PWS 1000-MAY 2001 PROPOSAL INPUT DATA SHEET CLIENT'S NAME CONSULTANT'S NAME PROJECT LOCATION Type of boiler

: Type of fuel : M/s. Sriram EPC Limited AFBC 100% Rice Husk 60,000 66 495+/-5 130 60-100 30 60 250 20 150 812.95 660.70 131.68 281.55 Balanced Natural Bottom Bi-drum kg/hr kg/cm2(g) deg.C deg.C % deg.C (Performance) % m (Assumed) % deg.C kcal / kg kcal / kg kcal / kg deg.C balanced / forced natural / forced bottom / top single / bi drum

Boiler capacity ( Net / Gross ) : SH Outlet pressure : SH Outlet temperature : FW temp at eco. inlet : SH temp. control range : Ambient temperature : Relative humidity : Site altitude : Excess air : Back end temperature : SH steam enthalpy : Drum steam enthalpy : Feed water enthalpy : Saturated water temp. : Type of draught : Type of circulation : Type of support : Number of drums :

Fuel Proximate / Ultimate analysis : ( % by weight for solid/liquied fuel ) / (% by volume for gaseous fuel) Units Rice Husk % 9.44 Moisture % 15.01 Ash % 36.67 Carbon % 4.57 Hydrogen % 0.18 Sulphur % 1.25 Nitrogen % 32.88 Oxygen kcal/kg 3275 GCV

Prepared by: JRE

M/s Sriram EPC Limited

Approved by: JRA

HEIGHT 0.0 304.8 609.6 914.4 1219.2 1524.0 1828.8 2133.6

CORRECTION 1.0 1.0 0.9 0.9 0.9 0.8 0.8 0.8

ALTITUDE

250 M 0 304.8 1 0.964 0.97

FACTOR

Prepared by: JRE

M/s Sriram EPC Limited

Approved by: JRA

BOILER FEED PUMP SELECTION Number of feed pumps Total Feed Water Flow (Boiler Peak) % of flow handled by each pump kg/hr % 2 66000 100 66000

PWS 1001-MAY 2001 Not applicable

Feed water flow at Peak (for each pump) kg/hr Feed water flow at MCR (for each pump) kg/hr Feed water temperature Feed water pressure Feed water density Design flow margin Design pressure margin deg.C kg/cm2(g) kg/cu.m % %

61200 (2% BD loss) 130 76.00 934.84 10 5

PRESSURE SCHEDULE : Steam pr. at battery limit Super heater header pressure Super heater S.V. set pr. Super heater pressure drop Max. drum operating pressure 1st drum S.V. set pressure 2nd drum S.V. set pressure Static head Pressure drop across economiser Pressure drop across HP heater Pressure drop across C.V. & piping BFP discharge pr. at Design condition Boiler feed pump capacity at MCR Boiler feed pump capacity at Design kg/cm2(g) kg/cm2(g) kg/cm2(g) kg/cm2(g) kg/cm2(g) kg/cm2(g) kg/cm2(g) kg/cm2(g) kg/cm2(g) kg/cm2(g) kg/cm2(g) kg/cm2(g) cu.m / hr cu.m / hr 66 66.25 70.50 margin % 6.415 6 76.50 77.00 77.50 (Boiler design pr.) 1.5 1.00 0.0 3.5 87.68 65.47 77.66 938 MWC 835 MWC DUE to VFD

Prepared by: JRE

M/s Sriram EPC Limited

Approved by: JRA

PWS 1002-MAY 2000 FD FAN FLOW AND HEAD CALCULATION 100% Rice Husk 86113 86113 100 deg.C deg.C % % % 33 50 15 56 5 1 % mmwg 100 -25

Total air flow with worst fuel Total air flow with performance fuel Percentage of air handled by FD fans Air temp. at FD fan inlet at MCR Air temp. at FD fan inlet at design condition FAN margin in flow Fan margin in variable head Leakage Considered No. of fans % of flow handled by each fan Air pressure at FD fan suction ( loss due to ventury , silencer etc. ) DRAUGHT LOSS AT MCR CONDITION Flow meter Silencer Air heater Grate bar Burner RDL Across fluidised bed Across air nozzle Ducting & damper Other losses Total pressure drop FD fan MCR flow rate FD fan design flow rate FD fan design head

kg/hr kg/hr

mmwg mmwg mmwg mmwg mmwg mmwg mmwg mmwg mmwg mmwg cu.m/s cu.m/s mmwg

20 20 40 0 0 480 125 40 0 725 22.39 27.18 862

31.2 31.2 62.4 0 0 480 195 62.4 0 862.2 GrasimEg(75 t) 870

27.18

Prepared by: JRE

M/s Sriram EPC Limited

Approved by: JRA

PWS 1003-MAY 2000 ID FAN FLOW AND HEAD CALCULATION 100% Rice Husk Flue gas flow rate at MCR for worst fuel Flue gas flow rate at MCR for perform. fuel Flue gas temp. at ID fan inlet at MCR Flue gas temp. at ID fan inlet at design FAN margin in flow Fan margin Leakage considared No. of ID fans % of flow handled by each fan Gas density at ID fan Inlet for performance fuel Gas density at ID fan Inlet for design fuel DRAUGHT LOSS AT MCR CONDITION Combustion chamber Cyclone Secondary superheater Primary superheater Boiler bank Economiser Air heater ESP pressure drop MDC/Wet Scrubber/Bag filter pr. drop Ducting & Damper Chimney loss Other losses Total pressure drop ID fan MCR flow rate ID fan design flow rate ID fan design head mmwg mmwg mmwg mmwg mmwg mmwg mmwg mmwg mmwg mmwg mmwg mmwg mmwg cu.m/s cu.m/s mmwg 5 0 0 10 5 30 25 25 0 40 10 0 150 36.34 46.70 195 46.70 % kg/cu.m kg/cu.m kg/hr. kg/hr. deg.C deg.C % % % 99188 99188 150 160 25 30 5 1 100 0.796 0.774

Prepared by: JRE

M/s Sriram EPC Limited

Approved by: JRA

0 FUEL NOZZLE AND PA FAN SELECTION TYPE OF FUEL : .100 % Rice Husk Nozzle size Coal feed Biomass rate 4 inch, 114.3 od 6.02 thk 5 inch, 141.3 od 6.55 thk 6 inch, 168.3 od 7.11 thk 800 kg/hr 1250 kg/hr 1800 kg/hr feed rate 350 kg/hr 550 kg/hr 795 kg/hr

PWS 1005-MAY 2000

Qty.of worst fuel fired kg/hr

100 % Rice Husk 15683

Selected nozzle feedkg/hr rate

795

No. of fuel nozzles : With peak : Without peak :

24 21.700 19.727

Number of PA fans % of primary air handled by each fan Selected number of nozzles Selected number of bed sections Fuel feed line pipe OD Fuel feed line pipe thickness Air temp. at fan inlet at MCR Air temp. at fan inlet at design PA fan flow margin PA fan head margin PA fan design head

% %

1 100 24 6 168.3 7.11 160 180 10 15 800

PA fan flow at MCR PA fan flow at design PA fan MCR head

cu.m/s cu.m/s mmwg

8.95 10.30 696

Prepared by: JRE

M/s Sriram EPC Limited

Approved by: JRA

PIS 1006 - MAY 2000 TECHNICAL SPECIFICATION FOR ID FAN * * * * * Quantity Working fluid Site altitude Type of control Fan speed : : : : : 1 Flue Gas 250 m above MSL IDC/VFD Manual 1000 rpm

DescriptionFlow cu.m/s

Design MCR-1

Operating Inlet temp. deg.C pressure mmwg 46.70 160 -190 36.34 150 -145

Outlet Devolope Gas pressure d densitykgm mmwg pressure 3 5 195 0.774 5 150 0.796

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

Prepared by: JRE

M/s Sriram EPC Limited

Approved by: JRA

TECHNICAL SPECIFICATION FOR FD FAN * * * * * Quantity Working fluid Site altitude Type of control Fan speed : : : : : 2 Air 250 M above MSL IGV/VFD Manual 1500 rpm

Description

Design MCR-1

Flow Operating Inlet cu.m/s temp. deg.C pressure mmwg 27.18 50 -25 22.39 33 -25

Outlet Devolope pressure d mmwg pressure 837 862 700 725

REMARKS : Mechanical design of fan should be at 50*C

Prepared by: JRE

M/s Sriram EPC Limited

Approved by: JRA

TECHNICAL SPECIFICATION FOR PA FAN * * * * * Quantity Working fluid Site altitude Type of control Fan speed : : : : : 2 Hot Air 250 M above MSL IGV/VFD Manual 1500 rpm

Description

Design MCR

Flow Operating Inlet cu.m/s temp. deg.C pressure mmwg 10.30 180 820 8.95 160 820

Outlet Devolope pressure d mmwg pressure 1620 800 1516 696

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

Prepared by: JRE

M/s Sriram EPC Limited

Approved by: JRA

PIS 1008 - MAY 2000

TECHNICAL SPECIFICATION FOR BOILER FEED PUMP * * * * Quantity Working fluid Type of control Pump speed Description

NOT APPLICABLE

2 Feed Water FCV/ARC/VFD 3000 rpm Flow Operating Discharg cu.m/hr temp. deg.C e Pressure 77.66 130 87.68 65.47 130

Design MCR

Remarks

Prepared by: JRE

M/s Sriram EPC Limited

Approved by: JRA

PIS 1009 - MAY 2000 POLUTION CONTROL EQUIPMENT SPECIFICATION

Type of equipment Quantity Design gas temp. Maximum draught loss Outlet dust loading Type of fuel

Electro Static Precipitator 1 140 Deg.C 25 mmwg 50 mg/N.cu.m 100% Rice Husk mmwg Nm3/hr m3/sec kg/m3 gm/N.cu.m -110 92,012 39.60 0.796 21

Inlet pressure Design gas flow rate Design gas flow rate Gas density Inlet dust loading

Flue gas analysis ( % by weight ) H2O CO2 SO2 N2 O2 : : : : : 9.283 21.021 0.063 65.679 3.954

Ash composition analysis ( % by weight ) Sio2 Al2o3 Fe2O3 CaO MgO Na2O K2O TiO2 Mn3o4 So3 P2o5 BaO SrO ZnO : : : : : : : : : : : : : :

Consider standard analysis

REMARKS : Site Elevation 250 M above MSL(Assumed) Prepared by: JRE Approved by: JRA

M/s Sriram EPC Limited

TECHNICAL SCHEDULE
PWS 1011 NOV 2000 PROJECT NO: CLIENT: M/s. Sriram EPC Limited TYPE: Two Nos 67 Tph / 67 Ata / 485 +/ -5 *C SH /FWT 200 * C Rice Husk fired Bottom Supported AFBC Boilers I 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 II 1 2 3 III 1 2 3 4 5 6 7 9 IV 1 2 3 4 5 6 7 8 9 10 11 12 13 OPERATING PARAMETERS MCR Generation Peak Generation (hrs in hrs) 1/2 hr per shift Steam outlet pressure Steam outlet temperature Steam Temperature Control Range Feed Water Temp.at eco inlet Ambient Temperature Relative Humidity Boiler Design Pressure Feed Pump Discharge Pressure-design Draught Losses In Gas Side(ID) MCR Draught Losses In Air Side (FD) MCR Draught Losses In Air Side (PA) MCR Particulate Emission Sox Emission NOX Emission Final Steam Quality (TDS) / (SIO2) Drum safety valves set pressure S.H. safety valve set pressure FUEL Type Load for Each Fuel Size/Pressure/Temp. ULTIMATE ANALYSIS FOR Fuel Moisture Ash Carbon Hydrogen Sulphur Nitrogen Oxygen GCV ANALYSIS BY VOLUME FOR GASEOUS FUELS Sio2 : Al2o3 : P2o5 : CaO : MgO : Na2O : K2O : TiO2 : Fe2O3 : Mn3o4 : So3 : GCV KCAL/NM3 (KCAL/KG) NCV KCAL/NM3 (KCAL/KG) Units % % % % % % % kcal/kg 9.44 15.01 36.67 4.57 4.57 1.25 32.88 3275 Not Applicable % % % % % % % % % % % KG/HR KG/HR 2 Kg / cm (g) oC % MCR oC oC % Kg / cm2g Kg / cm2g mmWG mm WG mm WG mg/NM3 ppm-dv ppm - dv ppm kg/cm2(g) kg/cm2(g) 60,000 66000 66 495+/-5 60-100 130 30 60 77.50 87.68 150 725 696 50 Not Applicable Not Applicable 0.1/0.02 77.00 77.50 70.50 Rice Husk 100%

Not Applicable

PREPARED BY PROPOSAL ENGINEER

APPROVED BY HEAD-PE

M/s. Sriram EPC Limited

V 1 2 3 4 5 6 VI 1 2 3 4 5 6 7 8 VII 1 2 3 4 5 6 VIII 1 2 3 4 5 6 7 IX 1 2 3 4 5 6 7 8 X 1 2 3 4 5

LIME STONE ANALYSIS Ca CO3 Mg CO3 H2O INERTS Size requirements Reactivity EFFICIENCY AND FUEL FIRING Efficiency On GCV At MCR Efficiency On NCV At MCR Tolerance On Efficiency Fuel Fired At MCR Excess Air In Furnace Sulphur Removal Ca to Sulphur molar ratio Limestone firing MCR GAS VELOCITY PROFILE AT MCR Fluidising Velocity Average through Sec. Superheater Average through Pri. Superheater Average through Boiler Bank Average through FF Section Average through Air heater GAS TEMPERATURE PROFILE Bed Temperature Furnace Exit Gas Temp. Secondary Super Heater Exit Primary Super Heater Exit Boiler Bank Exit Forced Flow Secn Exit Air Heater Exit STEAM WATER AIR TEMPERATURE PROFILE Steam At Primary Super Heater I/L Steam At Primary Super Heater O/L Steam At Attemperator O/L Steam At Secondary Super Heater O/L Water At Forced Flow Section Inlet Water At Forced Flow Section Outlet Air At Air Heater O/L Attemperator Spray STOKERS Type Depth (Sprocket centres) Width Number Of Stokers Drive KW x RPM x No.

% % % %

Not Applicable

% % % Kg / Hr % % % Kg/hr

M/s. M/s. M/s. M/s. M/s. M/s.

Refer Data Sheet

oC oC oC oC oC oC oC

oC oC oC oC oC oC oC % Not Applicable mm mm

M/s. Sriram EPC Limited

XI 1 2 3 XII 1 2 3 4 5 6 7 8 XIII 1 2 3 4 5

BURNERS No. of Burners Capacity Each Type BED FOR AFBC BOILER Type Depth Width Bed plate thickness Number Of Compartments Number Of Coal nozzle/Mixing nozzles Number of Air nozzles Static/expanded bed height COMBUSTION CHAMBER DIMENSIONS Type Width Depth Cooled Height Total Height Litres/hr Not Applicable

mm mm mm

mm

Under Bed Fuel Feeding 10000 3900 25 4 24 Nos of 6" Size 95 NOS/SQ.M 915 (Expanded bed height from Air nozzle top)

mm mm mm mm mtr

Membrane wall with bottom portion refractory lining (51 mm OD x 4.00 mm thk. Pitch 100 mm) 4300 10400 10200 12.50 (2.3 m ht. of 212 mm thk Castable Refractory lining at Bottom)

XIV 1 2 3 4 5 XV 1 2 XVI 1.0 1.1 1.2 1.3 1.4 2.0 2.1 2.3 2.4 2.5 3.0

BACK PASS DIMENSIONS Type Width Depth Height Total Height AIR HEATER PLATE DETAILS Top (WidthxDepthxThk.) Bottom (WidthxDepthxThk.) DETAILS OF PRESSURE PARTS Steam Drum Inside Diameter Shell Length Thickness MOC Of Shell & Head Mud Drum Inside Diameter Shell Length Thickness MOC Of Shell & Head HEADERS ZONE

mm mm mm mtr

MS Casing 5 mm thk. 4300 3085 13000(Alloy Steel ducting of 5mm thk to be considered for 5500mm length from bank tubes outlet to Economer)

mm mm

2 Nos.5400 x 2560 x 20 2 Nos.5400 x 2560 x 25

mm mm mm

1372 5200 80 mm min finished SA 516 GR 70

mm mm mm

914 5200 55 mm minimum finished SA 516 GR 70

NOS. 4 4 1 1

3.1 3.3 3.4 3.5 3.6 3.9 4.0

Bed coil evaporator headers Furnace headers Primary SH I/L Primary O/L Hdr. Secondary SH I/L Secondary O/L Hdr. Bed SH inlet Hdr. Bed SH outlet Hdr. Forced flow headers

ODX THK mmxmm 273.1 x 25.4 273.1 x 25.4 219.1 X 20.62 273.1x 25.4

Total Length (m) 46.0 35.0 5 15 Not Applicable 12.0 6.0 7.0

MOC SA 106 Gr B SA 106 Gr B SA 106 Gr.B SA 335 P11

2 2 2

273.1 x28.58 273.1 x 28.58 168.3 x 18.26

SA 335 P11 SA 335 P22 SA 106 Gr B

M/s. Sriram EPC Limited

4.0

PIPINGS ZONE NOS. 4 2 4 10 2 1 1 1 1 1 1 1 1 1 1 1 1 ODX THK mmxmm 273.1 x 18.26 273.1 x 18.26 219.1 x 14.27 168.3 x 14.27 168.3 x 14.27 273.1 x 20.62 219.1 x 20.26 273.1 x 20.62 219.1x 20.62 219.1 x 18.26 610 x 28.58 48.3 x 3.68 273.1 x 15.07 219.1 x 15.07 219.1x 18.26 168.3 x 14.27 168.1 x 14.27/168.3 x 10.97 88.9 x 5.49 26.7 x 2.87 48.8 x 3.68 114.3 x 6.02 60.3 x 3.91/88.9 x 5.49 Total Length (m) 60 25 60 110 10 25 5 20 15 55 7 150 10 10 15 40 60 MOC SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 335 P11 SA 335 P11 SA 335 P11 SA 335 P11 SA 335 P11 SA 335 P11 SA 106 Gr.B SA 106 Gr A SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.19

Down comers Down comers Down comers Risers Drum to PSH link PSH to BSH-I link Attemperator Piping BSH-II to BSH-III link BSH outlet link up to MSSV MSSV to Turbine Emergency Stop Valve Common Steam Distribution Header Spray water piping from feed water line to DS/PRDS Feed pump suction header (Common for Two Boiler) Feed pump discharge header (Common for Two Boiler) Feed water piping ( from Deaerator to BFP Suction Header ) Feed water piping ( From BFP discharge Header to FCV inlet) Feed water piping ( From FCV to Drum)

4.25 4.26 4.27 4.28 4.32 4.33

4.34

4.35 4.36 4.37 4.38 4.39 4.40

Boiler Initial filling from one point nearer boiler to drain header HP/LP dosing system dilution water line from one point nearer boiler column. Raw water quenching line for IBD tank from a terminal point near boiler Flash steam piping to deaerator Minimum recirculation piping,Balance leak off piping from individual BFP to deaerator Target Plates and Temporary Piping as required for steam blowing with motor operated isolation valve HP/LP dosing system piping from the dosing skid to economiser outlet feed pipe/suction pipe to boiler feed pupms. Feed piping from Dearetor to Boiler suction Header Steam piping from turbine Extraction to Dearetor Steam piping from main steam line to PRDS Steam line from PRDS outlet to Dearator Steam Piping from PRDS line to Air Ejector Condensate piping from condensate to Dearetor

1 1 1 1 1 1

70 30 40 20 100/100

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

33.4 x 3.38

145

SA 213 TP304

1 1 1 1 1 1

273.1 x 15.07 219.1 x 15.09 88.9 x 14.27 141.3 x 9.53 60.3 x 5.54 323.9 x 14.27

20 35 30 25 30 30

SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B SA 106 Gr.B

M/s. Sriram EPC Limited

5.0

TUBES ZONE TYPE U Tube Membrane Membrane Pendent Effective HS m2 140 800 960 28 ODxTHK mm x mm 51 x 6.35 BS 3059 ST 51 x 4.90 BS 3059 ST Not Applicable 44.5 x 4.0 & 4.5 BS 3059 ST BS 3059 ST 44.5 X 4.50 BS 3059 ST MOC 440 S2 360 S2 440 S2 (25%) & 620 S2(75%) 620/622 S2

5.1 5.2 5.3 5.4 5.5

Bed tubes * Furnace tubes (Circumferential Area) Encl. W/W Tubes Pri.S.H.tubes Secondary SH tubes(BSH)

5.5 5.6 5.7

Boiler Bank tubes Forced flow tubes Air heater tubes (FD) **

In line Horizontal Staggered Gas through

270 1000 2050

51.0 x 4.0 38.1 x 4.06 63.5 x 2.35

BS 3059 ST 360 S2 BS 3059 ST 360 S2 IS 3601 ERW /BS 6323 PARTV ERW(Last 6 rows of tubes to be consider corten steels)

5.8 5.9

Water wall fins Fins for Bank Area * Bed Tubes to be provided with MS Studs (Dia 8mm x 18 mm) Qty 147550 Nos. * SS Ferrules at Airheater inlet to be considered ( 1484 nos)

50 mm wide - 6 IS 2062,5000 m Length mm thk 53 mm wide- 6 mm IS 2062,120 mm length thk

XVII 1.0 1.1 1.2 1.3 1.5 XVIII 1 2 3 4 XIX 1 2 3 4 XX 1

POLLUTION CONTROL EQUIPMENT Type of equipment Fuel Case Design I/L gas Flow Design I/L gas temp. Design I/L Dust Load Design O/L dust load CHIMNEY Type Number off Top diameter Height ASH DRAINS/COOLERS Number of bed ash drains Diameter and MOC Number of ash coolers Type of ash coolers BUNKER - SILOS, TANKS & VESSELS DESCRIPTION Fuel - Bunker

m3 / sec oC gm / Nm3 mg/Nm^3

Electrostatic Precipitator (3 field) 100% Rice Husk 39.60 140 21 50 Not Applicable

mm M

mm

12 150 6 Air Cooled LINING 2 mm SS lining in the bottom conical portion of bunker MOC SA 516 GR 70 MOC SA 516 GR 70 ORIENTATION Side Bunker REMARKS with supporting structure

CAPACITY (M3) 100 m3 ( 10 Nos Conical Hoppers) 10 m3 161 TPH 54 M^3

2 3

Bed Matrial Bunker Deaerator Deaerator storage tank

Dearator to be mounted on top of TG control room(+11)

Blow Down Tank

Common BD CBD Boiler Quality Material and IBD tank - IS 2062 material tank for both CBD & Common IBD .

M/s. Sriram EPC Limited

Notes: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Structural steel from firing floor . Plant Location : Punjab Structure occupied volume : m^3 Operating floor is at 6 mtr elevation which is RCC by Customer One no Rotary feeder with Feeding chute from up to furnace to be consider. Two nos Hydrasteps to be consider. SS tip/MS base Air & Coal Nozzles .For Estm. SS to be considered. One no Hydro test pump along with all fittings and piping,Valves and water tank to be provided. Pneumatically operated IGV at inlet of FD ,ID, & PA fans . 9 nos RAV for all fly ash hoppers to be provided. One no o2 Analyser in flugas line. Monorails and electric hoist for lifting fans and feed pumps. Canopy for boiler & Side Cladding from roof level to steam drum operating floor level. VFD for Fuel Feeders,ID & FD Fans And Boiler Feed pumps. Air ducting and gas ducting thk 4 &5 mm respectively Sample coolers-4 nos Special tools and tackles to be considered. OFA nozzles with required ducting & expansion joints, dampers to be provided. Material of OFA nozzles facing furnace radiation should be SS. Bunker chute thickness to be consider 8 mm. 3 x 100 % Boler Feed pumps for Two Boliers Manual isolation valve and manual bypass valve has to be provided in main steam piping . One no PRDS of 0.8 to 8 tons capacity for temperature of 67 ksca/11 ksca. Soot Blowers LRSB at SH zone 2 Nos and RSB - 4 Nos Deaerator pressure control valve is sized to control the pressure from 11 ksca to 5 ksca as considered in Sriram EPC 35 tons Boiler. One no manual operated isolation valve with integral bypass valve to be consider after the motorised MS stop valve.

M/s. Sriram EPC Limited

Client: M/s. Sriram EPC Limited XXI Sl.No

AUXILIARIES
EQUIPMENT NOS CAPA HEA TEMP Oc ATTACHMEN MOTOR Remarks (W+SB) CITY D T& KW X rpm cu.m / CONTROL (TENTATIVE) sec 10.30 800 180 IGV/VFD 1+0 132 x 1500 Pneumatic Operated for ESTM 27.18 862 50 1+0 IGV/VFD 360 x 1500 Pneumatic Operated (VFD is in our scope) 46.70 195 160 1+0 IGV/VFD 160 x 1000 Pneumatic Operated (VFD is in our scope) 2+0 0.37/1500 12 1.5 / 1500 1 1.5 / 1500 (VFD is in our scope) (VFD is in our scope) 2 1 1 1 2+1 2+1 2+1 77.66 938 130 4.0 / 1500 & 0.06 / 1500 0.37 / 1500 0.55 / 1500 0.55 / 1500 320/2900 0.75/1500 0.75/1500

1 2 3 4 5 6 7 a c c d 8 9 10

PA Fan 1 x 100% -Constant speed driven FD Fan 1 x 100% - VFD driven ID Fan 1 x 100% - VFD driven Agitators Pocket feeders with VFD Rotary feeder with VFD for rice straw feeding Motorised Valves Main Steam Stop Valve with Integral Bypass Start-up Vent isolation valve CBD valve IBD valve Common Items BF Pumps 3 x 100% - VFD Driven. LP Dosing Pumps HP Dosing Pumps

M/s Sriram EPC Limited

Project : Boiler :

M/s. Sriram EPC Limited Two Nos 67 Tph / 67 Ata / 485 +/ -5 *C SH /FWT 200 * C Furnace tube (Circumferential Area) Calculations

Si..No 1

Description Side Walls No of Tubes Length of Tubes Value of PI no of side walls tube size area

Unit

Value

104 13.5 3.141593 nos 2 mm 51.0 m^2 450

nos m

Front Walls No of Tubes Length of Tubes Value of PI no of side walls tube size area 42 24 3.141593 nos 1 mm 51 m^2 162 nos m

Rear Walls No of Tubes Length of Tubes Value of PI no of side walls tube size area total area margin total area with margin fins for water wall margin fins length considering margin 42 22 3.141593 nos 1 mm 51 m^2 148 m^2 % m^2 m % m 759 5 797 4721 5 4957 nos m

Project : M/s. Sriram EPC Limited Flue gas density calculation Sl.No 1 2 4 5 6 Description Molecular Weight Gas pressure at ESP inlet Gas Outlet Temp Gas Density at ESP inlet at Outlet Temp Sp volume of Gas at ESP inlet Unit MW MMWC *C Kg/m3 Nm3/Kg 100% Kutch Lignite 28.91 110 150 0.799 0.807

Sl.No 1 2 3 4 5 6 7 8 9 10

Spray water qty calculation Description Unit Steam flow at D.S.H. outlet kg/hr Spray water pressure kg/cm2(g) Spray water temperature deg c Spray water enthalpy kcal/kg Steam pressure at D.S.H. inlet kg/cm2(g) Steam temperature at D.S.H. inlet deg c Steam enthalpy at D.S.H. inlet kcal/kg Steam pressure at D.S.H.outlet kg/cm2(g) Steam temperature at D.S.H. outlet deg c kcal/kg Steam enthalpy at D.S.H. outlet Spray water quantity Percentage of spray kg/hr %

DS 67000 77 130 #NAME? 71.8 470 #NAME? 70 445 #NAME? #NAME? #NAME?

M/s Gallantt Metal Limited

Sl. No 1 2 3 4 5 6 7 8 9 10 11 12 13

Description Bed evaporator header Furnace water wall header PSH inlet header PSH outlet header Bed SH I/L Hdr. Bed SH O/L Hdr. ECO inlet header ECO outlet header Drum to PSH link PSH to BSH-I link BSH-II to BSH-III link Main steam piping (Upto MSSV) MSSV to Common steam distribution header Common steam distribution header Spray water piping from feed water line to DS Feed water piping form FCV to Eco inlet Feed water piping from Eco to drum

Header & Piping Thickness Calculation Desi Outside Design Thickne gn diamete Temp Material ss (mm) Pres r (mm) Deg. C sure 273.1 21.44 78 289.00 SA 106 Gr B 273.1 21.44 78 289.00 SA 106 Gr B 219.1 18.26 78 289.00 SA 106 Gr.B 273.1 21.44 78 470.00 SA 335 P11 273.1 25.40 78 450.00 SA 335 P11 273.1 28.58 78 495.00 SA 335 P11 219.1 15.07 80 130.00 SA 106 Gr B 168.3 14.27 79 215.00 SA 106 Gr B 168.3 10.97 78 270.00 SA 106 Gr B 273.1 18.26 78 450.00 SA 335 P11 273.1 18.26 78 475.00 SA 335 P11 219.1 219.1 18.26 15.09 78 66 495.00 SA 335 P11 495.00 SA 335 P11

Minimu Min. Allowable "Ligament m thick % Margin Stress Efficiency thicknes availabl Available (kg/m^2) (%) s e (mm) 1202.53 15.19 18.76 0.5500 23.52 1202.53 14.65 18.76 0.5700 28.04 1202.53 10.59 15.98 0.6350 50.89 968.78 16.35 18.76 0.6350 14.77 984.53 17.06 22.23 0.5800 30.29 817.30 20.12 25.01 0.5800 24.29 1202.53 11.75 13.19 0.6055 12.26 1202.53 8.78 12.49 0.6055 42.23 1202.53 5.67 9.60 1.0000 69.36 989.03 10.47 15.98 1.0000 52.55 963.71 10.74 15.98 1.0000 48.77 817.30 817.30 10.42 8.71 15.98 13.20 0.9500 1.0000 53.37 51.58

14 15 16 17

323.9 48.3 168.3 141.3

21.44 3.68 10.97 9.53

66 78 78 78

495 SA 335 P11 130 SA 106 Gr B 130 SA 106 Gr B 215 SA 106 Gr B

817.30 1202.53 1202.53 1202.53

12.59 2.13 5.67 4.86

18.76 3.22 9.60 8.34

1.0000 1.0000 1.0000 1.0000

49.05 50.87 69.36 71.60

M/s Sriram EPC Limited

18 19 20 21 22 23 24 25

Feed pump suction header Feed pump Discharge header Feed piping from deaerator to boiler suction header Steam piping from turbine extraction to Dearetor Steam piping from main steam line to PRDS Steam piping from PRDS outlet to Dearetor Condensate piping from condensate to dearator steam piping from PRDS to Ejector

273.1 168.3 273.1 168.3 88.9 141.3 219.1 60.3

9.27 10.97 9.27 7.11 11.13 9.53 10.97 3.91

3 78 3 5 66 11 2 11

130 SA 106 Gr B 130 SA 106 Gr B 130 SA 106 Gr B 250 SA 106 Gr B 250 SA 335 P11

1202.53 1202.53 1202.53 1202.53 817.30 1202.53 1202.53 1202.53

1.08 5.67 1.08 1.08 3.57 1.32 0.93 1.00

8.11 9.60 8.11 6.22 9.74 8.34 9.60 3.42

1.0000 1.0000 1.0000 1.0000 1.0000 1.0000 1.0000 1.0000

651.09 69.36 651.09 474.45 173.11 529.98 936.48 241.06

250 SA 106 Gr B 45 SA 106 Gr B 200 SA 106 Gr B

M/s Sriram EPC Limited

DRUM THICKNESS CALCULATION - SA 516 GR. 70 STEAM DRUM S.No. Description 1 Design pressure, Wp 2 Maximum Working Temperature, T1 4 Drum I/D PREMISSIBLE WORKING STRESS (f) = Et / 1.5 5 6 7 8 9 10 11 12 13 14 Et = Yield Stress at Metal temperature(From ASME Section-II,Part D) Et = Yield Stress at Metal temperature(From ASME Section-II,Part D) f = Et / 1.5 Thickess of Drum Shell Provided, T1 Liagment efficiency Tmin, ((Wp x I/D) / (2 x f x E - Wp)) + 0.762 thickness of shell (if >60mm) stress value reduction (>60mm) actual stress value Actual thickness,T2 2 % reducion in stress for every 10 mm increase in shell thickness psi Kg/cm^2 Kg/cm^2 mm % mm mm % Kg/cm^2 mm page507 29100 2046.41 1364.28 80 0.57 72.71 12.71 3 1323.35 75.06 Units Kg/cm^2 (g) C F mm

77.5 320 608 1372 page16 Allo.Sress 19400

1364.28

M/s Gallant Metal Limited

Steam Drum Water Holding Capacity Calculations

description steam drum ,ID height between NWL & LWL height between LWL &LLWL height below LLWL ( H) radius of drum Distance between NWL and LLWL Angle A Radiant valueof A steam drum length value of PI water volume below LLWL water volume for half of the drum water volume between NWL&LLWL water volume for dished end portion total water volume water flow specific volume of water at drum operating pressure water holding time

symbol

R1

unit m m m m m m Deg Rad m m3 m3 m3 m3 m3 kg/hr m3/kg sec

value 1.372 0.125 0.05 0.511 0.686 0.175 75.2203684 1.31284309 4.7 3.14159265 2.36 3.47 1.12 0.12616924 1.24 67000 0.0013562 73 ata 49.23

M/s Gallantt Metal Limited

Header Sizing
Sl. No. Description Outside dia ( mm) 273.1 2 3 4 5 6 7 8 Furnace water wall header PSH inlet header PSH outlet header Bed I/L Hdr. Bed SH O/L Hdr. ECO inlet header ECO outlet header 273.1 219.1 273.1 273.1 273.1 219.1 168.3 Header thk. (mm) 21.44 0.23022 21.44 18.26 21.44 25.40 28.58 14.27 14.27 0.18258 0.23022 0.2223 0.21594 0.19056 0.13976 27000 67000 67000 67000 67000 147500 67000 74 73 70.5 70 67 77 75 289.00 289.00 470 445 495.0 130 215 #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? 3 m/s 0.1500 0.1200 0.1500 0.1200 2 m/s 2 m/s Inside dia m 0.23022 Fluid flow (kg/hr) 27000 Operating pressure (ksc(a)) 74 Operating temp. (deg. C) 289.00 Specific volume (m3/kg) #NAME? Actual velocity (m/s) #NAME? Velocity m/s/mmID #NAME? Velocity m/s/mmID (max limit) 3 m/s

Bed evaporator header

M/s Gallantt Metal Limited

Sl. No.

Description

Outside dia ( mm) 168.3 273.1 273.1 219.1

Pipe thk. (mm) 10.97 18.26 18.26 18.26

No of Lines

Piping Sizing Fluid Operating flow pressure (kg/hr) ksc(a) 67000 67000 67000 67000 73 70.5 69 67.00

Operating temp. (deg. C)

Specific volume (m3/kg) #NAME? #NAME? #NAME? #NAME?

Actual velocity (m/s) #NAME? #NAME? #NAME? #NAME?

Allowable Velocity m/s 17.56 28.39 27.63 40-50

1 2 3 4

5 6

Drum to PSH link PSH to BSH-I link BSH-II to BSH-III link Main steam piping (Upto MSSV) MSSV to Common steam distribution header Common steam distribution header Spray water piping from feed water line to DS Feed water piping ( From FCV to Eco inlet) Feed water piping ( From Eco outlet to Drum) Feed pump suction header Feed pump Discharge header Feed piping from deaerator to boiler suction header

2 1 1 1

288 460 470 495

219.1 323.9

15.09 21.44

1 1

67000 134000

67 67

495 495

#NAME? #NAME?

#NAME? #NAME?

40-50 0.12/mmID

48.3

3.68

3000

76

130

#NAME?

#NAME?

0.9-1.0

168.1

10.97

67000

76

130

#NAME?

#NAME?

1.5-2.1

9 10 11

141.3 273.1 168.3

9.53 9.27 10.97

1 1 1

67000 135000 135000

76 3 77

215 130 215

#NAME? #NAME? #NAME?

#NAME? #NAME? #NAME?

1.5-2.1 0.6 - 0.9 1.8-2.4

12

273.1

9.27

135000

130

#NAME?

#NAME?

06 - 0.9

M/s Gallantt Metal Limited

13

Steam piping from turbine extraction to Dearetor Steam piping from main steam line to PRDS Steam piping from PRDS outlet to Dearetor Condensate piping from condensate to dearator Steam piping from PRDS to Air ejector

168.3

7.11

15000

11

200

#NAME?

#NAME?

35-61

14

88.9

11.13

8000

67

495

#NAME?

#NAME?

35-61

15

141.3

9.53

9000

11

200

#NAME?

#NAME?

35-61

16 17

219.1 60.3

10.97 5.54

1 1

67000 1000

0.1 11

44 200

#NAME? #NAME?

#NAME? #NAME?

0.6 - 0.7 30-50

M/s Gallantt Metal Limited

Project Capacity

M/s. Sriram EPC Limited 67 TPH /67 Ata / 495 +/-5 *C

Motor Rating Sizing Calculations Fuel Description Boiler Feed Pumps 3 x 100% Capacity Head Density of feedwater Pump efficiency Motor power Margin on motor rating Motor rating with margin Motor selected FD Fans 1 x 100 % Capacity Head Fan efficiency Motor power Margin on motor rating Motor rating with margin Motor selected ID Fan 1 x 100 % Capacity Head Fan efficiency Motor power Margin on motor rating Motor rating with margin Motor selected PA Fan 1 x 100 % Capacity Head Fan efficiency Motor power Margin on motor rating Motor rating with margin Motor selected Unit m3/hr mwc Kg/m^3 % KW % KW KW 100% Rice Husk MCR 65.47 835 934.84 0.7 198.81

DESIGN 77.66 938 934.84 0.72 257.58 10 283.33 290 DESIGN 27.18 862 0.80 287.19 10 315.91 320 DESIGN 46.70 195 0.72 124.01 10 136.41 160 DESIGN 10.30 800 0.70 115.38 10 126.92 132

m3/sec mmwc % KW % KW KW

MCR 22.39 725 0.78 204.04

m3/sec mmwc % KW % KW KW

MCR 36.34 150 0.70 76.34

m3/sec mmwc % KW % KW KW

MCR 8.95 696 0.75 81.41

Prepared by: JRE

Approved by: JRA M/s Gallantt Metal Limited

Project Name Boiler Parameters Fuel Fired ESP Selection Description Flue Gas Flow rate (for the worst fuel fired) Flue Gas temp. at ESP inlet Flue Gas Sp. Volume Fuel Flow rate Margin considered on gas flow % of Ash in Fuel % of Fly Ash carry over Gas volume flow rate = ( F x Vs ) x [(1+ (M/100)] Total Ash generation = ( Fr x A ) / 100 Quantity of Fly Ash carry over = ( Ag x Ac ) / 100 ESP Inlet Gas Volume ESP Inlet Dust Concentration ESP Inlet Gas temperature Note : IDC used

M/s. Sriram EPC Limited Two Nos 67 Tph / 67 Ata / 485 +/ -5 *C SH /FWT 200 * C K.Lignite/Imp Coal/Dolo Char

Symbol F T Vs Ff M A Ac G Ag Q Gv D Tg

Unit Kg / hr degree C Nm3 / Kg Kg / hr % % % Nm3 / hr Kg / hr Kg / hr Nm3 / hr gm / Nm degree C

3

100% Rice Husk 99,188 140 0.811 15,683 10 15.01 70 80,408.97 2,354.02 1,647.81 88,449.86 20.49 50.00 21

gm/Nm^3

Heat duty calculation SI.No 1 2 3 4 5 7 Description Total boiler duty Primary SH duty BSH duty Bed Coil duty Economiser duty Furnace duty Unit x10^6 kcal/hr x10^6 kcal/hr x10^6 kcal/hr x10^6 kcal/hr x10^6 kcal/hr x10^6 kcal/hr 100% Indian coal 45.88 10.79 3.48 15.71 6.29 9.61 100% Wsh.Rjts 48.14 10.90 3.48 15.71 6.5 11.55

Project Name Boiler Parameters

M/s. Sriram EPC Limited 60 Tph /67 Ata / 485+/-5*C

Description

Unit

100 % Rice husk Single 17512 800 0.85 4 103.0 100

Type of Bunker Fuel qantity Density of fuel Filling factor Hours of fuel storage Storage volume of Twin bunker Bunker volume Considered

Kg/hr Kg/m^3 Hrs m^3 m^3

Auxiliary Power Consumption

Boiler Type: Boiler Parameters: Fuel: Sl.n EQUIPMENT o

AFBC Client: M/s. Sriram EPC Limited Project No: Pressure: Ata: 67, Temp: (Deg.C) 495+/-5 Capacity: 67 tph, FWT (Deg.C): 130 100% Imp NOS Design MCR Design MCR Eff. Eff Power Power Capacity Capacity Head Head Design MCR Design MCR kW m3/sec or kW m3/hr

M/s. Sriram EPC Limited

MOTOR KW X rpm

Motor kw

P MCR / P rated

Motor Eff. Rated (%)

Motor Motor Total Power With 3% Commit Eff MCR Power Consumption Margin ted (%) Consum at MCR kW Cont. equip ption at MCR kW

1 2 3 4 5 5 6 7 8 9

FD Fans- 1 X 100% PA Fan 1 X 100% ID Fan 1 X 100% Pocket Feeders Pocket Feeders(Over bed Feeding) HP dosing pumps Agitators ESP LP dosing pumps Boiler Feed Pumps Total for With 3% Margin

W 1 1 1 12 1 1 2 1 1 1

SB 0 0 0 0 0 1 0 0 1 1

27.18 10.30 46.70

22.39 8.95 36.34

862 800 195

725 696 150

0.80 0.7 0.72

0.78 0.75 0.7

287.19 115.38 124.01

204.04 81.41 76.34 1.2 1.2 0.6 0.296 0.6 198.81

320/1500 132 / 1500 160 / 1000 1.5 / 1500 1.5 / 1500 0.75 / 1500 0.37 / 1500 0.75 / 1500 290/2900

320 132 160 1.5 1.5 0.75 0.37 0.75 290

0.638 0.617 0.477

0.945 0.948 0.945

0.937 0.93 0.93 0.9 0.9 0.9 0.9 0.9 0.915

217.76 87.54 82.09 1.33 1.33 0.67 0.33 0.67 217.28

77.66

65.47

938

835

0.72

0.7

257.58

0.686

0.945

217.76 87.54 82.09 16.00 1.33 0.67 0.66 45.00 0.67 217.28 669

224.29 90.17 84.55 16.48 1.37 0.69 0.68 45.00 0.69 223.80 687.71

For one Boiler For two Boilers

669

688

1337.98

1375.42

Prepared by: JRE

Approved by: JRA M/s. Gallantt Metal Limited