Ref.

: GIL/Mktg/G/1789
Date : 01/06/2009

National Thermal Power Corporation Ltd.

4th Floor, Engineering office Complex,
Plot No. A-8A, Sector- 24,
Noida- 201301(UP)
Kind Attn : Mr. Atul Shrivastva – AGM & CTF (Jhajjar & Ennore)
Job : 6 Nos. IDCT for NTECL’s VALLUR TPP ( 3 x 500 MW)
Sub : Thermal Design & Hydraulic Design.
Ref : Your Transmittal no. CC:PE:0260:135:3533 Dt. 28.05.09
Dear Sir,
Please find attached herewith following for your scrutiny & approval.

Sr. NTPC / GIL Rev. Title of drg./doc. Earlier Purpose Remark

no. Drawing/Document No. No. Status s
1 0260-135-PVM-U-001 R2 Thermal design incl. R1 For --
GIL/TMS/873/CT/2 calculations for Air CAT- Approval
Pressure drop, Velocity IVR
Pressure Ratio alongwith
CT Performance Curve.

Thanking you and assuring you of our best services at all times.

In all faithfulness,
For Gammon India Limited

R. B. Sainani
GM – Mktg.

Digitally signed by
Sanjiv Mehrotra
Date: 2009.06.15
16:57:25
GMT+05:30
Reason: CAT IV
Location:
NTPCEOC
 SPECTRUM

NOTE ON THERMAL DESIGN AND HYDRAULIC CALCULATIONS

THERMAL
We had enclosed extracts of BS 4485 concerning Clause 8.7 that details the “Effect
of salinity on heat transfer” along with the thermal design calculations. It is clear from
Clause 8.7.2 that the changes in density (increases with salinity) and specific heat
(decreases with salinity) do not have an impact on the thermal design.

Further, Clause 8.7.3 recommends correction of vapour pressure using the “mole
fraction” that is dependent on salinity. This correction will reduce the vapour pressure
as it involves multiplication with the mole fraction, which is <1 for sea water. And this
corrected value of vapour pressure is to be used for calculating the enthalpies at the
inlet and outlet to determine the “mean driving force” available.

In view of the above recommendations in BS 4485, we had followed the design

procedure detailed there in. Hence, no correction to density and specific heat (Cp)
values need be made while calculating the heat load on the water side. The
correction to vapour pressure need only be applied on the air side to determine the
mean driving force that is reduced due to silinity. In fact not applying the density and
Cp corrections (on water side) and applying vapour pressure correction (on air side)
will result in a conservative design. This is the intension behind the codal
recommendation.

For the Vallur project, the comparison of both methods is as under:

Without Correction to Density & Cp With Correction to Density, Cp &
(Correction only to Vapour Pressure) Vapour Pressure

Water Flow 30,000 x 1,000 kg/hr 30,000 x 1,050 kg/hr (Density is as per
3,00,00,000 kg/hr 3,15,00,000 kg/hr tender. This is
high & incorrect)
Range 10.5oC 10.5oC

Cp 1 kcal/kg/oC 0.952 kcal/kg/oC

Heat Load(Hw) 3 x 107 x 10.5 x 1 3.15 x 107 x 10.5 x 0.952

3.15 x 108 kcal/hr 3.14874 x 108 kcal/hr

Heat of Evaporated
Water (He) Evaporation Loss
x t2 x Cp
(496013.4144 kg/hr
x 32.5 x 1)
16120435.97 kcal/hr
Evaporation Loss
x t2 x Cp
(496013.4144 kg/hr
x 32.5 x 0.952)
15346655.04 kcal/hr

(Hw+He) 3.15 x 108 + 16120435.97 3.14874 x 108 + 15346655.04

331120436 kcal/hr 330220655 kcal/hr

∆H (40.29 - 21.064) (40.29 - 21.064)

19.226 kcal/kg 19.226 kcal/kg
Dry Air Flow
‘G’ 1,72,22,688 kg/hr 1,72,22,688 kg/hr

Heat Load(Ha) 17222688 x 19.226 17222688 x 19.226

331123399.5 kcal/hr 331123399.5 kcal/hr
 SPECTRUM

As can be seen from the above, following BS 4485 recommendations result in a

conservative design.

Further, the water density of 1050 kg/m3 specified in the tender is incorrect as it does
not compare with the salinity levels given. For the design salinity level at 1.5 COC,
the water density is 1025 kg/m3 as per calculations. We have still followed the tender
specifications.

HYDRAULIC

Please note that friction loss is always attributed to head loss in straight pipes due to
friction. Head loss in valves and fittings is due to change in flow direction or velocity
and not due to friction. This is the reason why we had considered 10% margin on
friction losses, i.e. head loss through straight pipes. However, if we have to consider
10% margin on total head loss, it is still possible with a small modification in the
piping system to stay within the available pumping head limit of 13 mWC. But this will
be unnecessary margin as the friction loss in straight pipes is calculated using
William & Hazen’s formula, which is quite conservative (head loss is double)
compared to the more popular and common used Darcy & Weisbach method.

Anyway, to ensure that our designs are approved faster, we have considered 10%
margin on the total head loss. This will result in a pumping head of 13.05 mWC
instead of 13 mWC. To bring back the head to within 13 mWC, we have eliminated a
bend in the last header pipe (600 NB) that connects to the 600 NB riser (for the last
cell). The joint between the last header pipe and riser will be a ‘T’ instead of a bend
to save on head loss. We will provide a ‘blind flange’ at the end of the header. This
detail is shown in the revised sketch in the pumping head calculations page.
GAMMON SPECTRUM
IDCT Design Calculations [3x500 MW Vallur TPP of NTPC]

1 Design Requirements

Circulating Water Flow 30000 m3/hr

o
HWT 43 C
o
CWT 32.5 C
o
Inlet Design WBT 27.8 C
%
Relative Humidity 60
o
Range 10.5 C
o
Approach 4.7 C
Chlorides (as CaCO3) 36943.5 ppm @ 1.5 CoC
Pumping Head above FGL 13 mWC
Sill top above FGL 300 mm

2 Selected Data

Type of Tower IDCF with cells in-line

Type of Fill Slotted V bar
No. of Working Cells 8
Total no. of Cells per IDCT 9
Cell Length 14.3 m
Cell Width 21 m
No. of Air Inlets 2
Pumping Head above Sill 12.7 mWC
Friction Losses 1 mWC
Static Head above FGL 12 mWC max.
Top of Fill above FGL 10.7 m
Fill Height 5.4 m
Air Inlet top above FGL 5.3 m
Air Inlet Area per Cell 143 m2
Cell Area 300.3 m2
Water Loading Rate 12.48751 m3/hr/m2
Liquid to Gas Loading (L/G) 1.742
KaV/L 1.923
Dry Air Flow Rate (G) 598.01 kG/sec/cell

3 Thermal Calculations

Properties of Air Inlet [1] Outlet [2]

o
Wet_Bulb Temperature (wbt) C 27.8 40.41
o
Dry_Bulb Temperature (dbt) C 34.51 40.41
Relative Humidity (rh) % 60 100
Enthalpy (h) kCal/kG 21.064 40.29
Dry Air Density (⌠a) m3/kG 1.10550 1.04230
Moisture (w) kG/kG 0.0207 0.0495
Air mixture/vapour Density (⌠av) kG/m3 1.13320 1.0935

4 Air Flow and Pressure Drops

a Air Inlet
G 598.01 kG/sec/cell
Moisture in Inlet Air (w1) 0.0207 kG/kG
Air mixture/vapour Density at Inlet 1.1332 kG/m3
(⌠av1)
Air Flow through Air Inlet 538.6417 m3/sec/cell
Air Inlet Area 143 m2
Air Velocity through Inlet 3.767 m/sec
Pressure Drop through Air Inlet 1.8726 mmWC

b Fill
G 598.01 kG/sec/cell
Moisture in Air through Fill (w_avr) 0.0351 kG/kG (average)
Air mixture/vapour Density through Fill 1.11335 kG/m3 (average)
(⌠av_avr)
Air Flow through Fill 555.9798 m3/sec/cell (average)
Fill Area 300.3 m2
Air Velocity through Inlet 1.851 m/sec (average)
Pressure Drop through Fill + 6.837 mmWC
Distribution
GAMMON SPECTRUM
IDCT Design Calculations [3x500 MW Vallur TPP of NTPC]

c Distribution + Drift Eliminator (D/E)

G 598.01 kG/sec/cell
Moisture in Air through D/E 0.0495 kG/kG
Air mixture/vapour Density through 1.0935 kG/m3
D/E (⌠av2)
Air Flow through D/E 573.9474 m3/sec/cell
D/E Area 300.3 m2
Air Velocity through D/E 1.911 m/sec
Pressure Drop through D/E 0.903 mmWC

d Plenum/Fan Entry
G 598.01 kG/sec/cell
Moisture in Air through Plenum 0.0495 kG/kG
Air mixture/vapour Density through 1.0935 kG/m3
Plenum (⌠av2)
Air Flow through Plenum 573.947412 m3/sec/cell
Pressure Drop through D/E 0.581 mmWC

e Velocity Pressure through Fan

G 598.01 kG/sec/cell
Moisture in Air through Fan 0.0495 kG/kG
Air mixture/vapour Density through 1.0935 kG/m3
Fan (⌠av2)
Air Flow through Fan 573.947412 m3/sec/cell
Fan Diameter 10 m
Hub Diameter 2 m
Effective Area of Flow (A1) 75.408 m2 =(Fan Area - Hub Area)
Air Velocity through Fan 7.611 m/s
Velocity Pressure through Fan 3.229 mmWC Vp1

f Velocity Pressure through Stack

Exit
G 598.01 m3/sec/cell
Moisture in Air through Fan 0.0495 kG/kG
Air mixture/vapour Density through 1.0935 kG/m3
Fan (⌠av2)
Air Flow through Fan 573.947412 m3/sec/cell
Stack Diameter at Exit 11.133 m
Stack Area at Exit 97.363 m
Air Velocity through Fan 5.895 m2
Velocity Pressure through Stack 1.937 mmWC
Exit Vp2

g Velocity Recovery through Stack

Velocity Recovery 0.969 mmWC =(Vp1-Vp2)*0.75

h Fan Static Pressure

Static Pressure including recovery 9.225 mmWC =Pressure Drops (Air Inlet + Fill +
Distribution + Drift Eliminator + Plenum -
Velocity Recovery)

i Fan Total Pressure

Total Pressure 12.453 mmWC =Fan Static Pressure + Vp1

5 Check for Heat Balance (as per Clause 8.7 of BS 4485, Part 3 for "Effect of Salinity on Heat Transfer"
(Extract from BS 4485 attached)
Water Flow Rate (L) 31500000 kG/hr ⌠w = 1050 kg/m3 as per specs
o
Range (R ) 10.5 C (Actual⌠w for the design salinity is 1025 kg/m3)
G 17222688 kG/hr
Evaporation Loss (Ev) 496013.4144 kG/hr =G*(w2-w1)
Specific Heat of Water (Cp) 0.952 kCal/kG/oC
o
Cold Water Temperature (t2) 32.5 C
Heat Lost by circulating Water 330220655.04 kCal/hr =L*R*Cp+Ev*t2*Cp
Enthalpy of Air at Inlet (h1) 21.064 kCal/kG
Enthanpy of Air at Outlet (h2) 40.29 kCal/kG
Heat Gain by Air 331123399.488 kCal/hr =G*(h2-h1)
Heat Gain by Air ≥ Heat Lost by circulating Water
GAMMON SPECTRUM
IDCT Design Calculations [3x500 MW Vallur TPP of NTPC]

6 KaV/L Calculation as per Tchebycheff Method

(Standard International Psychrometric Equations are used for determining air properties)
L/G 1.742
o
Range 10.5 C
o
WBT 27.8 C
h1 88.64 kJ/kg
h2 = h1+L/G*Range*Cp 165.04 kJ/kg

T oC T in oK hw, kJ/kg ha, kJ/kg hw-ha 1/(hw-ha)

32.5 T2 305.65 h1 88.64
33.55 T2+0.1*Range 306.7 119.64 h1+0.1*L/G*Range*Cp 96.28 23.36 0.0428
36.7 T2+0.4*Range 309.85 140.44 h1+0.4*L/G*Range*Cp 119.20 21.24 0.0471
38.8 T1-0.4*Range 311.95 156.12 h2-0.4*L/G*Range*Cp 134.48 21.64 0.0462
41.95 T-0.1*Range 315.1 182.83 h2-0.1*L/G*Range*Cp 157.40 25.43 0.0393
43 T1 316.15 h2 165.04
KaV/L = Range/4*Σ1/(hw-ha)*Cp Σ1/(hw-ha) 0.1754
KaV/L Required = 1.923
KaV/L Provided = 1.923
KaV/L Provided ≥ KaV/L Required
GAMMON SPECTRUM

Hot Water Piping System for Vallur IDCTs Package

HW Duct

1600 dia. 600 dia. Risers

TP
2200 dia.
1600 dia.

Friction Loss Through Straight Pipes

Hazen & Willams Method

Dia Vel C S L Pd
2.2 2.193329 100 0.002299 2 0.004598
1.6 2.073381 100 0.003004 29 0.087118
1.6 2.073381 100 0.003004 13 0.039053
1.6 1.814208 100 0.002346 13 0.030497
1.6 1.555036 100 0.001763 13 0.022924
1.4 1.692556 100 0.002411 13 0.031340
1.4 1.354045 100 0.001595 13 0.020732
1 1.990446 100 0.004820 13 0.062656
1 1.326964 100 0.002275 13 0.029571
0.6 1.843005 100 0.007585 13 0.098603
0.6 1.843005 100 0.007585 11 0.083433
Total Friction Loss Thorough Straight Pipes 0.510523

Head Loss Through Valves & Fittings

as per Cranes'

TEE [Branch Flow; K=60f]

Flow [m3/s] Dia. [m] Vel [m/s] Vh [mmWC} f K Pd [mmWC]
1875 0.6 1.843005 0.173123 0.013229 0.793757 0.137417
0.137417
TEE [Flow thru Run; K=20f]
Flow [m3/s]
30000 2.2 2.193329 0.245193 0.010364 0.207282 0.050824
0.050824
WELDED ELBOWS [K=20f for 90Ɵ & 10f for 45Ɵ]
Flow [m3/s] Dia. [m] Vel [m/s] Vh [mmWC} f K Pd [mmWC]
15000 1.6 2.073381 0.219109 0.010973 0.219468 0.048087
1875 0.6 1.843005 0.173123 0.013229 0.264586 0.045806
0 0.6 0.000000 0.000000 0.013229 0.264586 0.000000
15000 1.6 2.073381104 0.219108522 0.0109734 0.109734 0.024044
0.11794
REDUCERS [theeta=15 deg]
d1 [m] d2 [m] K2 V1 [m/s] V2 [m/s] mmWC Pd [mmWC]
2.2 1.6 0.175898 2.073381 1.096664 0.061298 0.010782
1.6 1.4 0.041768 2.031067 1.555036 0.123249 0.005148
1.4 1 0.196557 1.990446 1.015534 0.052564 0.010332
1 0.6 0.515865 1.843005 0.663482 0.022437 0.011574
0.037836
B/F Valves [K=20f] as per Manufacturer
Flow [m3/s] Dia. [m] Vel [m/s] Vh [mmWC} f K Pd [mmWC]
15000 1.6 2.071496 0.218710 0.010973 0.219468 0.048000
1875 0.6 1.841330 0.172808 0.013229 0.264586 0.045723
0.093722
Discharge Losses 0.9 0.818369 0.003793 0.003793

Friction Loss Through Straight Pipes 0.510523

Head Loss Through Valves & Fittings 0.441530
10% Margin on Losses (friction+head loss) 0.09521
Total Pressure Loss Through Straight Pipes, Valves & Fittings 1.047258

Static Head Requirement

Sill above FGL 0.3 mWC
Air Inlet Height 5 mWC
Fill Height 5.4 mWC
Bottom of Pipe level above Fill top 0.7 mWC
Head required for distribution system 0.55 mWC
Total Static Head Required 11.95 mWC
Total Pressure Loss Through Straight Pipes, Valves & Fittings 1.047 mWC
Total Pumping Head Required 12.997 mWC
GAMMON 3x500 MW VALLUR TPP Design Data: Range=10.5oC
Approach = 4.7oC
L/G = 1.742
KaV/L = 1.923

TOWER CHARACTERISTIC CURVE

10
KaV/L

0.1
0.1 1 10
L/G
GAMMON SPECTRUM

Performance Curves
90% Water Flow

35

34

33

32

31
CWT(deg.C)

30

29

28

27

26

25
20 21 22 23 24 25 26 27 28 29 30
Ambient WBT(deg.C)

8.4R 10.5R 12.6R

GAMMON SPECTRUM

Performance Curves
100% Water Flow

35

33
CWT(deg.C)

31

29

27

25
20 21 22 23 24 25 26 27 28 29 30
Ambient WBT(deg.C)

8.4R 10.5R 12.6R

GAMMON SPECTRUM

Performance Curves
110% Water Flow

37

35

33
CWT(deg.C)

31

29

27

25
20 21 22 23 24 25 26 27 28 29 30
Ambient WBT(deg.C)

8.4R 10.5R 12.6R