INDEXSrno.CALCULATIONSSheet no.1Air Flowrate Conversion12Chiller Calculation23Thermic Fluid Calcualtion34Pressure Drop Calculation45Brake Kilowatt calculation56LPG Vapor pressure Calculation67Nm3 to M3 Conversion78Pump Efficiency Calculation89Expansion Tank Volume Calculation910Air Flowrate for HSD fired Heater1011Specific Heat Calculations1112Heat Flux Calculation121314NOTE :Input CellOut Cell

Airflowrate conversionBACK TO INDEXAIR FLOWRATE CONVERSIONOUTPUTINPUT1AT NORMAL CONDITIONSSTANDARD CONDITIONSVolumetric Flowrate of Air from Standard ConditionsV10NM3/hrPressure1.013BarTemperature298KelvinVolumeCFMVolumetric Flowrate of Air from Actual ConditionsV20NM3/hr0M3/hrNORMAL CONDITIONS2AT STANDARD CONDITIONSPressure1.013BarVolumetric Flowrate of Air from Normal ConditionsV30SM3/hrTemperature273KelvinM3/hr45VolumeCFMCFM26.4860025Volumetric Flowrate of Air from Actual ConditionsV40SM3/hr0M3/hrACTUAL CONDITIONS3At ACTUAL CONDITIONSPressure1.023BarVolumetric Flowrate of Air from Normal ConditionsV50AM3/hrTemperature323KelvinVolumeCFMVolumetric Flowrate of Air from Standard ConditionsV60AM3/hr0M3/hr

Chiller UnitBACK TO INDEXCHILLER UNIT CALCULATION1Chiller for recovery unitVolumetric flowrate of Product450m3/hrDensity999kg/m3Integrated Part Load Value / Non Standard Part Load CalculationMass Flow rate of Product :( m1) 449550kg/hrSpecific Heat ( cp1)1.01 kcal/kg CiKw/Tr atTemperature in ( T1)38.3deg C100 % load0.777Temperature out ( T2)33.3deg C75 % load0.752DT ( T1-T2)5deg C50 % load0.77925 % load0.847 Heat Duty, m1*cp1*DT2270227.5Kcal/hrIPLV or NPLV0.7109589628Let Mass Flow rate of water m2kg/hrHeat gain for waterm2*cp2* DT2Kcal/hrHere, cp21.01 kcal/kg CWater Temperature in ( T3)7deg CWater Temperature out ( T4)12deg CDT2 ( T4-T3)5deg CHencem2*cp2* DT22270227.5Kg/hr(NOTE: Heat Gain = Heat Loss)m2449550Kg/hrChilled Water TR 750.2404163913TR( 1 TR = 3026 kcal/hr)Losses 5%Gross TR 787.7524372108TR2Vapour Recovery CondensorsMassflow rate of Product (m1) 200kg/hrSpecific Heat ( cp1)0.3782 kcal/kg CTemperature in ( T1)25deg CTemperature out ( T2)20deg CDT ( T1-T2)5deg Cm1*cp1*DT378.2Kcal/hrlatent heat()86.8Kcal/kg(Note: Phase Change)m1* 17360Kcal/hrTotal heat duty, (m1*cp1*DT + m1* )17738.2Kcal/hrHeat gain by water17738.2Kcal/hr(NOTE: Heat Gain = Heat Loss)Here, cp21.01 kcal/kg CWater Temperature in ( T3)7deg CWater Temperature out ( T4)12deg CDT2 ( T4-T3)5deg Cmass flow rate of water m23512.5148514851Kg/hrChilled Water TR 5.8619299405TRLosses5%Gross TR6.1550264375TRChilled Water TR for one No. VRC6.155TRNo Of VRC units operating at same condition1.000Total Chilled water TR6.16TRTotal Chiller capacity required for Styrene chiller + Nos. of VRC 794TR1Process LoadDiameter of Tank13MHeight of Tank26MVolume of the Tank3451.0395299684M3% of liquid Filled in tank100%Volume of liquid in Tank3451.0395299684M3Density Of Liquid907.5Kg/M3Mass of Liquid3131818.37344631KgInitial Temperature of Fluid20Deg CFinal Temperature of Fluid35Deg CDelta Temperature 15Deg CSpecific Heat of Liquid0.46Kcal/Kg.Deg CTotal Heat Load Required21609546.7767796Kcal2Heat Loss from the TankHeat Tranfer Coefficient (W/m2.Deg C)Heat Transfer Coefficient of Product5000Kcal/hr.m2.Deg CFlue Gases2000 - 5000Heat Transfer Coefficient of Outside Fluid5000Kcal/hr.m2.Deg CAir - Industrial Gases5000 - 10000Thickness of Plate0.01mOrganic Liquid5000Thermal Conductivity of Metal Plate48.48Kcal/hr.m.Deg COrganic Vapors5000Thickness of Insulation0.075mLight Hydrocarbons5000Thermal Conductivity of Insulation0.03786Kcal/hr.m.Deg CHeavy Hydrocarbons2000Overall Heat Transfer Coefficient0.5046455555Kcal/hr.m2.Deg CHeat Transfer Fluid5000Diameter of Tank13mHeight of Tank26mI/P5000W/m2.DegCSurface area of Tank1061.8583169134m2O/P4302.925989673Kcal/hr.m2.Deg CInitial Temperature of Fluid25Deg CFinal Temperature of Fluid50Deg CAmbient Air Temperature55Deg CMetal Thermal Conductivity48.48Kcal/hr.m.Deg CDelta T15Deg CInsulation Thermal Conductivity0.03786Kcal/hr.m.Deg CDelta T230Deg CDelta T lmtd13.9527656638Deg CHeat Loss from the Tank7476.758033785Kcal/hrTotal Head load21609546.7767796KcalTime required to rise the temperature2890.229519149hrs120.4262299645DaysTime required for per Degree rise in temperature8.028415331Days

Thermic FluidBACK TO INDEXTHERMIC FLUID HEATER CALCULATION1Given Heat Load4000000Kcal/HrThermic Fliud PropertiesAtmospheric170 Deg200 Deg220 DegSpecific Heat (Kcal/Kg.Deg C)0.4610.5840.6120.6212Thermic Fluid HeaterDensity (Kg/M3)875769745737Density737Kg/M3Viscosity (cP)29.61.0050.7180.65Specific Heat at given Temperature0.621Kcal/Kg Deg CTemperature in (T1)180Deg CTemperature Out (T2)220Deg CDelta T 40Deg CTHERMAL EXPANSION CALCULATIONMass Flowrate of Thermic Fluid 161030.595813205Kg/HrThermal Expansion Coefficient Of Therminol 550.000960 / Deg CVolumetric Flowrate218.4947025959M3/HrSystem Volume at Fill Temperature8.50 m3Ambient Temperature30 Deg C3HSD Fuel ConsumptionOperating Temperature220 Deg CDensity826Kg/M3Volume at Operating Temperature10.05 m3Calorific Value10500Kcal/KgExpanded Volume1.55 m3Mass Flowrate of Thermic Fluid 380.9523809524Kg/HrEXPANSION TANK VOLUME3.10 m3
Avinash Ashok Patil: Avinash Ashok Patil:Note:Thumb Rule:1/4 th full at room temp3/4 th full at operating conditionVolumetric Flowrate0.4612014297M3/Hr461.2014297244Lit/HrEfficiency Of TFH8700.00 %Operating Duty of Burner in terms of KilowattsMass Flowrate of Thermic Fluid 437.8762999453Kg/HrOperating load in Kcal/hr700000Volumetric Flowrate0.5301165859M3/Hr530.1165858902Lit/HrOperating load in kW813.9444444444Heater Actual Capacity4597701.14942529Kcal/hrAir Flowrate Calculation for HSD Fired Burner4Process LoadMass Flowrate of HSD 64.0000 Kg/hrDiameter of Tank14.5MMass Flowrate of Air1120.0000 Kg/hrHeight of Tank27MVolumetric Flowrate of Air914.2857 m3/hrVolume of the Tank4458.5090240665M3% of liquid Filled in tank25%Volume of liquid in Tank1114.6272560166M3Density Of Liquid1020Kg/M3Mass of Liquid1136919.80113695KgDelta Temperature 2Deg CSpecific Heat of Liquid0.54Kcal/Kg.Deg CTotal Heat Load Required1227873.3852279Kcal/HrTotal Hours of Heating24HrHeat Load 0.0511613911MKcal/Hr5Loses in TankHeat Transfer Coefficient on wet wall1722Kcal/hr.m2.Deg CNOTEHeat Transfer Coefficient on Dry wall4303Kcal/hr.m2.Deg CHeat Tranfer Coefficient (W/m2.Deg C)Thermal Conductivity of Metal48.48Kcal/hr.m.Deg C1Flue Gases2000 - 5000Thickness of Plate0.008m2Air - Industrial Gases5000 - 10000Thermal Conductivity of Insulation0.03786Kcal/hr.m.Deg C3Organic Liquid5000Thickness of Insulation0.1m4Organic Vapors5000Overall Heat Transfer Coeeficient0.3784598484Kcal/hr.m2.Deg C5Light Hydrocarbons5000Diameter of Tank17.5m6Heavy Hydrocarbons2000Height of Tank27m7Heat Transfer Fluid5000Surface area of Tank1484.4025288212m2Temperature of Liquid140Deg CI/P5000W/m2.DegCTemperature of Outside Medium13Deg CO/P4302.925989673Kcal/hr.m2.Deg CDelta Temp127Deg CHeat Loss Through Tank71346.9180091646Kcal/hrMetal Thermal Conductivity48.48Kcal/hr.m.Deg CInsulation Thermal Conductivity0.03786Kcal/hr.m.Deg C6Coil Length CalculationInlet Temperature of Hot Fluid200Deg COutlet Temperature of Hot Fluid170Deg CInlet Temperature of Cold Fluid120Deg COutlet Temperature of Cold Fluid140Deg CT(A)60Deg CT(B)50Deg CDelta T(LTMD)54.8481494775Deg COverall Heat Transfer Coefficient1116Kcal/hr.m2.Deg CHeat Load600000Kcal/hrArea of Coil9.8022342362m2Diameter of coil0.05mLength of Coil62.4029612817mPlate Thickness 0.004mDensity of Material7850Kg/m3Weight of Coil307.7901550178Kg

Pressure Drop CalculationBACK TO INDEX Pipe Line Pressure Drop CalculationsDiameter0.5meterVelocity0.001m/sE for CS0.000046m FittingEq. Length (m)Density1000kg/m3E for SS0.000015mOrdinary Ent.1.4Dynamic Viscosity0.001kg/m-sBorda Entrance2.52Length50meterViscosity Conversions90 Standard Elb.2.52FromTo90 L-Sweep Elb. 1.64Reynold's No.500Cst0Cp45 Elbow1.18Tee Side Outlet5.08Flow is Laminar0Cp0kg/msStraight Tee1.64Gate Valve0.543/4 Contraction0.540.000046mFor Laminar FlowFor Turbulent FlowFm0.032FmNAP0.0000001631mlcPERROR:#VALUE!mlcLamiar flow is independent of /D Input cellOutput cell

Brake Kilowatt BACK TO INDEXMOTOR RATINGMotor ratingInputsValueUnitsConversion355Flow80m3/hrPressure4Kg/cm2315Head30.88m250Specific Gravity0.896Head44.6428571429m200180Hydraulic Kilowatt6.0235621956kW160150Efficiency of Pump80%Flow 352.1979352396gpm132Head101.312335958ft125Brake Kilowatt9.2239041327kW110Efficiency65.3038248109%Valid for flow 100-1000 gpm & Head 50-300 feet90Efficiency of Motor88.1%7555Motor Rating required11.5167929012kW45No. Poles.2 Pole (3000 rpm)37Standard Motor Rating Available15kW302218.515IE2 Motor Rating (Bharat Bijlee)11Kilowatt2 pole (3000 rpm)4 pole (1500 rpm)6 pole (1000 rpm)9.33559595.1957.53159595.1955.52509595.194.93.720094.995.194.82.218094.89594.71.516094.794.994.61.115094.694.794.40.7513294.594.794.30.5512594.394.6940.3711094.194.593.79093.894.293.17593.29492.72 Pole (3000 rpm)5592.993.592.24 Pole (1500 rpm)4592.593.191.76 Pole (1000 rpm)379292.790.93091.392.390.42290.991.689.718.590.391.288.71589.490.6881188.889.887.29.388.189.3867.58788.784.35.585.587.781.83.783.286.379.82.281.384.378.11.579.682.875.91.177.481.472.90.7574.879.6690.5572.275.100.37070.10

LPG Vapor PressureBACK TO INDEXLPG Vapour Pressure Calculations (Temp Range -188 C to 642 C)ComponentABCDETmin (K)Tmax (K)Methane14.6667-570.9-3.33732.20E-091.31E-0590.67190.58Ethane20.6973-1134.1-5.2514-9.88E-116.77E-0690.35305.42Propane21.4469-1.46E+03-5.2613.28E-113.73E-0685.46369.82Butane27.0441-1.90E+03-7.1805-6.68E-114.22E-06134.86425.18Temp.= 973K700CVapour Pressure of Methane1.28E+04mmHgVapour Pressure of Ethane17882317524.60mmHgVapour Pressure of Propane57423244.06mmHgVapour Pressure of Butane42115875.17mmHgMole fraction of Methane0.5Mole fraction of EthaneMole fraction of Propane0.5Mole fraction of ButaneLPG Vapour Pressure28718029.7165258mmHg37786.8812059551Kg/cm2Input cellOutput cell

Nm3 to m3BACK TO INDEXNm3/hr to m3/hrVolume in Nm3/hrVn1200 Nm/hrPressure under NTPPn1.0130000 BarTemperature under NTP in Deg KTn273 KRelative Humidity at siteRH10000 %Temperature at site in Deg CTc30 Deg CTemperature at site in Deg KTs303 KAtmospheric pressure at sitePs1.013000 BarVapour PressureVp0.0413996 Bar0.1597Actual volume in m3/hrVs1388.6185611233Actual volume in cfmVs817.202023221

Pump Efficiency BACK TO INDEXEFFICIENCY OF PUMPSCENTRIFUGALType of PumpCENTRIFUGALRECIPROCATINGApplicable Range of Flowrate3 - 2000 M3/HRGEARSCREWCapacity3.0000 M3/HRPUMPXabcdX1.0986122887CENTRIFUGAL1.0986-14.3525.39-1.8710.0213a-14.35RECIPROCATING1.09869.49968562.50584-17.02891.549111b25.39GEAR1.732119.922373.40776300c-1.871SCREW3.000040.5950.3154-0.00050d0.0213Efficiency1131.38 %

EXPANSION TANK VOLUMEBACK TO INDEXEXPANSION TANK VOLUME CALCULATIONTemperatureDesign CaseCheck CaseTemp Density Temp Density Minimum Operating Temp25.00 Deg C875.00 Kg/m3200.00 Deg C745.00 Kg/m3Maximum Operating temp200.00 Deg C745.00 Kg/m3220.00 Deg C737.00 Kg/m3Volume of Process line 8.00 m3Volume of Heater System0.50 m3Total System volume8.50 m3Mass of total hold up7437.50 KgVolume of oil required based on density at max operating temp9.98 m3Expansion Volume1.48 m3With 20% margin1.78 m3Check Case (For volume with margin)Volume of oil required based on density at min operating temp9.98 m3Volume of oil required based on density at max operating temp10.09 m3Expansion Volume0.11 m3Max Expansion of volume including process upset1.59 m3Design is adequateNote:Thumb Rule:1/4 th full at room temp3/4 th full at operating conditionVolume of Expansion Tank Required3.56 m3
Avinash Ashok Patil: Avinash Ashok Patil:Note:Thumb Rule:1/4 th full at room temp3/4 th full at operating condition

Air FlowrateBACK TO INDEXAir Flowrate Calculation for HSD fired HeaterHSD Calorific Value10500 Kcal/Kg% of Sulphur0.05 - 0.25 %Combustion Products of HSD are CO2,H20 & SO2Burning 1 Kg of HSD release :CO23.15 KgH2O1.08 KgSO20.04 KgTotal O2 Required 3.27 KgO2 present in Fuel0.00 KgQuantity of Dry Air Required per kilograms of HSD14.22 KgHSD Consumed per hour64.0000 Kg/hrAir required 909.9130 Kg/hr% Excess Air Considered15.00%Total Air Consumption1046.4000 Kg/hrDensity Of Air1.2900 Kg/m3Total Air Consumption in M3811.1628 m3/hr

Specific HeatBACK TO INDEXCONSTANTABCDETminTmaxProductformulaMolecular wtSpecific HeatPRODUCTSStyreneC8H8104128.2432942663Styrene71.2010.0547670.00064793-0.00000069870.0000000002-173 Deg C1227 Deg CVAMC4H6O28698.7752825634VAM27.6640.233660.000062106-0.00000016970.0000000001-173 Deg C1227 Deg CSpecific HeatCp = A + BT + CT^2 + DT^3 + ET^4 (KJ/Kmol.K)Select the ProductStyreneSelect from Dropdown listFormulaC8H8Molecular Weight104Temperature25.00 Deg CTemperature298.0000 KOperating TemperatureSpecific Heat128.24329430.2945088605

Heat FluxBACK TO INDEXASME Sec 2 Part.DCS A36SS 304InsulationHeat Flux CalculationMaterialTempThermal ConductivityKcal/(Deg C. Hr. m)TempThermal ConductivityKcal/(Deg C. Hr. m)MaterialThermal ConductivityKcal/(Deg C. Hr. m)SS 3042060.451.94358445132014.812.7278981768Rock wool0.0450.038699690420750Inside Temperature20.00 Deg CMean Temperature50.0000 Deg CCS A365059.851.42758857935015.313.1578947368Mineral wool0.040.034399724850725outside Temperature80.00 Deg C7558.950.65359477127515.813.5878912969Glass Wool0.040.034399724875700Plate MaterialSS 3041005849.879600963210016.213.9318885449100675Thickness of Material0.0100 m1255749.019607843112516.614.2758857929505050125650Thermal Conductivity Of Material 113.1578947415055.948.07361541111501714.619883040913.157894736813.157894736813.1578947368150625InsulationRock wool17554.747.04162366717517.515.049879601175600Thickness of Material0.0500 m20053.646.09563123520017.915.393876849200575Thermal Conductivity Of Material 20.038699690422552.545.149638802922518.315.73787409722555025051.444.203646370825018.615.995872033250525Heat Flow46.4123271127550.343.25765393882751916.33986928127550030049.242.311661506730019.416.6838665291300475Diameter of Tank13.00m32548.141.365669074632519.817.0278637771325450Height of Tank26.00m3504740.419676642635020.117.2858617131350425Surface area of Tank1327.32m237545.939.473684210537520.517.629858961137540040044.938.613691090540020.817.8878568971400375Net heat loss/ gain through Tank61604.1444 Kcal/hr42543.837.667698658442521.218.231854145242535045042.736.721706226445021.518.489852081245032547541.635.775713794347521.918.833849329247530050040.534.829721362250022.219.091847265250027552539.333.797729618252522.619.435844513252525055038.232.851737186155022.919.69384244935502255753731.81974544257523.320.037839697357520060035.830.78775369860023.620.295837633360017562534.729.84176126596252420.639834881362515065033.528.809769521865024.320.897832817365012567532.327.777777777867524.721.241830065467510070031.226.83178534577002521.49982800147007572530.125.885792913772525.421.84382524947255075029.125.025799793675025.722.101823185475020