TABLE OF CONTENT

SL. NO DESCRIPTION PAGE NO.

1 PURPOSE AND SCOPE 4
2 DESIGN INPUT 4
3 ASSUMPTIONS 4
4 METHODOLOGY AND ACCEPTANCE CRITERIA 5
5 CALCULATIONS 5
6 RESULTS 5
7 REFERENCES 5
8 ATTACHMENTS 5
1.0 PURPOSE AND SCOPE
1.1
1.2
1.3
1.4
2.0 DESIGN INPUT
Value Unit Reference
2.1 2 nos. 7.2
2.2 2 nos. 7.3
2.3 1 nos. 7.3
2.4 2 nos. 7.3
2.5 2 nos. 7.3
2.6 1 % 7.3
2.7 80 % 7.3
2.8 72 hrs 7.3
2.9 2 nos. 7.2
2.10 2000 cum 7.2
2.11 2 nos. 7.2
2.12 1000 cum 7.2
2.13 2 nos. 7.3
2.14 1 nos. 7.3
2.15 3 nos. 7.3
2.16 2 nos. 7.3
3.0 ASSUMPTIONS (UV - Unverified , V - Verified, J - Engineering Judgment)
3.1 ASSUMPTIONS FOR DM MAKE UP REQUIRED DURING NORMAL OPERATION
3.1.1 2010 T/hr HBD
3.1.2 5 cum/hr UV
3.1.3 5 cum/hr UV
3.1.4 500 cum UV
3.1.5 7 days UV
3.1.6 4 nos. UV
3.1.7 1 cum/hr UV
3.1.8 50 cum/cycle UV
3.1.9 24 hrs UV
3.1.10 General margin on pump capacity for design purpose 10 % J
3.2 ASSUMPTIONS FOR BOILER CLEAN UP PROCESS DURING COMMISSIONING
3.2.1 15 % UV
3.2.2 3 hrs UV
3.2.3 21 hrs UV
3.3 ASSUMPTIONS FOR BOILER STEAM BLOWING PROCESS DURING COMMISSIONING
3.3.1 40 % UV
3.3.2 3 minutes UV
3.3.3 20 nos. UV
3.3.4 5 % UV
3.3.5 14 hrs UV
3.4 ASSUMPTIONS FOR BOILER COLD START UP PROCESS
3.4.1 15 % UV
3.4.2 5 hrs UV
3.4.3 10 hrs UV
3.4.4 600 cum UV
Total no. of MB feed pump
Total no. of working MB feed pump
Total no. of RO-II feed pump
Rated BMCR of each 660 MW Unit at 100% load
Operation cyclle for CPU during clean up / start up process
Boiler fill up volume required
Make up requirement for CCW Expansion tank
Make up requirement for Hydrogen generation plant
Regeneration water requirement for individual DM chain
Recovery of RO-IInd stage
Operation cycle for individual MB unit
Make up requirement for Power cycle chemical feed system
Percent BMCR minimum flow requirement during cold start up
Total hour of blowdown
Make up requirement for CPU regeneration
Operation cycle for individual CPU unit under normal condition
Percent BMCR for minimum flow requirement during clean up
Total no. of CPU units under operation (for both units)
Time period of each steam blow
Total number of steam blow per day
% BMCR flow as steam drain loss during standby mode
Total hour of recirculation
Chain Capacity of RO-II (BWRO) system
Design capacity of RO-II feed pump
Design capacity of MB feed pump
Total hours of boiler operation
Total no. of RO-II units
Total no. of DM tanks
Total hours of recirculation
No. of Units
Power cycle make-up as percent of rated BMCR
No. of RO-IInd stage chain working
No. of MB streams working
Total no. of MB units
Capacity of each DM tank
Total no. of CST
Capacity of each CST
Total no. of working RO-II feed pump
Total hours of blow down
Percent of BMCR for Steam blow period
The purpose of this calculation is to determine the following:
Chain Capacity of MB
4.0 METHODOLOGY AND ACCEPTANCE CRITERIA
4.1
4.2
4.3
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
4.5
4.6
4.7
4.8
4.9
5.0 CALCULATIONS
5.1
6.0 RESULTS
6.1 65 cum/hr
6.2 90 cum/hr
6.3 33 cum/hr
6.4 45 cum/hr
6.5 75 cum/hr
6.6 100 cum/hr
6.7 45 cum/hr
6.8 57 cum/hr
7.0 REFERENCES
7.1 Not Attached
7.2 Not Attached
7.3 Not Attached
7.4 Not Attached
8.0
8.1
Selected Capacity of each MB (net)
Selected Capacity of each RO stream
Design capacity of MB feed pump
Selected Capacity of MB feed pump
Design capacity of RO-II feed pump
Selected Capacity of RO-II feed pump
One unit under commisioning clean up cycle and other unit under steam puffing operation case is not considered since the time gap
between comissioning of two units will be sufficient so that the second unit comissioning clean up starts only after completion of steam
blowing operation of first unit.
One unit is under commissioning and the other unit is in normal running condition
One unit is undergoing steam puffing and the other unit is in normal running condition
For a single regeneration of individual MB unit DM water of 50 cum is considered (Regeneration water quantity is subjected to change
based on finalised vendor input). DM water required for regeneration of MB will be provided from DM water stortage tank.
Both the units are in normal operation
One unit is undergoing cold start-up and the other unit is in normal operation
The considerations done for DM water requirement under different conditions are as follows:
One unit is under commissioning and the other unit is in cold start up condition.
Sizing Calculation of RO-DM Plant
Contract Document
DCD for DM Plant
ATTACHMENTS
All the assumptions made under Sl. No. 3.1.2 to 3.1.5, 3.1.9, 3.2, 3.3 and 3.4 are to be verified from BTG vendor and modified input, if
any, shall be provided.
Design MB chain capacity (net)
Design RO-II stream net output capacity (individual)
HBD
Refer Attachment 8.1 for sizing calculation of Desalination Plant and RO-MB Plant
Cases indicated under Point no. 4.4.2 and 4.4.4 is of more than one day occurance. Since RO-DM chain capacity cannot cater to these
requirements alone, hence the excess DM water requirement (Refer Attachment-8.1) have to be met from reserved storage capacity.
These operations have to be intermittent in nature so as to allow the storage volume to be refilled depending on total number of days of
the operation.
BTG inputs are required to verify all the assumed data as indicated in the RO-DM chain sizing calculation. In case, data received from
BTG supplier varies significantly from the present assumptions, the consideration made in the design will get modified accordingly.
Calculation for Water Balance Diagram
The calculated design parameters of DM Plant are as follows:
Design margin of 10% is considered on rated pump capacity for each services in Desalination and RO-MB plant except for RO HP feed
pump.
Sizing calculation is subjected to change based on modification in regeneration and backwash water flow rates after receipt of finalised
vendor data.
One unit is undergoing steam puffing and the other unit is in cold start up condition
There will be 2 nos. of MB units out of which one unit will be under operation and the other will work as regeneration standby unit.
Each MB unit will be running for at least 48 hours of continuous operation between two successive regenerations. Both Stage-1 & Stage-
2 RO will be operating for 24 hrs on continuous basis.
2
2
2
2
2
S.No. Formula Unit Value Remarks
A
A.1 Q1 T/hr 2010
A.2 N nos. 2
A.3 P % 1
A.4 Q
W1 cum/hr 5
A.5 Q
W2 cum/hr 5
A.6 Q
W3 cum 500
A.7 Tcpu day 7
Ncpu nos. 4
A.7 Q
W4
cum/hr 1
A.8 N1 nos. 1
A.11
Q2=[(Q1*N*P/100*)+Q
W1
+ Q
W2
+Q
W3
/Tcpu/24*
Ncpu+Q
W4
]
cum/hr 63.5 Considering Both Units
A.12 Q3 cum/cycle 50
A.13 Tcmb hrs 72
A.14 Q4=Q2+Q3/Tcmb cum/hr 65
cum/day 1560
A.15 Rec % 80
A.16 Q
ROf
=Q4*N1/(Rec/100) cum/hr 81.25
B
B.1 Q1 T/hr 2010
B.2 P1 % 15
B.3 T1 hrs 3
B.4 R1 hrs 21
B.5 Q
W3
cum 500
B.6 T2 24
B.7
Qc = (Q1*P1/100*T1) +
Q
W3
/T2*24
cum/day 1404.5
cum/hr 59
C
C.1 P2
%
40
C.2 T2
minutes
3
C.3 N1
nos.
20
C.4 P3 % 5
C.5 T3 hrs 14
C.6
Q
SB
=
Q1*P2/100*T2/60*N1 +
Q1*P3/100*T3
cum/day 2211
cum/hr 92.125
Total cycle time between consecutive regeneration
DM make up required for Hydrogen generation plant
Total DM water required for clean up cycle process
DM water required for CPU regeneration
Recovery of RO-II unit
Net DM water required at MB outlet
Gross Capacity required for individual MB chain
Total no. of CPU units under operation (for both units)
DM MAKE-UP DURING STEAM BLOWING OPERATION
Total hours of boiler operation
Total feed water required for RO-II unit
Total hours of recirculation
DM make up required for CCW expansion tank make up
DM water required for CPU regeneration
Power cycle make-up as percent of rated BMCR
ATTACHMENT-8.1: SIZING CALCULATION FOR RO-DM PLANT
DM MAKE-UP UNDER NORMAL CONDITION
DM MAKE-UP DURING COMMISSIONING CLEAN UP CYCLE
DM make up required for Power cycle chemical feed system
Percent BMCR for minimum flow requirement during clean up
% BMCR flow as steam drain loss during standby mode
Particulars
Considering Single unit
Rated B.M.C.R at 100% load of each 660 MW Unit
Total DM water required for steam blowing operation
Rated B.M.C.R at 100% load of each 660 MW Unit
Operation cyclle for CPU during clean up / start up process
Total hours of blow down
Regeneration water requirement for individual MB
No. of Units
Operation cycle for individual CPU unit under normal condition
No. of working MB streams
Percent of BMCR for Steam blow period
Time period of each steam blow
Total number of steam blow per day
Considering Single unit
D
D.1 P4
%
15
D.2 T4 hrs 5
D.3 T5 hrs 10
D.4 Q
W3
cum 500
D.5 V1 cum 600
D.6
Qcs = Q1*P4/100*T4 +
Q
W3
+V1
cum/day 2607.5
cum/hr 108.6458333
E
E.1 Q4 cum/day 2293.757143
cum/hr 95.57321429
E.2 Q5 cum/day 3100.257143
cum/hr 129.177381
E.3 Q6 cum/day 4012
cum/hr 167.167
E.4 Q7 cum/day 4818.5
cum/hr 200.7708333
E.5 Q8 cum/day 3496.757143
145.6982143
F
F.1 Q
DM
cum/hr 65 Normal requirement
F.2 N4 2
F.3 N5 2
F.4 Q
MB
cum/hr 65
F.5 Q
BWRO
cum/hr 33
F.6
Qw = MIN
(Q
MB
*N4,Q
BWRO
*N5)
cum/hr
65
QW cum/day 1560
F.7 Qm=Qw/(Rec/100) cum/hr 81.25
F.8 N2 nos. 2
F.9 V2 cum 2000
F.10 N3 nos. 2
F.11 V3 cum 1000
F.12 V
T
= N2*V2+N3*V3
cum 6000
This situation may continue
for more than one day.
This situation may continue
for more than one day.
Total no. of DM tanks
Total storage volume available
RO-DM CHAIN SIZING CALCULATION
Total no. of RO-II units
This situation should not
continue for more than one
day since cold start up
operation is a single day
process in general.
This situation should not
continue for more than one
day since cold start up
operation is a single day
process in general.
DM water required when one unit is under commissioning and the
other is under normal operation
This situation should not
continue for more than one
day since cold start up
operation is a single day
process in general.
Selected working capacity of RO-DM
Total no. of MB units
DM water required when one unit is under cold start up condition and
other is in normal operation
Total DM water required for cold start up operation
Total hour of blowdown
Percent BMCR minimum flow requirement during cold start up
DM WATER REQUIREMENT FOR SIMULTENEOUS OPERATION - DIFFERENT CASE STUDY
DM water required when one unit is under steam blowing and other
under normal operation
Capacity of each MB unit
DM water required when one unit is under steam blowing and other
under cold start up condition
DM water required for CPU regeneration
Capacity of each DM tank
Total no. of CST
Capacity of each RO unit
Capacity of each CST
DM water required when one unit is under commissioning and other
under cold start up condition
Available maximum RO-DM chain capacity
Total hour of recirculation
Boiler fill up volume required
DM MAKE-UP DURING COLD START UP OPERATION
Considering Single unit
Required maximum feed water to RO-DM Plant
F.13 Q4 cum/day 2293.757143
F.14 Q9 = Q4-QW cum/day 733.7571429
F.15 Q5 cum/day 3100.257143
F.16 Q10=Q5-QW cum/day 1540.257143
F.17 V4 cum 2452.0
OK, since its a single day
operation the same will be
met from total storage of
DM water i.e. 4000 cum
(Refer F.12)
F.18 V5 cum 3258.5
OK, since its a single day
operation the same will be
met from total storage of
DM water i.e. 4000 cum
(Refer F.12)
F.19 V6 cum 1936.8 Hence OK
G
G.1 N6 nos. 2
G.2 N7 nos. 1
G.3 N8 nos. 3
G.4 N9 nos. 2
G.5 P5 % 10
G.6 Q11=Q4/N7 cum/hr 65
G.7 Q
PDM
=Q11*(1+P5/100) cum/hr 75
G.8 Q13=Q
ROf
/N9
cum/hr 40.625
G.9
Q
PBWRO
=Q13*(1+P5/100)
cum/hr 45
Refer Point no. 4.6 in Input
& Result sheet
Refer Point no. 4.6 in Input
& Result sheet
DM chain sizing for Case given against E.2
Total no. of MB feed pump
DM storage required for Case given against E.5
Excess DM water required
Excess DM water required
Total no. of RO-II feed pump
Total no. of working RO-II feed pump
Capacity of MB feed pump based on normal requirement
General margin on pump capacity for design purpose
Capacity of RO-II feed pump based on normal requirement
Design capacity of MB feed pump
RO-DM PLANT PUMP SIZING CALCULATION
Total no. of working MB feed pump
DM storage required for Case given against E.3
Design capacity of RO-II feed pump
DM water requirement for Case given against E.1
DM storage required for Case given against E.4