2500

2450

2400

2350

2300

2250

2200

2150

2100

2050

2000

1950

1900

1850

1800

1750
1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200
 DESIGN OF FLANGES & PIPE THICKNESS LWSS TO SHARACHALI AREA TEHSIL JUBBAL DISTT.SHIMLA (HP) STAGE II

1) INPUT DATA

Static Head 369.80 Mts Pipe Dia 80 mm Velocity of flow 1.243311 Mt/Sec Pipe 1978-1992 Latest With up to
Code date ammendments
Total Head 412.16 Mts Outer dia 88.9 mm RL of Delivery point 2048 Mt
Yst Grade 210
Frictional Losses 42.36084 Mts Length of 930 Mts RD of delivery point 2550 Mt
Pipe GI PIPE 1239 Latest With up to
Terminal Head 3 Mts date ammendments

RD 1620 1650 1680 1710 1740 1770 1800 1830 1860 1890 1920 1950 1980 2010 2040 2070 2100 2130 2160 2190 2220 2250 2280
RL 1753 1764 1774 1783 1789 1796 1803 1809 1813 1819 1827 1835 1843 1852 1862.00 1873 1887 1902 1921 1927 1939 1949 1959

2) CALCULATIONS OF FLANGE TABLES & PIPE THICKNESS

Static Head 298 287 277 268 262 255 248 242 238 232 224 216 208 199 189 178 164 149 130 124 112 102 92

Total Head for 340.36 327.99 316.63 306.26 298.89 290.53 282.16 274.80 269.43 262.06 252.70 243.33 233.96 223.60 212.23 199.86 184.50 168.13 147.76 140.40 127.03 115.66 104.30
design of flanges

Flange Table 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 28 17 17 17 17 17

Surge Pressure 155 155 155 155 155 155 155 155 155 155 155 155 155 155 155 155 155 155 155 155 155 155 155

Field Test pressure for

Thickness of pipe
Shall be Max of
1.5*Static head 447 431 416 402 393 383 372 363 357 348 336 324 312 299 284 267 246 224 195 186 168 153 138
1.5* total pressure 511 492 475 459 448 436 423 412 404 393 379 365 351 335 318 300 277 252 222 211 191 173 156
Total pressure+ 496 483 472 462 454 446 438 430 425 417 408 399 389 379 368 355 340 324 303 296 282 271 260
Surge pressure

Field Test Pressure 511 492 475 462 454 446 438 430 425 417 408 399 389 379 368 355 340 324 303 296 282 271 260

Design Pressure 766 738 712 693 681 669 656 645 637 626 612 598 584 569 551 533 510 485 455 444 424 407 390
(1.5*FTP)

Type of Pipe MSERW MSERW MSERW MSERW MSERW MSERW MSERW MSERW MSERW MSERW MSERW MSERW MSERW MSERW MSERW MSERW MSERW GI(H) GI(H) GI(H) GI(H) GI(H) GI(H)

Thickness of pipe as 2.65 2.60 2.51 2.44 2.40 2.36 2.32 2.28 2.25 2.21 2.16 2.11 2.06 2.01 1.95 1.88 1.80 1.71 1.60 1.57 1.49 1.43 1.37
per 1978-1992 for YST
210 Grade

Corrosion factor (mm) 3.65 3.60 3.51 3.44 3.40 3.36 3.32 3.28 3.25 3.21 3.16 3.11 3.06 3.01 2.95 2.88 2.80 2.71 2.60 2.57 2.49 2.43 2.37
1.00

Provide thickness (mm) 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40 4.40 -------------- -------------- --------------
 2310 2340 2370 2400 2430 2460 2490 2520 2550 2580 2610 2640 2670 2700 2730 2760 2790
1970 1979 1990 1999 2007 2016.00 2025.00 2036 2048 2063 2076 2090 2101 2118 2133 2147 2158.0

81 72 61 52 44 35 26 15 3 -12 -25 -39 -50 -67 -82 -96 -107 2051 2051 2051 2051

91.93 81.57 69.20 58.83 49.47 39.10 28.73 16.37 3.00 -13.37 -27.73 -43.10 -55.47 -73.83 -90.20 -105.57 -117.93 2167.15 2167.15 2167.15 2167.15

17 17 17 5 5 5 5 5 5 5 5 5 5 5 5 5 5 0 0 0 0

155 155 155 155 155 155 155 155 155 155 155 155 155 155 155 155 155 155 155 155 155

122 108 92 78 66 53 39 23 5 -18 -38 -59 -75 -101 -123 -144 -161 3077 3077 3077 3077
138 122 104 88 74 59 43 25 5 -20 -42 -65 -83 -111 -135 -158 -177 3251 3251 3251 3251
247 237 225 214 205 195 184 172 158 142 128 112 100 82 65 50 37 2323 2323 2323 2323

247 237 225 214 205 195 184 172 158 142 128 112 100 82 65 50 37 3251 3251 3251 3251

371 355 337 321 307 292 276 258 238 213 192 168 150 122 98 75 56 4876 4876 4876 4876

GI(H) GI(H) GI(H) GI(H) GI(H) GI(H) GI(H) GI(H) GI(H) GI(H) GI(H) GI(H) GI(H) GI(H) GI(H) GI(H) GI(H) MSERW MSERW MSERW MSERW

1.31 1.25 1.19 1.13 1.08 1.03 0.97 0.91 0.84 0.75 0.68 0.59 0.53 0.43 0.35 0.26 0.20 17.20 17.20 17.20 17.20

2.31 2.25 2.19 2.13 2.08 2.03 1.97 1.91 1.84 1.75 1.68 1.59 1.53 1.43 1.35 1.26 1.20 18.20 18.20 18.20 18.20

-------------- -------------- GI (HEAVY WITH APPROPPRIATE FLANGES-------------------------- -------------- -------------- -------------- -------------- -------------- -------------- -------------- -------------- -------------- -------------- -----------------
2.608
DATA: -
Tensile Strength 320 MPa Yield stress 195 Mpa
factor of safety 3
Joint Efficiency 0.75
% age variation in thickness -10 %
Corrosion factor 1.5 mm

HEAVY CLASS PIPES

S.No. Nominal Outer dia Thickness Minm Effective Test Max Test Test Allowable
dia of thickness Thickness pressure Pressure Pressure head in
pipe as per code
mm mm mm mm mm MPa MPa Mpa Mts

1 15 21.80 3.25 2.925 1.425 10.46 5.00 5.00 3.75

2 20 27.30 3.25 2.925 1.425 8.35 5.00 5.00 3.75
3 25 34.20 4.05 3.645 2.145 10.04 5.00 5.00 3.75
4 32 42.90 4.05 3.645 2.145 8.00 5.00 5.00 3.75
5 40 48.80 4.05 3.645 2.145 7.03 5.00 5.00 3.75
6 50 60.80 4.50 4.05 2.55 6.71 5.00 5.00 3.75
7 65 76.60 4.50 4.05 2.55 5.33 5.00 5.00 3.75
8 80 89.90 4.85 4.365 2.865 5.10 5.00 5.00 3.75
9 100 115.00 5.40 4.86 3.36 4.67 5.00 4.67 3.51
10 125 140.80 5.40 4.86 3.36 3.82 3.82 3.82 2.86
11 150 166.50 5.40 4.86 3.36 3.23 3.23 3.23 2.42

MEDIUM CLASS
S.No. Nominal Outer dia Thickness Minm Effective Test Max Test Test Allowable
dia of thickness Thickness pressure Pressure Pressure head in
pipe
mm mm mm mm mm MPa MPa Mts Mts

1 15 21.80 2.65 2.385 1.385 10.17 5.00 500.00 375

2 20 27.30 3.25 2.925 1.925 11.28 5.00 500.00 375
3 25 34.20 3.25 2.925 1.925 9.01 5.00 500.00 375
4 32 42.90 3.25 2.925 1.925 7.18 5.00 500.00 375
5 40 48.80 3.25 2.925 1.925 6.31 5.00 500.00 375
6 50 60.80 3.65 3.285 2.285 6.01 5.00 500.00 375
7 65 76.60 3.65 3.285 2.285 4.77 5.00 500.00 375
8 80 89.90 4.05 3.645 2.645 4.71 5.00 500.00 375
9 100 115.00 4.50 4.05 3.05 4.24 4.24 424.35 318
10 125 140.80 4.85 4.365 3.365 3.82 3.82 382.39 287
11 150 166.50 4.85 4.365 3.365 3.23 3.23 323.36 243
Allowable
With new As per IS 2825
Formula

11.4719 11.19018
9.160714 8.811594
11.00724 10.7066
8.775 8.421053
7.714088 7.356125
7.360609 7.004292
5.842363 5.509791
5.592964 5.266847
5.127652 4.815478
4.188068 3.911525
3.541622 3.295329

Allowable

11.14989 10.85476
12.375 12.13793
9.878289 9.54299
7.875 7.516779
6.9229 6.570667
6.595683 6.247971
5.235215 4.919599
5.163487 4.850152
4.654565 4.359089
4.1943 3.917488
3.546892 3.300334
 Analysis of manufacturing bend of 80 mm dia.from parent pipes(Duly flanged )

Dia. 80 Outer dia. 88.9 mm

Flange Table 28 Weight 4.026 kg
Weight of one nut & bolt 0.229 Dia. Of 0.200 mtr.
flange
No. of nuts & bolts 8 M16
Quantity unit Rate Amount
Cost of cutting parent pipes to manufacture 83.820 cm 1.25 104.78
bend=3xPIxD

Cost of welding of portions in two layers (Three 167.64 cm 2.50 419.10

piece bend)=3x2xPIxD

Cost of gasket ((Dia of flange)²*8.8) 0.352 kg 160 56.32

Cost of welding of flanges to bend 111.76 cm 2.50 279.40

Cost of flanges with nuts & bolts=2x weight of 9.884 kg. 58.24 575.64
flange + 8 x weight of one nut & bolt
Total cost of bend 1435.24
Add 10% C.P+5% O.H charges 215.29
Cost of one bend 1650.53
Consider 3% bend on over all 0.333 each 1650.53 549.62
length.hence,No.of bends per 10 rmt.=0.333

Less 1/6th of cost of flanges on account of 91.60

consider 6 mtr. Length of each pipe

Actual cost of bend 458.02

Say Rs. 458 only

Analysis of manufacturing bend of 80 mm dia.from parent pipes(Duly flanged )

Dia. 80 Outer dia. 88.9 mm

Flange Table 17 Weight 3.299 kg
Weight of one nut & bolt 0.219 Dia. Of 0.200 mtr.
flange
No. of nuts & bolts 8 M16
Quantity unit Rate Amount
Cost of cutting parent pipes to manufacture 83.820 cm 1.25 104.78
bend=3xPIxD
Cost of welding of portions in two layers (Three 167.64 cm 2.50 419.10
piece bend)=3x2xPIxD
Cost of gasket ((Dia of flange)²*8.8) 0.352 kg 160 56.32

Cost of welding of flanges to bend 111.76 cm 2.50 279.40

Cost of flanges with nuts & bolts=2x weight of 8.350 kg. 58.24 486.30
flange + 8 x weight of one nut & bolt

Total cost of bend 1345.90

Add 10% C.P+5% O.H charges 201.88

Cost of one bend 1547.78

Consider 3% bend on over all 0.333 each 1547.78 515.41
length.hence,No.of bends per 10 rmt.=0.333

Less 1/6th of cost of flanges on account of 85.90

consider 6 mtr. Length of each pipe

Actual cost of bend 429.51

Say Rs. 429.5 only

Analysis of manufacturing bend of 80 mm dia.from parent pipes(Duly flanged )

Dia. 80 Outer dia. 88.9 mm

Flange Table 5 Weight 2.608 kg
Weight of one nut & bolt 0.209 Dia. Of 0.190 mtr.
flange
No. of nuts & bolts 4 M16
Quantity unit Rate Amount
Cost of cutting parent pipes to manufacture 83.820 cm 1.25 104.78
bend=3xPIxD
Cost of welding of portions in two layers (Three 167.64 cm 2.50 419.10
piece bend)=3x2xPIxD

Cost of gasket ((Dia of flange)²*8.8) 0.318 kg 160 50.83

Cost of welding of flanges to bend 111.76 cm 2.50 279.40

Cost of flanges with nuts & bolts=2x weight of 6.888 kg. 58.24 401.16
flange + 8 x weight of one nut & bolt
Total cost of bend 1255.26
Add 10% C.P+5% O.H charges 188.29
Cost of one bend 1443.55
Consider 3% bend on over all 0.333 each 1443.55 480.70
length.hence,No.of bends per 10 rmt.=0.333
Less 1/6th of cost of flanges on account of 80.12
consider 6 mtr. Length of each pipe
Actual cost of bend 400.59

Say Rs. 400.6 only

 Economical Dia Statement and Design of Pumping Machinary
Name of Work :- PROVIDING LWSS TO HALLAU ,SHALLAN & ARNOUT IN TEHSIL CHOPAL DISTT. SHIMLA (HP) STAGE-II
DATA:
1) Length of pumping(Rising) main = 930 m 0 T. Length = 930 12) Value of `C' = 100 RATES FOR G.I. PIPES
2) R.L. of discharge (last) point = 7896.7 m; Pipe class = S [S =>Spl.,H =>Heavy & M =>Med] 13) Cost of pumping unit per KW = Rs 5000 /= Per KW Dia Medium Heavy Special
3) R.L.of Pump Shaft /central axis= 7526.9 m 14) Rate of Interest 8% 32 175.65 200 250
4) Low Water level in sump well = 7526.9 m .'. T Static head +3m res.head= 372.8 m 15) Life of elec.motor & pump set = 15 years 40 189.9 217.6 272
5) Pumping hrs.@ the end of 15Yrs.= 4 hrs 16) Energy charges per unit = Rs. 2.45 /= Per KW 50 245.4 289.9 362.38
6) No.of working Pumpsets provided= 1 & Standby= 1 [1=100%,0.5=50% &0=nil stdby] 17) Water available from Other Source = 0 Lt/Day 65 299 350.4 438
7) Construction Period = 4 yrs. 80 365.5 418.7 523.38
8) Percentage rate of increase = 1.61% 100 509.9 587.85 734.81
CALCULATION OF ULTIMATE POPULATION Population Input CALCULATION OF WATER REQUIREMENT:
Person Students +HOSPTL Hostel Hotel Employee Pilgrim 7) Initial Total Water Requirement. = 59080 Lt/Day 125 648.25 715.95 894.94
9) Water requirement per capita per day= 70 10 450 135 180 45 10 8) Initial Net Water Requirement. Q1= 59080 Lt/Day 150 763.1 844.4 1055.5
10) Population as per Census 1991 615 9) Intermed. Total Water Requirement = 72520 Lt/Day Spl.Class
11) Present population in 2009 793 0 0 0 0 0 10) Intermed. Net Water Requirement, Q2=* 72520 Lt/Day (for (for P/M) 200 1266.6 1266.6
CALCULATIONS: 11) Ultimate Total Water Requirement = 90020 Lt/Day 250 1519.92 1519.92
1 Popu.i/c Const. Period = 2010 844 0 0 0 0 0 0 12) Ultimate Net Water Requirement, Q3= 90020 Lt/Day= 90.02 300 1823.9
2 Intermediate Popu.after15 yrs = 1036 0 0 0 0 0 0 13) Combined efficency of pumpset = 0.60 Kld 350 2188.68
3 Ultimate Popu. after 30 years = 1286 0 0 0 0 0 0 400 2626.42
1ST 15 YRS. 2ND 15 YRS 1ST 15 YRS. 2ND 15 YRS 450 3151.7
4 Discharge at installation = 0.059 mld 0.07252 17) Avg.hrs of pumping avg. discharge= 3.6293436293 3.6111975117 500 3782.04
5 Discharge at the end of 15 Yrs.= 0.073 mld 0.09002 18) KW. required per m Head = 0.082 0.102
6 Average dicharge = 0.066 mld 0.08127 19) Annual Energy charges per KW = 3247.6745946 3231.4367589
-
S. PIPE FRICTION HEAD VELOCITY Total head (m.) for 930 m. length 1st stage flow 2nd stage flow COST OF PIPE First Stage Economics Second Stage Economics Overall Dia for
N. SIZE Loss /1000 mtr in m/s including 372.8 372.8 m. static head 0.07252 mld 0.09002 mld 930 Mtr. Annual Capitalised Total Annual Capitalised Initial Capital Cost for which
in ---------------- ------------------- ---------------- ---------------- ---------------- --------------- ------------ ------------------ ------------------ ------------------ ---------------- ---------------- ----------- ---------------- ------------------ -------------- Energy Energy Capitalised Energy Energy Investment for 30 Yrs. cost is
mm 1st 2nd 1st 2nd 1st stage TOTAL 2nd stage TOTAL KW 1 Cost of KW 2 Pump COST Total Cost Cost Cost Cost Cost P/Set & annual minimum
stage stage stage stage FRICTION OTHER HEAD FRICTION OTHER HEAD Reqd.i/e Pump Reqd.i/e Cost IN per Cost Elect Charges
flow flow flow flow LOSSES LOSSES H1 LOSSES LOSSES H2 Standby (Ths.Rs) Standby (Ths.Rs) metre (Th.Rs) (Th.Rs) (Th.Rs) (Ths.Rs) (Ths.Rs) (Ths.Rs) (Ths.Rs) (Ths.Rs)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 -
1 40 754.15771031 1125.424263346 4.0064375806 4.9732420161 701.36667059 70.13666706 1144.3033 1046.64456491 104.664456491 1524.1090214 188.32806383 941.64031915 311.366 1556.8297715 272 252.96 305.81413418 2578.12 3772.721403347 503.07969512 4241.14 1765.457736292 5538.17914 0
2 50 254.37505447 379.6021102493 2.5641200516 3.1828748903 236.56880066 23.65688007 633.02568 353.029962532 35.3029962532 761.132958785 104.18260341 520.91301705 155.4947 777.47354927 362.38 337.0134 169.17559715 1426.21 2284.136409297 251.23566062 2118.01 881.6613848248 3165.79779 0
3 65 70.880731779 105.7748190558 1.5172307998 1.8833579233 65.919080554 6.591908055 445.31099 98.3705817219 9.83705817219 481.007639894 73.288745674 366.44372837 98.26686 491.33428358 438 407.34 119.0089987 1003.29 1777.071590067 158.77156649 1338.50 557.1771094729 2334.2487 0
4 80 25.783068595 38.4758924876 1.0016093952 1.243310504 23.978253794 2.397825379 399.17608 35.7825800135 3.57825800135 412.160838015 65.695917896 328.47958948 84.20189 421.00942536 523.38 486.7434 106.67948176 899.35 1714.568671838 136.0465333 1146.92 477.4281431654 2191.99682 80
5 100 8.696548996 12.97779909116 0.6410300129 0.7957187226 8.0877905663 0.808779057 381.69657 12.0693531548 1.20693531548 386.07628847 62.819161286 314.09580643 78.87297 394.36487255 734.81 683.3733 102.00809708 859.96 1857.433367246 127.43651456 1074.33 447.2130016339 2304.64637 0
TABLE shows that the most economical size of main = 80 mm Dia Pipe
* DESIGN OF B.H.P. OF PUMPING MACHINARY *
DESIGN CALCULATIONS :--
1 Total pipe length i/c 10% for bends etc 1023 6 Losses of head on delivery side:
1 Suction & delivery components: Suction Side | Delivery Side 2 Design Discharge (carrying capacity) 435.456 KLd a) Due to friction in delivery pipe= 0.005 m
a) Dia of pipes : 100 mm | 150 mm 3 Design discharge per Pump 435.456 KLd b) Loss in reflux valve = 0.010 m | v' = 0.2852057
b) Length of pipe : 8m | 4m 4 Losses in suction side: c) Loss in sluice valve = 0.001 m|
c) Nos. of `Bends' provided : 1 no. 1 no. a) Frictional losses in suction pipe 0.070 m d) Losses in bends = 0.009 m |v^2/2g= 0.0041459
2 Dia of rising main = 80 mm b) Loss of head at entrance 0.016 m |Assuming e) Losses in Tee = 0.000 m|
3 Static Delivery Lift = 369.8 m (From PSL to delivery pt.) c) Lossin of head in foot valve 0.031 m | K =0.78 7 Total losses in delivery side = 0.024 m
4 Static suction lift (from pump = 0 m .`.Tl.head = 369.8 m d) Loss of head in bends 0.046 m |v= 0.64171273055 8 Frictional losses in rising main = 26.41385383793 m
-shaft level to LWL.) e)Losses due to i)Vapour tension 0.240 m |v^2/2g a) Exit losses = 0.051241561911 m|v = 1.0026761
5 Peak water requirement /Day = 0.8393518519 lps say 0.84 lps ii)Altitude,@ 1.15 m/1000m above MSL 0.518 m|= 0.02098854376 b) Residual head = 3 |
6 Pumping huurs = 4 Hours ( 72.576 Kld) iii) Velocity head 0.021 m 9 Total head to work out BHP = 399.4740639194 m
7 No. of pumping sets = 1 no. & 1 no. Standby iv) Low barometer 0.370 m 10 Total BHP of pumps reqd. @ 60% eff.= 44.74109515897 HP
8 Length of rising main = 930 m 5 Total loss of head on suction side: 11 BHP of each pump required >>> = 44.74109515897 HP + 10% = 49.215205
9 Level of P/Station above M.S.L.= 450 m a) For calculating NPSHA 1.312 m 12 NPSH available = 9.017810714872 m
10 Coeff. of roughness of pipes,C = 100 b) For calculating B.H.P. 0.185 m PUMP DESIGN OUTPUT -
Use total 2 Sets of 40 HP each i/c 1 Stand-by
Note: NPSHR should always be less than NPSHA by at least 0.60 m Duty per Pump: a) Capacity= 5.04 lps b)Total head = 399.4741