60 tph technical shedule

8/13/2019 60 Tph Technical Shedule

1/32

PWS 1000-MAY 2001

Type of fuel : 100% Rice Husk

60,000

66

495+/-5

130

60-100

30

60

250

20150

812.95

660.70

131.68

281.55

Balanced

Natural

Bottom

Bi-drum

Units Rice Husk

Moisture % 9.44

Ash % 15.01

Carbon % 36.67

Hydrogen % 4.57

Sulphur % 0.18

Nitrogen % 1.25

Oxygen % 32.88

GCV kcal/kg 3275

PROPOSAL INPUT DATA SHEET

( % by weight for solid/liquied fuel ) / (% by volume for gaseous fuel)

Fuel Proximate / Ultimate analysis :

bottom / top

single / bi drum

Type of support :

Number of drums :

kcal / kg

SH steam enthalpy :

Drum steam enthalpy :

kcal / kg

kcal / kg

Feed water enthalpy :

m (Assumed)

deg.C%

deg.C

Type of draught :

SH temp. control range :

deg.C

%

deg.C

Back end temperature :

Type of circulation :

balanced / forced

natural / forced

Ambient temperature :

Relative humidity :

Site altitude :

Saturated water temp. :

deg.C (Performance)

Excess air :

%

CLIENT'S NAME

CONSULTANT'S NAME -

M/s. Sriram EPC Limited

kg/hr

kg/cm2(g)

-PROJECT LOCATION

Type of boiler : AFBC

Boiler capacity ( Net / Gross ) :

SH Outlet pressure :

SH Outlet temperature :

FW temp at eco. inlet :

Prepared by:

JRE M/s Sriram EPC LimitedApproved by:

JRA


2/32

HEIGHT CORRECTION

0.0 1.0

304.8 1.0

609.6 0.9

914.4 0.9

1219.2 0.91524.0 0.8

1828.8 0.8

2133.6 0.8

ALTITUDE 250 M

0 1

304.8 0.964

FACTOR 0.97

Prepared by:


JRA


3/32

PWS 1001-MAY 2001

BOILER FEED PUMP SELECTION Not applicable

Number of feed pumps 2

Total Feed Water Flow (Boiler Peak) kg/hr 66000

% of flow handled by each pump % 100

Feed water flow at Peak (for each pump) kg/hr 66000

Feed water flow at MCR (for each pump) kg/hr 61200 (2% BD loss)

Feed water temperature deg.C 130

Feed water pressure kg/cm2(g) 76.00

Feed water density kg/cu.m 934.84

Design flow margin % 10

Design pressure margin % 5

PRESSURE SCHEDULE :

Steam pr. at battery limit kg/cm2(g) 66

Super heater header pressure kg/cm2(g) 66.25

Super heater S.V. set pr. kg/cm2(g) 70.50 margin % 6.415

Super heater pressure drop kg/cm2(g) 6

Max. drum operating pressure kg/cm2(g) 76.50

1st drum S.V. set pressure kg/cm2(g) 77.00

2nd drum S.V. set pressure kg/cm2(g) 77.50 (Boiler design pr.)

Static head kg/cm2(g) 1.5

Pressure drop across economiser kg/cm2(g) 1.00

Pressure drop across HP heater kg/cm2(g) 0.0

Pressure drop across C.V. & piping kg/cm2(g) 3.5

BFP discharge pr. at Design condition kg/cm2(g) 87.68 938 MWC

Boiler feed pump capacity at MCR cu.m / hr 65.47 835 MWC DUE to VFD

Boiler feed pump capacity at Design cu.m / hr 77.66

Prepared by:


JRA


4/32

PWS 1002-MAY 2000

FD FAN FLOW AND HEAD CALCULATION

100% Rice

Husk

Total air flow with worst fuel kg/hr 86113

Total air flow with performance fuel kg/hr 86113

Percentage of air handled by FD fans 100

Air temp. at FD fan inlet at MCR deg.C 33

Air temp. at FD fan inlet at design condition deg.C 50

FAN margin in flow % 15

Fan margin in variable head % 56

Leakage Considered % 5

No. of fans 1

% of flow handled by each fan % 100

Air pressure at FD fan suction mmwg -25

( loss due to ventury , silencer etc. )

DRAUGHT LOSS AT MCR CONDITION

Flow meter mmwg 20 31.2

Silencer mmwg 20 31.2

Air heater mmwg 40 62.4

Grate bar mmwg 0 0

Burner RDL mmwg 0 0

Across fluidised bed mmwg 480 480

Across air nozzle mmwg 125 195

Ducting & damper mmwg 40 62.4

Other losses mmwg 0 0

GrasimEg(75 t)

Total pressure drop mmwg 725 862.2 870

FD fan MCR flow rate cu.m/s 22.39

FD fan design flow rate cu.m/s 27.18 27.18

FD fan design head mmwg 862

Prepared by:


JRA


5/32

PWS 1003-MAY 2000

ID FAN FLOW AND HEAD CALCULATION

100% Rice

Husk

Flue gas flow rate at MCR for worst fuel kg/hr. 99188

Flue gas flow rate at MCR for perform. fuel kg/hr. 99188

Flue gas temp. at ID fan inlet at MCR deg.C 150

Flue gas temp. at ID fan inlet at design deg.C 160

FAN margin in flow % 25

Fan margin % 30

Leakage considared % 5

No. of ID fans 1

% of flow handled by each fan % 100

Gas density at ID fan Inlet for performance fuel kg/cu.m 0.796

Gas density at ID fan Inlet for design fuel kg/cu.m 0.774

DRAUGHT LOSS AT MCR CONDITION

Combustion chamber mmwg 5

Cyclone mmwg 0

Secondary superheater mmwg 0

Primary superheater mmwg 10

Boiler bank mmwg 5

Economiser mmwg 30

Air heater mmwg 25

ESP pressure drop mmwg 25

MDC/Wet Scrubber/Bag filter pr. drop mmwg 0

Ducting & Damper mmwg 40

Chimney loss mmwg 10

Other losses mmwg 0

Total pressure drop mmwg 150

ID fan MCR flow rate cu.m/s 36.34

ID fan design flow rate cu.m/s 46.70 46.70

ID fan design head mmwg 195

Prepared by:


JRA


6/32

0 PWS 1005-MAY 2000

FUEL NOZZLE AND PA FAN SELECTION

Nozzle size Coal feed Biomass 100 % Rice

Husk

rate feed rate Qty.of worst fuel fire kg/hr 15683

4 inch,

114.3 od 800 350

6.02 thk kg/hr kg/hr Selected nozzle fee kg/hr 795

5 inch,

141.3 od 1250 550

6.55 thk kg/hr kg/hr No. of fuel nozzles : 24

6 inch,

168.3 od 1800 795 With peak : 21.700

7.11 thk kg/hr kg/hr Without peak : 19.727

Number of PA fans 1

% of primary air handled by each fan 100

Selected number of nozzles 24

Selected number of bed sections 6

Fuel feed line pipe OD 168.3

Fuel feed line pipe thickness 7.11

Air temp. at fan inlet at MCR 160

Air temp. at fan inlet at design 180

PA fan flow margin % 10

PA fan head margin % 15

PA fan design head 800

PA fan flow at MCR cu.m/s 8.95

PA fan flow at design cu.m/s 10.30

PA fan MCR head mmwg 696

TYPE OF FUEL : .100 % Rice Husk

Prepared by:


JRA


7/32

PIS 1006 - MAY 2000

TECHNICAL SPECIFICATION FOR ID FAN

* Quantity : 1* Working fluid : Flue Gas

* Site altitude : 250 m above MSL

* Type of control : IDC/VFD Manual

* Fan speed : 1000 rpm

Design 46.70 160 -190 5 195 0.774

MCR-1 36.34 150 -145 5 150 0.796

Gas

densitykgm

3

Operating

temp. deg.C

Inlet

pressure

mmwg

Outlet

pressure

mmwg

Devolope

d

pressure

Description ow cu.m/s

REMARKS : Mechanical design of fan should be at 250*C

Prepared by:


JRA


8/32

TECHNICAL SPECIFICATION FOR FD FAN

* Quantity : 2

* Working fluid : Air

* Site altitude : 250 M above MSL* Type of control : IGV/VFD Manual


Design 27.18 50 -25 837 862

MCR-1 22.39 33 -25 700 725

Description Flow

cu.m/s

Operating

temp. deg.C

Inlet

pressure

mmwg

Outlet

pressure

mmwg

Devolope

d

pressure


Prepared by:


JRA


9/32

TECHNICAL SPECIFICATION FOR PA FAN

* Quantity : 2

* Working fluid : Hot Air

* Site altitude : 250 M above MSL* IGV/VFD Manual


Design 10.30 180 820 1620 800

MCR 8.95 160 820 1516 696

Description Flow

cu.m/s

Operating

temp. deg.C

Inlet

pressure

mmwg


Type of control :

Outlet

pressure

mmwg

Devolope

d

pressure

Prepared by:


JRA


10/32

PIS 1008 - MAY 2000

NOT APPLICABLE

* Quantity 2

* Working fluid Feed Water

* Type of control FCV/ARC/VFD

* Pump speed 3000 rpm

Design 77.66 130 87.68

MCR 65.47 130

Remarks

Flow

cu.m/hr

Operating

temp. deg.C

Discharg

e

Pressure

TECHNICAL SPECIFICATION FOR BOILER FEED PUMP

Description

Prepared by:


JRA


11/32

PIS 1009 - MAY 2000

POLUTION CONTROL EQUIPMENT SPECIFICATION

Type of equipment : Electro Static Precipitator

Quantity 1

Design gas temp. 140 Deg.C

Maximum draught loss 25 mmwg

Outlet dust loading 50 mg/N.cu.m

Type of fuel 100%

Rice

Husk

Inlet pressure mmwg -110

Design gas flow rate Nm3/hr 92,012Design gas flow rate m3/sec 39.60

Gas density kg/m3 0.796

Inlet dust loading gm/N.cu.m 21

Flue gas analysis

( % by weight )

H2O : 9.283

CO2 : 21.021

SO2 : 0.063

N2 : 65.679

O2 : 3.954

Ash composition analysis

( % by weight )

Sio2 :

Al2o3 :

Fe2O3 :

CaO :

MgO :

Na2O :

K2O : Consider standard analysis

TiO2 :Mn3o4 :

So3 :

P2o5 :

BaO :

SrO :

ZnO :

REMARKS : Site Elevation 250 M above MSL(Assu

Prepared by:


JRA


12/32

PWS 1011 NOV 2000

PROJECT NO:

CLIENT:

TYPE:

I OPERATING PARAMETERS

1 MCR Generation KG/HR 60,000

2 Peak Generation (hrs in hrs) 1/2 hr per shift KG/HR 66000

3 Steam outlet pressure Kg / cm2(g) 66

4 Steam outlet temperature oC 495+/-5

5 Steam Temperature Control Range % MCR 60-100

6 Feed Water Temp.at eco inlet oC 130

7 Ambient Temperature oC 30

8 Relative Humidity % 60

9 Boiler Design Pressure Kg / cm2g 77.50

10 Feed Pump Discharge Pressure-design Kg / cm2g 87.68

11 Draught Losses In Gas Side(ID) MCR mmWG 150

12 Draught Losses In Air Side (FD) MCR mm WG 725

13 Draught Losses In Air Side (PA) MCR mm WG 69614 Particulate Emission mg/NM3 50

15 Sox Emission ppm-dv Not Applicable

16 NOX Emission ppm - dv Not Applicable

17 Final Steam Quality (TDS) / (SIO2) ppm 0.1/0.02

18 Drum safety valves set pressure kg/cm2(g) 77.00 77.50

19 S.H. safety valve set pressure kg/cm2(g) 70.50

II FUEL

1 Type Rice Husk

2 Load for Each Fuel 100%

3 Size/Pressure/Temp.

III ULTIMATE ANALYSIS FOR Fuel

Units

1 Moisture % 9.442 Ash % 15.01

3 Carbon % 36.67

4 Hydrogen % 4.57

5 Sulphur % 4.57

6 Nitrogen % 1.25

7 Oxygen % 32.88

9 GCV kcal/kg 3275

IV ANALYSIS BY VOLUME FOR GASEOUS FUELS

1 Sio2 : %

2 Al2o3 : %

3 P2o5 : %

4 CaO : %

5 MgO : %

6 Na2O : %7 K2O : %

8 TiO2 : %

9 Fe2O3 : %

10 Mn3o4 : %

11 So3 : %

12 GCV KCAL/NM3 (KCAL/KG)

13 NCV KCAL/NM3 (KCAL/KG)

PREPARED BY APPROVED BY

PROPOSAL ENGINEER HEAD-PE

TECHNICAL SCHEDULE

M/s. Sriram EPC Limited

Two Nos 67 Tph / 67 Ata / 485 +/ -5 *C SH /FWT 200 * CRice Husk fired Bottom Supported AFBC Boilers

Not Applicable


13/32

V

1 Ca CO3 %

2 Mg CO3 %

3 H2O %4 INERTS %

5 Size requirements

6 Reactivity

VI EFFICIENCY AND FUEL FIRING

1 Efficiency On GCV At MCR %

2 Efficiency On NCV At MCR %

3 Tolerance On Efficiency %

4 Fuel Fired At MCR Kg / Hr

5 Excess Air In Furnace %

6 Sulphur Removal %

7 Ca to Sulphur molar ratio %

8 Limestone firing MCR Kg/hr

VII GAS VELOCITY PROFILE AT MCR

1 Fluidising Velocity M/s.2 Average through Sec. Superheater M/s.

3 Average through Pri. Superheater M/s.

4 Average through Boiler Bank M/s.

5 Average through FF Section M/s.

6 Average through Air heater M/s.

VIII GAS TEMPERATURE PROFILE

1 Bed Temperature o C

2 Furnace Exit Gas Temp. o C

3 Secondary Super Heater Exit o C

4 Primary Super Heater Exit o C

5 Boiler Bank Exit o C

6 Forced Flow Secn Exit o C

7 Air Heater Exit o C

IX STEAM WATER AIR TEMPERATURE PROFILE

1 Steam At Primary Super Heater I/L o C

2 Steam At Primary Super Heater O/L o C

3 Steam At Attemperator O/L o C

4 Steam At Secondary Super Heater O/L o C

5 Water At Forced Flow Section Inlet o C

6 Water At Forced Flow Section Outlet o C

7 Air At Air Heater O/L o C

8 Attemperator Spray %

X STOKERS

1 Type

2 Depth (Sprocket centres) mm

3 Width mm

4 Number Of Stokers

5 Drive KW x RPM x No.

Not Applicable

LIME STONE ANALYSIS

Not Applicable

Refer Data Sheet


14/32

XI BURNERS

1 No. of Burners

2 Capacity Each Litres/hr 3 Type

XII BED FOR AFBC BOILER

1 Type

2 Depth mm

3 Width mm

4 Bed plate thickness mm

5 Number Of Compartments

6 Number Of Coal nozzle/Mixing nozzles

7 Number of Air nozzles

8 Static/expanded bed height mm

XIII COMBUSTION CHAMBER DIMENSIONS

1 Type mm

2 Width mm

3 Depth mm

4 Cooled Height mm

5 Total Height mtr

XIV BACK PASS DIMENSIONS

1 Type

2 Width mm

3 Depth mm

4 Height mm

5 Total Height mtr

XV AIR HEATER PLATE DETAILS

1 Top (WidthxDepthxThk.) mm

2 Bottom (WidthxDepthxThk.) mm

XVI DETAILS OF PRESSURE PARTS

1.0

1.1 Inside Diameter mm

1.2 Shell Length mm

1.3 Thickness mm

1.4 MOC Of Shell & Head

2.0

2.1 Inside Diameter mm

2.3 Shell Length mm

2.4 Thickness mm

2.5 MOC Of Shell & Head

3.0

ZONE NOS. ODX THK

mmxmm

Total Length (m) MOC

3.1 Bed coil evaporator headers 4 273.1 x 25.4 46.0 SA 106 Gr B

3.3 Furnace headers 4 273.1 x 25.4 35.0 SA 106 Gr B

3.4 Primary SH I/L

Primary O/L Hdr.

1

1

219.1 X 20.62

273.1x 25.4

5

15

SA 106 Gr.B

SA 335 P11

3.5 Secondary SH I/L

Secondary O/L Hdr.

3.6 Bed SH inlet Hdr. 2 273.1 x28.58 12.0 SA 335 P11

3.9 Bed SH outlet Hdr. 2 273.1 x 28.58 6.0 SA 335 P22

4.0 Forced flow headers 2 168.3 x 18.26 7.0 SA 106 Gr B

SA 516 GR 70

HEADERS

Mud Drum

914

5200

4

24 Nos of 6" Size

SA 516 GR 70

915 (Expanded bed height from Air nozzle top)

4300

3085

1372

MS Casing 5 mm thk.

Steam Drum

Under Bed Fuel Feeding

10000

3900

Not Applicable

25

95 NOS/SQ.M

80 mm min finished

13000(Alloy Steel ducting of 5mm thk to be considered for 5500mm

length from bank tubes outlet to Economer)

2 Nos.5400 x 2560 x 20

12.50 (2.3 m ht. of 212 mm thk Castable Refractory lining at Bottom)

Membrane wall with bottom portion refractory lining (51

mm OD x 4.00 mm thk. Pitch 100 mm)

4300

10200

10400

5200

55 mm minimum finished

Not Applicable

2 Nos.5400 x 2560 x 25


15/32

4.0 PIPINGS

ZONE NOS. ODX THK

mmxmm

Total Length (m) MOC

4.1 Down comers 4 273.1 x 18.26 60 SA 106 Gr.B4.2 Down comers 2 273.1 x 18.26 25 SA 106 Gr.B

4.3 Down comers 4 219.1 x 14.27 60 SA 106 Gr.B

4.4 Risers 10 168.3 x 14.27 110 SA 106 Gr.B

4.5 Drum to PSH link 2 168.3 x 14.27 10 SA 106 Gr.B

4.6 PSH to BSH-I link 1 273.1 x 20.62 25 SA 335 P11

4.7 Attemperator Piping 1 219.1 x 20.26 5 SA 335 P11

4.8 BSH-II to BSH-III link 1 273.1 x 20.62 20 SA 335 P11

4.9 BSH outlet link up to MSSV 1 219.1x 20.62 15 SA 335 P11

4.10 MSSV to Turbine Emergency Stop Valve 1 219.1 x 18.26 55 SA 335 P11

4.11 Common Steam Distribution Header 1 610 x 28.58 7 SA 335 P11

4.12 Spray water piping from feed water line to

DS/PRDS

1 48.3 x 3.68 150 SA 106 Gr.B

4.13 Feed pump suction header (Common for Two

Boiler)

1273.1 x 15.07 10 SA 106 Gr A

4.14 Feed pump discharge header (Common for Two

Boiler)

1219.1 x 15.07 10

SA 106 Gr.B

4.15 Feed water piping ( from Deaerator to BFP

Suction Header )

1219.1x 18.26 15

SA 106 Gr.B

4.16 Feed water piping ( From BFP discharge Header

to FCV inlet)

1168.3 x 14.27 40

SA 106 Gr.B

4.19 Feed water piping ( From FCV to Drum) 1 168.1 x

14.27/168.3 x

10.97

60 SA 106 Gr.B

4.25 Boiler Initial filling from one point nearer boiler to

drain header

1 88.9 x 5.49 70 SA 106 Gr.B

4.26 HP/LP dosing system dilution water line from one

point nearer boiler column.

1 26.7 x 2.87 30 SA 106 Gr.B

4.27 Raw water quenching line for IBD tank from a

terminal point near boiler

1 48.8 x 3.68 40 SA 106 Gr.B

4.28 Flash steam piping to deaerator 1 114.3 x 6.02 20 SA 106 Gr.B4.32 Minimum recirculation piping,Balance leak off

piping from individual BFP to deaerator

1 60.3 x 3.91/88.9

x 5.49

100/100 SA 106 Gr.B/SA 106 Gr. B

4.33 Target Plates and Temporary Piping as required

for steam blowing with motor operated isolation

valve

1

4.34 HP/LP dosing system piping from the dosing skid

to economiser outlet feed pipe/suction pipe to

boiler feed pupms.

1 33.4 x 3.38 145 SA 213 TP304

4.35 Feed piping from Dearetor to Boiler suction

Header

1 273.1 x 15.07 20 SA 106 Gr.B

4.36 Steam piping from turbine Extraction to Dearetor 1 219.1 x 15.09 35 SA 106 Gr.B

4.37 Steam piping from main steam line to PRDS 1 88.9 x 14.27 30 SA 106 Gr.B

4.38 Steam line from PRDS outlet to Dearator 1 141.3 x 9.53 25 SA 106 Gr.B

4.39 Steam Piping from PRDS line to Air Ejector 1 60.3 x 5.54 30 SA 106 Gr.B4.40 Condensate piping from condensate to Dearetor 1 323.9 x 14.27 30 SA 106 Gr.B


16/32


17/32

Notes:

1 Structural steel from firing floor .

2 Plant Location : Punjab

3 Structure occupied volume : m^3

4 Operating floor is at 6 mtr elevation which is RCC by Customer

5 One no Rotary feeder with Feeding chute from up to furnace to be consider.

6 Two nos Hydrasteps to be consider.

7 SS tip/MS base Air & Coal Nozzles .For Estm. SS to be considered.

8 One no Hydro test pump along with all fittings and piping,Valves and water tank to be provided.

9 Pneumatically operated IGV at inlet of FD ,ID, & PA fans .

10 9 nos RAV for all fly ash hoppers to be provided.

11 One no o2 Analyser in flugas line.

12 Monorails and electric hoist for lifting fans andfeed pumps.

13 Canopy for boiler & Side Cladding from roof level to steam drum operating floor level.

14 VFD for Fuel Feeders,ID & FD Fans And Boiler Feed pumps.

15 Air ducting and gas ducting thk 4 &5 mm respectively

16 Sample coolers-4 nos

17 Special tools and tackles to be considered.

18

19 Bunker chute thickness to be consider 8 mm.

20 3 x 100 % Boler Feed pumps for Two Boliers

21 Manual isolation valve and manual bypass valve has to be provided in main steam piping .

22 One no PRDS of 0.8 to 8 tons capacity for temperature of 67 ksca/11 ksca.

23 Soot Blowers LRSB at SH zone 2 Nos and RSB - 4 Nos

24 Deaerator pressure control valve is sized to control the pressure from 11 ksca to 5 ksca as considered in Sriram EPC 35 tons Boiler.

25 One no manual operated isolation valve with integral bypass valve to be consider after the motorised MS stop valve.

OFA nozzles with required ducting & expansion joints, dampers to be provided. Material of OFA nozzles facing furnace radiation should be

SS.


18/32

Client: M/s. Sriram EPC Limited

XXI AUXILIARIESSl.No EQUIPMENT NOS

(W+SB)

CAPA

CITY

cu.m /

HEA

DTEMP

Oc ATTACHMEN

T &

CONTROL

MOTOR

KW X rpm

(TENTATIVE)

Remarks

1 PA Fan 1 x 100% -Constant speeddriven 1 + 0 10.30 800 180 IGV/VFD 132 x 1500 Pneumatic Operated forESTM

2 FD Fan 1 x 100% - VFD driven 1 + 0 27.18 862 50 IGV/VFD 360 x 1500 Pneumatic Operated (VFD is

in our scope)3 ID Fan 1 x 100% - VFD driven 1 + 0 46.70 195 160 IGV/VFD 160 x 1000 Pneumatic Operated (VFD is

in our scope)4 Agitators 2 + 0 0.37/1500

5 Pocket feeders with VFD 12 1.5 / 1500

6 Rotary feeder with VFD for rice

straw feeding

1 1.5 / 1500 (VFD is in our scope)

7 Motorised Valves (VFD is in our scope)

a Main Steam Stop Valve with Integral

Bypass

2 4.0 / 1500 &

0.06 / 1500

c Start-up Vent isolation valve 1 0.37 / 1500

c CBD valve 1 0.55 / 1500

d IBD valve 1 0.55 / 1500

Common Items

8 BF Pumps 3 x 100% - VFD Driven. 2 + 177.66 938 130 320/2900

9 LP Dosing Pumps 2 + 1 0.75/1500

10 HP Dosing Pumps 2 + 1 0.75/1500

M/s Sriram EPC Limited


19/32

Project : M/s. Sriram EPC Limited

Boiler : Two Nos 67 Tph / 67 Ata / 485 +/ -5 *C SH /FWT 200 * C

Si..No Description Unit Value

1 Side Walls

No of Tubes nos 104

Length of Tubes m 13.5

Value of PI 3.141593

no of side walls nos 2

tube size mm 51.0

area m^2 450

2 Front Walls

No of Tubes nos 42

Length of Tubes m 24



tube size mm 51

area m^2 162

3 Rear Walls

No of Tubes nos 42

Length of Tubes m 22



tube size mm 51

area m^2 148

total area m^2 759

margin % 5

total area with margin m^2 797

fins for water wall m 4721

margin % 5

fins length considering margin m 4957

Furnace tube (Circumferential Area) Calculations


20/32

Project :M/s. Sriram EPC Limited

Sl.No Description Unit100% Kutch

Lignite

1 Molecular Weight MW 28.91

2 Gas pressure at ESP inlet MMWC 110

4 Gas Outlet Temp *C 150

5 Gas Density at ESP inlet at Outlet Temp Kg/m3 0.799

6 Sp volume of Gas at ESP inlet Nm3/Kg 0.807

Sl.No Description Unit DS

1 Steam flow at D.S.H. outlet kg/hr 67000

2 Spray water pressure kg/cm2(g) 77

3 Spray water temperature deg c 130

4 Spray water enthalpy kcal/kg #NAME?

5 Steam pressure at D.S.H. inlet kg/cm2(g) 71.8

6 Steam temperature at D.S.H. inlet deg c 470

7 Steam enthalpy at D.S.H. inlet kcal/kg #NAME?

8 Steam pressure at D.S.H.outlet kg/cm2(g) 70

9 Steam temperature at D.S.H. outlet deg c 445

10 Steam enthalpy at D.S.H. outlet kcal/kg #NAME?

Spray water quantity kg/hr #NAME?

Percentage of spray % #NAME?

Flue gas density calculation

Spray water qty calculation

M/s Gallantt Metal Limited


21/32

Header & Piping Thickness Calculation

Sl. No Description

Outside

diamete

r (mm)

Thickne

ss (mm)

Desi

gn

Pres

sure

Design

Temp

Deg. C

Material

Allowable

Stress

(kg/m^2)

Minimu

m

thicknes

s

Min.

thick

availabl

e (mm)

"Ligament

Efficiency

(%)

% Margin

Available

1 Bed evaporator header 273.1 21.44 78 289.00 SA 106 Gr B 1202.53 15.19 18.76 0.5500 23.52

2 Furnace water wall header 273.1 21.44 78 289.00 SA 106 Gr B 1202.53 14.65 18.76 0.5700 28.043 PSH inlet header 219.1 18.26 78 289.00 SA 106 Gr.B 1202.53 10.59 15.98 0.6350 50.89

4 PSH outlet header 273.1 21.44 78 470.00 SA 335 P11 968.78 16.35 18.76 0.6350 14.77

5 Bed SH I/L Hdr. 273.1 25.40 78 450.00 SA 335 P11 984.53 17.06 22.23 0.5800 30.29

6 Bed SH O/L Hdr. 273.1 28.58 78 495.00 SA 335 P11 817.30 20.12 25.01 0.5800 24.29

7 ECO inlet header 219.1 15.07 80 130.00 SA 106 Gr B 1202.53 11.75 13.19 0.6055 12.26

8 ECO outlet header 168.3 14.27 79 215.00 SA 106 Gr B 1202.53 8.78 12.49 0.6055 42.23

9 Drum to PSH link 168.3 10.97 78 270.00 SA 106 Gr B 1202.53 5.67 9.60 1.0000 69.36

10 PSH to BSH-I link 273.1 18.26 78 450.00 SA 335 P11 989.03 10.47 15.98 1.0000 52.55

11 BSH-II to BSH-III l ink 273.1 18.26 78 475.00 SA 335 P11 963.71 10.74 15.98 1.0000 48.77

12

Main steam piping (Upto

MSSV) 219.1 18.26 78 495.00 SA 335 P11 817.30 10.42 15.98 0.9500 53.37

13

MSSV to Common steam

distribution header 219.1 15.09 66 495.00 SA 335 P11 817.30 8.71 13.20 1.0000 51.58

14

Common steam distribution

header 323.9 21.44 66 495 SA 335 P11 817.30 12.59 18.76 1.0000 49.05

15

Spray water piping from feed

water line to DS 48.3 3.68 78 130 SA 106 Gr B 1202.53 2.13 3.22 1.0000 50.87

16

Feed water piping form FCV

to Eco inlet 168.3 10.97 78 130 SA 106 Gr B 1202.53 5.67 9.60 1.0000 69.36

17

Feed water piping from Eco

to drum 141.3 9.53 78 215 SA 106 Gr B 1202.53 4.86 8.34 1.0000 71.60



22/32

18 Feed pump suction header 273.1 9.27 3 130 SA 106 Gr B 1202.53 1.08 8.11 1.0000 651.09

19 Feed pump Discharge header 168.3 10.97 78 130 SA 106 Gr B 1202.53 5.67 9.60 1.0000 69.36

20

Feed piping from deaerator to

boiler suction header 273.1 9.27 3 130 SA 106 Gr B 1202.53 1.08 8.11 1.0000 651.09

21

Steam piping from turbine

extraction to Dearetor 168.3 7.11 5 250 SA 106 Gr B 1202.53 1.08 6.22 1.0000 474.45

22

Steam piping from main

steam line to PRDS 88.9 11.13 66 250 SA 335 P11 817.30 3.57 9.74 1.0000 173.11

23

Steam piping from PRDS

outlet to Dearetor 141.3 9.53 11 250 SA 106 Gr B 1202.53 1.32 8.34 1.0000 529.98

24

Condensate piping from

condensate to dearator 219.1 10.97 2 45 SA 106 Gr B 1202.53 0.93 9.60 1.0000 936.48

25

steam piping from PRDS to

Ejector 60.3 3.91 11 200 SA 106 Gr B 1202.53 1.00 3.42 1.0000 241.06



23/32

DRUM THICKNESS CALCULATION - SA 516 GR. 70

STEAM DRUM

S.No. Description Units

1 Design pressure, Wp Kg/cm^2 (g) 77.5

2 Maximum Working Temperature, T1 C 320F 608

4 Drum I/D mm 1372

PREMISSIBLE WORKING STRESS (f) = Et / 1.5 page16

page507 Allo.Sress

5 Et = Yield Stress at Metal temperature(From ASME Section-II,Part D) psi 29100 19400

6 Et = Yield Stress at Metal temperature(From ASME Section-II,Part D) Kg/cm^2 2046.41

7 f = Et / 1.5 Kg/cm^2 1364.28 1364.28

8 Thickess of Drum Shell Provided, T1 mm 80

9 Liagment efficiency % 0.57

10 Tmin, ((Wp x I/D) / (2 x f x E - Wp)) + 0.762 mm 72.71

11 thickness of shell (if >60mm) mm 12.71

12 stress value reduction (>60mm) % 3

13 actual stress value Kg/cm^2 1323.35

14 Actual thickness,T2 mm 75.06

2 % reducion in stress

for every 10 mm increase in

shell thickness

M/s Gallant Metal Limited


24/32

descript ion symbo l un it value

steam drum ,ID m 1.372

height between NWL & LWL m 0.125

height between LWL &LLWL m 0.05

height below LLWL ( H) m 0.511

radius of drum R1 m 0.686

Distance between NWL and LLWL m 0.175

Angle A Deg 75.2203684

Radiant valueof A Rad 1.31284309

steam drum length m 4.7

value of PI 3.14159265

water volume below LLWL m3 2.36

water volume for half of the drum m3 3.47water volume between NWL&LLWL m3 1.12

water volume for dished end portion m3 0.12616924

total water volume m3 1.24

water flow kg/hr 67000

specific volume of water at drum operating pressure m3/kg 0.0013562 73 ata

water holding time sec 49.23

Steam Drum Water Holding Capacity Calculations



25/32

Sl. No. Description Outside

dia

( mm)

Header

thk.

(mm)

Inside

dia

m

Fluid

flow

(kg/hr)

Operating

pressure

(ksc(a))

Operating

temp. (deg.

C)

Specific

volume

(m3/kg)

Actual

velocity

(m/s)

Velocity

m/s/mmID

Velocity

m/s/mmID

(max limit)

1 Bed evaporator header

273.1 21.44

0.23022 27000 74 289.00 #NAME? #NAME? #NAME? 3 m/s

2 Furnace water wall

header 273.1 21.44

0.23022 27000 74 289.00 #NAME? #NAME? #NAME? 3 m/s

3 PSH inlet header 219.1 18.26 0.18258 67000 73 289.00 #NAME? #NAME? #NAME? 0.1500

4 PSH outlet header 273.1 21.44 0.23022 67000 70.5 470 #NAME? #NAME? #NAME? 0.1200

5 Bed I/L Hdr. 273.1 25.40 0.2223 67000 70 445 #NAME? #NAME? #NAME? 0.1500

6 Bed SH O/L Hdr. 273.1 28.58 0.21594 67000 67 495.0 #NAME? #NAME? #NAME? 0.1200

7 ECO inlet header 219.1 14.27 0.19056 147500 77 130 #NAME? #NAME? #NAME? 2 m/s

8 ECO outlet header 168.3 14.27 0.13976 67000 75 215 #NAME? #NAME? #NAME? 2 m/s

Header Sizing



26/32


27/32

13

Steam piping from

turbine extraction to

Dearetor 168.3 7.11 1 15000 11 200 #NAME? #NAME? 35-61

14

Steam piping from main

steam line to PRDS 88.9 11.13 1 8000 67 495 #NAME? #NAME? 35-61

15

Steam piping from

PRDS outlet to Dearetor 141.3 9.53 1 9000 11 200 #NAME? #NAME? 35-61

16

Condensate piping from

condensate to dearator 219.1 10.97 1 67000 0.1 44 #NAME? #NAME? 0.6 - 0.7

17

Steam piping from

PRDS to Air ejector 60.3 5.54 1 1000 11 200 #NAME? #NAME? 30-50



28/32


29/32

Project Name M/s. Sriram EPC Limited

Boiler Parameters Two Nos 67 Tph / 67 Ata / 485 +/ -5 *C SH /FWT 200 * C

Fuel Fired K.Lignite/Imp Coal/Dolo Char

ESP Selection

Description Symbol Unit 100% Rice Husk

Flue Gas Flow rate(for the worst fuel fired)

F Kg / hr 99,188

Flue Gas temp. at ESP inlet T degree C 140

Flue Gas Sp. Volume Vs Nm3

/ Kg 0.811

Fuel Flow rate Ff Kg / hr 15,683

Margin considered on gas flow M % 10

% of Ash in Fuel A % 15.01

% of Fly Ash carry over Ac % 70

Gas volume flow rate

= ( F x Vs ) x [(1+ (M/100)]G Nm

3/ hr 80,408.97

Total Ash generation = ( Frx A ) / 100 Ag Kg / hr 2,354.02

Quantity of Fly Ash carry over

= ( Ag x Ac) / 100Q Kg / hr 1,647.81

ESP Inlet Gas Volume Gv Nm3/ hr 88,449.86

ESP Inlet Dust Concentration D gm / Nm3 20.49

ESP Inlet Gas temperature Tg degree C 50.00

21Note : IDC used gm/Nm^3


30/32

SI.No Description Unit 100% Indian coal 100% Wsh.Rjts

1 Total boiler duty x10^6 kcal/hr 45.88 48.14

2 Primary SH duty x10^6 kcal/hr 10.79 10.90

3 BSH duty x10^6 kcal/hr 3.48 3.48

4 Bed Coil duty x10^6 kcal/hr 15.71 15.71

5 Economiser duty x10^6 kcal/hr 6.29 6.5

7 Furnace duty x10^6 kcal/hr 9.61 11.55

Heat duty calculation


31/32

Project Name M/s. Sriram EPC Limited

Boiler Parameters 60 Tph /67 Ata / 485+/-5*C

Description Unit 100 % Rice

husk

Type of Bunker SingleFuel qantity Kg/hr 17512

Density of fuel Kg/m^3 800

Filling factor 0.85

Hours of fuel storage Hrs 4

Storage volume of Twin bunker m^3 103.0

Bunker volume Considered m^3 100


32/32

Auxiliary Power Consump

Boiler Type: AFBC Client: M/s. Sriram EPC Limited Project No: Boiler Parameters: Pressure: Ata: 67, Temp: (Deg.C) 495+/-5 Capacity: 67 tph, FWT (Deg.C): 130

Fuel:

Sl.n

o

EQUIPMENT Design

Capacity

m3/sec or

m3/hr

MCR

Capacity

Design

Head

MCR

Head

Eff.

Design

Eff

MCR

Power

Design

kW

Power

MCR kW

M

KW

W SB

1 FD Fans- 1 X 100% 1 0 27.18 22.39 862 725 0.80 0.78 287.19 204.04 32

2 PA Fan 1 X 100% 1 0 10.30 8.95 800 696 0.7 0.75 115.38 81.41 132

3 ID Fan 1 X 100% 1 0 46.70 36.34 195 150 0.72 0.7 124.01 76.34 160

4 Pocket Feeders 12 0 1.2 1.5

5 Pocket Feeders(Over bed Feeding) 1 0 1.2 1.5

5 HP dosing pumps 1 1 0.6 0.76 Agitators 2 0 0.296 0.3

7 ESP 1 0

8 LP dosing pumps 1 1 0.6 0.7

9 Boiler Feed Pumps 1 1 77.66 65.47 938 835 0.72 0.7 257.58 198.81 29

Total for

With 3% Margin

NOS

100% Imp

Prepared by:

JRE M/s. Gallantt Metal Limited

60 tph technical shedule

Documents