Hydraulic Ash Disposal

I.
General Description
I.1. General description and Scope of work
- Ash pond 2 is one of ash storage are for Mong Duong 2 TPP project located at Quang Ninh province.
- This Hydraulic calculation document shall be shown how many pressures loss through system when
transferring ash slurry from tie-in point to largest discharge point inside ash pond 2 which total distance
about 7 km. Based on result of analysis calculation, give recommendations to Owner (if any).
I.2. Applicable codes, standards and other
[1] - ASME B31.11 Slurry Transportation Piping System

[2] - ASME B31.3 Process Piping System
[3] - Technical specification issued by AES - VCM.

[4] - Piping Handbook (7th Edition).
[5] - Pipe Flow 2, Multi-phase flow Assurance (2013).
II. Pipeline Selection and Pressure Loss calculation
II.1. General
The velocity of slurry in pipelines shall be in the range 1.8 m/s to 2.5m/s to avoid increasing the wear rate
of the pipeline (if operating velocity above 2.5m/s) and risks of settling out and causing a blockage inside
pipeline (if operating velocity below 1.8m/s). This slurry is nonNewtonian fluid so that the formula of
Durand equation will be applied to calculate the friction loss of slurry.
where i = friction loss for slurry, ft (m) water per ft (in) iw - friction loss for water, ft (ill)
water per ft (m) at same velocity
C[) = drag coefficient of suspended solid particle settling in fluid of infinite extent
s = specific gravity of solid particles
The difference i - iw represents an increase in pressure drop due to the presence of solids in the slurry.
The effect of particle size on slurry pressure drop is accounted for by the inclusion of the drag coefficient
CD .
In most industrial applications, the particle size is not uniform, so the equation above can be written as
follows:
where Cvi = volume fraction of solids having size di

di = particle size of /th fraction
CDi = drag coefficient of particle having size dị
N = total number of size fractions into which given particle size distribution is
divided
Step 1: Calculation CDRew2 based on input data.
CDRew2 = Pl(4gd3(ps - Pl)/(3ụ2gc2

Whereas:
CD - Drag coefficient
d - Particle diameter (m)
g - Acceleration due to gravity (9.81 m/s2)
Pl - Density of liquid (kg/m3)
ps - Density of solid particle (kg/m3)
Rew = d Pl W o/(gụ) w0 - settling velocity (m/s) ụ - viscosity of liquid (kg.s/m).
Step 2: Find the drag coefficient of particles of individual size fraction based on result of step 1
Drag coefficient Cl) of spherical particles settling in liquid. ca = 4gil(p, — Pl)/ pw^pr], where
rf — particle diameter (ft), w„ = settling velocity (ft/s), g — acceleration due to gravity (32.2 ft/s2). p, = particle
density (ib/ft3). p = liquid density (lb/ft3).
Source: Piping handbook, seventh edition.

Step 3: Calculation of friction loss of slurry
Calculation follows below equation:
iw - friction loss for water (mH2O/m) were calculated by software.
i - Friction loss for slurry

Cvi - volume fraction of solid having size di
CDi - Drag coefficient of particle having size di
N - Total number of size fraction into which given particle size distribution is divided.
II.2. Input Data
Calculation hydraulic for slurry and water return base on Ash pipeline - Arrangement drawing
and below basic data.
TABLE 1: INPUT PARAMETERS
NO. PARAMETERS SYMBOL UNIT Value Remarks
Density of liquid phase PL kg/m3 Assumed

1 1000
Density of solid (fly ash, bed ash +
2 PS kg/m3 2000 Assumed
gypsum) phase
3 Dynamic viscosity of water - carrying ML mPa.s 0.466 Assumed

liquid (T=60oC)
4 Pipeline material specification for ASME A106, Grade B, DN200,

slurry Sch. 120
5 Pipeline material specification for ASME A53, Grade B, DN200, Sch.

water return 40
6 Inside diameter of slurry pipeline ID m 0.1826
7 Inside diameter of water return ID m 0.2027

pipeline
For one
8 Designed flow V m3/h 220
pipeline
With 4 Cases that one case has difference concentration of weight, the calculation density of
mixture, concentration volume of solid in mixture and velocity has shown in Table
2.
TABLE 2: PHYSICAL PROPERTIES OF SLURRY FLOW.
NO. PARAMETERS SYMBOL UNIT CASE 1 CASE 2 CASE 3 CASE 4
1 Concentration by Weight Cw % 50 60 65 70
2 Density of liquid phase PL kg/m3 1000
3 Density of solid (fly ash, PS kg/m3 2000

NO. PARAMETERS SYMBOL UNIT CASE 1 CASE 2 CASE 3 CASE 4
bed ash + gypsum) phase
1428.5 1538.4
4 Density of slurry mixture PM kg/m3 1333.3 1481.48
7 6
3
5 Concentration by Volume of Cv % 0.3333 0.4286 0.4815 0.5385

solid in mixture
Dynamic viscosity of water -
6
carrying liquid (T=60oC)
ML mPa.s 0.466
7 Velocity v m/s 2.96 2.3 2.1 1.8
The data of water return was showed in Table 3.
TABLE 3: PROPERTIES OF WATER FLOW.
NO. PARAMETERS SYMBOL UNIT Value Remark
1 Density of water PL kg/m3 1000
Dynamic viscosity of water -

2
carrying liquid (T= 22.8oC)
ML mPa.s 0.942
3 Temperature (Max./Normal) T oC 42/22.8
4 Pressure at max. temperature P kg/cm2 8.6
5 Flow rate Q m3/h 200
II.3. Data of sizing particle distribution
The particle size distribution is one of the important information that needs to calculate
hydraulic of slurry. Due to lack of information for design, the data was calculated based on:
- The P&ID drawings (Issued for construction revision) of Ash handling system - T10206-XG02-
P1ETG-110001~110009, T10206-XG02-P2ETG-110011~ 110016, T10206-XG02-P1ETA-
510001/510002, T10206-XG02-P2ETA-510003/510004 of Mong Duong 2 BOT TPP project
to define the rate (% by weight) and size of particle of ash (see more detail in appendix 1).
- From the ash and gypsum production figures used in the design issued in technical
specification by AES - VCM (Page 4, item 2.1.1 - Ash transport system), the particle size
distribution had assumed as below table 4:
TABLE 4: THE PARTICLE SIZE DISTRIBUTION
Particle dimension Weight of solid (%)

(mm)
5 1.762
2 3.493
1.5 5.093
1 14.634
0.5 12.556
0.49 1.888
0.145 1.888
0.14 25.872
0.04 25.872
0.035 0.472
0.006 6.468
Total 100
Note:
- The calculation result of particle size distribution was based on P&IDs of Ash Handling
System of Mong Duong 2 BOT TPP project (Issue for Construction version) and Consultant's
experience on TPP, the more detail please see Appendix 1.
II.4. Result
The friction loss summarization of system is showed in Table 5:
TABLE 5: TOTAL PRESSURE LOSS OF SYSTEM.
Pressure Total
Pipe Total drop/ pressure
Item Service
Pipe ID, Pipe Fitting, equivalent Velocity, 100m, drop,
m length, m pcs length, m m/s kg/cm2 kg/cm2
1 Return Water 0.2027 5391 98 5708.8 1.721 0.1439 8.2
2 Slurry 50% 0.1825 7494.9 105 7801.5 2.96 1.0969 85.6
3 Slurry 60% 0.1825 7494.9 105 7801.5 2.3 1.3608 106.2
4 Slurry 65% 0.1825 7494.9 105 7801.5 2.1 1.5074 117.6
5 Slurry 70% 0.1825 7494.9 105 7801.5 1.8 1.6653 129.9
Note:
- Total Pipe length and Number of fitting are estimated follow new updates arrangement
drawing. As attach file, the Final calculation and result of pressure drop will submit after received
Final arrangement drawing.
The detail calculation cases of slurry and water are showed in attachments:
• ATTACHMENT-1: SIZING PARTICLE DISTRIBUTION.

• ATTACHMENT-2: HYDRAULIC CALCULATION OF 50% SLURRY.
• ATTACHMENT-6: GRAPH OF PRESSURE LOSS OF 4 CASES.
• ATTACHMENT-7: HYDRAULIC CALCULATION OF WATER RETURN.
II.5. Conclusion
From the above table 4 and results of 4 cases hydraulic calculation (attachment 2 to 4) it is may
draw some below conclusion:
- This smaller dimension particles slurry will create the pressure loss per 100 pipe length less
than the large.
- The percentage (%) of particles size also affects the friction slurry losses: The proportion of
small sized particles higher will cause the increased friction losses decreased compared with
larger particles.
- To finalize the friction loss for whole of HCSD to largest point Ash pond 2, these parameters
should be defined based on Plant's real slurry sample: Density of
slurry, particle size distribution and ration of bottom ash handling and gypsum from FGD
system,
III. Pipeline design detail
The pipeline duty is to transport ash slurry from tie-in point to discharge points at the ash pond
No. 2.
The pipeline design is to be based on ASME code B31.11 - 2oo2 Edition.
Nominal diameter DN200 (8”)
Outside diameter 219.1 mm
Pipe wall thickness nominal 18.26 mm
Inner diameter 182.6 mm
Design temperature 600C for slurry and 420C for water return
Design pressure 172 bar for slurry &

10 bar for water return
Wall thickness tolerance ± 12.5 % i.e. ±2.3 mm
Corrosion and erosion allowable 3 mm
Piping material Seamless ASTM A106, Grade B for slurry &

ASTM A53, Grade B for water return
IV. General pipeline design disciplines
The hydrostatic test pressure for the welded/assembled pipeline shall be 1.25 times the design
pressure of the pipeline.
Pipe Bend: The pipe bend with R=5D shall be applied to all turning points.
Expansion: The function of the expansion section is to compensate the total expansion of the
pipeline. The expansion loop will be applied at any necessary area.
The expansion of the pipeline can be calculated by below formula:
AL = Lo a • AT
AL = length difference
Lo = Original length
a = expansion coefficient
AT = temperature difference
Spool pieces: The spool pieces will be applied for only slurry pipeline at every 500m length of
straight pipe routing and at inlet/outlet of culverts. For other turning point the spool piece also applied for
every 500m length of total.
The high density fluid slurry with special and uniformity characteristics will be transferred to the
Ash pond No. 2 by piping system, when the system stop fully or a part the piping will be flushing and
soaking by water for next working shift. Besides that, the branch creating to mainline will be made high
risk of overstress these points or original forming blockage. From above reasons the design of vent and
drain point for the ash slurry pipelines shall be not applied.
ATTACHMENT-1_SIZING PARTICLE DISTRIBUTION
Mong Duong 2: Ash Pond 2 EPC Project
Result for % by Mass

Item/Parameter Unit Value Dimension of particle
Plant weight (ton/h)
FLY ASH HANDLING SYSTEM
Air Pre-heater (Refer to T10206-XG02-P1ETG-110003, Rev. 1, date 30.05.2013)

Bulk density kg/m3 800
Designed conveying rate
ton/h 5 10
Particle size:
Max. lump size mm 5
size for d10 mm 0.035 Particle size=< 35pm 10 1
Particle size=< 1mm 5 0.5
Particle size=<1.5mm 3 0.3

Economizer (Refer to T "10206-XG02-P1ETG-110001/110002, Rev.1, date
30.05.2013)
ton/h 8.1 16.2
Particle size:
Max. lump size mm 5
size for d10 mm 0.035 Particle size=< 35pm 10 1.62


Particle size=<1.5mm 3 0.486
ESP Field 1 (Refer to T10206-XG02-P1ETG-110004/110011, Rev.1, date

30.05.2013)
750~
Bulk density kg/m3
800
ton/h 92.8 185.6
Particle size:
Max. lump size mm 1
d90 mm 0.14 Particle size =< 140pm 90 167.04
d50 mm 0.04 Particle size=< 40pm 50 92.8
Particle size below =<

5 9.28
500pm

30.05.2013)
750~
Bulk density kg/m3
800
ton/h 69.36 138.72
Particle size:
Max. lump size mm 1



5 6.936
500pm

30.05.2013)
750~
ton/h 13.88 27.76
Particle size:
Max. lump size mm 1
d10 mm Particle size =< 6pm 2.776

0.006 10
Particle size below =< 5 1.388
500pm

30.05.2013)
750~
ton/h 2.78 5.56
Particle size:
Max. lump size mm 1


Particle size below =< 5 0.278

500pm

30.05.2013)
750~
ton/h 0.554 1.108
Particle size:
Max. lump size mm 1

5 0.0554
500pm
30.05.2013)
750~
ton/h 0.11 0.22
Particle size:
Max. lump size mm 1

5 0.011
500pm

Total output capacity ton/h 385.168
Distribution by weight mm
Particle size=< 6 pm 9.32 35.897
Particle size=< 145pm 87.28 336.17
Particle size =< 1mm 5.00 19.258
Particle size =<1.5mm 0.20 0.786
FROM FGD SYSTEM (Refer the FGD system- T10206-BN02-P0HTD- 540001)

Output capacity ton/h 17 34
Particle size (Assumed) mm 50.00 17

Particle size =< 500 pm
Particle size =< 1 mm 95.00 32.3
Particle size =< 1.5 mm

5.00 1.7
FROM BOTTOM ASH HANDLING SYSTEM (Refer P&ID T10206-XG20-

P1ETA-510001~510004, Rev.1, 6/2/2013, for construction)
Output capacity ton/h 70 140
Particle size distribution

mm 15.00 21
(Assumed) Particle size below 0.5mm
Particle size=< 1mm 30.00 42


Particle size=<1.5mm 25.00 35
Based on new update documents: T10206-XW01-P0ZEN-310001, Rev.0, 16th,

Feb, 2012 provided by AES date May, 7th, 2014
The bottom ash system ton/h 24.038 48.076

(worst case)
Particle size mm 15.00 7.2114
500pm
Particle size=< 1mm 30.00 14.423
Particle size=<1.5mm 25.00 12.019
The fly ash system ton/h 96.154 192.308

(worst case)
Particle size distribution mm Particle size=< 6 pm 9.32 17.923
Particle size=< 145pm 87.28 167.84
Particle size =<1.5mm 0.20 0.3924
The FGD by-product 37.37

(worst case)

Particle size distribution mm 50.00 18.68

Particle size =< 500 pm
Particle size =< 1 mm 95.00 35.498
Particle size =< 1.5 mm

5.00 1.8683
ATTACHMENT-2
HYDRAULIC CALCULATION OF 50% CONCENTRATION
Fluid: Ash Slurry
Case 1 50% Concentration
Project: Mong Duong 2 BOT TPP project
Doc. No: AP2-SD9-AES-TPL-CALC-MEC-001 Rev.B
Input Data Assumed
Solid density: 2000 kg/m3 The particle size distribution
Liquid density 1000 kg/m3 Dia, mm % Weight of solid %volume in mixture
Viscosity of liquid 0.000466 Pa.s 5 1.762 0.587312
Pipe ID 0.1825 m 2 3.493 1.164293
Pipe Roughness 0.046 1.5 5.093 1.697668
Velocity 1.8 m/s 1 14.634 4.878082
Volume fraction 33.333333 0/ 0.5 12.556 4.185360
%
Weight concentration 50 0/ 0.49 1.888 0.629451
% 0.145 1.888 0.629451
0.14 25.872 8.624157
0.04 25.872 8.624157
0.035 0.472 0.157363
0.006 6.468 2.156039
Total 100.000 33.333333
Slurry density 1333.3333 kg/m3
Result
where Cl) = drag coefficient

d = particle diameter, ft (m)
g - acceleration due to gravity. 32.2 ft/s2 (9.81 m/s2) p,
— density of solid particle. Ibm/ft3 (kg/m3)
Pl = density of liquid, lbm/ft3 (kg/m3)
wo = settling velocity, ft/s (m/s)
Find the drag coefficient of particles of individual size

fraction
Particle size diameter, m CDRewA2 Rei Cdi
0.005 7521474.6 5600 0.63
Drag coefficient Cp of spherical particles settling in liquid. Cp = 4gd(p, - pi)l [3IV?pj]. where tl = particle
0.002 481374.37 880 0.718 diameter (ft). = settling velocity (ft/s). g = acceleration due to
gravity (32.2 ft/s2), pf = particle density (Ib/ft3), pi = liquid density (Ib/fl3),
0.0015 203079.81 715 0.76

0.001 60171.797 415 0.879
0.0005 7521.4746 82 1.11
0.00049 7079.1517 79 1.12
0.000145 183.44124 6.2 9.4
0.00014 165.11141 6.1 9.6
0.00004 3.850995 0.1 440
0.000035 2.5798658 0.1 440
0.000006 0.0129971 0.1 440
Friction loss of slurry
(1)
where c„ — volume fraction of solids having size d,
di — particle size of ith fraction
Qw = drag coefficient of particle having size if;
N — total number of size fractions into which given particle size distribution is
divided
i — friction loss for slurry, ft (m) water per ft (m)

i„ = friction loss for water, ft (m) water per ft (m) at same velocity
Co = drag coefficient of suspended solid particle settling in fluid of infinite
extent
5 = specific gravity of solid particles
di(m) Cvi*(CDi)A-0.75
0.005 0.008305453
0.002 0.014926876
0.0015 0.020856551
0.001 0.053735025
0.0005 0.038702638
0.00049 0.005781609
0.000145 0.001172509
0.00014 0.015812962
0.00004 0.000897692
0.000035 1.638E-05
0.000006 0.000224423
Sub Total 0.1604321
Frcition loss of slurry follow equation (1)
i = 6.32957082 * i water
Follow Line sizing software, pressure loss of water is: 0.1733 kg/cm2/100m
The friction loss of slurry pipeline: 1.09691462 kg/cm2/100m
ATTACHMENT-3
HYDRAULIC CALCULATION OF 60% CONCENTRATION
Fluid: Ash Slurry
Input Data Assumed
Pipe ID 0.1825 m 2 3.493 1.496948
Pipe Roughness 0.046 1.5 5.093 2.182716
Velocity 1.8 m/s 1 14.634 6.271820
Volume fraction 42.857143 0/ 0.5 12.556 5.381177
Weight concentration 60 %
0/ 0.49 1.888 0.809295
%
0.145 1.888 0.809295
0.14 25.872 11.088202
0.04 25.872 11.088202
0.035 0.472 0.202324
0.006 6.468 2.772050
Total 100.000 42.857143
Slurry density 1428.5714 |kg/m3
Result
*r of liquid

g = acceleration due to gravity, 32.2 ft/s2 (9.81 m/s2) p,
= density of solid particle. lbm/ft3 (kg/m3)
Pt — density of liquid, Hull/ft3 (kg/m3)
w„ = settling velocity, ft/s (m/s)

fraction
0.005 7521474.6 5600 0.63 Part ide Reynolds Number, Re_
Drag coefficient Co of spherical particles settling in liquid. Co = 4gd(p, - p,)l

0.002 481374.37 880 0.718 |3W» ft], where d = particle diameter (ft), H’c = settling velocity (ill's), g = acceleration due to gravity
2
(32.2 ft/s2), ft = particle density (Ib/ft1). ft = liquid density (lb/ft]).
0.0015 203079.81 715 0.76

0.001 60171.797 415 0.879
0.0005 7521.4746 82 1.11
0.00049 7079.1517 79 1.12
0.000145 183.44124 6.2 9.4
0.00014 165.11141 6.1 9.6
0.00004 3.850995 0.1 440
0.000035 2.5798658 0.1 440
0.000006 0.0129971 0.1 440
(1)
where c„; = volume fraction of solids having size di
di = particle size of ith fraction
CDi = drag coefficient of particle having size di
N - total number of size fractions into which given particle size distribution is
divided
i = friction loss for slurry, ft (tn) water per ft (m)

i„ - friction loss for water, ft (ill) water per ft (ill) at same velocity
CD = drag coefficient of suspended solid particle settling in fluid of infinite extent
Particle size diameter, m Cvi*(Cdi)A-0.75

0.005 0.01067844
0.002 0.019191698
0.0015 0.026815566
0.001 0.069087889
0.0005 0.049760535
0.00049 0.007433497
0.000145 0.001507512
0.00014 0.020330951
0.00004 0.001154175
0.000035 2.10599E-05
0.000006 0.000288544
Sub total 0.206269866
Friction loss of slurry follow equation (1)
i = 7.85230534 i water
Follow Line sizing software, pressure loss of water is: 0.1733 kg/cmi 2/100m
The Friction loss of slurry pipeline: 1.36080452 kg/cm2/100m
ATTACHMENT-4
HYDRAULIC CALCULATION OF 65% SLURRY CONCENTRATION
Fluid: Ash Slurry
Input Data Assumed
Pipe ID 0.1825 m 2 3.493 1.681756
Pipe Roughness 0.046 1.5 5.093 2.452187
Velocity 1.8 m/s 1 14.634 7.046119
Volume fraction 48.148148 0/ 0.5 12.556 6.045520
0/ 0.49 1.888 0.909208
% 0.145 1.888 0.909208
0.14 25.872 12.457116
0.04 25.872 12.457116
0.035 0.472 0.227302
0.006 6.468 3.114279
Total 100.000 48.148148
Slurry density I 1481.48151kg/m3
Result
*r of liquid
where CD - drag coefficient

d = particle diameter, ft (ill)
g - acceleration due to gravity. 32.2 ft/s2 (9.81 m/s2)
Ps = density of solid particle. lbm/ft3 (kg/m3) Pl =
density of liquid. lbm/ft3 (kg/m3) w„ = settling
velocity, ft/s (m/s)
Find the drag coefficient of particles of individual size fraction

0.005 7521474.6 5600 0.63
0.002 481374.37 880 0.718
0.0015 203079.81 715 0.76 Drag coefficient Cp of spherical particles settling in liquid. Cp = 4gd(p, - pi)/ pMVprị. where d = particle
diameter (ft), = settling velocity (ft/s), g = acceleration due to
gravity (32.2 ft/s2), p, = particle density (lb/ft5), p = liquid density (lb/ft').
0.001 60171.797 415 0.879
0.0005 7521.4746 82 1.11
0.00049 7079.1517 79 1.12
0.000145 183.44124 6.2 9.4
0.00014 165.11141 6.1 9.6
0.00004 3.850995 0.1 440
0.000035 2.5798658 0.1 440
0.000006 0.0129971 0.1 440
(1)
where Cvi = volume fraction of solids having size di
di = particle size of ith fraction
N — total number of size fractions into which given particle size distribution is divided
i = friction loss for slurry, ft (tn) water per ft (m)

i„ = friction loss for water, ft (m) water per ft (tn) at same velocity
Co — drag coefficient of suspended solid particle settling in fluid of infinite extent
5 = specific gravity of solid particles

0.005 0.011996765
0.002 0.021561043
0.0015 0.03012613
0.001 0.077617258
0.0005 0.055903811
0.00049 0.008351212
0.000145 0.001693625
0.00014 0.022840945
0.00004 0.001296666
0.000035 2.36599E-05
0.000006 0.000324166
Sub total 0.231735282
Friction loss of slurry foll ow equation (1)
i = 8.698269 i water
Follow Line sizing software, pressure loss of water is: 0.1733 kg/cm i 2/100m
The Friction loss of slurry pipeline: 1.50741 kg/cm2/100m
ATTACHMENT-5
HYDRAULIC CALCULATION OF 70% SLURRY CONCENTRATION
Fluid: Ash Slurry
Input Data Assumed
Solid density: 2000 kg/m3 The particle size d istribution
Pipe ID 0.1825 m 2 3.493 1.880781
Pipe Roughness 0.046 1.5 5.093 2.742386
Velocity 1.8 m/s 1 14.634 7.879979
Volume fraction 53.8461538 0/ 0.5 12.556 6.760966
0/ 0.49 1.888 1.016806
%
0.145 1.888 1.016806
0.14 25.872 13.931330
0.04 25.872 13.931330
0.035 0.472 0.254202
0.006 6.468 3.482833
Total 100.000 53.846154
3
Slurry density 1538.46154 kg/m
Result
*r of liquid

g = acceleration due to gravity. 32.2 ft/s2 (9.81 m/s2) p,
= density of solid particle. lbm/ft' (kg/m3)
Pl = density of liquid. Ibm/ft' (kg/m3)
H’„ = settling velocity, ft/s (m/s)

fraction
Pirtcte Arpdat NưrMr At.
Drag coefficient Cp of spherical particks settling in liquid. Cp - igdip, - p)1 |3W‘,2p|.

where </ • partkk diameter (ft). w, ■ settling velocity (ft/s). g • acceleration due Co gras It) (312 ft/s). p, *
0.005 7521474.58 5600 0.63 particle density (Ib'ft'l. pl - liquid density (Ib/ft ’).
0.002 481374.373 880 0.718

0.0015 203079.814 715 0.76
0.001 60171.7966 415 0.879
0.0005 7521.47458 82 1.11
0.00049 7079.1517 79 1.12
0.000145 183.441243 6.2 9.4
0.00014 165.11141 6.1 9.6
0.00004 3.85099498 0.1 440
0.000035 2.57986578 0.1 440
0.000006 0.01299711 0.1 440
(1)
where c„ = volume fraction of solids having size d,

di = particle size of /th fraction
N = total number of size fractions into which given particle size distribution is
divided
i = friction loss for slurry, ft (nt) water per ft (nt)
/„. = friction loss for water, ft (nt) water per ft (nt) at same velocitv cn — drag
coefficient of suspended solid particle settling in fluid of infinite extent

0.005 0.013416501
0.002 0.024112646
0.0015 0.033691352
0.001 0.086802732
0.0005 0.062519647
0.00049 0.009339522
0.000145 0.001894054
0.00014 0.025544016
0.00004 0.001450117
0.000035 2.64599E-05
0.000006 0.000362529
Sub total 0.259159575
Friction loss of slurry follow equation (1)
i = 9.6093067 i water
Follow Line sizing software, pressure loss of water is: 0.1733 kg/cmi 2/100m
The friction loss of slurry pipeline: 1.6652929 kg/cm2/100m
Grap of pressrue loss 4 cases
Water return.PRN
TTACHMENT-5: HYDRAULIC CALCULATION OF WATE

**DATA FILENAME ------------ : WATER RETURN.LNS
**LIST FILENAME ------------ : WATER RETURN.PRN
1. --------------------------------------- PROJECT NO. :
2. LINE ------------------ NO. : POETN07BR003
3. ----------------------------------------- FLOWSHEET NO :
4. --------------------------------------- TEMPERATURE(degree C)-: 22.80
5. --------------------------------------- PRESSURE(Kg/cm2 G) : 6.80
6. --------------------------------------- PHASE : Water
7. --------------------------------------- CLASS : CS
8. --------------------------------------- NOMINAL DIAMETER (in)-: 8
9. --------------------------------------- FLOWRATE (Kg/hr) : 199332.20
10. -------------------------------------- DENSITY (Kg/m3) : 996.6610
11. -------------------------------------- VISCOSITY (cp) :
------------------------------------------ 0.9420
12. -------------------------------------- MOLECULAR WEIGHT :
------------------------------------------ 18.000
13. -------------------------------------- ROUGHNESS (mm) :
VELOCITY VELOCITY0.0460
Nom. ID Act. ID ------------------------------------------ PRES. DROP PRES. DROP
(in) (in) 14.SAFETY FACTOR(m/sec)
(ft/sec) ------------ : 1.200(psi/100ft) (Kg/cm2/100m)
4.000 4.026 22.192 6.764 20.2809 4.6646
5.000 5.047 14.122 4.304 6.3698 1.4651
6.000 6.065 9.779 2.981 2.5001 0.5750
8.000 7.981 5.647 1.721 0.6255 0.1439
10.000 10.020 3.583 1.092 0.2007 0.0462
12.000 12.000 2.498 0.761 0.0821 0.0189
14.000 13.250 2.049 0.625 0.0503 0.0116
Nom. ID Act. ID 1.0 V.H. 1.0 V.H. Re. No. MOODY FAC.
(in) (in) (lb/ft/s2) (kg/m/s2)
4.000 4.026 15322.28 22801.01 7.31E+05 0.0171
5.000 5.047 6204.19 9232.43 5.83E+05 0.0167
6.000 6.065 2975.06 4427.17 4.85E+05 0.0164
8.000 7.981 992.18 1476.45 3.69E+05 0.0162
10.000 10.020 399.34 594.26 2.94E+05 0.0162
12.000 12.000 194.13 288.88 2.45E+05 0.0163
14.000 13.250 130.60 194.35 2.22E+05 0.0164
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Hydraulic Ash Disposal

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Hydraulic Ash Disposal

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I.

I.1. General description and Scope of work

[1] - ASME B31.11 Slurry Transportation Piping System

[3] - Technical specification issued by AES - VCM.

where Cvi = volume fraction of solids having size di

Step 1: Calculation CDRew2 based on input data.

CDRew2 = Pl(4gd3(ps - Pl)/(3ụ2gc2

Source: Piping handbook, seventh edition.

iw - friction loss for water (mH2O/m) were calculated by software.

i - Friction loss for slurry

TABLE 1: INPUT PARAMETERS

NO. PARAMETERS SYMBOL UNIT Value Remarks

Density of liquid phase PL kg/m3 Assumed

3 Dynamic viscosity of water - carrying ML mPa.s 0.466 Assumed

4 Pipeline material specification for ASME A106, Grade B, DN200,

5 Pipeline material specification for ASME A53, Grade B, DN200, Sch.

6 Inside diameter of slurry pipeline ID m 0.1826

7 Inside diameter of water return ID m 0.2027

TABLE 2: PHYSICAL PROPERTIES OF SLURRY FLOW.

NO. PARAMETERS SYMBOL UNIT CASE 1 CASE 2 CASE 3 CASE 4

2 Density of liquid phase PL kg/m3 1000

3 Density of solid (fly ash, PS kg/m3 2000

5 Concentration by Volume of Cv % 0.3333 0.4286 0.4815 0.5385

7 Velocity v m/s 2.96 2.3 2.1 1.8

The data of water return was showed in Table 3.

TABLE 3: PROPERTIES OF WATER FLOW.

NO. PARAMETERS SYMBOL UNIT Value Remark

1 Density of water PL kg/m3 1000

Dynamic viscosity of water -

3 Temperature (Max./Normal) T oC 42/22.8

4 Pressure at max. temperature P kg/cm2 8.6

5 Flow rate Q m3/h 200

II.3. Data of sizing particle distribution

TABLE 4: THE PARTICLE SIZE DISTRIBUTION

Particle dimension Weight of solid (%)

2 Slurry 50% 0.1825 7494.9 105 7801.5 2.96 1.0969 85.6

3 Slurry 60% 0.1825 7494.9 105 7801.5 2.3 1.3608 106.2

4 Slurry 65% 0.1825 7494.9 105 7801.5 2.1 1.5074 117.6

5 Slurry 70% 0.1825 7494.9 105 7801.5 1.8 1.6653 129.9

• ATTACHMENT-1: SIZING PARTICLE DISTRIBUTION.

III. Pipeline design detail

Nominal diameter DN200 (8”)

Outside diameter 219.1 mm

Pipe wall thickness nominal 18.26 mm

Inner diameter 182.6 mm

Design pressure 172 bar for slurry &

Wall thickness tolerance ± 12.5 % i.e. ±2.3 mm

Corrosion and erosion allowable 3 mm

Piping material Seamless ASTM A106, Grade B for slurry &

IV. General pipeline design disciplines

Mong Duong 2: Ash Pond 2 EPC Project

ATTACHMENT-1_SIZING PARTICLE DISTRIBUTION

Result for % by Mass

FLY ASH HANDLING SYSTEM

Air Pre-heater (Refer to T10206-XG02-P1ETG-110003, Rev. 1, date 30.05.2013)

Max. lump size mm 5

size for d10 mm 0.035 Particle size=< 35pm 10 1

size for d50 mm 0.145 Particle size=< 145pm 50 5

size for d90 mm 0.49 Particle size=< 490pm 90 9

Particle size=< 1mm 5 0.5

Particle size=<1.5mm 3 0.3

Particle size=< 2mm 1 0.1

Particle size=< 5mm 1 0.1