Reinforcement of Rabigh Power Plant Saudi Electricity Company

Contents

1. PURPOSE
2. SUMMARY
3. REFERENCE
4. DESIGN INPUT
5. CALCULATION

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Reinforcement of Rabigh Power Plant Saudi Electricity Company

1.0 PURPOSE

To determine Seawater Chorination Plant equipment sizing.

2.0 SUMMARY
Design inlet flow in m3/hr = 14700

Chlorinator capacity selected in kg/hr= 90.0

No. of Chlorinator= 2.0 (1W+1SB)

3.0 REFERENCE
Electro chlorination calculation sheet

4.0 DESIGN INPUT

CW of cooling tower pump flow in m3/hr= 90000 (For 3 pumps for each Cooling tower)

Cooling tower make-up pumps flow in m3/hr= 12000 (For 2 pumps)

No. of Cooling tower 2

Raw water pump flow in m3/hr= 2000 (For 2 pumps)

Chlorine continuous dosing demand in ppm = 2.0

Cooling tower flow shock dosing demand in ppm = 5.0

Chlorine shock dosing demand in ppm = 5.0

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Reinforcement of Rabigh Power Plant Saudi Electricity Company

5.0 CALCULATION

Sl no Description Values Unit Remarks

To be check based on vendor

1 No of trains 2
Catalouge w.r.t available capacity
2 No of working trains 1
3 No of standby trains 1
Assuming the maximum Flow is
runout condition of pumps, Hence
4 Inlet continuous Flow in m3/day 336000 m3/day
total normal flow has been
considered.

total flow including Cooling towers

5 Inlet continuous Flow in m3/hr 14000 m3/hr
Make up water + Raw water for WTP
6 Design Margin 5% Assumed
7 Design Inlet continuous Flow in m3/hr 14700 m3/hr
8 Operation hours 24 Hrs/day
9 Design Inlet continuous Flow in m3/day including margin 5% 352800 m3/day
10 Duration of shock dosing in one cycle for Total flow to Intake 0.5 hr/cycle In a shift of 8 hours for 30 min
11 Duration of shock dosing Total flow to Intake 1.5 hr/Day
12 Duration of continuous dosing in one cycle 7.5 hr/cycle
13 Duration of one cycle of dosing 8 hr/cycle One shift considered with 8 hrs
14 Dosing cycles in one day 3 cycle/day
15 Total time period for continuous dosing 22.5 hr/day
16 Total time period for Cooling tower flow shock dosing 1.5 hr/day
17 Total time period for intake flow shock dosing 1.33 hr/day
18 Dosing cycles in one day for cooling towers 4.0 cycle/day
19 Duration of shock dosing in one cycle for Total cooling towers 0.33 hr/cycle

Chlorinator Capacity
20 Cl reqd for continuous dosing in kg/hr 29.4 Kg/hr
21 Cl reqd for continuous dosing in kg/day 662 Kg/day
22 Cl reqd for shock dosing for total intake flow in kg/hr 73.5 Kg/hr
23 Cl reqd for shock dosing for total intake flow in kg/day 110.3 kg/day
24 Cl reqd for Cooling tower flow shock dosing in kg/hr 900.0 Kg/hr
25 Cl reqd for Cooling tower flow shock dosing in kg/day 1200 Kg/day
26 Total Cl reqd in kg/day 1972 Kg/day
27 Average Cl reqd in kg/hr 82.2 Kg/hr
28 No of Chlorinators 2.0 Nos.
29 No of Chlorinators in operation 1.0 Nos.
30 Chlorinator capacity required 82.2 Kg/hr
31 Chlorinator capacity selected 90.0 Kg/hr

Pump Capacity
Average Design concentration is
32 Strength of chlorine solution after EC 0.2% assumed as 2000 mg/ltr, i.e. 0.2%
Solution (w/w).
33 Cl solution reqd in m3/day 986 m3/day
34 Average Cl solution reqd in m3/hr 41.1 m3/hr
35 No of continuous dosing pumps 2.0
36 No of continuous dosing pumps (in operation) 1.0
37 Continuous dosing pump flowrate reqd. 14.7 m3/hr
38 Continuous dosing pump flowrate selected 17.0 m3/hr with 10% flow margin
39 No of shock dosing pumps 2.0 Nos.
40 No of shock dosing pumps (in operation) 1.0 Nos.
41 Shock dosing pump flowrate reqd for intake 36.8 m3/hr
42 Shock dosing pump flowrate selected for intake 41.0 m3/hr with 10% flow margin
43 No of shock dosing pumps 4.0 Nos.
44 No of shock dosing pumps (in operation) 2.0 Nos.
45 Shock dosing pump flowrate reqd for cooling towers 450.0 m3/hr
46 Shock dosing pump flowrate selected for cooling towers 495.0 m3/hr with 10% flow margin
47 No of Sea Water Booster pumps 2.0 Nos.
48 No of Sea Water Booster pumps (in operation) 1.0 Nos.
49 Water loss due from feed due to strainer backwash 5.0% Assumed
50 Hence, Sea Water Booster pumps flowrate reqd. 43.2 m3/hr
47 Sea Water Booster pump flowrate selected 47.6 m3/hr with 10% flow margin
48 H2 gas generated for each kg Cl2 generated 0.03 kg h2/kg Cl2
49 Hence, normal H2 gas generation rate 2.54 kg/hr
50 H2 gas density at NTP condition 0.09 kg/m3
51 Hence, H2 gas generated in Nm3/hr (max) 28 Nm3/hr
Assumed value of pressure (approx
52 LEL of hydrogen gas 4.65% @6-8 bar-g). To be validated by
Vendor.
53 Minimum dilution considered as % of LEL 25.0%
H2 concentration target <2%
54 Hence, total air dilution required 1.2%
(Assumed)
55 Dilution air flow required during design operation 2426 Nm3/hr
56 No of blowers 2.0 Nos.
57 No of blowers (in operation) 1.0 Nos.
58 Air Blower flow selected 2700 Nm3/hr with ~10% flow margin

Chlorine solution storage Tank Capacity

59 Chlorine solution inlet flowrate in tank 41.1 m3/hr
60 Continuous Chlorine solution outlet flow from tank 14.7 m3/hr
61 Accumulation in tank per hour 26.4 m3/hr
62 Duration of continuous dosing per cycle 7.5 hr/cycle
63 Total soln accumulation in one continuous dos. cycle 197.8 m3
64 Hence, minimum effective capacity of tank reqd. 197.8 m3
65 Solution Retention time considered 1 hr
66 Minimum eff. Capacity considered for each tank 239 m3 w/Rention of 1 hour generation
67 Each Tank's effective capacity selected 240 m3
68 Each Tank's geometric capacity considered 240 m3
69 No of tanks 2 Nos. (1W + 1SB)

EC N-Pit (For CIP waste and Sea Water Area Drain)

70 Quantity 1
71 No of Compartment per pit 2
72 Capacity per compartment 10.0 m3 Revalidate with vendor
73 Length 2.5 m
74 Width 2.5 m
75 Depth 1.6 m
76 Free Board Height 0.5 m
77 Dead Volume Height 0.3 m
78 Total Height 2.4 m

EC N-Pit Pumps
79 Quantity 2 Nos. (1W + 1SB)
80 Capacity 10 m3/hr Revalidate with vendor

HCl tank
81 Quantity 1
82 Capacity per compartment 2.0 m3 Assumed and Revalidate with vendor
83 Length 1.0 m
84 Width 1.0 m
85 Depth 2.0 m
86 Free Board Height 0.5 m
87 Dead Volume Height 0.3 m
88 Total Height 2.8 m

HCl Circulating pump

89 HCL solution concentration 2.5 to 5%
90 pump quantity 2 Nos. (1W+1SB)
Assumed and Revalidated with
91 Pump Capacity 10.0 m3/hr
Vendor
NaOH pump for Neutralization
91 NaOH solution concentration 48- 50%
92 pump quantity 2 Nos. (1W+1SB)
Assumed and Revalidated with
93 Pump Capacity 0.35 m3/hr
Vendor
NaOH tank
94 Quantity 1
95 Capacity per compartment 1.0 m3 Assumed and Revalidate with vendor
96 Length 1.0 m
97 Width 1.0 m
98 Depth 1.0 m
99 Free Board Height 0.5 m
100 Dead Volume Height 0.3 m
101 Total Height 1.8 m

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