Design Basis Report For Balance of Plant Equipments (Mechanical)

DESIGN BASIS REPORT
FOR BALANCE OF PLANT

EQUIPMENTS
(MECHANICAL)
R4 Revised as per SCPL

04 06.01.15 S. Vijayasekar T. Thanapal BRR
comments dt. 03.01.15
Revised as per SCPL
R3 03 31.12.14 S. Vijayasekar T. Thanapal BRR
Revised as per SCPL
Revised as per MOM
dated 17.10.14
Initial submission for
00 18.05.2013 S. Sennakesavan T. Thanapal BRR
approval
Rev No Date Description Prepared Verified Approved
PROJECT 1 X 50 MW EXTN.THERMAL POWER PLANT
CUSTOMER M/s. SPECTRUM COAL & POWER LIMITED.
EPC CONTRACTOR M/s. ISGEC HEAVY ENGINEERING LIMITED.
Date 06.01.15
DOCUMENT NO JP0025-75990100-DBR-001 Rev 04
No. of pages 68
DESIGN BASIS REPORT –BALANCE OF PLANT EQUIPMENTS
DOCUMENT ID JP0025-75990100-DBR-001 REVISION : 04

ITEM CODE DBR001 QUANTITY :-
DESCRIPTION DESIGN BASIS REPORT
CONTENTS
S.NO. DESCRIPTION PAGE NO.
INTRODUCTION 3
1.
PROJECT DETAILS & SITE DATA 3
2. AIR COOLED CONDENSER 4

3. WATER SYSTEM 10
4. AUXILIARY COOLING TOWER 15
5. MISCELLANEOUS PUMPS 17
6. COAL HANDLING SYSTEM 22
ASH HANDLING SYSTEM
DENSE PHASE BED ASH HANDLING SYSTEM 36
7.
DENSE PHASE FLY ASH HANDLING SYSTEM 36
HDSD SYSTEM 41
8. EOT CRANE 43
COMPRESSED AIR SYSTEM
INSTRUMENT AND SERVICE AIR COMPRESSOR 43
9.
AIR DRIER 44
AIR RECEIVER 44
10. RCC CHIMNEY 47
11. EXHAUST VENTILATION SYSTEM 48
12. AIR CONDITIONING SYSTEM 50
13. FIRE FIGHTING SYSTEM 51
14. PIPING SYSTEMS 56
15. LAYOUT FACILITIES 61
16. CODES AND STANDARDS 64
17. LIST OF DRAWINGS 68
PROJECT :
1 X 50MW EXTN. THERMAL POWER PLANT FOR
PROJECT ID : JP0025
M/s. SPECTRUM COAL & POWER LIMITED.
PREPARED BY VERIFIED BY APPROVED BY DATE : 06.01.15
S.VIJAYASEKAR T. THANAPAL BRR SHEET : 2 of 68

01.00.00 INTRODUCTION
01.00.01 The purpose of this design basis report is to elaborate the sizing and specification of
BOP equipments and systems for the extension of 50MW thermal power plant
proposed at the village Ratija, District Korba and state Chattisgarh.
01.01.00 PROJECT DETAILS & SITE DATA
S.No. Description Unit

A Site details
Engineering, Procurement, Supply, Construction,
1. Project Title Erection & Commissioning of 1 x 50 MW
washery coal reject based Thermal power plant
2. Client M/s. Spectrum Coal & Power Limited.
3. EPC contractor M/s. Isgec Heavy Engineering Limited
4. Owner’s Consultant --
Village Ratija, , Dist. Korba, Chhattisgarh,
5. Plant Location
Latitude - 22o 20’ N Longitude - 82o 42’ E
6. Power Plant Capacity MW 50
7. Seismic Co-efficient zone Zone – III as per IS 1893 - 2005
8. Design Wind Velocity m/s As per IS 875, Part 3 – 39 m/s
9. Wind Direction NE-SW
10. Area classification Safe , Non- hazardous & Non- Corrosive
B Meteorological data
Tropical, Very dry and hot summer, dry & cold
11. Climate winter and good rainfall in monsoon
accompanied with strong wind
Ambient Temperature:
12. °C 08 / 46 / 35 (Performance)
(Min. / Max. / Average)
Relative Humidity :
13. % 33 / 83 /60 (Performance)
(Min. / Max. / Average)
Wet Bulb Temperature :
14. °C 28
(design)
Design Temperature for
15. °C 50
Electrical equipments
Average annual rainfall /
16. mm 1429.1 mm / 877.1 mm
Highest rainfall in a month
Plant Elevation above Mean
17. 319.5 m
Sea Level
18. Nearest Railway Station Gevra road station (25 KM)
19. Nearest Airport Domestic - Raipur (~200 kms)
20. Nearest town Korba – 30 KM
21. Nearest harbor Paradweep (~600 kms)
PROJECT :
PROJECT ID : JP0025

02.00.00 AIR COOLED CONDENSER
02.00.01 Air cooled condenser and its auxiliaries shall be provided for cooling of turbine
Exhaust steam. The proposed Air-cooled condenser is designed for 50 MW TMCR
condition with design ambient temperature as 38°C to maintain 0.18 bar (a) exhaust
pressure during 50 MW generation.
Air cooled condenser Unit Details
ACC type Forced Draft, direct air cooled, ‘A’ frame

Design ambient temperature °C + 38°C
Quantity nos 1
Turbine exhaust orientation Towards bottom.

100 %
105 % Top HP
TMCR
Description TMCR heater out
(Guarantee (VWO
Condition) condition
condition)
Exhaust steam flow kg/hr 143123 151366 146566
Kg/Cm2
Exhaust steam pressure 0.18 0.2 0.18
(a)
Steam exhaust Enthalpy kcal/kg 563 564.7 564.2
Condensate temperature
°C 57.4 59.7 57.4
(° C)
Heat load Kcal/hr 72362989 76439830 74279649
No. of cells 9
No. of streets Three
Type of fin Aluminum KL / LL Fined tube
Steam duct material IS 2062. Non IBR
Dumping Tube arrangement Not applicable

CEP pumps
Quantity 2 no. (1W +1S)
Type Horizontal centrifugal type
Pump capacity & Head 190 m3/hr & 150 MWC (Tentative)
PROJECT :1 X 50MW EXTN. THERMAL POWER PLANT FOR

PROJECT ID : JP0025

Margin on flow and head % 10 % and 5 % respectively.

Casing SA 216 Gr. WCB
Impeller CF8M / CA6NM
Shaft AISI 410
Casing wearing ring CF8M / CA6NM
Condensate storage tank
Quantity : One (1)

: Horizontal with Dished ends & Saddle
Type
supported.
: Suitable for 10 minutes storage time
Capacity
(Normal water level to Low water level).
Material of Construction : IS 2062 Gr.B
Corrosion Allowance 1.6 mm
Finned Tubes
MOC Carbon Steel to SA-214(ERW)
Type Circular.
Fins
MOC Aluminum.
Type KL / LL Finned tube.
Ejector
Hogging ejector
Quantity 1 X 100 %
Capacity 70% vacuum in 30 minutes
No. of Stages One (1).
Holding Ejector
Quantity 2 X 100 %
No. of Stages Two (2).
Inter / After condenser tubes
Stainless Steel (ERW)
MOC
Manual changeover of hogging to holding
Changeover ejector and working to standby holding
ejector

PROJECT ID : JP0025


Fans
Blades MOC FRP
33 % of fan motor (3 fans) shall be provided
Motor
with VFD.
Fan speed RPM 61 m/s (120000 ft/min.)
Motor rating KW 110
Semi Automatic fin cleaning system will be

provided and the same shall function while
Fin cleaning system
ACC in service.
Drain pot (Hot well)
Quantity (1) no. of hot well shall be provided
Vertical attached with Exhaust Steam duct

Type
& Supported from bottom floor.
Capacity CuM 1.2
Material of Construction IS 2062
Corrosion Allowance 1.6 mm
Insulation Not Applicable.
Draining time of hot well Approx. 5 minutes
Drain pot pumps (Hot well)
Quantity Two (2) nos. (1W+1S)
Type Horizontal, Centrifugal
Margin on flow and head % 10 % and 5% respectively.
MOC

PROJECT ID : JP0025

Casing SA216 Gr. WCB
Impeller CF8M / CA6NM
Shaft AISI 410
Casing wearing ring CF8M / CA6NM
ACC support RCC up to Fan deck level
Terminal points
Exhaust steam At the outlet of turbine matting flange

Condensate from Air cooled
At the inlet of Deaerator.
condenser
At the inlet flange of Ejector motive steam
Auxiliary steam to ejector
header.
Face velocity (air) across tube

m/s 1.95 (Average)
bundle
Air side fouling factor m² K/W 0.0001
Steam side fouling factor m² K/W 0.00005

Corrosion allowance for
mm 1
ducting and manifolds
ACC continuous operating Kg/cm2
0.16 to 0.25
pressure range (a)
Dephlegmator Provided
Refer attached drawing no: JP0025-75610100-
P&I Diagram
PID-001
5% over the calculated area as per TMCR
Margin on heat transfer area
condition
O2 level in condensate at CEP
Cc/lit Later
discharge with 3% make up
2.1 Brief description of Air cooled Condenser

2.1.1 The ACC shall be of forced draft, direct air cooled and ‘A’ frame type, with the steam
distribution manifold at the top and with drain manifolds at the bottom. The condenser
elements shall be of finned tubes, arranged in parallel, on either side of the “A” frame, in
PROJECT : 1 X 50MW EXTN. THERMAL POWER PLANT FOR

PROJECT ID : JP0025

two sections called the main condenser section and the vent or Dephlegmator sections.
The arrangement shall be such that the steam flows and condenses inside the tubes
with the cooling air flowing outside the tubes. The air flow outside the tubes shall be
cross flow type entering the tube bundles at the bottom and leaving the bundles at the top.
2.1.2 The ACC shall be divided into a number of modules with each of the modules served by
one fan. Each of the modules shall be designed with a number of condenser tube bundles
and a vent/ dephlegmator bundle.
2.1.3 The exhaust steam duct from the turbine exhaust flange and up to the inlet of the steam
distribution manifold shall be of all welded construction with necessary expansion joints for
limiting the thermal load on the turbine and the ACC and also to restrict the expansion
stresses in the ducting itself. At the turbine end necessary transition piece shall be provided
for connecting the circular ducting to the rectangular outlet flange of the turbine. Necessary
bifurcation in the ducting shall be provided for supplying the exhaust steam to the multiple
modular rows of the ACC. Necessary supports and guides for the ducting shall be provided.
Adequate number of access openings shall be provided in the horizontal run of the steam
duct and in the ACC steam manifold.
2.1.4 An adequately designed drain pot (hot well) shall be provided in the horizontal portion of
the steam ducting immediately down stream of the turbine exhaust. The hot well shall be
adequate for receiving the initial condensate from the ducting (at the time of start up),
condensate from the gland steam condenser, LP Heater normal drain and low temperature
drains from the piping. The condensate from the hot well shall be pumped to the
condensate storage tank.
2.1.5 A rupture disc designed to rupture at a pressure of 0.3 kg/Sq.cm (g) shall be located at a
suitable location in the steam ducting with proper venting arrangement to a location outside
the building.
2.1.6 RCC supporting Structure including Fan Deck & deck slab, supporting columns, beams,
condensate tank supporting structure with platform, duct supports, ejector-supporting
structure with platform, stair case & walk way shall be provided
2.1.7 All Gratings and handrails shall be of Mild steel painted type.
PROJECT :
PROJECT ID : JP0025

2.1.8 2 MT chain pulley block with monorail for maintenance of fans, fan motors and gear box
shall be provided
2.1.9 Mineral wool Insulation with aluminum cladding for condensate storage tank and
condensate piping from CEP discharge up to inlet of Deaerator shall be provided.
2.1.10 Surface preparation shall be of with wire brush cleaning and Painting shall be two coats of
anti-corrosive primer (min. 35 micron DFT / coat) (as per IS 2074) + two coats of synthetic
enamel finish paint (min. 35 DFT/ coat) (as per IS 2932). The total dry film thickness of
Primer and finish coat shall be minimum 140 DFT microns combined for all painting
applicable area’s of ACC and it’s auxiliaries.
2.1.11 Air cooled condenser design will provide adequate bowing and sloping of tubes to assure
complete drainage of tubes.
2.1.12 Thermal performance of ACC will be measured at TG exhaust flange.
2.1.13 The ACC design will ensure no steam back flow is possible in any operating condition in
case of non operation of fan.
2.1.14 Entire operation and control of Air cooled condenser including Sequence control of fans, hot
well level control, condensate tank level control & CEP minimum recirculation control shall
be from Main control room. Detailed control philosophy of Air cooled condenser shall be
provided during detail engineering.
PROJECT :
PROJECT ID : JP0025

03.00.00 WATER SYSTEM
03.01.00 RAW WATER STORAGE TANK (Not in Isgec scope)
03.01.01 Existing raw water storage tank shall be applicable for this extn. Power plant.
03.02.00 WATER TREATMENT PLANT (Not in Isgec scope)
03.02.01 Water treatment plant is totally Excluded from Isgec scope of supply (Shall be Suitably
sized by M/s.SCPL)
03.02.01.1 DM Water shall be taken from existing MB outlet line and if required booster pump
will be provided to feed the DM tank. 250 m^3 IS2062 Gr.B MSEP tank (1no.) shall be
provided for storing the DM water which is available from existing water treatment
plant. This water shall be utilized for initial filling of boiler and make-upping at
condensate storage tank to compensate the DM water loss occurred during boiler blow
down. GA of DM Tank is attached herewith.
03.02.01.2 Filtered / soft water shall be taken from existing soft water storage tank by extending
existing CT Make-water pump suction header to have a suction source of Isgec
proposed CT Make-up pump.
03.02.01.3 Isgec will take necessary tapping for raw water from existing raw water reservoir /
piping and / or ETP discharge (Tapping point will be finalized during mutual
discussion) for further distribution up to individual consuming points like Boiler (for
Blow down quenching), HCSD, etc.
03.02.01.4 Potable and Service water storage tanks (2m^3 HDPE / each) shall be provided at the
top of control room for drinking and other sanitary water requirements of proposed
plant. Source of tapping for the same shall be taken from existing inlet piping of
potable & service water tanks.
03.02.01.5 Quality and Quantity requirement of initial filling & make-up water for Boiler cooling
tower make-up, raw water and service water shall be as per the following.
I. Quantity requirement of Boiler make-up, cooling tower make-up and service

water:
(a) Boiler make-up

S.
Description unit Quantity Remarks
No
1. Boiler capacity m3/hr 215
2. Boiler Blow down loss m3/hr 6.45 3% in Boiler capacity.
PROJECT :
PROJECT ID : JP0025

Total make up water to

3. m3/hr 6.45 As per Sl. No.(2)
the boiler
(b) Cooling tower make-up
S.
No
1. Cooling tower capacity m3/hr 910
0.05% of cooling tower
2. Drift loss m3/hr 0.455
capacity.
(Temperature difference: 8 /
3. Evaporation loss m3/hr 11.91 6.11)
% of cooling tower capacity.
((Evaporation loss /
(Cycles of concentration – 1))
4. Blow down loss m3/hr 2.5225
– (Drift loss)).
Cycles of concentration: 5
Total make up water to
5. m3/hr ~14.9 (2)+(3)+(4)
the cooling tower
(c) Raw water
S.
No
1. HCSD m3/hr 40 As per Isgec Reference data
Boiler blow down
2. m3/hr 10 As per Isgec Reference data
quenching
Semi automatic fin
Intermittent filling of 1 m3
3. cleaning system for m3/hr 1
tank
ACC
Total service water
4. required at m3/hr 51 (1)+(2)+(3)
consumption point
M/s. SCPL has to provide the raw water quantity 51 m³/hr considering 24 hours
operation at one point near proposed CFBC Boiler column.
(d) Potable & Service water
S.
No
Drinking and Service 45 liters per head per day
1. m3/hr ~1
water requirement (Assume - 22 persons /

PROJECT ID : JP0025

Shift)
II. Quality requirement of Boiler and Cooling tower make-up:
(a) Boiler make-up

Description Unit Feed water Boiler Water
Total Hardness (max.) ppm Nil Nil
pH Value at 25° C - 8.8 – 9.2 9.1 – 10.1
Oxygen (Max.) ppm 0.007 Not Traceable
Iron (max.) ppm 0.01 Nil
Copper (max.) ppm 0.005 Nil
Silica (Max.) ppm 0.02 0.02
Total CO2 (Max.) ppm Nil Nil
Permanganate (Max.) ppm Nil Nil
Total Dissolved Solids (Max.) ppm 0.15 100
Total suspended Solids (Max.) ppm Nil Nil
Oil (Max.) ppm Nil Nil
Specific electric conductivity at
µS / cm 0.3 200
25° C
Residual Hydrazine (Max.) ppm 0.01 – 0.02 -
Residual Phosphate (Max.) ppm - 5-20
(b) Cooling tower make-up
Sl.No. Description Unit Value

1. Conductivity at 25°C µ Ohm/c 104
2. Total alkalinity as CaCO3 ppm 37.3
3. Chloride as Cl ppm 30
4. Total hardness as CaCO3 ppm 30.4
5. Calcium as CaCO3 ppm 20.8
6. Magnesium as CaCO3 ppm 9.6
7. Total dissolved solids ppm 600
8. pH 8.6

PROJECT ID : JP0025

DM TANK THICKNESS CALCULATION
CALCULATION FOR SHELL PLATE THICKNESS (As per IS 803)
S.No Notation Description Unit Value Formula / Ref
1 Tank volume m3 250
2 H Height of the tank m 9.5
3 D Diameter of the tank m 6
4 G Specific gravity of Liquid - 1
5 Material selected IS 2062 gr B
6 Sd Allowable stress N/mm2 165.00 As per cl. 5.1.1
7 E Efficiency factor - 0.7
8 CA Corrosion allowance mm 1.50

(4.9(H - 0.3)DG /
9 design Thickness as per sec 6.3.3.1 mm 3.84
Sd*E)+C
Min nominal thickness as per CL.
10 mm 5.00
6.3.3.2
11 t Required thickness mm 5.00 Max of 9 &10
12 Provided thickness mm 6
CALCULATION FOR ROOF PLATE THICKNESS (As per IS 803)
S.No Notation Description Unit Value
1 We considered Self supporting cone roof
2 θ Angle as per IS803 guidelines - 9.5 TO 37 DEG
3 θ Sin-1 (S) Deg (º) 9.5

0.165806279
5 t Thickness as per sec 6.4.5 mm 8.74 D/(5*SINθ)+C
Min nominal thicness (5mm) +
6 mm 6.50
corrosion allowance
7 t Required thickness mm 8.74 max of 5 & 6
PROJECT :
PROJECT ID : JP0025

8 Provided thickness 10
CALCULATION FOR BOTTOM PLATE THICKNESS (As per IS 803)
Min nominal thickness (6mm) +

1 mm 7.50
corrosion allowance as per cl 6.2.1
2 Provided bottom plate thickness mm 10
Effluent conveying methodology
Boiler blow down – Shall be conveyed through the drain trench sloped towards guard pond
Cooling tower blow down – Shall be conveyed through piping sloped towards guard pond
Waste water:
Plant domestic waste and sanitary water shall be collected by gravity to septic tank / soak pit for
anaerobic treatment.
PROJECT : 1 X 50MW EXTN. THERMAL POWER PLANT FOR

PROJECT ID : JP0025

04.00.00 AUXILIARY COOLING TOWER
04.00.01 Main features / highlights of cooling tower
S.
Description Value
No
 Counter flow
1 Type of cooling tower
 Induced draft fan
Cold water Basin with partition wall : RCC
Casing & superstructure : RCC
Fan deck : RCC
Fan stack : FRP
Hot water basin : RCC
Staircase : RCC
Fill support & louvers : RCC
Fills - PVC Film flow type.
Drift eliminator – Multi pass herringbone type / PVC
Cellular type / Double pass blade type.
Fan – Axial flow Propeller type
Fan blade – FRP
2 Construction Features Fan drive- Energy efficient motor
Spray nozzle – Polypropylene low pressure non clog.
Gear box –Spherical bevel cum helical will be
provided if required.
Common steel suction header shall be provided for
interconnecting cold water basins of all cells and
common suction headers for circulating water pumps
Vibration switch & level indicators will be provided
for fan & gearbox.
Hand railing will be provided at fan deck level
Common lifting arrangement for Fan, gearbox &
motor will be provided.
Two speed motor will be provided.
Cold water outlet
3 33
temperature in Deg C
Hot water inlet temperature
4 41
in Deg C
Design wet bulb temperature
5 28
in Deg C
6 Range in Deg C 8
7 Approach in Deg C 5

PROJECT ID : JP0025

Relative Humidity %
(a) Performance/Design : 60
8.
(b) Maximum : 83
(c) Min
: 33
9 Cooling water treatment Sodium hypochlorite dosing system
04.00.02 Sizing calculation
Cooling water
S. No Description Remarks
Flow in CMH
1. Boiler feed pump 10 Isgec boiler utility data
2. Sample cooler 12 Isgec boiler utility data
3. Rotary ash cooler 460 Isgec boiler utility data
Fluid coupling for Boiler feed

4. 42 Isgec boiler utility data
pump (Oil coolers)
5. Alternator air cooler 160 As per TG vendor data
6. Lube oil cooler 120 As per TG vendor data

As per Isgce reference
7. Ash handling system 20
data.
Total cooling water
8. 824 Sum of (1) to (7)
requirement.
9. Margin 10%
10. Capacity of cooling tower 910

Selected capacity of cooling
11. 910
tower
2 (1 working +
12. No. of cells
1 stand by)
13. Selected Capacity of each cell 910

PROJECT ID : JP0025

05.00.00 MISCELLANEOUS PUMPS
05.00.01 Specification
S.
No Pump Boiler initial
Name Auxiliary DM Water filling and Cooling
cooling water transfer Deaerator tower make-
pumps pumps emergency up pumps
filling pumps
Description
Centrifugal Centrifugal
Centrifugal Centrifugal
Horizontal Horizontal
Type Horizontal Horizontal
Split casing / End suction
End suction End suction
End suction
Filtered /
Cooling
1. Medium DM Water DM Water Softened
Water
water
Quantity in
2. 2 (1W+1S) 2 (1W+1S) 1 (1W+0S) 2 (1W+1S)
nos.
3. Flow in CMH 910 10 90 16.5
4. Head in mWC 45 40 110 30
5. NPSH (A) Flooded Flooded Flooded Flooded
6. Speed in rpm 1460 1460 2900 1460
7. Motor KW Later Later Later Later

Material of
8.
construction
Casing CI FG -260 CF8M CF8M CI FG -260
Casing wear
Bronze CF8M CF8M Bronze
ring
Impeller Bronze CF8M CF8M Bronze
Shaft Carbon steel SS316 SS316 Carbon steel
Base plate IS2062 IS2062 IS2062 IS2062

Gland
Non -asbestos Non -asbestos Non -asbestos Non -asbestos
packing

PROJECT ID : JP0025

05.00.02 Sizing Calculation
ACW PUMP HEAD AND FLOW CALCULATIONS
FLOW
1 Generator air cooler 160 CMH As per TG Vendor

data.
2 Lube oil cooler 120 CMH
3 Boiler feed pump 10 CMH
4 Fluid coupling for Boiler feed pump 42
5 Sample cooler 12 CMH As per Isgec data
6 Rotary ash cooler 460 CMH
7 Ash handling system (For surge hoppers). 20 CMH
8 Total 824 CMH 1+2+3+4+5+6+7
9 No. of pumps 1W + 1S
Capacity of pump considering 10 %
10 910 CMH (8) * (1.10)
margin.
11 Selected capacity of pump. 910 CMH
HEAD
Line losses (including fittings, valves,
12 10 MWC
etc.,)
13 Pressure required at the system inlet 20 MWC
14 Static head 10 MWC
15 Total head 40 MWC 12+13+14
16 Head of pump considering 10 % margin. 44 (15) * (1.10)
17 Selected head of pump 45 MWC
ACW PUMP
Design flow per pump 910 CM/H Selected
Design head 45 mWC Selected

PROJECT ID : JP0025

DM WT PUMP HEAD AND FLOW CALCULATIONS
FLOW
1 Capacity of Boiler 215 TPH
2 Blow down losses 6.45 CM/H 3% considered
3 Total DM make up water to the boiler 6.45 CM/H
4 No. of pumps 1W + 1S
5 Flow per pump 6.45 CM/H
7 Margin considered 10.00%
8 Design flow per pump 7.095 CM/H
9 Selected flow for pump 10 CM/H
HEAD
10 15 mWC
etc.,)
Make up @
11 Static head 10 mWC
condensate tank
12 Level control valve pressure drop 5 mWC
13 Flow element pressure drop 5 mWC
14 Total head 35 mWC (10)+(11)+(12)+(13)
15 Margin on head 10.00%
16 Selected head 38.5 mWC
DMWT PUMP
Design flow per pump 10 CM/H Selected

PROJECT ID : JP0025

BOILER INITIAL FILLING & DEAERATOR EMERGENCY FILLING PUMP HEAD

AND FLOW CALCULATIONS
FLOW
1 Boiler pressure parts water volume 180 m^3

BIF pump capacity considering 2 hours
2 90 CMH
fill up
3 No. of pumps 1W
4 Flow per pump 90 CMH
5 Design flow per pump 90 CMH
HEAD
6 15 mWC
etc.,)
Top level of riser
pipe of steam drum
(highest elevation
of water fill in
boiler) (or)
deaerator
emergency fill up
(57+25)
8 Total head 97 mWC (6)+(7)
9 Margin on head 10%
10 Design head 107 mWC
BIF PUMP
Selected flow per pump 90 CMH Selected
Selected head 110 mWC Selected
PROJECT :
PROJECT ID : JP0025

CTMWT PUMP HEAD AND FLOW CALCULATIONS
FLOW
1 Cooling tower flow 910 CM/H (1 W + 1 S) Cells.

1.63 % of cooling
2 Makeup required 14.9 CM/H
tower capacity
3 No. of pumps 1W+1S As per contract
4 Flow per pump 14.9 CM/H
5 Margin considered 10.00%
6 Design flow per pump 16.5 CM/H
7 Selected flow for pump 16.5 CM/H
HEAD
7 15 mWC
etc.,)
10 Total head 25 mWC
11 Margin on head 10%
12 Design head 27.5 mWC
CTMW PUMP
Design flow per pump 16.5 CM/H Selected
05.00.02.1 Apart from above, Existing Raw water transfer pump, potable & service water transfer
pump, Fire Fighting Pumps, Other make-up pumps and de-watering pumps will be
utilized for interfacing. All interface/ terminal points design/ supply and work are
will be in Isgec scope.
PROJECT :
PROJECT ID : JP0025

06.00.00 COAL HANDLING SYSTEM
Coal handling system is envisaged in this project to feed the coal to proposed 215 TPH
CFBC Boiler for continuous firing.
06.00.01 Coal shall be carried from existing coal handling system by extending tripper
conveyor up to proposed boiler Coal bunker.
One more stand-by tripper conveyor shall also be provided which shall get the coal
feeding from existing two way chutes and transfer to the proposed boiler coal bunker.
06.00.02 Coal handling system shall be complete with dust extraction system at bunker area of
the proposed boiler. Dust extraction system bag filter shall be with conventional cage
type bags.
06.00.03 The schematic drawing is attached as Drg no: JP0025-75990200-PFD-001
06.00.04 Maximum moisture including surface and inherent –7.81%. (Best coal @ 2168.40
kcal/kg)
06.00.05 The Fuel size considered to be as follows:

Size Analysis – Coal
Sr.No. Size %Wt.

1 + 8 mm 0.00
2 - 8 mm – 6 mm 8.70
3 - 6 mm – 4 mm 21.74
4 - 4 mm – 2 mm 30.43
5 - 2 mm – 1 mm 21.74
6 - 1 mm 17.39
7 Total 100.00
[
06.00.05.1 Bulk density:
Washery Reject : 800 kg/m3 (for capacity calculation).

900 kg/m3 (for load & power calculation).
PROJECT :
PROJECT ID : JP0025

06.00.06 COAL HANDLING SYSTEM SIZING CALCULATION
Washery Reject quantity in TPH (@1800 kcal/kg):

Maximum steam generation at boiler
Outlet while firing Washery Reject
@ 1800 kcal/kg = 215 TPH
= Boiler outlet steam flow (TPH) * (Outlet steam enthalpy – Feed Water
enthalpy) (Kcal/kg)
Gross calorific value (Kcal/kg) * Boiler efficiency (%)
= 215 * (828-242.67)
1800 * 0.842
= 83.03 TPH
Washery Reject quantity in TPH (@1529 kcal/kg):
Maximum steam requirement at boiler

Outlet while firing Washery Reject
@ 1800 kcal/kg = 215 TPH
= Boiler outlet steam flow (TPH) * (Outlet steam enthalpy – Feed Water
enthalpy) (Kcal/kg)
Gross calorific value (Kcal/kg) * Boiler efficiency (%)
= 215 * (828-242.67)
1529 * 0.816
= 100.853 TPH
From the above, Washery Reject quantity @ 1529 kcal/kg is coming as maximum
i.e. ~101 TPH.
Selected coal handling system capacity is 300 TPH.
Operating hours for coal handling system = (101*24) / 300 hours.
Coal handling system operating hours required = 8 hours
Coal handling system shall be suitable for 24 hrs operation duty.

PROJECT ID : JP0025

800mm width belt tripper conveyor shall be provided to match with existing tripper
conveyor.
06.00.07 TECHNICAL DETAILS OF BELT CONVEYOR:
BELT CONVEYOR
Description Unit BC-01 (C-8) BC-02 (C-9)
1 Process Specification
1.1 Application/Location Conveying Conveying
1.2 Duty Condition 24 Hrs 24 Hrs
1.3 Material to handle Coal Coal
1.4 Bulk density
-For Power Calculation Kg/m3 900 900
-For Capacity Calculation Kg/m3 800 800
1.5 Moisture content % 7 to 8 7 to 8
1.6 Particle size mm Fines Fines

o
1.7 Temperature c Ambient Ambient
2 Mechanical Specification
2.1 General
2.1.1 Specification according to DIN / CEMA / Other D/C/O IS:11592:2000 IS:11592:2000
2.1.2 Surcharge Angle Degrees 25.00 25.00
2.1.3 Rated capacity t/hr 300.00 300.00
2.1.4 Design capacity t/hr 375.00 375.00
2.1.5 Troughing Angle Degrees 35.00 35.00
2.1.6 Belt Speed m/s 2.60 2.60
PROJECT :
PROJECT ID : JP0025

2.1.7 Belt width mm 800.00 800.00
2.1.8 Conveyor C/C-Horizontal Mtr 40.00 96.00

Existing
Conveyor Complete New
Modification conveyor
considered
2.1.9 Belt Inclination (Max) Degrees 0.00 0.00
2.1.10 Lift m 3.00 3.00
2.1.11 Profile Horizontal Horizontal
2.1.12 No of feed Points Nos 1.00 1.00
2.1.13 Type of take up VGT VGT
2.1.14 Take up weight Kg 847.7 847.7
2.2 Special Design
2.2.1 Reversible / Travelling / Slewable R/T/S Existing Tripper New Tripper
2.3 Belt :
2.3.1 Max Tension N 11414 11414
2.3.2 Total Length of the belt (Aprox) m 92.00 220.80
2.3.3 Surface Profile Cut Edge Cut Edge
2.3.4 Reinforcement - fabric / steel cord F/S F F
2.3.5 No of piles 3 3
2.3.6 Belt rating KN/m 400/3 400/3
2.3.7 Type of carcass Fabric Fabric
2.3.8 Type of cover Nylon Nylon
2.3.9 Thickness of top cover mm 5.00 5.00
2.3.10 Thickness of bottom cover mm 2.00 2.00
PROJECT :
PROJECT ID : JP0025

2.3.11 Belt Weight Kg/m 9.04 9.04
2.3.12 Grade FR FR
2.4 Belt cleaner -
2.4.1 Head end

Segmented Segmented
2.4.2 Primary Sprung Sprung Loaded
Loaded Type Type
Sprung
2.4.3 Secondary Sprung Loaded
Loaded
BMH / Kavery / BMH / Kavery /
2.4.4 Make
Techno fab Techno fab
2.5 Return
2.5.1 Type V Type V Type
2.5.2 Rubber hardness Shore A 55-60 55-60
2.5.3 Rubber thickness mm 20 20
2.6 Skirt Board
2.6.1 Length- mm 4000 4000
2.6.2 Total Length mm 4000 4000
2.6.3 M S Plate thickness mm 6 6
2.6.4 Liner thickness mm 10 10
2.6.5 Liner material Sail Hard Sail Hard
2.6.6 Skirt Rubber Thk mm 10 10
2.6.7 Skirt Rubber Hardness Shore A 60 (+/-)5 60 (+/-)5
2.8 Carring Idlers

3 Roll
2.8.1 Type 3 Roll Troughing
Troughing
2.8.2 Trough Angle Deg 35 35
PROJECT :
PROJECT ID : JP0025

2.8.3 Pipe Dia. mm 114.30 114.30
2.8.4 Pipe Length mm 315 315
2.8.5 Shaft Material / Dia.at Brg. /mm En-8 / 25 mm En-8 / 25 mm
2.8.6 Idler Spacing mm 1200 1200
2.9 Return Idlers
2.9.1 Type 1 Roll 1 Roll
2.9.3 Pipe Dia. mm 114.30 114.30
2.10 Impact Idlers

3 Roll Pickling 3 Roll Pickling
2.10.1 Type
Type Type
2.10.3 Pipe Dia. mm 88.9 88.9
2.10.7 Idler Ring Dia mm 139.7 139.7
2.10.8 Idler Ring Hardness % 55 (+/- 5%) 55 (+/- 5%)
2.11 SA Carring Idlers
2.11.1 Spacing mm 15000 15000
2.12 SA Return Idlers
PROJECT :
PROJECT ID : JP0025

2.12.1 Spacing mm 30000 30000
2.13 Pulleys
Spherical Roller Spherical Roller
2.13.1 Type of bearing
Brg. Brg.
2.13.2 Make of bearing SKF/FAG SKF/FAG
2.13.3 Rubberised Yes / No Yes Yes
2.13.4 Make of Plummer Block Masta /Sibco Masta /Sibco
2.13.5 Life of bearing Hrs 40000 40000
2.13.6 Shell Material IS:2062 IS:2062
2.13.7 Shaft material En-8 En-8
2.14 Head Pulley
2.14.1 - Shell Dia mm 508 508
2.14.2 - Shell Thk mm 12 12
2.14.3 - Shell Length mm 950 950
2.14.4 - Shaft Dia at Brg mm 100 100
2.14.5 - Shaft length mm 2050 2050
2.14.6 -Lagging Material Rubber Rubber
2.14.7 -Lagging Material Hardness Shore A 55 (+/- 10) 55 (+/- 10)
2.14.8 -Lagging Thk mm 12 12
2.14.9 -Lagging Pattern Herring Bone Herring Bone
2.14.10 -Qty 1 1
2.15 Tail / Take up / Bend Pulley
2.15.1 - Shell Dia mm 406 406
2.15.2 - Shell Thk mm 10 10
PROJECT :
PROJECT ID : JP0025

2.15.5 - Shaft length mm 1750 1750
2.15.9 -Lagging Pattern Plain Plain
2.16 Snub Pulley
2.16.1 - Shell Dia mm 323 323
2.16.2 - Shell Thk mm 10 10
2.16.5 - Shaft length mm 1750 1750
2.16.9 -Lagging Pattern Plain Plain
2.16.10 -Qty 1 1
3 Drive :
3.1 Motor -
4 Pole Squerrel 4 Pole Squerrel

3.1.1 Type
Cage Induction Cage Induction
3.1.2 Absorbed power At Pulley Periphery KW 19.42 19.42
3.1.3 Motor Rating KW 30.00 30.00
PROJECT :
PROJECT ID : JP0025

3.1.4 Speed rpm 1440 1440

S-1/
S-1/ Continuous
3.1.5 Duty Continuous
Duty
Duty
3.1.6 Voltage V 415 (+/-10%) 415 (+/-10%)
3.1.7 Frequency Hz 50 (+/-5%) 50 (+/-5%)
3.1.8 Service factor 1.15 1.15
3.1.9 Protection IP-55 IP-55

ABB/ Seimens/ ABB/ Seimens/
3.1.10 MAKE
Marathon Marathon
3.2 Gear box -
3.2.1 Service Factor 1.5 1.5
3.2.2 Ratio 14 14
3.2.3 Hold Back yes / no No No
3.2.4 Model DDE DDE

Greaves
/Elecon Greaves /Elecon
3.2.5 Make
/Bonfiglioli /Bonfiglioli /Shanti
/Shanti
3.3 High speed coupling -
3.3.2 Type Pin-Bush Pin-Bush
3.3.3 Make Elecon/ Fenner Elecon/ Fenner
3.3.4 Model DDE DDE
3.4 Low speed coupling -
3.4.2 Type Geared Geared
PROJECT :
PROJECT ID : JP0025

3.4.3 Make Elecon/ Fenner Elecon/ Fenner
3.4.4 Model DDE DDE
4 Safety and Supervisory :
4.1 Pull cord switch, Type
4.2 Pull cord Max. spacing (Min one pair) Mtr 15 15
4.3 zero speed switches 1 1
4.4 Belt Sway Switch Nos 15 15
4.5 Guards( Pulley, couplings etc.) Lot Applicable Applicable
5 Technological Structure
5.1 Size of stringer ISMC-125 ISMC-125
5.2 Size of short support ISMC-125 ISMC-125
5.3 Conveyor hood Cover Not Applicable Not Applicable

Throughout the
Throughout the
5.4 Deck Plate length of
length of conveyor
conveyor
5.5 Bottom Seal Plate
- Applicable / not Applicable Not Applicable Not Applicable
6 Discharge Chute
6.1 - Hood on Discharge chute 6 mm thk MS 6 mm thk MS
6.2 -Mother Plate thickness mm 6 6
6.3 -Liner thickness mm 10 10
6.4 -Liner material Sail Hard Sail Hard
7 Frames
Fabricated /
7.1 -Drive Fabricated / ISMC
ISMC
7.2 -Pulley (Head frame / Tail frame) ISMC ISMC
PROJECT :
PROJECT ID : JP0025

Painting Specification For Structural Steel

8
and Hand Rail
8.1 Surface Preparation Wire Brush Wire Brush
8.2 Primer Red Oxide Red Oxide

Nos /
8.2.1 - Coat /DFT of each coat 2 / 35 2 / 35
Microns
Synthetic
8.4 Finish Paint Synthetic Enamel
Enamel
Nos /
8.4.1 - Coat /DFT of each coat 2 / 35 2 / 35
Microns
8.5 Total DFT Microns 120-140 120-140
9 Tripper Details
9.1 Tripper Pulley 508 x 950 x 12 508 x 950 x 12
9.2 Tripper Speed m/min 10 10
9.3 Tripper trolley Rating KW 3.7 / S4 Duty 3.7 / S4 Duty
9.4 Tripper drive Geared Motor with Brake
9.5 Tripper Frame IS:2062 IS:2062
Typical trailing cable arrangement detail is attached herewith (Drg. No.: JP0025-75440100-LYT-001)
Dust Extraction system ( Bag Filter) is considered for transfer points and bunker floor and the dust
emission level will be below 50 mg/Nm3.
Walkway of 750mm width on one side and 500mm width on other side along the conveyors shall
be provided. Walkways are provided with MS painted handrails with toe plate. Coal handling
conveyor layout shall be submitted separately.
Conveyor gallery shall be of closed type. Suitable exhaust fans shall be provided in the conveyor
gallery.
2 numbers of cross over walkway platform (1000 mm width) for interconnection of two galleries
R3
will be provided.
Motor Power calculations shall be provided during detail engineering.
PROJECT :
PROJECT ID : JP0025

DATA SHEET FOR BELT WEIGHER
A) TECHNICAL SPECIFICATION
MATERIAL Coal
BULK DENSITY 800 Kg/ CuM
CAPACITY Design / Rated 375 / 300 TPH
BELT WIDTH 800 mm
BELT SPEED 2.6 M/sec.
INCLINATION Horizontal tripper conveyor
IDLER TROUGHING Three Role type 35 Deg. Angle
TYPE OF IDLER Troughed Idlers
IDLER DIA 114.3 mm
BELT TYPE 315/3, Top-5mm, Bottom-2mm, FR , Nylon
BELT WEIGHT 8.8 Kg/mtr
BELT THICKNESS 12.9 mm
SYSTEM ACCURACY ±.5% on F.S
RATE INDICATION Digital
TOTALIZER Digital
ENCLOSURE Weatherproof - IP 65
B) LOADCELL
MAKE Precia Molen / Sartorius / IPA
TWIN frame with single idler machined idler
TYPE
supported on dual single point load cell
CAPACITY 375 TPH
WEIGHING RANGE 75 to 375 TPH with duel weighing setting
MIN. WEIGHING CAPACITY (MTPH) 75
MAX. WEIGHING CAPACITY (MTPH) 375
AVERAGE WEIGHING CAPACITY (MTPH): 90
ACCURACY ±.5% on F.S
PROTECTION Load cell are SS:IP68
C) ENCODER(Non Inductive Proximity Sensor)
MAKE P & F or Equivalent
TYPE Pulse output
RESOLUTION
D) BELT WEIGHER INDICATOR
Mounting Panel Mountable
ENCLOSURE Panel protection is IP65
DIMENSION 500 x 500 x 300 mm (Panel Size)
INDICATION Digital by 7 segment 13 mm
PROJECT :
PROJECT ID : JP0025

DISPLAYS a) Flow rate : B) Total weight

CALIBRATION Full digital software calibration through key pad
INPUT mV from loadcell & Digital Input from Tacho
OUTPUT 4-20 Ma proportional to rate
TYPE OF SENSOR AC / Pulse Tacho OutPut
DETAILS OF INDICATION
DIGITAL RATE INDICATOR PROVIDED
DIGITAL TOTALIISER PROVIDED

Yes. Belt Scale controller of I - 400 Graphic Terminal
DETAILS OF REMOTE INDICATION PANEL
and same will be mounted in the panel
CHART RECORDER PROVIDED
RATE INDICATOR PROVIDED
CALIIBRATION WEIGHT , TEST CHAIN &

Yes
CHAIN REELING DRUM INCLUDED
EQUIPMENT IS SUITABLE FOR DUSTY

Yes
ATMOSPHERE
Type of power supply reqd. - Voltage, Phase, 240 V ±10%, 50 Hz ± 3% of Single Phase
Frequency & Variations
Total load demand (KW) Vendor to specify
Quantity of belt weigher 2 nos.
R3
PROJECT :
PROJECT ID : JP0025

DATA SHEET OF ELECTRICAL HOIST

Type of hoist Wire Rope Electric Hoist
Hoist duty Class II.
Capacity 2 Ton
Lift (Mtrs.)- Qty. 40 Mtrs
Model Shall be given after detailed engg.
Hoisting speed (M/Min. 3.0 M/m
Traverse speed (M/Min.) 10.0 M/m,
3.75 KW / 5.0 HP
Sq. Cage Crane Duty
Hoist Motor(KW)
960 RPM
ABB / Siemens make
0.55 KW / 0.75 HP
Sq. Cage Crane Duty
Trolley Motor (KW)
960 RPM
ABB / Siemens make
Hoist Brake AC EH Thruster type
Wire rope
Wire rope size 14 mm dia
No. of rope falls 3 Fall
Min. Factor of safety of rope 6
Type & Material of gears Helical type / EN-9
Rope Drum Seamless pipe
Sheaves M.S.
Hook As per is:3815
Trolley wheel Single Flanged EN-9
Bearings Ball Bearing
Power supply required 415 V. 3 Ph. 50 C/S A.C.
Control Panel (mounted on hoist) Yes
Control Voltage 220 V. 1 Ph. AC
Limit switches Provided
Electric cables Provided from JB.
Power feeding arrangement Festoon cable type
Pendant cable control cable PVC Copper
Lubrication Splash
Suitable beam size ISMB-300
Head room size 1200 mm
PROJECT :
PROJECT ID : JP0025

07.00.00 ASH HANDLING SYSTEM
The ash handling system shall comprise of:
 Dense phase pneumatic bed ash handling system.
 Dense phase pneumatic fly ash handling system.
07.01.00 BED ASH HANDLING SYSTEM
07.01.01 Bed ash shall be evacuated by Bed Ash Cooler Hoppers. Beneath each collection
hopper, suitable water cooled M.S. Surge Hopper & bypass chute, manually operated
isolation plate valve and Ash Conveying Vessel with RF type level Probe shall be
provided for initiation of conveying cycles.
07.01.02 The Ash from the Conveying Vessels shall be conveyed through individual ash
conveying pipeline of suitable size (100 NB) M.S. ERW (heavy class, as per IS: 1239)
complete with M.S. flanges, gaskets, M.S. fasteners and long radius (R=5D) alloy cast
iron bends of 400 to 450 BHN hardness (in segments of 45 deg or to suit).
07.01.03 Ash conveying pipeline shall terminate on top of existing Bed Ash Silo (RCC) of 460
m3 with the help of Individual terminal Boxes. Suitable opening shall be provided on
top of silo for this purpose.
07.01.04 The capacity calculation is attached below.
07.01.06 Quantity of cooling water required / vessel shall be provided during detail design.
07.01.07 Cast iron Ash conveying vessel shall be of 9 CFT or 12 CFT capacity with operating
pressure of 4.5 kg/cm2 (g) shall be provided. Ash conveying vessels shall be kept in
above ground only.
07.01.08 Metallic expansion joint (SS) shall be provided between hopper and ash vessel.
07.01.09 Integral fixed type screen for bottom ash shall be provided and the handling of over
sized particle will be through manual trolley once in shift. The screen size shall be of
10 mm.
R3
07.01.10 Suitable capacity of Reverse pulse jet Bag filter and level probe (High) will be
provided at top of Bed ash silo.

PROJECT ID : JP0025

07.02.00 FLY ASH HANDLING SYSTEM
07.02.01 System below ECO/APH Hoppers:
07.02.01.1 Fly Ash shall be evacuated from ECO Hopper and APH Hopper. Beneath each
collection hopper, suitable M.S. Surge Hopper, manually operated isolation plate valve
and Ash conveying Vessel are provided. RF Type Level Probe is provided in the surge
hopper for initiation of conveying cycles.
07.02.01.2 The Ash Conveying Vessel shall be connected through common conveying pipeline of
suitable size (100 NB) M.S. ERW (heavy class, as per IS: 1239) complete with M.S.
flanges, gaskets, M.S. fasteners and long radius (R=5D) alloy cast iron bends of 400 to
450 BHN hardness (in segments of 45º or to suit).
07.02.01.3 Pipeline shall terminate on top of existing fly ash Silo of 700 m3 with the help of
Terminal Box arrangement. . Suitable opening shall be provided on top of silo for this
purpose.
07.02.01.4 Cast iron Ash conveying vessel shall be of 9 CFT or 12 CFT capacity with operating
pressure of 4.5 kg/cm2 (g) shall be provided. Ash conveying vessels shall be kept in
above ground only.
07.02.01.5 Metallic expansion joint (SS) shall be provided between hopper and ash vessel.
07.02.01 Suitable capacity of Reverse pulse jet Bag filter and level probe (High) will be
provided at top of Fly ash silo.
R3
07.02.02 System below ESP Hoppers:
07.02.02.1 There shall be seven fields in ESP having two hoppers per field. Beneath each ESP
hopper, suitable M.S. adopter / suitable capacity surge chute, a manually operated
isolation plate valve and an Ash Conveying Vessel shall be provided. Set of fluidizing
pads shall be provided in surge hoppers for free flow of ash into ash conveying vessel.
RF type level probe shall be provided in ash conveying vessel to initiate the conveying
cycles. Suitable opening shall be provided on top of silo for this purpose.
07.02.02.2 The Ash Vessels below ESP 1st field & ESP 2nd field hoppers shall be connected
through individual ash conveying pipelines. The vessels beneath ESP 3rd, 4th, 5th, 6th&
7th field hoppers shall be connected in series through a common ash-conveying
pipeline in two rows. Each ash conveying pipelines shall be of suitable size M.S. ERW
PROJECT :
PROJECT ID : JP0025

(heavy class, as per IS: 1239) complete with M.S. flanges, gaskets, M.S. fasteners and
long radius (R=5D) Alloy C.I. bends (in segments of 45º or to suit). Each ash conveying
line shall terminate on top of existing Fly Ash silo of 750 m3 with the help of terminal
boxes.
07.02.03 The capacity calculation is attached below.
07.03.00 CONVEYING AIR COMPRESSORS
07.03.01 Common 3 No. (2W+1S) screw type oil lubricated compressors with receivers has been
considered for supplying Conveying air to transmit the ash from respective collection
points to silo and fluidization of ash hoppers.
07.03.02 Conveying air compressor capacity shall be selected in such a way that to convey the
total actual ash collected with 30% margin.
07.03.03 Conveying air requirement calculation for worst coal @ BMCR condition, Conveying
air compressor capacity & PID of conveying air compressor shall be submitted during
detail engineering.
07.04.00 Bulk density:
Bed ash Fly ash

For capacity calculation 650 kg/m3 650 kg/m3
For Load calculation 1600 Kg/m3. 1600 Kg/m3.
07.05.00 Sizing calculation
100 % Worst Coal – 1416 Kcal /

Description Unit
Kg. GCV (BMCR)
Total fuel fired kg/hr 107918
Design Ash % % 70%
Total ash generated kg/hr 75543

PROJECT ID : JP0025

07.06.00 Ash Distribution Sheet
No. of Quantity of ash in

Location Temperature Density Remarks
points each point - kg/h
Normal Design Normal Design (Typical)

Bed ash 3 7555 11331 200-250 350 650
Air heater Below
2 944 3777 245 300 650
Economiser ash
Air heater in pass
2 944 3777 140-150 200 650
II ash Ash
ESP Ash quantities
collection provided
ESP first field 1 41738 49102 140-150 200 650 are per
hopper
ESP second field 1 6261 49102 140-150 200 650 only.
ESP third field 1 939 3777 140-150 200 650
ESP fourth field 1 141 3777 140-150 200 650
ESP fifth field 1 21 1888 140-150 200 650
ESP Sixth field 1 3 1888 140-150 200 650
ESP Seventh field 1 0.56 1888 140-150 200 650
Total ash per
58546 130310
hopper
Total Ash 75543 160526
Ash particle size distribution
Sieve analysis % by Air heater below Air heater ash

Bed ash ESP ash
mass Economiser ash in pass II
0-63 micron 0.21 54.36 59.72 77.66
63-75 micron 0.13 33.65 21.19 12.99
75-150 micron 9.87 11.61 17.32 8.68
150-300 micron 26.59 0.36 1.22 0.33
300-600 micron 31.61 0.02 0.4 0.21
600micron -1.18 mm 10.03 - 0.15 0.13
1.18-2.36 mm 12.95 - - 0
2.36-4.75 mm 6.06 - - -
4.75 – 25 mm 2.55 - - -
PROJECT :
PROJECT ID : JP0025

Design Basis Report For Balance of Plant Equipments (Mechanical)

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Design Basis Report For Balance of Plant Equipments (Mechanical)

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DESIGN BASIS REPORT

FOR BALANCE OF PLANT

R4 Revised as per SCPL

Rev No Date Description Prepared Verified Approved

PROJECT 1 X 50 MW EXTN.THERMAL POWER PLANT

CUSTOMER M/s. SPECTRUM COAL & POWER LIMITED.

EPC CONTRACTOR M/s. ISGEC HEAVY ENGINEERING LIMITED.

DOCUMENT ID JP0025-75990100-DBR-001 REVISION : 04

S.NO. DESCRIPTION PAGE NO.

2. AIR COOLED CONDENSER 4

11. EXHAUST VENTILATION SYSTEM 48

12. AIR CONDITIONING SYSTEM 50

13. FIRE FIGHTING SYSTEM 51

14. PIPING SYSTEMS 56

15. LAYOUT FACILITIES 61

16. CODES AND STANDARDS 64

17. LIST OF DRAWINGS 68

DOCUMENT ID JP0025-75990100-DBR-001 REVISION : 04

01.01.00 PROJECT DETAILS & SITE DATA

S.No. Description Unit

DOCUMENT ID JP0025-75990100-DBR-001 REVISION : 04

02.00.00 AIR COOLED CONDENSER

Air cooled condenser Unit Details

ACC type Forced Draft, direct air cooled, ‘A’ frame

Turbine exhaust orientation Towards bottom.

Dumping Tube arrangement Not applicable

Type Horizontal centrifugal type

PROJECT :1 X 50MW EXTN. THERMAL POWER PLANT FOR

DOCUMENT ID JP0025-75990100-DBR-001 REVISION : 04

Air cooled condenser Unit Details

Margin on flow and head % 10 % and 5 % respectively.

Quantity : One (1)

PROJECT :1 X 50MW EXTN. THERMAL POWER PLANT FOR

DOCUMENT ID JP0025-75990100-DBR-001 REVISION : 04

Air cooled condenser Unit Details

Motor rating KW 110

Semi Automatic fin cleaning system will be

Drain pot (Hot well)

Quantity (1) no. of hot well shall be provided

Vertical attached with Exhaust Steam duct

Capacity CuM 1.2

Material of Construction IS 2062

Corrosion Allowance 1.6 mm

Insulation Not Applicable.

Draining time of hot well Approx. 5 minutes

Drain pot pumps (Hot well)

Quantity Two (2) nos. (1W+1S)

Type Horizontal, Centrifugal

Margin on flow and head % 10 % and 5% respectively.

PROJECT :1 X 50MW EXTN. THERMAL POWER PLANT FOR

DOCUMENT ID JP0025-75990100-DBR-001 REVISION : 04

Air cooled condenser Unit Details

Casing SA216 Gr. WCB

Impeller CF8M / CA6NM

Shaft AISI 410

Casing wearing ring CF8M / CA6NM

ACC support RCC up to Fan deck level

Exhaust steam At the outlet of turbine matting flange

Face velocity (air) across tube

Steam side fouling factor m² K/W 0.00005

2.1 Brief description of Air cooled Condenser

PROJECT : 1 X 50MW EXTN. THERMAL POWER PLANT FOR