Page 1 of 12

FALGUNI SAHA
2009.08.25
13:55:45
+05'30'
BHEL DOCUMENTS NO.: PE-DC-320-154-A001
DEPTT: MECHANICAL AUXILIARY
REV. NO. 1 DATE:
2X500 MW TPS CHANDRAPUR EXPANSION PROJECT. SHEET
BHEL - PS-PEM: PPEI, PLOT NO-25, BHEL, NOIDA, SECTOR-16A, UP-201301.
DOCUMENT TITLE:
DESIGN PHILOSOPHY FOR
LP CHEMICAL DOSING SYSTEM.
1. 0 BRIEF DESCRIPTION OF THE SYSTEMS:
The Chemical Dosing System shall consist of Low Pressure (LP) Chemical dosing system and
NaOH dosing system at ECW Tank. LP dosing system shall be Hydrazine, Ammonia and NaOH
dosing system.
2.0 DESIGN BASIS
Chemical dosing system will be designed to dose required quantity of chemicals to maintain the
quality of boiler feed water and ECW system
3.0 LOW PRESSURE CHEMICAL DOSING:

3.1 HYDRAZINE DOSING SYSTEM:(TOTAL NO OF SKID= 2 NOS)
(Refer drg no. PE-DG-320-154-A001)
Residual oxygen present in feed water can be detrimental to feed cycle equipments. In order to
control the same continuous dosing of dilute solution of hydrazine is done at Boiler Feed
suction line immediately below the Deaerator storage tank only. Though provision has been
kept to dose hydrazine at Condensate discharge header at CPU outlet, Condensate Transfer
pump discharge header and Boiler filling line also, but dosing shall be done at one place at a
time. For this purpose one (1) no. skid mounted Hydrazine dosing system shall be provided.
Dosing system shall mainly comprise the following:
3.1.1 HYDRAZINE PREPRATION CUM METERING TANK (1 No)
A Hydrazine preparation cum metering tank for preparation and measuring the dilute Hydrazine
solution shall be provided. The tank shall be provided with accessories like motorized stirrer,
breather with vent, level gauge, level switch and overflow drain. A filling connection is provided
to fill the concentrated solution by hand pump in the tank.
The solution is then dosed to the required point with the help of dosing pumps.
3.1.2 HYDRAZINE DOSING PUMPS (TOTAL 2 Nos.)
Two nos.(2X100%) Positive displacement plunger type Dosing pumps with relief valves has
been provided.
A Y type strainer (2 x100%) shall be common for both pumps.
3.1.3 HAND PUMP (1 NO.)
A hand pump complete with flexible hose and couplings for transferring hydrazine from drum at
ground level to measuring tank is provided.
3.1.4 ASSOCIATED PIPING, VALVES ETC:
As indicated in the drawing and Data sheet-A.
3.1.5 CONTROL & INSTRUMENTATION
The normal mode of operation of hydrazine dosing system shall be from DDC MIS including ON
/ OFF command to individual pumps. However a local control panel consisting of Start Stop
push buttons, Indicating Lamp, Local / Remote selection, stroke position indicator, Rise / lower
push button to stroke position, local annunciation to be mounted & stroke position indicator on
the lamp shall be provided.
The normal mode of operation of dosing system shall be through DDC MIS, Local remote
selection is to be done with from remote (CR) and indication for the same should be provided
on local panel.
Local annunciation system shall be microprocessor based. All the local annunciations shall be
Page 2 of 12
BHEL DOCUMENTS NO.: PE-DC-320-154-A001
DEPTT: MECHANICAL AUXILIARY
REV. NO. 1 DATE:
2X500 MW TPS CHANDRAPUR EXPANSION PROJECT. SHEET
BHEL - PS-PEM: PPEI, PLOT NO-25, BHEL, NOIDA, SECTOR-16A, UP-201301.
DOCUMENT TITLE:
DESIGN PHILOSOPHY FOR
LP CHEMICAL DOSING SYSTEM.
suitably duplicated for which bidder shall provide free changeover contacts (1 NO + 1NC) rating
0.25 amp. / 220 V DC, 5.0 Amp, 240 V AC at the local panel.
The ON / OFF commands for individual pumps from local push buttons shall act on the
respective drives through DDC MIC.
The stroke position & adjustment will be done from DDC MIS and the stroke actuator shall be
suitable for accepting 4-20 mA DC signal. The pumps shall be provided with 24 V DC, 2-wire
LVDT Type position feed back transmitter to generate 4-20 mA DC signal to indicate stroke
position.
Following interlocks shall be provided.
At Low level in the tank.
x Running Dosing Pump shall be tripped.
x Stirrer motor of the tank shall be tripped.
Following annunciation shall be provided in DDCMIS and LCP.
x Running Dosing Pump trip.
x Stirrer motor trip
x Tank level low.
3.1.6 FLUSHING
Condensate tapped from Condensate water line shall be used for flushing the various pipes
lines and pumps of the system as shown in P &I drawing.
3.2 AMMONIA DOSING SYSTEM :(TOTAL NO OF SKID= 2 NOS)
(Refer drg no. PE-DG-320-154-A002)
Boiler feed water/Condensate water should have proper pH in order to protect the system from
corrosion. In order to control the same dosing of dilute solution of Ammonia is done at
Condensate discharge header at CPU outlet only. Though provision has been kept to dose
ammonia at Boiler Feed suction line immediately below the Deaerator storage tank,
Condensate Transfer pump discharge header and Boiler filling line also, but dosing shall be
done at one place at a time. For this purpose one (1) no. skid mounted ammonia-dosing system
shall be provided. Dosing system shall mainly comprise the following:
3.2.1 SOLUTION PREPRATION CUM METERING TANK (1 No.)
A solution-preparation cum metering tank for preparation and measuring the dilute Ammonia
solution shall be provided. The tank shall be provided with accessories like motorized stirrer,
breather with vent, level gauge, and level switch, overflow drain. A filling connection is provided
to fill the concentrated solution by hand pump in the tank.
The solution is then dosed to the required point with the help of dosing pumps.
3.2.2 AMMONIA DOSING PUMPS (TOTAL 2 NOS)
Two nos. (2X100%) Positive displacement plunger type Dosing pumps with motor, relief valves
has been provided.
A Y type strainer (2 x100%) shall be common for both pumps.
3.2.3 HAND PUMP (1 NO.)
A hand pump complete with flexible hose and couplings for transferring Ammonia from drum at
ground level to measuring tank is provided.
3.2.4 ASSOCIATED PIPING, VALVES ETC:
As indicated in the drawing and Data sheet-A.
R1
Page 3 of 12
BHEL DOCUMENTS NO.: PE-DC-320-154-A001
DEPTT: MECHANICAL AUXILIARY
REV. NO. 1 DATE:
2X500 MW TPS CHANDRAPUR EXPANSION PROJECT. SHEET
BHEL - PS-PEM: PPEI, PLOT NO-25, BHEL, NOIDA, SECTOR-16A, UP-201301.
DOCUMENT TITLE:
DESIGN PHILOSOPHY FOR
LP CHEMICAL DOSING SYSTEM.
3.2.5 CONTROL & INSTRUMENTATION
The normal mode of operation of Ammonia dosing system shall be from DDC MIS including ON
/ OFF command to individual pumps. However, a local control panel consisting of Start Stop
push buttons, Indicating Lamp, Local / Remote selection, stroke position indicator, Rise / lower
push button to stroke position, local annunciation to be mounted & stroke position indicator on
the lamp shall be provided.
The normal mode of operation of dosing system shall be through DDC MIS, Local remote
selection is to be done with from remote (CR) and indication for the same should be provided
on local panel.
Local annunciation system shall be microprocessor based. All the local annunciations shall be
suitably duplicated for which bidder shall provide free changeover contacts (1 NO + 1NC) rating
0.25 amp. / 220 V DC, 5.0 Amp, 240 V AC at the local panel.
The ON / OFF commands for individual pumps from local push buttons shall act on the
respective drives through DDC MIC.
The stroke position & adjustment will be done from DDC MIS and the stroke actuator shall be
suitable for accepting 4-20 mA DC signal. The pumps shall be provided with 24 V DC, 2-wire
LVDT Type position feed back transmitter to generate 4-20 mA DC signal to indicate stroke
position.
Following interlocks shall be provided.
At Low level in the tank.
x Running Dosing Pump shall be tripped.
x Stirrer motor of the tank shall be tripped.
Following annunciation shall be provided in DDCMIS and LCP.
x Running Dosing Pump trip.
x Stirrer motor trip
x Tank level low.
3.3 NaOH DOSING SYSTEM: :(TOTAL NO OF SKID= 2 NOS)
(Refer drg no. PE-DG-320-154-A003)
Sodium Hydroxide (NaOH) dosing system is provided to dose NaOH solution in Equipment
cooling water lines to increase pH upto 9.5. The sodium hydroxide dosing is done in the ECW
cycle during the initial fill and for the compensation of cooling water for any leakage during
normal run. The 1% solution of NaOH is prepared manually by opening the inlet valve of DM
water and adding NaOH lye in basket. The NaOH is being dissolved by locally starting the
motorized stirrer. The dosing is done manually as per requirements of desired pH in ECW line
judged by trial basis. Normally the leakage is occasionally and of small quantity . At the low
level of solution in tank the solution is to be prepared again.
The dosing system consists of following.
3.3.1 ASSOCIATED PIPING, VALVES ETC:
As indicated in the drawing and Data sheet-A.
3.3.2 CONTROL & INSTRUMENTATION
The normal mode of operation of NaOH dosing system shall be from Local Control Panel.
Local annunciation system shall be microprocessor based. All the local annunciations shall be
suitably duplicated for which bidder shall provide free changeover contacts (1 NO + 1NC) rating
0.25 amp. / 220 V DC, 5.0 Amp, 240 V AC at the local panel.
Following inter-locks shall be provided at low Level in the mixing/storage tank.
Page 4 of 12
BHEL DOCUMENTS NO.: PE-DC-320-154-A001
DEPTT: MECHANICAL AUXILIARY
REV. NO. 1 DATE:
2X500 MW TPS CHANDRAPUR EXPANSION PROJECT. SHEET
BHEL - PS-PEM: PPEI, PLOT NO-25, BHEL, NOIDA, SECTOR-16A, UP-201301.
DOCUMENT TITLE:
DESIGN PHILOSOPHY FOR
LP CHEMICAL DOSING SYSTEM.
Running Stirrer motor of the tank shall be tripped.
Following fault indications shall be provided in DDCMIS and LCP:
x Stirrer motor trip
x Tank level low.
3.2.5 FLUSHING
Condensate tapped from condensate line shall be used for flushing the various pipelines and
pumps of the system as shown in P&I drawing.
4.0 DESIGN BASIS:
The following drawings/data sheets are enclosed for the reference:
PE-DG-320-154-A001 P&ID for Hydrazine dosing system.
PE-DG-320-154-A002 P&ID for Ammonia dosing system.
PE-DG-320-154-A003 P&ID for NaOH dosing system.
DATA SHEET A For above systems.
ANNEXURE-I Design Calculation for the above system.
Page 5 of 12
BHEL DOCUMENTS NO.: PE-DC-320-154-A001
DEPTT: MECHANICAL AUXILIARY
REV. NO. 1 DATE:
2X500 MW TPS CHANDRAPUR EXPANSION PROJECT. SHEET
BHEL - PS-PEM: PPEI, PLOT NO-25, BHEL, NOIDA, SECTOR-16A, UP-201301.
DOCUMENT TITLE:
DESIGN PHILOSOPHY FOR
LP CHEMICAL DOSING SYSTEM.
DATA SHEET A
Sl no. Description HYDRAZINE DOSING
SYSTEM
AMMONIA DOSING
SYSTEM
NaOH DOSING
SYSTEM
1.1.0 No. of skids per unit One (1) One (1) One (1)
1.1.1 No. of skids per station Two (2) Two (2) Two (2)
1.2.0 SOLUTION PREPARATION CUM METERING TANK
1.2.1 No. of tanks per Skid One (1) One (1) One (1)
1.2.2 Capacity 1200 Ltr. 1200 Ltr. 1000 Ltr.
1.2.3 Type Conical End. Conical End. Conical End.
1.2.4 Material of the tank SS-304 SS-304 SS-304
1.2.5 Thickness 3 mm. 3 mm. 3 mm.
1.2.6 Motorised Stirrer/agitator Provided Provided ( Provided
1.2.7 Breather with vent Provided Provided Provided
1.2.8 Level switch Provided Provided Provided
1.2.9 Level gauge Provided Provided Provided
1.2.10 Hand pump with flexible
hose.
One (1) One (1) Not applicable.
Dissolving basket Not applicable. Not applicable. Provided
1.3.0 METERING PUMP
1.3.1 Type of pump Positive displacement (Plunger type) Not applicable.
1.3.2 Mode of control Manual Manual Not applicable.
1.3.3 No. of pumps motor
assembly.
Two (2) nos. (2X100%) Two (2) nos. (2X100%) Not applicable.
1.3.4 Capacity (LPH) 0-50 LPH 0-50 LPH Not applicable.
1.3.5 Discharge pressure
(Kg/Cm
2
)
45 Kg/Cm
2
45 Kg/Cm
2
Not applicable.
1.3.6 All Wetted parts of pumps. SS-304 SS-304 Not applicable.
1.4.0 STRAINERS Not applicable.
1.4.1 No. of strainers Two (2X100%) Two (2X100%) Not applicable.
1.4.2 Type Y-Type Y-Type Not applicable.
1.4.3 Material of screen SS 304 SS 304 Not applicable.
1.4.4 Mesh Size 50(BS) 50(BS) Not applicable.
1.5.0 PIPING
1.5.1 Material SS-304 SS-304 SS-304
1.5.2 Material code ------------------ASTM A 312 TP 304 (Seamless)------
1.5.3 Diameter Main, Sampling & Drain Pipe-25 NB and Overflow pipe-25 NB
1.6.0 VALVES
1.6.1 Body, Cover, Yoke & Trim
Material
SS-304 SS-304 SS-304
1.6.2 Weld ends Socket weld ends Socket weld ends Socket weld ends
1.7.0 Fittings Forged steel to A182 F304, Dimension to ANSI B 16.11 socket weld ends.
1.8.0 Structural steel IS 2062 IS 2062
1.9.0 Flanges Pump suction /
discharge
-----------------ANSI B 16.5 CL 150 / ANSI B 16.5 CL 300----
1.9.1 RATING
1.9.1.1 Suction side ----------------------------Class ASA 150-----------------------------
1.9.1.2 Discharge side ----------------------------Class ASA 300-----------------------------
Page 6 of 12
DESIGN BASIS & CAPACITY SELECTION CRITERIA
HYDRAZINE DOSING
INPUT DATA
-MAX FLOW RATE AT DEARATOR OUTLET A T/HR 1720
-OPERATING PRESSURE AT DEARATOR OUTLET B KG/CM2(g) = 6.5
-DISSOLVED O2 AT DEARATOR OUTLET C ppm = 0.007
-NO. OF DEARATORS D No. = 1
-MAX FLOW RATE AT CEP DISCHARGE E M3/HR = 1386
-OPERATING PRESSURE AT CEP DISCHARGE F KG/CM2(g) = 26.5
-DISSOLVED O2 AT CEP DISCHARGE G ppm. = 0.021
-RESIDUAL HYDRAZINE AT HP/LP BFP DISCHARGE H ppm. = 0.02
-CONCENTRATION OF HYDRAZINE SOLUTION TO BE
DOSED
I % = 0.5
-PUMP INCREASED CAPACITY FACTOR K = 70
-CONCENTRATION OF HYDRAZINE IN MEASURING TANK CM % 35
-CAPACITY OF THE TANK REQUIRED FOR L Hrs. = 24
-MARGIN ASSUMED FOR TANKS FOR SIZING M % = 20
HYDRAZINE DOSING AT DEARATOR OUTLET
PUMP SIZING
QUANTITY OF HYDRAZINE REQUIRED (QH) Gm/Hr. = A(2*C+H)*50 / 32 = 91.38
VOLUMETRIC FLOW Ltrs. (VFH) LPH = QH / I*100 / 1000 = 18.28
DESIGN CALCULATION FOR 500 MW. (REV-1)
CaL Page 1
HENCE PUMP CAPACITY REQUIRED LPH = VFH * 100 / K = 26.11
PUMP SELECTED CAPACITY LPH = = 50
DISCHARGE PRESSURE OF PUMP SELECTED KG/CM2(g) = = 45.00
HYDRAZINE DOSING AT CEP DISCHARGE
PUMP SIZING
QUANTITY OF HYDRAZINE REQUIRED (QH) Gm/Hr. = E(2*G+H)*50 / 32 = 134.27
VOLUMETRIC FLOW Ltrs. (VFH) LPH = QH / I*100 / 1000 = 26.85
HENCE PUMP CAPACITY REQUIRED LPH = VFH * 100 / K = 38.36
PUMP SELECTED CAPACITY LPH = = 50
DISCHARGE PRESSURE OF PUMP SELECTED KG/CM2(g) = = 45.00
TANK SIZING
CAPACITY OF THE TANK REQUIRED MXS Ltrs. = MAX(VFH )*
L*D*(100+M)/100
= 773.39
CAPACITY OF THE TANK SELECTED (X) Ltrs. = = 1200.00
FINAL PARAMETERS SELECTED FOR HYDRAZINE DOSING
PUMP CAPACITY (LPH) 50
PUMP PRESSURE Kg/CM2(g) 45
PREPERATION CUM METERING TANK CAPACITY (Ltrs.) 1200
CaL Page 1
Page 7 of 12
AMMONIA DOSING
INPUT DATA
-MAX FLOW RATE AT DEARATOR OUTLET A M3/HR 1720
-OPERATING PRESSURE AT DEARATOR OUTLET B KG/CM2(g) = 6.5
-NO. OF DEARATORS D No. = 1
-MAX FLOW RATE AT CEP DISCHARGE E M3/HR = 1386
-OPERATING PRESSURE AT CEP DISCHARGE F KG/CM2(g) = 26.5
-AMMONIA DOSING RATE G PPM 0.25
-CONCENTRATION OF AMMONIA SOLUTION TO BE DOSED I % = 2
-CONCENTRATION OF AMMONIA SOLUTION IN
MEASURING TANK
O % = 30
-PUMP INCREASED CAPACITY FACTOR K = 70
-CAPACITY OF THE TANK REQUIRED FOR L Hrs. = 24
-MARGIN ASSUMED FOR TANKS FOR SIZING M % = 20
AMMONIA DOSING AT DEARATOR OUTLET
PUMP SIZING
QUANTITY OF AMMONIA REQUIRED (QH) Gm/Hr. = A * G = 430.00
VOLUMETRIC FLOW Ltrs. (VFH) LPH = QH *100 / I / 1000 = 21.50
HENCE PUMP CAPACITY REQUIRED LPH = VFH * 100 / K = 30.71
PUMP SELECTED CAPACITY LPH = = 50
AMMONIA DOSING AT CEP DISCHARGE
PUMP SIZING
CaL Page 2
QUANTITY OF AMMONIA REQUIRED (QH) Gm/Hr. = E * G = 346.50
VOLUMETRIC FLOW Ltrs. (VFH) Ltrs. = QH *100 / I / 1000 = 17.33
HENCE PUMP CAPACITY REQUIRED LPH = VFH * 100 / K = 24.75
PUMP SELECTED CAPACITY LPH = = 50
DISCHARGE PRESSURE OF PUMP SELECTED KG/CM2(g) = = 45.00
TANK SIZING
CAPACITY OF TANK REQUIRED (RX) Ltrs. = max(VFH) * L*D*M = 619.20
CAPACITY OF TANK SELECTED (X) Ltrs. = = 1200.00
FINAL PARAMETERS SELECTED FOR AMMONIA DOSING
PUMP CAPACITY (LPH) 50
PUMP PRESSURE Kg/CM2(g) 45
PREPERATION CUM METERING TANK CAPACITY (Ltrs.) 1200
CaL Page 2
Page 8 of 12
INPUT DATA
NORMAL FLOW RATE OF ECW LINES M3/HR = 3943
LEAKAGE FROM ECW LINE (SAY) % = 1
RATE OF SODIUM HYDROXIDE SOLUTION TO BE DOSED(
NTPC RECOMM.)
PPM = 2
STRENGTH OF NAOH SOLUTION TO BE PREPARED IN THE
TANK
% = 1
TANK SIZING
BASED ON LEAKAGE
TOTAL LEAKAGE OF WATER IN ONE HR M3 = 39.43
QUANTITIY OF 100% SODIUM HYDROXODE REQUIRED GR/HR = 78.86
VOLUME OF NAOH SOLUTION REQD GR = 7886
LTR 7.886
TANK SIZE REQUIRED FOR ONE DAY LTR = 189.26
TANK SIZE SELECTED LTR 500.00
BASED ON INITIAL FILLING IN ECW Cycles
VOLUME OF DM WATER IN ECW LINE FOR BOILER
AUXILIARY
M3 = 142
VOLUME OF DM WATER IN ECW TANK FOR BOILER
AUXILIARIES
M3 = 10
VOLUME OF DM WATER IN ECW LINE FOR TG AUXILIARY M3 = 101
VOLUME OF DM WATER IN ECW TANK FOR TG
AUXILIARIES
M3 = 10
MAX VOLUME OF DM WATER FOR PASSIVATION M3 = 263
QUANTITIY OF SODIUM HYDROXODE 100% REQUIRED GR = 526.00
VOLUME OF NAOH SOLUTION REQD GR = 52600
LTR = 52.6
DESIGN CALCULATION FOR SODIUM HYDROXIDE TANK
CaL Page 3
TANK SIZE SELECTED LTR = 1000.00
FINAL PARAMETERS SELECTED FOR SODIUM HYDROXIDE
DOSING SYSTEM
TANK CAPACITY (Ltr) = 1000
CaL Page 3
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