PP7 EXTENSION 3 PROJECTINDUSTRIAL & OILY WATER DRAINAGE EQUIPMENT & PIPE LINE SIZING

TABLE OF CONTENTS

Table of Contents 1

1. Purpose 2

2. Design Basis & Assumptions 2

3. References 3

4. Attachments 3

5. Computation 3

6. Result & Conclusion 6

PP7 Extension 3 Project - Units 23 & 24 SAR687-XW01-OOGM-B22200 Sheet REV DOILY WATER EQUIPMENT & PIPE LINE SIZING 1

1. PURPOSE

1.1 To calculate the individual and common oil collection pit size for the GSU and Unit auxilliary transformer.1.2 To calculate the G.T wash water collection tank size.1.3 To calculate the G.T fuel oil drain tank size.1.4 To calculate capacity & Head of common oil collection pit sump pump.1.5 To calculate capacity & Head of G T wash water tank sump pump.1.6 To calculate capacity & Head of G T fuel oil drain tank drain pump.1.7 To calculate sump pumps (common oil collection pit & G T wash water tank) discharge pipe size

2. DESIGN BASIS & ASSUMPTION

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8 Individual GT Fuel Oil drain Tank capacity has been selected as 2.0 m3 per contract agreement.

2.9

2.10

2.11

2.12

2.13

2.14

2.15 For sizing of the sump pump discharge pipe, a velocity limit of 2.0 m/sec has been considered in this calculation.

PP7 Extension 3 Project - Units 23 & 24 SAR687-XW01-OOGM-B22200 Sheet REV DOILY WATER EQUIPMENT & PIPE LINE SIZING 2

The individual oil collection pit size for the GSU and unit auxilliary transformer shall hold 50% of the individual transformer oil capacity. The LV Transformer 00UBD near the Electrical Bldg shall have a pit underneath with sufficient capacity for oil content and 10 minutes deluge water.Per Reference 3.1, the common oil collection pit size for the GSU and unit auxilliary transformer shall hold 100% of the GSU transformer oil capacity and 10 minutes fire water spillage in the event of fire Areva dwg for Unit Auxiliary Transformer (Reference 3.5) indicates both oil volume as 2848 litre, and Oil weight as 3200 Kg. But oil volume data appears to be wrong (density of oil considered as more than 1.0), therefore a density of 900 kg/m3 (0.9 gm/cc) for transformer oil have been assumed and oil volume have been re-calulated accordingly. Even though the fluid within the common oil collection pit would be a mixture of oil & water, but for the purpose of working out the head of collection pit sump pump, fluid is considered as only water. A margin of 10% on the calculated head of pump has been considered to compensate the approximation in fluid quality considered in this calculation.

The location of common G T wash water tank has yet to be identified on the Plant Layout Dwg (Reference 3.8). Therefore for the purpose of estimation of pipe length (from GT # 23 & 24 wash water tank to existing wash water tank of unit # 21 & 22), the GT wash water tank has been assumed to be located towards eastern side of Unit # 24. This assumption would result in maximum length of piping thus a conservative design.

Detail piping layout is yet to be developed, therefore all pipe length have been estimated based on present layout and a margin of 50% over the estimated length has been considered in this calculation for the purpose of pump head.One wash water volume (for both compressor & turbine ) of GT # 23, & one wash water volume (both compressor & turbine ) of GT # 24 has been considered for sizing the common GT wash water collection tank. If more than one wash is required per day, then the collected wash water would be first transferred to existing wash water drain tank of unit 21 & 22 through sump pump so as to accomodate fresh wash water volume of the second wash.

For sizing the capacity of sump pump located at common transformer oil collection pit, decanting time of collection pit has been considered as 5 Hrs. For working out the static head of the sump pump located at common transformer oil collection pit, a depth of 5.0m has been considered for collection pit. For sizing the capacity of sump pump located at G T Wash Water tank, a decanting time of 40 min has been considered in this calculation.

For working out the static head of the sump pump located at G T Wash Water tank, a depth of 3.0m , an elevation difference of 1.0m with respect to existing Wash Water tank of units 21 & 22.

For sizing the capacity of sump pump located at G T Oil Drain Tank, a decanting time of 0.5 hrs has been considered in this calculation. For working out the static head of the sump pump located at G T Oil Drain tank, a depth of 3.0m has been considered for GT Fuel Oil drain tank.

3. REFERENCES

3.13.2 Siemens Letter No: SAR687-0401-3574-SAG/BEM 0175 Dated 2004-09-01 (Attachment -4.1).3.3 Calculation fire fighting system and pipe line sizing doc. No. SAR687-XW01-OOSG-B22100, Rev B3.4 Hyundai transformer outline dwg for 132 kv GSU for oil volume, Rev 1 (Attachment 4.2)

3.5

3.6 Flow Diagram : Water Oil & GT Wash Water Drainage System, Dwg No: SAR-687-XG07-00GM-B21800 Rev-C (Att-4.4)3.7 General Layout PP7 Ext-III, Dwg No: SAR 687-UC07-UZ-010001 Rev- B3.8 Plant Layout PP7 Ext-III, Dwg No: SAR 687-UC07-UZ-010002 Rev- B3.9 PP7-Ext-II Site Utility Layout, Dwg No: SBG-GEX-1000, Rev-07

3.10 PP7-Ext-II Equipment Arrangement Floor Plan Unit 21, 22 , Dwg No: SBG-MEX-3410, Rev-03.11 Crane Handbook (Attachment 4.5)

4. ATTACHMENTS4.1 Siemens Letter No: SAR687-0401-3574-SAG/BEM 0175 Dated 2004-09-01 (2 pages).4.2 Dimension drawing for GSU transformer by Hyundai, Rev 1 (1 page)4.3

4.4 P & ID : Water Oil & GT Wash Water Drainage System, Dwg No: SAR-687-XG07-00GM-B23200 Rev-B (1 page)4.5 Extract of Crane Hand Book for D'arcy formula (2 pages).4.6 Schematic pipe layout sketch (1 page)4.7 Equivalent pipe lengths for various sections ( 1 page)4.8 Extract of Crane Hand Book for L/D ratios (2 pages).

5. COMPUTATION5.1 Calculation of GSU transf., unit auxilliary transf. & LV transf. 00UBD, 23/24BFT individual oil pit Capacity

a Oil volume for the GSU transformer = 56000 lit Ref. 3.4b Oil wight for the unit auxilliary transformer = 3200 kg Ref. 3.5c Density of the transformer oil = 0.9 gm/c.c Ref 2.3d Oil volume for the unit auxilliary transformer = 3555.6 lite Size of the oil pits below the transformers = 50 % of oil capacity of the transformer Ref. 2.1f Req. size of the oil pits below unit auxilliary transformer 1777.8 lit i.e 1.8

(5.1d X 5.1e)g Selected Capacity of the unit aux transformer oil p 1.8 (Liquid Volume)h Req. size of the oil pit below GSU transformer = 28000 lit i.e 28

(5.1a X 5.1e) i Selected Capacity of the GSU transformer oil pit 28 (Liquid Volume)j Fire water Flow Rate for GSU Transformer during fire = 5119 lpm Ref. 3.3, item 5.1.7k Duration of fire water flow considered = 10 minute Ref 2.2l Total fire fighting water volume required 51190 lit

m Required size of the common oil pit (5.1 a + 5.1 l) = 107190 lit i.e 107.2n Selected Capcity of the common oil collection pit = 108.0 (Liquid Volume)o Oil volume for the LV transformer 00UBD = 1305.0 litp Fire water Flow Rate for LV Transformer during fire = 380 lpmq Duration of fire water flow considered = 10 minute Ref 2.2r Total fire fighting water volume required 3800 lits Required size of the common oil pit (5.1 o + 5.1 r) = 5105.0 lit i.e 5.1t Selected Capacity of the LV Transformer pit = 5.1 (Liquid Volume)u Oil volume for the LV transformer 23/24BFT = 510.0 litw Selected Capacity for 23/24BFT Transf. pit 0.51 (Liquid Volume)

5.2 Calculation of GT wash water collection tank sizea Volume of water required for 1 water wash per GT = 1315 gal i.e 5.0 Ref 4.1b Volume of wash water for 2 GT for 1 wash = 10.0c Selected Capacity of the GT WW Collection Tank = 10.0 (Liquid Volume)

5.3 Calculation of GT fuel oil drain tank sizea Selected size of the GT fuel oil drain tank = 2 Ref 2.8

5.4 Calculation of sump pump capacity for the common oil collection pit.a Volume of the oily water to be transferred by the pump = 108.0 Ref. 5.1 nb Duration considered to empty the tank = 5 hr Ref 2.9c Capacity of the sump pump for the common oil pit = 22

(5.4a / 5.4b)PP7 Extension 3 Project - Units 23 & 24

SAR687-XW01-OOGM-B22200Sheet

REV DOILY WATER EQUIPMENT & PIPE LINE SIZING 3

Design Criteria - Water oil, wash water drain and oily water drainage System ( Doc No: SAR687-XU00-00GM-B20800, Rev-B)

Areva dimension drawing for Unit auxilliary transformer for oil weight, Rev 2 & ABB dimension drawing for LV transformer 00UBD for oil weight, Rev 1 (Attachment 4.3)

Areva dimension drawing for Unit auxilliary transformer for oil weight, Rev 2 & ABB dimension drawing for LV transformer 00UBD for oil weight, Rev 1 (3 pages)

m3

m3

m3

m3

m3

m3

m3

m3

m3

m3

m3

m3

m3

m3

m3/hr

5.5 Calculation of sump pump capacity for the wash water tank.a Vol. of the wash water to be transferred by the pump = 10 Ref. 5.2 cb Duration considered to empty the tank = 40 min 0.6666667 hr Ref 2.11c Capacity of the sump pump for the wash water tank = 15

(5.5a / 5.5b)

5.6 Calculation of sump pump capacity for the fuel oil drain tank.a Vol. of GT drain oil to be transferred by the pump = 2 Ref. 5.3ab Duration considered to empty the tank = 0.5 hr Ref 2.13c Capacity of the sump pump for the fuel oil drain tank = 4

(5.6a / 5.6b)

5.7 Calculation of sump pump head & discharge pipe size for the common oil collection pit.5.7.1 Calculation of pipe size

a Fuel oil flow at the pump discharge = 22 Refer 5.4cb Maximum recommended flow velocity = 2.0 m/s Refer 2.15c Flow area required for this section = 0.003056

[ 5.7.1a / 5.7.1b ]d Pipe diameter required in this section = 62.4 mm

e Selected pipe size for this section (NB) = 80 mmf Pipe outside diameter (OD) = 88.90 mm (considering sch 40 pipe)g Thickness of the pipe (t) = 5.49 mm (considering sch 40 pipe)h Actual pipe inside diameter = 77.92 mm i.e 0.256 ft

[ 5.7.1f - 2 X 5.7.1g ] i.e 3.068 ini Actual velocity of the oily water = 1.28 m/s i.e 4.20 ft/sec i.e < 2.0m/sec

5.7.2 Calculation of pressure drop in the pump discharge pipe lineAs per D'arcy formula pressure drop in psi is given by Refer 4.5

Pressure drop = ….Eq - 1144 X D X 2g

where, r = density in lb/cu.ftf = friction factorL = Equivalent length of pipe in ft.v = mean velocity of flow in ft/secD = internal diameter of pipe in ftg =

a Density of the fluid assumed = 1.0 gm/ccb Viscosity of water at room temperature = 1.000 cp Ref 2.4c Reynolds number = 6.31 X rate of flow in lb/hr Refer 4.5

internal dia in inch X viscosity in centipoise= 99763

From Reynolds no. vs friction factor chart in page 3-9 of CRANE handbook Refer 4.5Friction factor of the pipe for oil flow = 0.023 (for Reynolds no. >2000)

= 0.00 (for Reynolds no. <2000)Putting the following values in equation 1,

r = 1.0000 gm/c.c i.e 62.43 lb/cu.ftf = 0.02300L = 156.0 m i.e 511.81 ft Ref 4.7v = 4.2028 ft/secD = 0.256 ft g = 32.20

d Pressure drop in the fuel oil line in this section = 5.47545 psi Refer Eq 1e Frictional head loss in the discharge line = 3.85 MLC

[ 5.7.2d / 5.7.2a ]

5.7.3 Calculation of common oil collection pit sump pump heada Friction Head loss in the discharge line = 3.85 MLCb Depth of the common oil collection pit considered = 5 m Ref 2.10c Required head of the pump for common oil collection pit 8.85 MLC

Margin considered 10 %d Selected pump head for the common oil collection pit = 10 MLC

PP7 Extension 3 Project - Units 23 & 24SAR687-XW01-OOGM-B22200

SheetREV DOILY WATER EQUIPMENT & PIPE LINE SIZING 4

m3

m3/hr

m3

m3/hr

m3/hr

m2

[ (5.7.1c X 4 / p )^0.5 ]

[ 5.7.1a / (p (5.7.1h)^2)/4 ]

r X f X L X v2

acceleration due to gravity, 32.2 ft/s2

ft/s2

5.8 Calculation of sump pump head & discharge pipe size for the GT wash water collection tank.5.8.1 Calculation of pipe size

a Wash water flow at the pump discharge = 15 Refer 5.5cb Maximum recommended flow velocity = 2.0 m/s Refer 2.15c Flow area required for this section = 0.002083

[ 5.8.1a / 5.8.1b ]d Pipe diameter required in this section = 51.5 mm

e Selected pipe size for this section (NB) = 50 mmf Pipe outside diameter (OD) = 60.30 mm (considering sch 40 pipe)g Thickness of the pipe (t) = 3.91 mm (considering sch 40 pipe)h Actual pipe inside diameter = 52.48 mm i.e 0.172 ft

[ 5.8.1f - 2 X 5.8.1g ] i.e 2.066 ini Actual velocity of the wash water = 1.93 m/s i.e 6.32 ft/sec i.e < 2.0 m/sec

5.8.2 Calculation of pressure drop in the pump discharge pipe lineAs per D'arcy formula pressure drop in psi is given by Refer 4.5

Pressure drop = ….Eq - 1144 X D X 2g

where, r = density in lb/cu.ftf = friction factorL = Equivalent length of pipe in ft.v = mean velocity of flow in ft/secD = internal diameter of pipe in ftg =

a Density of the GT wash water = 1.0 gm/ccb Viscosity of water at room temperature = 1 cpc Reynolds number = 6.31 X rate of flow in lb/hr Refer 4.5

internal dia in inch X viscosity in centipoise= 100994

From Reynolds no. vs friction factor chart in page 3-9 of CRANE handbook Refer 4.5Friction factor of the pipe for wash water flow = 0.0225 (for Reynolds no. >2000)

= 0.0000 (for Reynolds no. <2000)Putting the following values in equation 1,

r = 1.0000 gm/c.c i.e 62.43 lb/cu.ftf = 0.02250L = 74.0 m i.e 242.78 ft Ref 4.7v = 6.3172 ft/secD = 0.172 ft g = 32.20

d Pressure drop in the wash water drain line in this section 8.52303 psi Refer Eq 1e Head loss in the discharge line = 5.99 MLC

[ 5.5.2d / 5.5.2a ]

5.8.3 Calculation of GT wash water sump pump heada Frictional head loss in the discharge line = 5.99 MLC Ref 5.8.2 eb Depth of the GT Wash Water collection tank considered= 4 m Ref 2.12c Required head of the GT wash water pump = 9.99 MLC

Margin considered 10 %d Selected GT wash water pump head = 11.00 MLC

5.9 Calculation of sump pump head for the GT fuel drain oil tank.a Discharge head assumed tanker loading = 3 mb Depth of the GT fuel oil drain tank considered = 3 m Ref 2.14c Required head of the pump for GT drain oil tank = 6 MLCd Selected pump head for the GT drain oil tank = 7 MLC

5.10 Drain pipes from the individual transformer pits to common collection tanka Drain pipe from the GSU Transformer pit = 200 mm (Assumed)b Drain pipe from the Unit Auxiliary Transformer pit 150 mm (Assumed)

5.11 LV transformer 00UBD pit will be provided with truck emptying facilities (50mm size)

PP7 Extension 3 Project - Units 23 & 24SAR687-XW01-OOGM-B22200

SheetREV DOILY WATER EQUIPMENT & PIPE LINE SIZING 5

m3/hr

m2

[ (5.8.1c X 4 / p )^0.5 ]

[ 5.8.1a / (p (5.8.1h)^2)/4 ]

r X f X L X v2

acceleration due to gravity, 32.2 ft/s2

ft/s2

6.0 RESULT & CONCLUSION6.1 Individual and common oil collection pit capcity for the GSU and Unit auxilliary transformer.

Capacity of the individual oil collection pits under unit transformer 1.8 (Liquid Volume Refer 5.1 gCapacity of the individual oil collection pit under GSU transformer 28 (Liquid Volume Refer 5.1 iCapacity of the individual oil collection pit under LV transformer 5.1 (Liquid Volume Refer 5.1 tCapacity of the common oil collection pit 108.0 (Liquid Volume Refer 5.1 n

6.2 G.T wash water collection tank size. 10 (Liquid Volume Refer 5.2c

6.3 G.T fuel oil drain tank size. 2 Refer 5.3a

6.4 Capacity & Head of common oil collection pit sump pump.Sump pump capacity 22 Refer 5.4cSump pump head 10 MLC Refer 5.7.3d

6.5 Capacity & Head of G T wash water tank sump pump.Sump pump capacity 15 Refer 5.5cSump pump head 11 MLC Refer 5.8.3d

6.6 Capacity & Head of G T fuel oil drain tank drain pump.Sump pump capacity 4 Refer 5.6cSump pump head 7 MLC Refer 5.9d

6.7 Sump pumps (common oil collection pit & G T wash water tank) discharge pipe size Sump pump for common oil collection pit 80 mm Refer 5.7.1eSump pump GT wash water tank 50 mm Refer 5.8.1e

6.8 Transformer pits drain pipes (GSU & Unit Auxiliary Transfromers)GSU Transformer pit drain pipe 200 mm Refer 5.10 aUnit Auxiliary Transformer pit drain pipe 150 mm Refer 5.10 b

6.9 Individual and Common oil collection pit capacity for the GSU, Unit auxilliary & LV transformer.Size of the individual oil collection pits under unit auxiliary transfor Refer to Relevant Civil DwgSize of the individual oil collection pit under GSU transformer Refer to Relevant Civil DwgSize of the individual oil collection pit under LV transformer Refer to Relevant Civil DwgSize of the individual oil collection pit under 23BFT & 24BFT transfo Refer to Relevant Civil Dwg

Width (mm) Remark

8500.0 4500.0 2823.5 500.0 3323.5 3300.0

3600.0 2000.0 1388.9 400.0 1788.9 1800.0

Size of the GT Drain Tank Pit 3000.0 2225.0 - - - TBD

PP7 Extension 3 Project - Units 23 & 24 SAR687-XW01-OOGM-B22200 Sheet REV D

m3

m3

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m3

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m3/hr

m3/hr

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Length (mm)

Liquid Level (mm)

Free Board (mm)

Depth (mm)

Use Depth (mm)

Size of the common oil collection Tank

Size of the GT Wash Water Collectiom Tank

Awaiting Vendor Dwg

OILY WATER EQUIPMENT & PIPE LINE SIZINGSAR687-XW01-OOGM-B22200

6REV D