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 Chain Capacity of MB1.2 Chain Capacity of RO-II (BWRO) system1.3 Design capacity of MB feed pump1.4 Design capacity of RO-II feed pump

2.0 DESIGN INPUT Value Unit Reference

2.1 No. of Units 2 nos. 7.22.2 Total no. of MB units 2 nos. 7.32.3 No. of MB streams working 1 nos. 7.32.4 Total no. of RO-II units 2 nos. 7.32.5 No. of RO-IInd stage chain working 2 nos. 7.32.6 Power cycle make-up as percent of rated BMCR 1 % 7.32.7 Recovery of RO-IInd stage 80 % 7.32.8 Operation cycle for individual MB unit 72 hrs 7.32.9 Total no. of DM tanks 2 nos. 7.2

2.10 Capacity of each DM tank 2000 cum 7.22.11 Total no. of CST 2 nos. 7.22.12 Capacity of each CST 1000 cum 7.22.13 Total no. of MB feed pump 2 nos. 7.32.14 Total no. of working MB feed pump 1 nos. 7.32.15 Total no. of RO-II feed pump 3 nos. 7.32.16 Total no. of working RO-II feed pump 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 Rated BMCR of each 660 MW Unit at 100% load 2010 T/hr HBD3.1.2 Make up requirement for Power cycle chemical feed system 5 cum/hr UV3.1.3 Make up requirement for CCW Expansion tank 5 cum/hr UV3.1.4 Make up requirement for CPU regeneration 500 cum UV3.1.5 Operation cycle for individual CPU unit under normal condition 7 days UV3.1.6 Total no. of CPU units under operation (for both units) 4 nos. UV3.1.7 Make up requirement for Hydrogen generation plant 1 cum/hr UV3.1.8 Regeneration water requirement for individual DM chain 50 cum/cycle UV3.1.9 Operation cyclle for CPU during clean up / start up process 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 Percent BMCR for minimum flow requirement during clean up 15 % UV3.2.2 Total hours of blow down 3 hrs UV3.2.3 Total hours of recirculation 21 hrs UV

3.3 ASSUMPTIONS FOR BOILER STEAM BLOWING PROCESS DURING COMMISSIONING

3.3.1 Percent of BMCR for Steam blow period 40 % UV3.3.2 Time period of each steam blow 3 minutes UV3.3.3 Total number of steam blow per day 20 nos. UV3.3.4 % BMCR flow as steam drain loss during standby mode 5 % UV3.3.5 Total hours of boiler operation 14 hrs UV

3.4 ASSUMPTIONS FOR BOILER COLD START UP PROCESS

3.4.1 Percent BMCR minimum flow requirement during cold start up 15 % UV3.4.2 Total hour of blowdown 5 hrs UV3.4.3 Total hour of recirculation 10 hrs UV3.4.4 Boiler fill up volume required 600 cum UV

The purpose of this calculation is to determine the following:

4.0 METHODOLOGY AND ACCEPTANCE CRITERIA

4.1

4.2

4.3

4.4 The considerations done for DM water requirement under different conditions are as follows:

4.4.1 One unit is under commissioning and the other unit is in cold start up condition.4.4.2 One unit is under commissioning and the other unit is in normal running condition4.4.3 One unit is undergoing steam puffing and the other unit is in cold start up condition4.4.4 One unit is undergoing steam puffing and the other unit is in normal running condition4.4.5 One unit is undergoing cold start-up and the other unit is in normal operation4.4.6 Both the units are in normal operation

4.5

4.6

4.7

4.8

4.9

5.0 CALCULATIONS

5.1 Refer Attachment 8.1 for sizing calculation of Desalination Plant and RO-MB Plant

6.0 RESULTS

The calculated design parameters of DM Plant are as follows:

6.1 Design MB chain capacity (net) 65 cum/hr6.2 Selected Capacity of each MB (net) 90 cum/hr6.3 Design RO-II stream net output capacity (individual) 33 cum/hr6.4 Selected Capacity of each RO stream 45 cum/hr6.5 Design capacity of MB feed pump 75 cum/hr6.6 Selected Capacity of MB feed pump 100 cum/hr6.7 Design capacity of RO-II feed pump 45 cum/hr6.8 Selected Capacity of RO-II feed pump 57 cum/hr

7.0 REFERENCES

7.1 HBD Not Attached7.2 Contract Document Not Attached7.3 DCD for DM Plant Not Attached7.4 Calculation for Water Balance Diagram Not Attached

8.0 ATTACHMENTS

8.1 Sizing Calculation of RO-DM Plant

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.

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.

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.

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.

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.

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.

Sizing calculation is subjected to change based on modification in regeneration and backwash water flow rates after receipt of finalised vendor data.

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.

2

2

2

2

2

ATTACHMENT-8.1: SIZING CALCULATION FOR RO-DM PLANT

S.No. Particulars Formula Unit Value Remarks

A DM MAKE-UP UNDER NORMAL CONDITION

A.1 Rated B.M.C.R at 100% load of each 660 MW Unit Q1 T/hr 2010A.2 No. of Units N nos. 2A.3 Power cycle make-up as percent of rated BMCR P % 1A.4 DM make up required for Power cycle chemical feed system cum/hr 5A.5 DM make up required for CCW expansion tank make up cum/hr 5A.6 DM water required for CPU regeneration cum 500A.7 Operation cycle for individual CPU unit under normal condition Tcpu day 7

Total no. of CPU units under operation (for both units) Ncpu nos. 4A.7 DM make up required for Hydrogen generation plant cum/hr 1A.8 No. of working MB streams N1 nos. 1

A.11 Net DM water required at MB outlet cum/hr 63.5 Considering Both Units

A.12 Regeneration water requirement for individual MB Q3 cum/cycle 50A.13 Total cycle time between consecutive regeneration Tcmb hrs 72A.14 Gross Capacity required for individual MB chain Q4=Q2+Q3/Tcmb cum/hr 65

cum/day 1560A.15 Recovery of RO-II unit Rec % 80A.16 Total feed water required for RO-II unit cum/hr 81.25

B DM MAKE-UP DURING COMMISSIONING CLEAN UP CYCLE

Considering Single unit

B.1 Rated B.M.C.R at 100% load of each 660 MW Unit Q1 T/hr 2010B.2 Percent BMCR for minimum flow requirement during clean up P1 % 15B.3 Total hours of blow down T1 hrs 3B.4 Total hours of recirculation R1 hrs 21B.5 DM water required for CPU regeneration cum 500B.6 Operation cyclle for CPU during clean up / start up process T2 24

B.7 Total DM water required for clean up cycle process cum/day 1404.5

cum/hr 59

C DM MAKE-UP DURING STEAM BLOWING OPERATION

Considering Single unit

C.1 Percent of BMCR for Steam blow period P2 % 40

C.2 Time period of each steam blow T2 minutes 3

C.3 Total number of steam blow per day N1 nos. 20

C.4 % BMCR flow as steam drain loss during standby mode P3 % 5C.5 Total hours of boiler operation T3 hrs 14

C.6 Total DM water required for steam blowing operation cum/day 2211

cum/hr 92.125

QW1

QW2

QW3

QW4

Q2=[(Q1*N*P/100*)+QW1+

QW2+QW3/Tcpu/24* Ncpu+QW4]

QROf=Q4*N1/(Rec/100)

QW3

Qc = (Q1*P1/100*T1) + QW3/T2*24

QSB = Q1*P2/100*T2/60*N1 +

Q1*P3/100*T3

D DM MAKE-UP DURING COLD START UP OPERATION

Considering Single unit

D.1 Percent BMCR minimum flow requirement during cold start up P4 % 15

D.2 Total hour of blowdown T4 hrs 5D.3 Total hour of recirculation T5 hrs 10

D.4 DM water required for CPU regeneration cum 500

D.5 Boiler fill up volume required V1 cum 600

D.6 Total DM water required for cold start up operation cum/day 2607.5

cum/hr 108.64583333

E DM WATER REQUIREMENT FOR SIMULTENEOUS OPERATION - DIFFERENT CASE STUDY

E.1 Q4 cum/day 2293.7571429

cum/hr 95.573214286

E.2 Q5 cum/day 3100.2571429

cum/hr 129.17738095

E.3 Q6 cum/day 4012

cum/hr 167.167

E.4 Q7 cum/day 4818.5

cum/hr 200.77083333

E.5 Q8 cum/day 3496.7571429

145.69821429

F RO-DM CHAIN SIZING CALCULATION

F.1 Selected working capacity of RO-DM cum/hr 65 Normal requirementF.2 Total no. of MB units N4 2F.3 Total no. of RO-II units N5 2

F.4 Capacity of each MB unit cum/hr 65

F.5 Capacity of each RO unit cum/hr 33

F.6 Available maximum RO-DM chain capacitycum/hr

65

QW cum/day 1560F.7 Required maximum feed water to RO-DM Plant Qm=Qw/(Rec/100) cum/hr 81.25F.8 Total no. of DM tanks N2 nos. 2F.9 Capacity of each DM tank V2 cum 2000F.10 Total no. of CST N3 nos. 2F.11 Capacity of each CST V3 cum 1000

F.12 Total storage volume available cum 6000

QW3

Qcs = Q1*P4/100*T4 + QW3+V1

DM water required when one unit is under commissioning and the other is under normal operation This situation may continue

for more than one day.

DM water required when one unit is under steam blowing and other under normal operation This situation may continue

for more than one day.

DM water required when one unit is under commissioning and other under cold start up condition

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 steam blowing and other under cold start up condition

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 cold start up condition and other is in normal operation

This situation should not continue for more than one

day since cold start up operation is a single day

process in general.

QDM

QMB

QBWRO

Qw = MIN (QMB*N4,QBWRO*N5)

VT = N2*V2+N3*V3

F.13 DM water requirement for Case given against E.1 Q4 cum/day 2293.7571429F.14 Excess DM water required Q9 = Q4-QW cum/day 733.75714286

F.15 DM chain sizing for Case given against E.2 Q5 cum/day 3100.2571429F.16 Excess DM water required Q10=Q5-QW cum/day 1540.2571429

F.17 DM storage required for Case given against E.3 V4 cum 2452.0

F.18 DM storage required for Case given against E.4 V5 cum 3258.5

F.19 DM storage required for Case given against E.5 V6 cum 1936.8 Hence OK

G RO-DM PLANT PUMP SIZING CALCULATION

G.1 Total no. of MB feed pump N6 nos. 2G.2 Total no. of working MB feed pump N7 nos. 1G.3 Total no. of RO-II feed pump N8 nos. 3G.4 Total no. of working RO-II feed pump N9 nos. 2G.5 General margin on pump capacity for design purpose P5 % 10G.6 Capacity of MB feed pump based on normal requirement Q11=Q4/N7 cum/hr 65

G.7 Design capacity of MB feed pump cum/hr 75

G.8 Capacity of RO-II feed pump based on normal requirement cum/hr 40.625

G.9 Design capacity of RO-II feed pump cum/hr 45

Refer Point no. 4.6 in Input & Result sheet

Refer Point no. 4.6 in Input & Result sheet

OK, since it’s a single day operation the same will be met from total storage of DM water i.e. 4000 cum (Refer F.12)

OK, since it’s a single day operation the same will be met from total storage of DM water i.e. 4000 cum (Refer F.12)

QPDM =Q11*(1+P5/100)

Q13=QROf/N9

QPBWRO =Q13*(1+P5/100)