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July 10, 2012

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FIRST ISSUE /2012.07.09 GFA

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THE SOCIALIST REPUBLIC OF VIET NAM


NAM NON HYDROPOWER PROJECT

CONTRACT 08/HD-BVC-P2
Package TB-01



SUPPLY OF ELECTRO-MECHANICAL EQUIPMENT

BETWEEN
PURCHASERBAN VE HYDROPOWER JOINT STOCK COMPANY
EVNHPC BAN VE
SUPPLIER
ZHEFU-HYDROCHINA ZHONGNAN

TITLE
Calculation for Low-pressure Compressed Air System
DOCUMENT
NUMBER
ZFH- NON- 20 - CXE- ED- 00 -
0 01
DATE 2012.07.05
SHEET 11
July 10, 2012


VietnamNan Non HPP
Auxiliary System Calculation



Calculation for Low-pressure Compressed
Air System


Detailed Design Stage




HydroChina Zhongnan Engineering Corporation
2011.07





July 10, 2012







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Checked by:


Designed by:










CATALOGUE
GENERAL DESCRIPTION OF CALCULATION ........................................................................... - 1 -
1 BASIC INFORMATION OF THE POWER PLANT ................................................................ - 1 -
2 COMPRESSED AIR CONSUMPTION OF BRAKING SYSTEM OF UNITS ....................... - 2 -
2.1 AIR CONSUMPTION OF BRAKING SYSTEM OF UNITS ................................................................ - 2 -
2.2 AIR VESSEL VOLUME CALCULATION ........................................................................................ - 3 -
2.3 DIAMETER SELECTION OF THE MAINS FOR THE BRAKING SYSTEM OF UNITS: ........................ - 3 -
3 MAINTENANCE AIR CONSUMPTION ................................................................................... - 4 -
3.1 MAINTENANCE AIR CONSUMPTION CALCULATION ................................................................ - 4 -
3.2 COMPRESSOR PRODUCTION RATE CALCULATION ................................................................... - 5 -
3.3 MAINTENANCE AIR VESSEL VOLUME CALCULATION ............................................................... - 5 -
3.4 DIAMETER SELECTION OF AIR SUPPLY MAINS FOR PNEUMATIC TOOLS IN POWERHOUSE: ..... - 6 -
4 CONCLUSION .............................................................................................................................. - 6 -





- 1 -
General description of calculation

1) Objectives and Requirements
The calculation aims to check the parameters of equipment and piping of the
low-pressure compressed air system.
2 References
- Drawing No. ZFH-NON-20-SCA-TC-00-001 Principle diagram of low-pressure
compressed air system .
- The information provided by unit manufacturer and Powerhouse Layout
Drawing.
3) Calculation principles and assumptions
The low-pressure compressed air system is used for braking system of units, the
shaft maintenance seal and pneumatic tools in powerhouse. Due to the insufficient
data of air consumption of equipment, part of the air consumption is estimated with
reference to similar power-plants.

1 Basic information of the power plant
Installation Capacity: 210MW
Setting elevation of unit: 61.80m
Normal supply level: 83.00m
Maximum head Hmax: 9.87m
Rated head Hr: 7.20m
- 2 -
Minimum head Hmin: 6.34m
Runner diameter D1: 4.80m
The whole plant low-pressure compressed air system will have a rated pressure of
0.8MPa, mainly serving the pneumatic tools in powerhouse, braking system of units,
and shaft maintenance seal.

2 Compressed air consumption of braking system of units
2.1 Air Consumption of braking system of units
As the unit adopts braking by one compression, calculation of volume of braking air
leakage and pipe air supply is made based on the brake and pipe volume and two
units to be braked simultaneously. The compressed air consumption for one unit
braking operation is 30 liters as provided by the unit manufacturer (Zhefu). The total
air consumption for one unit braking is calculated by the following formula:
Pa
tP q
Q
z z
Z
1000


Qztotal air quantity for one unit brakingfree air
qzthe air flow during the braking process under the operating pressure
l/s
tBraking times, 60s
PzBraking air pressure, 0.8MPa
PaAtmospheric pressure0.1MPa
The result of calculation is: air consumption quantity for one unit braking is
- 3 -
QZ=30*0.8/1000/0.1=0.24m
3
.
2.2 Air vessel volume calculation
The compressed air for unit braking is mainly from the air vessel, and the volume of
air vessel shall assure that the pressure inside the vessel is not lower than the min.
braking pressure after the unit braking air consumption. The volume of air vessel is
calculated by the following formula:

z
a z
g
P
ZP Q
V


In the formula:
VgAir vessel volume (m
3
)
Qztotal air consumption for one unit brakingfree air
Zthe number of units to be braked simultaneously2
z
P
the allowable air pressure drop before and after braking, 0.2 MPa
PaAtmospheric Pressure0.1MPa.
After the calculation, the result is: Vg=0.24 m
3

One air vessel with a rated pressure of 0.8MPa and a volume of 1.6m
3
adopted in the
system can meet the braking requirements.

2.3 Diameter selection of the mains for the braking system of units:
The main pipe diameter is calculated by the following formula:
v
Q
d


- 4 -
In the formula:
dinner diameter of pipe (m)
Qthe air flow under the working pressure. The braking air flow is
0.048 m
3
/minand the air flow is 0.048860=0.0001 m
3
/s at the
working pressure 0.8MPa
vair flow velocity inside pipe, taking 10 m/s
The result is d=0.003mThe DN32 stainless pipe adopted in the schematic system
can meet the requirements of air supply mains for braking.

3 Maintenance air consumption
3.1 Maintenance Air Consumption Calculation
The maintenance air consumption will make reference to similar power plants. The
following pneumatic tools are considered:
- two sets of S-60 pneumatic grinders,
- one set of C4-5 pneumatic chipper,
- one set of ZL-6 pneumatic drill, and
- one set of QB6 pneumatic wrench.
Air consumption of S-60 pneumatic grinder
Air consumption with no load 0.2 m
3
/min
Air consumption with load 0.4 m
3
/min
Air consumption of C4-5 pneumatic chipper 0.5m
3
/min
- 5 -
Air consumption of ZL-6 pneumatic drill 0.3m
3
/min
Air consumption of QB6 pneumatic wrench 0.4m
3
/min
Total air consumption of pneumatic tools
Q=20.4+10.5+0.3+0.4=2.0 m
3
/min
3.2 Compressor production rate calculation
According to the bidding documents, the air compressor shall be shared by the
braking system of units and pneumatic tools in powerhouse. The production rate of
air compressor is calculated by the formula below
Production rate of Compressor:
Q
K
=Q
Z
Z/ T+KQ=0.16*2/10+1.2*2.0=2.432m
3
/min
T full pressure recover time of air vesseltaking T=10min ;
Kair-leakage factor , taking 1.2
As shown in the calculation results, the two compressors with a discharging
pressure of 1.0MP and a production rate of 2.5 m
3
/min adopted in the system can
meet the requirement of low-pressure compressed air system.

3.3 Maintenance air vessel volume calculation
The main purpose of maintenance air vessel is to relieve the pressure fluctuation of
compressor.

1

k
K
g
P
Q
V
Vgair vessel volume (m
3
)
Q
K
production rate of compressorm
3
/min
- 6 -
P
k
rated operating pressure of compressor0.8 Map=8kg/cm
2

Vg=2.5/9=0.28m
3

The one air vessel with a rated pressure of 0.8MPa and a volume of 2.0m
3
adopted in
the system can meet the requirements of pneumatic tools in powerhouse..

3.4 Diameter selection of air supply mains for pneumatic tools in powerhouse:
The diameter of mains is calculated by the following formula

v
Q
d


In the formula
dinner diameter of pipe (m)
Qthe flow rate under working pressure. As the production rate of the
compressor is 2.5 m
3
/min, the flow rate is 2.5860=0.0052 m
3
/s at
the working pressure 0.8MPa.
the flow velocity inside pipe, taking 10 m/s.
The result is d=0.0257mThe DN40 stainless pipe adopted in the schematic drawing
can meet the requirements of air supply mains for pneumatic tools in powerhouse.
4 Conclusion
The air consumption of various purposes from above calculations is shown in the
following table

- 7 -
Air Consumer
Air Consumption
Quantity
Compressor
production rate
(Calculation
result
Air vessel volume
(Calculation
result
Diameter of
mainsmm
Pneumatic tools
in powerhouse
2.0 m
3
/min
2.5m
3
/min
0.28m
3
DN20
Braking system
of units
0.032m
3
/once 0.24m
3
DN32

For the braking system of units, two air compressorsone in service and one
standby should be providedThe pneumatic tools in powerhouse may share the
same air compressors with the braking system of units. The air vessel shall only
serve for pressure stabilization. According to our check on the main equipment of
the low-pressure compressed air system, the two air compressorswith a discharge
pressure of 0.8 MPaa production rate of 2.5 m
3
/mina motor power of 18.5kW , a
voltage of 380V, and an efficiency of 98%, one in service and one standbyand two
air vessels (one 2.0 m
3
and the other 1.6 m
3
, with a rated pressure of 0.8Map; one for
braking system of unitsone for pneumatic tools in powerhouse and pressure
stabilization and also standby for the braking system of unitscan meet the
requirements of low-pressure compressed air system. But air consumption for
pneumatic tools in powerhouse can not occur simultaneously with air consumption
for other purposes. For the specific parameters see the schematic drawing of the
low-pressure compressed air system.

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