COAL HANDLING SYSTEM

CHHABRA THERMAL POWER PROJECT

STAGE-I, PHASE-II, 2X250 MW

RAJASTHAN RAJYA VIDYUT UTPADAN NIGAM LTD., RAJASTHAN

CHHABRA THERMAL POWER PROJECT

STAGE I, PHASE-II, 2 X 250 MW
UNIT # 3&4

DESIGN BASIS REPORT

OF
VENTILATION SYSTEMS
FOR
W.T.3 COMPLEX, TUNNEL OF CONVEYOR BCN-1(2) & TH-1(2)

Job No.

OWNER

RAJASTHAN RAJYA VIDYUT UTPADAN NIGAM LTD., RAJASTHAN

OWNERS CONSULTANT

TCE CONSULTING ENGINEERS LIMITED, BANGALORE

EPC AGENCY

THE INDURE PVT LTD,INDURE HOUSE, NEW DELHI

SYSTEM SUPPLIER

WRC ENGINEERING CO. PVT. LTD., V.U.NAGAR, GUJARAT

I-3062

Name
Prepared By

J.P. PATEL

Date
18.01.2012

P.M. PATEL

20.01.2012

Checked By
Approved By
Document No.
Rev. No.
1.
2.

I-3062-VS-DBR-1022

Record of Revisions
Particulars
Date
Revised Based on TCE Comments Ref No.:
19.05.2012
TCE.5225A/ME/AV/811-107 dated 11.04.2012
Revised Based on TCE Comments Ref No.:
20.03.2012
TCE.5225A/ME/AV/811-115 dated 28.09.2012

VNT-01-R2

Rev No. 2

Checked By

Approved By

PM

PM

AP

PM

COAL HANDLING SYSTEM

CHHABRA THERMAL POWER PROJECT
STAGE-I, PHASE-II, 2X250 MW

TABLE OF CONTENTS
Sr.
No.
01.0
02.0
03.0
04.0
05.0
06.0
07.0
08.0
09.0
10.0
11.0
11.1
11.2
12.0
13.0
14.0
15.0

Description
Introduction
General Description of Ventilation System
Standard & Code
Layout
Design Criteria
Friction loss calculation
Selection of Fan (Supply & Exhaust)
Equipment Summery
Schematic (SLD) Supply Air System
Schematic (SLD) Exhaust Air System
General Arrangement Drawing of Fan with MOC
Attachments:
Supply Air C.F. Fan
Exhaust Air C.F. Fan
General Arrangement Drawing of Air Intake Louver with Filter Frame
General Arrangement Drawing of Supply Air Filter
General Arrangement Drawing of Supply Air Grill
General Arrangement Drawing of Exhaust Air Grill

VNT-01-R2

Page
No.
02
02
02
02
02
05
06
07
09
10
11

Page 1 of 8

COAL HANDLING SYSTEM

CHHABRA THERMAL POWER PROJECT
STAGE-I, PHASE-II, 2X250 MW

01.0

Introduction.
This document covers description of Ventilation System, equipment sizing, design philosophy
for various components of Ventilation System and design philosophy for the control and
operation 0f Ventilation System for 2 x 250 MW, Units # 3 & 4 (Stage-I, Phase-II) of Chhabra
Thermal Power Station.

02.0

General Description of Ventilation System.

Ventilation System is comprised of Supply Air System and Exhaust Air System.
Supply Air System consists of Air Filters, Centrifugal Supply Air fan with Outlet flexible
connection Vibration isolation Pad and foundation bolts, Inlet Air Louver, Ducting with Supply
Air Grills.
Exhaust Air System consists of Centrifugal Exhaust Air Fan with Inlet flexible connection,
Vibration isolation Pad and foundation bolts, Ducting with Exhaust Air Grills. R2

03.0

Standard and Codes.

The applicable standards and codes for various major equipment of Ventilation System are as
given below.
1.
2.
3.
4.

04.0

IS:655
IS:4894
IS:3588
IS:277

Specification for Metal Air Duct

Centrifugal Fan
Specification for electric Axial Fan
Specification of GI Sheet

R1

Layout.
Ventilation System for Wagon Tippler-3 Building and Tunnel of Conveyor BCN-1(2) is located at
TH-1 building.

05.0

Design Criteria.
05.1

Design Ambient Condition.

05.2

The following ambient conditions given in Project Information of NIT would be

considered for sizing of Supply and Exhaust Fan.
Design ambient temperature
Design relative humidity
Site elevation

05.3

VNT-01-R2

:
:
:

46.3 C
20% to 80%
400 M above MSL

R1

Design requirements.

As stated in technical specification for Ventilation system, suitable ventilation system is

provided for underground portion of Wagon Tippler-3 Building along with Tunnel of
Conveyor BCN-1(2) and Part of TH-1(2).
Fresh and Filtered air is brought in to under-ground portion of Wagon Tippler Building.
Page 2 of 8

COAL HANDLING SYSTEM

CHHABRA THERMAL POWER PROJECT
STAGE-I, PHASE-II, 2X250 MW

12 air changes are considered for supply air system.

A set of filters are provided before intake Centrifugal Fan. C.F. Fan will deliver required air
in to GI Sheet Duct and there-after it will be distributed in to Wagon Tippler Building
through supply air grills located at specific locations.
Suitable quantity of supply air grills are considered at regular intervals.
We have considered exhaust air volume as 90 % of supply air volume.R2
Suitable quantity of Exhaust air grills are considered at regular intervals.
Air velocity considered for design will be less than 10 m/sec in Supply & Exhaust GI
Ducting.

05.4

Supply and Exhaust Air Capacity.

Volume of Ventilated area for Supply and Exhaust air is calculated as below:

1.
2.
3.
4.
5.
6.

W.T.-3 Complex Area

Elevation at -13.200 floor
Elevation at -13.200 floor
Elevation at -17.900 floor
Tunnel of Conveyor BCN-1(2)
Transfer Tower TH-1(2)
Floor elevation -5.115
Floor elevation -8.315

Length
meter

Width
meter

Height
meter

Volume
m3

16.80
12.15
14.15
65.00

8.70
11.50
11.50
3.80

5.50
5.50
4.40
3.00

803.880
768.487
715.990
741.000

13.80
13.80

10
10

8.32
2.90

Total Volume (V) = VSA+VSB+VSC+VSD+VSE+VSF

-VSA
-VSB
-VSC
-VSD

1148.160 -VSE
400.200 -VSF
4577.717

We are considering 12 air changes per hour for Supply air system
= 4577.717 x 12
= 54932.604
m3/hr.
We have considered Supply Air Ventilation System of 55000 m3/hr.

VS-01

We are considering Exhaust air system as 90 % of Supply air volume R2

= 55000 x 90 %
= 49500
m3/hr.
We have considered Exhaust Air Ventilation System of 49500 m3/hr. R2
05.5

VE-01

Selection of Supply Air Filters.

We have considered HDPE washable type air filters with filtering efficiency of 95%
down to 5 microns for Supply Air Ventilation System.
We have selected standard air W fold type air filters suitable to fit 610x610 mm
size with filter cloth area of 0.5 m2 each filter. (Please refer G.A. Drawing for cloth
area)
We have considered air velocity of 1.8 m/sec at filter inlet.
Considering Supply Air System capacity of 55000 m3/hr. and velocity of air entering
filters as 1.8 m/sec., calculated cloth area will be ((55000/3600)/1.8)= 8.49 m2.

VNT-01-R2

Page 3 of 8

COAL HANDLING SYSTEM

CHHABRA THERMAL POWER PROJECT
STAGE-I, PHASE-II, 2X250 MW

Considering unit air filter cloth area as 0.5 m2, calculated total numbers of filter are
(8.49/0.5)=16.98 numbers. We have selected 20 (5x4) numbers of supply air filters
for Supply Air Ventilation system.
05.6

Selection of Supply & Exhaust Air Ducting & Grills.

We have considered duct air velocity of 10 m/sec. for supply & exhaust air ducting.
We have considered grill air velocity of 4 m/sec. for supply & exhaust air grills.
We have considered grill spacing of maximum 5 meter distance.
We have considered duct support at maximum 3 meter distance with / without tie
rod as per civil requirements.

1) Based on calculation for individual space volume and considered air change for supply air,
we have considered space volume for Supply Air Ventilation System as under:
A. 13800 m3/hr
B. 5000 m3/hr
C. 17300 m3/hr
D. 18900 m3/hr
Sr.
No.

Air Volume
M3/hr

TH-1 (2) of Floor at Elevation -5.115

TH-1 (2) of Floor at Elevation -8.315
W.T.3 Hopper Area of Floor at Elevation -17.900 & Tunnel of
Conveyor BCN-1(2)
W.T.3 Hopper Area of Floor at Elevation -13.200
Duct Size
Length mt

Width mt

Air Velocity
m/sec

Number of Grill and Grill Size

A. Calculation for Duct Size and Grill for Supply Air VNT System for TH-1(2) of Floor at
Elevation -5.115
01
13800
0.700
0.560
9.78
3 No. S.A. Grill 350 x 300 mm
02
9200
0.650
0.400
9.83
3 No. S.A. Grill 350 x 300 mm
3 No. S.A. Grill 350 x 300 mm
03
4600
0.400
0.350
9.13
B. Calculation for Duct Size and Grill for Supply Air VNT System for TH-1(2) of Floor at
Elevation -8.315
5 No. S.A. Grill 300 x 250 mm
04
5000
0.400
0.350
9.92
C. Calculation for Duct Size and Grill for Supply Air VNT System for Tunnel of Conveyor
BCN-1(2) up to W.T.-3 Complex
3 No. S.A. Grill 325 x 250 mm
06
36200
1.200
0.850
9.86
3 No. S.A. Grill 325 x 250 mm
07
32740
1.150
0.800
9.89
3 No. S.A. Grill 325 x 250 mm
08
29280
1.050
0.800
9.68
3 No. S.A. Grill 325 x 250 mm
09
25820
1.050
0.700
9.76
3 No. S.A. Grill 325 x 250 mm
10
22360
0.900
0.700
9.86
Note: For duct design volume of air for WT-3 Apron Feeder area pass from this duct.
D. Calculation for Duct Size and Grill for Supply Air
Feeder Area
11
18900
0.800
0.700
9.38
12
13500
0.700
0.560
9.57
13
8100
0.525
0.450
9.52
VNT-01-R2

VNT System for W.T.-3 Complex Apron

4 No. S.A. Grill 325 x 300 mm
4 No. S.A. Grill 325 x 300 mm
6 No. S.A. Grill 325 x 300 mm
Page 4 of 8

COAL HANDLING SYSTEM

CHHABRA THERMAL POWER PROJECT
STAGE-I, PHASE-II, 2X250 MW

2) Based on calculation for individual space volume and considered air change for exhaust air,
we have considered space volume for Exhaust Air Ventilation System as under: R2
A. 12400 m3/hr
B. 4300 m3/hr
C. 15800 m3/hr
D. 17000 m3/hr
Sr.
No.

Air Volume
M3/hr

TH-1 (2) of Floor at Elevation -5.115

TH-1 (2) of Floor at Elevation -8.315
W.T.3 Hopper Area of Floor at Elevation -17.900 & Tunnel of
Conveyor BCN-1(2)
W.T.3 Hopper Area of Floor at Elevation -13.200
Duct Size
Length mt

Width mt

Air Velocity
m/sec

Number of Grill and Grill Size

A. Calculation for Duct Size and Grill for Exhaust Air VNT System for TH-1(2) of Floor at
Elevation -5.115
01
12400
0.650
0.550
9.63
4 No. E.A. Grill 350 x 325 mm
02
6200
0.450
0.400
9.57
4 No. E.A. Grill 350 x 325 mm
B. Calculation for Duct Size and Grill for Exhaust Air VNT System for TH-1(2) of Floor at
Elevation -8.315
5 No. E.A. Grill 275 x 225 mm
03
4300
0.400
0.300
9.95
C. Calculation for Duct Size and Grill for Exhaust Air VNT System for Tunnel of Conveyor
BCN-1(2) up to W.T.-3 Complex
3 No. E.A. Grill 300 x 250 mm
04
32800
1.125
0.875
9.26
3 No. E.A. Grill 300 x 250 mm
05
29640
1.100
0.800
9.36
3 No. E.A. Grill 300 x 250 mm
06
26480
1.075
0.725
9.44
3 No. E.A. Grill 300 x 250 mm
07
23320
1.000
0.675
9.60
3 No. E.A. Grill 300 x 250 mm
08
20160
0.925
0.625
9.69
Note: For duct design volume of air for WT-3 Apron Feeder area pass from this duct.
D. Calculation for Duct Size and Grill for Exhaust Air VNT System for W.T.-3 Complex
Apron Feeder Area
5 No. E.A. Grill 375 x 325 mm
09
17000
0.750
0.650
9.69
5 No. E.A. Grill 375 x 325 mm
10
8500
0.500
0.475
9.94

VNT-01-R2

Page 5 of 8

COAL HANDLING SYSTEM

CHHABRA THERMAL POWER PROJECT
STAGE-I, PHASE-II, 2X250 MW

06.0

Friction Loss Calculation

06.1

Supply Air Ventilation System.

Wagon Tippler-3 Hopper Complex, Conveyor BCN-1(2) & Part of TH-1(2)

Section

R Factor

Duct L

Duct W

Duct H

01-02
02-03
03-04
04-05
02-06
06-07
06-08
08-09
09-10
10-11
11-12
12-13
13-14
14-15

55000
13800
9200
4600
41200
5000
36200
32740
29280
25820
22360
18900
13500
8100

0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9

5.00
5.00
5.00
5.00
1.50
23.00
15.00
15.00
15.00
15.00
15.00
25.00
20.00
30.00

1.250
0.700
0.650
0.400
1.200
0.400
1.200
1.150
1.050
1.050
0.900
0.800
0.700
0.525

1.250
0.560
0.400
0.350
1.000
0.350
0.850
0.800
0.800
0.700
0.700
0.700
0.560
0.450

A
B
C
D
06.2

Velocity

9.78
9.78
9.83
9.13
9.54
9.92
9.86
9.89
9.68
9.76
9.86
9.38
9.57
9.52
Total
Add Filter Losses
Add Grill Losses
Add S.F (10%)
Total

F.L.

0.29
0.67
0.87
1.10
0.10
5.90
1.14
1.22
1.24
1.37
1.52
2.48
2.57
5.19
25.66
25.00
2.00
5.27
57.93

Exhaust Air Ventilation System. R2

Wagon Tippler-3 Hopper Complex, Conveyor BCN-1(2) & Part of TH-1(2)

Section

01-02
02-03
03-04
02-05
05-06
05-07
07-08
08-09
09-10
10-11
11-12
12-13
A
B
C
VNT-01-R2

R Factor

Duct L

Duct W

Duct H

49500
12400
6200
37100
4300
32800
29640
26480
23320
20160
17000
8500

0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9

5.00
10.00
10.00
5.00
20.00
15.00
15.00
15.00
15.00
20.00
20.00
20.00

1.200
0.650
0.450
1.050
0.400
1.125
1.100
1.075
1.000
0.925
0.750
0.500

1.200
0.550
0.400
1.050
0.300
0.875
0.800
0.725
0.675
0.625
0.650
0.475

Velocity

9.55
9.63
9.57
9.35
9.95
9.26
9.36
9.44
9.60
9.69
9.69
9.94
Total
Add Grill Losses
Add S.F (10%)
Total

F.L.

0.29
1.37
2.06
0.33
5.68
1.03
1.13
1.24
1.39
2.08
2.29
3.73
22.63
2.00
2.463
27.093
Page 6 of 8

COAL HANDLING SYSTEM

CHHABRA THERMAL POWER PROJECT
STAGE-I, PHASE-II, 2X250 MW

07.0

Selection of Fan (Supply and Exhaust Air).

We have considered 10% margin for fan capacity selection over calculated system capacity.
We have selected Centrifugal Fan for Supply Air System. R2
We have selected Centrifugal Fan for Exhaust Air system. R2

07.1

07.2

Supply Air Fan.

07.1.1
07.1.2

Type
Capacity

:
:

07.1.3
07.1.4
07.1.5

Static Pressure
Motor kW
Fan efficiency

:
:
:

Backward Curve Centrifugal SWSI

60500 m3/hr.
(55000 x 1.1 = 60500)
75 mm WG
30.00 / 4 Pole
60% R2

Exhaust Air Fan. R2

07.2.1
07.2.2

Type
Capacity

:
:

07.2.3
07.2.4
07.2.5

Static Pressure
Motor kW
Fan efficiency

:
:
:

Backward Curve Centrifugal SWSI

54450 m3/hr.
(49500 x 1.1 = 54450)
50 mm WG
18.50 / 4 Pole
50%

Reference formulas:
1. Power Calculation:
Abs HP
= CFM x Fan Pressure
6356 x 25.4 x Fan Eff.
2. Friction Loss in Duct:
(Hand Book of Air Conditioning System Design Carrier)
Total P = 0.03 f (L/d1.22) (V/1000)1.82
Where:P
f
L
d
V

=
=
=
=
=

friction loss (in wag)

interior surface roughness (0.9 for MS)
length of duct (ft)
duct diameter (in) equivalent diameter for rectangular duct work
air velocity (fmp)

3. Sample Calculation:
A.

5 meter
1.25 meter
1.25 meter
Duct air velocity
9.78 m/sec
Roughness factor
0.9 (as per ASHRAE)
01. Convert the same as per calculation requirements
B. We have Duct Size
Length
49.2126 inch
Width
49.2126 inch
VNT-01-R2

We have Duct Size

Length
Width
Height

Page 7 of 8

COAL HANDLING SYSTEM

CHHABRA THERMAL POWER PROJECT
STAGE-I, PHASE-II, 2X250 MW

Height

16.4042 feet
Duct air velocity
1925 fpm
Roughness factor
0.9 (as per ASHRAE)
Convert rectangular duct to round De= 1.30x(a*b)0.625/(a+b)0.25
duct
03. Total P = 0.03 f (L/d1.22) (V/1000)1.82
(Hand Book of Air Conditioning System Design Carrier)
P friction loss (in wag)
F interior surface roughness (0.9 for MS)
L length of duct (ft)
D duct diameter (in)
V air velocity (fmp)
Calculated answer comes to: 0.29 mm WC
08.0

Equipment Summery.
08.1

Supply Air Side W.T.-3

08.1.1 Centrifugal Fan
Capacity
Model
Static pressure
Drive motor

:
:
:
:

60500 M3/Hr.
WRC-BC-SWSI-445-N
75 mmWG
30.0 kW x 4 Pole
Qty: 01 No.

08.1.2 Supply Air Filters

610x610x50 mm

Qty: 20 Nos.

08.1.3 Supply Air Grill

350 x 300 mm
300 x 250 mm
325 x 250 mm
325 x 300 mm

Qty:
Qty:
Qty:
Qty:

09 Nos.
05 Nos.
15 Nos.
14 Nos.

08.1.4 GI. Ducting and Duct Support etc. 1 Lot IS:655 GI Sheet
08.2

Exhaust Air Side W.T.-3 R2

08.2.1 Centrifugal Fan
Capacity
Model
Static pressure
Drive motor
08.2.2 Exhaust Air Grill
350 x 325 mm
275 x 225 mm
300 x 250 mm
375 x 325 mm

:
:
:
:

54450 M3/Hr.
WRC-BC-SWSI-402-N
50 mmWG
18.50 kW x 4 Pole
Qty: 01 No.
Qty:
Qty:
Qty:
Qty:

08 Nos.
05 Nos.
15 Nos.
10 Nos.

08.2.3 GI. Ducting and Duct Support etc. 1 Lot IS:655 GI Sheet
VNT-01-R2

Page 8 of 8