DF POWER SYSTEMS PVT LTD

BANGALORE

Document Sample Calculations for PG Test

Document No DFPS/M-4-45-015-B1021

Project 1X27MW Green Power Plant

Owner Shree Raipur Cement Plant,

Chattisgarh

Page 1 of 10
 Contents

Sl No Description Page No

1.0 Steam Flow calculation 3

2.0 Specific Heat Calculation 4

3.0 Air Ingress Calculation 5

4.0 Flue gas flow rate Calculation 6

5.0 Particulate Matter Concentration 9

Page 2 of 10
1. STEAM FLOW CALCULATION

The following are the Flow Nozzles being considered for Steam flow measurement:-

SL. NO. DESCRIPTION TAG NO. REMARKS

PH SH Outlet 11-FE-201
1 MP Steam Total MP Steam flow
AQC SH Outlet 12-FE-211 (Located at upstream of MP
common distribution Header)
PH SH Outlet 11-FE-211
2 LP Steam
AQC SH Outlet 12-FE-212

DESIGN AND MEASURED PARAMETERS

Steam Flow
SL. Design Measured
DESCRIPTION UOM derived from REMARKS
NO. Values values (A)
curves (B)
AQC NM3/hr 176042 184800 -
1 Gas flow
PH NM3/hr 406250 426300 -
AQC C 600 520 -
2 Gas Temp.
PH C 285 280 -
PH TPH 18.8 18.3 18.1
MP Steam
3 AQC TPH 34.0 # 29.2 29.0
Total MP Steam flow TPH 52.8 47.5 -
PH TPH 12.5 13.2 13.05
LP Steam
4 AQC TPH 3.5 4.2 4.0
Total LP Steam flow TPH 16.0 - -
NOTE:-
# - Calculated by deducting the PH Boiler MP Steam flow from the Total MP Steam flow measured
at the flow nozzle located in the upstream of MP common Distribution header.

ACCEPTANCE CRITERIA

Measured steam flow rate is higher than the steam flow rate derived from the curves, which
proves the Boiler steam generation capability is better and fulfills the contractual
requirement.

ENCLOSURES:-

1. Annexure I : AQC Boiler Curves

a. MP Steam flow vs Gas flow w.r.t temperature
b. LP Steam flow vs Gas flow w.r.t temperature
2. Annexure II : PH Boiler Curves
a. MP Steam flow vs Gas flow w.r.t temperature
b. LP Steam flow vs Gas flow w.r.t temperature

Page 3 of 10
2. SPECIFIC HEAT CALCULATION AS PER GB 10180 STANDARD (THERMAL
PERFORMANCE TEST CODE FOR INDUCTRIAL BOILERS)

Formula for calculating the Average Specific Heat Capacity at Constant Pressure (Cp)
is as below:-

RO'2 cRO2 + N 2' cN2 + O2' cO2 + CO' cco + H2' cH2 +
Cp =
100
Where:-

cRO2 , c N2cO2 : Average specific heat Correction factors (Refer table for values)

Cp : Dry flue Gas Average Specific Heat capacity at Constant pressure

RO2 : 0.01(CO2 + CO + H2S)

N 2' , O 2' , CO ' , H 2' : Measured values from flue gas

Average Specific Heat (kJ/m3 C) Correction Factors

Temp C c RO2 cN 2 cO2 c H 2O c CO cH2 c CH 4 c DUST c AIR
0 1.5998 1.2946 1.3059 1.4943 1.2992 1.2766 1.5 0.7955 1.3183
10 1.6099 1.2947 1.3071 1.4954 1.2995 1.278 1.5591 0.7997 1.3194
20 1.6199 1.2948 1.3083 1.4965 1.2997 1.2794 1.5682 0.8039 1.32
30 1.6299 1.2949 1.3095 1.4976 1.3 1.2808 1.5773 0.8081 1.3206
40 1.6399 1.295 1.3107 1.4987 1.3002 1.2822 1.5864 0.8123 1.3212
50 1.6499 1.2951 1.3119 1.4998 1.3005 1.2836 1.5955 0.8165 1.3218
100 1.7003 1.2958 1.3176 1.5052 1.3017 1.2908 1.6411 0.8374 1.3243
150 1.7438 1.2978 1.3266 1.5317 1.304 1.294 1.7 0.8521 1.3281
160 1.7525 1.2982 1.3284 1.5154 1.3046 1.2946 1.7118 0.855 1.3289
170 1.7612 1.2986 1.3302 1.5171 1.3052 1.2952 1.7236 0.8579 1.3297
180 1.769 1.299 1.332 1.5188 1.3058 1.2958 1.7354 0.8608 1.3305
190 1.7786 1.2994 1.3338 1.5205 1.3066 1.2964 1.7472 0.8637 1.3313
200 1.7873 1.2996 1.3352 1.5223 1.3071 1.2971 1.7589 0.8667 1.3318
300 1.8627 1.3067 1.3561 1.5424 1.3167 1.2992 1.8861 0.8918 1.3423
600 0.9504
800 0.9797
900 1.0048
Calculated Average Specific Heat Correction factors by Interpolation:
275 1.8454 1.3051 1.3513 1.5378 1.3145 1.2987 1.8570 0.8861 1.3399
285 1.8514 1.3056 1.3530 1.5394 1.3153 1.2989 1.8670 0.8880 1.3407

Page 4 of 10
Sl. Design Test
Description UOM Remarks
No Value Value
1 Flue gas Design Temp OC 285 275
2 CO2' % 28.1 30
'
3 CO % 0 0 Not applicable
4 RO2 0.281 0.3
5 N 2' % 59.5 67
6 O 2' % 5.4 3
7 H 2' O % 7 6.9
8 Dust Concentration gm/Nm3 55 37.43
kJ/m3 C 1.4513 1.3582
CP
kCal/m3 C 0.3466 0.3244

CP =
(0.3 1.8454) + (67 1.3051) + (3 1.3513) + (6.9 1.5378) + (37.43 0.8861)
100
Cp = 1.3582 kJ/m3 C

Cp = 0.3244 kCal/m3 C

3. AIR INGRESS CALCULATION

a. Across PH Boiler (Based on Oxygen measurement):-

ph =
(O out O in )
(21 O out )
Where:-
Oin - Inlet Oxygen quantity
Oout - Outlet Oxygen quantity
SL. NO. DESCRIPTION UOM VALUE
1 OIn % 3.00
2 OOut % 3.70
Air Ingress

ph =
(3.7 3.0) % 4.04
(21 3.7)

Page 5 of 10
 b. Across AQC Boiler (Based on Inlet & Outlet Gas flow measurement):-

Formula for calculating air ingress across AQC Boiler:-

(Qin QOut)
AQC =
(Qin )
Where:-
Qin - Inlet Gas quantity
Qout - Outlet Gas quantity
SL. NO. DESCRIPTION UOM VALUE
1 QIn Nm3/hr 297,129
2 QOut Nm3/hr 296,978
Air Ingress

AQC =
(297 ,129 296 ,978 ) % 0.05
x 100
297 ,129

4. FLUE GAS FLOW RATE CALCULATION:-

a. Volume of Water vapour collected under sampling condition:-

V =
(V C 22 . 4 )

Tm

760
V
(1000 18 ) 273 (P Bar P m )
Where:-

VC Water Condensate 17 ml

Tm Meter temperature 313 K

PBar Barometric Pressure 725 mmHg

Pm Meter Pressure 55 mmHg

VV Equivalent Vapour of condensate under sampling - m3

condition

VV =
(17 22 . 4 ) 313

760
(1000 18 ) 273 (725 55 )

VV = 0.02751344 m3

Page 6 of 10
 b. Moisture content of flue gas:-

VV
M = 100
(V V + V m )
Where:-

VV Equivalent Vapour of condensate under sampling 0.02751344 m3

condition

Vm Total gas volume 0.4 m3

M (Bws) Moisture content of flue gases, % by mass - %

0.02751344
M (B ws ) = 100
(0.02751344 + 0.4)

M (Bws) = 6.4356904 %

c. Dry & Wet Molecular weight Calculation:-

i. ORSAT Analysis:-

Carbon di-oxide, % by volume : 30 %

Oxygen, % by volume : 3%
Nitrogen [100 (CO2-O2)], % by volume : [100-(30+3)] = 67 %

ii. Dry molecular weight Md (gm/gm-mole) :-

M d = 0 . 44 (% CO 2 )+ 0 .32 (% O 2 ) + 0 . 28 (% N 2 )
M d = 0 . 44 (30 )+ 0 . 32 (3 ) + 0 . 28 (67 )

Md = 32.92 gm/gm-mole

iii. Wet molecular weight, Ms (gm/gm-mole) :-

M s = M d (1 B ws ) + 18 B ws
M s = 32.92(1 (6.4356904 /100)) + (18 (6.4356904 /100))

Ms = 31.9598 gm/gm-mole

Page 7 of 10
 d. Gas velocity Calculation:-

Vs =
Kp Cp ( ps ) T s (abs )
(P s M s )

Where:-

Vs Flue gas velocity - m/sec

KP Constant 34.97 -

CP Pitot tube Co-efficient 0.854 -

ps Velocity head at traverse point Refer Calculation table mmWC

Ts(abs) Absolute flue gas temperature Refer Calculation table K

Ps Absolute flue gas pressure

Ps = PBar (Pg/13.6) = 725 + (-45/13.6) 728.31 mmHg
PBar = 725 mmHg / Pg = -45 mmWC

Ms Wet molecular weight 31.9598 gm/gm-mole

CALCULATION TABLE
Vs
Ts Ts(abs) ( ) Vs (avg)
Test ps Kp Cp ps T s ( abs )
Location (K) (P s )
(C) M s (m/s)
= [Ts+273]
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AVG
A 12 13 15 16 17 11 13 14 13 14 14 15 13 13 13 14 13.75 278 551 17.04
17.36
B 15 14 14 16 14 12 14 15 15 16 16 17 15 14 14 15 14.75 280 553 17.68

Flue gas velocity, Vs = 17.36 m/s

Page 8 of 10
 e. Formula to calculate the Volumetric flow rate

T std Ps
Q sd = V s (avg ) A
T s (abs )avg P std

Where:-

Vs (avg) Stack gas velocity 17.36 m/sec

A Area (Based on Duct dia of 4.1m) 13.19585 m2

Tstd Absolute temperature at standard conditions 298 K

Ts(abs) avg Average Absolute flue gas temperature 552 K

Ps Absolute flue gas pressure 728.31 mmHg

Pstd Absolute pressure at standard conditions 760 mmHg

298 728 . 31
Q sd = 17 . 36 13 . 19585 760
552

Qsd = 118.502385 Nm3/s

f. Iso-kinetic flow rate Calculation :-

T mc
1 ws
Ps B
100
I m = 60 ,000 V s A n
T
s ( abs ) P bar Hc

Where:-

Im Iso-kinetic flow rate - LPM

60,000 Conversion factor for m3/s to LPM - -

Vs Flue gas velocity 17.36 m/s

An Cross section area of nozzle

0.0000636 m2
(Diameter d = 9mm) = (x d 2)/4 =(x 0.009 2)/4

Tmc Dry gas meter temperature = 35C + 273 308 K

Ts (abs) Flue gas temperature = ((278+280)/2) + 273 552 K

Ps Absolute flue gas pressure 728.31 mmHg

Pbar Barometric Pressure 725 mmHg

Hc Meter vacuum pressure 40 mmHg

Bws Moisture content of flue gases 6.4356904 % (v/v)

308
I m = 60 ,000 17 . 36 0 . 0000636
552
728 . 31
(
725 40 1

6 . 4356904
100
)
Im = 36.78 LPM

Page 9 of 10
5. PARTICULATE MATTER CONCENTRATION:-

a. Standard Volume of Flue Gas:-

The extracted volume of flue gas measured by the dry gas meter at meter temperature and
pressure is corrected to the standard conditions (25C & 760mmHg) by using the following
formula :-

V m ( std ) = V m std
T (P bar H )
T m P std

Where:-

Vm (std) Standard volume of gas sampled through the dry - Nm3

gas meter, at 298K & 760mmHg

Vm = Final Dry gas meter reading - Initial Dry gas

Vm 1.103 m3
meter reading for 30min = 6.228 5.125

Tstd Absolute temperature at standard conditions 298 K

Tm Dry gas meter temperature = 30C + 273 303 K

Pbar Barometric Pressure 725 mmHg

H Average vacuum pressure at meter 40 mmHg

Pstd Absolute pressure at standard conditions 760 mmHg

V m (std ) = 1 . 103 298 ( 303

) (725 40 )
760

Vm (Std) = 0.97804 Nm3

b. Particulate matter concentration :-

M n
C 's =
V m ( std )

Where:-

Cs Concentration of particulate matter in flue gas - g/Nm3

Vm (std) Standard volume of gas sampled through the dry 0.97804 Nm3
gas meter, at 298K & 760mmHg

Mn Total amount of particulate matter collected 49.95 gm

= Final weight Initial weight = 52.30 2.35

C ' s = 49 . 95
0 . 97804

Cs = 51.07 g/Nm3

Page 10 of 10
 ANNEXURE - I : AQC BOILER CURVES

MP Steam & Tem. of AQC Boiler

40

35

30
29.0
600
MP Steam Flow t/h

25 550
540
20 530
520
15 510
500
10

0
140800(80%) 149600(85%) 158400(90%) 167200(95%) 176000(100%) 184800(105%) 193600(110%)
Gas Flow Nm/h
 LP Steam & Tem. of AQC Boiler

4.5
4
3.5 600
LP Steam Flow t/h

3 550
540
2.5
530
2
520
1.5 510
1 500

0.5
0
140800(80%) 149600(85%) 158400(90%) 167200(95%) 176000(100%) 184800(105%) 193600(110%)
Gas Flow Nm/h
 ANNEXURE - II : PH BOILER CURVES

MP Steam &Tem. of PH Boiler

40

35 345
30 315
MP Steam Flow t/h

25 285
280
20
18.1 275
15
270
10 265

5 255

0
324800(80%) 345100(85%) 365400(90%) 385700(95%) 406000(100%) 426300(105%) 446600(110%)
Gas Flow Nm/h
 LP Steam & Tem. of PH Boiler

16

14 345
13.05
12 315
LP Steam Flow t/h

10 285

8 280
275
6
270
4
265
2
255
0
324800(80%) 345100(85%) 365400(90%) 385700(95%) 406000(100%) 426300(105%) 446600(110%)
Gas Flow Nm/h