FUEL CONSUMPTION

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

COMBUSTION AIR REQUIREMENT

(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:

Kg O2 /
Kg O2 / FLUE GAS CONDITION (Kg/Kg FUEL)
Constituents % BY WT Kg FUEL
Kg COMP 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

¤ Theoritical air required = ( Total amount of kg O2/ kg of fuel)*100/23

4.378 kg/kg of fuel

¤ Excess Air required(Dry) = Excess air percentage * Theoritical air Required

0.876 kg/kg of fuel

¤ Total dry air = Theoritical air required + excess air required

5.254 kg/kg of fuel

¤ Nitrogen In Flue Gas = (Total Dry Air *0.77) + Flue Gas Condition N2
NITROGEN IN FLUE GAS 4.051 Kg/Kg FUEL

¤ Oxygen in Excess Air = Excess Air required * 0.23

OXYGEN IN EXCESS AIR 0.201 Kg/Kg FUEL

¤ Moisture In Gas = (Total Dry air * Air moisture) + Flue gas Condition Moisture
MOISTURE IN GAS 0.354 kg/kg of fuel

¤ Total Combustion Air required = Fuel Consumption * Dry Air

TOTAL COMBUSTION AIR REQUIRED 174.072 TPH

FLUE GAS GENERATION

FLUE GAS ANALYSIS:

PRODUCT MOL WT WT/100 KG FUEL No. MOLES/100 KG FUEL VOL% WT% mi / åmi

CO2 44 128.3 2.915 15.07 6.63 0.222

H2O 18 23.8 1.321 6.83 1.23 0.041
O2 32 20.14 0.629 3.25 1.04 0.035
N2 28 405.13 14.461 74.73 20.937 0.7
SO2 64 1.4 0.022 0.11 0.072 0.002
TOTAL * 578.77 19.35 100 29.91 *

¶ = Total Weight/kg of fuel

Flue Gas Generated
100

Flue gas generated = 5.7877 kg/kg of fuel

Total Flue Gas

¶ = Fuel Consumption * Flue Gas generated
Generated
Total Flue Gas
= 191756.96 kg/hr
Generated

Fan Power Calculation

» FD Fan 100% Flow 60% Flow
Actual
1 Air Mass Flow - 174071.63 kg/hr 104442.98 kg/hr
Temperature of the
2 - 40 ºC
Medium

¶ For Air, Density of the Medium at 0C is 1.293 kg/m3

Density of the
3 - 1.1278 kg/m3
medium

4 Actual Head required - 640 mm of WC

¶ - Air Mass Flow

Air Volumetric Flow
Density of the medium

5 Air volumetric Flow = 154351.61 m3/hr

= 42.88 m3/s 25.73 m3/s

Design

1 Margin in Flow - 10%

2 Margin In Head - 25%

¶ Design Flow - Air Volumetric Flow * Increase in Margin In flow

3 Design Flow - 47.16 m3/s 28.30 m3/s

¶ Design Head - Actual Head * Increase in Margin in Head

4 Design Head - 800 mm of WC
5 Fan Efficiency - 80 %
6 Motor Efficiency - 92 % 100 %
Margin in Drive
7 - 0
capacity

¶ Power Consumption Air Volumetric Flow * Actual Head required

at equipment shaft -
(Actual) 102* Fan Efficiency

8 Power Consumption - 336.28 KW 201.77 KW

¶ Power Consumption Design Flow * Design Head

at Motor Terminal -
(Design) Fan Efficiency*Motor Efficiency
9 Power Consumption - 502.59 KW 277.43 KW

Drive Rating with

¶ - Power Consumption at Motor Terminal * (1+ margin in drive capacity)
Margin
Drive rate with
- 502.59 KW 277.43 KW
margin

» PA Fan

Actual
1 Air mass flow 29027.4 kg/hr
2 Temperature of the medium 150 ºC
3 Density of the medium 0.83 kg/m3
4 Actual head required 560 mm of WC
5 Air / Flue gas volumetric flow 9.66 m3/sec
Design
6 Margin in Flow 10 %
7 Margin in Head 25 %
8 Design Flow 10.63
9 Design Head 700
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 100% FLOW 60% FLOW

Actual
Air / Flue gas mass flow 191757.0 kg/hr 115054.2 kg/hr
Temperature of the medium 140 ºC 140 ºC
Density of the medium 0.85 kg/m3 0.85 kg/m3
Actual head required 160 mm of WC 160 mm of WC
Air / Flue gas volumetric flow 62.32 m3/sec 37.39 m3/sec
Design
Margin in Flow 10 % 10 %
Margin in Head 25 % 25 %
Design Flow 68.55 m3/sec 41.13 m3/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
kg/cm²
Chimney Calculation

Input:
Fuel Quantity - 19674 kg/hr DESIGN BASIS
Flue gas Qunantity - 140094 m3/sec
Exit Gas Temperature
Density = Mass/ Volume Density of gas mixture
Velocity of gas
So Volume = Mass/Density
- 44.73 m3/sec
Sulpur Percentage - 0.36 %
Total So2 produced(Q) - 2*%S*Fuel Flow Rate
= 23854.901 kg/hr
Chimney Height - 14*Q0.3
= 288.01 m
Chimney Flue Gas Quantity in m3 / hr
Crosssectional =
area in m2 Velocity Of Gas in m/s

= 2.24 m2
Chimney Top Diameter = [4*Area/(22/7)]0.5
= 1.69 m
DESIGN BASIS

Exit Gas Temperature 135 C

Density of gas mixture 0.87 kg/m3
Velocity of gas 20 m2
Ash Generation
¶ Total Ash Generation = Fuel Consumption in kg/hr * Percentage of Ash Con
Total Ash Generation = 15406.3 kg /hr
Ash Density For Storage Capacity
= 600.0 kg/m3
Calculation
Ash Density For Structural Design = 1200.0 kg/m3

BED ASH FLY ASH

S No Description ESP
Bed Economizer Air Heater
FIELD I
1 Ash Temperature 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 1300 2500 2500 3500

* Temperature of ash at bed ash cooler outlet

* Percentage of Ash Contenrt

FLY ASH
ESP ESP FIELD
FIELD II III
140 140

6.3 0.7
150 150

971 108
1456 162
1 1

971 108
1456 162

3500 3500
MOTOR SIZING CALCULATION FOR A GIVEN PUMP
INPUT
1 Flow(Q) - 800 m3/hr
2 Head(H) - 42 mWC
3 Density - 988 kg/m3
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
PRESSURE DROP CALCULATION ID FAN

ITEM NO ITEM DESCRIPTION LENGTH WIDTH BREADTH EQUI. DIA FLOW AREA GAS RATE
mm mm mm mm m2 m3/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
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 m2

3 Pressure Drop = (f * Length in m) * (Gas rate/(width in m * breadth in m)^2 * 0.865 * (1/(2

(we use the same formulas for the discharge side also)

1 Total Discharge on suctio = 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 - C
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

m)) - 1.64)^2
breadth in m)^2 * 0.865 * (1/(2*9.81*equivalent diameter in m))

onomiser and airpreheater

Discharge on Delivery Side - Chimney Draft

Pump Efficiency Calculation
Input Data

1 Pump Flow m³/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/m³ 996
water
8 Acceleration m/s² 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

of Water * 9.81 KW
NPSH ANALYSIS CALCULATION FOR CEP PUMP

1 Number of pumps 2 (2*100% As per Contract Documen

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
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
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

Available Pressure + Static Head - Piping Friction loss - Strainer loss

1 kg/cm2 = 10 mlc

W Terminal Point

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

e head - Suction head

eric Pressure
Available pressure + Static Head - Piping friction loss - Strainer loss - Vapour pr of water at operating temperature
ater at operating temperature