Space for stamping (Review and validation status):
Project Name:
LEPCL 660 MW CFPP, Karachi
Owner’s Name:
LUCKY ELECTRIC POWER COMPANY LIMITED
Owner’s Engineer:
FICHTNER GMBH & CO KG
EPC Contractor:
SEPCOIII ELECTRIC POWER CONSTRUCTION CORPORATION., LTD.
EPC Contractor’s Engineer:
POWERCHINA HEBEI ELECTRIC POWER DESIGN & RESEARCH
INSTITUTE CO., LTD.
Revision history
Rev.
A
Date
20/07/2018
Created by
Schommer
Checked by
Weisenburger
Approved by
Weisenburger
Description
Initial issue
Description of the latest revision
Cross checked by
Department
Name
Date
Participant
WUHAN BOILER COMPANY LTD.
Customer’s Document Code:
Scale
Other Document Code (if any)
A4
Responsible dept.
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Format
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Weisenburger
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Document Type
Project Document Code
Design Concept
QML/10/B/-----2FS--/DO/030
Document title, Subtitle
Document Status
Air and flue gas ducts –
Process design
Released
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C000083_00030_7030
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Table of Contents
1.
Objective ............................................................................................................................................................... 3
2.
Scope of Application ........................................................................................................................................... 3
3.
Reference Documents ........................................................................................................................................ 3
4.
Terminology, Definitions, Abbreviations ........................................................................................................ 3
5.
Air, flue gas and cold gas duct design ............................................................................................................ 4
6.
7.
5.1.
General Approach ............................................................................................................................................ 4
5.2.
Excerpt from Fichtner specification ................................................................................................................. 4
5.3.
Design data air, flue gas and cold gas ducts .................................................................................................. 5
5.3.1.
Design data cold air ducts .......................................................................................................... 5
5.3.2.
Design data hot air ducts ............................................................................................................ 5
5.3.3.
Design data flue gas ducts ......................................................................................................... 8
5.3.4.
Design data cold gas ducts ........................................................................................................ 9
Duct routing ........................................................................................................................................................ 10
6.1.
Air from suction point to hot air header.......................................................................................................... 10
6.2.
Hot air from header to OFA nozzles .............................................................................................................. 10
6.3.
Hot air from header to PC / Oil burner and CG nozzles ............................................................................... 11
6.4.
Hot air from header to burnout grate ............................................................................................................. 11
6.5.
Hot primary air from header to FGRD ........................................................................................................... 12
6.6.
Cold gas to furnace nozzles and FGRD (PA) ............................................................................................... 12
6.7.
Flue gas from furnace to RAPH..................................................................................................................... 13
Attachments ....................................................................................................................................................... 13
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1.
OBJECTIVE
This document summarizes the process design data of the air and flue gas ducts.
2.
SCOPE OF APPLICATION
This document is an internal design document. The process data are valid for Qasim Lucky power plant
exclusively.
3.
REFERENCE DOCUMENTS
QML_10_B_H----2FS--_PF_001_Rev.B – Air and Flue Gas Scheme
QML_00_B_-----2PD--_DO_004_BTC for various loads and coal range
4.
TERMINOLOGY, DEFINITIONS, ABBREVIATIONS
PC
LLW
ULW
NCV
BMCR
OFA
PA
FD fan
ID fan
RAPH
FGRD
RSC
FC
RDS-PP
Performance coal for guarantee calculations
Coal quality with minimum calorific value and maximum water content
Coal quality with maximum calorific value and minimum water content
Net calorific value (lower heating value)
Boiler maximum continuous rating
Over fire air
Primary air
Forced draught fan
Induced draught fan
Regenerative air preheater
Flue gas resuction duct
Reference Site Conditions
fouled conditions
Reference Designation System for Power Plants
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5.
AIR, FLUE GAS AND COLD GAS DUCT DESIGN
5.1.
General Approach
The duct design considers the maximum volume flow firing LLW lignite at 105% MCR (BMCR) load under
fouled conditions, respectively single line operation at 60% BMCR load. For the dimensioning of the cold gas
ducts operation with ULW has to be considered.
The specified design velocities are the following:
•
max. allowable air velocity:
20 m/s
•
max. allowable flue gas velocity:
16 m/s
According to GE Stuttgart common practice the cold air ducts (duct sections 1 – 3) are designed with 14 m/s
and the air intake (duct section 0) with 5 m/s (rain hood + bird and trash trap screen on FD fan suction side).
The cold gas ducts are designed with 20 m/s.
The following boundary conditions shall be considered for design:
•
Site altitude: + 8 m above sea level
•
Average ambient pressure: 991 mbar (RSC)
•
Ambient temperature: 35.2 °C (RSC)
•
Absolute air humidity: 0.0245 kg/kg dry air
The duct numbers given in the following tables refer to the “Air and flue gas flow diagram” (actual flow diagram
shall be taken as reference for duct numbering). Please note that the given cross sections are required
minimum cross sections.
The following assumptions are basis for the design:
•
temperature increase of FD fan:
4K
•
temperature increase of ID fan:
4K
•
RAPH leakage air:
64.5 kg/s (9% of total air to furnace /
100% BMCR/LLW/FC)
21.5 kg/s (4.2% of total air to furnace /
60% BMCR/LLW/single line)
•
air temperature downstream RAPH:
381°C (100% BMCR/LLW/FC)
325.2°C (60% BMCR/LLW)
•
flue gas temperature downstream RAPH:
200°C (100% BMCR/LLW/FC)
171.4°C (60% BMCR/LLW/single line)
The parameter might be subject to change after the final selection of the components like fans and RAPH.
5.2.
Excerpt from Fichtner specification
As the FD and ID fans as well as RAPH has to be designed for 2x 60% BMCR, the above-mentioned velocities
are also considered for the relevant ducts (“one line” ducts)
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5.3.
Design data air, flue gas and cold gas ducts
5.3.1.
Design data cold air ducts
Duct number
-
Name of duct section
-
Load Case
Description
Fuel
Number of sections
Mass flow
Volume flow wet s.t.p.
Density wet s.t.p.
operational temperature
Pressure difference
Pressure abs.
Volume flow eff.
Design velocity
Required duct dimension
min. cross section
5.3.2.
% BMCR
kg/s
Nm³/h
kg/Nm³
°C
mbar
mbar
m³/s
m/s
0
Air intake
from outside
60%/1 line
basic fouling
LLW
2
481,4
1.360.719
1,274
35,0
0,0
991
436,0
5,0
1
Air upstream
FD-Fan
60%/1 line
basic fouling
LLW
2
481,4
1.360.719
1,274
35,0
-6,5
985
438,9
14,0
2
Air downstream
FD-Fan
60%/1 line
basic fouling
LLW
2
481,4
1.360.719
1,274
39,0
44,0
1035
422,9
14,0
3
Air downstream
SCAPH
60%/1 line
basic fouling
LLW
2
481,4
1.360.719
1,274
39,0
35,0
1026
426,6
14,0
m²
87,3
31,4
30,3
30,5
7
Hot Air
distributor
60%/1 line
basic fouling
LLW
1
353,1
998.119
1,274
325,2
25,0
1016
605,9
20,0
8
% BMCR
kg/s
Nm³/h
kg/Nm³
°C
mbar
mbar
m³/s
m/s
6
Air flow downstr.
RAPH
60%/1 line
basic fouling
LLW
2
459,9
1.299.951
1,274
325,2
25,0
1016
789,1
20,0
100%
FC
LLW
1
40,0
113.056
1,274
381,0
25,0
1016
75,0
20,0
9
Grate air to one
grate section
100%
FC
LLW
2
20,0
56.528
1,274
381,0
15,0
1006
37,9
20,0
9a
Grate air to one
grate zone
100%
FC
LLW
6
6,7
18.843
1,274
381,0
15,0
1006
12,6
20,0
m²
39,5
30,3
3,8
1,9
0,7
Design data hot air ducts
Duct number
-
Name of duct section
-
Load Case
Description
Fuel
Number of sections
Mass flow
Volume flow wet s.t.p.
Density wet s.t.p.
operational temperature
Pressure difference
Pressure abs.
Volume flow eff.
Design velocity
Required duct dimension
min. cross section
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Duct number
-
10
11
12
13
14
Name of duct section
-
SA to OFA
one boiler side
SA to OFA
1 big nozzle
SA to OFA
2 small nozzles
SA to OFA
3 small nozzles
SA to OFA
1 small nozzle
% BMCR
kg/s
Nm³/h
kg/Nm³
°C
mbar
mbar
m³/s
m/s
100%
FC
LLW
2
50,0
141.321
1,274
381,0
20,0
1011
94,3
20,0
100%
FC
LLW
4
11,0
31.062
1,274
381,0
12,0
1003
20,9
20,0
100%
FC
LLW
2
11,2
31.712
1,274
381,0
12,0
1003
21,3
20,0
100%
FC
LLW
2
16,8
47.569
1,274
381,0
12,0
1003
32,0
20,0
100%
FC
LLW
10
5,6
15.856
1,274
381,0
12,0
1003
10,7
20,0
m²
4,7
1,0
1,1
1,6
0,53
-
15
16
17
18
19
-
PA+SA to 1 PC
burner + cooling
air to 1 oil burner
and 1 CG nozzle
PA to 1 FGRD
Cooling air to 1
CG nozzle
SA to 1 PC
burner
SA to burner air
nozzles
% BMCR
kg/s
Nm³/h
kg/Nm³
°C
mbar
mbar
m³/s
m/s
100%
FC
LLW
8
67,9
191.843
1,274
381,0
20,0
1011
127,9
20,0
BCM
8
13,3
37.567
1,274
347,4
18,0
1009
23,8
20,0
100%
FC
LLW
8
0,9
2.473
1,274
381,0
18,0
1009
1,7
20,0
100%
FC
LLW
8
51,2
144.797
1,274
381,0
17,0
1008
96,9
20,0
100%
FC
LLW
8
47,9
135.301
1,274
381,0
12,0
1003
91,0
20,0
m²
6,4
1,2
0,1
4,8
4,5
Load Case
Load Description
Fuel
Number of sections
Mass flow
Volume flow wet s.t.p.
Density wet s.t.p.
operational temperature
Pressure difference
Pressure abs.
Volume flow eff.
Design velocity
Required duct dimension
min. cross section
Duct number
Name of duct section
Load Case
Load Description
Fuel
Number of sections
Mass flow
Volume flow wet s.t.p.
Density wet s.t.p.
operational temperature
Pressure difference
Pressure abs.
Volume flow eff.
Design velocity
Required duct dimension
min. cross section
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Duct number
-
20
21
Name of duct section
-
SA to 1 SA burner
level
SA to 1/2 SA
burner level
% BMCR
kg/s
Nm³/h
kg/Nm³
°C
mbar
mbar
m³/s
m/s
100%
FC
LLW
24
16,0
45.100
1,274
381,0
12,0
1003
30,3
20,0
100%
FC
LLW
48
8,0
22.550
1,274
381,0
12,0
1003
15,2
20,0
22
Core and
ceramic air to 1
PC burner
100%
FC
LLW
8
3,4
9.496
1,274
381,0
12,0
1003
6,4
20,0
m²
1,5
0,8
0,4
Duct number
-
25
26
Name of duct section
-
Core air to 1 PC
nozzle
SA to one oil
burner
% BMCR
kg/s
Nm³/h
kg/Nm³
°C
mbar
mbar
m³/s
m/s
100%
FC
LLW
16
1,2
3.306
1,274
381,0
12,0
1003
2,2
20,0
40%
basic fouling
oil
8
29,2
82.390
1,274
280,0
18,0
1009
46,6
20,0
m²
0,12
2,3
Load Case
Load Description
Fuel
Number of sections
Mass flow
Volume flow wet s.t.p.
Density wet s.t.p.
operational temperature
Pressure difference
Pressure abs.
Volume flow eff.
Design velocity
Required duct dimension
min. cross section
Load Case
Load Description
Fuel
Number of sections
Mass flow
Volume flow wet s.t.p.
Density wet s.t.p.
operational temperature
Pressure difference
Pressure abs.
Volume flow eff.
Design velocity
Required duct dimension
min. cross section
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24
Ceramic air to 1
PC burner
Core air to PC
nozzles
100%
FC
LLW
8
1,0
2.883
1,274
381,0
12,0
1003
1,9
20,0
100%
FC
LLW
8
2,3
6.613
1,274
381,0
12,0
1003
4,4
20,0
0,10
0,22
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5.3.3.
Design data flue gas ducts
Duct number
-
28
29
Name of duct section
-
Flue gas
downstream Eco
Flue gas
upstream APH
% BMCR
kg/s
Nm³/h
kg/Nm³
°C
mbar
mbar
m³/s
m/s
100%
FC
LLW
1
903,7
2.643.325
1,231
420,3
-10,0
981
1926,0
16,0
60%/1 line
basic fouling
LLW
2
650,5
1.895.924
1,235
353,4
-8,0
983
1245,6
16,0
60%/1 line
basic fouling
LLW
2
672,0
1.956.690
1,236
171,4
-30,0
961
932,9
16,0
60%/1 line
basic fouling
LLW
2
672,0
1.956.690
1,236
171,4
-36,0
955
938,7
16,0
60%/1 line
basic fouling
LLW
2
638,9
1.860.306
1,236
171,4
-38,0
953
894,4
16,0
m²
120,4
77,8
58,3
58,7
55,9
Duct number
-
33
34
Name of duct section
-
Load Case
Load Description
Fuel
Number of sections
Mass flow
Volume flow wet s.t.p.
Density wet s.t.p.
operational temperature
Pressure difference
Pressure abs.
Volume flow eff.
Design velocity
Required duct dimension
min. cross section
Load Case
Load Description
Fuel
Number of sections
Mass flow
Volume flow wet s.t.p.
Density wet s.t.p.
operational temperature
Pressure difference
Pressure abs.
Volume flow eff.
Design velocity
Required duct dimension
min. cross section
30
31
32
Flue gas
Flue gas
Flue gas
downstream APH downstream ESP upstream ID fan
Flue gas
downstream ID Flue gas to stack
fan
% BMCR
kg/s
Nm³/h
kg/Nm³
°C
mbar
mbar
m³/s
m/s
60%/1 line
basic fouling
LLW
2
638,9
1.860.306
1,236
176,4
20,0
1011
852,5
16,0
100%
FC
LLW
1
942,2
2.749.688
1,234
200,0
1,0
992
1351,7
16,0
m²
53,3
84,5
Please note: dimensions of ducts number 30 to 34 are for information only as they are not in scope of GE.
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5.3.4.
Design data cold gas ducts
Duct number
-
Name of duct section
Load Case
Load Description
Fuel
Number of sections
Mass flow
Volume flow wet s.t.p.
Density wet s.t.p.
operational temperature
Pressure difference
Pressure abs.
Volume flow eff.
Design velocity
Required duct dimension
min. cross section
35
% BMCR
kg/s
Nm³/h
kg/Nm³
°C
mbar
mbar
m³/s
m/s
m²
36
37
Cold gas
Cold gas
downstream CG
Cold gas to FGRD
upstream CG fan
fan to one
furnace side
100%
basic fouling
basic fouling
basic fouling
ULW
ULW
ULW
2
2
2
100,0
71,0
60,00
283.666
201.403
170.199
1,269
1,269
1,269
171,2
175,0
175,0
-38,0
25,0
20,0
953
1016
1011
136,3
91,6
77,76
20,0
20,0
20,0
6,8
4,6
3,9
Duct number
-
37a
38
39
Name of duct section
-
Cold gas to
furnace
Cold gas to one
furnace nozzle
Cold gas to one
FGRD
% BMCR
kg/s
Nm³/h
kg/Nm³
°C
mbar
mbar
m³/s
m/s
100%
basic fouling
ULW
2
25,00
70.916
1,269
175,0
20,0
1011
32,40
20,0
100%
basic fouling
ULW
8
6,3
17.729
1,269
175,0
20,0
1011
8,1
20,0
basic fouling
ULW
8
15,0
42.550
1,269
175,0
20,0
1011
19,44
20,0
m²
1,6
0,40
1,0
Load Case
Load Description
Fuel
Number of sections
Mass flow
Volume flow wet s.t.p.
Density wet s.t.p.
operational temperature
Pressure difference
Pressure abs.
Volume flow eff.
Design velocity
Required duct dimension
min. cross section
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6.
DUCT ROUTING
The following 3D models of ducts illustrate the status of routing. This might be subject to change during
detailed engineering phase.
6.1.
Air from suction point to hot air header
6.2.
Hot air from header to OFA nozzles
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6.3.
Hot air from header to PC / Oil burner and CG nozzles
6.4.
Hot air from header to burnout grate
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6.5.
Hot primary air from header to FGRD
6.6.
Cold gas to furnace nozzles and FGRD (PA)
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6.7.
Flue gas from furnace to RAPH
7.
ATTACHMENTS
The attached process flow diagram depicts schematically the air, flue gas and cold gas ducting including the
duct numbers for reference of the duct process design data.
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
19
18
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
A
A
16
M
M
M
M
flue gas
resuction duct
primary air
flue gas
resuction duct
primary air
flue gas
resuction duct
primary air
flue gas
resuction duct
B
M
M
B
arrangement of coal burners
and startup / ignition burners
primary air
M
M
39
arrangement of over fire air nozzles
(2x, stacked)
slag removal
37
2
M
M
M
M
M
M
13
1
flue gas
extraction
(2x, stacked)
front wall
hot air
to burner
hot air
to burner
D
(2x, stacked)
D
8
5
7
(2x, stacked)
M
10
ignition air
4
front wall
11
12
rear wall
OFA
14
C
rear wall
M
C
3
6
hot air to OFA
pulverized coal burners
E
hot air
to burner
15
M
38
hot air to burner and primary air
M
37a
ignition air
M
hot air
to burner
M
M
F
17
18
22
M
M
M
M
coal bunker
M
M
M
coal bunker
coal bunker
M
M
M
M
M
M
M
M
M
M
M
M
M
3
M
2
aspiration
from outside
1
0
G
21
FD fan
M
M
M
M
coal
burner
M
secondary air
M
M
M
M
M
coal
burner
secondary air
ignition air
ignition air
M
M
M
M
M
H
secondary air
ignition air
ignition air
secondary air
M
M
M
M
SCAPH
23
G
M
20
7
6
M
coal
burner
coal
burner
24
19
26
H
M
M
M
M
M
M
M
M
M
M
30
31
ESP
M
32
M
coal
burner
M
M
coal
burner
M
M
coal
burner
M
coal
burner
M
33
ID fan
RAPH
M
F
cold gas
M
coal bunker
E
oil startup / ignition burners
29
25
36
J
J
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
K
28
flue gas from boiler
M
M
M
M
M
M
M
M
M
M
M
M
M
M
cold gas system
M
M
M
34
M
M
M
M
M
M
M
L
M
M
M
M
M
M
M
M
M
M
RAPH
M
beater wheel mill
L
M
M
ESP
M
M
beater wheel mill
M
M
M
M
M
35
grate air
M
K
stack
or cooling tower
FGD
beater wheel mill
M
ID fan
beater wheel mill
M
M1
M2
M3
M4
M
N
M
M
flue gas
resuction duct
primary air
flue gas
resuction duct
primary air
flue gas
resuction duct
primary air
flue gas
resuction duct
Q
M
M
hot air to burner and primary air
M
M
primary air
M
M
FD fan
SCAPH
M
M
M
M
M
M
Q
cold gas
8
R
N
aspiration
from outside
M
M
M
M
9
R
OFA
9a
M
to furnace
hopper
hot air to OFA
longitudinal
pusher type grate
cooling air
S
S
cool air
dry ash removal
hot air
to burner
ignition air
M
arrangement of CG nozzles
T
M
M
U
rear wall
front wall
M
hot air
to burner
M
ignition air
T
hot air
to burner
hot air
to burner
ignition air
U
flue gas
extraction
legend:
flue gas
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
coal
burner
secondary air
M
M
M
M
M
M
M
M
coal
V
Project Name:
LEPCL 660 MW CFPP, Karachi
M
coal
burner
M
air
M
M
M
coal
burner
M
M
coal bunker
secondary air
M
M
M
M
coal bunker
secondary air
M
V
M
M
ignition air
M
coal bunker
secondary air
M
coal bunker
coal
burner
M
OWNER:
M
Lucky Electric Power Company Limited
W
W
M
M
M
M
coal
burner
M
M
M
coal
burner
M
M
M
coal
burner
M
OWNER'S
ENGINEER:
FICHTNER GMBH & CO KG
coal
burner
M
SEPCOIII ELECTRIC POWER CONSTRUCTION
EPC
CONTRACTOR:
M
M
M
X
M
M
M
M
M
M
M
M
M
M
M
M
M
M
CORPORATION., LTD.
M
M
M
M
M
EPC
CONTRACTOR's
DESIGN INSITITUTE:
M
Other Doc NO.
REV.
Customer's Doc NO.
REV.
Q M L 1 0 B H - - - - 2 F S - - P F 0 0 1
Project Doc No.
M
M
DESIGN & RESEARCH INSTITUTE CO., LTD.
M
Y
M
M
M
M
Sobiecki
12.04.2018
Schommer
DWG.NO
Air and Flue Gas Scheme
WBS CODE
CHECKED BY
M
WT.
Z
SCALE
WELD REVIEWED BY
M
M
M
M
beater wheel mill
[
B
A
over fire air system modified
Schommer
Revision
Schommer
04.07.2018
12.04.2018
M
beater wheel mill
M8
M7
FORMAT
REVIEWED BY
0
REV.
B
STANDARD BY
beater wheel mill
M6
of
TECH REVIEWED BY
M
beater wheel mill
Z
Page
M
M
Y
C000083/00 034-0001
12.04.2018
DESIGNED BY
M
X
POWERCHINA HEBEI ELECTRIC POWER
APPROVED BY
M5
12.04.2018
Wuhan Boiler Co.,Ltd.
Schommer
© Copyright 2018 All right reserved. The information herein is proprietary and technically exclusive content that is solely owned by General Electric Company and/or its Affiliates.Thus, it is being provided with the explicit expectation of
[
restricted and privileged use. All persons or legal entities receiving this information shall be deemed by act of its receipt to have contractually agreed to make no duplications. Reproductions of any nature by any means,modifications,
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1
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DATE
disclosures, or use any portion of this material; except as expressly authorized in writing by General Electric Company and/or its legitimate Affiliates
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