PROCESS DESIGN CALCULATIONS

FOR TUBE SETTLER IN WATER TREATMENT PLANT

5.0 (C) TUBE SETTLER
Raw water Flow
Recycle Flow
Design Flow

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Shape of unit
Length/ Breadth of Tube Settler provided

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100
5
100+5
105
4
105/4
26.250
26250.000
1093.750
Square
11.40

Tube Pack Data:

Shape
Cross sectional area
Hydraulic radius
Settling area : 60 Slope
Settling area : 55 Slope
Vertical Space between Tubes
Angle of inclination

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Hexagonal - Chevron
120 x 44
mm x mm
0.015
m
11
m/m
13
m/m
0.044
m
55

Settling area of Tube Pack, corresponding to the inclination,

based on the effective volume of Tube Pack

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1.00
m/m/h
0.70
1* 0.7
0.70
m/m/h
0.00000080
m/s
20.00
C
0.000001003
m/s
0.0000008/0.000001003
0.798
0.7*0.798
0.558
m/m/h
0.700
m/m/h
1.000
11.4*11.4
129.960
m
129.96*1
129.960
m
11.4*1 *(1/TAN55)
7.982
m
129.96-7.982
121.978
m
121.978*13
1585.709
m

Actual Settling rate on the horizontal projected area of Tube Pack

1093.75 / 1585.709
0.690
m/m/h
0.70
m/m/h
Hence O.K.

Number of units provided

So, Design flow per Tube Settler

Select, Settling rate on the horizontal projected area of Tube Pack

Apply the probability factor,as recommended by theTube Pack Vendor
Revised Settling rate on the horizontal projected area of Tube Pack
Kinematic viscosity of water at 30C
Design temperature of water
Kinematic viscosity of water at 20C
Correction Factor for Settling rate, w.r.t. Kinematic viscosity
Corrected Settling rate
Selected Settling rate on the horizontal projected area of Tube Pack
Selected vertical depth of Tube Pack
Plan area of the Tube Settler
Volume of Tube Pack provided
Loss of volume of Tube Pack, on account of inclination
Effective volume of Tube Pack

<

Mld
Mld
Mld
nos.
Mld
m/d
m/h
m

Check for the performance of the Tube Settler:

Sedimentation takes place in the length following the transition length and it will retain all particles
with a settling velocity less than Vs.

Vs

= V. k / { [sin + (Ls/d)cos ] }

Where,
Vs = Settling velocity, m/m/h

Ls = Settling length of Tube

d = depth of water in a Tube at right angle to the direction of flow, m
= angle of inclination of Tube Pack to the horizontal
k = a coefficient
= 1.33 for Hexagonal Tubes
Schiller formula to calculate transition length:

Lt = 0.0288 NR .D
Where,
Lt = Transition length
V = Average velocity of flow in the Tubes, m/h.m
= U / sin
U = Average upward velocity, m/h.m
= Surface loading rate of the Settling Tank
= Rate of flow / Tube entrance area
= Kinematic viscosity of water, m/s
NR = Reynolds Number

0.00000086

m/s

Ls = L - Lt
Where,
L = Length of Tube
Ls = Settling length of Tube
Plan area of the Tube Settler

=
11.4*11.4
=
129.96
m
The tube entrance area is reduced due to the thickness of the tube pack and also due to the supporting
structure provided.
The support width of minimum 60 mm is recommended at a centre-to-centre distance of 1000 mm, in a
square grid.
No. of supporting angles, lengthwise @ 1m c-c spacing
=
(11.4/1)+1
=
12.40
nos.
Say
=
13.00
nos.
No. of supporting angles, breadthwise @ 1m c-c spacing
=
(11.4/1)+1
=
12.40
nos.
Say
=
13.00
nos.
=
65.000
mm
Width of supporting angle of standard size, provided
=
0.065
m
Plan area lost by the supporting angles of width 65 mm
=
(11.4*13*0.065)+(11.4*13*0.065
-(13*13*0.065*0.065)
=
0.768
m
=
3.00
% of plan area
Plan area lost by the thickness of the Tube Pack
=
3%*129.96
=
3.899
m
Total area of obstruction for flow through Tube Pack
=
0.768+3.899
=
4.667
m
Tube entrance area
=
129.96-4.667
=
125.293
m
Average upward velocity, U
=
1093.75/125.293
=
8.730
m/h
Average velocity of flow in the Tubes, V
=
U / sin
=
8.73 / sin 55
=
10.657
m/h
=
0.003
m/s
Hydraulic radius, R ( = CSA / Wetted perimeter)
Equivalent diameter, D ( = 4 R)

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0.01500
4*0.015
0.060

Reynolds Number, NR

VR

m
m

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0.003*0.015/0.00000086
51.632

Transition length of Tube

Settling length of Tube, Ls

Relative settling length of tube = Ls/d

Coefficient k for Hexagonal shaped Tubes
Vs

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0.0288*NR*D
0.0288*51.632*0.06
0.089
m
L - Lt
1-0.089
0.911
0.911/0.044
20.700
1.33

V. k / { [sin + (Ls/d)cos ] }

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10.657*1.33/((sin55+20.7*cos55))
1.117
m/m/h
0.690
Hence O.K.

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11.40
1093.75

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0.025
m/s
1093.75 / 3600 / 0.025
12.15
m
12.15 / 11.4
1.066
m
1.00
m
0.30
m
0.65 + 1 + 1.066 + 1 + 0.3
4.016
m
4.05
m
Hence O.K.

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250
m/m/d
26250/250
105.000
m
105/(2*(11.4-(1/TAN 55)
4.907
6.000
nos.
6*2*((11.4)-(1/TAN55))
128.398 m
1093.75 / 128.398
8.52
m/m/h
204.44
m/m/d
250.00
m/m/d
Hence O.K.
30.000
Mld
30000.000
m/d
30000 / 128.398
233.65
m/m/d

Unit Size
Length / Breadth of Tube Settler provided
Flow per Tube Settler
Approx.liquid height above the top of the tube pack
Vertical Height of Plates
Horizontal velocity in the clarification shall be 0.02 to 0.03 m/s.
Horizontal Velocity in the clarification zone selected
C/S area of clarification zone required below Tube Pack
Height of the Clarification zone required
Depth of the sludge compression zone provided
Space provided for sludge scrapper
Side water depth of unit required
SWD provided

Provide V-Notch weir plates on the inner side of overflow launders.

Recommended weir loading for Tube Settler
Length of weir to be provided
No.of overflow launders to be provided
Say
Approx.length of weir provided in each Tube Settler
Discharge rate at design flow over the weir

Design Hydraulic flow per Tube Settler

Discharge rate at design Hydraulic flow over the weir

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Size: 4 Nos. Tube Settlers, each of 11.4 m x 11.4 m x 4.05 m SWD

0.65
1.00

m
m/h
0.3038 m/s
m
m