm

Q = flow rate, Tonnes/hr.

w = Velocity, m/sec

= Volume of medium, Kg/m
3


Pressure drop calculation:

The pipe sizes calculated based on the above recommended
velocities do not relieve the designer to check the adequacy of pipe
size from the flow friction consideration.


PIPING
Pressure drop calculations are of prime necessity in
determining:

a) The selected inside diameter meets the available
pressure drop in the case of main steam, cold reheat,
hot reheat and auxiliary steam lines and miscellaneous
water lines.

b) The discharge pressure of the pump (boiler feed
pump and condensate extraction pump).


PIPING
For finding the frictional pressure drop in pipelines
Darcys Formula can be universally used for almost all
the fluids. With suitable restrictions for gases and
vapours. As long as the pressure drop is around 10% of
starting point pressure (which is true in most of the
steam lines in thermal power station). Darcys formula
for pressure drop can be used since the specific volume
change in the line due to pressure loss will have little
effect on calculated pressure drop.

PIPING
Calculation to determine the pressure drop in the pipe is made
according to formula:

a) For straight pipe

flw
2

AP = ----------------- kg/cm
2

20000 g
c
dv

b) For bends, elbows, tees, valves, etc.
Kw
2

AP = ----------------- kg/cm
2

20000 g
c
v

PIPING
Where,

f= Friction factor found from a graph between Reynolds No. and
Relative roughness.
K= resistance coefficient for fittings there are established based on
experiments and are available in a standard table in various books.
l= length of pipe in meters
V= velocity in m/sec
g
c
= gravitational constant 9.81 m/sec
2

d= inside diameter of pipe in meter
v= specific volume in m
3
/sec.



PIPING
a) Water (non-expansive flow) in compressible fluids.

l w
2
x
AP= ---- x ------------ h x
di 2g

AP= absolute pressure in lb/ft
2


l= length of pipe line in ft.

di= inside diameter of pipe in ft.

PIPING
w= velocity of flow in ft/sec
= specific gravity in lb/cu.ft (water = 62 lb/cu.ft)
g= acceleration due to gravity (=32.2 ft/sec
2
)
h= geodesic height in ft for lines other than horizontal
= friction factor number dimension
+= ascending lines
= descending lines

0
= for horizontal lines.

Pressure decreases in linear perspective with the length
of the line, while the velocity remains unchanged.


PIPING