dbr ventilation

COAL HANDLING SYSTEM

CHHABRA THERMAL POWER PROJECT

STAGE-I, PHASE-II, 2X250 MW

VNT-01-R2

RAJASTHAN RAJYA VIDYUT UTPADAN NIGAM LTD., RAJASTHAN

CHHABRA THERMAL POWER PROJECT STAGE I, PHASE-II, 2 X 250 MW

UNIT # 3&4

DESIGN BASIS REPORT OF

VENTILATION SYSTEMS FOR

W.T.3 COMPLEX, TUNNEL OF CONVEYOR BCN-1(2) & TH-1(2)

OWNER RAJASTHAN RAJYA VIDYUT UTPADAN NIGAM LTD., RAJASTHAN

OWNERS CONSULTANT TCE CONSULTING ENGINEERS LIMITED, BANGALORE

EPC AGENCY THE INDURE PVT LTD,INDURE HOUSE, NEW DELHI

SYSTEM SUPPLIER WRC ENGINEERING CO. PVT. LTD., V.U.NAGAR, GUJARAT

Job No. I-3062 Name Date Prepared By J.P. PATEL 18.01.2012

Checked By

Approved By P.M. PATEL 20.01.2012

Document No. I-3062-VS-DBR-1022 Rev No. 2 Record of Revisions

Rev. No. Particulars Date Checked By Approved By

1. Revised Based on TCE Comments Ref No.: TCE.5225A/ME/AV/811-107 dated 11.04.2012

19.05.2012 PM PM

2. Revised Based on TCE Comments Ref No.: TCE.5225A/ME/AV/811-115 dated 28.09.2012

20.03.2012 AP PM




VNT-01-R2 Page 1 of 8

TABLE OF CONTENTS Sr. No.

Description Page No.

01.0 Introduction 02 02.0 General Description of Ventilation System 02 03.0 Standard & Code 02 04.0 Layout 02 05.0 Design Criteria 02 06.0 Friction loss calculation 05 07.0 Selection of Fan (Supply & Exhaust) 06 08.0 Equipment Summery 07 09.0 Schematic (SLD) Supply Air System 09 10.0 Schematic (SLD) Exhaust Air System 10 11.0 General Arrangement Drawing of Fan with MOC 11

Attachments: 11.1 Supply Air C.F. Fan 11.2 Exhaust Air C.F. Fan 12.0 General Arrangement Drawing of Air Intake Louver with Filter Frame 13.0 General Arrangement Drawing of Supply Air Filter 14.0 General Arrangement Drawing of Supply Air Grill 15.0 General Arrangement Drawing of Exhaust Air Grill





01.0 Introduction.

This document covers description of Ventilation System, equipment sizing, design philosophy for various components of Ventilation System and design philosophy for the control and operation 0f Ventilation System for 2 x 250 MW, Units # 3 & 4 (Stage-I, Phase-II) of Chhabra Thermal Power Station.

02.0 General Description of Ventilation System.

Ventilation System is comprised of Supply Air System and Exhaust Air System. Supply Air System consists of Air Filters, Centrifugal Supply Air fan with Outlet flexible connection Vibration isolation Pad and foundation bolts, Inlet Air Louver, Ducting with Supply Air Grills. Exhaust Air System consists of Centrifugal Exhaust Air Fan with Inlet flexible connection, Vibration isolation Pad and foundation bolts, Ducting with Exhaust Air Grills.

03.0 Standard and Codes.

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The applicable standards and codes for various major equipment of Ventilation System are as given below.

1. IS:655 Specification for Metal Air Duct 2. IS:4894 Centrifugal Fan 3. IS:3588 Specification for electric Axial Fan 4. IS:277 Specification of GI Sheet R1

04.0 Layout.

Ventilation System for Wagon Tippler-3 Building and Tunnel of Conveyor BCN-1(2) is located at TH-1 building.

05.0 Design Criteria.

05.1 Design Ambient Condition.

05.2 The following ambient conditions given in Project Information of NIT would be considered for sizing of Supply and Exhaust Fan.

Design ambient temperature : 46.3 0

05.3 Design requirements.

C Design relative humidity : 20% to 80% R1 Site elevation : 400 M above MSL

As stated in technical specification for Ventilation system, suitable ventilation system is

provided for underground portion of Wagon Tippler-3 Building along with Tunnel of Conveyor BCN-1(2) and Part of TH-1(2).

Fresh and Filtered air is brought in to under-ground portion of Wagon Tippler Building.





12 air changes are considered for supply air system. A set of filters are provided before intake Centrifugal Fan. C.F. Fan will deliver required air

in to GI Sheet Duct and there-after it will be distributed in to Wagon Tippler Building through supply air grills located at specific locations.

Suitable quantity of supply air grills are considered at regular intervals. We have considered exhaust air volume as 90 % of supply air volume. Suitable quantity of Exhaust air grills are considered at regular intervals.

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Air velocity considered for design will be less than 10 m/sec in Supply & Exhaust GI Ducting.

05.4 Supply and Exhaust Air Capacity.

Volume of Ventilated area for Supply and Exhaust air is calculated as below: Length

meter Width meter

Height meter

Volume m

3

W.T.-3 Complex Area 1. Elevation at -13.200 floor 16.80 8.70 5.50 803.880 -VSA 2. Elevation at -13.200 floor 12.15 11.50 5.50 768.487 -VSB 3. Elevation at -17.900 floor 14.15 11.50 4.40 715.990 -VSC 4. Tunnel of Conveyor BCN-1(2) 65.00 3.80 3.00 741.000 -VSD Transfer Tower TH-1(2) 5. Floor elevation -5.115 13.80 10 8.32 1148.160 -VSE 6. Floor elevation -8.315 13.80 10 2.90 400.200 -VSF Total Volume (V) = VSA+VSB+VSC+VSD+VSE+VSF 4577.717 We are considering 12 air changes per hour for Supply air system = 4577.717 x 12 = 54932.604 m3 /hr. We have considered Supply Air Ventilation System of 55000 m3 VS-01 /hr. We are considering Exhaust air system as 90 % of Supply air volume

R2 = 55000 x 90 % = 49500 m3 /hr.

We have considered Exhaust Air Ventilation System of 49500 m3/hr. VE-01 R2

05.5 Selection of Supply Air Filters.

We have considered HDPE washable type air filters with filtering efficiency of 95% down to 5 microns for Supply Air Ventilation System. We have selected standard air W fold type air filters suitable to fit 610x610 mm size with filter cloth area of 0.5 m2 each filter. (Please refer G.A. Drawing for cloth area) We have considered air velocity of 1.8 m/sec at filter inlet. Considering Supply Air System capacity of 55000 m3/hr. and velocity of air entering filters as 1.8 m/sec., calculated cloth area will be ((55000/3600)/1.8)= 8.49 m2.





Considering unit air filter cloth area as 0.5 m2

05.6 Selection of Supply & Exhaust Air Ducting & Grills.

, calculated total numbers of filter are (8.49/0.5)=16.98 numbers. We have selected 20 (5x4) numbers of supply air filters for Supply Air Ventilation system.

We have considered duct air velocity of 10 m/sec. for supply & exhaust air ducting. We have considered grill air velocity of 4 m/sec. for supply & exhaust air grills. We have considered grill spacing of maximum 5 meter distance. We have considered duct support at maximum 3 meter distance with / without tie rod as per civil requirements.

1) Based on calculation for individual space volume and considered air change for supply air, we have considered space volume for Supply Air Ventilation System as under:

A. 13800 m3 TH-1 (2) of Floor at Elevation -5.115 /hr B. 5000 m3 TH-1 (2) of Floor at Elevation -8.315 /hr C. 17300 m3 W.T.3 Hopper Area of Floor at Elevation -17.900 & Tunnel of

Conveyor BCN-1(2) /hr

D. 18900 m3 W.T.3 Hopper Area of Floor at Elevation -13.200 /hr

Sr. No.

Air Volume M3

Duct Size

/hr Air Velocity

m/sec Number of Grill and Grill Size

Length mt Width mt

A. Calculation for Duct Size and Grill for Supply Air VNT System for TH-1(2) of Floor at Elevation -5.115

01 13800 0.700 0.560 9.78 3 No. S.A. Grill 350 x 300 mm 02 9200 0.650 0.400 9.83 3 No. S.A. Grill 350 x 300 mm 03 4600 0.400 0.350 9.13 3 No. S.A. Grill 350 x 300 mm

B. Calculation for Duct Size and Grill for Supply Air VNT System for TH-1(2) of Floor at Elevation -8.315

04 5000 0.400 0.350 9.92 5 No. S.A. Grill 300 x 250 mm

C. Calculation for Duct Size and Grill for Supply Air VNT System for Tunnel of Conveyor BCN-1(2) up to W.T.-3 Complex

06 36200 1.200 0.850 9.86 3 No. S.A. Grill 325 x 250 mm 07 32740 1.150 0.800 9.89 3 No. S.A. Grill 325 x 250 mm 08 29280 1.050 0.800 9.68 3 No. S.A. Grill 325 x 250 mm 09 25820 1.050 0.700 9.76 3 No. S.A. Grill 325 x 250 mm 10 22360 0.900 0.700 9.86 3 No. S.A. Grill 325 x 250 mm Note: For duct design volume of air for WT-3 Apron Feeder area pass from this duct.

D. Calculation for Duct Size and Grill for Supply Air VNT System for W.T.-3 Complex Apron Feeder Area

11 18900 0.800 0.700 9.38 4 No. S.A. Grill 325 x 300 mm 12 13500 0.700 0.560 9.57 4 No. S.A. Grill 325 x 300 mm 13 8100 0.525 0.450 9.52 6 No. S.A. Grill 325 x 300 mm





2) Based on calculation for individual space volume and considered air change for exhaust air,

we have considered space volume for Exhaust Air Ventilation System as under:

R2

A. 12400 m3 TH-1 (2) of Floor at Elevation -5.115 /hr B. 4300 m3 TH-1 (2) of Floor at Elevation -8.315 /hr C. 15800 m3 W.T.3 Hopper Area of Floor at Elevation -17.900 & Tunnel of

Conveyor BCN-1(2) /hr

D. 17000 m3 W.T.3 Hopper Area of Floor at Elevation -13.200 /hr

Sr. No.

Air Volume M3

Duct Size

/hr Air Velocity

m/sec Number of Grill and Grill Size

Length mt Width mt

A. Calculation for Duct Size and Grill for Exhaust Air VNT System for TH-1(2) of Floor at Elevation -5.115

01 12400 0.650 0.550 9.63 4 No. E.A. Grill 350 x 325 mm 02 6200 0.450 0.400 9.57 4 No. E.A. Grill 350 x 325 mm

B. Calculation for Duct Size and Grill for Exhaust Air VNT System for TH-1(2) of Floor at Elevation -8.315

03 4300 0.400 0.300 9.95 5 No. E.A. Grill 275 x 225 mm

C. Calculation for Duct Size and Grill for Exhaust Air VNT System for Tunnel of Conveyor BCN-1(2) up to W.T.-3 Complex

04 32800 1.125 0.875 9.26 3 No. E.A. Grill 300 x 250 mm 05 29640 1.100 0.800 9.36 3 No. E.A. Grill 300 x 250 mm 06 26480 1.075 0.725 9.44 3 No. E.A. Grill 300 x 250 mm 07 23320 1.000 0.675 9.60 3 No. E.A. Grill 300 x 250 mm 08 20160 0.925 0.625 9.69 3 No. E.A. Grill 300 x 250 mm Note: For duct design volume of air for WT-3 Apron Feeder area pass from this duct.

D. Calculation for Duct Size and Grill for Exhaust Air VNT System for W.T.-3 Complex Apron Feeder Area

09 17000 0.750 0.650 9.69 5 No. E.A. Grill 375 x 325 mm 10 8500 0.500 0.475 9.94 5 No. E.A. Grill 375 x 325 mm





06.0 Friction Loss Calculation

06.1 Supply Air Ventilation System.

Wagon Tippler-3 Hopper Complex, Conveyor BCN-1(2) & Part of TH-1(2)

Section Q R Factor Duct L Duct W Duct H Velocity F.L.

01-02 55000 0.9 5.00 1.250 1.250 9.78 0.29 02-03 13800 0.9 5.00 0.700 0.560 9.78 0.67 03-04 9200 0.9 5.00 0.650 0.400 9.83 0.87 04-05 4600 0.9 5.00 0.400 0.350 9.13 1.10 02-06 41200 0.9 1.50 1.200 1.000 9.54 0.10 06-07 5000 0.9 23.00 0.400 0.350 9.92 5.90 06-08 36200 0.9 15.00 1.200 0.850 9.86 1.14 08-09 32740 0.9 15.00 1.150 0.800 9.89 1.22 09-10 29280 0.9 15.00 1.050 0.800 9.68 1.24 10-11 25820 0.9 15.00 1.050 0.700 9.76 1.37 11-12 22360 0.9 15.00 0.900 0.700 9.86 1.52 12-13 18900 0.9 25.00 0.800 0.700 9.38 2.48 13-14 13500 0.9 20.00 0.700 0.560 9.57 2.57 14-15 8100 0.9 30.00 0.525 0.450 9.52 5.19

Total 25.66 A Add Filter Losses 25.00 B Add Grill Losses 2.00 C Add S.F (10%) 5.27 D Total 57.93

06.2 Exhaust Air Ventilation System.

R2

Wagon Tippler-3 Hopper Complex, Conveyor BCN-1(2) & Part of TH-1(2)

Section Q R Factor Duct L Duct W Duct H Velocity F.L.

01-02 49500 0.9 5.00 1.200 1.200 9.55 0.29 02-03 12400 0.9 10.00 0.650 0.550 9.63 1.37 03-04 6200 0.9 10.00 0.450 0.400 9.57 2.06 02-05 37100 0.9 5.00 1.050 1.050 9.35 0.33 05-06 4300 0.9 20.00 0.400 0.300 9.95 5.68 05-07 32800 0.9 15.00 1.125 0.875 9.26 1.03 07-08 29640 0.9 15.00 1.100 0.800 9.36 1.13 08-09 26480 0.9 15.00 1.075 0.725 9.44 1.24 09-10 23320 0.9 15.00 1.000 0.675 9.60 1.39 10-11 20160 0.9 20.00 0.925 0.625 9.69 2.08 11-12 17000 0.9 20.00 0.750 0.650 9.69 2.29 12-13 8500 0.9 20.00 0.500 0.475 9.94 3.73

Total 22.63 A Add Grill Losses 2.00 B Add S.F (10%) 2.463 C Total 27.093





07.0 Selection of Fan (Supply and Exhaust Air).

We have considered 10% margin for fan capacity selection over calculated system capacity. We have selected Centrifugal Fan for Supply Air System. We have selected Centrifugal Fan for Exhaust Air system.

R2

R2

07.1 Supply Air Fan.

07.1.1 Type : Backward Curve Centrifugal SWSI 07.1.2 Capacity : 60500 m3

(55000 x 1.1 = 60500) /hr.

07.1.3 Static Pressure : 75 mm WG 07.1.4 Motor kW : 30.00 / 4 Pole 07.1.5 Fan efficiency : 60%

R2

07.2 Exhaust Air Fan.

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07.2.1 Type : Backward Curve Centrifugal SWSI 07.2.2 Capacity : 54450 m3

(49500 x 1.1 = 54450) /hr.

07.2.3 Static Pressure : 50 mm WG 07.2.4 Motor kW : 18.50 / 4 Pole 07.2.5 Fan efficiency : 50%

Reference formulas:

1. Power Calculation: Abs HP =

2. Friction Loss in Duct:

CFM x Fan Pressure 6356 x 25.4 x Fan Eff.

(Hand Book of Air Conditioning System Design Carrier) Total P = 0.03 f (L/d1.22) (V/1000)1.82

3. Sample Calculation:

Where: P = friction loss (in wag)

f = interior surface roughness (0.9 for MS) L = length of duct (ft) d = duct diameter (in) equivalent diameter for rectangular duct work V = air velocity (fmp)

A. We have Duct Size Length 5 meter Width 1.25 meter Height 1.25 meter Duct air velocity 9.78 m/sec Roughness factor 0.9 (as per ASHRAE)

01. Convert the same as per calculation requirements B. We have Duct Size Length 49.2126 inch Width 49.2126 inch





Height 16.4042 feet Duct air velocity 1925 fpm Roughness factor 0.9 (as per ASHRAE) Convert rectangular duct to round

duct De= 1.30x(a*b)0.625/(a+b)0.25

03. Total P = 0.03 f (L/d1.22) (V/1000)1.82 (Hand Book of Air Conditioning System Design Carrier)

P friction loss (in wag) F interior surface roughness (0.9 for MS) L length of duct (ft) D duct diameter (in) V air velocity (fmp) Calculated answer comes to: 0.29 mm WC

08.0 Equipment Summery.

08.1 Supply Air Side W.T.-3

08.1.1 Centrifugal Fan Capacity : 60500 M3

Model : WRC-BC-SWSI-445-N /Hr.

Static pressure : 75 mmWG Drive motor : 30.0 kW x 4 Pole

Qty: 01 No. 08.1.2 Supply Air Filters 610x610x50 mm Qty: 20 Nos.

08.1.3 Supply Air Grill 350 x 300 mm Qty: 09 Nos. 300 x 250 mm Qty: 05 Nos. 325 x 250 mm Qty: 15 Nos. 325 x 300 mm Qty: 14 Nos.

08.1.4 GI. Ducting and Duct Support etc. 1 Lot IS:655 GI Sheet

08.2 Exhaust Air Side W.T.-3

R2

08.2.1 Centrifugal Fan Capacity : 54450 M3

Model : WRC-BC-SWSI-402-N /Hr.

Static pressure : 50 mmWG Drive motor : 18.50 kW x 4 Pole

Qty: 01 No. 08.2.2 Exhaust Air Grill 350 x 325 mm Qty: 08 Nos. 275 x 225 mm Qty: 05 Nos. 300 x 250 mm Qty: 15 Nos. 375 x 325 mm Qty: 10 Nos.

08.2.3 GI. Ducting and Duct Support etc. 1 Lot IS:655 GI Sheet

DBR-VNT-VNT01-R12-19052012-01DBR-VNT-VNT01-R12-19052012-02TABLE OF CONTENTS

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