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PROJECT : BALANCE WORK MAKE UP WATER & DRINKING WATER SYSTEM FOR 7
MTPA EXPANSION STEEL AUTHORITY OF INDIA LIMITED BHILAI STEEL PLANT ( BSP )
BHILAI_Pkg.078A
Prepared for
MECON LIMITED
On Behalf of
VOLTAS LIMITED
Index
1. Introduction................................................................................................................ 5
2. CFD Data ..................................................................................................................... 6
2.1 Geometry Details................................................................................................... 6
2.1.1 Main Header Pipeline ......................................................................................... 7
2.1.2 Branching-1 Pipeline ........................................................................................... 9
2.1.3 Branching-2 Pipeline ......................................................................................... 10
2.1.4 Branching-3 Pipeline ......................................................................................... 12
2.1.5 Branching-4 Pipeline ......................................................................................... 13
2.1.6 Branching-5 Pipeline ......................................................................................... 15
2.1.7 Branching-6 Pipeline ......................................................................................... 16
2.1.8 Branching-7 Pipeline ......................................................................................... 18
2.1.9 Branching-8 Pipeline ......................................................................................... 20
2.1.10 Branching-9 Pipeline ....................................................................................... 21
2.1.11 Branching-10 Pipeline ..................................................................................... 23
2.2 Boundary Conditions & Material Properties ......................................................... 26
2.2.1 Material Properties ........................................................................................... 26
2.2.2 Boundary Conditions ........................................................................................ 26
2.3 Assumptions for simulation ................................................................................. 28
3. CFD Cases Description ............................................................................................... 28
4. Pipeline Analysis Cases Observations ........................................................................ 28
Appendix A – Pipeline Analysis Model Layout ............................................................... 29
Appendix B – Main Header Pipeline Package’s .............................................................. 30
Appendix C – Results of Branching-1 Pipeline ................................................................ 32
Appendix D – Results of Branching-2 Pipeline................................................................ 34
Appendix E – Results of Branching-3 Pipeline ................................................................ 36
Appendix F – Results of Branching-4 Pipeline ................................................................ 38
Appendix G – Results of Branching-5 Pipeline................................................................ 40
Appendix H – Results of Branching-6 Pipeline................................................................ 42
Appendix I – Results of Branching-7 Pipeline ................................................................. 44
Appendix J – Results of Branching-8 Pipeline ................................................................. 46
Appendix K – Results of Branching-9 Pipeline ................................................................ 48
Appendix L – Results of Branching-10 Pipeline .............................................................. 50
Drinking Water & Industrial Water Pipeline Analysis
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1. Introduction
Network of Pipelines are mandatory for fluid transportation. Here, the Water is supplied
from pumps to the branching’s & then to the consumer packages with the help of pipelines, which
contains bends, valves, reducers, etc. In perspective of a complex system, pressure drop across
the pipeline network is an essential factor which is unavoidable and accounts the efficiency of the
complete system. Pressure drop is also necessary to estimate the pumping power required to
overcome the head losses and bring out the desired volumetric flow rates as per the requirement.
1D CFD can be used to investigate the pressure drop across Pipeline networks. 1D CFD
can be a tool to ensure effective design of Pipelines. Using 1D CFD package, it is possible to
easily estimate critical parameters at initial stages of design. CFD can be used to address
problems with existing geometrical or performance errors like Low or high pressure drop between
inlet and outlet. Such problems may lead to lower efficiency of the equipment and also increase
the cost of performance. Therefore, 1D CFD can provide insight in the behavior of the system and
contribute in resolving the problem along with ensuring cost effective and optimum design.
Software Overview:
The analysis is conducted using advanced FlowMaster tool. FlowMaster is the leading
general purpose 1D computational fluid dynamics (CFD) solution for the modeling and analysis
of fluid mechanics in complex piping systems of any scale. 1D FlowMaster has been applied
extensively worldwide for different engineering applications. 1D FlowMaster solves numerically
the Darcy’s Equation which is phenomenological equation relates the head loss, or pressure loss,
due to friction along a given length of pipe to the average velocity of the fluid flow.
Friction factor for pressure loss calculation is evaluated based on Colebrook-White and Hazen
William equation’s. The FlowMaster version 7.9.3 is used in the 1D CFD simulation.
Drinking Water & Industrial Water Pipeline Analysis
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2. CFD Data
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Fig 2.1.2 Geometry Details- Branching’s of Drinking & Industrial Water Pipeline
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25 BOF On 5 On 5
27 HMDS On 5 On 15
077-1 WTP-1 On 10 On 5
026-CCP On 5 On 10
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28 LDP On 2 On 15
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DN150xDN65 DN200xDN150 1 1
Reducers
DN65xDN50 DN150xDN50 1 1
090A-LAB BLDG On 1 On 1
031-HMHS (TLRS) On 5 On 15
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011-01B PBS-(BTPG) On 1 On 15
001-SE-01 On 1 On 2
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DN250xDN250 DN600xDN500 1 1
DN250xDN50 DN600xDN50 2 2
T-Junctions
DN150xDN50 DN150xDN150 1 1
DN150xDN100 DN150xDN50 1 1
Bends/Elbows - - 34 34
Reducers DN250xDN50 DN600xDN400 1 1
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Inlet
Pressure Inlet 70 mWc
(MARODA Plant-II)
Outlet 1509 m3/h
Mass Flow Outlet
(Packages of Branching's) (Total Consumption at package outlets)
Inlet
Pressure Inlet 80 mWc
(MARODA Plant-I)
Outlet 6036 m3/h
Mass Flow Outlet
(Packages of Branching's) (Total Consumption at package outlets)
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Fig B.2 Drinking Water Pipeline Layout for Main Header (FlowMaster)
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Fig B.3 Industrial Water Pipeline Layout for Main Header (FlowMaster)
Table B.1: Pressure Details at Consumer Package Entry for Main Header Pipeline
Drinking Water Pipeline Industrial Water Pipeline
Flow Available Pressure at Flow Available Pressure at
Package
Rate Package Entry Rate Package Entry
3
(m /h) (kgf/cm2) (mWc) (m /h) (kgf/cm2)
3
(mWc)
071A HTSS-48
1 5.34 53.43 4 5.82 58.16
SUBSTATION (6/18)
071A HTSS-73
1 4.80 48.05 4 6.39 63.88
SUBSTATION (18/18)
FWPH for MARODA-I 26 4.73 47.32 - - -
077-02 FWPH OHP-A 26 5.69 56.99 - - -
061 OHP Part-B 17 5.60 56.07 392 5.25 52.58
Total Flow Rate &
Minimum Pressure in 71 4.80 48.05 400 5.25 52.58
Main Header
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Fig C.2 Drinking Water Pipeline Layout Showing Pressure for Branching-1 (FlowMaster)
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Fig C.3 Industrial Water Pipeline Layout Showing Pressure for Branching-1 (FlowMaster)
Table C.1: Pressure Details at Consumer Package Entry for Branching-1 Pipeline
Drinking Water Pipeline Industrial Water Pipeline
Flow Available Pressure at Flow Available Pressure at
Package
Rate Package Entry Rate Package Entry
3
(m /h) (kgf/cm2) (mWc) (m /h) (kgf/cm2)
3
(mWc)
011-01A-PBS (STB) 5 4.80 47.97 10 5.95 59.47
011-01B PBS (STG) 2 4.80 47.97 - - -
117 Welfare building 5 4.76 47.56 - - -
116B Tap Hole Mass
5 4.72 47.23 5 5.71 57.10
Shop
011-01B PBS - CT 2 4.80 48.05 835 5.71 57.10
Total Flow Rate &
Minimum Pressure in 19 4.72 47.23 850 5.71 57.10
Branching-1
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Fig D.2 Drinking Water Pipeline Layout Showing Pressure for Branching-2 (FlowMaster)
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Fig D.3 Industrial Water Pipeline Layout Showing Pressure for Branching-2 (FlowMaster)
Table D.1: Pressure Details at Consumer Package Entry for Branching-2 Pipeline
Drinking Water Pipeline Industrial Water Pipeline
Flow Available Pressure at Flow Available Pressure at
Package
Rate Package Entry Rate Package Entry
(m3/h) (kgf/cm2) (mWc) (m3/h) (kgf/cm2) (mWc)
61 OHP Part-B 21 5.04 50.41 58 5.78 57.84
071-A HTSS-46
1 5.10 50.99 4 5.76 57.59
SUBSTATION (3/18)
60 ORE Handling Plant 10 5.73 57.35 100 5.69 56.86
077-02 FWPH OHP-B 26 4.72 47.23 - - -
Total Flow Rate &
Minimum Pressure in 58 4.72 47.23 162 5.69 56.86
Branching-2
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Fig E.2 Drinking Water Pipeline Layout Showing Pressure for Branching-3 (FlowMaster)
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Fig E.3 Industrial Water Pipeline Layout Showing Pressure for Branching-3 (FlowMaster)
Table E.1: Pressure Details at Consumer Package Entry for Branching-3 Pipeline
Drinking Water Pipeline Industrial Water Pipeline
Available Pressure at Available Pressure at
Package Flow Rate Flow Rate
Package Entry Package Entry
(m3/h) (kgf/cm2) (mWc) (m3/h) (kgf/cm2) (mWc)
071-A HTSS-61
1 4.83 48.29 4 5.87 58.65
SUBSTATION (10/18)
25 BOF 5 4.79 47.89 5 5.82 58.25
27 HMDS 5 4.67 46.66 15 5.51 55.15
71-A HTSS-63
1 4.30 42.99 4 5.87 58.74
SUBSTATION (11/18)
077-1 WTP-1 10 4.23 42.26 5 5.04 50.41
026-CCP 5 4.29 42.91 10 4.98 49.84
123- FERRO ALLOY
2 4.85 48.46 2 5.87 58.74
STORAGE YARD
Total Flow Rate &
Minimum Pressure in 29 4.23 42.26 45 4.98 49.84
Branching-3
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Fig F.2 Drinking Water Pipeline Layout Showing Pressure for Branching-4 (FlowMaster)
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Fig F.3 Industrial Water Pipeline Layout Showing Pressure for Branching-4 (FlowMaster)
Table F.1: Pressure Details at Consumer Package Entry for Branching-4 Pipeline
Drinking Water Pipeline Industrial Water Pipeline
Available Pressure at Available Pressure at
Package Flow Rate Flow Rate
Package Entry Package Entry
(m3/h) (kgf/cm2) (mWc) (m3/h) (kgf/cm2) (mWc)
071-A HTSS-71A
1 4.76 47.56 4 5.57 55.72
SUBSTATTION (16/18)
071-A HTSS-71A
1 3.97 39.73 4 5.40 54.00
SUBSTATION (17/18)
077-02 FWPH for
26 3.64 36.38 - - -
MARODA-II
Total Flow Rate &
Minimum Pressure in 28 3.64 36.38 8 5.40 54.00
Branching-4
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Fig G.2 Drinking Water Pipeline Layout Showing Pressure for Branching-5 (FlowMaster)
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Fig G.3 Industrial Water Pipeline Layout Showing Pressure for Branching-5 (FlowMaster)
Table G.1: Pressure Details at Consumer Package Entry for Branching-5 Pipeline
Drinking Water Pipeline Industrial Water Pipeline
Available Pressure at Available Pressure at
Package Flow Rate Flow Rate
Package Entry Package Entry
(m3/h) (kgf/cm2) (mWc) (m3/h) (kgf/cm2) (mWc)
071-A HTSS-68
1 4.64 46.42 4 5.93 59.31
SUBSTATION (14/18)
77-02 EXTERNAL WATER
18.3333 4.64 46.42 50 5.93 59.31
SYSTEM for WTP-1 (URM)
077-02 EXTERNAL WATER
SYSTEM FOR WTP-3 & 4 18.3333 4.50 45.03 50 5.92 59.23
(URM)
077-02 EXTERNAL WATER
SYSTEM FOR WTP-2 18.3333 4.50 45.03 50 5.87 58.65
(URM)
117 PROJECT BUILDING
5 4.50 45.03 0 5.87 58.65
WELFARE
47 (URM) C-35
7 4.50 45.03 7 5.87 58.65
SUBSTATION
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70 AUGMENTATION OF
2 4.75 47.48 10 5.97 59.71
EXISTING MSDS
49-03 REHEATING
FURNACES FOR 5 4.74 47.40 50 5.25 52.45
UNIVERSAL RAIL MILL
125-02 (URM) ACVS FOR
URM & RAIL WELDING, 5 4.74 47.40 50 5.11 51.15
RAIL MILL
071-A HTSS-70
1 4.69 46.91 4 5.11 51.15
SUBSTATION (15/18)
077-02 FWPH for URM
26 4.50 45.03 - - -
AREA
Total Flow Rate &
Minimum Pressure in 107 4.74 47.40 275 5.11 51.15
Branching-5
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Fig H.2 Drinking Water Pipeline Layout Showing Pressure for Branching-6 (FlowMaster)
Fig H.3 Industrial Water Pipeline Layout Showing Pressure for Branching-6 (FlowMaster)
Table H.1: Pressure Details at Consumer Package Entry for Branching-6 Pipeline
Drinking Water Pipeline Industrial Water Pipeline
Flow Available Pressure at Available Pressure at
Package Flow Rate
Rate Package Entry Package Entry
(m3/h) (kgf/cm2) (mWc) (m3/h) (kgf/cm2) (mWc)
20 SINTER PLANT 15 4.89 48.86 150 58.41 5.84
071-A HTSS-43
1 4.87 48.70 4 58.41 5.84
SUBSTATION (1/18)
077-02 FWPH for SINTER
26 4.86 48.62 - - -
PLANT-III
Total Flow Rate &
Minimum Pressure in 42 4.86 48.62 154 58.41 5.84
Branching-6
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Fig I.2 Drinking Water Pipeline Layout Showing Pressure for Branching-7 (FlowMaster)
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Fig I.3 Industrial Water Pipeline Layout Showing Pressure for Branching-7 (FlowMaster)
Table I.1: Pressure Details at Consumer Package Entry for Branching-7 Pipeline
Drinking Water Pipeline Industrial Water Pipeline
Available Pressure at Available Pressure at
Package Flow Rate Flow Rate
Package Entry Package Entry
3 2 3
(m /h) (kgf/cm ) (mWc) (m /h) (kgf/cm2) (mWc)
Pump House-3 BASE
8 4.92 49.19 31 6.54 65.43
BLENDING PACKAGE
071-A HTSS-47 SUBSTATION
1 4.88 48.78 4 6.40 64.05
(4/18)
071-A HTSS-45 SUBSTATION
1 4.90 49.03 4 6.52 65.25
(2/18)
62 NEW COAL HANDLING
20 2.66 26.59 380 6.54 65.43
PLANT
071-A HTSS-60 SUBSTATION
1 2.62 26.19 4 6.50 64.97
(9/18)
122 LAB RMP-III 1 2.62 26.19 1 6.50 64.97
28 LDP 2 2.62 26.19 15 6.48 64.88
140 PIPE CONVEYOR 2 2.61 26.10 6 6.45 64.51
077-02 FWPH for REMP-III 26 2.65 26.51 - - -
Total Flow Rate & Minimum
62 2.61 26.10 445 6.40 64.05
Pressure in Branching-7
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Fig J.2 Drinking Water Pipeline Layout Showing Pressure for Branching-8 (FlowMaster)
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Fig J.3 Industrial Water Pipeline Layout Showing Pressure for Branching-8 (FlowMaster)
Table J.1: Pressure Details at Consumer Package Entry for Branching-8 Pipeline
Drinking Water Pipeline Industrial Water Pipeline
Available Pressure at Available Pressure at
Package Flow Rate Flow Rate
Package Entry Package Entry
(m3/h) (kgf/cm2) (mWc) (m3/h) (kgf/cm2) (mWc)
114 COMPRESSED AIR
5 4.80 48.05 130 5.96 59.55
STATION-4
071A HTSS-56 SUBSTATION
1 4.80 47.97 4 5.96 59.55
(7/18)
071A HTSS-57 SUBSTATION
1 4.80 47.97 4 5.96 59.55
(8/18)
117 PROJECT WELFARE
5 4.70 46.99 - - -
BUILDING
117 PROJECT BUILDING DNW 5 4.73 47.32 - - -
077-02 FWPH for BLAST
26 4.80 47.97 - - -
FURNACE
090A-LAB BLDG 1 4.70 46.99 1 5.96 59.55
076-GAS BOOSTING STATION 2 4.81 48.13 40 5.99 59.88
011-01C PBS DM PLANT 500 4.82 48.21 15 5.96 59.55
031-HMHS (TLRS) 5 4.82 48.21 15 5.95 59.47
010-BLAST FURNACE-8 120 4.83 48.29 1230 5.93 59.31
Total Flow Rate & Minimum
671 4.70 46.99 1439 5.93 59.31
Pressure in Branching-8
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Fig K.2 Drinking Water Pipeline Layout Showing Pressure for Branching-9 (FlowMaster)
Fig K.3 Industrial Water Pipeline Layout Showing Pressure for Branching-9 (FlowMaster)
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Table K.1: Pressure Details at Consumer Package Entry for Branching-9 Pipeline
Drinking Water Pipeline Industrial Water Pipeline
Available Pressure at Available Pressure at
Package Flow Rate Flow Rate
Package Entry Package Entry
(m3/h) (kgf/cm2) (mWc) (m3/h) (kgf/cm2) (mWc)
001 COKE OVEN
15 4.89 48.86 7.5 5.82 58.25
PROPER
002 CDCP 15 4.89 48.86 7.5 5.82 58.25
003A BY PRODUCT
15 4.89 48.86 375 5.82 58.25
PLAN
071A HTSS-48
1 4.89 48.86 4 5.82 58.25
SUBSTATION (5/18)
64 BASE BLENDING
8 4.89 48.86 31 5.82 58.25
PLANT (PUMPHOUSE 2 )
011-01B PBS-(BTPG) 1 4.78 47.80 15 5.87 58.65
64 BASE BLENDING
25 4.78 47.80 40 5.87 58.65
PLANT (PUMPHOUSE 1)
FWPH for CO 26 4.89 48.86 - - -
001-SE-01 1 4.82 48.21 2 5.87 58.65
Total Flow Rate &
Minimum Pressure in 107 4.78 47.80 482 5.82 58.25
Branching-9
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Fig L.2 Drinking Water Pipeline Layout Showing Pressure for Branching-10 (FlowMaster)
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Fig L.3 Industrial Water Pipeline Layout Showing Pressure for Branching-10 (FlowMaster)
Table L.1: Pressure Details at Consumer Package Entry for Branching-10 Pipeline
Drinking Water Pipeline Industrial Water Pipeline
Available Pressure at Available Pressure at
Package Flow Rate Flow Rate
Package Entry Package Entry
(m3/h) (kgf/cm2) (mWc) (m3/h) (kgf/cm2) (mWc)
125-01 ACVS FOR BOF &
5 4.70 46.99 100 5.13 51.31
CCP
49-1 REHEATING FURNACE
5 4.69 46.91 40 5.73 57.27
FOR BAR & ROD MILL
071-A HTSS-65
1 4.69 46.91 4 5.73 57.27
SUBSTATUION (13/18)
077-1 (NAMED AS 77-02 IN
PLOT PLAN) EXTERNAL 240 4.67 46.74 1200 5.73 57.35
WATER SYSTEM FOR SMS-III
077-02 EXTERNAL WATER
SYSTEM FOR WTP-6 & 7 0 4.69 46.91 345 5.73 57.27
(BRM)
077-02 EXTERNAL WATER
5 4.65 46.50 5 5.63 56.29
SYSTEM FOR WTP-5 (BRM)
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Results of Simulation:
Fig 4 Straight Pipe showing Pressure Value at Inlet & Outlet (FlowMaster)
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.........................(1)
Friction factor, f is calculated based on Colebrook-White and Hazen Williams equations as given
below,
If Reynold’s number, Re < 2000
.........................(2)
.........................(3)
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For Re > 4000, friction factor is calculated below based on equation (3),
𝟎.𝟐𝟓
f= = 0.02599
[𝒍𝒐𝒈((𝟎.𝟎𝟔𝟏/(𝟑.𝟕 𝑿 𝟒𝟗.𝟑𝟑)) + (𝟓.𝟕𝟒 / 𝟑𝟓𝟕𝟐𝟔.𝟒𝟐𝟒𝟑^𝟎.𝟗))]^𝟐
Therefore, pressure drop in straight pipe of DN50 is calculated based on simplified Darcy’s
equation (1) given below,