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Boiler Details

1 Type of Boiler - CFBC


2 Circulation - Natural
3 Support - Top Supported
Input Details
1 Steam Flow - 135 TPH
2 Steam Pressure - 87 ata 89.891
3 Steam temperature - 515 C
4 Steam Enthalpy - 818.25 kcal/kg
5 Feed Water Temperature at Economizer inlet - 200 C
6 Enthalpy of Feed water - 203.52 kcal/kg
7 Calorific value of fuel - 3131 kcal/kg
8 Efficiency of the boiler - 80 %
Steam Flow x ( Steam Enthalpy - Feed Water Enthalpy )

Fuel Consumption =
GCV of Fuel x Boiler Efficiency
Fuel Consumption = 33.1 TPH
= 33131.8 kg/hr
(Given data)
FUEL COMPOSITION:
C = 35.00 % STEAM GEN CPTY = 135 TPH
H2 = 2.10 % SH OUTLET PR = 89.89 Kg/Sq.cm(g)
N2 = 0.58 % SH OUTLET TEMP = 515 Deg C
M = 5.00 % GCV = 3131 Kcal/Kg
O2 = 10.12 % EXCESS AIR = 20 %
S = 0.70 % RH = 60 %
ASH = 46.50 % Tamb = 32 Deg C
TOTAL = 100.00 % AIR MOISTURE = 0.022 Kg/Kg DRY AIR
COMBUSTION CALCULATION:
CO2 SO2 M N2
C 35 2.667 0.933 1.283
H2 2.1 8 0.168 0.188
N2 0.58 0 0 0.0058
O2 10.12 0 -0.101
S 0.7 1 0.007 0.014
M 5 0 0 0.05
ASH 46.5 0 0
TOTAL - - 1.007 1.283 0.014 0.238 0.0058

= 4.378 kg/kg of fuel


FUEL CONSUMPTION
FLUE GAS CONDITION (Kg/Kg FUEL)
Constituents
Theoritical air required = ( Total amount of kg O2/ kg of fuel)*100/23
COMBUSTION AIR REQUIREMENT
Kg O2 /
Kg FUEL
% BY WT
Kg O2 /
Kg COMP

= 0.876 kg/kg of fuel

= 5.254 kg/kg of fuel

NITROGEN IN FLUE GAS = 4.051 Kg/Kg FUEL

OXYGEN IN EXCESS AIR = 0.201 Kg/Kg FUEL

MOISTURE IN GAS = 0.354 kg/kg of fuel

=174.072 TPH
FLUE GAS ANALYSIS:
PRODUCT MOL WT VOL% WT% mi / mi
CO2 44 15.07 6.63 0.222
H2O 18 6.83 1.23 0.041
O2 32 3.25 1.04 0.035
N2 28 74.73 20.937 0.7
SO2 64 0.11 0.072 0.002
TOTAL * 100 29.91 *
=
Flue gas generated = 5.7877 kg/kg of fuel

Total Flue Gas


Generated
= Fuel Consumption * Flue Gas generated
Total Flue Gas
Generated
= 191756.96 kg/hr
FD Fan 100% Flow 60% Flow
Actual
1 Air Mass Flow - 174071.63 kg/hr 104442.98 kg/hr
2
Temperature of
the Medium
- 40 C
1.321
20.14
Nitrogen In Flue Gas = (Total Dry Air *0.77) + Flue Gas Condition N2
Moisture In Gas = (Total Dry air * Air moisture) + Flue gas Condition Moisture
Total Weight/kg of fuel
100
Flue Gas
Generated
128.3 2.915
23.8
WT/100 KG FUEL No. MOLES/100 KG FUEL
0.629
405.13 14.461
578.77 19.35
FLUE GAS GENERATION
Fan Power Calculation
1.4 0.022
Total Combustion Air required = Fuel Consumption * Dry Air
TOTAL COMBUSTION AIR REQUIRED
Excess Air required(Dry) = Excess air percentage * Theoritical air Required
Oxygen in Excess Air = Excess Air required * 0.23
Total dry air = Theoritical air required + excess air required

3
Density of the
medium
- 1.1278 kg/m
3
4
Actual Head
required
- 640 mm of WC
-
5 Air volumetric Flow = 154351.61 m
3
/hr
= 42.88 m
3
/s 25.73 m
3
/s
Design
1 Margin in Flow - 10%
2 Margin In Head - 25%
Design Flow -
3 Design Flow - 47.16 m
3
/s 28.30 m
3
/s
Design Head -
4 Design Head - 800 mm of WC
5 Fan Efficiency - 80 %
6 Motor Efficiency - 92 % 100 %
7
Margin in Drive
capacity
- 0

8
Power
Consumption
- 336.28 KW 201.77 KW

9 Power Consumption - 502.59 KW 277.43 KW

Drive Rating with


Margin
-
Drive rate with
margin
- 502.59 KW 277.43 KW

Actual
1 Air mass flow 29027.4 kg/hr
2 Temperature of the medium 150 C
3 Density of the medium 0.83 kg/m
3
4 Actual head required 560 mm of WC
5 Air / Flue gas volumetric flow 9.66 m
3
/sec
Design
6 Margin in Flow 10 %
7 Margin in Head 25 %
8 Design Flow 10.63
9 Design Head 700
Air Volumetric
Flow Density of the medium
PA Fan
Power
Consumption at
Motor Terminal
(Design)
-
Power
Consumption at
equipment shaft
(Actual)
-
Fan Efficiency*Motor Efficiency
Air Volumetric Flow * Actual Head required
102* Fan Efficiency
Air Volumetric Flow * Increase in Margin In flow
Air Mass Flow
For Air, Density of the Medium at 0C is 1.293 kg/m
3
Actual Head * Increase in Margin in Head
Power Consumption at Motor Terminal * (1+ margin in drive capacity)
Design Flow * Design Head
10 Fan efficiency 70 %
11 Motor Efficiency 92 %
12 Margin in drive capacity 0 %
Result
13 Power consumption at Equipment shaft (Actual) 75.78 kW
14 Power consumption at Motor terminal (Design) 113.26 kW
15 Drive rating with margin 113.26 kW
ID Fan
Actual
Air / Flue gas mass flow 191757.0 kg/hr 115054.2 kg/hr
Temperature of the medium 140 C 140 C
Density of the medium 0.85 kg/m
3
0.85 kg/m
3
Actual head required 160 mm of WC 160 mm of WC
Air / Flue gas volumetric flow 62.32 m
3
/sec 37.39 m
3
/sec
Design
Margin in Flow 10 % 10 %
Margin in Head 25 % 25 %
Design Flow 68.55 m
3
/sec 41.13 m
3
/sec
Design Head 200 mm of WC 200 mm of WC
Fan efficiency 70 % 70 %
Motor Efficiency 92 % 100 %
Margin in drive capacity 0 % 0 %
Result
Power consumption at Equipment shaft(Actual) 139.66 kW 83.79 kW
Power consumption at Motor terminal(Design) 208.72 kW 115.22 kW
Drive rating with margin 208.72 kW 115.22 kW
100% FLOW 60% FLOW
kg/cm
Input:
Fuel Quantity - 19674 kg/hr DESIGN BASIS
Flue gas Qunantity - 140094
m
3
/sec
Exit Gas Temperature
Density of gas mixture
Velocity of gas
- 44.73
m
3
/sec
Sulpur Percentage - 0.36 %
Total So
2
produced(Q)
- 2*%S*Fuel Flow Rate
= 23854.9 kg/hr
Chimney Height -
= 288.01 m
= 2.24
m
2
= 1.69 m
Chimney Calculation
Density = Mass/ Volume
So Volume = Mass/Density
14*Q
0.3
Chimney Top Diameter = [4*Area/(22/7)]
0.5
Chimney
Crosssectional
area in m2
=
Flue Gas Quantity in m3 / hr
Velocity Of Gas in m/s
DESIGN BASIS
Exit Gas Temperature 135
C
Density of gas mixture 0.87
kg/m
3
Velocity of gas 20
m
2
Ash Generation
Total Ash Generation = Fuel Consumption in kg/hr * Percentage of Ash Contenrt
Total Ash Generation = 15406.3 kg /hr
= 600.0 kg/m
3
= 1200.0 kg/m
3
BED ASH
Bed Economizer Air Heater
ESP FIELD
I
1 Ash Temperature C 250* 330 180 140
2 % of Ash Collection
a. Actual 10 10 10 63
b. Design ( % of Actual ) 200 200 200 150
3 Ash Collection Rate kg / hr
a. Actual 1541 1541 1541 9706
b. Design 3081 3081 3081 14559
4 No. of Collection Points 6 2 1 1
5 Ash Collection Rate / Hopper kg / hr
a. Actual 257 770 1541 9706
b. Design 514 1541 3081 14559
6 Conveying Distance meters
a. Horizontal
b. Vertical
c. Total
7 Bottom Level of Ash Hopper from
Finished Floor Level mm 1300 2500 2500 3500
* Temperature of ash at bed ash cooler outlet
S No Description
FLY ASH
Ash Density For Storage Capacity
Calculation
Ash Density For Structural Design
Fuel Consumption in kg/hr * Percentage of Ash Contenrt
ESP FIELD
II
ESP FIELD
III
140 140
6.3 0.7
150 150
971 108
1456 162
1 1
971 108
1456 162
3500 3500
FLY ASH
MOTOR SIZING CALCULATION FOR A GIVEN PUMP
INPUT
1 Flow(Q) - 800 m
3
/hr
2 Head(H) - 42 mWC
3 Density - 988 kg/m
3
4 Pump Efficiency- 80 %
5 Motor Efficiency- 70 %
OUTPUT
1 Pumping power - 9.8 * Density * Q * H KW
1000 * 3600
2 Motor Rating - Pumping power KW
Pump Efficiency * Motor Efficiency
1 Pumping power - 90.36907 KW
2 Motor Rating - 161.3733 KW
ID FAN
ITEM NO LENGTH WIDTH BREADTH EQUI. DIA FLOW AREA GAS RATE
mm mm mm mm m2 m
3
/sec
FAN SUCTION SIDE
Pressure drop across Boiler,Economiser & Air preheater all together
1 35 Degree Bend - 750 2500 - - 25.5
2 Rectangular duct 2262 750 2500 1153.8 1.05 25.5
3 Rectangular duct 1000 1880 1020 1322.5 1.37 25.5
4 Rectangular duct 1301 1880 1020 1322.5 1.37 25.5
5 44 Degree Bend - 1880 1020 - - 25.5
6 Rectangular duct 2017 1880 1020 1322.5 1.37 25.5
7 90 Degree Bend - 2040 2400 - - 51.0
8 Rectangular duct 11561 2040 2400 2205.4 3.82 51.0
9 90 Degree Bend 2 nos 2040 2400 - - 51.0
10 Rectangular duct 13943 2040 2400 2205.4 3.82 51.0
11 Expander - - - - - -
12 ESP - - - - - -
13 Reducer Size N.A - - - - -
14 90 Degree Bend - 2400 2040 - - 51.0
15 21 Degree Bend 2 nos 2400 2040 - - 51.0
16 Rectangular duct 511 2040 2400 2205.4 3.82 51.0
17 Rectangular duct 1500 2040 2400 2205.4 3.82 51.0
18 Rectangular duct 3768 1020 2400 1431.6 1.61 51.0
19 30 Degree Bend - 1020 2400 - - 25.5
20 Rectangular duct 1500 1020 2400 1431.6 1.61 25.5
21 Reducer 1020 X 2400 - 1313 X 1412 25.5
21A Suction Box - - - 1130 1 25.5
FAN DISCHARGE SIDE
22 Rectangular duct 5000 800 1250 975.6 0.75 25.5
23 90 Degree Bend - 800 1250 - - 25.5
24 Rectangular duct 1000 800 1250 975.6 0.75 25.5
25 90 Degree Bend+exit loss - 800 1250 - - 25.5
26 Chimney 20000 - - 2000 3.14 51.0
Chimney Natural Draft
Total Head on Fan
Formula's for the above calculations
For Degree Bend Plates Fan Suction Side
1 f = 1
((1.82*log(Gas rate * 3600 * 0.865 * Equivalent dia in m)) - 1.64)^2
Width in m * Breadth in m * 0.0745
PRESSURE DROP CALCULATION
ITEM DESCRIPTION
2 Velocity = Gas rate/(Width in m * Breadth in m) m/sec
3 Pressure drop= 17.923 * (Velocity)^2 *f mm of Wc
(273+126)
For Rectangular Duct
1 Equivalent Diameter = 2 * (Width * Breadth) / (Width+Breadth) mm
2 Flow Area = (22/7) * ( Equivalent Diameter/2000) ^ 2 m
2
3 Pressure Drop = (f * Length in m) * (Gas rate/(width in m * breadth in m)^2 * 0.865 * (1/(2*9.81*equivalent diameter in m))
(we use the same formulas for the discharge side also)
1 Total Discharge on suction= Suction+Pressure drop across boiler,economiser and airpreheater
2 Chimney Natural Draught = (Chimney length in m) * (1.16 - 0.865)
3 Total Head on Fan = Total Discharge on Suction Side + Total Discharge on Delivery Side - Chimney Draft
f VELOCITY PR.DROP REMARKS
m/sec mm W.C
60
0.062 13.6 0.52
0.012 13.6 0.19
0.012 13.3 0.07
0.012 13.3 0.09
0.10 13.3 0.79
0.012 13.3 0.14
0.85 10.4 4.6
0.012 10.4 0.3
0.09 10.4 0.98
0.012 10.4 0.36
- - -
- - 25
- - 7.59
0.25 10.4 1.4
0.17 10.4 1.66
0.012 10.4 0.01
0.012 10.4 0.04
0.011 20.8 0.55
0.08 10.4 0.39
0.013 10.4 0.07
0.50 13.78 4.26
0.80 25.5 22.5
TOTAL 131.51
0.012 25.5 1.76
0.17 25.5 5.5
0.012 25.5 0.35
0.90 25.5 25.3
0.012 16.2 1.4
TOTAL 34.31
= 5.9
= 160.00
((1.82*log(Gas rate * 3600 * 0.865 * Equivalent dia in m)) - 1.64)^2
(f * Length in m) * (Gas rate/(width in m * breadth in m)^2 * 0.865 * (1/(2*9.81*equivalent diameter in m))
Suction+Pressure drop across boiler,economiser and airpreheater
Total Discharge on Suction Side + Total Discharge on Delivery Side - Chimney Draft
Pump Efficiency Calculation
Input Data
1 Pump Flow m/s 0.4
2 Motor power Kw 325
3 Suction Head m 1
4 Delivery Head m 55
5 Motor Efficiency % 88
6 Type of Drive Direct
Coupled
7 Density of kg/m 996
water
8 Acceleration m/s 9.81
due to gravity
Output Data
a Hydraulic Power kW 211.05
b Shaft Power kW 286.00
c Pump Efficiency % 73.79
Formula's Used
1 Hydraulic Power - Pump flow * ( Delivery Head - Suction Head ) * Density of Water * 9.81 KW
1000
2 Shaft Power - Motor Power * Motor Efficiency KW
3 Pump Efficiency - Hydraulic Power / Shaft Power * 100
Pump flow * ( Delivery Head - Suction Head ) * Density of Water * 9.81 KW
1 Number of pumps 2 (2*100% As per Contract Document)
2 Number of operating pumps 1 1 Stand by
FLOW CALCULATION
1 Flow of water through the pump (TPH) 168
2 Makeup water at 3%(TPH) 5.04
3 Total flow (TPH) 173.04
4 Margin on total flow at 10% (TPH) 17.304
5 Rated flow per pump (TPH) 190.34
HEAD CALCULATION
SUCTION SIDE
1 Available pressure (bar a) 0.128 Hotwell pressure
2 Static head (m) 5.45
3 Piping friction Loss (mlc) 0.2
4 Strainer Loss (mlc) 0.5 Assumed
5 Suction Head (mlc) 6.06
DISCHARGE SIDE
1 Pressure required at
makeup water heater I/L (bar a) 14
2 Static Head (m) 18.5 Up to TBW Terminal Point
3 Piping friction Loss (mlc) 5
4 Pressure drop across SJAE Condenser (mlc) 5 As per Vendor
5 Pressure drop across flow element (mlc) 5 Assumed
6 Total variable loss (mlc) 15
7 Considering 10% margin on variable loss (mlc) 16.5
8 Total Discharge Head (mlc) 177.8
TOTAL DEVELOPED HEAD (DYNAMIC HEAD):
1 Total Developed head (mlc) 171.74 Discharge head - Suction head
NPSHa CALCULATION
1 Available pressure (bar a) 0.128 Atmospheric Pressure
2 Static Head (m) 5.45
3 Piping friction loss (mlc) 0.2
4 Strainer Loss (mlc) 0.5 Assumed
5 Vapour pressure of water
at operating temperature (bar a) 0.136
NPSH ANALYSIS CALCULATION FOR CEP PUMP
6 Available NPSHa (m) 5.920
CEP DESIGN PARAMETERS
1 Pump type Horizontal - Centrifugal
2 Rated flow per pump (TPH) 190.344
3 Pump rated TDH (mlc) 171.74
4 Available NPSHa (mlc) 5.920
(2*100% As per Contract Document)
Make up water % * Flow of water through pump
Flow of Water Through Pump+Makeup Water
Total percentage * Percentage of margin in flow
Total Flow + Margin On Total Flow
Hotwell pressure
Available Pressure + Static Head - Piping Friction loss - Strainer loss
1 kg/cm
2
= 10 mlc
Up to TBW Terminal Point
As per Vendor
Piping loss + Pressure Drop Across SJAE Condenser =+ Pressure drop across flow element
(15 * 0.1) + 15
Pressure required at makeup water heater + static head+ margin on variable loss
Discharge head - Suction head
Atmospheric Pressure
Available pressure + Static Head - Piping friction loss - Strainer loss - Vapour pr of water at operating temperature
Piping loss + Pressure Drop Across SJAE Condenser =+ Pressure drop across flow element
Available pressure + Static Head - Piping friction loss - Strainer loss - Vapour pr of water at operating temperature