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TABLE OF CONTENT SL. NO
DESCRIPTION
PAGE NO.
1
PURPOSE AND SCOPE
4
2
DESIGN INPUT
4
3
ASSUMPTIONS
4
4
METHODOLOGY AND ACCEPTANCE CRITERIA
5
5
CALCULATIONS
5
6
RESULTS
5
7
REFERENCES
5
8
ATTACHMENTS
5
1.0
PURPOSE AND SCOPE
1.1 1.2 1.3 1.4
The purpose of this calculation is to determine the following: Chain Capacity of MB Chain Capacity of RO-II (BWRO) system Design capacity of MB feed pump Design capacity of RO-II feed pump
No. of Units Total no. of MB units No. of MB streams working Total no. of RO-II units No. of RO-IInd stage chain working Power cycle make-up as percent of rated BMCR Recovery of RO-IInd stage Operation cycle for individual MB unit Total no. of DM tanks Capacity of each DM tank Total no. of CST Capacity of each CST Total no. of MB feed pump Total no. of working MB feed pump Total no. of R O-II feed pump Total no. of working R O-II feed pump
Value
Unit
Reference
2 2 1 2 2 1 80 72 2 2000 2 1000 2 1 3 2
nos. nos. nos. nos. nos. % % hrs nos. cum nos. cum nos. nos. nos. nos.
Rated BMCR of each 660 MW Unit at 100% load Make up requirement for Power cycle chemical feed system Make up requirement for CCW Expansion tank Make up requirement for CPU regeneration Operation cycle for individual CPU unit under normal condition Total no. of CPU units under operation (for both units) Make up requirement for Hydrogen generation pl ant Regeneration water requirement for individual DM ch ain Operation cyclle for CPU during clean up / start up process General margin on pump capacity for design purpose
2010 5 5 500 7 4 1 50 24 10
T/hr cum/hr cum/hr cum days nos. cum/hr cum/cycle hrs %
HBD UV UV UV UV UV UV UV UV J
ASSUMPTIONS FOR BOILER CLEAN UP PROCESS DURING COMMISSIONING
Percent BMCR for minimum flow requirement during clean up Total hours of blow down Total hours of recirculation
15 3 21
% hrs hrs
UV UV UV
40 3 20 5 14
% minutes nos. % hrs
UV UV UV UV UV
15 5 10 600
% hrs hrs cum
UV UV UV UV
ASSUMPTIONS FOR BOILER STEAM BLOWING PROCESS DURING COMMISSIONING
Percent of BMCR for Steam blow period Time period of each steam blow Total number of steam blow per day % BMCR flow as steam drain loss during standby mode Total hours of boiler operation ASSUMPTIONS FOR BOILER COLD START UP PROCESS
Percent BMCR minimum flow requirement during cold start up Total hour of blowdown Total hour of recirculation Boiler fill up volume required
4.0
METHODOLOGY AND ACCEPTANCE CRITERIA
4.1
There will be 2 nos. of MB units out of which one unit will be under operation and the other will work as regeneration standby unit. Each MB unit will be running for at least 48 hours of continuous operation between two successive regenerations. Both Stage-1 & Stage2 RO will be operating for 24 hrs on continuous basis.
4.2
For a single regeneration of individual MB unit DM water of 50 cum is considered (Regeneration water quantity is subjected to change based on finalised vendor input). DM water required for regeneration of MB will be provided from DM water stortage tank.
4.3 4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6
Design margin of 10% is considered on rated pump capacity for each services in Desalination and RO-MB plant except for RO HP feed 2 pump. The considerations done for DM water requirement under different conditions are as follows: One unit is under commissioning and the other unit is in cold start up condition. One unit is under commissioning and the other unit is in normal running condition One unit is undergoing steam puffing and the other unit is in cold start up condition One unit is undergoing steam puffing and the other unit is in normal running condition One unit is undergoing cold start-up and the other unit is in normal operation Both the units are in normal operati on
4.5
One unit under commisioning clean up cycle and other unit under steam puffing operation case is not considered since the time gap between comissioning of two units will be sufficient so that the second unit comissioning clean up starts only after completion of steam blowing operation of first unit.
4.6
Cases indicated under Point no. 4.4.2 and 4.4.4 is of more than one day occurance. Since RO-DM chain capacity cannot cater to these requirements alone, hence the excess DM water requirement (Refer Attachment-8.1) have to be met from reserved storage capacity. These operations have to be intermittent in nature so as to allow the storage volume to be refilled depending on total number of days of the operation.
4.7
All the assumptions made under Sl. No. 3.1.2 to 3.1.5, 3.1.9, 3.2, 3.3 and 3.4 are to be verified from BTG vendor and modified input, if any, shall be provided.
4.8
Sizing calculation is subjected to change based on modification in regeneration and backwash water flow rates after receipt of finalised vendor data.
4.9
BTG inputs are required to verify all the assumed data as indicated in the RO-DM chain sizing calculation. In case, data received from BTG supplier varies significantly from the present assumptions, the consideration made in the design will get modified accordingly.
5.0
CALCULATIONS
5.1
Refer Attachment 8.1 for sizing calculation of Desalination Plant and RO-MB Plant
6.0
RESULTS
The calculated design parameters of DM Plant are as follows: 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8
Design MB chain capacity (net) Selected Capacity of each MB (net) Design RO-II stream net output capacity (individual) Selected Capacity of each RO stream Design capacity of MB feed pump Selected Capacity of MB feed pump Design capacity of RO-II feed pump Selected Capacity of RO-II feed pump
7.0
REFERENCES
7.1 7.2 7.3 7.4
HBD Contract Document DCD for DM Plant Calculation for Water Balance Diagram
Not Attached Not Attached Not Attached Not Attached
ATTACHMENT-8.1: SIZING CALCULATION FOR RO-DM PLANT S.No. A
A.1 A.2 A.3 A.4 A.5 A.6 A.7
Formula
Unit
Value
Q1 N P QW1 QW2 QW3 Tcpu Ncpu QW4 N1
T/hr nos. % cum/hr cum/hr cum day nos. cum/hr nos.
2010 2 1 5 5 500 7 4 1 1
Q2=[(Q1*N*P/100*)+Q W1+ QW2+QW3/Tcpu/24*
cum/hr
63.5
cum/cycle hrs cum/hr cum/day % cum/hr
50 72 65 1560 80 81.25
T/hr % hrs hrs cum
2010 15 3 21 500 24
cum/day
1404.5
cum/hr
59
40
Particulars
Remarks
DM MAKE-UP UNDER NORMAL CONDITION
A.7 A.8
Rated B.M.C.R at 100% load of each 660 MW Unit No. of Units Power cycle make-up as percent of rated BMCR DM make up required for Power cycle chemical feed system DM make up required for CCW expansion tank make up DM water required for CPU regeneration Operation cycle for individual CPU unit under normal condition Total no. of CPU units under operation (for both units) DM make up required for Hydrogen generation plant No. of working MB streams
A.11
Net DM water required at MB outlet
Considering Both Units
Ncpu+QW4] A.12 A.13 A.14
Regeneration water requirement for individual MB Total cycle time between consecutive regeneration Gross Capacity required for individual MB chain
A.15 A.16
Recovery of RO-II unit Total feed water required for RO-II unit
B
Rec QROf =Q4*N1/(Rec/100)
DM MAKE-UP DURING COMMISSIONING CLEAN UP CYCLE
B.1 B.2 B.3 B.4 B.5 B.6
Rated B.M.C.R at 100% load of each 660 MW Unit Percent BMCR for minimum flow requirement during clean up Total hours of blow down Total hours of recirculation DM water required for CPU regeneration Operation cyclle for CPU during clean up / start up process
B.7
Total DM water required for clean up cycle process
% BMCR flow as steam drain loss during standby mode Total hours of boiler operation
nos. % hrs
C.6
Total DM water required for steam blowing operation
cum/day
2211
cum/hr
92.125
P3 T3
5 14
QSB = Q1*P2/100*T2/60*N1 + Q1*P3/100*T3
Considering Single unit
D
DM MAKE-UP DURING COLD START UP OPERATION
D.1
Percent BMCR minimum flow requirement during cold start up
D.2 D.3 D.4
Total hour of blowdown Total hour of recirculation
D.5 D.6
Total DM water required for cold start up operation
E
P4
DM water required for CPU regeneration
% hrs hrs cum
5 10 500
Boiler fill up volume required
V1
cum
600
Qcs = Q1*P4/100*T4 + QW3+V1
cum/day
2607.5
cum/hr
108.6458333
DM water required when one unit is under commissioning and the other is under normal operation
E.2
DM water required when one unit is under steam blowing and other under normal operation
E.3
DM water required when one unit is under commissioning and other under cold start up condition
Q4
cum/day cum/hr
Q5
cum/day cum/hr
E.5
DM water required when one unit is under steam blowing and other under cold start up condition
DM water required when one unit is under cold start up condition and other is in normal operation
Q6
Q7
Q8
2293.757143 This situation may continue for more than one day. 95.57321429 3100.257143 This situation may continue for more than one day. 129.177381
cum/day
4012
cum/hr
167.167
cum/day
4818.5
cum/hr
200.7708333
cum/day
3496.757143 145.6982143
F
This situation should not continue for more than one day since cold start up operation is a single day process in general. This situation should not continue for more than one day since cold start up operation is a single day process in general. This situation should not continue for more than one day since cold start up operation is a single day process in general.
RO-DM CHAIN SIZING CALCULATION
F.1
Selected working capacity of RO-DM
QDM
F.2 F.3 F.4
Total no. of MB units Total no. of RO-II units Capacity of each MB unit
N4 N5 QMB
cum/hr
65
F.5
Capacity of each RO unit
QBWRO
cum/hr
33
F.6
Available maximum RO-DM chain capac ity
F.7 F.8 F.9 F.10 F.11
Required maximum feed water to RO-DM Plant Total no. of DM tanks Capacity of each DM tank Total no. of CST Capacity of each CST Total storage volume available
F.12
Considering Single unit
DM WATER REQUIREMENT FOR SIMULTENEOUS OPERATION - DIFFERENT CASE STUDY
DM water requirement for Case given against E.1 Excess DM water required
Q4 Q9 = Q4-QW
cum/day cum/day
2293.757143 733.7571429
Refer Point no. 4.6 in Input & Result sheet
F.15 F.16
DM chain sizing for Case given against E.2 Excess DM water required
Q5 Q10=Q5-QW
cum/day cum/day
3100.257143 1540.257143
Refer Point no. 4.6 in Input & Result sheet
F.17
DM storage required for Case given against E.3
V4
cum
2452.0
OK, since it’s a single day operation the same will be met from total storage of DM water i.e. 4000 cum (Refer F.12)
F.18
DM storage required for Case given against E.4
V5
cum
3258.5
OK, since it’s a single day operation the same will be met from total storage of DM water i.e. 4000 cum (Refer F.12)
F.19
DM storage required for Case given against E.5
V6
cum
1936.8
Hence OK
N6 N7 N8 N9 P5 Q11=Q4/N7
nos. nos. nos. nos. % cum/hr
2 1 3 2 10 65
QPDM =Q11*(1+P5/100)
cum/hr
75
Q13=QROf /N9
cum/hr
40.625
cum/hr
45
G
RO-DM PLANT PUMP SIZING CALCULATION
G.1 G.2 G.3 G.4 G.5 G.6
Total no. of MB feed pump Total no. of working MB feed pump Total no. of RO-II feed pump Total no. of working RO-II feed pump General margin on pump capacity for design purpose Capacity of MB feed pump based on normal requirement
G.7
Design capacity of MB feed pump
G.8
Capacity of RO-II feed pump based on normal requirement
