ATMOSPHERIC BLOWDOWN TANK

PROCESS DESIGN REPORT

Client's Name: Galliford Try

Contractor's Name:

Project Title: Hull Biomass UK LLP 1

Location: Hull, United Kingdom

Job Number: MI-17085

HP Document No. MI-17085-PR-CR-002

Client Doc. No. HULL_06_SPEC_10_51726_0

Current Revision: 4 - Re-Issued for Review

4 22/08/17 Re-Issued for Review D.L. - -

3 13/06/17 Re-Issued for Review G.N. D.L. -

2 30/05/17 Latest Issue S.P. - -

1 04/05/17 Re-Issued for Review D.L. - -

Prepared By Checked By Approved By
Revision Date Description
Signatures

This document is issued by Harris Pye DMCC, Dubai UAE. The information contained in this document is the confidential property of
Harris Pye. It cannot be disclosed, copied or used for any purpose without written approval from Harris Pye. If you are not authorised
to possess this document, please destroy it immediately.
 Client: Galliford Try Doc. No. MI-17085-PR-CR-002
Project: Hull Biomass UK LLP 1 Tag No. T-06-17023
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
2 of 49_____
PROCESS DESIGN REPORT 4 22/08/17

REVISION HISTORY

Rev. Date Description Comments / Revised parts

0 21/04/17 Re-Issued for Review First revision

1 04/05/17 Re-Issued for Review Second Revision

2 13/06/17 Re-Issued for Review Third Revision

3 13/06/2017 Re-Issued for Review Fourth Revision

4 8/22/2017 Re-Issued for Review Review of all the calculations

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 Client: Galliford Try Doc. No. MI-17085-PR-CR-002
Project: Hull Biomass UK LLP 1 Tag No. T-06-17023
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 4 22/08/17 4 of 49_____

TABLE OF CONTENTS

Revision History 2
Contents 3
Design Input Data 4
Assumptions 5
Nozzles Sizing 6
N1 - Inlet 6
N2 - Deaerator Feedwater Tank Drain and Overflow 6
N3 - Boiler Intermittent Blowdown 8
N4 - Sootblower Condensate 11
N5 - Flash Tank Liquor 13
N6 - Service Water 14
N7 - Vent 14
N8 - Water Outlet 17
N9 - Drain 17
Instrumentation 17
N10 - Level Indicator Transmitter 17
N11 - Pressure Indicator Transmitter 18
N12 - Temperature Indicator Transmitter 18
Vessel Sizing 20
Vessel Diameter for Gravity Separation 20
Calculation of Vessel Height 22
References 24

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 Client: Galliford Try Doc. No. MI-17085-PR-CR-002
Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 6 of 49_ ____
4 22/08/17

DESIGN INPUT DATA

Flash Tank Design Data Units Value

Operating Pressure [bar(a)] 1.01
Operating Temperature [°C] 100.0
Design Pressure [bar(a)] 1.5
Design Temperature [°C] 260.0

Blowdown flash Intermittent Sootblower Deaerator

Stream Description Units
tank Blowdown Condensate Overflow
Flow Rate [kg/h] 738.3 2,000 1,000 1,020
[kg/s] 0.205 0.556 0.278 0.283
Pressure [bar(a)] 3.40 48.80 28.75 3.46
Temperature [°C] 40.0 262.4 231.5 138.5
Saturation Temperature [°C] 137.8 262.4 231.5 138.5
Enthalphy [kJ/kg] 167.8 1,146.9 997.3 582.6
Quality [-] 0.000 0.000 0.000 0.000
Density [kg/m³] 928.0 779.78 825.09 927.50
Viscosity [cP] 0.200 0.101 0.115 0.199
Volumetric Flow [m³/s] 0.00022 0.0007 0.0003 0.0003
Specific Heat [kJ/kg K] 4.281 5.012 4.695 4.283
Thermal Conduct. [W/m K] 0.685 0.602 0.638 0.685
Notes:
(1) Flash Steam and liquid Outlet stream properties are calculated by heat and mass balance.

Physical Constants Symbol Unit Value

Acceleration of gravity g [m/s²] 9.81
Pi π [-] 3.14

After Flashing

Blowdown flash Intermittent Sootblower Deaerator

Stream Description Units
tank Blowdown Condensate Overflow
Flow Rate [kg/h] 738.3 2,000 1,000 1020.0
[kg/s] 0.205 0.556 0.278 0.283
Pressure [bar(a)] 1.01 1.01 1.01 1.01
Temperature [°C] 40.1 100.0 100.0 100.0
Enthalphy [kJ/kg] 167.8 1146.9 997.3 582.6
Quality [-] 0.000 0.323 0.256 0.072
Density [kg/m³] 992.2 1.85 2.33 8.19
Volumetric Flow [m³/s] 0.00021 0.2999 0.1192 0.0346
Specific Heat [kJ/kg K] 4.217 3.527 3.669 4.062
Notes:
(1) Flash Steam and liquid Outlet stream properties are calculated by heat and mass balance.

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 Client: Galliford Try Doc. No. MI-17085-PR-CR-002
Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 7 of 49_ ____
4 22/08/17

Stream Intermittent
Units Blowdown flash tank Sootblower Condensate Deaerator Overflow
Description Blowdown
Liquid Vapour Liquid Vapour Liquid Vapour Liquid Vapour
Flow Rate [kg/h] 738.30 0.00 1354.92 645.08 743.77 256.23 946.12 73.88
[kg/s] 0.21 0.00 0.38 0.18 0.21 0.07 0.26 0.02
Density [kg/m³] 992.16 0.00 1.85 0.60 958.35 0.60 958.35 0.60
Volume flow rate [m³/s] 0.0002 0.00 0.2032 0.30 0.0002 0.12 0.0003 0.03
Pressure [bar(a)] 1.01 0.00 1.01 1.01 1.01 1.01 1.01 1.01
Temperature [°C] 40.07 0.00 100.01 100.01 100.01 100.01 100.01 100.01
Enthalphy [kJ/kg] 167.90 0.00 419.13 2675.58 419.13 2675.58 419.13 2675.58

Stream Description Units Two Phase Inlet into the vessel

Liquid Vapour
Flow Rate [kg/h] 3,783.1 975.2
[kg/s] 1.05 0.27
Pressure [bar(a)] 1.01 1.01
Daniele Lanzano:
Temperature [°C] 40.1 40.1
too low...
Enthalphy [kW] 1,425.30 8,027
Quality [-] 0 1
Density [kg/m³] 958.348 0.598
Viscosity [cP] 0.282 0.012
Volumetric Flow [m³/s] 0.0011 0.453
Specific Heat [kJ/kg K] 4.217 2.078
Thermal Conductivity [W/m K] 0.678 0.025
Notes:
(1) Two-Phase mixture after blowdown valve, in the blowdown line.
(2) Flash Steam and liquid Outlet stream properties are calculated by heat and mass balance.
(3) Mixture viscosity approximated with saturated liquid viscosity.

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Client: Galliford Try Doc. No. MI-17085-PR-CR-002

Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 4 22/08/17

692284769.xlsx
 Client: Galliford Try Doc. No. MI-17085-PR-CR-002
Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 4 22/08/17 9 of 49_____

ASSUMPTIONS

The following assumptions were made for the design of the atmospheric blowdown tank:

1. The operating pressure in the flash tank is established by the backpressure in the vent line and associated piping. The vessel
operating pressure shall not exceed 5 psi (0.35 barg). The pressure will be the atmospheric pressure plus the pressure drops
of the flashed steam in the vent line. In the following, a preliminary vent piping routing is assumed for back pressure
calculation, to be verified after pipe routing and vessel sizing. Tipically, the backpressure is limited to 1 Psi (0.069 barg) by
2. design.
The vapor-liquid separation in the vessel is mainly achieved by gravity settling of the liquid droplets and by action of the
inlet device. Tipically, the backpressure is limited to 1 Psi (0.069 barg) by design.
3. For gravity settling, the momentum equation reduces to a balance of the gravity and drag forces at steady state. This allows
to calculate a terminal velocity, which is the superficial velocity around the liquid droplets under equilibrium conditions.
The sizing of the vessel diameter will be made here according to [ref 3], so that the steam space velocity is ≤ 11 ft/s (3.35
m/s).
4. The Dearator Overflow has been assumed as the 21% of the total dearator inlet flow.

5. The boiler drains are assumed to be cold (T ≤ 40°C) and at atmospheric pressure (boiler drained after shutdown).
Therefore, the cold drained water has a small residence time in the vessel.

6. The standing liquid in the vessel is assumed to be pseudo-stratified, and cold water from the bottom part of the vessel is
discharged after cooling to ≤ 40°C. The water remaining in the vessel after discharge is cooled down. typically, the quantity
of water to be cooled lies below the NWL. The cooling is achieved through heat losses from the vessel surface.

7. In case the time to cool down the standing water is higher than the time between blodown cycles, service water will be
injected automatically in the lower part of the vessel, to help cool down the water prior to discharge to foul drainage
system.

8.
In the design case, the Sootblower condensate, the Intermittent Blowdown and th Deaerator Overflow are assumed to occur
simultaneously, even if in the probability of occurrence of such event is low in normal operation.

9. The frequency of the blowdown cycles and of the sootblowing considered are:
- 12 intermittent blowdowns and these are open sequentially for a max period of 30 seconds. The daily Intermittent
Blowdown water consumption is 600 kg/day.
- The total sootblowers condensate flow rate is 2,000 kg/h, as per information received from Boiler OEM.

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 Client: Galliford Try Doc. No. MI-17085-PR-CR-002
Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 11 of 49_____
4 22/08/17
Rev NOZZLES SIZING
In this section, the main vessel inlet and outlet nozzles, as well as instrument nozzles will be sized.

1. Boiler Drains Header Inlet (N1)

Due to the lack of information the Boiler Drains Header inlet diameter has been considered to be 2".

2. Deaerator overflow (N2)

The Deaerators Overflow and Drain flow in the inlet piping and nozzle to the Atmospheric Blowdown vessel is, in general,
a 2-phase mixture. In fact, flashing of the fluid would occur in the drain line when the Deaerator Overflow valve is open.

The following table summarizes the properties of the inlet fluid to the Deaerator overflow (OF) nozzle.

Two-Phase Inlet to
Description Units Design Condition (3)
Vessel (1)
- Norm Vapor Liquid
Flow Rate min [kg/h] 1,020 74 946
[kg/s] 0.283 0.021 0.263
Pressure p [bar(a)] 1.014 1.014 1.014
Temperature T [°C] 100.0 100.0 100.0
Enthalphy h [kJ/kg] 582.6 2675.6 419.1
Quality x [-] 0.072 1 0
Density ρ [kg/m³] 8.19 0.60 958.3
Viscosity μ [cP] 0.199 (2) 0.012 0.282
Volumetric Flow Q [m³/s] 0.035 0.034 0.0003
Notes:
(1) Two-Phase mixture after Actuated valve AV-06-07028, in the drain line.
(2) Mixture viscosity approximated with saturated liquid viscosity.
(3) Design condition taken as the peak flow condition. The flash pressure in this case was assumed equal
to the vessel operating pressure.

Determination of the flow regime in the inlet line

Since the inlet to the vessel is a multiphase fluid, the determination of the flow regime in the inlet line is very important for
the inlet nozzle sizing and for the efficient separation of the two components. Normally, the inlet nozzle of a blowdown
tank is sized for Annular or Spray flow. Other flow regimes, such as Slug, Plug and Froth are not recommended.

Table below summarizes the Deaerator overflow line data.

Description Unit Deaerator OF Line Data Nozzle Size

Line Number - - 06-200-BFW-CS1-035 06-200-BFW-CS1-H25
Material - - Carbon Steel Carbon Steel
Nominal Diameter DN - 200 200
NPS - 8 8
Outside Diameter OD mm 219.1 219.1
Schedule Sch. - 40 40
Thickness t mm 8.18 8.18
Inside Diameter ID mm 202.7 202.7

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Client: Galliford Try Doc. No. MI-17085-PR-CR-002

Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 4 22/08/17
Rev NOZZLES SIZING
Flow Area A m² 0.03228 0.03228
Flow Velocity v m/s 1.1 1.1 OK

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 Client: Galliford Try Doc. No. MI-17085-PR-CR-002
Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
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4 22/08/17
Rev NOZZLES SIZING

The velocity obtained is not high, so it is possible to proceed with the maximum velocity allowed in two phase flows.

The maximum velocity in a two-phase line is usually established by the erosional limit, which can be calculated according
to:

𝑉_𝑒𝑟=(100 ∙0.3048)/√(𝜌_𝑚 ) (100) (0.3048)

= = 42.6 m/s [Ref.5]
(8.2) (0.0624)

Taking this as a base it has been possible to determine the flow regime in the new line, using a flow map from the literature
[Ref.1]. To use this map, some flow parameters must be calculated, and used as input to the chart axes. The insersection
point gives the flow regime in the pipe with sufficient accuracy for practical applications.
σ = Fluid surface tension = 0.051 N/m

Gl = Liquid mass velociry = 8.14 kg/m² s

Gv = Vapor mass velocity = 0.64 kg/m² s = 0.13 lbm/ft² s

𝜆 = 〖 (𝜌_𝑣^′ 𝜌_𝑙^′ ) 〗 ^0.5=[(𝜌_𝑣/1.2)

(𝜌_𝑙/1,000)]^0.5 = 0.69

𝜓 = 0.073/𝜎 [((𝜇_𝑙∕0.001))/ 〖 (𝜌_𝑙∕1000) 〗

^2 ]^(1/3)
= 9.65

𝑋 = (𝐺_𝑙 𝜆 𝜓)/𝐺_𝑣
= 85.4

𝑌 = 𝐺_𝑣/𝜆
= 0.19 lbm/ft² s

Because of the intermittance of the mass

flow, the stratfied flow has been
considered acceptable for this
application.

However, there is some intrinsic

uncertainty in the actual flow pattern,
but this method was considered
acceptable for the scope of this work.
Therefore, the line and chosen
nozzle size are adequate.

Figure 1 - Determination of the flow

regime in the inlet piping [Ref.1].

Nozzle sizing

To size the nozzle, a maximum (conservative) value for the kinetic energy per unit volume (ρv²) is usually specified, and
the nozzle diameter calculated iteratively based on this value.

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Client: Galliford Try Doc. No. MI-17085-PR-CR-002

Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 4 22/08/17
Rev NOZZLES SIZING

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 Client: Galliford Try Doc. No. MI-17085-PR-CR-002
Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
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Rev NOZZLES SIZING

The feed nozzle size and the type of feed inlet device (if any) have an impact on the vapor / liquid separation that can be
achieved. The feed nozzle is normally sized to limit the momentum of the feed. The limitation depends on whether or not a
feed inlet device is installed.

(ρv²) ≤ 9,000 kg/m s² (recommended value for a tangential inlet)

Check of (ρv²) value with chosen nozzle diameter.

(ρv²) = (8.2) (1.1)² = 9 kg/m s² Nozzle Size is Acceptable

The entrance loss, with the assumption of incompressible flow (Δp≤10% Pin), and A1/A2 → 0 is given by:
(𝑉_1^2)/2 (1−𝐴_1/𝐴_2 )^2=(𝑉_1^2)/2
Δpentr = = 0.5736 Pa

Finally, the pressure drop due to the change in direction of the fluid inside the vessel due to the tangential inlet would
need to be estimated.
However, since the calculation of the pressure drop of a 2-phase fluid changing direction is very involved, this loss will
be conservatevely estimated as 1.5 times the entrance loss, to be conservative.

Thus:
Δpbp = 1.5*Δpentr = 0.8604 Pa

Δptotal = Δpentr+Δpbp = 1 Pa = 1E-05 bar

3. Intermittent Blowdown Inlet (N3)

The Intermittent Blowdown flow in the inlet piping and nozzle to the Atmospheric Blowdown vessel is, in general, a 2-
phase mixture. In fact, flashing of the fluid would occur in the blowdown line, when the IBD valve is open.

The following table summarizes the properties of the inlet fluid to the IBD nozzle.

Two-Phase Inlet to
Description Units Design Condition (3)
Vessel (1)
- Norm Vapor Liquid
Flow Rate min [kg/h] 2,000 645 1,355
[kg/s] 0.556 0.179 0.376
Pressure p [bar(a)] 1.014 1.014 1.014
Temperature T [°C] 100.0 100.0 100.0
Enthalphy h [kJ/kg] 1,146.9 2675.6 419.1
Quality x [-] 0.323 1 0

Density ρ [kg/m³] 1.85 0.60 958.3

Viscosity μ [cP] 0.101 (2) 0.012 0.282
Volumetric Flow Q [m³/s] 0.300 0.299 0.0004
Notes:
(1) Two-Phase mixture after blowdown valve, in the blowdown line. Assumption of BD valve as close as
possible to the tank.
(2) Mixture viscosity approximated with saturated liquid viscosity.
(3) Design condition taken as the peak flow condition. The flash pressure in this case was assumed equal
to the vessel operating pressure.
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Client: Galliford Try Doc. No. MI-17085-PR-CR-002

Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 4 22/08/17
Rev NOZZLES SIZING
Design condition taken as the peak flow condition. The flash pressure in this case was assumed equal
to the vessel operating pressure.

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 Client: Galliford Try Doc. No. MI-17085-PR-CR-002
Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
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PROCESS DESIGN REPORT 17 of 49_____
4 22/08/17
Rev NOZZLES SIZING
Determination of the flow regime in the inlet line

Since the inlet to the vessel is a multiphase fluid, the determination of the flow regime in the inlet line is very important for
the inlet nozzle sizing and for the efficient separation of the two components. Normally, the inlet nozzle of ablowdown tank
is sized for Annular or Spray flow. Other flow regimes, such as Slug, Plug and Froth are not recommended.

Table below summarizes the Intermittent Blowdown line data.

In the first column, the calculated velocity assuming same line size upstream and downstream of the BD Valve is
shown. The velocity in this case is exceeding the erosional limit velocity. For this reason, the line size was recalculated to
achive safe results and the optimal size is shown in the second column.

Description Unit IBD Line Data Nozzle Size

Line Number - - 06-40-BB-AS1-HXX 06-150-BB-1CS-H32D
Material - - Carbon Steel Carbon Steel
Nominal Diameter DN - 40 150
NPS - 1.1/2 6
Outside Diameter OD mm 48.3 168.3
Schedule Sch. - 80 40
Thickness t mm 5.08 7.11
Inside Diameter ID mm 38.1 154.1
Flow Area A m² 0.00114 0.01865
Flow Velocity v m/s 263.0 16.1 OK

A preliminary calculation of the velocity in the existing line shows that for the two-phase mixture, the velocity is
unrealistic. Therefore, the line has to be resized to avoid such high velocities.
The maximum velocity in a two-phase line is usually established by the erosional limit, which can be calculated according
to:

𝑉_𝑒𝑟=(100 ∙0.3048)/√(𝜌_𝑚 ) (100) (0.3048)

= = 89.6 m/s [Ref.5]
(1.9) (0.0624)

Taking this as a base, the new line size has been calculated iteratively, and the flow regime in the new line was determined,
using a flow map from the literature [Ref.1]. To use this map, some flow parameters must be calculated, and used as input
to the chart axes. The insersection point gives the flow regime in the pipe with sufficient accuracy for practical applications.

σ = Fluid surface tension = 0.059 N/m

Gl = Liquid mass velocity = 20.19 kg/m² s

Gv = Vapor mass velocity = 9.61 kg/m² s = 1.97 lbm/ft² s

𝜆 = 〖 (𝜌_𝑣^′ 𝜌_𝑙^′ ) 〗 ^0.5=[(𝜌_𝑣/1.2) = 0.69
(𝜌_𝑙/1,000)]^0.5

𝜓 = 0.073/𝜎 [((𝜇_𝑙∕0.001))/ 〖 (𝜌_𝑙∕1000) 〗

^2 ]^(1/3)
= 8.36

𝑋 = (𝐺_𝑙 𝜆 𝜓)/𝐺_𝑣
= 12.1

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Client: Galliford Try Doc. No. MI-17085-PR-CR-002

Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 4 22/08/17
Rev NOZZLES SIZING
𝑌 = 𝐺_𝑣/𝜆
= 2.85 lbm/ft² s

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 Client: Galliford Try Doc. No. MI-17085-PR-CR-002
Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
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Rev NOZZLES SIZING

The flow pattern in the inlet piping

is annular, as recommended for
similar applications.

However, there is some intrinsic

uncertainty in the actual flow
pattern, but this method was
considered acceptable for the scope
of this work.

Therefore, the line and chosen

nozzle size are adequate.

Figure 2 - Determination of the flow

regime in the inlet piping [Ref.1].

Nozzle sizing

To size the nozzle, a maximum (conservative) value for the kinetic energy per unit volume (ρv²) is usually specified, and
the nozzle diameter calculated iteratively based on this value.

The feed nozzle size and the type of feed inlet device (if any) have an impact on the vapor / liquid separation that can be
achieved. The feed nozzle is normally sized to limit the momentum of the feed. The limitation depends on whether or not a
feed inlet device is installed.

(ρv²) ≤ 9,000 kg/m s²

Check of (ρv²) value with chosen nozzle diameter.

(ρv²) = (1.9) (16.1)² = 478 kg/m s² Nozzle Size is Acceptable

The entrance loss, with the assumption of incompressible flow (Δp≤10% Pin), and A1/A2 → 0 is given by:
(𝑉_1^2)/2 (1−𝐴_1/𝐴_2 )^2=(𝑉_1^2)/2
Δpentr = = 129 Pa

Finally, the pressure drop due to the change in direction of the fluid inside the vessel due to the tangential inlet would need
to be estimated.
However, since the calculation of the pressure drop of a 2-phase fluid changing direction is very involved, this loss will be
conservatevely estimated as 1.5 times the entrance loss, to be conservative.
Thus:

Δpbp = 1.5*Δpentr = 193.5 Pa

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Client: Galliford Try Doc. No. MI-17085-PR-CR-002

Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 4 22/08/17
Rev NOZZLES SIZING
Δptotal = Δpentr+Δpbp = 322 Pa = 0.0032 bar

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 Client: Galliford Try Doc. No. MI-17085-PR-CR-002
Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
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PROCESS DESIGN REPORT 4 22/08/17 21 of 49_____

Rev NOZZLES SIZING

4. Sootblowers Condensate Inlet (N4)

The Sootblowers Drain flow in the inlet piping and nozzle to the Atmospheric Blowdown vessel is, in general, a 2-phase
mixture. In fact, flashing of the fluid would occur in the condensate line, when the SBC valve is open.

The following table summarizes the properties of the inlet fluid to the SBC nozzle.

In the first column, the calculated velocity assuming same line size upstream and downstream of the steam trap set
is shown. The velocity in this case is exceeding the erosional limit velocity. For this reason, the line size was recalculated
to achive safe results and the optimal size is shown in the second column.

Two-Phase Inlet to
Description Units Design Condition (3)
Vessel (1)
- Norm Vapor Liquid
Flow Rate min [kg/h] 1,000 256 744
[kg/s] 0.278 0.071 0.207
Pressure p [bar(a)] 1.014 1.014 1.014
Temperature T [°C] 100.0 100.0 100.0
Enthalphy h [kJ/kg] 997.3 2675.6 419.1
Quality x [-] 0.256 1 0
Density ρ [kg/m³] 2.33 0.60 958.3
Viscosity μ [cP] 0.282 (2) 0.012 0.282
Volumetric Flow Q [m³/s] 0.119 0.119 0.0002
Notes:
(1) Two-Phase mixture after blowdown valve, in the blowdown line. Assumption of SBC valve as close
as possible to the tank.
(2) Mixture viscosity approximated with saturated liquid viscosity.
(3) Design condition taken as the peak flow condition. The flash pressure in this case was assumed equal
to the vessel operating pressure.

Determination of the flow regime in the inlet line

Since the inlet to the vessel is a multiphase fluid, the determination of the flow regime in the inlet line is very important for
the inlet nozzle sizing and for the efficient separation of the two components. Normally, the inlet nozzle of a blowdown
tank is sized for Annular or Spray flow. Other flow regimes, such as Slug, Plug or Froth are not recommended.

Table below summarizes the Sootblower condensate line data.

Description Unit SBD Line Data Nozzle Size

Line Number - - 06-25-CNS-6CS-H33 06-100-CND-1CS-H33A
Material - - Carbon Steel Carbon Steel
Nominal Diameter DN - 25 100
NPS - 1 4
Outside Diameter OD mm 33.4 114.3
Schedule Sch. - 80 40
Thickness t mm 4.55 6.02
Inside Diameter ID mm 24.3 102.3
Flow Area A m² 0.00046 0.00821
Flow Velocity v m/s 257.0 14.5 OK

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Rev NOZZLES SIZING

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The maximum velocity in a two-phase line is usually established by the erosional limit, which can be calculated according
to:

𝑉_𝑒𝑟=(100 ∙0.3048)/√(𝜌_𝑚 ) (100) (0.3048)

= = 79.9 m/s [Ref.5]
(2.3) (0.0624)

Taking this as a base, the new line size has been calculated iteratively, and the flow regime in the new line was determined,
using a flow map from the literature [Ref.1]. To use this map, some flow parameters must be calculated, and used as input
to the chart axes. The insersection point gives the flow regime in the pipe with sufficient accuracy for practical applications.

σ = Fluid surface tension = 0.059 N/m

Gl = Liquid mass velociry = 25.16 kg/m² s

Gv = Vapor mass velocity = 8.67 kg/m² s = 1.77 lbm/ft² s

𝜆 = 〖 (𝜌_𝑣^′ 𝜌_𝑙^′ ) 〗 ^0.5=[(𝜌_𝑣/1.2)
(𝜌_𝑙/1,000)]^0.5 = 0.69

𝜓 = 0.073/𝜎 [((𝜇_𝑙∕0.001))/ 〖 (𝜌_𝑙∕1000) 〗

^2 ]^(1/3)
= 8.36

𝑋 = (𝐺_𝑙 𝜆 𝜓)/𝐺_𝑣
= 16.8

𝑌 = 𝐺_𝑣/𝜆
= 2.57 lbm/ft² s

The flow pattern in the inlet piping

is spray, as recommended for
similar applications.

However, there is some intrinsic

uncertainty in the actual flow
pattern, but this method was
considered acceptable for the scope
of this work.

Therefore, the line and chosen

nozzle size are adequate.

Figure 3 - Determination of the flow

regime in the inlet piping [Ref.1].

Nozzle sizing

To size the nozzle, a maximum (conservative) value for the kinetic energy per unit volume (ρv²) is usually specified, and
the nozzle diameter calculated iteratively based on this value.

The feed nozzle size and the type of feed inlet device (if any) have an impact on the vapor / liquid separation that can be
achieved. The feed nozzle is normally sized to limit the momentum of the feed. The limitation depends on whether or not a
feed inlet device is installed.

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(ρv²) ≤ 9,000 kg/m s²

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4 22/08/17
Rev NOZZLES SIZING
Check of (ρv²) value with chosen nozzle diameter.

(ρv²) = (2.3) (14.5)² = 489 kg/m s² Nozzle Size is Acceptable

The entrance loss, with the assumption of incompressible flow (Δp≤10% Pin), and A1/A2 → 0 is given by:

(𝑉_1^2)/2 (1−𝐴_1/𝐴_2 )^2=(𝑉_1^2)/2

Δpentr = = 104.9 Pa

Finally, the pressure drop due to the change in direction of the fluid inside the vessel due to the tangential inlet would need
to be estimated.

However, since the calculation of the pressure drop of a 2-phase fluid changing direction is very involved, this loss will be
conservatevely estimated as 1.5 times the entrance loss, to be conservative.
Thus:

Δpbp = 1.5*Δpentr = 157.35 Pa

Δptotal = Δpentr+Δpbp = 262 Pa = 0.0026 bar

5. Blowdown liquor Inlet (N5)

To size the flash tank inlet, a nozzle size (and line size) is assumed and the fluid velocity is checked. The criteria for liquid
outlet nozzles is usually based on the fluid velocity, as follows:

0.6 m/s ≤ v ≤ 1.2 m/s

Two-Phase Inlet to
Description Units Design Condition (3)
Vessel (1)
- Norm Vapor Liquid
Flow Rate min [kg/h] 738.3 - 738.3
[kg/s] 0.205 - 0.205
Pressure p [bar(a)] 3.40 - 1.014
Temperature T [°C] 40.00 - 40.07
Enthalphy h [kJ/kg] 167.836 - 167.90
Quality x [-] 0.000 - 0.00
Density ρ [kg/m³] 992.16 - 992.16
Viscosity μ [cP] 0.20 - 0.20
Volumetric Flow Q [m³/s] 0.0002 - 0.0002

Description Unit BL Line Data Nozzle Size

Line Number - - 06-20-BB-1CS-H27 06-20-BB-1CS-H31
Material - - Carbon Steel Carbon Steel
Nominal Diameter DN - 20 20
NPS - 3/4" 3/4"
Outside Diameter OD mm 26.7 26.7
Schedule Sch. - 40 40
Thickness t mm 2.87 2.87
Inside Diameter ID mm 20.9 20.9

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Flow Area A m² 0.00034 0.00034
Flow Velocity v m/s 0.6 0.6 OK

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6. Service Water Inlet (N6)

The mass flow rate of the service water has been calculated considering the heat loss of the Atmospheric Blowdown Tank
and the H&M balance of that device. The blowing time ot the process has been given by the Boiler OEM as being 6 min,
and on our side it has been assumed to be composed of 3 sessions per day: one every 8 hours.

Description Units Service Water Inlet

- Norm
Flow Rate min [kg/h] 1,000.0
[kg/s] 0.278
Pressure p [bar(a)] 13.00
Temperature T [°C] 15.00
Enthalphy h [kJ/kg] 64.23
Quality x [-] 0.000
Density ρ [kg/m³] 999.660
Viscosity μ [cP] 1.137
Volumetric Flow Q [m³/s] 0.00028

To size the service water inlet, a nozzle size (and line size) is assumed and the fluid velocity is checked. The criteria for
liquid inlet nozzles is usually based on the fluid velocity, as follows:

0.5 m/s ≤ v ≤ 1.2 m/s

Description Unit SW Line Data Nozzle Size

Line Number - - 06-25-PW-1CG-H20 06-25-PW-1CG-H20
Material - - Carbon Steel Carbon Steel
Nominal Diameter DN - 25 25
NPS - 1" 1"
Outside Diameter OD mm 33.4 33.4
Schedule Sch. - 80 80
Thickness t mm 4.55 4.55
Inside Diameter ID mm 24.3 24.3
Flow Area A m² 0.00046 0.00046
Flow Velocity v m/s 0.599 0.6

For this application it has been considered that 1" nozzle diameter was acceptable.

7. Vent Nozzle (N7)

The vent nozzle shall be sized to relief all the flash steam developed in the vessel, so that the backpressure in the piping and
vent silencer are less than 0.35 bar, usually. This allows the atmospheric blowdown tank to operate always around
atmospheric pressure. In the following, to size the vent line, the total amount of steam flashed in the tank from the various
inlets will be computed, considering simultaneous IBD, SB warm-up cycles and deaerator overflow and assuming a
configuration of the vent piping, to be confirmed after final pipe routing. Finally, the vent line can be sized, so that the
steam velocity lies within the typical velocities for low pressure steam (15 m/s ≤ vs ≤ 20 m/s), which will minimize water
(and chemical) entrainment with the steam as well as the noise in the vent pipe.

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Rev NOZZLES SIZING

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Steam Vented to Atmosphere (1) Units Steam Flow in Vent Line from
- IBD SB Drain DeA OF Total
Flow Rate min [kg/h] 645.1 256.2 73.9 330
[kg/s] 0.179 0.071 0.021 0.092
Pressure p [bar(a)] 1.01 1.01 1.01 1.01
Temperature T [°C] 100.0 100.0 100.0 100.0
Enthalphy h [kJ/kg] 2,676 2,676 2,676 2,676
Quality x [-] 1.0 1.0 1.0 1.0
Density ρ [kg/m³] 0.60 0.60 0.60 0.60
Viscosity μ [cP] 0.012 0.012 0.012 0.012
Volumetric Flow Q [m³/s] 0.299 0.119 0.034 0.153
Notes:
(1) Assumption of simultaneous discharge of IBD, SB drain and DeA Overflow in the Design Case.

With the total steam flow in the vent nozzle (and piping), the minimum required diameter of the vent nozzle is:
𝐷/1000≥√(4/𝜋∙𝑄_𝑠/𝑣_𝑚𝑎𝑥 )
(4) (0.153)
= = 0.099 m
(3.14) (20)
where:
D = Minimum Inside Diameter of the flash tank vessel = 98.778 mm
vmax = Maximum velocity of steam in the vent nozzle = 20 m/s
Qs = Flash steam max volumetric flow rate = 0.153 m³/s

The following table summarizes the chosen Vent nozzle data, obtained after iteration.

Description Unit
Line Number - - -
Material - - Carbon Steel
Pipe Size NPS - 10
Nominal Diameter DN - 250
Outside Diameter OD mm 273
Schedule Sch. - STD
Thickness t mm 9.27
Inside Diameter ID mm 254.5
Flow Area A m² 0.0509
Flow Velocity v m/s 3.01

With the chosen vent size, the pressure drop in the vent line is then calculated, and the backpressure added to the
atmospheric pressure to determine a new value of the vessel operating pressure. After a few iterations, the vessel pressure
converges and the final values for the operating pressure, amount of flashed steam and vessel size are found.

Even though the calculation would suggest to chose a smaller diameter in order to increse the velocity through the nozzle,
following Ref. [10] the diameter selected has been 10". This is to account for all the uncertainties in the input design data
received from the client, which might result in an excessive increase of the backpressure in case the flow rates were
understimated.

Pressure Drop in Vent Line

This calculation assumes a typical vent piping configuration and a vent silencer pressure drop of 6 mbar. The pressure drop
across the vent piping should be limited to 1 psi (0.069 bar), to ensure that the pipe is of sufficient size to vent the steam,
and prevent an increase in the atmospheric blowdown 692284769.xlsx
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This calculation assumes a typical vent piping configuration and a vent silencer pressure drop of 6 mbar. The pressure drop
across the vent piping should be limited to 1 psi (0.069 bar), to ensure that the pipe is of sufficient size to vent the steam,
and prevent an increase in the atmospheric blowdown tank pressure.

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Taking the chosen pipe size as per the above table, the pressure drop in the vent piping will be the sum of friction (or
distributed) pressure drop and concentrated (or minor) pressure drops, as per the following. The static head losses are
neglected in the calculations.
〖∆𝑝〗 _𝑣= 〖∆𝑝〗 _𝑓+ 〖∆𝑝〗 _𝑐+ 〖∆𝑝〗 _𝑠=𝑓 𝐿/𝐷 𝜌 𝑣^2/2+∑_𝑖▒ 〖𝐾 _(𝑖 ) 𝜌 𝑣^2/2+𝜌𝑔(𝑧_2−𝑧_1 ) 〗

where:

Δpf = Frictional pressure drops

Δpc = Concentrated or minor pressure drops
Δps = Static head loss = 58.7 Pa = 0.00059 bar
f = Friction factor (Darcy)
L = Pipe length = 10.0 m (assumed)
D = Pipe inside diameter = 254.5 mm
v = Fluid (steam) velocity = 3.0 m/s
Ki = Velocity head loss coefficients in piping (K-value) = Depending on pipe fittings, valves, etc.

The calculation of the friction factor starts with the computation of the Reynolds Number:

𝑅𝑒=𝜌𝑣𝐷/𝜇 (0.6) (3) (254.5)

= = 37,396 Turbulent
0.012
Once the Reynolds number is calculated, several correlations are available in the literature for the calculation of the friction
factor. These correlations are usually given as a function of the of another dimensionless parameter, called relative pipe
roughness (ε/D). In the following, the Zigrang and Sylvester formula will be used. This correlation has a reasonable
accuracy for this application.

ε = Absolute pipe roughness = 0.0457 mm

ε/D = Relative pipe roughness = 0.0001796

f = 0.02283

10.0 (3)²
Δpf = 0.02283 0.60 = 2.4 Pa = 0.00002 bar
0.2545 2

To calculate the minor pressure drops, a piping configuration with the following fittings, valves, etc. is assumed, to be
confirmed after piping layout.

Fitting type Tot. No. K-value

90° Bend 4 0.75
45° Bend 2 0.35
Total K-value 3.7

The total minor losses, including also the pressure drop in the vent silencer, are:

Δpsil = 6 mbar = 600 Pa

(3)²
Δpc = 3.7 0.60 + 600 = 610.1 Pa = 0.00610 bar
2

Total pressure drop in the vent line, with the chosen vent nozzle and piping diameter, is:

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Δpv = Δpf + Δpc + Δps = 0.00002 + 0.00610 + 0.00059 = 0.0067 bar

Atmospheric Blowdown Operating Pressure = 1.020 bar OK

8. Liquid Outlet Nozzle (N8)

To size the oultet liquid/liquor line, a nozzle size (and line size) is assumed and the fluid velocity is checked. The criteria
for liquid outlet nozzles is usually based on the fluid velocity, as follows:

0.6 m/s ≤ v ≤ 1.2 m/s

Description Unit Outlet Liq./Liquor Line

Line Number - - -
Material - - A 106 Gr.B
Nominal Diameter DN - 40
Outside Diameter OD mm 48.3
Schedule Sch. - 80
Thickness t mm 5.1
Inside Diameter ID mm 38.1
Flow Area A m² 0.0011
Flow Velocity v m/s 0.96 OK

9. Drain

The Drain outlet nozzle has been designed following [10]. The chosen diameter is 2".

10. Instrumentation

10.1 Level Instrument Nozzles (N10 - N12)

The following table summarizes the main data for the Level Instrument Nozzles [Ref.7].

Description Units Instrument Nozzles Data

N2 N1
Instrument Tag No. - LIT-06-17304
Instrument Type - Level Transmitter N11
Control Range mm 600 3/4"
Visible Range mm - 3/4"
Level Control

Nozzle Material - P265GH HWL N10 B

Range

Number of Nozzles - 2
Nozzle Size NPS 3/4" NWL
600

DN 20
600

LWL
Nozzle Schedule Sch. 80
Nozzle Outside Diameter mm 26.7 3/4"
100

Distance between nozzle CL mm 600

N10 A

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N10 A
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10.2 Pressure Instrument Nozzle (N11)

The following table summarizes the main data for the Pressure Instrument Nozzle [Ref.7].

Description Units Nozzle Data

Instrument Tag No. PIT-06-17402 N2
Instrument Type Pressure Transmitter
Nozzle Nominal Size NPS 3/4"
DN 20 3/4" N11
Nozzle Schedule Sch. 80
Nozzle Outside Diameter mm 26.7

HWL
1200

NWL

LWL

10.3 Temperature Instrument Nozzle (N12)

The following table summarizes the main data for the Temperature Instrument Nozzle [Ref.7].

Description Units Nozzle Data

Instrument Tag No. TIT-06-17604
Temperature
Instrument Type Transmitter
Nozzle Nominal Size NPS 1/2"
DN 15
Nozzle Schedule Sch. 80
Nozzle Outside Diameter mm 21.3

For the Temperature transmitter position see "Vessel Sizing" at page 22.

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The nozzles sizes, rate and type are shown in the following table:

NOZZLES: Q.TY SIZE RATE TYPE

H1 - MAN-HOLE 1 20" 150# SO RF

N1 - Boiler Drains Header Inlet 1 2" 150# SO RF
N2 - Deaerator Feedwater Tank Drain and
1 8" 150# SO RF
Overflow
N3 - Boiler Intermittent Blowdown 1 6'' 150# SO RF
N4 - Sootblower Condensate 1 4" 150# SO RF
N5 - Flash Tank Liquor 1 3/4" 150# SW RF
N6 - Service Water 1 1" 150# SW RF
N7 - Vent 1 10'' 150# SO RF
N8 - Water Outlet 1 2" 150# SO RF [1]
N9 - Drain 1 1 1/2 " 150# SW RF w/attached piping
N 10A & B Level Indicators 2 3/4" 150# SW RF
N11 Pressure Indicators 1 3/4" NPT
N12 Temperature Transmitter 1 1/2" NPT

REMARKS
[1] Internal deep pipe with syphon breaker (hole)

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An atmospheric blowdown vessel is typically sized, as a flash tank, to achieve proper separation of the water droplets by
gravity settling and to avoid water entrainment with the flashed steam. This is achieved, in the steam space, by decreasing the
steam velocity to a value below the critical velocity for separation of the water droplets and by locating the inlet nozzles at a
proper distance from the standing liquid High Level (HWL).

Therefore, the combined effect of nozzle size, inlet nozzle configuration and/or devices, and vessel diameter allow for
minimum entrainment and good steam-water separation in the vessel.

In the following, the vapor space will be sized, to achieve a velocity of ≤ 11 ft/s (3.35 m/s), as per recommendations in [Ref.3].
This will be also compared to an empirical calculation of the critical settling velocity for water droplets, by using the Souders
and Brown correlation [Ref.1,2,10]. However, a derating factor to account for the absence of a mist eliminator will have to be
applied to this correlation. Then, the liquid volume will be calculated, based on the chosen diameter, the NWL and the HWL of
the vessel will be established, and the total total vessel height (TL-TL) determined.

1. Vessel Diameter for Gravity Separation.

The blowdown flash vessel will be able to separate the liquid droplets larger than 150 μm by gravity.
Dp = 150 μm = 1.5E-04 m

The terminal velocity, according to the Intermediate Law assumption is:

𝑢_𝑡=0.154 (𝑔^0.71 𝐷_𝑝^1.14
(𝜌_𝑙−𝜌_𝑔 )^0.71)/(𝜌_𝑔^0.29 𝜇_𝑔^0.43 )

where:

ρl = Saturated liquid density = 958.3 kg/m³

ρg = Saturated flash steam density = 0.6 kg/m³
μg = Flash steam viscosity = 1.2E-05 kg/m s (= cP/1000)

Substituting,
(
0.154) (.) (4.37E-05) (130.82)
ut = = 0.669 m/s
(7.322) (0.00773)

Check for Intermediate Law assumption: (2 < Re < 500)

𝑅𝑒=(𝑢_𝑡 𝐷_𝑝 (0.669) (0.00015) (0.6)

𝜌_𝑔)/𝜇_𝑔 = = 4.89 OK
0.01227

An alternative method to calculate the terminal velocity makes use of the following general formula:
𝑢_𝑡=1.15√(( 〖 𝜌〗 _𝑔 𝐷_𝑝 ( 〖𝜌 _𝑙−𝜌 〗_𝑔))/( 〖 𝜌〗
_𝑔 𝐶_𝐷 ))

Since CD is dependent on Re, and thus on the terminal velocity, an iterative approach would be required. However, using a the
following correlation, together with the following Figure 4, the terminal velocity is eliminated and the drag coefficient can be
directly calculated.

〖𝐶 _𝐷 𝑅𝑒 〗^2=( 〖 0.13 ∙ 〖 10 〗 ^8 𝜌 〗 _𝑔 𝐷_𝑝^3 (1.30E+07) (0.6) (3.38E-12) (958)

( 〖𝜌 _𝑙−𝜌 〗 _𝑔))/(𝜇_𝑔^2 ) = = 167.01
0.000151

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Figure 4 - Drag Coefficient

determination from CD(Re)² [Ref.3].

(9.81) (0.00015) (957.8)

CD ≈ 7.0 Hence, the terminal velocity: ut = 1.15 = 0.667 m/s
(0.6) (7)
The difference between the two values of the terminal velocity calculated with the two above methods is ≈ 0.31 %, hence
acceptable.

Taking the lower value of the two terminal velocities calculated above (conservative), the required vessel diameter can be
calculated, with the vapor velocity being less than the terminal velocity, to avoid entrainment:
𝐷/1000≥√(4/𝜋∙𝑄_𝑎/𝑢_𝑡 )
(4) (0.4528)
= = 0.930 m
(3.14) (0.667)
where:

D = Minimum Inside Diameter of the atmospheric tank = 930 mm

ut = Terminal velocity for liquid droplets = 0.667 kg/m³
Qa = Flash steam max volumetric flow rate = 0.4528 m³/s

Vessel Diameter

Typically, a blowdown vessel is sized to contain the water quantity (liquid) from two intermittent Blowdown cycles, plus the
vapor space above the water. The latter is sized to achieve proper water droplet separation, and to have a vapor velocity lower
than the critical gravity separation velocity.

Ref.8 recommends a maximum velocity of 11 ft/s (3.35 m/s) in the steam space, as a commonly used value to allow for proper
separation e minimization of water re-entrainment.

Thus, the minimum vesel diameter to satisfy the above condition would be:
𝐷_𝑣/1000≥√(4/𝜋∙𝑄_𝑠/𝑉_𝑚 )
(4) (0.453)
= = 0.41 m say 500 mm
(3.14) (3.35)

where:

Dv = Minimum Required Diameter of vessel steam space = 500 mm

Vm = Maximum velocity for droplet separation = 3.35 m/s
Qs = Flash steam volumetric flow rate (max) = 0.453 m³/s

Considering the resuls obtained and the uncertainties in the design data provided by the Client and boiler OEM, a high safety
factor it has been considered the following vessel diameter:

692284769.xlsx
 39 of 49___ __

Client: Galliford Try Doc. No. MI-17085-PR-CR-002

Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 4 22/08/17
Rev VESSEL SIZING
Dves = Vessel diameter = 1200 mm

692284769.xlsx
 Client: Galliford Try Doc. No. MI-17085-PR-CR-002
Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 40 of 49___ __
4 22/08/17
Rev VESSEL SIZING
2. Calculation of Vessel Height

The starting point for the vessel height determination, following the procedure in [Ref.3], is the determination of the volume of
water after one cycle of intermittent blowdown and of drains, which will be the amount stored in the tank up to the Normal
Water Level (NWL). On the other hand, the volume of water after two cycles would be stored in below the vessel High Water
Level (HWL).

In this case, however, there are additional water inlet at high temperature apart from the IBD, which need to be stored in the
vessel. Therefore, the volume of water stored in the vessel for cooling will be the volume of water after a certain amount of
time, corresponding to the longest cycle duration among the high-temperature streams (IBD, SB Drains and Deaerator
Overflow).
The other streams, such as the CBD Liquor or boiler drains, do not need to be stored, as they are entering the vessel at low
temperature and could be discharged after a small amount of time to allow for settling of any deposit that might be carried over
with the fluid.

The duration of one cycle in design case is the maximum of the cycle duration of IBD, SB condensate and the DOF Deaerator
overflow.

τIBD = 360 s τSB = 360 s τDOF = 60 s

Total water volume after each cycle with its duration τi, is then:

𝑉_𝑤=∑_𝑖▒ 〖𝑄 _𝑖 𝜏_𝑖 〗
= τIBD∙QIBD + τSB∙QSB + τDOF∙QDOF + τBFT∙QBFT = 360∙(0.21)+360∙(0.38)+60∙(946.12) = 0.17 m³

The Normal Water Level (NWL) height from the bottom of the vessel, assuming a 2:1 semi-ellipsoidal bottom head, is:

𝐻_𝑁𝑊𝐿=(4𝑉_𝑤)/(𝜋𝐷_𝑣𝑒𝑠^2 )+𝐷_𝑣𝑒𝑠/4 4 ∙ 0.17 1.2

= + = 0.45 m Say 500 mm
(3.14) (1.2)² 4

Whereas, the High Water Level (HWL),

𝐻_𝐻𝑊𝐿=(8𝑉_𝑤)/(𝜋𝐷_𝑣𝑒𝑠^2 )+𝐷_𝑣𝑒𝑠/4 8 ∙ 0.17 1.2

= + = 0.60 m Say 600 mm
(3.14) (1.2)² 4

The total cylindrical length of the vessel, from tangent line to tangent line (TL-TL), is then calculated with the following
formula, modified from [Ref.3] to incorporate HP experience:

HT-T = HHWL + 1.75 Dves = 600 + 1.75 ∙ 1200 = 2698 mm say 2700 mm

Total vessel height, including bottom and top heads, will be:

Assuming a 2:1 Elliptical head, with depth:

Hhead = 0.25 ∙ Dves = 0.25 ∙ 1200 = 300.0 mm

Ht,ves = HT-T + 2 Hh = 2698 + 1.75 ∙ 300 = 3223.0 mm

Finally, the distance of the inlet nozzles from the bottom tangent line can be estimated as

692284769.xlsx
 41 of 49___ __

Client: Galliford Try Doc. No. MI-17085-PR-CR-002

Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 4 22/08/17
Rev VESSEL SIZING
Dn = HHWL + 1.00 Dves = 600 + 1 ∙ 1200 = 1800 mm say 1800 mm

Dn' = HT-T - Dn = 2700 - 1800 = 898 mm to top TL

692284769.xlsx
 Client: Galliford Try Doc. No. MI-17085-PR-CR-002
Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 4 22/08/17 42 of 49___ __

Rev VESSEL SIZING

Total vessel inside volume, is:

𝑉_(𝑡,𝑣𝑒𝑠)=𝐻𝑇−𝑇∗(𝜋𝐷_𝑣^2)/4+2 (𝜋𝐷_𝑣^3)/24 2700·(3.14) (1.2)² (3.14) (1.2)³

= + 2 = 3.51 m³
4 24

The following figure shows a sketch of the vessel, with highlighted the main dimensions of nozzles and vessel parts.
Vent
N7

Distance of the inlet nozzles from the bottom tangent line

H head Dn = 1800 mm
Distance from tangent line to tangent line
N1 N4 N2
HT-T = 2700 mm
High water level
Dves=1200 mm Anti-Siphon Hole 10 mm HHWL = 600 mm
Normal water level
Man-hole
H T-T H nwl = 500 mm
Dn
N8 Head height

N5 H head = 300 mm
N6
600 mm Hhwl
100 mm Hnwl

H head N12 TT max 6" from the bottom

600 mm
N9 4 Legs

Boiler Drains Header Inlet N1 Intermittent

Blowdown
N3

H1 N7 Water Outlet
N8

Deaerator
Sootblower Condensate Overflow N2
N4

692284769.xlsx
 43 of 49___ __

Client: Galliford Try Doc. No. MI-17085-PR-CR-002

Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 4 22/08/17
Rev VESSEL SIZING

692284769.xlsx
]
Client: Galliford Try Doc. No. MI-17085-PR-CR-002
Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
44 of 49_____
PROCESS DESIGN REPORT 4 22/08/17

INSULATION THICKNESS

Calculate the insulation thickness for PP (?), using the EN 12241 standard.

692284769.xlsx 09/19/2023
 45 of 49_____

]
Client: Galliford Try Doc. No. MI-17085-PR-CR-002
Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
PROCESS DESIGN REPORT 4 22/08/17

692284769.xlsx 09/19/2023
 Client: Galliford Try Doc. No. MI-17085-PR-CR-002
Project: Hull Biomass UK LLP 1 Tag No. T-06-17081
Location: Hull, United Kingdom Job No. MI-17085
ATMOSPHERIC BLOWDOWN TANK Rev. Date Sheet
46 of 49_____
PROCESS DESIGN REPORT 4 22/08/17

REFERENCES

[1] Green, D.W.; Perry, R.H. - Perry's Chemical Engineering Handbook, 8th Ed. (2008).
[2] Ludwig, E.E. - Applied Process Design Vol. 1, 3rd Ed. (1999).
[3] GPSA Engineering Data Book, Vol. I & II, 12th Ed. (2004).
[4] Towler, G.; Sinnott, R. - Chemical Engineering Design (2008).
[5] API 14E - Recommended Practice for Design and Installation of Offshore Production Platforms and Piping Systems,
5th Ed. (1991)
[6] Drawing No. HULL_01_DWG_19_70017_D - Blowdown System P&ID
[7] NB-27, Sizing a blow off vessel

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692284769.xlsx
 Client: Galliford Try Doc. No. -
Project: Hull Biomass Plant UK Line No. 06-250-STM-CS1-H18
Location: Hull, UK Job No. MI-17085
Rev. Date 48 of 49
Sheet
CALCULATION SHEET
0 09/05/17
Atmospheric Blowdown Tank Air Vent Pressure Drop

1 Fluid data and Thermophysical Properties

2 Mass Flow m 975.200 kg/h ###
3 0.271 kg/s
4 Pressure @ HP Tie-in required 1.020 bar(a)
5 Pressure drop in Bleed NRVs (already accounted for) 0 mbar
6 0.00 bar
7 Pressure @ HP Tie-in p 1.020 bar(a)
8 Saturation Temperature T 100.2 °C
9 Density ρ 0.601 kg/m³
10 Specific Volume v 1.663 m³/kg ###
11 Volume Flow Q 1,621.7 m³/h
12 Enthalpy h 2,675.8 kJ/kg
13 Specific Heat cp 2.08 kJ/kg °C
14 Viscosity μ 0.012 cP
15 Thermal Conductivity k 0.02 W/m °C
16 Pipe data
17 Material CS
18 Absolute Roughness e 0.0457 mm
Daniele Lanzano:
19 Pipe Nominal Diameter NPS 10 in
It is the conversion of the
20 Pipe Outside Diameter OD 273.0 mm
Daniele
nominal Lanzano:in inches
diameter
21 Pipe Schedule Sch. 40
it has to be taken from the
22 Pipe Thickness t 9.27 mm spec
pipe
23 Inside Diameter ID 254.5 mm
24 Flow Area A 0.051 m²
25 Relative Roughness e/D 0.00018
26 Straight Length L 10 m
27 Elevation Change Δz 10 m
28 Valves and Fittings No. K (Vel. Heads) ρV²
K = Δpfit
29 No. of gate valves (fully open) 0 0.17 2
30 T-piece (straight) 0 0.4
31 T-piece (Tee) 0 1
32 No. Check Valves 0 2
33 No 90° Elbows 4 0.75
34 K Total (velocity head) 3
35 Fluid Dynamic Calculations
36 Mass Velocity G 5.33 kg/m² s
37 Fluid Velocity u 8.86 m/s
38 Reynolds Number Re 110,427
39 Friction factor calculation (Darcy)
40 Zigrang and Sylv. Factor A -3.657
41 Friction factor Z&D fZ&D 0.0186
42 Churchill friction factor
43 A Factor A 1.18E+21
44 B Factor B 3.17E-08
45 Friction factor Churchill fC 0.0186
46 Chosen Friction factor f 0.0186
47 Pressure drops summary
48 Friction losses 0.0002 bar
49 Valves and fitting losses 0.0007 bar
50 Elevation pressure drop 0.0006 bar
51 Total Pressure Drop HP Piping 0.0015 bar
52 LPPH Inlet Steam
53 SteamPressure at junction ps 1.019 bar(a)
 Flash Steam NOTES
2
to Deaerator [1] Assumption of cold boiler
draining.
Intermittent Blowdown 7

Sootblower Condensate 8

Note [1] Hot Make-up

Boiler Drains 9 to Deaerator

Deaerator Overflow & 10 HOLDS

Drains
11 Vent Steam

Flash
Tank
Continuous Blowdown 1 T-06-
17026
6
Atmospheric
Blowdown Tank
T-06-17081

3 4
Make-up Water KEY
LCV
Preheater 12 Water
HE-06-17083 Saturated Steam
Make-up Water from Condensate
5
Treatment Plant To Drain System Intermittent Cond.
TCV
Foul Water

STREAM 1 2 3 4 5 6 7 8 9 10 11 12
Continuous Flash Tank Cold Hot Intermittent Sootblower Deaerator Blowdown
Description Flash Steam Cold Liquor Boiler Drains Vent Steam
Blowdown Liquor Make-up Make-up Blowdown Condensate Overflow Tank Outlet
Flow [kg/h] #NAME? #NAME? #NAME? #NAME?
Temperature [°C] #NAME? #NAME? #NAME? 20
Pressure [bar(a)] 48.8 #NAME? #NAME? 4
Density [kg/m³] #NAME? #NAME? #NAME? 998.3
Volume Flow [ m³/h] #NAME? #NAME? #NAME?

STREAM 13 14 0 19/09/23 Issued For Review GN LM

Rev Date Description Drawn Checked Approved
Description
Job No. Client: Site: HULL, UNITED
GALLIFORD TRY
Flow [kg/h] MI-17085 KINGDOM
Temperature [°C] Title:
Pressure [bar(a)]
BLOWDOWN SYSTEM PROCESS FLOW
Density [kg/m³]
DIAGRAM
Volume Flow [ m³/h]

Doc. No. Size: A4

MI-17085-PR-PF-001
Sheet: 01 of 01