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Power plant and calculations

Power plant and calculation site basically includes the detailed study of power plant operation and maintenance, its related all
calculations and thumb rules. It also involves detailed troubleshooting guides for operation and maintenance of power plant pr
and equipments.

Thumb rules for power plant

BOILER:
Boiler heating surface (M2) = Boiler capacity in kg/hr/(17–18)..Ex: 115 TPH boiler
will have heating surface = (115 X 1000/17 or 18) = 6390 to 6750 M2 (Appx.)......
Boiler flue gas ducting size (M2) = Boiler capacity in TPH/15.
No. of open tubes in steam drum for water recirculation = 30–31% of total no. of
tubes present.
Deaerator steam venting capacity = Deaeration capacity X 0.1%.
Super heater safety valve relieving capacity at full open condition in TPH = Boiler
MCR X 36–38%.......Ex: 125 TPH Boiler has SH safety valve of relieving capacity =
(125 X 36/100) = 45 TPH.
Drum safety valve (1 no.) relieving capacity at full open condition in TPH = Boiler
MCR X 46–48%.
All boiler safety valves (super heater and drum safety valves) relieving capacity at
full open condition= Boiler MCR X 125–130%.
Safety valves pop up pressure = Operating pressure X 106–107%.Ex: A boiler
operating pressure of 110 kg/cm2 has safety valve set at 110 X 106/100 =116.6
kg/cm2.
Boiler start up vent steam blow capacity 30–35% of boiler MCR on full open
condition.
Boiler CBD water flow is 0.8 to 2% of steam generating capacity of the boiler.
Drum man hole door size 410 mm X 310 mm (Elliptical).
 Boiler drum hold up capacity is 2–4 minutes at MCR operation.
Feed water velocity in Economiser coils 0.6 to 1 meter/sec.
Pressure drop in Economiser coils 0.5 to 1 kg/cm2.
Flue gas Pressure drop in ESP 25 to 30 mmwc.
A travelling grate Boiler ID fans motor rated capacity in KW = Boiler capacity TPH X
200%.....Ex: A boiler of capacity 75 TPH requires ID fan motor of rated KW = 75 X
200/100 = 150 KW each
A travelling grate Boiler ID fans (2 Nos) capacity (m3/sec.) with 25% extra margin =
Boiler Capacity(TPH) X 95%.....Ex: A 100 TPH boiler has two ID fans of each
capacity =100 X 95/(100 X 2) = 47.5 m3/sec.

TOP-6 BEST POWER PLANT O&M BOOKS

Mass of flue gas generated = Mass of air per kg of fuel to be burned + 1.
Boiler fans power consumption = Total plant auxiliary consumption X 35–38%.
Boiler feed pumps power consumption = Total plant auxiliary consumption X 35–
38%.
Turbine auxiliary power consumption = Total plant auxiliary consumption X 10–12%.
Fuel handling power consumption = Total plant auxiliary consumption X 4%.
For every 1% increase in bagasse moisture, boiler efficiency reduces by 0.27% and
vice versa.
For every 5% increase in excess air for bagasse, boiler efficiency decreases by
0.18% and vice versa.
For every 100 kcal/kg increase in bagasse GCV, boiler efficiency increases by 1.2%
and vice versa.
For every 0.5% increase of Hydrogen in bagasse, boiler efficiency decreases by
0.8–1% and vice versa.
For every 10 °C increase in flue gas temperature, boiler efficiency decreases by
0.45% and vice versa.
For every 100 kcal/kg increase in GCV of coal, boiler (TG) efficiency increases by
0.36% and vice versa.
Boiler peak load = Boiler MCR X 110%.
Minimum possible duration of boiler peak load is 30 minutes/shift.
Minimum stable operating load on the boiler is around 30% of boiler MCR.
Total dissolved solids = Conductivity X 06.

It's all about HP HEATERS

TURBINE AND AUXILIARIES:

Control oil pump capacity = AOP/MOP capacity X 10%.
Emergency oil pump capacity = AOP/MOP capacity X 25%.
Lube oil required for gear box = Total lube oil circulating X 60–65%.
Lube oil required for generator = Total lube oil circulating X 8–10%.
Lube oil required for turbine = Total lube oil circulating X 20–25%.
Lube oil outlet temperature = Lube oil inlet temperature + 15–20 °C.
Cooling tower evaporation loss = Turbine exhaust steam to condenser X 80–90%.

Also read:RULES OF THUMB IN WATER TREATMENT PLANT

MAINTENANCE:
Minimum allowable bearing clearance in mm = 0.00185 X bearing ID
Maximum allowable bearing clearance in mm = 0.00254 X bearing ID.
Bearing grease top up quantity = 0.05 X b X d, b = bearing width in mm, d =
bearing OD in mm.
Hub size = 2 X Shaft diameter.
Shaft Key size, width = (d/4) + 2, thickness = d/6, (d = diameter of shaft).
Minimum span for pipe line supporting in meter = (7√d)/3, where d = pipe OD in
inches.
Threading length of half threaded bolt = 2d + 6 mm (if bolt length l <150 mm) and
2d + 12 mm (if bolt length l >150 mm).
Spanner size = Bolt major diameter (mm) X 1.5.
Nut thickness = 0.9 X d, d = nut size.
Bolt head thickness = 0.8 X d, d = major diameter of bolt.
Washer Internal diameter = D + 1…mm.
Washer outer diameter = 2D + 3……mm.
Washer thickness = D/8, where D is OD of washer.
Diameter of bolt head across the flat ends = 1.5 X d + 3 mm.
Welding current required for welding (Amps) = Welding rod size (mm) X 40 +/- 20.
 Pipe weight/foot = (dt − t2) X 4.85...kg/foot, (pipe OD in inches & t is thickness of
pipe in inch).
Pipe line spacing = Flange size of maximum diameter pipe + Smallest pipe size +
Insulation thickness + 25 mm.
Preheating of steel is done if %C + %Mn/4 is >0.58.
Boiler platform loading capacity 500 kg/m2.
Boiler fire man floor platform loading capacity 1000 kg/m2.
Brinnel hardness number (BHN) = Rockwell hardness number X 10.8.
Bearing, grease or lip seals have a design life of less than 2000 hours. In a
constantly running pump this would be only 83 days.
FUEL HANDLING:
Tail pulley, bend pulley and take up pulley Outer diameter = Head pulley OD X
80%.
Snub pulley OD = Head pulley OD X 60%.
PCS (Pull Chord Switch) are placed at every 15 meters along the length of
conveyor.
BSS (Belt Sway Switch) are placed at every 30 meter along the length of conveyor.
Carrying and return self aligning transoms are placed at every 20 meters along the
length of the belt.
Horizontal chain conveyor motor capacity = Chain span X Fuel handling capacity /
80
Example: A chain conveyor of capacity 100 TPH & having centre to center distance 30 meters
requires motor of capacity 100 X 30 / 80 =37.5 KW to drive the conveyor safely
PUMPS:
Pump shutoff head = Design head X 1.07.
Pump efficiency with cold water is less than pump efficiency with hot water
Safe operating speed of boiler feed pumps is 55–60% of rated speed.
Boiler feed pumps suction strainer pressure drop should be 0.04 to 0.06 kg/cm2.
The pumps best efficiency point (B.E.P.) is between 80% and 85% of the shut off
head.
A double suction pump can run with less N.P.S.H. or at faster speed without
cavitating.
Multistage pumps reduce efficiency 2% to 4%.
1% capacity of pump will reduce on every 0.025 mm increase in wear ring
clearance.
Suction piping should be at least one size larger than the suction flange of the
pump.
Pumps piped in series must have the same capacity (impeller width and speed).
Pumps piped in parallel must have the same head (impeller diameter and speed).
A centrifugal pump can handle 0.5% air by volume. At 6% it will probably become
air bound and stop pumping. Cavitation can occur with any amount of air.
A Vortex pump is 10% to 15% less efficient than a comparable size end suction
centrifugal pump.
There should be at least 10 diameters of pipe between the suction of the pump and
the first elbow.
ELECTRICAL:
Rating current of motor = 1.36 X hp or 1.79 3 KW.
Starting current of a single phase motor (1 to 10 HP) = 3 X Motor full load current.
Starting current of a three phase motor (up to 15 HP) = 2 X Motor full load current.
Starting current of a three phase motor (>15 HP) = 1.5 X Motor full load current.
Current carrying capacity of copper cable: 2 amps/mm2.
Earthling resistance for single pit is <2 ohm.
Voltage between neutral and earth <2 V.
Resistance between neutral and earth <1 ohm.
Motor body earthing strip size:
85 SWG GI Wire for motors <5.5 KW.
25 X 6 mm GI Strip for motors 5.5 to 22 KW and Lighting and control panels.
40 X 6 mm GI Strip for motors 5.5 to 22 KW.
50 X 6 mm GI Strip for motors >55 KW and D.G and Exciter Panel.
Motor insulation resistance = (20 X voltage)/(1000 + 2 X motor KW).
Single phase motor draws 7 amps current per HP.
Three phase motor draws 1.25 to 1.36 amps current per HP.
No load current of three phase motor is 30 to 40% of full load current of motor.
Submersible pump takes 0.4 KWH of extra energy at 1 meter drop of Water.
 Creepage Distance 5 18 to 22 mm/KV for moderate polluted air and 25 to 30
mm/KV for highly polluted air.
Minimum Bending Radius for LT Power Cable is 12 X diameter of Cable.
Minimum Bending Radius for HT Power Cable is 20 X diameter of Cable.
Minimum Bending Radius for Control Cable is 10 X diameter of Cable.
Insulation Resistance Value for Panel = 2 X KV rating of the panel.
Test Voltage (AC for Meggering = (2 X Name Plate Voltage) + 1000.
Test Voltage (DC for Meggering = (2 X Name Plate Voltage).
Current Rating of Transformer = KVA X 1.4.
No load current of Transformer = <2% of Transformer rated current.
There are 4 Nos. of earth pits per transformer (2 No. for body and 2 No. for neutral
earthing).
Diesel generator set produces 3 to 3.5 KWH/liter of diesel.
DG less than or equal to 1000 KVA must be in a canopy.
DG greater than 1000 KVA can either be in a canopy or skid mounted in an
acoustically treated room.
DG fuel storage tanks should be a maximum of 990 Litter. Storage tanks above this
level will trigger more stringent explosion protection provision.

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Opportunities for energy conservation in power plant

at May 08, 2020

Labels: energy conservation & thumb rules in power plant

1 comment:
Anonymous 22 July 2022 at 23:39

Boiler heating surface area given thumb rule is not matching in high pressure boiler say
Pressure >165 kg/cm2

Reply

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