Professional Documents
Culture Documents
by C J GUPTA
Date: 2009.09.14
10:28:14
GMT+05:30
Reason: CAT I
Location:
NTPCEOC
NTPC Drawing no 0330-155-PVM-U-037 Rev 3
Customer: APCPL Contractor : TRF Ltd
Design Basis Report for Dust Extraction System (Wet) for Coal Crusher House
Indira Gandhi Super Thermal Power Project
Reference: i) GA of Crusher House
SYSTEM DESCRIPTION
Venturi Scrubber type’s wet dust collection system shall be provided at Crusher House for extracting the dust
From Vibrating Screen and Shuttle Conveyors.
The systems shall operate on the principle of dust laden air with water by collision in the Venturi throat
forming a mass of larger particles and separate along in the form of slurry. The mist eliminator is provided
after the Venturi Scrubber for moisture entrainment which allows the fresh air to get escaped through the
Fan and fan exhaust duct. A water seal tank is provided below for proper sealing of the system. The
Centrifugal Fan creates a high suction through the Venturi collects the dusts from dust generation points (in
this case Vibrating Grizzly Feeder and receipt of Shuttle Conveyors) through a duct network. The dust laden
air comes in contact with water in the Venturi and encounter collision while passing through a throat
(reduced area). The pressure drop across the Venturi throat is directly proportional with the cleaning
efficiency.
The slurry is taken into a pit where the dust gets settled at the bottom and clear water over flows under
normal sedimentation process. The clear water is taken into the common pond (Client) through a surface
drainage system.
This particular system shall cover the Crusher House Dust Extraction system at EL+4.000 & EL +21.000
Levels, i.e Shuttle Conveyor and Vibrating Screen respectively. The Conveyor 1A/1B and 2A/2B shall be
covered under Dry Fog system.
The Venturi Scrubber units along with Fans and other accessories shall be located at the ground floor beside
conveyor 2A/2B as shown in the sketch. There will be a provision of twin unit dedicated for individual system. Around
16 m x 16 m is envisaged for the entire units. The duct shall be entered into the building at EL+4.000 level and
ranch out two separate ducts to cover the Shuttle Conveyors as shown in the sketch.
The main duct shall enter into the Floor at EL+15000 Level and run along the roof up to the cutout already
made available as shown. The riser duct will come to next level of EL+21.000 and cater all the Vibrating Screen
as shown in the sketch. By this way the fouling with monorail can be avoided.
The Velocity considered in the main duct as 15 to 21 m/sec and Suction Hood face velocity as 1.5 – 2.0 m/sec.
Necessary dampers shall be provided along with the hood for balancing and isolation purpose.
Fan would be with inlet damper, Flexible connection and necessary drive arrangement. The Fan exhaust
duct shall be up to a suitable height with canopy.
The Venturi would be with designed water quantity with Pipes, Valves and spraying arrangement with suitable nozzles.
The Nozzles shall be located on the ring uniformly in order to generate full water coverage in the throat of the
Venturi. Venturi throat shall have necessary throttling arrangement for creating the required pressure drop across the
Venturi. The system i.e. Fan shall be interlocked with the Conveyor drive. Depending on the loading of the
Conveyor, the control signal shall go to the Fan Motor to start.
__________________________________________________________________________________________________
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1
NTPC Drawing no 0330-155-PVM-U-037 Rev 3
Customer: APCPL Contractor : TRF Ltd
EXTRACTION AIR VOLUME CALCULATION
Please note that all equipment vig. C-1A/1B, VGS-1, 2, 3, 4; CR-1, 2, 3, 4; Sc-1, 2, 3, 4; and C-2A &
2B shall be working simultaneously as per operational sequence.
1.4 Work Zone dust 2 mg/m3 and or less at 2 m away from suction
level: hood, over ambient dust level, when both material
handling and DE system working
2
NTPC Drawing no 0330-155-PVM-U-037 Rev 3
Customer: APCPL Contractor : TRF Ltd
Material Handling Equipment vis – s – vis Fugitive Air Hoods
Volume Calculation
Extraction Air Volume shall be 58,300 m3/hr for one (1) Stream of
operation.
DUCTWORK:
Duct work have been designed based on 15 to 18 M/sec velocity considering the
extraction air volume flow rate manually operated dampers (MOD) have been provided
3
NTPC Drawing no 0330-155-PVM-U-037 Rev 3
Customer: APCPL Contractor : TRF Ltd
WATER SYSTEM :
Air volume flow rate for the system is 58,300 M³/HR with approx. 7% solid contents.
Based on scrubber efficiency of 95% dust elimation up to 10microns water qty. for
circulation.
Bleed water qty. shall be 12% of 90 m³/hr that is , 10.8m³/hr , say 11.0 m³hr.
Evaporation and drift loss shall be approx 3% of 90m³/hr that is 2.7m³/hr say
3.0 m³/hr.
Hence make up water qty. shall be approx (11+3.0)=14.0 m³/hr witch has to be provided
4
NTPC Drawing no 0330-155-PVM-U-037 Rev 3
Customer: APCPL Contractor : TRF Ltd
TECHNICAL DATA OF EQUIPMENT
1.3 MOC :
a) Inlet : SS 304 / 5 mm thk.
b) Pipe deck assly Ceramic coated 50 NB Pipes
c) Flooded Elbow : IS: 2062, 5 mm thk.
d) Cyclonic Scrubber : IS: 2062, 5 mm thk.
1.4 Scrubbing liquid (water) qty., 90.0 m3/hr
1.5 Make up liquid 14.0 m3/hr
5
NTPC Drawing no 0330-155-PVM-U-037 Rev 3
Customer: APCPL Contractor : TRF Ltd
4.0 ID FAN
Make FLAKT
Duty : To suck clean gas through Scrubber
Location : After Scrubber
Air volume Flow rate : 62000 m3/hr
Total Static pressure : 500 mm WG at 45oC
550 mm WG at 20oC
Location : Outdoor
Total Efficiency : Up to 82%
Operating speed : 965 RPM
Shaft power consumption (at 115 kW (approx.)
operating temp. 45oC) :
Motor rating : 132 kW / 6 Pole
MOC :
6
NTPC Drawing no 0330-155-PVM-U-037 Rev 3
Customer: APCPL Contractor : TRF Ltd
Painting As per NTPC spec.
6.0 PIPE WORK
Size : As per flow rate
MOC : IS : 1239, Carbon Steel, ERW,
Medium
Valves : Gate valves, Non Return valves of CI
construction.
Where Q is the flow rate, m³/hr.; A is the area of pipe (in final), M2; V is the fluid velocity inside the
pipe, M/S.
7
NTPC Drawing no 0330-155-PVM-U-037 Rev 3
Customer: APCPL Contractor : TRF Ltd
ANNEXURE –1
(c) Under size / sized material. Size range in mm (Avg) from VGS : (-) 20 mm
2nd paragraph states “Note that very dry or dusty material may require flow rates
1.5 to 2.0 times these values”.
Multiplying factor of 1.5 have been considered for dry & dusty nature of material factor
i.e. coal.
However, the material transfer above 1.0 M fall, we have considered additional hoods
(H7A, H7A’, H8A, H8A’), as per guidelines of ACGIH (VS-50-20, Pg. 10-70).
NOTE :- Relevant pages of ACGIH photocopy attached.
8
NTPC Drawing no 0330-155-PVM-U-037 Rev 3
Customer: APCPL Contractor : TRF Ltd
The Coal Handling Package have two (2) Nos. COAL HANDLING CIRCUITS viz. starting with
Conveyor – 1A or 1B and ending with Conveyor – 2A or 2B respectively.
Individual Dust Extraction and Treatment System (DETS) for each Coal Circuit have been
provided, viz. DE-1 and DE-2.
DETS hoods have been provided for Vibrating Grizzly Screen and Shuttle Conveyors, viz. on
equipment VGS-1/2, SC-1/3 and SC-1/3 (disch. end), for DE-1 and similarly for equipment
VGS-3/4, SC-2/4 and SC2/4 (disch. end) for DE-2.
Same concept shall be followed for both the Circuits of Coal Handling Package, starting
through Conveyor – 1A or 1B, with option of VGS – 1 OR 2 / VGS – 3 or 4 operation etc as
well as operation of SC – 1 or 2 / SC – 3 or 4, and C – 2A or C – 2B for proper operational
synchronization.
9
NTPC Drawing no 0330-155-PVM-U-037 Rev 3
Customer: APCPL Contractor : TRF Ltd
Both Coal Handling Circuits shall work at a time or can work together.
Select the coal handling circuits, starting with Conveyor – 1A or Conveyor – 1B with option of
VGS and downstream conveyors. Start the ID Fan of respective DE system, viz. DE-1 or DE-
2 with inlet damper full open.
Start the Material Handling system, as selected for operation. Start the Recirculating Water
Pump. Check the valve GV-1, GV-3 and GV-4 is open with Bleed on. Also please check that
GV-7, Make up water is on. If level switch signals “LOW” – pump will stop.
10
NTPC Drawing no 0330-155-PVM-U-037 Rev 3
Customer: APCPL Contractor : TRF Ltd
3. SLURRY DISPOSAL
Slurry, as generated, from the operation of SCRUBBER shall be collected in
3
RECIRCULATION TANK (RT) of approx. 10 m cap. RT have two compartments. One
compartment is for suction of Recirculation Water Pump and the other compartment is for
Slurry Water, which needs to be periodically disposed off through TIMER CONTROL VALVE
(Y-103) on to SETTLING TANK, at ground level.
Function of SETTLING TANK is to give time for settlement of heavy dust of slurry water at
bottom and the water to flow at top.
The water with fine coal particles coalesced shall be drained out, by overflowing, to nearest
surface drain.
The slurry shall be removed from Settling Tank bottom, by scrapping it with shovel, manually,
once in a week,.
The slurry, as collected, shall be dried for reuse or mix with plant ash for further treatment.
11
NTPC Drawing no 0330-155-PVM-U-037 Rev 3
Customer: APCPL Contractor : TRF Ltd
12
NTPC Drawing no 0330-155-PVM-U-037 Rev 3
Customer: APCPL Contractor : TRF Ltd
13
NTPC Drawing no 0330-155-PVM-U-037 Rev 3
Customer: APCPL Contractor : TRF Ltd
Clarification on Water Circulation Rate and Bleed Water quantity (Ref. pf. 4.0 of DBR – Pg. 4 of 15)
Hence, it translates that 2 M3/Hr Water circulation rate of 1700 M3/Hr circulation
rate of 1700 M3/Hr dedusting volume flow rate need to be considered (MKS
system), which is equal to 1.2 M3/Hr per 1000 M3/Hr dedusting volume flow
rate.
Further to limit the 3% solid content in Recirculation Air qty. (being pumped), a
factor of 1.3 (In-house design norms) to be applied over. 1.2 M3/Hr water
circulation pumping rate, i.e. (1.2 x 1.3) = 1.56 M3/Hr (12 GPM/1000 CFM).
Again for similar application, Bleed Water flow rate shall be 12% of Water
Circulation rate i.e., 90 x 0.12 = 10.8 M3/Hr. This NORMS are also In House
Design norms based on similar application.
Hence, Make Up Water quantity shall be sum of Bleed Water qty. and
Evaporation of Drift loss i.e., (11 + 3 ) = 14.0 M3/Hr.
14
NTPC Drawing no 0330-155-PVM-U-037 Rev 3
Customer: APCPL Contractor : TRF Ltd
Hence, 2 M3 dust have to be removed, to keep to solid ratio limited to 3%. Pinch valve
operation of 5 min. for every 30 minutes. Remove approx. 3M3 slurry of which approx. solid
content is 50% i.e. 1.5 M3 solid is removed for every 30 minutes. Thus for 1 hour of
system, approximately 6M3 slurry with solid content of 3M3 is discharge to settling tank.
Hence, effectively less than 3% in recirculating water is maintained.
Further approximately 12% of pump flow rate is discharged as bleed off tapping approx. 11.0
M3 /Hr from Recirculating Tank, thus keeping the solid content well below 3% ie., 2.65%.
Considering 3% of recirculating water quantity ((90 M3 /Hr.) i.e. 2.7 M3 /Hr. and 11.0 M3
/Hr., make up water quantity of (11 + 2.7) = 13.7 ~ 14 M3 /Hr. Shall be augmented.
15
PRESSURE DROP CALCULATION FOR DE SYSTEM
DE-1 SYSTEM REV.:- 2
Zone Air Qty Dia Velocity St.Run Entry Bends (Deg) Equiv. Equiv. Total Loss Of Run 1VP Hood Damper Static Gov. Remark
(Cm/hr (MM (M/S) (M) (Deg) length length length per Suct Loss Press. Press
) of of (M) M (1.25V (0.25 VP) (WG) (WG)
entry bend P)
H1-D 4000 280 18.04 4.33 1-30° 2-90°,1-30° 2.80 14.72 21.85 1.10 24.04 24.04
H2-D 4000 280 18.04 0.50 0.50 1.10 0.55 0.55 24.04
H3-D 4000 280 18.04 2.96 1-30° 1-90°,1-60° 2.80 9.90 15.66 1.10 17.23 17.23
D-C 12000 485 18.04 8.47 1-30° 1-90°,1-60° 5.40 20.80 34.67 0.70 24.27 19.95 24.93 4.99 54.19 78.23
H7-B 14500 530 18.26 25.41 4-90°,1-60° 64.40 89.81 0.60 53.89 20.42 25.53 5.11 84.52 84.52
H1'-A 4000 280 18.04 5.07 1-30° 2-90°,1-30° 2.80 14.72 22.59 1.10 24.85 24.85
H2'-A 4000 280 18.04 1.10 1.10 1.10 1.21 1.21 24.85
H3'-A 4000 280 18.04 3.70 1-30° 1-90°,1-60° 2.80 9.90 16.40 1.10 18.04 18.04
A-B 12000 485 18.04 6.35 1-30° 1-90°,1-60° 5.40 20.80 32.55 0.70 22.79 19.95 24.93 4.99 52.70 70.74
B-C 26500 720 18.08 8.29 8.29 0.45 3.73 3.73 88.25
H8-E 14500 530 18.26 21.36 3-90°,1-60° 50.40 71.76 0.60 43.06 20.42 25.53 5.11 73.69 73.69 88.25+9.04=97.29
C-E 38500 870 17.99 4.13 1-30° 1-60° 11.00 15.00 30.13 0.30 9.04 9.04 UP TO E PR.DROP
97.29
E-SCRUB 53000 1020 18.02 51.08 3-90°,2-30°,2-45° 147.20 198.28 0.25 49.57 49.57 146.86 97.29+49.57=146.86