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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 :
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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
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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
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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
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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
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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
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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
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TECHNICAL SPECIFICATION FOR FD FAN
* Quantity : 2
* Working fluid : Air
* Site altitude : 250 M above MSL* Type of control : IGV/VFD Manual
* Fan speed : 1500 rpm
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
REMARKS : Mechanical design of fan should be at 50*C
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TECHNICAL SPECIFICATION FOR PA FAN
* Quantity : 2
* Working fluid : Hot Air
* Site altitude : 250 M above MSL* IGV/VFD Manual
* Fan speed : 1500 rpm
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
REMARKS : Mechanical design of fan should be at 250*C
Type of control :
Outlet
pressure
mmwg
Devolope
d
pressure
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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
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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
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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
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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
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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
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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
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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.
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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
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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
Value of PI 3.141593
no of side walls nos 1
tube size mm 51
area m^2 162
3 Rear Walls
No of Tubes nos 42
Length of Tubes m 22
Value of PI 3.141593
no of side walls nos 1
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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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