g

H
Q
PUMP
MOTOR

POWER RATING
KG/M3
DENSITY OF MOTOR
M/S2
ACC DUE TO GRAVITY
M
HEAD
M3/H
FLOW

1000
9.81
55
1150

EFFICIENCY OF PUMP %

APPROX

80

EFFICIENCY OF MOTOR %

APPROX

95

P(KWH)=

XgXHXQ
PUMP X MOTOR

XgXHXQ
PUMPX MOTOR
P(W)=
KW

172356.25
0.76
226784.5395
226.7845395

0.319444

BOILER FEED PUMP - 4500KW

FLOW (Q)
HEAD (H)
PUMP EFFICIENCY
DENSITY ()

593
2064
77.3
1000

M3/Hr
M
%
KG/M3

ACC DUE TO GRAVITY

MOTOR EFFICIENCY
P

9.81
96.3

M/S2
%

0.164722

M3/S

P=
XgXHXQ
PUMPXMOTOR
p(w)
P(Kw)

XgXHXQ
PUMPXMOTOR
3335269.2
0.744399
4480485.868
4480.485868

CONDENSATE EXTRACTION PUMP - 400KW

M3/Hr
450
M
219
%
77.7
PUMP EFFICIENCY
DENSITY ()
KG/M3
990.6
ACC DUE TO
M/S2
9.81
GRAVITY
FLOW (Q)
HEAD (H)

MOTOR EFFICIENCY

0.125 M3/S

95

P=

XgXHXQ
PUMPXMOTOR

XgXHXQ
PUMPXMOTOR

266024.3918
0.73815

P(W)
P(KW)

360393.4048
360.3934048

CLOSED CIRCUIT COOLING WATER PUMP-400KW

FLOW-Q
M3/Hr
1900 0.527778 m3/s
HEAD-H
M
60
DENSITY ()
KG/M3
1000
EFFICIENCY OF PUMP-P
%
86.9
EFFICIENCY OF MOTOR-m %
93.7
ACC DUE TO GRAVITY g
M/S2
9.81

P=

xGxHxQ
P xm
xGxHxQ
P xm

P=

p-w
P-kw

310650
0.814253

381515.3
381.5153

310650
0.814253

JACKIN OIL PUMP-400KW

FLOW-Q
M3/Hr
HEAD-H
M
DENSITY ()
KG/M3
EFFICIENCY OF PUMP-P
%
EFFICIENCY OF MOTOR-m
%
ACC DUE TO GRAVITY g
M/S2

P=

1900
60
1000
86.9
93.7
9.81

xGxHxQ
P xm
xGxHxQ
P xm

P=

p-w
P-kw

0.527777778 m3/s

310650
0.814253

381515.3275
381.5153275

310650
0.814253

VACCUMP PUMP FLOW-Q

M3/Hr
HEAD-H
M
DENSITY ()
KG/M3
EFFICIENCY OF PUMP-P
%
EFFICIENCY OF MOTOR-m
%
ACC DUE TO GRAVITY - g
M/S2

PIPE SIZING CALCULATIONS

FLOW
AREA
VELOCITY
PRESSURE
TEMPERTATURE
SPECIFIC VOLUME
DENSITY

TPH
M2
M/S
KG/CM2
Deg.C
M3/KG
KG/M3

M3/HR

ID=

595(FLOWXSPEC VOLUME)/VELOCITY

Q=A*V
A=

SPEC VOLUME=1/DENSITY

MAIN STEAM LINE

TEMP DEG.C
545
147

PRESSURE-KG/CM2
OD-mm
THK-mm
FLOW-TPH
VELOCITY-M/S

273.1
25.4
230.4
?
64
V=

64

KG/S

3.14/4*(273.1*273.1)*V
0.001093118

3.14/4*d2

PRESSURE
TEMPERATURE
ALLOWABLE STRESS
OD
WELD JOINT EFFICEINCY

PRESSURE DROP CALCULATIONS

AS PER DARCY - WEISBACH EQUATION
P= (fXLXv2)/(2XgXd)

P-diff in pressure (kg/m2)

f-Darcy Friction Factor
v-Velocity in (m/s)
g-acceleration (9.81m/s2)
d-ID of pipe (mm)
DARCY FRICTION
FACTOR

CARBON STEEL
CARBON STEEL
ALLOY STEEL

PIPING MATERIALS
SA106Gr.B C-0.3%, RT1/2Mo
SA106Gr.C C-0.35%, RT1/2Mo
SA335P11 11/4CR-1/2MO-SI
SA335P22 21/4cr-1Mo
SA335P91 9CR-1MO-V

S.NO
1
2
3
4
5
6
7
8
9
10
11

DESCRIPTION
POWER PIPING
PROCESS PIPING
OIL TRANSPORTAION
REFRIGERANT PIPING
SEAMLESS PIPES & FITTINGS
FACE TO FACE FINISHING
PIPE FLANGES
BUTT WELDING
SOCKET WELDING
VALVES
PIPES

ASME CODE
ASME B31.1
ASME B31.3
ASME B31.4
ASME B31.5
ASME B36.1
B16.1
B16.5
B16..9
B16.11
B16.34
B16.36

RULES FOR BOILER

ASME

PUMP
S.NO

DESCRIPTION

JACKING OIL PUMP

BOILER FEED PUMP

3
4
5
6

7
8
9
10

SUPPLIER/TYPE
SULZER/MULTI STAGE BARREL
CASING PUMPS

CONDENSATE EXTRACTION
SULZER/VERTICAL
PUMP
HOT WATER PUMP
SULZER/HORIZONTAL TYPE
VACCUMP PUMP
FLOWSERVE/SINGLE STAGE DOUBLE
CLSOED CIRCUIT COOLING SUCTION,HORIZONTALLY
WATER PUMP
SPLIT,VOLUTE TYPE-CENTRIFUGAL
PUMP
End Suction Back Pullout single stage
INITIAL FILL PUMP
Centrifugal Pumps

FLOW-M3/HR

593
450
70

1900

150

HEAD-M

PUMP
RATED
POWER-KW

MOTOR
EFFICIENCY

TEMPDeg.C

NO OF
STAGES

2064

4500

77.3

180.9

219

342.1

77.7

46

210.5

53.04/55.8

72.78/71.4

83.5

60

357

86.9

50

160

110

70

50

CAPACITY

SPEED

37.1LPM

2700 RPM

2900 RPM

MOTOR
MOTOR RATING
18.5KW, 415V AC

DISCHARGE
PRESSURE
285KG/CM2-g

400KW

110KW

15 Kg/cm2

CCCW PUMP-1900M3/Hr
S.NO
1
2
3
4
5
6
7
8
9
10
11

DESCRIPTION
PLATE HEAT EXCHANGER INLET
BED ASH COOLER
PA FAN
SA FAN
ID FAN
INSTRUMENT AIR & COMPRESSED AIR
GENERATOR COOLER
BFP
VACCUMP PUMP
LUBE OIL COOLER-1
LUBE OIL COOLER-2

CCCW PUMP-1900M3/Hr
PRESSURE-Kg/Cm2

TEMP-Deg.C

FLOW-M3/Kg

44

1700

5.7

37

265

5.7

37

250

5.7

37

629

5.7
5.7

37
37

250
1394

EFFCIENECY OF BOILER
AS PER CEA RULES
EFFICIENCY OF BOILER (b)=
b
A
M
H
GCV

EFFICINECY OF BOILER
ASH
MOISTURE
HYDROGEN
GROSS CALORIFIC VALUE

VALUES

C
#

%
%
%
%
KCAL/KG

CONTRACT
6
4.59
26
4800

ASH-%
HYDROGEN-%
MOISTURE-%
GCV-Kcal/Kg

92.5-{{(50XA)+630(M+9

CALCULATION
50*A
9H
M+9H
630*(M+9H)
A+C
#/GCV

OL COAL
300
41.31
67.31
42405.3
42705.3
8.8969375

10-Aug
6
3.44
26
4800

10-Aug
300
30.96
56.96
35884.8
36184.8
7.5385

EFFICIENCY OF BOILER (b)=

OLD COAL
10-Aug
NEW COAL
SEPL

Y OF BOILER

92.5-{{(50XA)+630(M+9H)/GCV}}

NEW COAL
7
4.2
34
4200

SEPL-Imported
1.19
5.24
24.85
5830

NEW COAL
350
37.8
71.8
45234
45584
10.853333

SEPL-Imported
59.5
47.16
72.01
45366.3
45425.8
7.791732419

92.5-{{(50*6)+630(26+9*4.89)}/4800}

b
b
b
b

83.6
84.96
81.65
84.71

%
%
%
%

BOILER PARAMETERS
CAPACITY
MAIN STEAM O/L TEMP
MAIN STEAM O/L PRESSURE
FEED WATER INLET-TEMP
REHEAT STEAM FLOW
REHEAT STEAM I/L PRESSURE
REHEAT STEAM I/L TEMP
REHEAT STEAM O/L PRESSURE
REHEAT STEAM O/L TEMP
BLOW DOWN-3%

487
540
134
249
396
26.5
315
25.2
540
14.61

TPH
Deg.C
Bar

MAIN STEAM O/L

(540 Deg,134Bar)

3437.43

KJ/KG

FEED WATER INLET (249Deg.C)

1080.9

KJ/KG

Deg.C
TPH
Bar
Deg.C
Bar
Deg.C
TPH

ENTHALPHY

ENTHALPHY-REHEAT
REHEAT I/L (26.5Bar,315Deg.)

3041.9

KJ/KG

REHEAT O/L (25.2Bar,540Deg)

3554.78

KJ/KG

ENTHAPHY-BLOWDOWN-3%MAKEUP
BLOWDOWN

1571.2

KJ/KG

WEIGHT OF FUEL REQUIRED FOR BOIL

PLANT HEAT RATE (Kcal/Kwh) =

Weight of Fuel (Wf)

A
B
C

Wf=
KG/HR
TPH

PLANT HEAT RATE

GCV
KWH GENERATION

OLD
A X C/B
149062.5
149.0625

CONTRACT
KCAL/KWH
2385
KCAL/KG
4800
300
300

NEW
A X C/B
177142.86
177.14286

EQUIRED FOR BOILER

Weight of Fuel X GCV/
KWH Generation
Plant Heat Rate X Kwh
Generation/GCV

OLD COAL NEW COAL

2385
2480
4800
4200
300000
300000

HEAT RATE OF TURBINE=

SPECIFIC FUEL CONSUMPTION X CALORIFIC VALUE

HR

Turbine HEAT RATE

Q1
Q2
h1
h2
h3
h4
P

MAIN STEAM INLET FLOW

REHEAT STEAM INLET FLOW
Enthalphy of Main Steam Inlet
Enthalphy of Feed water at HP-Heater-2 outlet
Enthalphy of Hot Reheat Steam Inlet
Enthalphy of Cold Reheat Steam
Power output of Generator

HR=

Q1(h1-h2)+Q2(h3-h4)/P

H1-H2
H3-H4
Q1(H1-H2)
Q2(H3-H4)
Q1(h1-h2)+Q2(h3-h4)
Q1(h1-h2)+Q2(h3-h4)/P

Kj/Kw Hr

2356.53
510.29
1086006851
197900667.8
1283907518
8559.38

TPH
TPH
Kj/Kg
Kj/Kg
Kj/Kg
Kj/Kg
KW
Kj/Kw Hr

Kj/Kg
Kj/Kg
Kj/Hr
Kj/Hr
Kj/Hr
Kj/Kw Hr

TPH

KG/H

KG/S

460.85
387.82
3437.43
1080.9
3551.78
3041.49
150000

460850
387820

128.0139
107.7278

Boiler Parameters
Capacity
Steam O/L pressure
Temperature
FW Inlet Temp
Reheat Steam
Reheat Steam I/L pressure
Reheat I/L temp
Reheat Steam O/L pressure
Reheat steam O/L temp

487 t/h
137 bar
545 Deg.c
249 Deg.c
396 t/h
26.5 bar
315 Deg.c
25.2 bar
540 Deg.c

Blow Down

3%(14.61 tph)

Enthalphy (Main Steam & Feed Water)

Steam O/L (137bar,540deg.c)
Feed Water
(249 Deg.c)

3437.43
1080.9

Enthalphy (Reheat Steam)

Reheat Steam I/L (26.5bar, 315 Deg.c)
Reheat Steam O/L (25.2bar,540 Deg.c)

3041.49
3551.78

Enthalphy (Blow Down Water)

Enthalphy (Blow Down Water)

1571.72

KJ/Kg
KJ/Kg

KJ/Kg
KJ/Kg

KJ/Kg

ASME SEC VIII-DIV1

AS PER UG-27
longitudinal stress
T=
T
P
Ro
S
E

PXRo/SE+0.4P
THICKNESS mm
DESIGN PRESSURE Kg/cm2
OUTSIDE RADIUS mm
Allowable stress Kg/cm2
Weld efficiency

THICKNESS CALCULATION : SURGE TANK T

10 SELECTED
P
1
Ro (Id)
3700
S
1406.1
E
0.75
PxRo
SxE
0.4*P
SxE+0.4*P
PxRo/SxE+0.4*P

3700
1054.575
0.4
1054.975
3.507192114

T
P
Ro
S
E

PHASE#2
THICKNESS mm
DESIGN PRESSURE Kg/cm2
OUTSIDE RADIUS mm
Allowable stress Kg/cm2
Weld efficiency

THICKNESS CALCULATION : SURGE TANK T

10 SELECTED
P
1
Ro (Id)
4550
S
1406.1
E
0.75
PxRo
SxE
0.4*P
SxE+0.4*P
PxRo/SxE+0.4*P

4550
1054.575
0.4
1054.975
4.31289841

S.NO
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
26
27

Pipe Size-Inch
1
2
3
4
5
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48

ASME B31.1 (L=1.5XD)

NB
PIPE OD
25
33.4
50
60.3
80
88.9
100
114.3
125
141.3
150
168.3
200
219.1
250
273.1
300
323.1
350
355.6
400
406.4
450
457.2
500
508
550
558.8
600
609.4
650
711.2
700
762
750
812.8
800
812.8
850
863.6
900
914.4
950
965.2
1000
1016
1050
1066.8
1100
117.6
1150
1168.4
1200
1219.2

THK

ELBOW SIZE
50
90
133
171
212
252
329
410
485
533
610
686
762
838
914
1067
1143
1219
1219
1295
1372
1448
1524
1600
176
1753
1829

STANDARD SIZES
Pipe Size in Inch
NB
1
25
2
50
3
80
4
100
5
125
6
150
8
200
10
250
12
300
14
350
16
400
18
450
20
500
22
550
24
600
26
650
28
700
30
750
32
800
34
850
36
900
38
950
40
1000
42
1050
44
1100
46
1150
48
1200

OD
33.4
60.3
88.9
114.3
141.3
168.3
219.1
273.1
323.1
355.6
406.4
457.2
508
558.8
609.4
711.2
762
812.8
812.8
863.6
914.4
965.2
1016
1066.8
117.6
1168.4
1219.2

ALLOWABLE STRESS F

FARENHEIT TO DEG C

F=
C=

SA 106 Gr. B
F=

KSI
KG/CM2

800
768
426.67
10.8
0.76

C=
Deg. F=

550
1022

Deg. C=
CODE

ALLOWABLE STRESS FOR DIFFERNECT MATERIALS

FARENHEIT TO DEG C

KSI TO Kg/Cm2

(Deg.c X 1.8)+32
(F-32)/1.8

KSI
Kg/Cm2

1
0.07

13.7
0.96

750
718
398.89
13
0.91

700
668
371.11
15.6
1.10

650
618
343.33
17.1
1.20

600
568
315.56
17.1
1.20

500
468
260.00
17.1
1.20

400
368
204.44
17.1
1.20

300
268
148.89
17.1
1.20

200
168
93.33
17.1
1.20

500
932

450
842

400
752

350
662

300
572

250
482

200
392

150
302

990
1022
125
93
51.67

850
818
454.44

900
868
482.22

100
212

50
122

30
86

950
918
510.00

1000
968
537.78

1100
1068
593.33

1200
1168
648.89

550