DBR-Complressed Air System-12.08.2019

DESIGN BASIS REPORT
FOR COMPRESSED AIR

SYSTEM
(MECHANICAL)
Updated As Per Final

01 29.06.19 B.G GDR JDV
Configuration
Re-submission for
00 08.08.18 S.Kanna RBK RBK
approval
Rev No Date Description Prepared Verified Approved
PROJECT 2 X 65 MW COGENERATION CAPTIVE POWER PLANT
GACL-NALCO ALKALIES & CHEMICALS PVT

CUSTOMER
LIMITED
CONSULTANT DESEIN PRIVATE LIMITED CONSULTING

ENGINEERS
EPC CONTRACTOR M/s. ISGEC HEAVY ENGINEERING LIMITED.
Date 29.06.19
DOCUMENT NO ES0153-75990100-DBR-0005 Rev 01
No. of pages 13
DESIGN BASIS REPORT FOR COMPRESSED AIR SYSTEM
DOCUMENT ID ES0153-75990100-DBR-0005 REVISION : 01
ITEM CODE DBR005 QUANTITY :-
DESCRIPTION DESIGN BASIS REPORT
CONTENTS
S.NO. DESCRIPTION PAGE NO.

INTRODUCTION
1. 3
PROJECT DETAILS & SITE DATA
COMPRESSED AIR SYSTEM
INSTRUMENT AND SERVICE AIR COMPRESSOR
2. 5
AIR DRIER
AIR RECEIVER
3. PIPING SYSTEMS 10
4. CODES AND STANDARDS 12
5. LIST OF DRAWINGS 12
PROJECT :
2 X 65MW COGEN CAPTIVE POWER PLANT FOR
GACL –NALCO ALKALIES & CHEMICALS PVT PROJECT ID : ES0153
LIMITED
PREPARED BY VERIFIED BY APPROVED BY DATE : 21.06.19
S.KANNA RBK RBK SHEET : 2 of 13
01.00.00 INTRODUCTION
01.00.01 The purpose of this design basis report is to elaborate the sizing and specification of BOP
equipments for 2X 65MW cogeneration captive power plant proposed at Dahej, Gujarat.
01.00.02 All technical parameters are mentioned in line with contract specification
01.01.00 PROJECT DETAILS & SITE DATA
S.No. Description Unit
A Site details
2 x 65 MW Captive Cogeneration Power Plant
1. Project Title
(CCPP) at Dahej, Gujarat, India
2. Client GACL- NALCO Alkalies & chemicals Pvt Ltd
3. EPC contractor M/s. Isgec Heavy Engineering Limited

Desein private limited,
Desein house,
4. Owner’s Consultant
Greater Kailash II
New Delhi 110 048
Village Dahej, Dist. Bharuch, Gujarat,
5. Plant Location Latitude - 21° 43’ 06.24” N
Longitude -72o 41’33.42” E
6. Power Plant Capacity MW 2x 65
7. Seismic Co-efficient zone Zone – III as per IS 1893 - 2002
8. Design Wind Velocity m/s As per IS 875, Part 3 – 47 m/s
9. Wind Direction SW-NE
10. Area classification Safe , Non- hazardous & Non- Corrosive
B Meteorological data
Ambient Temperature:
11. °C 11 / 45 /27 (Design & Performance)
(Min. / Max. / Average)
Relative Humidity :
12. % 32 / 89/70 (Design & Performance)
(Min. / Max. / Average)
Wet Bulb Temperature :
13. °C 28
(design)
Design Temperature for
14. °C 50
Electrical equipments
15. Average annual rainfall mm 710
Mm/h
16. Rainfall intensity 50
r
PROJECT :
LIMITED
S.No. Description Unit

Plant Elevation above Mean
17. 7m
Sea Level
10 km from dahej railway station & 40 Km from
18. Nearest Railway Station
bharuch railway station with broad gauge line
19. Nearest Airport Domestic - Baroda (~140 kms)
20. Nearest town Bharuch– 50 KM
21. Nearest harbor Magdalla, Surat(~110 kms)
PROJECT :
LIMITED
02.00.00 COMPRESSED AIR SYSTEM
02.00.01 The compressed air system will provide supply of compressed air having suitable pressure
and quality for Instrument & Control purpose use (Instrument Air) and for General Station
use (Plant Air) for the entire proposed power plant. The compressed air system starts from
inlet of the filter silencer of respective compressor and terminates at the Air drying plant and
after the Instrument Air receiver outlet nozzle for instrument air system. For Service air
system, the outlet air from compressor will terminate at Service air receiver for further
distribution.
02.00.02 Main features of Instrument & Service air Compressor
Instrument air Compressor
S. No Description Parameter
 Screw
1 Type of compressor  Oil free
 Water cooled
2 Free Air Delivery 565 CFM
5 (4W+1S)
3 No. of compressors (Stand-by unit common for
Instrument & service Air)
4 Delivery pressure 8.8 kg/cm² (g)
5 Design Ambient temperature 45 °C
Service air Compressor
 Screw
1 Type of compressor  Oil free
 Water cooled
2 Free Air Delivery 585 CFM
3 No. of compressors 2 (Both W)
4 Delivery pressure 7 kg/cm² (g)
5 Design Ambient temperature 45 °C
PROJECT :
LIMITED
02.00.03 Air Drier
1 Type of drier Refrigerant Type
2 Capacity of drier 900 CFM
3 No. of drier 5 (4W+1S)
4 Delivery pressure 7-8 kg/cm²(g)
5 Pressure Dew point temperature 2-3 °C
6 Atmosphere Dew point temperature -17 °C
02.00.04 Air Receiver
1 Type of receiver Vertical, Cylindrical
20 & 5 m³ for instrument air

2 Capacity of air receiver
and 10 m³ for service air.
5 No’s
(Instrument air – 2 No &
3 Quantity
Service air 2 No)
1 No 5m3 in WTP area
4 Delivery pressure 7-8 KG/CM2(G)
5 Material of construction IS 2062 E250 Gr.B
6 Design standard ASME section VIII-DIV 1
PROJECT :
LIMITED
02.00.05 Sizing calculation

Instrument air requirement
The total Instrument Air requirements shall be assessed by the following guideline:
Z = {(A+B) +C+D+E} x [1+ (mw+ml)/100] where,
A = Instrument Air requirement for SG & auxiliaries (continuous)
B = Instrument Air requirement (continuous) for TG & auxiliaries
C = Instrument Air requirement (continuous) for Water treatment plant and other facilities
D = Station C&I requirement (continuous).
E =Caustic soda and Chloromethane plant instrument air requirement (continuous)
mw = Wear & tear margin (10%)
ml = Leakage margin (10%)
Z = Total Instrument Air requirement
Air requirement
S. No Description Remarks
Flow in Nm3/hr
Instrument Air requirement for SG & As per MOM Dated 17-
A
auxiliaries (continuous) 10-18 (Point No. 26),
Instrument Air requirement 897 flow is increased to 897
B
(continuous) for TG & auxiliaries from 600.
Fuel handling
system(207) Water,
Instrument Air requirement
effluent and sewage
C (continuous) for Water treatment 352
treatment system(15)
plant and other facilities
Dense phase ash
handling system(130)
Station C&I requirement
D 10
(continuous).
Caustic soda and Chloromethane Caustic soda -400
E plant instrument air requirement 1100 Chloromethane plant-
(continuous) 700
Total instrument air requirement 2359 Sum of (A) to (E)
Wear & tear margin 10%
Leakage margin 10%
Total instrument air requirement
Z 2830
with margin
PROJECT :
LIMITED
P1 x V1 = P2 x V2
T1 T2
Where,
V1 = Volume of air required in Nm³/hr at P1=1.033 bar & T1=0 deg C or 273 K
V2 = Volume of air required in m³/hr
P2 = Ps – (RH x Pvap)
Ps= Atmospheric pressure at site elevation level of 7 m (1.0322 bar)
RH = Relative humidity in % (70%)
Pvap= Vapor Pressure at ambient temperature (T2) = 0.0933 bar
T2 = Temperature of Ambient air = 45 deg C
Actual requirement:
1.033 x 2830 = (1.0322-(0.70 x 0.0933)) x V2
273 (273+45)
V2 = 3523.35 m³/hr
= 2073.77 CFM
No of compressor working = 4
Required compressor capacity = 518 CFM
 Selected capacity of Instrument air compressor shall be 565 CFM
PROJECT :
LIMITED
Service air requirement

The total Service Air requirement shall be assessed by considering the following guideline:
Y = {(E+F) +G+H+I} x [1+ (mw+ml)/100] where
Y = Total service air requirement (continuous)
E = Service Air requirement (continuous) for SG, TG & auxiliaries.
F = Service Air requirement (continuous) for Water treatment plant and other facilities.
F = 10 NM³/hour
G= Service Air Requirement for AHP
H= Service Air Requirement for CHP
I= Service Air Requirement for Caustic soda and Chloromethane plant
mw = Wear & tear margin (10%)
ml = Leakage margin (10%)
The compressed air requirement shall be sum total of SA & IA requirements listed above (Z
+Y)
Air requirement
S. No Description Remarks
Flow in Nm3/hr
As per MOM Dated
Service Air requirement (continuous) 17-10-18 (Point No. 25),
E 1500
for SG, TG & auxiliaries. flow is increased to
1500 from 100.
Service Air requirement (continuous)
F for Water treatment plant and other 10
facilities.
G Service Air Requirement for AHP 10
H Service Air Requirement for CHP 10
500 x 0.6 =300 (60%
Service Air Requirement for Caustic
I 300 loading is considered
soda and Chloromethane plant
as it is Intermittent
Total service air requirement 1830 Sum of (E) to (I)
Wear & tear margin 0%
Leakage margin 0%
Total instrument air requirement
Y 1830
with margin
PROJECT :
LIMITED
P1 x V1 = P2 x V2
T1 T2
Where,
V1 = Volume of air required in Nm³/hr at P1=1.033 bar & T1=0 deg C or 273 K
V2 = Volume of air required in m³/hr
P2 = Ps – (RH x Pvap)
Ps= Atmospheric pressure at site elevation level of 7 m (1.0322 bar)
RH = Relative humidity in % (70%)
Pvap= Vapor Pressure at ambient temperature (T2) = 0.0933 bar
T2 = Temperature of Ambient air = 45 deg C
Actual requirement:
1.033 x 1830 = (1.0322-(0.70 x 0.0933)) x V2
273 (273+45)
V2 = 2278.35 m³/hr
Required service air = 1341 CFM
No of compressor working = 2
 Selected capacity of Service air compressor shall be 585 CFM x 2 No’s + 171 CFM* = 1341
* Instruments Air of 188 CFM is additionally available @ Instrument Air compressor for
continuous supply.
PROJECT :
LIMITED
i. Control Philosophy for compressors
The Compressor shall be controlled through Individual Microprocessor Based Control

Systems with Digital Display Facility. All the Safety Interlocks & Other Functions associated
with the Safe Operation of the Compressor shall be undertaken from Same Systems Only.
The Offered Microprocessor Based Control Systems shall be able to Communicate with
Centralized DCS (By purchaser) System through RS-485 modbus Protocol for monitoring
purpose only.
Detailed control philosophy shall be submitted during detail engineering.
03.00.00 PIPING SYSTEM
03.00.01 MATERIAL SELECTION
S
Service Pipe Material
No
IS 1239 Part-I Black Medium Class ≤ 150
Circulating water, auxiliary cooling water,
NB
1 raw water, service water and potable water
IS 3589 > 150 NB
piping
IS 2062
2 Service air applications IS 1239 Heavy grade
3 Instrument air applications IS 1239 Part-I GI pipes of heavy grade
03.00.02 VELOCITY CONSIDERED
Average velocity in Meter /

Description
Second
Pump suction 1
Pump delivery 2.5 (2 for cooling water system)

1.5
Service/potable water
03.00.03 Friction Losses in Piping/fitting

Pressure loss of pipes and fittings are calculated based on WILLIAM - HAZEN formula for the
worst path of the routing
PROJECT :
LIMITED
h = 21615.174xV1.852/ (C1.85 x ID1.167) – for pipes
h = k x( V2/2g) – for fittings

Where
h = Pressure loss due to friction in (mAq)
V = Velocity of the fluid (m/s)
C = Hazen Williams roughness constant
ID = Inside diameter of the pipe (m)
k = Resistance coefficient
g = 9.81 m/sec2
PROJECT :
LIMITED
04.00.00 CODES & STANDARDS
BS-726 - Measurement of Air Flow for Compressor.
ANSI-B16.5 - Steel Pipes Flanges and Fittings.

ASME PTC-9 - Performance Test Codes for Displacement Compressors, Vacuum Pumps and
Blowers.
BS-5169/1975 -Fusion Welded Steel Air Receiver.
ISO-7183 - Compressed Air Dryers - Specification and Testing.
ISO-7183 (Part-II) - Compressed Air Dryers - Performance rating.
IS-12258 - Technical supply condition for Screw Air Compressor.
BS-1571 - Simplified Acceptance Test for Air Compressor and Exhausters.
ISO 8753.1 - Filter quality classes.
Air Receiver – IS 2825
05.00.00 LIST OF DRAWINGS
S No Title Drawing no. Rev
1. P & ID FOR INSTRUMENT AND SERVICE ES0153-75990200-PID-0021 01

AIR SYSTEM
PROJECT :
LIMITED

DBR-Complressed Air System-12.08.2019

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DESIGN BASIS REPORT

FOR COMPRESSED AIR

Updated As Per Final

Rev No Date Description Prepared Verified Approved

PROJECT 2 X 65 MW COGENERATION CAPTIVE POWER PLANT

GACL-NALCO ALKALIES & CHEMICALS PVT

CONSULTANT DESEIN PRIVATE LIMITED CONSULTING

EPC CONTRACTOR M/s. ISGEC HEAVY ENGINEERING LIMITED.

S.NO. DESCRIPTION PAGE NO.

4. CODES AND STANDARDS 12

01.01.00 PROJECT DETAILS & SITE DATA

S.No. Description Unit

3. EPC contractor M/s. Isgec Heavy Engineering Limited

7. Seismic Co-efficient zone Zone – III as per IS 1893 - 2002

8. Design Wind Velocity m/s As per IS 875, Part 3 – 47 m/s

9. Wind Direction SW-NE

10. Area classification Safe , Non- hazardous & Non- Corrosive

S.No. Description Unit

20. Nearest town Bharuch– 50 KM

21. Nearest harbor Magdalla, Surat(~110 kms)

02.00.00 COMPRESSED AIR SYSTEM

02.00.02 Main features of Instrument & Service air Compressor

Instrument air Compressor

5 Design Ambient temperature 45 °C

Service air Compressor

02.00.03 Air Drier

1 Type of drier Refrigerant Type

2 Capacity of drier 900 CFM

3 No. of drier 5 (4W+1S)

4 Delivery pressure 7-8 kg/cm²(g)

5 Pressure Dew point temperature 2-3 °C

6 Atmosphere Dew point temperature -17 °C

02.00.04 Air Receiver

1 Type of receiver Vertical, Cylindrical

20 & 5 m³ for instrument air

5 Material of construction IS 2062 E250 Gr.B

6 Design standard ASME section VIII-DIV 1

02.00.05 Sizing calculation

V2 = Volume of air required in m³/hr

Ps= Atmospheric pressure at site elevation level of 7 m (1.0322 bar)

RH = Relative humidity in % (70%)

Pvap= Vapor Pressure at ambient temperature (T2) = 0.0933 bar

T2 = Temperature of Ambient air = 45 deg C

1.033 x 2830 = (1.0322-(0.70 x 0.0933)) x V2

 Selected capacity of Instrument air compressor shall be 565 CFM

Service air requirement

V2 = Volume of air required in m³/hr

Ps= Atmospheric pressure at site elevation level of 7 m (1.0322 bar)

RH = Relative humidity in % (70%)

Pvap= Vapor Pressure at ambient temperature (T2) = 0.0933 bar

T2 = Temperature of Ambient air = 45 deg C

1.033 x 1830 = (1.0322-(0.70 x 0.0933)) x V2

Required service air = 1341 CFM

i. Control Philosophy for compressors

The Compressor shall be controlled through Individual Microprocessor Based Control

Detailed control philosophy shall be submitted during detail engineering.

03.00.00 PIPING SYSTEM

03.00.01 MATERIAL SELECTION

3 Instrument air applications IS 1239 Part-I GI pipes of heavy grade

03.00.02 VELOCITY CONSIDERED

Average velocity in Meter /

Pump delivery 2.5 (2 for cooling water system)

03.00.03 Friction Losses in Piping/fitting