FIRST METHOD

Input parameters
Hot water temperature Cold water temperature Wet bulb temperature Range of cooling tower Approach Diameter of fan Diameter of fan hood Avarage air velocity at exit Density of water Density of air Specific heat capacity of water 40.5 29.5 26 11 3.5 3.8 3.9 6 1000 1.2 4.178 C C C C C m m m/s Kg/m^3 Kg/m^3 kj/kgK

Air mass flow rate of fan hood (G) Water mass flow rate( L) Water mass flow rate/air mass flow rate Enthalpy pick up water (H2-H1) = L/G(t2-t1)[1+0.0008(t2-32)] H2-H1

86.1202368 kg/s 111 kg/s/cell 1.288895666

26.6042295 BTU/lb of air

Heat balance calculation G(H2-H1) = L(T1-T2)+Ev x cold water temperature Heat removing capacity of water = Heat rejection rate in the process Heat removing capacity of the tower 1260.139399 Kcal/sec Heat rejection rate in the process 18184118.35 BTU/Hr

Is almost equal Hence Heat balance is established

Other Parameters
Air flow calculation Approach Range Drift loss Evaporation loss 71.766864 m^3/sec 3.5 C 11 C 0.3996 m^3/hr 6.725268 m^3/hr

Dry bulb teperature 30 C Wet bulb temerature 26 C Relative humidity 72 % If fan RPM reduced to 50%(an approximately 40% reduction in air flow rate)

0.1 bar at 45.8 C

29.5 C

COOLING TOWER DESIGN

Second method
104.9 85.1 78.8 19.8 6.3 F F F F F

Estimate outlet air temp

Enthalpy of air outlet at 37.5 C or 9 Enthapy of air inlet at wet bulb tem 2

L/G Air mass flow rate delta ha 1 BTU/Lb F T 85.1 87.08 95 96.98 102.92 104.9 has 53.1 55.13 63.04 64.83 70.94 73.02

Calculate tower characte

71.766864 m^3/sec 880966.3645 lb/hr/cell

0.111 m^3/sec/cell

399.6 m^3/hr/cell

BTU/lb of air

14.63233 Kcal/kg of air (Ka*V)/L Determine the loading factor as per Ka 4536501.837 Kcal/Hr 4580579.413 Kcal/Hr

This Tower characteristic Graph cooling w

86 F 78.8 F

40.5 C

Determine the tower dim Tower hight Area of tower

nd method
35 C 145 kj/kg 80 kj/kg 95 F 62.35 BTU/lb 34.4 BTU/lb

te outlet air temperature

f air outlet at 37.5 C or 99.5 F saturated air inlet at wet bulb tem 26 C or 78.8 F

1.411616 78.63327 Kg/s 13 kj/kg 5.59 BTU/lb

te tower characteristic by the simpsion rule

ha 34.4 37.195 48.375 51.17 59.555 62.35

has-ha 18.7 17.935 14.665 13.66 11.385 10.67

1/(has-ha) 0.053476 0.055757 0.06819 0.073206 0.087835 0.093721 0.071247

1.41069 the loading factor as per graph 2.5 GPM/ft^2 100 1111.5 lbs/hr/ft^2

ic Graph cooling water temperature 10F above wet bulb temperature

Determine the tower dimentions Tower hight Area of tower

15.67981 ft 121345.6 ft^2

4.779207 m 11273 m^2

S.No

Description Capacity of the system STG Water Cooled condenser Lube oil cooler

Cooling tower Continuous Intermitte nt 1793 Cum/hr 100 Cum/hr

MCW pump

ACW pump

1793 Cum/hr 100 Cum/hr

Generator cooler

100 Cum/hr

100 Cum/hr

Boiler Boiler feed water pump SWAS Coal spreader Ash Handling System Eco & APH ash hoppers

5 Cum/hr 8 Cum/hr 2 Cum/hr 0 Cum/hr

5 Cum/hr 0 Cum/hr 2 Cum/hr 0 Cum/hr

Compressor

10 Cum/hr

10 Cum/hr

Air compressor for instrument and service air

10 Cum/hr

10 Cum/hr

Condensate polishing unit Heat Exchanger

75 Cum/hr

75 Cum/hr

Side stream filteration (5% of Circulated water) Total No. of working Total capacity per unit Margin available Selected capacity 2095 Cum/hr 2 Nos. 1047 Cum/hr 5% 1100 Cum/hr 1793 Cum/hr 1 No. 1793 Cum/hr 6% 1900 Cum/hr

105 Cum/hr 407 Cum/hr 1 No. 407 Cum/hr 6% 430 Cum/hr

Cooling tower make-up water requirement 1 Cooling water inlet to cooling tower Cooling water outlet from cooling tower Cooling temperature range Cycles of concentration Evaporation loss Drift loss Blow down loss Total loss Make up water required for cooling tower 43 Deg C

2 3 4 5 6 7 8 9

35 Deg C 8 Deg C 5 1.45 % 0.05 % 0.31 % 1.8 % 37.97 Cum/hr

Remarks

Referred from HMBD Surendra project - 86.5 cum/hr. ITC STG contract document in PG annexure - 100 cum/hr. Surendra project - 75 cum/hr. ITC STG contract document in PG annexure - 100 cum/hr.

Preliminary data received from Boiler team through Email dt Referred from Surendra project - 5 cum/hr for ash hoppers. As per K.Kumar telecon by Mr.Aravind, It is not required

Referred from Surendra project - Instrument air compressor (90DegF to 104 DegF for 80 lpm = 4.8 cum/hr) Referred from Surendra project - Instrument air compressor (90DegF to 104 DegF for 80 lpm = 4.8 cum/hr) Heat balance calculation

As per contract, CT - 1100 cum/hr per cell MCWP - 1800 Cum/hr ACWP - 250 Cum/hr

Waste Heet Boiler Fabrication Schedule

Sr.#

Job Name
FlangesThick 20 x ID 2520 Preparing 97.4x4=390

One Unit W/kg 390

Qty. 3

Total W/kg 1170

Tacking Welding
Flanges Exhast & Inlet M20x1240 Preparing 197.5 49.4x4=197.5

592.5

Tacking Welding
Main Hole Flenge 12x 610 Prepairing 15.5x3=

46.5

139.5

Tacking Welding
Blind Flenges 8 x762 =28.5 Blind Plate 5x2500 Prepairing

4 Kgx3=85.5 5
Tacking Welding

3 193 3

0 579

Bottom FB 10X65X13.62m Tacking Welding

Main holl Shell 8 x 610x300 =36x3=

69.5

208.5

108

324

Rolling Tacking Welding

Inlet side saddle 8x1222x1350 = 71.4 kg

Rolling

Tacking Welding
Con Outer Shell Sheet 2500x2000 Prepairing

9 10 11

1056

3168

Rolling
Con inner shell OD 1237X L 734 mm Prepairing

365

1095

Rolling
Con sheet Prepairing

250

750

Rolling Tacking Both shell & con sheet

Ribs Plates 8x632x608-300= 6 109.2 No.

3 set

327.2

12

Tacking Welding
Coil Shell Prepairing 8x2500xL 3500

1774 x x

5322

13

Rolling Tacking

14

Welding x Coil Shell inner FB 59.4 6x60x3500 x 6 Coil inner Shell Dia 1220x 631 L 3500 Coil Shell Support 56.46 UNP100L635x12= Coil Shell,s Lifting Eye 3 x 15.75 5.25= Nut bolts M 20x80 = 0.2 x 33.6 168=33.6
Damper Inner plate 6X2500 231.5 Making

3 3 3 3 3 3

178.2 1893 169.38 47.25 100.8 694.5

15

Damper PL Instaling Damper Half set Pipe Making with shaft

249

747

15
Damper Pipe & barring,Shafit ,FB SB Body for Bairing out body x 2 Nos,
Damper Shell 8X2500X 3000 prepairing L

220 29.7 1486 x x x

3 3 3

660 89.1 4458

Shell Sheet Rooling

16

Shell Sheet Taking Shell Welding Waste Pipe hole 8 mm connection

3 3 1390.62

Exhast 5 MM 3 Shall,OD 463.54 1236 xL3050 Making Exhast 4 MM 2 Shell OD 1236 x L 3300 Making 402

1206

17

Exhast Reinforcement Plates each rings Exhast Reinforcement ring 6 Nos Exhast Shell Rooling Exhast Shell & FLG Taking Exhast Shell Welding Leg,Pad 8x800x1200x3= Legg Cover PL Steam Tank Tamplate 8 x 824 x 515 x 3Nos + FB 6mm-6450 Total Kg 98 9314.7

3Set

PL

20 21

780

3 3

2340

294 27943.55

Total Price 22

698589

23

edule
3 Perc 50% 20% 30% 50% 20% 30% 50% 20% 30% 100% 15% 35% 50% 50%

14
6

15
9

16
9

17
9

18
9

19
9

20

65

7.7

15% 20% 20% 45% 15% 20%

20% 45% 15% 20% 15% 20% 15% 20% 20% 25% 25% 50% 15% 2633 15% 20% 50% 100% 100% 100% 100%
79.08 79.08 79.08 79.08 105.44 250 1056
70 60 50 40 30 20 10 0 3

50% 50% 100%

1918.65

100% 100% 15% 20% 20% 50% 10% 40%

100%

100%

21
9 9

22
10

23
10

24
16

25
16

26
16

27
16

28
16

29

65

65

65

65 26 39 35 26

7.7

7.7

7.7

7.7

7.7

7.7

7.7

3.08

3.08

3.08

3.08

3.08 4.62

No material
28.8 28.8

35.4

35.4

35.4

No material

1056

365 250

365 250

10

10

16

16

16

16

16

16

16

79.08 105.44

79.08 105.44 263.6

631

632

249

222.9

222.9

No material

780

98

30
16 16

31
16

65 26 39 35 39 35 26 39 35

65 26

65 26 39 35

65 26 39 35

65 26 39

65 26 39 39 26 39 26

14

14 21

14 21

14 21

14

14

7.7

3.08 4.62

3.08 4.62

3.08 4.62

3.08 4.62 4.62 4.62 4.62 4.62

28.8 67.2 96 34.75 34.75 67.2 96 67.2 96

35.4

35.4

35.4

35.4

35.4

35.4

35.4

1056

365

Series1

109
16 16

109

109

633 56.3 15.75

116 116

116 116

116 116

220 29.7 222.9 297.2 297.2 297.2 297.2 297.2 297.2 743 29.7 29.7

220

220

743 15 15

780

780

98

98

10 Total W/KG 720

26 39 39

312 468 210 84 63 69.3 27.72 41.58 0 86.4 201.6 288 69.5 0 354 0 0 0 0 0

0 0 0 3168 0 1095 2669 0 0 327 0 0 2870 237.2 316.3 263.6

1896 56.3 15.75

348 348 249

660 89.1 668.7 891.6 891.6 2229 45 0 0 0 0 0 0 0 2340 0 294 24963

743 15