Compressed Air Sizing

PACO POWER PLANT

Calculation - Calculation For Compressed Air Sizing Document No: LTCA P-6036 CAS Project No: 12889-001

OWNER

Minera Panama S.A. EPC CONTRACTOR

SK E&C USA CONSULTING ENGINEER

SARGENT & LUNDY 55 EAST MONROE STREET CHICAGO. ILLINOIS 60603-5780

LLC

Minera Panama PACO Power Plant Project Project No 12889-001 Calc for Compressed Air Sizing

Calc No.: LTCA P-6036 CAS Rev A, 05Mar12 Page 1 of 6

SL. NO DESCRIPTION

PAGE NO.

1

PURPOSE AND SCOPE

2

2

DESIGN INPUT

2

3

ASSUMPTIONS

2

4

METHODOLOGY AND ACCEPTANCE CRITERIA

3

5

CALCULATIONS

3

6

RESULTS

4

7

REFERENCES

4

8

ATTACHMENTS

4

Minera Panama PACO Power Plant Project Project No 12889-001 Calc for Compressed Air Sizing

1

Calc No.: LTCA P-6036 CAS Rev B, 4Dec12 Page 2 of 6

PURPOSE AND SCOPE The purpose of this calculation is to determine the following : a. Air Compressor Design Capacity (common and catering to both Instrument air and service air) b. Instrument Air and Service Air Compressor Design Discharge Pressure. c. Instrument and Service Air Receiver Capacity. d. Instrument air Dryer Capacity Definitions : A. Standard Cubic Feet Per Minute (SCFM) - Compressed air flow in cubic feet per minute expressed in terms of “standard air” conditions, which are defined by ASME test codes as 1.013 Bar , 15°C and 0% relative humidity. Of these set conditions, SCFM actually defines a precise mass flow rate. B. Inlet Cubic Feet per Minute (ICFM) - Compressor capacity adjusted for actual pressure, temperature and humidity conditions at the compressor inlet. Expressed in cubic feet per minute.

2

DESIGN INPUT

2.1

3x50% oil free rotatory type air compressors fitted with after cooler and moisture separator are considered for IA & SA for 2 units

3

No

Ref. 7.1 & 7.6

2.2

Number of working air compressors for 2 Units

2

No

Ref. 7.1 & 7.6

2.3

Number of receivers

2.3.1

No. of SA Receivers

2

No

Ref. 7.1 & 7.6

2.3.2

No. of IA Receivers

2

No

Ref. 7.1 & 7.5

2.4

No. of Refrigerant type IA Dryers

2

No

Ref. 7.1 & 7.5

2.5

Instrument air demand for Pneumatic operated valve (for which instrument air requirement is not available) is considered as

1

2.6

Design atmospheric pressure

Pa

1.01

2.7

Maximum ambient dry bulb temp

ta

35.0

0

C

Ref. 7.1

2.8

Design Relative humidity

RH

84.0

%

Ref. 7.1

2.9

Margin for Compressor system leakage & expansion allowances

25.0

%

Ref. 7.1

2.10

Flow through each Service Air hose / tapping

20.0

Nm3/hr

13.0

SCFM

ICFM i.e.1 Ref. 7.2 CFM at Compressor inlet condition. Bar(a)

Ref. 7.1

EJ

2.11

Pressure loss across inlet air filter including piping

Pif

0.03

Bar

Ref. 7.2

2.12

Pressure loss across Instrument Air Dryer , filter and associated piping

Pid

0.50

Bar

Ref. 7.2

2.13

Maximum value of Minimum / Normal Pressure required at any Instrument Air User Point

Pt(max)

7.00

Bar(g)

Ref. 7.1

2.14

Maximum allowable pressure drop from the after filter on the instrument air dryer to the end user of the instrument air system as % of the instrument air system design pressure

10.00

%

Ref. 7.2

2.15

Material for SA Piping

ASTM A 106 Gr. B

Ref. 7.3

2.16

Material for IA Piping

Stainless steel ( SS 304 )

Ref. 7.3

3

ASSUMPTIONS (V: Verified; UV: Unverified; EJ: Engineering Judgment)

3.1

Atmospheric pressure at 15m

3.2

Maximum and normal flow of Service air requirements are assumed for various packages and shall be verified at a later date on receipt of inputs from package suppliers.

Pa

1.01

Bar(a)

EJ U

Refer Attachment 8.1 for values which are considered as unverified at this stage. 3.3

Maximum and normal flow of Instrument air requirements are assumed for various packages and shall be verified at a later date on receipt of inputs from package suppliers. Refer Attachment 8.2 for values which are considered as unverified at this stage.

U

Minera Panama PACO Power Plant Project Project No 12889-001 Calc for Compressed Air Sizing

Calc No.: LTCA P-6036 CAS Rev B, 4Dec12 Page 3 of 6

3.4

Service air tapings in service at any given time

20

%

EJ

3.5

Storage time (T) for SA & IA receiver sizing

1

min

EJ

3.6

IA consumption in compressor skid

F1

0

SCFM

V Ref 7.9

3.7

Electrochlorination System IA Consumption

F2

0

SCFM

V Ref 7.5

3.8

IA consumption for fly ash handling system

F3

560

SCFM

U Ref 7.11

3.9

IA consumption for bottom ash handling system

F4

940

SCFM

U Ref 7.12

3.10

Use factor of IA consumption in Fly & bottom Ash handling system, considering intermittent flow for filter cleaning

U1

20

%

EJ

4 4.1

METHODOLOGY AND ACCEPTANCE CRITERIA As per Mechanical Design Criteria Document , all the compressors for Instrument Air & Service Air system shall be identical and should be designed for parallel operation.

4.2

The design temperature for the compressor is operating temperature plus 50C

4.3

No. of Tappings in SA and IA have been considered as per the P&ID's

4.4

IA and SA air receivers are sized to minimize system pulsations and AC cycling.

4.5

Determine compressor capacity for plant IA and SA users. The compressor capacity calculated will be rounded up to nearest 50 Nm3/hr for selection of design capacity. Determine SA air receiver and IA air receiver capacity. The receiver capacity calculated will be rounded up to nearest 0.5 cum for selection of design storage volume

4.6 4.7

Compressor Discharge Pressure : a. The pressure drop through the air piping system must be considered. The air distribution system from receiver to end user should allow no more than 10% ΔP. b. Inlet filter pressure loss can be estimated at 0.5 Bar c. A 3% margin is considered to determine the IA/SA Compressor Design discharge pressure

4.8

Instrument air dryer will be sized for maximum instantaneous requirement of IA with a margin of 10% rounded up to nearest 50 Nm3/hr for selection of design capacity.

5 5.1

CALCULATIONS CALCULATION OF COMPRESSOR DISCHARGE TEMPERATURE

5.1.1

Maximum ambient dry bulb temp

5.1.2

Design Temperature

5.2

ta

35.0

0

taSELECTED

40.0

0

C C

CALCULATION OF COMPRESSOR DISCHARGE PRESSURE

5.2.1

Pressure loss across Instrument Air Dryer Skid

5.2.2

Maximum value of Minimum/Normal Pressure required at any Instrument Air user point

5.2.3

Maximum allowable pressure drop from the after filter on the instrument air dryer to the end user of the instrument air system as % of the IA compressor design discharge pressure.

5.2.4

IA compressor required design discharge pressure

Pd=[Pid+Pt(max)] / [1-0.01dP]

8.33

Bar(g)

5.2.5

IA Compressor specified design discharge pressure

Pdesigned= Pd*1.03

8.58

Bar(g)

5.2.6

Discharge pressure selected

PdSelected

8.6

Bar(g)

Bar(a)

5.3

0.50

Bar

7.00

Bar(g)

dP

10.0

%

CALCULATION FOR ICFM TO SCFM CONVERSION FOR SITE CONDITIONS

5.3.1

Saturation Vapor pressure at inlet temp.

5.3.2

Design inlet temp

5.3.3

Pressure loss across inlet air filter including piping

5.3.4

Design inlet pressure

5.3.5

Formula to convert ICFM to SCFM, per Ref MES-20.1 is

5.3.6

SCFM, for each CV corresponding to 1 ICFM demand

5.4

Pid Pt(max)

Psat

0.06

ti = taSELECTED

40.00

Pif

0.03

Bar

Pi = Pa - Pif

0.98

Bar

0.85

SCFM

0

C

[SCFM x Pa x (273+ti)] / [(Pi -(Pi/Pa) x (RH/100) x Psat)x 288]

CALCULATION FOR COMPRESSOR CAPACITY

5.4.1

SA requirement (Maximum)

a

976.6

SCFM

Ref. Attach. 8.1

5.4.2

IA requirement (Maximum)

b

994.7

SCFM

Ref. Attach. 8.2

5.4.3

Compressed Air Requirement

CAreq = a+b

1971.4

SCFM

3174.9

Nm3/hr

Minera Panama PACO Power Plant Project Project No 12889-001 Calc for Compressed Air Sizing

5.4.4

Margin for System Leakage and Expansion Allowances

5.4.5

Capacity of compressors calculated

5.4.6

No. of Compressor Working

5.4.7

Capacity of each Compressor calculated

5.4.8

5.5

5.5.2

Discharge Pressure of the compressor

5.5.3

Capacity of Air Receiver calculated

5.5.4

Capacity of Air Receiver selected (same for both Instrument and Service Air)

Discharge Pressure of the compressor Capacity of Air Receiver calculated

5.6.4

Capacity of Air Receiver selected (same for both Instrument and Service Air)

Nm3/hr

N

2.0

Qcal = CMreq / N

1232.1

SCFM

1984.3

Nm3/hr

QSELECTED

2250.0

Nm3/hr

QSELECTED

2250.0

Nm3/hr

PdSelected

8.6

Bar(g)

RECreq=[QSELECTED*Pa/PdSelect ed]*T

4.4

m3

Ref. 7.4

RECSELECTED

6.0

m3

Bid was 6m3

Maximum instantaneous IA requirement

5.7.2

Applicable margin

5.7.3

Calculated design Capacity of IA Dryer

b

994.7

SCFM

1603.0

Nm3/hr

PdSelected

8.6

Bar(g)

3.2

m3

Ref. 7.4

RECSELECTED

4.0

m3

Bid was 4m3

995

SCFM

Capacity of IA Dryer Selected

IAreq

DRYCALCULATED

DRYSELECTED

10.0

%

1094.2

SCFM

1762.3

Nm3/hr

2000.0

Nm3/hr

RESULTS Capacity of Each Air Compressor

2250.00

Nm3/hr

6.2

Compressor Discharge Pressure

8.60

Bar(g)

6.3

Service Air Receiver Capacity Selected

6.00

m3

6.4

Instrument Air Receiver Capacity Selected

4.00

m3

6.5

Capacity of IA Dryer

2000.00

Nm3/hr

REFERENCES

7.1

Functional Technical Specification, dt. 13th July 2011

7.2

S&L Standard Document No. MES- 20.1

7.3

Mechanical Design Criteria no. M0-1000

7.4

S&L Standard Document MSDI-18.1.2.4

7.5

IA P&ID, Dwg no. M1-0123 Sh1 to Sh 3

7.6

SA P&ID, Dwg no. M1-0122

7.7

Boiler Utility List dt. Aug 20 , 2012

7.8

Fisia Babcock Environment , Battery Limit Document dt. 19 Nov, 2012

7.9

Atlas Copco Utility List dated 2012.09.11.

7.10

Not Used

7.11

Fly Ash Handling System Bid - TechPro - "Design Basis _ Fly Ash"

7.12

Bottom Ash Handling System Bid - TechPro - "Design Basis _ Bottom Ash"

8

Ref. Attach. 8.1

RECreq=[QSELECTED*Pa/PdSelect ed]*T

6.1

7

Bid AC capacity of 2250.

CALCULATIONS FOR INSTRUMENT AIR DRYER CAPACITY

5.7.1

6

3968.7

CALCULATION FOR INSTRUMENT AIR RECEIVER CAPACITY

5.6.2

5.7.4

% SCFM

IA requirement (Maximum)

5.6.3

5.7

25.0 2464.2

CALCULATION FOR SERVICE AIR RECEIVER CAPACITY Rated Compressor Capacity

5.6

M CMreq = CAreq x M

Capacity of each Compressor selected

5.5.1

5.6.1

Calc No.: LTCA P-6036 CAS Rev B, 4Dec12 Page 4 of 6

ATTACHMENTS

8.1

Service Air Requirement

8.2

Instrument Air Requirement

Bid AC capacity of 2000.

Minera Panama PACO Power Plant Project Project No 12889-001 Calc for Compressed Air Sizing

Calc No.: LTCA P-6036 CAS Rev B, 4Dec12 Page 5 of 6

Attachment 8.1 : Service Air Tabulation SL.NO. AREA

NO. OF Use Factor TAPPINGS (%) as per P&ID

MAXIMUM / DESIGN FLOW, SCFM

VERIFICATION

1

TG Building

28

20

72.8

UV

2

Boiler area

4

20

10.4

UV

3

Chimney - CEMS

1

20

2.6

UV

4

Demineralization plant

2

20

5.2

UV

5

Fire water pump house

1

20

2.6

UV

6

Desalination plant

2

20

5.2

UV

7

CW pump house

2

20

5.2

UV

8

Silo utility area

2

20

5.2

UV

9

Fuel oil Area

4

20

10.4

UV

10

Admin building

0

20

0.0

UV

11

Compressor house

2

20

5.2

UV

REMARKS

Considering 13 SCFM per tapping shown in P&ID Ref. 7.6

Not required

12

Workshop

0

20

0.0

UV

13

Fire station building

1

20

2.6

UV

14

Electro chlorination plant

0

20

0.0

UV

15

Parking area

1

20

2.6

UV

16

Crusher house

1

20

2.6

UV

17

Stack Area

1

20

2.6

UV

18

Coal Handling plant

2

20

5.2

UV

19

CHP Switch Gear room

1

20

2.6

UV

20

Electrical Switch yard

1

20

2.6

UV

21

Control building

1

20

2.6

UV

22

Burner Atomizing Air

12

100

380.0

Ref. 7.7 (V)

33.53 SCFM/Atomizer

23

GRAND TOTAL OF TAPPINGS

57

VERIFICATION

Reference

Not required as independent AC

Not required as independent AC

528.2

Service Air Requirement Calculations

SL. No. Description

Flow Required SCFM

Use Factor %

MAXIMUM / DESIGN FLOW, SCFM

1

Ammonia Injection

0.0

0

0

V

Ref. 7.7

2

Acoustic Horn for SCR Soot Blower

6.21

100

6

V

Ref. 7.7

3

APH Aux Drive

600.0

0

0

4

APH Coil Purge

100.0

20

20

EJ

Ref. 7.2

5

Ash Handling system Poke Hole

65.0

20

13

UV

Ref. 7.2

3rd compressor would be turned on & only 1 motor fail at a time.

6

Requirement for one unit

39

Sl. No. 1+2+3+4+5

7

Requirement for two unit

78

Sl. No. 6*2

8

Estimated service air requirement for tappings

528.2

100

528

9

Sea Water FGD

260.0

100

260

V

Ref. 7.8

10

Water Treatment

10.0

100

10

UV

Haji Quote

11

Margin to cover SeenTec unknown

100.0

100

100

12

Maintenance / Ware house Tools

300.0

0

13

TOTAL SA REQUIREMENT

0 977

EJ

Not required as independent AC

Sl. No. 7+8+9+10+11+12

Minera Panama PACO Power Plant Project Project No 12889-001 Calc for Compressed Air Sizing

Calc No.: LTCA P-6036 CAS Rev B, 4Dec12 Page 6 of 6

Attachment 8.2 : Instrument Air Tabulation SL. DESIGNATION NO.

MAXIMUM / NORMAL Verified / REMARKS NUMBER OF TAPPINGS / FLOW, Unverified DESIGN INSTRUMENTS / VALVES AS PER FLOW, P&ID SCFM

SCFM

8.7

8.7

Ref. 7.7 (V) 0.62 SCFM / VALVE

A)

BTG AREA

1

BOILER & AUXILIARIES (ONE UNIT)

a)

Control Valves

b)

O2 Analyzer panel

1

0.6

0.6

Ref. 7.7 (V) 0.62 SCFM / PANEL

c)

Air Operated Valves

97

72.3

72.3

Ref. 7.7 (V) 0.75 SCFM / VALVE

d)

Actuator for FD Fan IGV

2

6.8

6.8

Ref. 7.7 (V) 3.42 SCFM / ACTUATOR

e)

Actuator for ID Fan IGV

2

6.8

6.8

Ref. 7.7 (V) 3.42 SCFM / ACTUATOR

14

f)

Actuator for PA Fan IGV

2

6.8

6.8

Ref. 7.7 (V) 3.42 SCFM / ACTUATOR

g)

Instrument for S.C.R

1

12.4

12.4

Ref. 7.7 (V) 12.42 SCFM

h)

On - Off Damper

8

68.1

68.1

Ref. 7.7 (V) 8.51 SCFM / DAMPER

i)

Control Dampers

20

36.0

36.0

Ref. 7.7 (V) 7.80 SCFM / DAMPER

2

ID FANS (ONE UNIT)

2

1.7

1.7

UV

Ref. 7.5

3

TG BUILDING CVs (ONE UNIT)

28

23.7

23.7

UV

Ref. 7.5

244.0

244.0

INSTRUMENT AIR REQUIREMENT FOR BTG AREA FOR TWO UNITS

488

488

4

CONVEYOR ROOM AND SILO VENT

40

25

UV

Ref 7.2

5

FLY ASH HANDLING PLANT

112

112

UV

F3 x U1

6

BOTTOM ASH HANDLING SYSTEM

188

188

UV

F4 x U1

7

DESALINATION PLANT

100

100

UV

From VA TECH Offer

8

WATER TREATMENT

60

60

UV

From Haji Quote

B)

INSTRUMENT AIR REQUIREMENT FOR CONTROL VALVES IN BOP AREA :

1

WATER TREATMENT PLANT

4

3.4

3.4

UV

Ref. 7.5

2

FUEL OIL AREA

2

1.7

1.7

UV

Ref. 7.5

3

COMPRESSOR HOUSE

0.0

0.0

UV

F1 - Refrig dryer so no air required

4

TO CEMS

1

0.8

0.8

UV

Ref. 7.5

5

TO ELECTRO CHLORINATION SYSTEM

0.00

0.00

UV

F2 - Separate AC for Electrochlorination

6

TO RAIN & RUNOFF WATER STORAGE

0.8

0.8

UV

Ref. 7.5

C)

TOTAL IA REQUIREMENT FOR BOP AREA AND 2 UNITS OF BTG AREA

995

980

INSTRUMENT AIR REQUIREMENT FOR BTG AREA FOR ONE UNIT

1

SL. 1+2+3 2 x (SL. 1+2+3)