COPYRIGHT AND CONFIDENTIAL The information in this document is the property of BHARAT HEAVY ELECTRICALS LTD.

EXCITER AIR COOLER

DATASHEET

DEVELOPMENT CONSULTANTS
PRIVATE LIMITED
Reviewed for general conformance with Contract
drawings and specifications.
ACTION :

1 Approved
2

Approved except as
noted. Forward final
drawing.

Disapproved.

For information/reference
only.

Information category with

comments. Resubmission
required.

Approved except as

3 noted. Resubmission
required.

Approval of Contract documents by the Consultant shall

not relieve the Seller of his responsibility for any errors
and fulfilment of Contract requirements.

Digitally signed by SANDIP

SARKAR
DN: cn=SANDIP SARKAR,
o=DCPL, ou=POWER-B,
email=sandipsarkar@in.dclgroup
.com, c=IN
Date: 2014.11.07 09:51:50 +05'30'

OPGC DOCUMENT NO. : BTG-XKC-DSH-E-0208

Rev : 01
CUSTOMER
ODISHA POWER GENERATION CORPORATION LTD.
PROJECT
JOB NO.
STATUS

RATING
CONTRACT

CONSULTANT

DISTRIBUTION
TO
NO
REV

01

DATE
7.10.14

ALTD

AG

CHKD

AG

UPDATED AS PER CUSTOMER

COMMENTS

IB VALLEY THERMAL POWER STATION

2X660 MW
DEVELOPMENT CONSULTANT PVT. LTD. KOLKATA
NAME SIGN DATE
BHARAT HEAVY ELECTRICALS DEPT
CODE
DESN
AG
-sd29.04.14
LTD.
Haridwar
CHD
AG
-sd29.04.14

APPD

SK

APPD

SK

-sd-

29.04.14

DOCUMENT TITLE :

EXCITER AIR COOLER DATASHEET

DEPTT

DOCUMENT NO :

HE-10821-16605-D

SIGN
DATE

Page 1 of

Rev -

01

EXCITER AIR COOLER DATA SHEET

1.01.

Number of coolers

2x50 %

1.02.

Type of cooler

Frame type

1.03.
i.
ii.
iii.

Material of
Tubes
Fin
Water box

iv.

Tube Plate

v.

Frame

vi.

Gasket

90:10 Cu Ni
Copper
Carbon steel, IS : 2062 Gr.B
or Equivalent
Carbon steel, IS : 2062 Gr.B
or Equivalent
Carbon steel, IS : 2062 Gr.B
or Equivalent
Rubber (Neoprene)

Design Code & Standard

TEMA-C

1.04.
1.05.
i.
ii.

Design Pressure
Shell Side
Tube Side

kg/cm2(g)
kg/cm2(g)

5
10

i.
ii.

Design Temperature
Shell Side
Tube Side

deg C
deg C

100
100

i.
ii.

Minimum Design Metal Temperature

Shell Side
deg C
Tube Side
deg C

0
0

i.
ii.

Operating Pressure
Shell Side
Tube Side

kg/cm2(g)
kg/cm2(g)

Ambient Air
--

1.09.

Tube Side Test Pressure

kg/cm2(g)

15 (minimum duration 30 min.)

1.010.

Total Heat Load

KW

500

1.011.

Heat Transfer Area Provided m2

1.012.

Total Gas Flow

m3/sec

15.5

1.013.

Inlet Gas Temperature

74.99

1.014.

Outlet Gas Temperature

43

1.015.

Total CW flow

m3/hr

200

1.06.

1.07.

1.08.

C
C

344.35

Page 2 of 5

1.016.

Design CW Inlet Temp

38

1.017.

Design CW Outet Temp

40.15

1.018.

Pressure Drop across Cooler MWC

On CW Side

3.74

1.019.

LMTD

deg C

15.37

1.020.

EMTD

deg C

15.2

1.021.

Heat Transfer Coeff.

W/m2-oC

105.125

1.022.

Tube Side Velocity

m/s

2.03

1.023.

Tube OD X tk. X LBTP

mm X mm X mm

--14 X 1 X 2470

1.024.

Number of Tubes per Cooler No.

245

1.025.

Min. Tube Plugging Margin %

10

1.026.

1.027.

Weight of the cooler

i.
Empty
ii.
Operating

C
C

Kg
Kg

1070
1195

Painting
As per hydrogen cooler drawing 01660570011C203

Page 3 of 5

THERMO HYDRAULLIC CALCULATION OF COOLER

Q=U AR LMTD
Where

Q
U
A
EMTD

Heat Load
Overall Heat Transfer Coefficient
Heat Transfer Area Required
Effective Mean Temperature Difference

Rated Condition
Q

=
=
=

500
500X1000
500000

U
EMTD

=
=

105.22
15.2

Therefore,
Area Required, AR
Area provided, AP

KW
W
W
W/m2-oC
deg C

=
=

(500000)/(15.2x105.12)
312.92 m2

344.35 m2

Margin on Area

=
=
=

((AP AR) x 100) / AR

((344.35-312.92)X100)/312.92
10.04%

Calculation For CW Side Pressure drop

CW Nozzle Size
CW Velocity Thro Nozzle

= Dia 139.6 x 5.0 Tk

= 2.10 m/sec
= 6.88 ft/sec

Tube End Loss (Combined inlet and Outlet)

Water Box Inlet Loss
Water Box outlet Loss

= 1.72 ft
= 0.76 ft
= 0.36 ft

Sum of above Losses

Friction Loss
(including gauge correction factor)

= 2.84 ft
=0.86M

---------

-- Curve A (fig .9) As per HEI

-- Curve B (fig. 9) As per HEI
-- Curve C (fig.9) As per HEI

(a)

= (0.00642V 1.75)/ Di 1.25

(refer clause 4.5; sheet 15 of HEI, Condenser)

Page 4 of 5

where
V
Di

=
=

Velocity in tubes in ft/s

Inside Diameter of Tubes in inch

Friction Loss

= (0.00642 X (6.66)1.75) / (0.4724)1.25

= 0.452 ft/ft of tube length

Temperature correction factor

(Corresponding to average CW temp. of 39.07 deg C)

0.94

(figure 7)

Friction loss ( As per HEI )

Avg. CW temp.

= 0.452x 0.94
= 0.424 ft / ft of length
= 0.424 m/m of length

Length of tube per pass

= 2.520 M

Total Length of tube

= 2 x 2.520
= 5.04 M

Pressure Drop in Tube

= 5.04 x 0.424
= 2.14 M

Total Pressure Drop

Pressure Drop Indicated in Data Sheet

(b)

= (a) + (b) =0.86+2.14 = 3.00 MWC

= 3.74 MWC

Page 5 of 5