BHEL point wise replies to NTPC comments
Sl.
NTPC Comments
No.
NTPC DRAWING NO: 9591-102-102-PVM-U-004
Vendor Drawing No: Null
Revision: 03
Drawing Title: DUCT DESIGN DATA & CALCULATION
Replies to NTPC Comments -Sheet 6 of 12: DUCT DESIGN DATA SHEET – GAS SYSTEM
1. As the size of the economizer bypass duct
is becoming too large and unit will not be
operating at 40% TMCR on regular basis,
so the economizer bypass duct shall be
designed for 50% TMCR for DC/BC/WC
whichever gives maximum flue gas flow.
Further care should be taken that at 50%
TMCR load condition with economizer
bypass damper full open, pressure drop
through the bypass duct should be such
that the desired flow can be achieved. To
obtain the desired economizer bypass
flow if some change in flue gas velocity
is required to limit the pressure drop,
same can be done.
Sheet 7 of 12 : DUCT DESIGN DATA SHEET –SCR AND FGD SYSTEM
2. Duct D2 shall be sized for 50% BMCR
load condition for DC/WC/BC whichever
gives maximum flue gas flow.
3. Duct D7A is the duct upto FGD bypass
damper and flue gas temp for this duct
shall be considered as 132 deg C.
4. Duct D7B is the duct from FGD bypass
damper to chimney. Flue gas temp for this
duct shall be considered as 55 deg C.
Please furnish the Duct D7B and D8
5. material separately to protect it from
corrosion.
6. Please revise schematic of Gas duct to
FGD accordingly.
BHEL Reply
Eco Bypass duct has been resized with an area of
15Sqm total (as per further discussions and decision
from NTPC vide email dt. 18-May-2017)
Eco bypass duct is sized for 320deg C at 50% and
above loads and to maintain 290 deg C at SCR inlet at
40% TMCR DC load.
Also NTPC to note that no control damper has been
provided at economizer outlet.
HPOUT condition is not considered as per NTPC’s
previous comments.
As per discussion with NTPC Dt.18-May-2017, ducts
D2, D5 have been sized for 50% BMCR WC and ducts
G2/D1 is sized for 60% BMCR WC. Also SCR bypass
duct (D4) has been sized for BMCR DC inline with
NTPC previous comments.
NTPC requirement incorporated, Duct D7B resized for
55 deg C.
Digitally signed
Signature Not Verified
by deepak jindal
Date: 2017.05.24
15:30:16 IST
Reason: CAT I
Location:
NTPCEOC
6mm Carbon steel duct has been provided.
Schematics revised as per NTPC comments.
pg. 1 of 2
Clarification on G1 duct from Economiser:

G1 DUCT

Yellow colour duct –G1 (single duct from economizer outlet) splits into two ducts G2/D1

pg. 2 of 2
 NTPC DRG. No.: 9591-102-102-PVM-U-004
JOB NO: NTPC LIMITED
STATUS: CONTRACT NTPC/TELANGANA SUPER THERMAL POWER PROJECT Phase-I
DISTRIBUTION 2 x 800 MW
STEAM GENERATOR ISLAND PACKAGE
TO Dept Name Sign Date
Code
No. of DRN
REV. Date ALTD CHD APPD BHARAT HEAVY ELECTRICALS LTD. DESN VRK/SKD -sd- 18.05.17
Feb VRK/ PVP BMM/ UNIT : HIGH PRESSURE BOILER PLANT
02 2017 SKD GV
CHD PVP -sd- 18.05.17
April VRK/ PVP BMM/ TIRUCHIRAPPALLI – 620 014
03 2017 SKD GV
APPD BMM/GV -sd- 18.05.17
May VRK/ PVP BMM/
04 2017 SKD GV
Revised Inline with NTPC TITLE
Comments. DUCT DESIGN DATA AND CALCULATIONS

DEPT. SCALE DRAWING NO.

SIGN.
DATE. SHEET 1 OF 12 REV 04
CAUTION: THIS DRAWING IS THE PROPERTY OF BHARAT HEAVY ELECTRICALS LTD., AND IS NOT TO BE REPRODUCED OR USED TO FURNISH ANY
INFORMATION FOR MAKING OF DRAWINGS OR APPARATUS EXCEPT WHERE PROVIDE FOR AGREEMENT WITH SAID COMPANY.
 DUCT DESIGN CRIT ERIA

PRIMARY AIR SYSTEM SECONDARY AIR SYSTEM FLUE GAS SYSTEM

Load/COA L BMCR- 60%BMCR- BMCR- 60%BMCR- BMCR 60%BMCR-
Worst Coal Worst Coal - Best Coal Best Coal - Worst Coal Worst Coal -
Single stream Single stream single stream

Selection Criteria (1) (2) (3) (4) (5) (6)

1 Ambient Conditions 27 oC / 60%RH 27 oC / 60%RH 27 oC / 60%RH 27 oC / 60%RH 27 oC / 60%RH 27 oC / 60%RH

2 Excess Air (%) 25 20 25 21.6 25 20

3 Furnace Leakage (t/h) - - 150.0 150.0 - -

4 APH Leakage (t/h) 278 132 228 30 417 132

Customer / Plant : NTPC / TELANGANA STPP, 2 x 800 MW

Engineer VRK/SKD Title : Duct Design Data and Calculations
Reviewer PVP Dwg. No.: 9591-102-102-PVM-U-004
Approver BMM/GV Sheet 2 of 12 Rev. 04
 DUCT DESIGN CRIT ERIA

SCR bypass Ducts

Load/COA L BMCR-
Design Coal

Selection Criteria (7)

1 Ambient Conditions 27 oC / 60%RH

2 20
Excess Air (%)

3 Furnace Leakage (t/h) 150.0

Customer / Plant : NTPC / TELANGANA STPP, 2 x 800 MW

Engineer VRK/SKD Title : Duct Design Data and Calculations
Reviewer PVP Dwg. No.: 9591-102-102-PVM-U-004
Approver BMM/GV Sheet 3 of 12 Rev. 04
 DUCT DESIGN DAT A SHEET - PRIM ARY AIR SYST EM

Selection
min. area
Flow per

per duct
Temper-

Velocity
Density

Volume

Sheet 2
Criteria
as per
Mass

ature
Duct
Item
Description

o
kg/h C kg/m3 m3/s m/s m2
Cold air to each PA fan P1 799000 27 1.149 193.2 16 12.1 2
PA outlet to AH P2 799000 35 1.119 198.3 16 12.4 2
Cold PA interconnection P3 799000 35 1.119 198.3 16 12.4 2
Hot air from each AH to hot air bus duct P4 632000 291 0.613 286.4 16 17.9 2
Hot air bus duct P5 527000 291 0.613 238.8 16 14.9 2
Hot air bus duct – Right (4 mills side) P6-A 399000 323 0.578 191.8 16 12.0 1
Hot air bus duct – Left (5 mills side) P6-B 498000 323 0.578 239.3 16 15.0 1
Cold air bus duct – Right (4 mills side) P7-A 154000 35 1.119 38.2 16 2.4 BMCR BC
Cold air bus duct – Left (5 mills side) P7-B 192000 35 1.119 47.7 16 3.0 BMCR BC
Cold air to each mill (tempering air) P8 34000 35 1.119 8.4 16 0.5 BMCR BC
Hot air to each mill P9 100000 323 0.578 48.1 16 3.0 1
Mixed air to each mill P10 112000 291 0.613 50.8 16 3.2 2

Customer / Plant : NTPC / TELANGANA STPP, 2 x 800 MW

Engineer VRK/SKD Title : Duct Design Data and Calculations
Reviewer PVP Dwg. No.: 9591-102-102-PVM-U-004
Approver BMM/GV Sheet 4 of 12 Rev. 04
 DUCT DESIGN DAT A SHEET - SECONDA RY AIR S YST EM

min. area per

Temperature
Mass Flow

Selection
per Duct

Velocity
Density

Volume

Sheet 2
Criteria
as per
duct
Item
Description

o
kg/h C kg/m3 m3/s m/s m2

4
Air to each FD Fan S1 1382000 27 1.149 334.1 16 20.9

4
FD outlet to AH S2 1382000 30 1.137 337.6 16 21.1

4
Sec. air SCAPH bypass duct S3 1382000 30 1.137 337.6 16 21.1

4
Hot secondary air from each AH to cross over S4 1352000 296 0.606 619.7 16 38.7

S5 3
Hot secondary air from cross over to WB Conn. Duct 1030000 327 0.578 494.6 16 30.9
S6
4
Cold secondary air interconnection S7 1382000 30 1.137 337.6 16 21.1

3
Hot secondary air interconnection S8 1030000 327 0.578 494.6 16 30.9

SO- 3
SOFA DUCTS 128875 327 0.578 62.4 16 3.9
1

Customer / Plant : NTPC / TELANGANA STPP, 2 x 800 MW

Engineer VRK/SKD Title : Duct Design Data and Calculations
Reviewer PVP Dwg. No.: 9591-102-102-PVM-U-004
Approver BMM/GV Sheet 5 of 12 Rev. 04
 DUCT DESIGN DAT A SHEET – GAS SYST EM

Temperature
Mass Flow

Selection
min. area
per Duct

per duct
Velocity
Density

Volume

Sheet 2
Criteria
as per
Item
Description

kg/h o
C kg/m3 m3/s m/s m2
Gas duct from Economiser G1 3471000 355 0.542 1778.9 13 136.8 5

Eco. to MDC tap-off G2/D1 2186000 321 0.573 1059.7 13 81.5 6

Gas duct from AH G3 2318000 130 0.842 764.7 13 58.8 6

Interconnection before ESP G4 2318000 130 0.842 764.7 13 58.8 6

Gas Duct to ESP G5 772667 130 0.842 254.9 13 19.6 6

Gas Duct to ESP G6 387000 130 0.842 127.7 13 9.8 6

Gas Duct from ESP G7 387000 130 0.842 127.7 15 8.5 6

Gas Duct from ESP G8 772667 130 0.842 254.9 15 17.0 6

ESP Outlet bus G9 2318000 130 0.842 764.7 15 51.0 6

Gas to ID fan G10 2318000 130 0.862 747.0 15 49.8 6

ID Fan discharge duct G11 2318000 130 0.862 747.0 15 49.8 6

Common Duct to Chimney G12 3888000 132 0.858 1258.7 15 83.9 5

Customer / Plant : NTPC / TELANGANA STPP, 2 x 800 MW

Engineer VRK/SKD Title : Duct Design Data and Calculations
Reviewer PVP Dwg. No.: 9591-102-102-PVM-U-004
Approver BMM/GV Sheet 6 of 12 Rev. 04
 DUCT DESIGN DAT A SHEET –SCR AND FGD S YST EM

Temperatu

Selection

Sheet 2&3
min. area
Flow per

per duct
Velocity
Density

Volume

Criteria
as per
Mass

Duct
Item

re
Description

kg/h o
C kg/m3 m3/s m/s m2
Eco. to MDC tap-off D1/G2 2186000 321 0.573 1059.7 13 81.5 6
MDC inlet duct D2 1735500 355 0.542 889.5 13 68.4 5
Economiser Bypass Duct # D3 179000 387 0.513 96.9 13 7.5 40% TMCR DC
SCR Bypass Duct D4 1639500 351 0.545 835.6 13 64.3 7
SCR Outlet to Airheater Duct D5 1735500 355 0.542 889.5 13 68.4 5
FGD System Ducts*
Duct to FGD D6 3888000 132 0.858 1258.7 15 83.9 5
Common Duct to Chimney (upto FGD 5
D7-A 3888000 132 0.858 1258.7 15 83.9
bypass damper)
Common Duct to Chimney (After FGD As per MOM dtd
bypass damper to chimney) D7-B - 55 1.059 1100 15 73.3 28-29.04 &
06.05.2016
Duct from FGD As per MOM dtd
D8 - 55 1.059 1100 15 73.3 28-29.04 &
06.05.2016

* FGD is in NTPC scope hence ducts are sized inline with NTPC comments. # - Based on email Dt.18-May-2017 from NTPC.

Customer / Plant : NTPC / TELANGANA STPP, 2 x 800 MW

Engineer VRK/SKD Title : Duct Design Data and Calculations
Reviewer PVP Dwg. No.: 9591-102-102-PVM-U-004
Approver BMM/GV Sheet 7 of 12 Rev. 04
Customer / Plant : NTPC / TELANGANA STPP, 2 x 800 MW
Engineer VRK/SKD Title : Duct Design Data and Calculations
Reviewer PVP Dwg. No.: 9591-102-102-PVM-U-004
Approver BMM/GV Sheet 8 of 12 Rev. 04
Customer / Plant : NTPC / TELANGANA STPP, 2 x 800 MW
Engineer VRK/SKD Title : Duct Design Data and Calculations
Reviewer PVP Dwg. No.: 9591-102-102-PVM-U-004
Approver BMM/GV Sheet 9 of 12 Rev. 04
Customer / Plant : NTPC / TELANGANA STPP, 2 x 800 MW
Engineer VRK/SKD Title : Duct Design Data and Calculations
Reviewer PVP Dwg. No.: 9591-102-102-PVM-U-004
Approver BMM/GV Sheet 10 of 12 Rev. 04
Customer / Plant : NTPC / TELANGANA STPP, 2 x 800 MW
Engineer VRK/SKD Title : Duct Design Data and Calculations
Reviewer PVP Dwg. No.: 9591-102-102-PVM-U-004
Approver BMM/GV Sheet 11 of 12 Rev. 04
Customer / Plant : NTPC / TELANGANA STPP, 2 x 800 MW
Engineer VRK/SKD Title : Duct Design Data and Calculations
Reviewer PVP Dwg. No.: 9591-102-102-PVM-U-004
Approver BMM/GV Sheet 12 of 12 Rev. 04