DESIGN BASIS REPORT FOR VENTILATION SYSTEM

(Air Compressor, Workshop, Store, and Switchyard area)

including Sizing Calculation
Owners comment RVH MG GTA
7 08.09.16
incorporated
Owners comment RVH MG GTA
6 17.08.16
incorporated
Owners comment RVH MG GTA
5 01.08.16
incorporated
Owners comment RVH MG GTA
4 02.04.16
incorporated
Owners comment RVH MG GTA
3 24.02.16
incorporated
Owners comment RVH MG GTA
2 12.11.15
incorporated
Owners comment
incorporated and RVH MG GTA
1 02.10.15
revised heat load
incorporated
0 01.06.15 For approval RVH MG GTA
Rev. Date Description PREP CHKD APPD
Project Title:
2x350MW COASTAL THERMAL POWER PLANT
Thamminapatnam, Nellore, AP
Owner :
MEENAKSHI ENERGY PRIVATE LIMITED

Project Management Consultant:

TRACTEBEL CONSULTING
ENGINEERS (P) LTD.,
Owner’s Engineer:
Steag Energy Services (India) Pvt. Ltd
BOP EPC Electro-Mechanical Contractor:

EDAC ENGINEERING LIMITED

BOP EPC Electro-Mechanical Contractor’s Engineer:

FICHTNER Consulting Engineers (India) Pvt. Ltd., Chennai

BOP Supplier / Package:

Industrial Fans India Private Limited/HVAC Package

Project No. Job No. Scale Sheet No.

- - - 1 of 16

Document No.: CTP-20-IN-M-DO-SA-2066

Sub-Contractor Drawing No.:-

Sub-Supplier:--
 MEENAKSHI ENERGY PRIVATE LIMITED
2x350MW COASTAL THERMAL POWER PLANT DESIGN BASIS REPORT FOR
THAMMINAPATNAM, NELLORE, AP VENTILATION SYSTEM (Air Compressor,
Workshop, Store and Switchyard area)

TABLE OF CONTENTS
1.0 Introduction....................................................................................................................................5

2.0 Function..........................................................................................................................................5

3.0 System Description.......................................................................................................................5

3.0 Codes and Standards...................................................................................................................5

4.0 Design Criteria...............................................................................................................................6

4.1 Design Condition.......................................................................................................................6

4.2 Design Requirements...............................................................................................................6

5.0 Layout Requirements...................................................................................................................7

6.0 Major Equipment Description......................................................................................................8

6.1 Axial Fans..................................................................................................................................8

6.2 Roof Ventilators, where applicable.........................................................................................9

6.3 Air Filters....................................................................................................................................9

6.4 Ducting, where applicable......................................................................................................11

6.5 Hangers and Supports, where applicable............................................................................11

6.6 Grilles, where applicable........................................................................................................11

6.7 Gravity Operated Back Draft Dampers................................................................................12

6.8 Thermal and Acoustic Insulation, where applicable...........................................................12

7.0 Electrical Requirements.............................................................................................................12

8.0 Operation and Control Philosophy............................................................................................13

Appendix 1 – Ventilation system sizing calculation............................................................................14

Appendix 2 – Heat Load details............................................................................................................15

Appendix 3 – Ventilation Air requirement as per Battery Vendor......................................................16

377818980.doc IFIPL Page 2 of 16

 MEENAKSHI ENERGY PRIVATE LIMITED
2x350MW COASTAL THERMAL POWER PLANT DESIGN BASIS REPORT FOR
THAMMINAPATNAM, NELLORE, AP VENTILATION SYSTEM (Air Compressor,
Workshop, Store and Switchyard area)
Abbreviation List

AC Alternating current

ACH Air Change per Hour

AHU Air Handling Unit

AMCA Air Movement and Control Association

ASRAE American Society of Heating, Refrigerating & Air-Conditioning

Engineers

BoP Balance of Plant

BS British Standards

CPU Condensate Polishing Unit

DBR Design Basis Report

DC Direct Current

DG Diesel Generator

DOL Direct on line

ESP Electrostatic Precipitator

GI Galvanized iron

GSS Galvanized steel sheet

IS Indian Standards

ISO International Standards Organization

IP Ingress Protection Classification

MCC Motor Control Centers

MS Mild steel

SSPC Steel Structures Painting Council

UPS Uninterrupted Power Supply

VDI The Association of German Engineers

VFD Variable Frequency Drive

377818980.doc IFIPL Page 3 of 16

 MEENAKSHI ENERGY PRIVATE LIMITED
2x350MW COASTAL THERMAL POWER PLANT
THAMMINAPATNAM, NELLORE, AP
Units
DESIGN BASIS REPORT FOR
VENTILATION SYSTEM (Air Compressor,
Workshop, Store and Switchyard area)

°C Degree centigrade

hZ Hertz

kW Kilowatts

mm Milli meters

m/s Meter/second

mmWc Millimeter water column

MW Mega watt

rpm Rotations per minute

SWG Standard Wire Gauge

V Volts

377818980.doc IFIPL Page 4 of 16

 MEENAKSHI ENERGY PRIVATE LIMITED
2x350MW COASTAL THERMAL POWER PLANT DESIGN BASIS REPORT FOR
THAMMINAPATNAM, NELLORE, AP VENTILATION SYSTEM (Air Compressor,
Workshop, Store and Switchyard area)

1.0 Introduction
This Design Basis Report (DBR) covers the design philosophy, selection criteria and
sizing calculation of Ventilation System for Air Compressor, Workshop, Store and
Switchyard area of 2 x 350MW Unit-3 & 4 (Phase II) Coastal Thermal Power plant at
Thamminapatnam. Nellore, Andhra Pradesh.

2.0 Function
The primary function of the ventilation system is to maintain an acceptable environment
by removing the internal heat, fumes, and gases generated from the plant / equipment
thereby limiting the temperature rise and maintaining a reasonable cleanliness inside the
building for proper functioning of the process equipment and their controls. Such
environment will also provide better working conditions for the operating & maintenance
personnel.

3.0 System Description

Mechanical ventilation will be adopted in the areas like pump house, compressor house,
switchgear room, etc. All mechanically ventilated areas will be ventilated by means of
supply air fans and exhaust fans or gravity operated back draft dampers as applicable or
only by exhaust fans in the areas where negative pressure is to be maintained.

General exhaust ventilation with wall mounted axial flow fans is considered for toilet
areas.

Ventilation system sizing calculation are given in Annexure 1.

3.0 Codes and Standards

The following list of codes and standards will be followed for the design of the ventilation
system

AMCA publication 99 : Standard handbook

AMCA standard 210 : Test code for air moving

BS: 848 : Method of performance

IS 277 Grade 275 : Galvanized steel sheet

IS:3588 : Electric axial flow fans

IS: 4894 : Centrifugal fans

377818980.doc IFIPL Page 5 of 16

 MEENAKSHI ENERGY PRIVATE LIMITED
2x350MW COASTAL THERMAL POWER PLANT DESIGN BASIS REPORT FOR
THAMMINAPATNAM, NELLORE, AP VENTILATION SYSTEM (Air Compressor,
Workshop, Store and Switchyard area)

4.0 Design Criteria

4.1 Design Condition
All mechanical ventilated areas will be designed for 15 – 20 air change rate per hour or
maintaining a maximum internal temperature of 3˚C above the summer ambient
temperature, i.e. 50˚C (47˚C+3˚C). Higher quantity of airflow from either of these 2
conditions shall be considered for selection of ventilation fan sizing.

The number of air changes per hour in mechanically ventilated areas shall be as follows:-

S. No Area Air Changes

1.
General areas 15

Various pump houses, switchgear/ MCC rooms,

2.
Battery rooms & other areas where gaseous 20
fumes are generated

4.2 Design Requirements

The design requirements that will be adopted while designing ventilation systems are as
follows;

 All mechanically ventilated areas shall be positively ventilated by means of

supply air fans, generally in combination with exhaust fan or roof extractors or
gravity operated back draft dampers. However, as exception, hazardous areas
and fumes/odour generating areas such as battery rooms, chemical storage
areas, and toilets shall be negatively ventilated by means of exhaust air fans/roof
exhausters.

 All the equipment of ventilation system will be designed for continuous duty for
continuous operation of 24 hours a day.

 Supply air fan catering for electrical switchgear/MCC. Rooms, cable galleries and
compressor rooms will be provided with pre-filters and fine filters, while supply air
fans for other areas shall be provided with pre-filter only.

 All ventilation system will operate on 100% fresh air. The exhaust fans or gravity
operated back draft dampers will be sized considering 85% of the supply air in
order to maintain positive pressure inside the rooms.

 Exhaust fans (wall mounted) will be provided for the areas where negative
pressure to be maintained.

377818980.doc IFIPL Page 6 of 16

 MEENAKSHI ENERGY PRIVATE LIMITED
2x350MW COASTAL THERMAL POWER PLANT DESIGN BASIS REPORT FOR
THAMMINAPATNAM, NELLORE, AP VENTILATION SYSTEM (Air Compressor,
Workshop, Store and Switchyard area)
 Continuous motor rating of fans (at 50˚C ambient) will be at least ten percent
(10%) above the maximum load demand of the fan at the design duty point.

 Battery rooms will be maintained under a negative pressure to prevent escape of

explosive gases to other areas.

 Kitchen, toilets will be kept under negative pressure to control the spread of
odours.

 Fan installed in areas having inflammable gases / battery room will have the
spark proof type of motors.

 The metal air ducts where provided will be made of G.S.S conforming to IS: 277
grade 275.

 Vibration of the rotating equipment will be designed for1.8 to 4.5 mm/sec as per
IS 12075/VDI.

 Painting will be provided as per Owner’s painting specification, details will be

included in the respective equipment GA drawing.

 The noise level will be equal to or less than 85 dBA at 1 meter distance from the
equipment.

5.0 Layout Requirements

Supply air fans will be mounted on the building or room walls or wall panel at a suitable
elevation from the floor level in such a way that it does not hinder material and personnel
movement and provides effective heat removal from the space. The exhaust fans will be
mounted on the building or room walls or wall panel at the maximum possible highest
elevation from the floor level. Gravity operated back draft dampers will be mounted on
the lower elevation of the walls.

Roof mounted exhaust fans will be mounted at the top of the building walls or room
roofs.

Supply air or exhaust air ducts, where required, to ensure proper ventilation of the
buildings/rooms will be routed along the building/room wall or supported from the roof.

6.0 Major Equipment Description

6.1 Axial Fans
a) Casing

377818980.doc IFIPL Page 7 of 16

 MEENAKSHI ENERGY PRIVATE LIMITED
2x350MW COASTAL THERMAL POWER PLANT DESIGN BASIS REPORT FOR
THAMMINAPATNAM, NELLORE, AP VENTILATION SYSTEM (Air Compressor,
Workshop, Store and Switchyard area)
The axial flow fan casing shall be of heavy gauge sheet construction and it shall be
spray or hot dip galvanized, properly reinforced for rigidity and shall be complete
with suitable supports

i) Access doors with suitable locking arrangement shall be provided in the casing
for easy access to the motor and impeller.

ii) Suitable motor brackets designed for rigid mounting of motors, shall be provided
for fans

b) Impeller

The axial flow fan impeller shall be of high efficiency aerofoil design. The blades
shall be mounted on a streamlined hub and the impeller shall be mounted directly
on the motor shaft. Final assembled fan motor unit shall be statically and
dynamically balanced.

c) Bearings:

The fan bearing may be ball, roller or sleeve bearings of self-aligning heavy duty
type with adequate capacity and life. Bearings shall be oil/grease lubricated and
provided with fittings for lubrication from outside and shall be located in easily
accessible position to facilitate maintenance.

d) Base Plate and Vibration Isolators

Base plate and vibration isolators, which may be double deflection rubber in shear
or rubber in compression type or spring type, shall be provided. With each fan
rubber bushes, washers wherever needed for vibration isolator in sufficient nos.
shall be included, as required, to ensure isolation of foundation from vibration of
equipment.

e) Inlet cones and Guards

Axial fan inlet cone shall be spun to have a smooth finish. Galvanized, square bird
screen shall be provided at the inlet.

f) Cowl

Rain protection cowls (outside) shall be designed to suit wall exhausters/supply fans
for protecting fans from rain. The cowls shall be provided with bird screen of heavy
gauge expanded metal netting.

377818980.doc IFIPL Page 8 of 16

 MEENAKSHI ENERGY PRIVATE LIMITED
2x350MW COASTAL THERMAL POWER PLANT DESIGN BASIS REPORT FOR
THAMMINAPATNAM, NELLORE, AP VENTILATION SYSTEM (Air Compressor,
Workshop, Store and Switchyard area)
g) Speed

The speed of axial flow fans shall not exceed 960 rpm for impeller dia exceeding
450 mm and shall not be greater than 1440rpm with impeller dia less than 450 mm.
However, for fans having static pressure of 30 mmWC or above, the speed of the
fan shall not exceed 1440 rpm for fan with impeller diameter of above 450 mm and
2800 rpm for fan with impeller diameter of 450 mm or less. The first critical speed of
rotating assembly shall be at least 25% above the operating speed.

h) Accessories

Accessories as required for satisfactory trouble free & safe operation of fans shall
be provided. For axial fans, necessary rain protection cowl, vibration isolators, bird
screens, etc, shall be provided.

6.2 Roof Ventilators, where applicable

The roof extractors shall be “COWL” type. Impeller shall be of axial flow type, cast
Aluminium in one piece and casing shall be heavy gauge sheet steel construction and
the same shall be spray or hot dip galvanized. In casing, access door with locking
arrangement be provided.

The cowl shall be designed for weather protection of the fan also inside of the roof on
which the extractor is installed. Galvanised bird screen be provided with the cowl. All
accessories, steel supports as required will be provided.

The speed of the fan is limited as per limitation given above for axial fans.

All accessories rain protection exhaust hood, transformation piece, vibration isolators,
steel supports vibration isolators, bird screen, etc. as required shall be provided.

6.3 Air Filters

a) Pre Filters

1) Filter medium:

i. Fibrous material (extruded polyethylene) or felt filter fabric; dry type with
element of 5 ply construction for Fabric type.

ii. V-fold galvanized wire mesh, inter spaced with a flat layer of galvanized wire
mesh for metallic type pre-filters.

2) Frame

GI sheet (minimum 18 gauge thick) or Aluminium alloy of (minimum 16 gauge)

supported by galvanised steel wire mesh of 10 mm square with handles.

377818980.doc IFIPL Page 9 of 16

 MEENAKSHI ENERGY PRIVATE LIMITED
2x350MW COASTAL THERMAL POWER PLANT
THAMMINAPATNAM, NELLORE, AP
3) Other requirements:
DESIGN BASIS REPORT FOR
VENTILATION SYSTEM (Air Compressor,
Workshop, Store and Switchyard area)

i. Suitable Aluminium spacers be provided for uniform air flow;

ii. Casing shall be provided with neoprene sponge rubber sealing.

iii. Capable of being cleaned by water flushing.

iv. Density of filter medium shall increase in the direction of air flow in case of
metallic filter.

4) Efficiency:

Average arrestance of 65-80% when tested in accordance with BS:

6540/ASHRAE – 52 - 76.

5) Location:

At the suction of each supply air fan

b) Fine Filters

1) Filter medium:

By pleating a continuous sheet of filter medium into closely spaced plates

separated by heavy corrugated aluminium spacers.

2) Frame:

Aluminium alloy of (minimum 16 gauge conforming to IS: 737) with handles.

3) Other requirements:

i. Suitable Aluminium spacers be provided for uniform air flow;

ii. Casing shall be provided with neoprene sponge rubber sealing.

iii. Capable of being cleaned by water flushing.

4) Efficiency:

Average arrestance of 80-90% when tested in accordance with BS:

6540/ASHRAE–52-76.

5) Location:

At the suction of each supply air fan

377818980.doc IFIPL Page 10 of 16

 MEENAKSHI ENERGY PRIVATE LIMITED
2x350MW COASTAL THERMAL POWER PLANT DESIGN BASIS REPORT FOR
THAMMINAPATNAM, NELLORE, AP VENTILATION SYSTEM (Air Compressor,
Workshop, Store and Switchyard area)
6.4 Ducting, where applicable
All duct work for ventilation system inclusive of accessories such as damper, vanes,
access doors, etc. will be fabricated from G.I sheets. All duct work will be properly
reinforced to prevent sagging, buckling or vibration. Interior of all ducts will be smooth
and free from obstruction.

The design air Velocity in any section of duct will not be exceeding 12.7 m/s. The
construction of ducts will conform to IS: 655.

All longitudinal joints for ventilation duct will be Pittsburgh Lock Seam type.

Transverse joints for the ventilation duct will be continuous around the four sides.

All joints, slips and seams will be made secure by riveting on centers. All construction
joints and seams will be reasonably sealed with suitable sealing compounds.

All main ductwork will be accessible throughout using fitted hinged access doors.

Canvas flexible connection will be provided at each connection between ductwork and
fan units to isolate vibration.

6.5 Hangers and Supports, where applicable

All ductwork will be provided with adequate hangers/supports to ensure rigid support and
to prevent vibration.

Hangers will be suspended from the ceiling by cinch anchor/expansion bolts.

All ducts running on the roof will be adequately fixed in position by angles. Ducts running
along the side walls will be supported by suitable steel membrane with expansion bolts.

6.6 Grilles, where applicable

All supply air grilles will have adjustable louver for desired spread and throw
requirement.

Maximum velocities shall not exceed 4m/s at grilles outlet.

The grille frame and louver shall be manufactured of at least 20SWG sheet and 22SWG
M.S. respectively.

All grilles shall be fitted with suitable gasket to prevent air leakage.

6.7 Gravity Operated Back Draft Dampers

Gravity operated back draft dampers (self-acting dampers) are provided to ensure
pressurization of the ventilated space. Dampers will be of gravity type designed such as
not to allow infiltration of air from outside. The louvers of the dampers will be freely

377818980.doc IFIPL Page 11 of 16

 MEENAKSHI ENERGY PRIVATE LIMITED
2x350MW COASTAL THERMAL POWER PLANT DESIGN BASIS REPORT FOR
THAMMINAPATNAM, NELLORE, AP VENTILATION SYSTEM (Air Compressor,
Workshop, Store and Switchyard area)
mounted on spindles to allow the damper to open freely with the pressure developed in
the premises. The damper will be provided with flange at inlet. The pressure inside the
ventilated space will be 2 - 3 mmWC above the atmospheric pressure.

6.8 Thermal and Acoustic Insulation, where applicable

The supply air duct that is exposed to direct sunlight shall be insulated with 50mm thick
(min.) resin bonded fibreglass wool / equivalent with aluminium cladding. The density of
insulation shall be 20 kg/m3 and the thermal conductivity shall be in the range of 0.043 –
0.049 w/m.k.

Acoustic insulation of 25 mm thick rigid fibre glass board covered with fibre glass tissue
sheet shall be provided on the inside of supply air ducting up to a distance of 5m from
supply air fans.

Thermal and acoustic insulation shall be done as per IS 8183.

The noise level will be equal to or less than 85 dBA at 1 meter distance from the
equipment.

7.0 Electrical Requirements

The ventilation system will be designed for operation on 415V ±10%, 50Hz, 3 Phase, 4
wire systems. Motors will be designed for a frequency variation of +/-5% and a combined
voltage & frequency variation of 10% absolute and will be designed to operate an
ambient temperature of 50°C.

The motor will be general purpose constant speed, squirrel cage three phase induction
type suitable for DOL start, energy efficient (>90% efficiency for motors above 30kW),
high power factor, low starting current, totally enclosed fan cooled type with IP-55
enclosure for both motor & terminal box. Motors installed in areas having inflammable
gases / battery room will be spark proof type.

The starting current with DOL starting inclusive of all tolerances will not be higher than
7.2 p.u.

The motor will be with sturdy cast iron body. All the motors offered will be suitable for S1
Continuous duty. All 415V motors will have class F insulation with the temperature rise
limited to class B as per IS:325.

The basis for motor ratings for maximum continuous motor ratings will be designed with
10% margin over maximum demand of the fan at the duty point input.

Space heater will be provided for motors rated at 30kW and above to maintain winding
temperature condition when motor is standstill.

377818980.doc IFIPL Page 12 of 16

 MEENAKSHI ENERGY PRIVATE LIMITED
2x350MW COASTAL THERMAL POWER PLANT DESIGN BASIS REPORT FOR
THAMMINAPATNAM, NELLORE, AP VENTILATION SYSTEM (Air Compressor,
Workshop, Store and Switchyard area)
Motor will be installed in such a way that the terminals box will be easily accessible for
cable connection, disconnection and maintenance job.

8.0 Operation and Control Philosophy

The fans (both supply and exhaust fans/roof ventilators) associated with mechanical
ventilation system shall be operated locally from the local starter panel.

Lamps shall be provided for indicating the status of fan operations (running/stop) in the
local panel.

Separate emergency local stop push button shall be provided for fans of Ventilation
system.

377818980.doc IFIPL Page 13 of 16

 MEENAKSHI ENERGY PRIVATE LIMITED
2x350MW COASTAL THERMAL POWER PLANT DESIGN BASIS REPORT FOR VENTILATION SYSTEM
THAMMINAPATNAM, NELLORE, AP (Air Compressor, Workshop, Store and Switchyard area)

Appendix 1 – Ventilation system sizing calculation

R
7

R
7
R
7

R
R
7
7

R
7

R
7

R
R 7
7

377818980.doc IFIPL Page 14 of 16

 MEENAKSHI ENERGY PRIVATE LIMITED
2x350MW COASTAL THERMAL POWER PLANT DESIGN BASIS REPORT FOR
THAMMINAPATNAM, NELLORE, AP VENTILATION SYSTEM (Air Compressor,
Workshop, Store and Switchyard area)

Appendix 2 – Heat Load details

377818980.doc IFIPL Page 15 of 16

 MEENAKSHI ENERGY PRIVATE LIMITED
2x350MW COASTAL THERMAL POWER PLANT DESIGN BASIS REPORT FOR
THAMMINAPATNAM, NELLORE, AP VENTILATION SYSTEM (Air Compressor,
Workshop, Store and Switchyard area)

Appendix 3 – Ventilation Air requirement as per Battery

Vendor
3.1 Switchyard Battery Room

377818980.doc IFIPL Page 16 of 16