Rei Vol I

CE THAR VESSELS LIMITED
M/s. REI AGRO LIMITED.

2 X 36 MW CAPTIVE POWER PLANT BOILERS (BG059 & BG060)
TABLE OF CONTENTS
SL. NO.
01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
DESCRIPTION
CONTRACT DATA SHEET SCHEDULES UTILITY SPECIFICATIONS & REQUIREMENT GENERAL DESCRIPTION OF BOILER PRINCIPLE OF FLUIDISED BED COMBUSTION WATER QUALITY REQUIREMENT METHOD OF WATER ANALYSIS PROCEDURE FOR HYDROSTATIC TESTING PROCEDURE FOR SLOW FIRING PROCEDURE FOR ALKALI BOILOUT PROCEDURE FOR STEAM BLOWING OPERATION ON LOW LOADS PROCEDURE FOR START UP OIL BURNER SYSTEM BOILER OPERATING INSTRUCTIONS CONTROL LOOPS TROUBLE SHOOTING CHART DOS AND DONTS INSPECTION AND MAINTENANCE SCHEDULE PRESERVATION OF BOILER
PAGE NO. 002 004 049 054 124 128 142 163 166 169 173 177 179 182 240 278 286 289 294
CONTRACT DATA SHEET

CUSTOMER LOCATION BOILER TYPE CAPACITY PRESSURE TEMPERATURE FUEL FIRING FEEDER TYPE M/s. REI AGRO LIMITED. KUTCH, GUJARAT. SINGLE DRUM WATER TUBE BOILER (FBC) 80 TPH 87 ATA 520 5C IMPORTED COAL & KUTCH LIGNITE POCKET FEEDER & DRAG CHAIN FEEDER TYPE OF FIRING BED SIZE FURNACE EXPANDED BED HEIGHT HEAT INPUT (Kcal/hr) FLUIDISED BED COMBUSTION 9529 X 4324 MM 952 MM 48760254 IMPORTED COAL 60266925 30% IMP. COAL + 70% K. LIGNITE HEATING SURFACE AREA (M) INTEGRAL ECONOMISER ASSY. BED COIL ASSY. HEATING SURFACE WATER WALL ASSY. PRIMARY CONVECTION SUPERHEATER ASSY. RADIANT SUPERHEATER ASSY. BED SUPERHEATER ASSY. TOTAL 2036.82 217.00 929.14 667.00 469.76 19.40 4369.17
CONTRACT DATA SHEET

SIZE LOCATION QTY. (Nos) STEAM DRUM SAFETY VALVE STEAM LINE CBD TANK 1 1 40 / 100 H2 25 / 50 G1 DEAERATOR 1 150 / 200 Q 5.10 23,224 8.00 1,204 93.54 22,615 2 (NB) / ORIFICE 50 / 100 J2 SET PRESSURE (Kg/cm) I) 103.00 ii) 104.00 RELIEVING CAPACITY OF VALVE (Kg/hr) i) 45,198 ii) 45,633 BW / FLANGED ANSI B16.5 900# / 150# BW / FLANGED ANSI B16.5 1500# / 150# FLANGED ANSI B16.5 150# / 150# FLANGED ANSI B16.5 150# / 150# END CONN.
SCHEDULES
SCHEDULES
VALVES
SPECIAL VALVES
INSTRUMENTS
LUBRICATION
VALVES SCHEDULE
CETHAR VESSELS (P) LIMITED

. TIRUCHIRAPALLI VALVES SCHEDULE
S.No. I
1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21
PROJECT : 2 X 80 TPH SINGLE DRUM WATER TUBE BOILER (FBC). CUSTOMER : M/s. REI AGRO LIMITED.,
RATING # END CONN. MODE OF OPERATION STATUTORY APPROVAL (IBR) QTY (Nos) BODY MATL. DESIGN PR.Kscg DESIGN TEMP. C DU No.
DWG. No. : BG059-00-09-4-005 REVISION : B
TAG No.
TYPE
SIZE
DESCRIPTION
REF DRG : BG059-00-09-0-002/NIL
P & I DIAGRAM FOR FEED LINE & STEAM LINE. (VALVES)

V1101 V1102 & V1103 V1104 & V1105 V1106 V1107 V1108 V1109 V1110 & V1113 V1114 V1115 V1116 & V1119 V1120 V1121 V1122 & V1125 V1126 & V1127 V1128A & V1128B V1129 & V1130 V1131 V1132 V1133 & V1134 V1135 & V1136 GLOBE GLOBE GLOBE NRV GLOBE GATE GATE GLOBE GATE GATE GLOBE GATE GATE GLOBE GLOBE GLOBE GLOBE NRV GATE GLOBE GLOBE 40 25 25 40 40 100 100 15 100 100 15 50 50 15 15 15 15 150 150 25 25 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 SW SW SW SW SW BW BW SW BW BW SW SW SW SW SW SW SW BW BW SW SW HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES 1 2 2 1 1 1 1 4 1 1 4 1 1 4 2 2 2 1 1 2 2 SA105 SA105 SA105 SA182F22 SA 105 SA216WCB SA216WCB SA105 SA216WCB SA216WCB SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA216 WCB SA216 WCB SA105 SA105 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 034 029 029 110 034 073 073 025 073 073 025 074 074 025 025 025 025 076 075 029 029
ISO VALVE FOR TCV. ISO VALVE FOR TCV INLET & OUTLET. ISO VALVE FOR BYPASS TCV INLET & OUTLET. CHECK VALVE FOR DE.SH INLET. ISO VALVE FOR DE.SH FEED INLET ISO VALVE FOR 100% FCV BYPASS INLET. ISO VALVE FOR 100% FCV BYPASS OUTLET. DRAIN VALVE FOR 100% FCV BYPASS INLET & OUTLET ISO VALVE FOR 100% FCV INLET. ISO VALVE FOR 100% FCV OUTLET. DRAIN VALVE FOR 100% FCV INLET & OUTLET. ISO VALVE FOR 30% FCV INLET. ISO VALVE FOR 30% FCV OUTLET. DRAIN VALVE FOR 30% FCV INLET & OUTLET. ROOT &ISO VALVE FOR FEED LINE PRESURE TRANSMITTER. DRAIN VALVE FOR FEED LINE PRESURE TRANSMITTER. ROOT & ISO VALVE FOR FEED LINE REMOTE PRESURE GAUGE. CHECK VALVE FOR ECONOMISER INLET ISO VALVES FOR FEED LINE ECONOMISER INLET ISO VALVE FOR ECONOMISER INLET HEADER DRAIN ROOT &ISO VALVE FOR AIR VENT AT ECO OUTLET TO STEAM DRUM LINK.
sheet 1 of 13

S.No.
1.22 1.23 1.24 1.25 1.26 1.27 1.28 1.29 1.30 1.31 1.32 1.33 1.34 1.35 1.36 1.37 1.38 1.39 1.40 1.41 1.42 1.43
RATING #
1500 1500 1500 250ATG 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500

DESIGN TEMP. C
210 315 315 315 315 315 315 315 315 315 315 315 315 315 315 315 315 315 315 315 350 500
TAG No.
V1137 & V1144 V1201 & V1202 V1203 TO V1206 V1207 V1208 & V1209 V1210 & V1211 V1212 & V1213 V1214 & V1215 V1216 & V1217 V1218 TO V1229 V1230 TO V1235 (A & B) V1236 TO V1239 V1240A & V1240B, V1241A & V1241B V1242 TO V1245 V1246 & V1247 (A & B) V1248 V1249 V1250 V1251 V1252 V1253 & V1254 V1255 & V1256
TYPE
GLOBE GLOBE GLOBE 3 WAY GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE NRV GLOBE GLOBE GLOBE GLOBE GLOBE
SIZE
40 40 25 15 25 15 25 25 15 25 15 25 15 25 15 25 25 25 15 40 25 25
END CONN.
SW SW SW SCR SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW
MODE OF OPERATION
HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL
STATUTORY APPROVAL (IBR)

YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES
QTY (Nos)
8 2 4 1 2 2 2 2 2 12 12 4 4 4 4 1 1 1 1 1 2 2
BODY MATL.
SA 105 SA105 SA105 SA182F6 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SS304 SA105 SA105 SA182F22
DESIGN PR.Kscg
140 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104
DU No.
034 034 029 052 029 025 029 029 025 029 025 029 025 029 025 029 053 029 113 034 029 030
DESCRIPTION
DRAIN VALVE FOR DE.SH FEED INLET ROOT & ISO VALVE FORAUXILIARY/ N2 CAPPING STUB AT STEAM DRUM ROOT & ISO VALVE FOR DRUM PRESSURE GAUGES. (LOCAL & REMOTE) 3 WAY VALVE FOR DRUM PRESSURE GAUGE. ROOT & ISO VALVE FOR DRUM PRESSURE TRANSMITTER. DRAIN VALVES FOR DRUM PRESSURE TRANSMITTER. ROOT & ISO VALVES FOR STEAM DRUM AIR VENT. ROOT & ISO VALVE FOR CSH INLET LINK AIR VENT ROOT & ISO VALVE FOR SATURATED STEAM SAMPLING. ROOT & ISO VALVES FOR DRUM LEVEL TRANSMITTERS . DRAIN VALVE FOR DRUM LEVEL TRANSMITTERS. ROOT & ISO VALVE FOR BICOLOR MULTIPORT WATER LEVEL GAUGE-I DRAIN VALVES FOR DRUM BICOLOR MULTIPORT WATER LEVEL GAUGE-I ROOT & ISO VALVE FOR BICOLOR MULTIPORT WATER LEVEL GAUGE-II DRAIN VALVES FOR DRUM BICOLOR MULTIPORT WATER LEVEL GAUGE-II ISO VALVE FOR HP DOSING LINE CHECK VALAE AT HP DOSING LINE TO STEAM DRUM ISO VALVE FOR CONTINUOUS BLOWDOWN LINE ISO VALVE FOR BLOWDOWN SAMPLING ISO VALVE FOR INTERMITTENT BLOW DOWN LINE ROOT & ISO VALVE FOR SSH INLET LINK AIR VENT ISO VALVE FOR BSH INLETLINK AIRVENT
sheet 2 of 13

S.No. TAG No.
V1257 TO V1260 (A & B) V1261 & V1264 V1265 V1266A & V1266B V1267 & V1268 V1269 V1270 & V1271 V1272 TO V1275, V1279 & V1280, V1286 & V1287, V1276 & V1277 V1278A & V1278B V1281 V1282 & V1283 V1284 & V1285 V1288 TO V1291 V1292A & V1292B, V1293A & V1293B V1294 V1295 & V1296 V1297 V1298 & V1299 V12100
RATING # END CONN.
SW

DESIGN TEMP. C
500
TYPE
SIZE
MODE OF OPERATION
HAND WHEEL

YES
QTY (Nos)
8
BODY MATL.
SA105
DESIGN PR.Kscg
104
DU No.
DESCRIPTION
1.44
GLOBE
25
1500
029
ROOT & ISO VALVE FOR BEDCOIL DRAIN
1.45 1.46 1.47 1.48 1.49 1.50
GLOBE GLOBE GLOBE GLOBE 3 WAY GLOBE
25 25 15 15 15 15
1500 1500 1500 1500 250 ATG 1500
SW SW SW SW SCD SW
HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL
YES YES YES YES YES YES
4 1 2 2 1 2
SA182F22 SA105 SS304 SA182F22 SA182 F6 SA182 F22
104 104 104 104 104 104
525 525 525 525 525 525
030 029 113 026 052 026
ROOT & ISO VALVE FOR BSH HEADER DRAIN ISO VALVE FOR BSH HEADER COMMAN DRAIN ROOT & ISO VALVE FOR STEAM LINE SAMPLING ROOT & ISO VALVE FOR STEAM LINE PRESSURE GAUGE 3 WAY VALVE FOR STEAM LINE PRESSURE GAUGE ROOT & ISO VALVE FOR STEAM LINE REMOTE PRESSURE GAUGE
1.51
GLOBE
25
1500
SW
HAND WHEEL
YES
SA182 F22
104
525
030
DRAIN VALVE FOR STEAM LINE
1.52 1.53 1.54 1.55 1.56 1.57 1.58 1.59 1.60 1.61 1.62 1.63
GLOBE GLOBE GATE GLOBE GLOBE GLOBE GLOBE NRV GLOBE GLOBE GLOBE GLOBE
15 15 100 40 25 15 15 250 25 40 40 40
1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500
SW SW BW SW SW SW SW BW SW SW SW SW
HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL
YES YES YES YES YES YES YES YES YES YES YES YES
2 2 1 2 2 4 4 1 2 1 2 1
SA182F22 SA182 F22 SA217WC9 SA182 F22 SA182F22 SA182 F22 SA182 F22 SA217WC9 SA182F22 SA105 SA105 SA105
104 104 104 104 104 104 104 104 104 97 97 97
525 525 525 525 525 525 525 525 525 330 330 330
026 026 044 035 030 026 026 114 030 034 034 034
ROOT & ISO VALVE FOR STEAM LINE PRESSURE TRANSMITTER DRAIN VALVE FOR STEAM LINE PRESSURE TRANSMITTER ISO VALVE FOR STARTUP STEAM VENT AT MAIN STEAM LINE ROOT & ISO VALVE FOR STEAM LINE AUXILARY VALVE ROOT & ISO VALVE FOR AIRVENT AT MAIN STEAM LINE ROOT & ISO VALVES FOR STEAM LINE FLOW TRANSMITTER DRAIN VALVES FOR STEAM STEAM LINE FLOW TRANSMITTER NRV AT MAIN STEAM LINE. ROOT & ISO VALVE FOR AIR VENT STUB. ISO. VALVE FOR SOOT BLOWER STUB INLET & OUTLET ISO. VALVE FOR SOOT BLOWER PRV. BYE PASS VALVE FOR SOOT BLOWER PRV.
sheet 3 of 13

S.No.
1.64 1.65 1.66 1.67 1.68 1.69 1.70 1.71 1.72
RATING #
1500 1500 1500 1500 1500 1500 1500 1500 1500

DESIGN TEMP. C
330 330 330 330 330 330 330 330 330
TAG No.
V12101 & V12104 V12105 V12106 V12107 V12108 TO V12111 V12112 & V12113 V12114 V12115 V12116
TYPE
GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE
SIZE
15 15 15 15 15 50 15 15 15
END CONN.
SW SW SW SW SW SW SW SW SW
MODE OF OPERATION
HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL

YES YES YES YES YES YES YES YES YES
QTY (Nos)
4 1 1 1 4 2 1 1 1
BODY MATL.
SA182 F22 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105
DESIGN PR.Kscg
97 30 30 30 30 30 30 30 30
DU No.
026 025 025 025 025 037 025 025 025
DESCRIPTION
DRAIN VALVES FOR SOOT BLOWER PRV. ISO. VALVE FOR SOOT BLOWER LINE PR. GAUGE STUB. ISO. VALVE FOR PREESURE TRANSMITTER. DRAIN VALVE FOR PREESURE TRANSMITTER. ISO. & DRAIN VALVE FOR ORIFICE FLOW METER. ISO. VALVE FOR SOOT BLOWER LINE. ROOT VALVE FOR STEAM TRAP. ISO VALVE FOR STEAM TRAP. BYBASS VALVE FOR STEAM TRAP.
II
2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10 2.11 2.12
P & I DIAGRAM FOR DEAERATOR & FEED PUMPS.

V0001 V0002A & V0002B V0003 V0004 & V0007 V0008 V0009 V0010 V0011 V0012 V0013 V0014 V0015 NRV GATE GATE GLOBE NRV GATE GATE NRV GLOBE NRV GLOBE GLOBE 200 150 200 15 200 200 80 80 50 50 15 15 150 150 150 800 150 150 150 150 800 800 800 800 F F F SW F F F F SW SW SW SW HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL YES YES YES YES YES YES YES YES NO NO NO NO 1 2 1 4 1 1 1 1 1 1 1 1 SA216WCB SA216WCB SA216WCB SA105 SA216 WCB SA216WCB SA216WCB SA216 WCB SA105 SA105 SA105 SA105 8 8 8 8 8 8 8 10 8 8 8 8 250 250 250 250 250 250 250 150 250 165 250 250 062 049 050 027 062 050 043 059 107 111 112 112
REF DRG : BG059-00-09-1-001/NIL

NRV AT TURBINE BLEED LINE TO DEAERATOR. ISO VALVE FOR DEARATOR PRESSURE CONTROL STATION INLET & BYBASS VALVE FOR PCV. ISO VALVE FOR DEARATOR PRESSURE CONTROL STATION OUTLET. DRAIN VALVES FOR DEARATOR PRESSURE CONTROL STATION . NRV FOR PCV OUTLET AT DEAERATOR ISO VALVE FOR SPARGER LINE ISO VALVE FOR INITIAL HEATING LINE NRV FOR INITIAL HEATING LINE AT DEAERATOR ISO VALVE FOR EMERGENCY FILLING. NRV FOR EMERGENCY FILLING. ISO VALVE FOR PRESSURE TRANSMITTER DRAIN VALVE FOR PRESSURE TRANSMITTER.
sheet 4 of 13

S.No.
2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 2.26 2.27 2.28 2.29 2.30 2.31 2.32 2.33 2.34
RATING #
800 150 800 800 800 800 150 150 150 150 150 800 800 150 150 150 150 800 800 800 800 800

DESIGN TEMP. C
250 250 250 155 155 155 155 155 155 155 155 155 155 250 250 250 250 326 326 155 155 155
TAG No.
V0016 & V0017 V0018 V0019 V0020 & V0021 V0022 & V0023 V0024 V0025 & V0026 V0027 V0028 V0029 V0030 TO V0032 V0033 TO V0038 V0039 TO V0041 V0042 V0043 V0044 V0045 V0046 V0047 V0048, V0050 & V0052 V0049, V0051 & V0053 V0054 & V0055
TYPE
GLOBE GATE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GATE GATE GATE GLOBE GLOBE NRV GATE NRV GATE NRV GATE GLOBE GLOBE GLOBE
SIZE
40 200 15 15 15 15 80 80 100 250 200 15 15 80 80 80 80 25 25 50 50 25
END CONN.
SW F SW SW SW SW F F F F F SW SW F F F F SW SW SW SW SW
MODE OF OPERATION
HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL

NO NO NO NO NO NO NO NO NO NO NO NO NO YES YES YES YES YES YES YES YES NO
QTY (Nos)
2 1 1 2 2 1 2 1 1 1 3 6 3 1 1 1 1 1 1 3 3 2
BODY MATL.
SA 105 SA216WCB SA105 SA105 SA105 SA105 SA216WCB SA216WCB SA216WCB SA216 WCB SA216 WCB SA105 SA105 SA216 WCB SA216 WCB SA216 WCB SA216 WCB SA105 SA105 SA105 SA105 SA105
DESIGN PR.Kscg
8 8 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
DU No.
036 050 112 112 112 112 039 039 108 051 050 112 112 059 043 059 043 056 041 038 038 105
DESCRIPTION
VAPOUR VENT VALVES AT DEAERATOR ISO VALVE FOR SPARE STUB ISO VALVE FOR DEAERATOR STORAGE TANK PRESSURE GAUGE. ISO VALVE FOR DEAERATOR LEVEL TRANSMITTER. DRAIN VALVE FOR DEAERATOR LEVEL TRANSMITTER. DRAIN VALVE FOR STORAGE TANK LEVEL STAND PIPE. DRAIN VALVE FOR STORAGE TANK. COMMAN DRAIN VALVE FOR STORAGE TANK. ISO VALVE FOR DEAERATOR STORAGE TANK OVER FLOW LINE ISO VALVE FOR DEAERATOR STORAGE TANK OUTLET. ISO VALVES FOR FEED PUMP SUCTION. ISO VALVES FOR DP SWITCHES ACROSS FEED PUMP SUCTION STRAINERS. DRAIN VALVE FOR FEED PUMP SUCTION STRAINERS. NRV FOR FLASH STEAM RECOVERY LINE AT DEAERATOR ISO VALVE FOR FLASH STEAM RECOEVRY LINE AT DEAERATOR. NRV FOR CONDENSATE WATER FROM HP HEATER DRAIN LEVEL CONTROL VALVE OUTLET. ISO VALVE FOR CONDENSATE WATER FROM HP HEATER DRAIN LEVEL CONTROL VALVE OUTLET. NRV FOR HP HEATER OPERATING VENT. ISO VALVE FOR HP HEATER OPERATING VENT. ISO VALVE FOR AUTO RECIRCULATION LINE. ISO VALVE FOR BALANCING LEAK OFF LINE DRAIN VALVE FOR BFP INLET HEADER.
sheet 5 of 13

S.No.
2.35 2.36 2.37 2.38 2.39 2.40 2.41 2.42 2.43 2.44 2.45 2.46 2.47
RATING #
800 1500 1500 1500 1500 1500 1500 1500 1500 250 ATG 1500 1500 1500

DESIGN TEMP. C
250 155 155 210 210 210 210 210 210 210 210 210 210
TAG No.
V0056A & V0056B V0101 V0102 V0103 V0104 V0105 & V0106 V0107 TO V0110 V0111A & V0111B , V0112A & V0112B V0113 & V0114 V0115 V0116 TO V0126 V0127 TO V0130 V0131A & V0131B , V0132A & V0132B
TYPE
GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE 3 WAY GLOBE GLOBE GLOBE
SIZE
25 50 50 15 15 25 15 15 15 15 15 15 15
END CONN.
SW SW SW SW SW SW SW SW SW SCR SW SW SW
MODE OF OPERATION
HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL

NO YES YES YES YES YES YES YES YES YES YES YES YES
QTY (Nos)
2 1 1 1 1 2 4 4 2 1 11 4 4
BODY MATL.
SA105 SA105 SA105 SA105 SA105 SA105 SA 105 SA105 SA105 SA182 F6 SA 105 SA 105 SA105
DESIGN PR.Kscg
10 150 150 150 150 150 150 150 150 150 150 150 150
DU No.
105 037 037 025 025 029 025 025 025 052 025 025 025
DESCRIPTION
ISO VALVE FOR DEARATOR LIQUID LEVEL SWITCH. ISO VALVE FOR PRDS LINE(SPRAY WATER LINE). ISO VALVE FOR DUMPING PRDS. DRAIN VALVE FOR PSL. TO SWAS( FEED LINE) DRAIN VALVE FOR BFP OUTLET HEADER. ROOT &ISO VALVE FOR FEED LINE FLOW TRANSMITTER. (BOILER - I) DRAIN VALVE FOR FEED LINE FLOW TRANSMITTER. (BOILER - I) ROOT & ISO VALVE FOR FEED LINE LOCAL PRESSURE GAUGE. 3 WAY VALVE FOR FEED LINE LOCAL PRESSURE GAUGE. ROOT & DRAIN VALVE FOR PSL. ROOT &ISO VALVE FOR FEED LINE FLOW TRANSMITTER. (BOILER - II) DRAIN VALVE FOR FEED LINE FLOW TRANSMITTER. (BOILER - II)
III
3.01 3.02 3.03 3.04 3.05 3.06 3.07
P & I DIAGRAM FOR AIR, FLUE GAS AND FUEL FEEDING SYSTEM.
V1301 & V1302 V1303 & V1304 V1305 V1306 & V1307 V1308 & V1309 V1310 & V1311 V1312 TO V1321 GATE GATE GATE GATE GATE GATE GATE 15 15 15 15 15 15 15 SCR SCR SCR SCR SCR SCR SCR HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL NO NO NO NO NO NO NO 2 2 1 2 2 2 10 GM GM GM GM GM GM GM 1 1 1 1 1 1 1 150 150 150 150 150 150 150 040 040 040 040 040 040 040
REF DRG : BG059-00-09-0-003/NIL

ISO VALVE FOR DT& DTP AT FD OUTLET ISO VALVE FOR AIR FOIL TRANSMITTER ISO VALVE FOR DTP AT BEFORE AIR HEATER ISO VALVE FOR DT& DTP BEFORE FD HEADER ISO VALVE FOR DTP AT BEFORE & AFTER PA FAN ISO VALVE FOR DT & DTP PA HEADER ISO VALVE FOR DT& DTP AT AIRBOX
sheet 6 of 13

S.No.
3.08 3.09 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18
RATING #
150 -

DESIGN TEMP. C
150 800 800 800 800 150 150 150 150 150 150
TAG No.
V1322 TO V1326 V1327 V1328 & V1329 V1330 & V1331 V1332& V1333 V1334 & V1335 V1336 & V1337 V1338 & V1339 V1340 V1341 TO V1342 V1343
TYPE
GATE GATE GATE GATE GATE GATE GATE GATE GATE GATE GATE
SIZE
100 15 15 15 15 15 15 15 15 15 15
END CONN.
FL SCR SCR SCR SCR SCR SCR SCR SCR SCR SCR
MODE OF OPERATION
HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL

NO NO NO NO NO NO NO NO NO NO NO
QTY (Nos)
5 1 2 2 2 2 2 2 1 2 1
BODY MATL.
CI GM GM GM GM GM GM GM GM GM GM
DESIGN PR.Kscg
1 1 1 1 1 1 1 1 1 1 1
DU No.
047 040 040 040 040 040 040 040 040 040 040
DESCRIPTION
ISO VALVE FOR AIRBOX DRAIN VALVE ISO VALVE FOR APG AT FURNACE ISO VALVE FOR DT& DTP AT FURNACE ISO VALVE FOR DT & DTP AT RSH ISO VALVE FOR DT& DTP AT CSH ISO VALVE FOR DT& DTP BEFORE ECONOMISER ISO VALVE FOR DT& DTP BEFORE AIR HEATER ISO VALVE FOR DT & DTP AFTER AIR HEATER ISO VALVE FOR DT AT ESP OUTLET ISO VALVE FOR DTP AT BEFORE AND AFTER ID FAN. ISO VALVE FOR PSH AT FURNACE
IV
4.01 4.02 4.03 4.04 4.05 4.06 4.07 4.08 4.09 4.10
P & I DIAGRAM FOR HP & LP DOSING SYSTEM.

V0057 V0058 V0059 & V0060 V0061 & V0062 V0063 & V0064 V0065 & V0066 V0067 V0068 V0069 V0501A & V0501B BALL BALL BALL NRV BALL BALL BALL NRV BALL BALL 25 25 25 25 25 15 25 25 25 25 800 800 800 800 800 800 800 800 800 800 SW SW SW SW SW SW SW SW SW SW HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL NO NO NO NO NO NO NO NO NO NO 1 1 2 2 2 2 1 1 1 2 SA182 F304 SA182 F304 SA182 F304 SA182 F316 SA182 F304 SA182 F304 SA182 F304 SA182 F316 SA182 F304 SA182 F304 3 3 3 10 10 10 10 10 3 3 50 50 50 50 50 50 150 150 50 50 241 240 241 109 241 241 241 241 241
REF DRG : BG059-00-09-3-004/NIL

ISO VALVE FOR LP DOSING TANK CHEMICAL INLET ISO VALVE FOR LP DOSING TANK WATER INLET. ISO VALVES FOR LP DOSING PUMP I & II SUCTION
CHECK VALVES FOR LP DOSING PUMP I & II DISCHARGE. ISO VALVES FOR LP DOSING PUMP I & II DISCHARGE. ISO VALVE LP DOSING LINE PRESSURE GAUGE. ISO VALVE FOR LP DOSING OUTLET. CHECK VALVE FOR LP DOSING OUTLET. DRAIN VALVE FOR HP DOSING TANK. ISO VALVE FOR LP DOSING TANK CHEMICAL & WATER INLET
sheet 7 of 13

S.No.
4.11 4.12 4.13 4.14 4.15 4.16
RATING #
800 800 1500 1500 1500 1500

DESIGN TEMP. C
50 50 50 50 50 50 031 031
TAG No.
V0502 V0503 TO V0505 V0506 TO V0508 V0509 TO V0511 V0512 TO V0517 V0518 & V0519
TYPE
BALL BALL GLOBE NRV GLOBE GLOBE
SIZE
25 25 25 25 25 25
END CONN.
SW SW SW SW SW SW
MODE OF OPERATION
HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL

NO NO YES YES YES YES
QTY (Nos)
1 3 3 3 6 2
BODY MATL.
SA182 F304 SA182 F304 SA182 F316 SA182 F316 SA182 F316 SA182 F316
DESIGN PR.Kscg
3 3 115 115 115 115
DU No.
241 241 031
DESCRIPTION
DRAIN VALVE AT HP DOSING TANK. ISO VALVE AT HPDOSING PUMP INLET ISO VALVE FOR AT HPDOSING PUMP OUTLET. CHECK VALVE AT HPDOSING PUMP OUTLET. ROOT & ISO VALVE FOR PRESSURE GAUGE AT HP DOSING LINE ISO VALVE FOR BOILER - II
P & I DIAGRAM FOR BLOW DOWN TANK & FLASH STEAM RECOVERY SYSTEM 0.01 V0075 & V0076 0.03 V0077 0.04 V0078 & V0079 0.05 V0080 & V0081 0.06 V0082 0.07 V0083 0.08 V0084 0.09 V0085 & V0086 0.09 V0087 0.10 V0088 0.11 V0089
NRV GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE 25 25 25 15 50 80 25 25 25 80 25 1500 800 800 800 800 150 800 800 800 150 800 SW SW SW SW SW F SW SW SW F SW HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL YES YES YES YES YES YES YES YES YES YES YES 2 1 2 2 1 1 1 2 2 1 1 SA105 SA105 SA105 SA105 SA105 SA216WCB SA105 SA105 SA105 SA216WCB SA105 7 7 7 7 7 7 7 7 7 3 3 315 200 200 200 200 200 200 200 200 200 200 053 032 032 027 038 039 032 032 032 039 032
REF DRG : BG059-00-09-3-008/NIL

CHECK VALVE FOR CBD LINE AT CBD TANK BOILER 1&2 FOR
ISO VALVE FOR BLOWDOWN TANK PRESSURE GAUGE ISO VALVES FOR BLOWDOWN TANK LEVEL TRNSMITTER DRAIN VALVES FOR BLOWDOWN TANK LEVEL TRNSMITTER ISO VALVE FOR CBD TANK DRAIN FLASH STEAM TO DEAERATOR STORAGE TANK AIRVENT VALVE AT CBD TANK ISO VALVE FOR CBD LEVEL CONTROL VALVE ISO VALVE FOR CBD LEVEL CONTROL VALVE BYBASS DRAIN VALVE FOR IBD TANK BY PASS VALVE FOR IBD TANK DRAIN LINE
P & I DIAGRAM FOR BED ASH COOLING SYSTEM 3.01 V1350

GATE 15 SCR HAND WHEEL NO 1 GM 1.0 150 040
REF DRG : BG059-00-09-3-009/NIL

ISO VALVE FOR DTP AT BED ASH COOLER AIR LINE
sheet 8 of 13

S.No. TAG No. TYPE SIZE RATING #
END CONN. MODE OF OPERATION STATUTORY APPROVAL (IBR) QTY (Nos) BODY MATL. DESIGN PR.Kscg DESIGN TEMP. C DU No.
DESCRIPTION REF DRG : BG059-00-09-3-010/NIL
P & I DIAGRAM FOR STARTUP OIL FIRING SYSTEM

8.01 8.02 8.03 8.04 8.05 8.06 8.07 8.08 8.09 8.10 8.11 8.12 V1801 V1802 V1803 V1804 & V1805 V1806 & V1807 V1808 & V1809 V1810 V1811 V1812 TO V1813 V1814 TO V1815 V1816 V1817 TO V1820 BALL BALL BALL BALL NRV BALL BALL BALL BALL BALL BALL BALL BFV BFV GATE 50 50 50 50 25 25 25 15 25 25 15 25 65 25 15 800 800 800 800 800 800 800 800 800 800 800 800 SW SW SW SW SW SW SW SW SW SW SW SW SCR SCR SCR HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO 1 1 1 2 2 2 1 1 2 2 1 4 4 4 1 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 MS MS GM 3 3 3 3 10 10 10 10 10 10 10 10 1.0 1.0 1.0 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 190 190 190 190 186 189 189 187 189 189 187 189 197 196 040
ISO VALVE FOR STARTUP OIL TANK INLET DRAIN VALVE FOR SERVICE OIL TANK ISO VALVE FOR STARTUP OIL TANK OUTLET ISO VALVE AT STARTUP OIL PUMP INLET CHECK VALVE AT STARTUP OIL PUMP OUTLET ISO VALVE AT STARTUP OIL PUMP OUTLET ISO VALVE FOR RETURN OIL LINE ISO VALVE FOR GEAR OIL PUMP OUTLET PRESSURE GAUGE ISO VALVE BEFORE DISCHARGE FILTERS ISO VALVE AFTER DISCHARGE FILTERS ISO VALVE FOR COMMON OIL HEADER PRESSURE GAUGE ISO VALVE FOR BURNER INLET ISO VALVE FOR COMBUSTION AIR LINE - I & II ISO VALVE FOR ATOMISING AIR LINE - I & II ISO VALVES FOR AIR PRESSURE GAUGE AT COMBUSTION AIR HEADER-I & II
3.01 V1351 TO V1354 3.02 V1355 TO V1358 3.03 V1359
P & I DIAGRAM FOR INSTRUMENTS AIR DISTRIBUTION SYSTEM

7.01 7.02 7.03 V0701 V0702 V1701 BALL BALL BALL 50 15 15 SCR SCR SCR HAND WHEEL HAND WHEEL HAND WHEEL NO NO NO 1 1 1 SS316 SS316 SS316 10 10 10 50 50 50 191 188 188
REF DRG : BG059-00-09-2-011/NIL

ISO VALVE AT INSTRUMENT AIR HEADER ISO VALVE FOR INSTRUMENT AIR HEADER PRSSURE SWITCH ISO VALVE FOR BOILER - I INSTRUMENT AIR LINES PRESSURE GAUGE
sheet 9 of 13

S.No.
7.04 7.05 7.06 7.07 7.08
RATING #
-

DESIGN TEMP. C
50 50 50 50 50
TAG No.
V1702 TO V1722 V2701 V2702 TO V2721 V0703 V0704 TO V0717
TYPE
BALL BALL BALL BALL BALL
SIZE
15 15 15 15 15
END CONN.
SCR SCR SCR SCR SCR
MODE OF OPERATION
HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL

NO NO NO NO NO
QTY (Nos)
21 1 20 1 14
BODY MATL.
SS316 SS316 SS316 SS316 SS316
DESIGN PR.Kscg
10 10 10 10 10
DU No.
188 117 117 188 188
DESCRIPTION
ISO VALVE AT BOILER - I INSTRUMENT AIR LINES ISO VALVE FOR BOILER - II INSTRUMENT AIR LINES PRESSURE GAUGE ISO VALVE AT BOILER - II INSTRUMENT AIR LINES ISO VALVE FOR TG HOUSE INSTRUMENT AIR LINES PRESSURE GAUGE ISO VALVE AT TG HOUSE INSTRUMENT AIR LINES
P & I DIAGRAM FOR TURBINE STEAM PIPING 0.01 V0201 0.02 V0202 0.03 V0203 0.04 V0204 0.05 V0205 & V0206 0.06 V0207 0.07 V0208 & V0209 0.08 V0210 & V0211 0.09 V0212 & V0213 0.10 V0214 & V0215 0.11 V0216 & V0217 0.12 V0218 & V0219 0.13 V0220 & V0221 0.14 V0222 & V0223 GATE GATE GATE GATE GLOBE 3 WAY GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE 250 250 50 25 15 15 15 15 25 25 15 25 50 25 1500 1500 1500 1500 1500 250ATG 1500 1500 1500 1500 1500 1500 1500 1500 BW BW SW SW SW SCR SW SW SW SW SW SW SW SW HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL YES YES YES YES YES YES YES YES YES YES YES YES YES YES 1 1 1 1 2 1 2 2 2 2 2 2 2 2 SA217WC9 SA217WC9 SA182F22 SA182F22 SA182F22 SA182F6 SA182F22 SA182F22 SA182F22 SA182F22 SA182F22 SA182F22 SA182F22 SA182F22 95 95 95 95 95 95 95 95 95 95 95 95 95 95 520 520 520 520 520 520 520 520 520 520 520 520 525 525 194 194 193 192 026 052 026 026 030 030 026 030 195 030
REF DRG : BG059-00-09-1-012/NIL

ISO VALVE FOR BOILER-I MAIN STEAM LINE TO TURBINE ISO VALVE FOR BOILER - II MAIN STEAM LINE TO TURBINE ISO VALVE FOR PRDS - I IN MAIN STEAM LINE. ISO VALVE FOR PRDS - II IN MAIN STEAM LINE. ROOT & ISO VALVE FOR PR. GAUGE STUB AT MAIN STEAM LINE TO TURBINE 3 WAY VALVE FOR TG INLET PRESSURE GAUGE. ROOT & ISO VALVE FOR TG INLET PRESSURE TRANSMITTER. DRAIN VALVES FOR TG INLET PRESSURE TRANSMITTER. DRAIN VALVES FOR TG INLET LINE DRAIN TO ATM. FLASH TANK. ROOT & ISO VALVES FOR TG INLET LINE AIR VENT. ROOT & ISO VALVE FOR PR. GAUGE STUB AT TG INLET. ROOT & ISO VALVE FOR DRAIN LINE IN TG INLET. ISO. VALVES FOR WARM UP VENT STUB. R00T & ISO VALVE FOR WARM UP VENT DRAIN.
sheet 10 of 13

S.No. TAG No. V0224 & V0225, V0228 & V0229 TYPE SIZE RATING #
END CONN. SW SW SW SW SW SW SW SW SW MODE OF OPERATION HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL STATUTORY APPROVAL (IBR) YES YES YES YES YES YES YES YES YES QTY (Nos) 4 2 4 2 1 2 2 4 2 BODY MATL. SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 DESIGN PR.Kscg 18 18 6 6 6 6 6 6 6 DESIGN TEMP. C 326 326 220 220 220 220 220 220 220 DU No.
DESCRIPTION
ROOT & ISO VALVE FOR DRAIN IN TG BLEED-I TO ATM. FLASH TANK. ROOT & ISO VALVE FOR AIR VENT STUB IN BLEEDI ROOT & ISO VALVE FOR DRAIN IN TG BLEED-II TO ATM. FLASH TANK. ROOT & ISO VALVE FOR AIR VENT STUB IN BLEEDII ISO. VALVE FOR PR. GAUGE STUB IN BLEED-II ROOT & ISO VALVE FOR TG BLEED - II PRESSURE TRANSMITTER. DRAIN VALVES FOR BLEED PRESSURE TRANSMITTER. ROOT & ISO VALVE FOR DRAIN IN TG BLEED-III TO ATM. FLASH TANK. ROOT & ISO VALVE FOR AIR VENT STUB.
0.15
GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE
25 25 25 25 15 15 15 25 25
800 800 800 800 800 800 800 800 800
032 032 032 032 027 027 027 032 032
0.16 V0226 & V0227 0.17 V0230 & V0231, V0234 & V0235
0.18 V0232 & V0233 0.19 V0236 0.20 V0237 & V0238 0.21 V0239 & V0240 0.22 V0241 & V0242, V0245 & V0246
0.23 V0243 & V0244
P & I DIAGRAM FOR PRDS I & II 0.24 V0251 & V0252 0.25 V0253A & V0253B GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE 25 25 25 15 15 15 25 25 25 1500 800 800 800 800 800 1500 800 800 SW SW SW SW SW SW SW SW SW HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL YES YES YES YES YES YES YES YES YES 2 2 1 2 2 2 2 2 1 SA182F22 SA105 SA105 SA105 SA105 SA105 SA182F22 SA105 SA105 95 8 120 8 8 8 95 26 120 520 250 155 250 250 250 520 350 155 030 032 032 027 027 027 030 032 032
REF DRG : BG059-00-09-2-013/NIL

ROOT & ISO VALVE FOR DRAIN AT PRDS I INLET. ISO VALVE FOR AIR VENT STUB. ISO VALVE FOR VARIABLE NOZZLE DE-SUPER HEATER TCV. ROOT VALVE FOR STEAM TRAP. ISO VALVE FOR STEAM TRAP. BYBASS VALVE FOR STEAM TRAP. ROOT & ISO VALVE FOR DRAIN AT PRDS II INLET. ROOT & ISO VALVE FOR AIR VENT STUB. ISO VALVE FOR FIXED NOZZLE DE-SUPER HEATER .
0.26 V0254 0.27 0.28 0.29 V0255A & V0255B V0256A&V0256 B V0257A & V0257B
0.30 V0258 & V0259 0.31 V0260A & V0260B
0.32 V0261
sheet 11 of 13

END CONN. SW SW SW SW SW SW SW SW MODE OF OPERATION HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL STATUTORY APPROVAL (IBR) YES YES YES YES YES YES YES YES QTY (Nos) 1 2 2 2 1 2 2 2 BODY MATL. SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 DESIGN PR.Kscg 26 26 26 26 26 26 26 26 DESIGN TEMP. C 350 350 350 350 350 350 350 350 DU No.
DESCRIPTION
ISO VALVE GLAND SEALING STEAM INLET. ROOT VALVE FOR STEAM TRAP. ISO VALVE FOR STEAM TRAP. BYBASS VALVE FOR STEAM TRAP. ISO. VALVE FOR EJECTOR INLET. ROOT VALVE FOR STEAM TRAP. ISO VALVE FOR STEAM TRAP. BYBASS VALVE FOR STEAM TRAP.
0.33 V0262 0.34 0.35 0.36 V0263A & VO263B V0264A & VO264B V0265A & VO265B
GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE
25 15 15 15 50 15 15 15
800 800 800 800 800 800 800 800
032 027 027 027 038 027 027 027
0.37 V0266 0.38 0.39 0.40 V0267A & V0267B V0268A & V0268B V0269A & V0269B
P & I DIAGRAM FOR DUMPING PRDS SYSTEM 0.41 V0276 & V0277 GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE 25 25 15 15 15 50 1500 800 800 800 800 1500 SW SW SW SW SW SW HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL YES YES YES YES YES YES 2 2 2 2 2 1 SA182F22 SA105 SA105 SA105 SA105 SA105 95 4 4 4 4 120 520 160 160 160 160 155 030 032 027 027 027 37
REF DRG : BG059-00-09-3-015/NIL

ROOT & ISO VALVE FOR DRAIN IN PRDS - III ROOT & ISO VALVE FOR AIR VENT STUB. ROOT VALVE FOR STEAM TRAP. ISO VALVE FOR STEAM TRAP. BYBASS VALVE FOR STEAM TRAP. ISO VALVE FOR VARIABLE DE-SUPER HEATER SPRAY INLET.
0.42 V0278 & V0279 0.43 V0280 & V0281 0.44 V0282 & V0283 0.45 V0284 & V0285 0.44 V0286
NOTES :
BW -BUTT WELD. SW- SOCKET WELD. SCR - SCREWED. F - FLANGED.
sheet 12 of 13

DESCRIPTION
PREPARED : B A REV VALVES SPECIFICATION REVISED AND VALVES DU No`s ARE ADDED VALVES ADDED PARTICULARS SIGN. 31.05.07 CHECKED :
27.02.07 APPROVED : DATE DATE : 19.12.2006
sheet 13 of 13

S.No. I TAG No. TYPE SIZE RATING #
DWG. No. : BG060-00-09-4-005. REVISION : B

DESCRIPTION
REF DRG : BG060-00-09-0-002/NIL
P & I DIAGRAM FOR FEED LINE & STEAM LINE.

GLOBE GLOBE GLOBE NRV GLOBE GATE GATE GLOBE GATE GATE GLOBE GATE GATE GLOBE GLOBE GLOBE GLOBE NRV GATE GLOBE GLOBE GLOBE GLOBE GLOBE 3 WAY 40 25 25 40 40 100 100 15 100 100 15 50 50 15 15 15 15 150 150 25 25 40 40 25 15 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 250ATA SW SW SW SW SW BW BW SW BW BW SW SW SW SW SW SW SW BW BW SW SW SW SW SW SCR HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES 1 2 2 1 1 1 1 4 1 1 4 1 1 4 2 2 2 1 1 2 2 8 2 4 1 SA105 SA105 SA105 SA182F22 SA 105 SA216WCB SA216WCB SA105 SA216WCB SA216WCB SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA216 WCB SA216 WCB SA105 SA105 SA 105 SA105 SA105 SA182F6 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 104 104 104 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 315 315 315 032 028 028 082 032 054 054 024 054 054 024 053 053 024 024 024 024 056 055 028 028 032 032 028 043
1.01 V2101 1.02 V2102 & V2103 1.03 V2104 & V2105 1.04 V2106 1.05 V2107 1.06 V2108 1.07 V2109 1.08 V2110 TO V2113 1.09 V2114 1.10 V2115 1.11 V2116 & V2119 1.12 V2120 1.13 V2121 1.14 V2122 TO V2125 1.15 V2126 & V2127 1.16 V2128A & V2128B 1.17 V2129 & V2130 1.18 V2131 1.19 V2132 1.20 V2133 & V2134 1.21 V2135 & V2136 1.22 V2137 TO V2144 1.23 V2201 & V2202 1.24 V2203 TO V2206 1.25 V2207
ISO VALVE FOR TCV. ISO VALVE FOR TCV INLET & OUTLET. ISO VALVE FOR BYPASS TCV INLET & OUTLET. CHECK VALVE FOR DE.SH INLET. ISO VALVE FOR DE.SH FEED INLET. ISO VALVE FOR 100% FCV BYPASS INLET. ISO VALVE FOR 100% FCV BYPASS OUTLET. DRAIN VALVE FOR 100% FCV BYPASS INLET & OUTLET ISO VALVE FOR 100% FCV INLET. ISO VALVE FOR 100% FCV OUTLET. DRAIN VALVE FOR 100% FCV INLET & OUTLET. ISO VALVE FOR 30% FCV INLET. ISO VALVE FOR 30% FCV OUTLET. DRAIN VALVE FOR 30% FCV INLET & OUTLET. ROOT &ISO VALVE FOR FEED LINE PRESURE TRANSMITTER. DRAIN VALVE FOR FEED LINE PRESURE TRANSMITTER. ROOT & ISO VALVE FOR FEED LINE REMOTE PRESURE GAUGE. CHECK VALVE FOR ECONOMISER INLET ISO VALVES FOR FEED LINE ECONOMISER INLET ISO VALVE FOR ECONOMISER INLET HEADER DRAIN ROOT &ISO VALVE FOR AIR VENT AT ECO OUTLET TO STEAM DRUM LINK. DRAIN VALVE FOR DE.SH FEED INLET ROOT & ISO VALVE FORAUXILIARY/ N2 CAPPING STUB AT STEAM DRUM ROOT & ISO VALVE FOR DRUM PRESSURE GAUGES. (LOCAL & REMOTE) 3 WAY VALVE FOR DRUM PRESSURE GAUGE.
sheet 1 of 5

S.No. TAG No. TYPE
GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE NRV GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE 3 WAY GLOBE
RATING #
1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 250 ATG 1500

DU No.
028 024 028 028 024 028 024 028 024 028 024 028 044 028 157 032 028 029 028 029 028 157 025 043 025
SIZE
25 15 25 25 15 25 15 25 15 25 15 25 25 25 15 40 25 25 25 25 25 15 15 15 15
END CONN.
SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SCD SW
MODE OF OPERATION
HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL

YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES
QTY (Nos)
2 2 2 2 2 12 12 4 4 4 4 1 1 1 1 1 2 2 8 4 1 2 2 1 2
BODY MATL.
SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SS304 SA105 SA105 SA182F22 SA105 SA182F22 SA105 SS304 SA182F22 SA182 F6 SA182 F22
DESIGN PR.Kscg
104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104
DESIGN TEMP. C
315 315 315 315 315 315 315 315 315 315 315 315 315 315 315 315 350 500 500 525 525 525 525 525 525
DESCRIPTION
ROOT & ISO VALVE FOR DRUM PRESSURE TRANSMITTER. DRAIN VALVES FOR DRUM PRESSURE TRANSMITTER. ROOT & ISO VALVES FOR STEAM DRUM AIR VENT. ROOT & ISO VALVE FOR CSH INLET LINK AIR VENT ROOT & ISO VALVE FOR SATURATED STEAM SAMPLING. ROOT & ISO VALVES FOR DRUM LEVEL TRANSMITTERS . DRAIN VALVE FOR DRUM LEVEL TRANSMITTERS. ROOT & ISO VALVE FOR BICOLOR MULTIPORT WATER LEVEL GAUGE-I DRAIN VALVES FOR DRUM BICOLOR MULTIPORT WATER LEVEL GAUGE-I ROOT & ISO VALVE FOR BICOLOR MULTIPORT WATER LEVEL GAUGE-II DRAIN VALVES FOR DRUM BICOLOR MULTIPORT WATER LEVEL GAUGE-II ISO VALVE FOR HP DOSING LINE CHECK VALAE AT HP DOSING LINE TO STEAM DRUM ISO VALVE FOR CONTINUOUS BLOWDOWN LINE ISO VALVE FOR BLOWDOWN SAMPLING ISO VALVE FOR INTERMITTENT BLOW DOWN LINE ROOT & ISO VALVE FOR SSH INLET LINK AIR VENT ISO VALVE FOR BSH INLETLINK AIRVENT ROOT & ISO VALVE FOR BEDCOIL DRAIN ROOT & ISO VALVE FOR BSH HEADER DRAIN ISO VALVE FOR BSH HEADER COMMAN DRAIN ROOT & ISO VALVE FOR STEAM LINE SAMPLING ROOT & ISO VALVE FOR STEAM LINE PRESSURE GAUGE 3 WAY VALVE FOR STEAM LINE PRESSURE GAUGE ROOT & ISO VALVE FOR STEAM LINE REMOTE PRESSURE GAUGE
1.26 V2208 & V2209 1.27 V2210 & V2211 1.28 V2212 & V2213 1.29 V2214 & V2215 1.30 V2216 & V2217 1.31 V2218 TO V2229 1.32 V2230 TO V2235 (A & B)
1.33 V2236 TO V2239 1.34 V2240A & V2240B, V2241A & V2241B
1.35 V2242 TO V2245 1.36 V2246 & V2247 (A & B)
1.37 V2248 1.38 V2249 1.39 V2250 1.40 V2251 1.41 V2252 1.42 V2253 & V2254 1.43 V2255 & V2256 V2257 TO V2260 1.44 (A & B) 1.45 V2261 TO V2264 1.46 V2265 1.47 V2266A & V2266B 1.48 V2267 & V2268 1.49 V2269 1.50 V2270 & V2271
sheet 2 of 5

END CONN.
SW SW SW BW SW SW SW SW BW SW SW SW SW SW SW SW SW SW SW SW SW SW

DU No.
MODE OF OPERATION
HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL

YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES
QTY (Nos)
8 2 2 1 2 2 4 4 1 2 1 2 1 4 1 1 1 4 2 1 1 1
BODY MATL.
DESIGN PR.Kscg
104 104 104 104 104 104 104 104 104 104 97 97 97 97 30 30 30 30 30 30 30 30
DESIGN TEMP. C
525 525 525 525 525 525 525 525 525 525 330 330 330 330 330 330 330 330 330 330 330 330
DESCRIPTION
V2272 TO V2275, 1.51 V2279 & V2280, V2286 & V2287, 1.52 V2276 & V2277 1.53 V2278A & V2278B 1.54 V2281 1.55 V2282 & V2283 1.56 V2284 & V2285 1.57 V2288 TO V2291 1.58 V2292 & V2293 (A,B) 1.59 V2294 1.60 V2295 & V2296 1.61 V2297 1.62 V2298 & V2299 1.63 V22100 1.64 V22101 TO V22104 1.65 V22105 1.66 V22106 1.67 V22107 1.68 V22108 TO V22111 1.69 V22112 & V22113 1.70 V22114 1.71 V22115 1.72 V22116
GLOBE GLOBE GLOBE GATE GLOBE GLOBE GLOBE GLOBE NRV GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE
25 15 15 100 40 25 15 15 250 25 40 40 40 15 15 15 15 15 50 15 15 15
1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500
SA182 F22 SA182F22 SA182 F22 SA217WC9 SA182 F22 SA182F22 SA182 F22 SA182 F22 SA217WC9 SA182F22 SA105 SA105 SA105 SA182 F22 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105
029 025 025 039 033 029 025 025 083 029 032 032 032 025 024 024 024 024 035 024 024 024
DRAIN VALVE FOR STEAM LINE ROOT & ISO VALVE FOR STEAM LINE PRESSURE TRANSMITTER DRAIN VALVE FOR STEAM LINE PRESSURE TRANSMITTER ISO VALVE FOR STARTUP STEAM VENT AT MAIN STEAM LINE ROOT & ISO VALVE FOR STEAM LINE AUXILARY VALVE ROOT & ISO VALVE FOR AIRVENT AT MAIN STEAM LINE ROOT & ISO VALVES FOR STEAM LINE FLOW TRANSMITTER DRAIN VALVES FOR STEAM STEAM LINE FLOW TRANSMITTER NRV AT MAIN STEAM LINE. ROOT & ISO VALVE FOR AIR VENT STUB. ISO. VALVE FOR SOOT BLOWER STUB INLET & OUTLET ISO. VALVE FOR SOOT BLOWER PRV. BYE PASS VALVE FOR SOOT BLOWER PRV. DRAIN VALVES FOR SOOT BLOWER PRV. ISO. VALVE FOR SOOT BLOWER LINE PR. GAUGE STUB. ISO. VALVE FOR PREESURE TRANSMITTER. DRAIN VALVE FOR PREESURE TRANSMITTER. ISO. & DRAIN VALVE FOR ORIFICE FLOW METER. ISO. VALVE FOR SOOT BLOWER LINE. ROOT VALVE FOR STEAM TRAP. ISO VALVE FOR STEAM TRAP. BYBASS VALVE FOR STEAM TRAP.
II
REF DRG : BG060-00-09-0-003/NIL
sheet 3 of 5

S.No. TAG No. TYPE
GATE GATE GATE GATE GATE GATE GATE GATE GATE GATE GATE GATE GATE GATE GATE GATE GATE GATE
RATING #
150 -

DU No.
037 037 037 037 037 037 037 041 037 037 037 037 037 037 037 037 037 037
SIZE
15 15 15 15 15 15 15 100 15 15 15 15 15 15 15 15 15 15
END CONN.
SCR SCR SCR SCR SCR SCR SCR FL SCR SCR SCR SCR SCR SCR SCR SCR SCR SCR
MODE OF OPERATION
HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL

NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO
QTY (Nos)
2 2 1 2 2 2 10 5 1 2 2 2 2 2 2 1 2 1
BODY MATL.
GM GM GM GM GM GM GM CI GM GM GM GM GM GM GM GM GM GM
DESIGN PR.Kscg
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
DESIGN TEMP. C
150 150 150 150 150 150 150 150 800 800 800 800 150 150 150 150 150 150
DESCRIPTION
ISO VALVE FOR DT& DTP AT FD OUTLET ISO VALVE FOR AIR FOIL TRANSMITTER ISO VALVE FOR DTP AT BEFORE AIR HEATER ISO VALVE FOR DT& DTP BEFORE FD HEADER ISO VALVE FOR DTP AT BEFORE & AFTER PA FAN ISO VALVE FOR DT & DTP PA HEADER ISO VALVE FOR DT& DTP AT AIRBOX ISO VALVE FOR AIRBOX DRAIN VALVE ISO VALVE FOR APG AT FURNACE ISO VALVE FOR DT& DTP AT FURNACE ISO VALVE FOR DT & DTP AT RSH ISO VALVE FOR DT& DTP AT CSH ISO VALVE FOR DT& DTP BEFORE ECONOMISER ISO VALVE FOR DT& DTP BEFORE AIR HEATER ISO VALVE FOR DT & DTP AFTER AIR HEATER ISO VALVE FOR DT AT ESP OUTLET ISO VALVE FOR DTP AT BEFORE AND AFTER ID FAN. ISO VALVE FOR PSH AT FURNACE
2.01 V2301 & V2302 2.02 V2303 & V2304 2.03 V2305 2.04 V2306 & V2307 2.05 V2308 & V2309 2.06 V2310 & V2311 2.07 V2312 TO V2321 2.08 V2322 TO V2326 2.09 V2327 2.10 V2328 & V2329 2.11 V2330 & V2331 2.12 V2332& V2333 2.13 V2334 & V2335 2.14 V2336 & V2337 2.15 V2338 & V2339 2.16 V2340 2.17 V2341 TO V2342 2.18 V2343
sheet 4 of 5


DESCRIPTION REF DRG : BG060-00-09-3-009/NIL
III
P & I DIAGRAM FOR BED ASH COOLING SYSTEM

GATE 15 SCR HAND WHEEL NO 1 GM 1.0 150 037
3.01 V2350
ISO VALVE FOR DTP AT BED ASH COOLER AIR LINE
IV
P & I DIAGRAM FOR STARTUP OIL FIRING SYSTEM

BALL BALL BALL BALL NRV BALL BALL BALL BALL BALL BALL BFV BFV BALL GATE 50 50 50 50 25 25 25 15 25 25 15 25 65 25 15 800 800 800 800 800 800 800 800 800 800 800 800 SW SW SW SW SW SW SW SW SW SW SW SW SCR SCR SCR HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL HAND WHEEL NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO 1 1 1 2 2 2 1 1 2 2 1 4 4 4 1 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 SA105 MS MS GM 3 3 3 3 10 10 10 10 10 10 10 10 1.0 1.0 1.0 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 119 119 119 119 118 120 120 121 120 120 121 120 123 122 037
REF DRG : BG060-00-09-3-010/NIL

ISO VALVE FOR STARTUP OIL TANK INLET DRAIN VALVE FOR SERVICE OIL TANK ISO VALVE FOR STARTUP OIL TANK OUTLET ISO VALVE AT STARTUP OIL PUMP INLET CHECK VALVE AT STARTUP OIL PUMP OUTLET ISO VALVE AT STARTUP OIL PUMP OUTLET ISO VALVE FOR RETURN OIL LINE ISO VALVE FOR GEAR OIL PUMP OUTLET PRESSURE GAUGE ISO VALVE BEFORE DISCHARGE FILTERS ISO VALVE AFTER DISCHARGE FILTERS ISO VALVE FOR COMMON OIL HEADER PRESSURE GAUGE ISO VALVE FOR BURNER INLET ISO VALVE FOR COMBUSTION AIR LINE - I & II ISO VALVE FOR ATOMISING AIR LINE - I & II ISO VALVES FOR AIR PRESSURE GAUGE AT COMBUSTION AIR HEADER-I & II
8.01 V2801 8.02 V2802 8.03 V2803 8.04 V2804 & V2805 8.05 V2806 & V2807 8.06 V2808 & V2809 8.07 V2810 8.08 V2811 8.09 V2812 TO V2813 8.10 V2814 TO V2815 8.11 V2816 8.12 V2817 TO V2820 3.01 V2351 TO V2354 3.02 V2355 TO V2358 3.03 V2359
NOTES :
PREPARED : B A REV VALVES SPECIFICATION REVISED AND DU No`s ARE ADDED VALVES ADDED PARTICULARS SIGN. 31.05.07 CHECKED :

sheet 5 of 5
SPECIAL VALVES SCHEDULE

PROJECT TIRUCHIRAPALLI SPECIAL VALVES SCHEDULE
S.No. I TAG No. TYPE SIZE RATING # END CONN. MODE OF OPERATION STATUTORY APPROVAL (IBR) QTY (Nos) BODY MATL. DESIGN DESIGN PR.Kscg TEMP. C DU No.
: 2 X 80 TPH SINGLE DRUM WATER TUBE BOILER (FBC). CUSTOMER : M/s. REI AGRO LIMITED.,
DWG. No. : BG059-00-09-4-007

.
REVISION : B
DESCRIPTION
REF DRG : BG059-00-09-0-002/NIL
BW BW SW SW SW BW/F BW/F BW/F F BW BW SW MOTORIZED MOTORIZED MOTORIZED MOTORIZED MOTORIZED YES YES YES YES YES YES YES YES YES YES YES YES 1 1 1 1 1 1 1 1 1 2 1 2 SA217WC9 SA217WC9 SA217WC9 SA 105 SA 105 SA216 WCB SA216 WCB SA217WC9 SA216WCB SA216WCB SA216WCB SA216WCB 93.58 93.58 93.58 104 104 103 104 93.58 21 525 525 525 315 315 307 307 330 200 200 200 067 066 066 064 065 115 116 117 118 100 100 101 MOTORISED VALVE FOR MAIN STEAM LINE STARTUP VENT MOTORISED VALVE FOR MSSV MOTORISED VALVE FOR MSSV INTEGRAL BYPASS MOTORISED ANGLE BLOWDOWN VALVE FOR CBD MOTORISED ANGLE BLOWDOWN VALVE FOR IBD SAFETY VALVE-I AT DRUM (ST.PR. 103) SAFETY VALVE-I AT DRUM (ST.PR. 104) SAFTEY VALVE AT MAIN STEAM LINE (ST.PR. 93.54) SAFETY VALVE AT SOOT BLOWER LINE FCV AT 100% FCV UPSTREAM FCV AT 30% FCV UPSTREAM TCV FOR BEFORE AND AFTER HP HEATER

GLOBE GATE GATE ANGLE ANGLE SLSV SLSV SLSV SLSV GLOBE GLOBE GLOBE 100 200 25 25 40 50/100 50/100 40/100 40/80 100 50 25 1500 1500 1500 1500 1500 900 900 1500 HOLD 1500 1500 1500
1.01 MOV1201 1.02 MOV1202A 1.03 MOV1202B 1.04 MOV1203 1.05 MOV1204 1.06 PSV 1201 1.07 PSV1202 1.08 PSV1203 1.09 PSV1204 1.10 FCV1101A & FCV1101B
1.11 FCV1102 1.12 TCV1101 & TCV1102
II
2.01
P & I DIAGRAM FOR DEAERATOR & FEED PUMPS.

MOV0101 TO MOV0103 GATE GATE GATE GATE VRV SLSV BALL GLOBE 150 200 200 150 40 100 100 150 900 900 900 900 150 150 150 150 BW BW BW BW F F F F MOTORIZED MOTORIZED MOTORIZED MOTORIZED YES YES YES YES NO NO NO YES 3 1 2 2 1 1 1 1 SA216WCB SA216WCB SA216WCB SA216WCB SA216WCB SA216WCB SA216WCB SA216WCB 150 150 150 150 10 10 10 10 155 210 210 210 155 155 155 250 069 068 068 069 070 119 071 205
REF DRG : BG059-00-09-1-001/NIL

MOTORISED VALVE FOR FEED PUMP I , II & III OUTLET MOTORISED VALVE FOR HP HEATER BYPASS MOTORISED VALVE FOR BEFORE AND AFTER HP HEATER MOTORISED VALVE FOR BOILER I & II. VRV AT DEAERATOR STORAGE TANK. SAFETY VALVE AT DEAERATOR STORAGE TANK. SOV FOR DEAERATOR OVERFLOW LINE. PNEMATIC OPERATED PCV FOR DEAERATOR.
2.02 MOV0104 2.03 2.04 MOV0105 & MOV0106 MOV0107 & MOV0108
2.05 VRV0001 2.06 PSV0001 2.07 SOV0001 2.08 PCV0001
sheet 1 of 2

PROJECT TIRUCHIRAPALLI SPECIAL VALVES SCHEDULE
S.No. TAG No. TYPE SIZE RATING # END CONN. MODE OF OPERATION STATUTORY APPROVAL (IBR) QTY (Nos) BODY MATL. DESIGN DESIGN PR.Kscg TEMP. C DU No.
: 2 X 80 TPH SINGLE DRUM WATER TUBE BOILER (FBC). CUSTOMER : M/s. REI AGRO LIMITED.,
DWG. No. : BG059-00-09-4-007

.
REVISION : B
DESCRIPTION
REF DRG : BG059-00-09-0-003/NIL
NO 5 CI 2 150 072 PNEUMATIC OPERATED SOLENOID VALVE FOR AIR BOX AIR BLEED COMPARTMENT 1 TO 5.
III
BFV 100 150 WAFER
3.01 SOV 1301 TO 1305
IV
P & I DIAGRAM FOR BLOW DOWN TANK & FLASH STEAM RECOVERY SYSTEM
GLOBE SLSV 25 HOLD 150 150 F F YES YES 1 1 SA216 WCC SA216 WCB 10 6 200 200 102 009
REF DRG : BG059-00-09-3-008/NIL

PNEUMATIC OPERATED BLOWDOWN LEVEL CONTROL VALVE SAFETY VALVE - AT CBD TANK
0.01 LCV 0001 0.02 PSV0004
P & I DIAGRAM FOR TURBINE STEAM PIPING

GATE 150 1500 BW YES 1 SA216 WC9 95 520 184
REF DRG : BG059-00-09-1-012/NIL

INTEGRAL MOTORISED BYPASS VALVE FOR DUMPING PRDS
0.01 MOV 0201
NOTES :
PREPARED : B A REV SPECIAL VALVES SPECIFICATION REVISED AND DU No`s ARE ADDED SPECIAL VALVES ADDED PARTICULARS SIGN. 31.05.07 CHECKED :
sheet 2 of 2

. TIRUCHIRAPALLI SPECIAL VALVES SCHEDULE
S.No. I TAG No. TYPE SIZE RATING #
DWG. No. : BG060-00-09-4-007 REVISION :A

DESCRIPTION
REF DRG : BG060-00-09-0-002/NIL

GLOBE GATE GATE ANGLE ANGLE SLSV SLSV SLSV SLSV GLOBE GLOBE GLOBE 100 200 25 25 40 50/100 50/100 40/100 40/80 100 50 25 1500 1500 1500 1500 1500 900 900 1500 HOLD 1500 1500 1500 BW BW SW SW SW BW/F BW/F BW/F F BW BW SW MOTORIZED MOTORIZED MOTORIZED MOTORIZED MOTORIZED YES YES YES YES YES YES YES YES YES YES YES YES 1 1 1 1 1 1 1 1 1 2 1 2 SA217WC9 SA217WC9 SA217WC9 SA 105 SA 105 SA216 WCB SA216 WCB SA217WC9 SA216WCB SA216WCB SA216WCB SA216WCB 93.58 93.58 93.58 104 104 103 104 93.58 21 525 525 525 315 315 307 307 330 200 200 200 049 048 048 050 051 084 085 086 087 078 078 080
1.01 MOV2201 1.02 MOV2202A 1.03 MOV2202B 1.04 MOV2203 1.05 MOV2204 1.06 PSV2201 1.07 PSV2202 1.08 PSV2203 1.09 PSV2204 1.10 FCV2101A & FCV2101B
MOTORISED VALVE FOR MAIN STEAM LINE STARTUP VENT MOTORISED VALVE FOR MSSV MOTORISED VALVE FOR MSSV INTEGARAL BYPASS MOTORISED ANGLE BLOWDOWN VALVE FOR CBD MOTORISED ANGLE BLOWDOWN VALVE FOR IBD SAFETY VALVE-I AT DRUM (ST.PR. 103) SAFETY VALVE-I AT DRUM (ST.PR. 104) SAFETY VALVE AT MAIN STEAM LINE (ST.PR. 104) SAFETY VALVE AT SOOT BLOWER LINE FCV AT 100% FCV UPSTREAM FCV AT 30% FCV UPSTREAM TCV FOR BEFORE AND AFTER HP HEATER
1.11 FCV2102 1.12 TCV2101 & TCV2102
II
3.01
SOV2301 TO SOV2305 BFV 100 150 F NO 5 CI 2 150 052
REF DRG : BG060-00-09-0-003/NIL
NOTES :
PREPARED : CHECKED A REV SPECIAL VALVES SPECIFICATION REVISED AND DU No`s ARE ADDED PARTICULARS SIGN. :

sheet 1 of 1
INSTRUMENTS SCHEDULE
Page 1 of 8
CETHAR VESSELS (P) LIMITED TIRUCHIRAPALLI. INSTRUMENTS LIST

TAG NO I
PT0003 PT1101 PT1201 PT1202 PT 1203 PT0201 PT0202
PROJECT
: 2 X 80 TPH SINGLE DRUM WATER TUBE BOILER (FBC). CUSTOMER : M/s. REI AGRO LIMITED.
DWG. No: BG059-00-09-4-006 RIVISION: B
SERVICE PRESSURE TRANSMITTERS.

DEAERATOR PRESSURE STEAM FEED LINE PRESSURE STEAM DRUM PRESSURE STEAM LINE PRESSURE PRESSURE TRANSMITTER AT SOOT BLOWER LINE STEAM LINE PRESSURE PRDS - II OUTLET PRESSURE
FLUID
PROCESS PARAMETER PRESSURE TEMP.(C) MAX. OP. MAX. OP.
TYPE
RANGE/ SPAN
UNIT
D/A
DIAL SIZE
QTY.
DU No.
P & ID No.
REMARKS
WATER WATER STEAM STEAM STEAM STEAM STEAM
6.7Kscg 150Kscg 104Kscg 104Kscg 25Kscg 95 Kscg 10 Kscg
8scg 112.3scg 93.58Kscg 86 Kscg 21Kscg 87 Kscg 6 Kscg
155 210 315 525 330 525 250
250 200 306 520 330 520 215
SMART SMART SMART SMART SMART -
0 - 10 0 - 160 0 - 160 0 - 160 0-30 0 to 160 0 to 10
Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm
A A A A A A A
1 1 1 1 1 1 1
163 162 162 162 176 162 163
BG059-00-09-1-001 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-2-012 BG059-00-09-2-012
II
LSLL0001 LS1401 LS1402 LSL0002 LSL0501 LS1403 & LS1404
LEVEL SWITCHES
LOW LEVEL SWITCH AT DEAERATOR STORAGE TANK LEVEL SWITCH FOR LIME STONE BUNKER LEVEL SWITCH FOR BED MATERIAL BUNKER LEVEL SWITCHE FOR LP DOSING TANK LEVEL SWITCH FOR HP DOSING TANK BUNKER LEVEL SWITCH WATER 8 Kscg 6.7 Kscg 250 155 MAGNETIC MM D 1 1 1 1 1 2 181 183 181 181 BG059-00-09-1-001 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-3-004 BG059-00-09-3-004 BG059-00-09-0-003
III
LT0001 LT1201A, LT1201B, LT1201C ULT1301& ULT1302 LT0004
LEVEL TRANSMITTERS.
DEAERATOR LEVEL CONTROL STEAM DRUM LEVEL - CONTROL ULTRA SONIC LEVEL TRANSMITTER CONTINUOUS BLOWDOWN TANK LEVEL CONTROL STEAM / WATER 6 Kscg 5 Kscg 200 165 SMART MINUS 1050 TO ZERO mmwc A STEAM / WATER STEAM / WATER 8 Kscg 104 Kscg 6.7 Kscg 93.58 Kscg 250 315 155 300 SMART SMART MINUS 1800 TO ZERO MINUS 670 TO ZERO mmwc mmwc A A 1 3 2 1 202 175 166 BG059-00-09-1-001 BG059-00-09-0-002 BG059-00-09-0-003 BG059-00-09-3-008
IV
FT0101 FT0102 FT1201 FT1301
FLOW TRANSMITTERS.
FEED WATER LINE FLOW (BOILER - I) FEED WATER LINE FLOW (BOILER - II) STEAM LINE FLOW AIR FLOW(AERO FOIL) WATER WATER STEAM AIR 112.3 Kscg 112.3 Kscg 104 Kscg 700 mmwc 126 Kscg 126 Kscg 86 Kscg 600 mmwc 200 200 525 50 210 210 520 42 ZERO TO 10000 ZERO TO 10000 ZERO TO 10000 ZERO TO 200 mmwc mmwc mmwc mmwc A A A A 1 1 1 1 164 99 164 165 BG059-00-09-1-001 BG059-00-09-1-001 BG059-00-09-0-002 BG059-00-09-0-003
V
TE 0001
THERMO COUPLES.
LENGTH DEAERATOR STORAGE TANK TEMPERATURE HP HEATER INLET STEAM / WATER 10 Kscg 6.7 Kscg 250 155 K - DUPLEX MINUS 670 TO ZERO 0-400 mmwc A 3 230 BG059-00-09-1-001 : 500 mm END CONN. :1/2" NPT (M) ADJUSTABLE GLAND.
TE0101
WATER
150Kscg
112.3Kscg
250
155
K - DUPLEX
231
BG059-00-09-1-001
TE0102
HP HEATER OUTLET
WATER
150Kscg
112.3Kscg
250
200
K - DUPLEX
0-400
231
BG059-00-09-1-001 LENGTH : 300 mm END CONN. :1/2" NPT (M) ADJUSTABLE GLAND.
TE1101
ECONOMISER OUTLET TEMPERATURE
WATER
104 Kscg
93.58 Kscg
280
262
K - DUPLEX
0 TO 300
231
BG059-00-09-0-002
TE1201
RSH INLET TEMPERATURE
STEAM
104 Kscg
91 Kscg
350
343
K - DUPLEX
0 TO 400
231
BG059-00-09-0-002
TE1202
RSH OUTLET TEMPERATURE
STEAM
103.2 Kscg
90 Kscg
525
492
K - DUPLEX
0 TO 500
231
BG059-00-09-0-002
sheet 1 of 8
Page 2 of 8
TAG NO
SERVICE
FLUID

106 Kscg 89 Kscg 485 470
TYPE
K - DUPLEX
RANGE/ SPAN
UNIT
D/A
DIAL SIZE
-
QTY.
DU No.
P & ID No.
LENGTH
REMARKS
: 300 mm END CONN. :1/2" NPT
TE1203
DE - SH. OUTLET TEMPERATURE
STEAM
0 TO 500
231
BG059-00-09-0-002
(M) ADJUSTABLE 400 mm LENGTH : GLAND.
TE1204
STEAM LINE TEMPERATURE
STEAM
106 Kscg
86 Kscg
525
520
K - DUPLEX
0 TO 600
232
BG059-00-09-0-002
TE1301
FD HEADER AIR TEMPERATURE
AIR
700 mmwc
600 mmwc
160
150
K - DUPLEX
0 TO 200
230
BG059-00-09-0-003
END CONN. :1/2" NPT (M) LENGTH : 500 mm ADJUSTABLE GLAND. END CONN. : 3/4"NPT(M)BS10 TABLE D ADJUSTABLE GLAND.
TE1302A & 1302B
BED TEMP. AT COMPARTMENT - I
FLUEGAS
800 mmwc
950
850
K - DUPLEX
0 - 1200
233
BG059-00-09-0-003
TE1303A & 1303B
BED TEMP. AT COMPARTMENT - II
FLUEGAS
800 mmwc
950
850
K - DUPLEX
0 - 1200
233
BG059-00-09-0-003 LENGTH : 3000 mm END CONN. :1/2" NPT (M) ADJUSTABLE GLAND.
TE1304A & 1304B
BED TEMP. AT COMPARTMENT - III
FLUEGAS
800 mmwc
950
850
K - DUPLEX
0 - 1200
233
BG059-00-09-0-003
TE1305A & 1305B
BED TEMP. AT COMPARTMENT - IV
FLUEGAS
800 mmwc
950
850
K - DUPLEX
0 - 1200
233
BG059-00-09-0-003
TE1306A & 1306B
BED TEMP. AT COMPARTMENT - V
FLUEGAS
800 mmwc MINUS mmwc MINUS mmwc MINUS mmwc 5
950
850
K - DUPLEX
0 - 1200
233
BG059-00-09-0-003
TE1307
FURNACE TEMPERATURE
FLUE GAS
MINUS
10 mmwc
900
740
K - DUPLEX
0 - 1200
234
BG059-00-09-0-003
TE1308
ECONOMISER INLET TEAMPERATURE
FLUE GAS
MINUS 125 mmwc
75
450
386
K - DUPLEX
0-500
230
BG059-00-09-0-003 LENGTH : 500 mm END CONN. :3/4" NPT (M) BS 10 TABLE D ADJUSTABLE GLAND.
TE1309
ECONOMISER OUTLET TEMPERATURE
FLUE GAS
MINUS 150 mmwc
75
260
242
K - DUPLEX
0-300
230
BG059-00-09-0-003
TE1310
AIRHEATER OUTLET TEMPERATURE
FLUEGAS
MINUS 200 mmwc
MINUS 125 mmwc
200
148
K - DUPLEX
0-300
230
BG059-00-09-0-003
TE1311 RTD1301A TO RTD1301B RTD1302A TO RTD1302B RTD1303A TO RTD1303B RTD1304A TO RTD1304B TE0201
ESPOUTLET TEMPERATURE
FLUEGAS
MINUS 200 mmwc
MINUS 125 mmwc
200
140
K - DUPLEX
0-300
230
BG059-00-09-0-003
RTD FOR FD FAN (DE & NDE)
AIR
100
60
RTD-DUPLEX
0 TO 600
235
BG059-00-09-0-003
RTD FOR ID FAN (DE & NDE)
AIR
100
60
RTD-DUPLEX
0 TO 600
235
BG059-00-09-0-003 LENGTH
RTD FOR PA FAN
AIR
100
60
RTD-DUPLEX
0 TO 600
235
: 100 mm END CONN. :1/2" NPT (M) BG059-00-09-0-003 ADJUSTABLE GLAND.
RTD FOR ID FAN MOTOR
AIR
100
60
RTD-DUPLEX
0 TO 600
235
BG059-00-09-0-003 LENGTH : 500 mm END CONN. :1/2" NPT (M) ADJUSTABLE 300 mm GLAND. LENGTH : END CONN. :1/2" NPT (M) ADJUSTABLE GLAND. LENGTH : 500 mm, VBE
MAIN STEAM LINE
STEAM
95 Kscg
87 Kscg
525
520
K - DUPLEX
0 to 600
230
BG059-00-09-2-012
TE0202
BLEED-II TEMPERATURE
STEAM
10 Kscg
6 Kscg
250
215
K - DUPLEX
0 to 300
231
BG059-00-09-2-012
VI
TG0001
TEMPERATURE GAUGES.
DEAERATOR STORAGE TANK TEMPERATURE HP HEATER INLET WATER 8 kscg 6.7 Kscg 250 155 MERCURY - IN STEEL MERCURY - IN STEEL MERCURY - IN STEEL MERCURY - IN STEEL MERCURY - IN STEEL MERCURY - IN STEEL 0-400 C 150 1 220 BG059-00-09-1-001
TG0101
WATER
150 kscg
112.3Kscg
250
155
0-400
150
222
END CONNECTION : 1/2" NPT (M) ADJUSTABLE GLAND. : 400 mm, VBE BG059-00-09-1-001 LENGTH END CONNECTION : 1/2" NPT (M) ADJUSTABLE GLAND.
TG0102
HP HEATER OUTLET
WATER
150Kscg
112.3Kscg
250
200
0-400
150
222
BG059-00-09-1-001
TG1201
STEAM TEMPERATURE AT STEAM LINE
STEAM
104kscg
86Kscg
525
520
0 - 600
150
223
BG059-00-09-0-002 LENGTH : 400 mm, VBE
TG 1202
SOOT BLOWER LINE TEMPERATURE
STEAM
104kscg
91Kscg
330
300
0-400
150
223
BG059-00-09-0-002
END CONNECTION : 1/2" NPT (M) ADJUSTABLE GLAND.
TG 0201
STEAM TEMPERATURE AT STEAM LINE
STEAM
95kscg
87Kscg
525
520
0 - 600
150
223
BG059-00-09-2-012
sheet 2 of 8
Page 3 of 8
TAG NO
SERVICE
FLUID

10 Kscg 6 Kscg 250 215
TYPE
MERCURY - IN STEEL
RANGE/ SPAN
UNIT
D/A
DIAL SIZE
150
QTY.
DU No.
P & ID No.
LENGTH
REMARKS
: 400 mm, VBE
TG 0202
BLEED-II TEMPERATURE
STEAM
0-300
221
BG059-00-09-2-012
PRESSURE GAUGES.
PG0001 PG1101 PG1201 PG1202 PG1203 PG1204 PG 1205 PG0002 & PG0003 PG0501TO PG0503 PG0004 DPG1801 DPG1802 PG1701 PG2701 PG0701 PG 0201 PG 0202 PG 0203 DEAERATOR STORAGE TANK STEAM LINE PRESSURE - REMOTE STEAM DRUM PRESSURE - LOCAL STEAM DRUM PRESSURE - REMOTE STEAM LINE PRESSURE - LOCAL STEAM LINE PRESSURE - REMOTE SOOT BLOWER LINE PRESSURE LP DOSING LINE PRESSURE HP DOSING LINE PRESSURE CONTINUOUS BLOWDOWN TANK PRESSURE STARTUP OIL FIRING LINE DIFF. PRESSURE STARTUP OIL COMMON HEADER BOILER - I INSTRUMENT AIR DISTRIBUTION LINE PRESSURE BOILER - II INSTRUMENT AIR DISTRIBUTION LINE PRESSURE TG HOUSE INSTRUMENT AIR DISTRIBUTION LINE PRESSURE MAIN STEAM LINE TG INLET TG BLEED - II STEAM WATER STEAM STEAM STEAM STEAM STEAM WATER WATER STEAM/WATER LDO LDO AIR AIR AIR STEAM STEAM STEAM 8.0 Kscg 150 kscg 104 Kscg 104 Kscg 104 Kscg 104 Kscg 25 Kscg 11 Kscg 110 Kscg 6 Kscg 8 Kscg 8 Kscg 10 Kscg 10 Kscg 10 Kscg 95 Kscg 95 Kscg 10 Kscg 6.7 Kscg 112.3Kscg 93.58 Kscg 93.58 Kscg 86 Kscg 86 Kscg 22scg 6 Kscg 108Kscg 5 Kscg 5 Kscg 2 Kscg 7 Kscg 7 Kscg 7 Kscg 87 Kscg 84 Kscg 6 Kscg 250 250 315 315 525 525 330 155 50 200 50 50 210 210 210 525 525 250 155 200 306 306 520 520 320 155 40 165 40 40 210 210 210 520 520 215 BOURDON BOURDON BOURDON BOURDON BOURDON BOURDON BOURDON BOURDON BOURDON BOURDON SEALED BOURDON SEALED BOURDON BOURDON BOURDON BOURDON BOURDON BOURDON BOURDON 0 - 16 0 TO 250 0 TO 250 0 TO 250 0 TO 250 0 TO 250 0 TO 40 0 - 16 0 - 250 0 -16 0 - 25 0 - 16 0 - 10 0 - 10 0 - 10 0 to 250 0 to 250 0 to 16 Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm 150 250 250 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 1 1 1 1 1 1 1 2 3 1 1 1 1 1 1 1 1 1 125 227 227 125 125 125 224 125 122 125 226 225 149 149 149 125 125 125
END CONNECTION : 1/2" NPT (M) ADJUSTABLE GLAND.
BG059-00-09-1-001 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-0-002 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-0-002 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-0-002 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-0-002 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-0-002 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-0-002 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-3-004 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-3-004 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-3-008 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-3-010 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-3-010 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-3-011 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-3-011 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-3-011 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-2-012 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-2-012 VBE , END CONN. : M20 X 1.5 (M) BG059-00-09-2-012 VBE , END CONN. : M20 X 1.5 (M)
VIII
I/P0001 I/P1101 & I/P1102 I/P1103A & I/P1103B I/P1104 I/P 1201 I/P1301 I/P1302 I/P1303 I/P 1304 LY0001
I/P CONVERTER.
PCV AT LP STEAM FROM PRDS I DE-SUPER HEATER STEAM TEMP. CONTROL DRUM LEVEL CONTROL-100% FCV. DRUM LEVEL CONTROL 30% FCV SOOT BLOWER PRS FD FAN SUCTION DAMPER CONTROL ID FAN SUCTION DAMPER CONTROL PA FAN SUCTIONDAMPER AIR HEATER BYPASS RPC CBD TANK LEVEL CONTROL COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 50 50 50 50 50 50 50 50 50 50 42 42 42 42 42 42 42 42 42 40 A A A A A A A A A A 1 2 1 1 1 1 1 1 1 1 BG059-00-09-1-001 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-3-008
IX
LG0001 & LG0002
LEVEL GAUGES.
DEAERATOR LEVEL GAUGE STEAM / WATER 8 Kscg 6.7 Kscg 250 155 TRANSPAREAN T CC : 1800 mm 2 237 BG059-00-09-1-001
sheet 3 of 8
Page 4 of 8
TAG NO
LG1201 & LG1202 LG0003 LG0501 LG0005 LG0006 LG1801
SERVICE
STEAM DRUM-DIRECT LEVEL GAUGE LP DOSINGTANK LEVEL HP DOSING TANK LEVEL CONTINOUS BLOWDOWN TANK LEVEL INTERMITTENT BLOWDOWN TANK LEVEL STARTUP OIL TANK LEVEL GAUGE
FLUID
STEAM / WATER WATER WATER STEAM / WATER STEAM / WATER OIL

104 Kscg 3 Kscg 3 Kscg 6 Kscg 6 Kscg 8 Kscg 93.58 Kscg 1.5 Kscg 1.5 Kscg 5 Kscg 2 Kscg 5 Kscg 315 50 50 313 200 50 306 42 40 170 135 42
TYPE
BICOLOUR MULTIPORT TUBULAR TUBULAR TUBULAR TUBULAR TUBULAR
RANGE/ SPAN
CC : 670 CC : 800 CC : 800 CC : 800 CC : 800 CC : 800
UNIT
mm mm mm mm mm mm
D/A
-
DIAL SIZE
-
QTY.
2 1 1 1 1 1
DU No.
158 126 123 236 236 216
P & ID No.
BG059-00-09-0-002 BG059-00-09-3-004 BG059-00-09-3-004 BG059-00-09-3-008 BG059-00-09-3-008 BG059-00-09-3-010
REMARKS
X
AFR0701A &AFR0701B AFR0702
AIR FILTER CUM REGULATOR

AIR FILTER REGULATOR FOR LP STEAM FROM PRDS I AIR FILTER REGULATOR FOR SOV AT DEAERATOR DRAIN COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 50 50 50 50 50 50 50 50 50 50 50 50 50 42 42 42 42 42 42 42 42 42 42 42 42 42 2 1 2 2 2 2 2 2 2 2 2 2 2 BG059-00-09-1-001 BG059-00-09-1-001 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-3-008
AIR FILTER REGULATOR FOR FEED LINE AFR1705A &AFR1705B 100% FCV AFR1706A &AFR1706B AFR1707A &AFR1707B AFR1708A & AFR1708B AIR FILTER REGULATOR FOR FEED LINE BYBASS 100% FCV AIR FILTER REGULATOR FOR FEED LINE 30% FCV AIR FILTER REGULATOR FOR SOOT BLOWER PRV
AIR FILTER REGULATOR FOR AFR1709A & AFR1709B TEMPERATURE CONTROL VALVE AIR FILTER REGULATOR FOR AFR1710A & AFR1710B TEMPERATURE CONTROL VALVE BYBASS AFR1701A &AFR1701B AIR FILTER REGULATOR FOR FD FAN AFR1702A &AFR1702B AIR FILTER REGULATOR FOR ID FAN AFR1703A &AFR1703B AIR FILTER REGULATOR FOR PA FAN AIR FILTER REGULATOR FOR AIR HEATER AFR1704A &AFR1704B BYPASS RPC AIR FILTER REGULATOR FOR CBD TANK AFR0705A &AFR0705B LCV
XI
AIR FILTER REGULATOR CUM LUBRICATOR

COMP. AIR COMP. AIR 7 Kscg 7 Kscg 2 Kscg 2 Kscg 50 50 42 42 2 1 BG059-00-09-0-003 BG059-00-09-3-009
AFRL1701 & AFRL1702 AFRL FOR SOLENOID COILBOX AFRL1715 AFRL FOR SOLENOID COILBOX
XII
PRS 1201
PRESSURE CONTROL VALVES

PRS AT SOOT BLOWER LINE STEAM 95 Kscg 86 Kscg 330 300 1 103 BG059-00-09-0-002
XIII
STR0001 & STR0003 ST1201 YST0001 & YST0002
STRAINER
STRAINER AT FEED PUMP INLET STEAM TRAP AT SOOT BLOWER LINE Y-TYPE STRAINER AT LP DOSING PUMP WATER STEAM WATER WATER OIL OIL 7 Kscg 25 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 2 Kscg 22 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 155 525 50 50 50 50 155 525 42 40 42 42 3 1 2 3 1 2 124 124 BG059-00-09-1-001 supplier scope BG059-00-09-0-002 During Piping Engineering BG059-00-09-3-004 BG059-00-09-3-004 BG059-00-09-3-010 Part of PS unit BG059-00-09-3-010 Part of PS unit
YST0501 TO YST0503 Y-TYPE STRAINER AT HP DOSING PUMP STR1801 STR1802 & STR1803 STRAINER AT STARTUP OIL TANK OUTLET STRAINER BEFORE STARTUP OIL COMMON HEADER
XIV
PRESSURE SWITCHES
sheet 4 of 8
Page 5 of 8
TAG NO
DPSH 0001TO DPSH 0003 PSL0101TO PSL0103 DPS 1201 PSH1301 PSL0701
SERVICE
DPSH AT FEED PUMP SUCTION STRAINER PSL FOR FEED PUMP DELIVERY DIFF. PRESSURE SWITCH AT SOOT BLOWER LINE PRESSURE SWITCH HIGH FOR FLUE GAS AT BED PSL FOR INSTRUMENT AIR DISTRIBUTION SYSTEM
FLUID
WATER COMP. AIR STEAM FLUE GAS COMP. AIR

7 Kscg 150 Kscg 25 Kscg MINUS 10 mmwc 10 Kscg 6 Kscg 112.3 Kscg 21 Kscg MINUS 5 mmwc 7 Kscg 155 250 330 900 50 155 155 300 740 42
TYPE
BELLOWS -
RANGE/ SPAN
0-500 0-500 0-25 MINUS 25 TO PLUS 25 0-10
UNIT
mmwc Kg/cm Kg/cm mmwc Kg/cm
D/A
D -
DIAL SIZE
-
QTY.
3 3 1 1 1
DU No.
182 177 173 174 203
P & ID No.
BG059-00-09-1-001 BG059-00-09-1-001 BG059-00-09-0-002 BG059-00-09-0-003 BG059-00-09-3-011
REMARKS
XV
LTM 0101 & LTM 0103 LTM0104 LTM0105 & LTM0106 LTM0107 & LTM0108 HTM0101 TO HTM0103 M1201 M1202A & M1202B M1203 & M1204 HTM1301 LTM1301 & LTM1302 GM1401 TO GM1405
MOTORS
MOTOR FOR FEED PUMP DELIVERY VALVE MOTOR FOR HP HEATER BYPASS MOTORISED VALVE MOTOR FOR HP HEATER I/L & O/L MOTORISED VALVE MOTOR FOR BOILER I & II FEED WATER ISO VALVE MOTOR FOR BFP MOTOR FOR START UP VENT VALVE MOTOR FOR MSSV MOTOR FOR CBD & IBD HT MOTOR FOR FD FAN LT MOTOR FOR PA FAN & ID FAN GEARED MOTOR FOR DRAGCHAIN FEEDER WATER AIR AIR AIR WATER STEAM STEAM STEAM AIR AIR FUEL FUEL WATER WATER 3 1 2 2 3 1 2 2 1 2 5 15 2 1 3 WATER ASH 1 1 2 STEAM 1 199 160 BG059-00-09-1-001 BG059-00-09-1-001 BG059-00-09-1-001 BG059-00-09-1-001 BG059-00-09-1-001 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-003
Motorized Valve supplier scope Motorized Valve supplier scope Motorized Valve supplier scope Motorized Valve supplier scope
Motorized Valve supplier scope Motorized Valve supplier scope Motorized Valve supplier scope
155 / 156 BG059-00-09-0-003 92 090 121 120 121 120 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-3-004 BG059-00-09-3-004 BG059-00-09-3-004 BG059-00-09-3-004 BG059-00-09-3-009 AHS VENDOR SCOPE BG059-00-09-3-010 Part of PS unit BG059-00-09-2-012
LTM1401 TO LTM1415 LT MOTOR FOR POCKET FEEDER LTM0001 & LTM0002 GM0001 LTM0501 & LTM0503 GM0501 GM1901 M1801 &M1802 M0201 MOTOR FOR LP DOSING PUMP MOTOR FOR LP DOSING AGITATOR MOTOR FOR HP DOSING PUMP MOTOR FOR HP DOSING AGITATOR MOTOR FOR BEDASH SCREW FEEDER MOTOR FOR STARTUP OIL PUMPS MOTOR FOR DUMPING PRDS MOTORISED VALVE
Motorized Valve supplier scope
XVI
ZT0001 ZT1101 ZT1102 ZT1103A ZT1103B ZT1104 ZT1201 ZT1202 ZT1203 ZT1301
POSITION TRANSMITTER
POSITION TRANSMITTER FOR PCV AT LP STEAM FROM PRDS I POSITION TRANSMITTER FOR TCV POSITION TRANSMITTER FOR TCV BYBASS POSITION TRANSMITTER FOR FCV101A POSITION TRANSMITTER FOR FCV101B POSITION TRANSMITTER FOR FCV102 POSITION TRANSMITTER FOR CBD LINE POSITION TRANSMITTER FOR IBD LINE POSITION TRANSMITTER FOR START UP VENT LINE POSITION TRANSMITTER FOR FD FAN 250 210 210 210 210 210 525 525 215 50 250 200 200 200 200 200 520 520 215 42 1 1 1 1 1 1 1 1 1 1 BG059-00-09-1-001 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-003
sheet 5 of 8
Page 6 of 8
TAG NO
ZT1302 ZT1303 ZT1304 ZT0004
SERVICE
POSITION TRANSMITTER FOR ID FAN POSITION TRANSMITTER FOR PA FAN POSITION TRANSMITTER FOR AIR HEATER BYPASS RPC POSITION TRANSMITTER FOR LCV AT CBD
FLUID

50 50 50 210 42 42 42 210
TYPE
RANGE/ SPAN
UNIT
D/A
DIAL SIZE
QTY.
1 1 1 1
DU No.
P & ID No.
BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-3-008
REMARKS
XVII
FE0101 FE0102 FE1201 FE1202
FLOW ELEMENT.
FLOW ELEMENT FOR HP HEATER INLET (BOILER - I) FLOW ELEMENT FOR HP HEATER INLET (BOILER - II) MSSV ELEMENT SOOT BLOWER STEAM INLET STEAM STEAM 103.2 Kscg 108 Kscg 86 Kscg 88 Kscg 525 520 520 515 ZERO TO 10000 0 - 600 mmwc mmwc A A 1 1 1 1 079 059 094 BG059-00-09-1-001 BG059-00-09-1-001 BG059-00-09-0-002 BG059-00-09-0-002 CVPL MAKE
XVIII
3WM0101 3WM0102 2WM1101
MANIFOLD
3WM FOR FLOW TRANSMITTER AT HP HEATER INLET (BOILER - I) 3WM FOR FLOW TRANSMITTER AT HP HEATER INLET (BOILER - II) 2WM FOR REMOTE PRESSURE GAUGE. (FEED LINE ) 1 1 1 2 4 1 1 245 245 BG059-00-09-1-001 BG059-00-09-1-001 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-002 BG059-00-09-0-003
2WM1201 & 2WM1202 2WM FOR REMOTE PRESSURE GAUGE. 3WM1201 TO 3WM1204 3WM1205 3WM1301 3WM FOR LEVEL TRANSMITTER AT STEAM DRUM 3WM FOR FLOW ELEMENT 3WAY VALVE FOR AIR FOIL TRANSMITTER
XIX
DT1301 DT1302 DT1303 DT1304 TO DT1308 DT1309 DT1310 & DT1311 DT1312 DT1313 DT1314 DT1315
DRAUGHT TRANSMITTERS
FD FAN DELIVERY PRESSURE FD HEADER PRESSURE PA HEADER PRESSURE AIR BOX PRESSURE FURNACE PRESSURE BEFORE AND AFTER SUPER HEATER ECONOMISER INLET PRESSURE ECONOMISER OUTLET PRESSURE AIR HEATER OUTLET PRESSURE ESP OUTLET PRESSURE AIR AIR AIR AIR FLUE GAS FLUE GAS FLUE GAS FLUE GAS FLUE GAS FLUE GAS 900 mmwc 900 mmwc 1400 mmwc 700mmc MINUS 10 mmwc MINUS 125 mmwc MINUS 125 mmwc MINUS 150 mmwc MINUS 250 mmwc MINUS 250 mmwc 800 mmwc 800 mmwC 1100 mmwc 500mmwc MINUS 5 mmwc MINUS 75 mmwc MINUS 75 mmwc MINUS 100 mmwc MINUS 125 mmwc MINUS 125 mmwc 50 160 160 160 900 525 525 260 150 150 42 150 150 150 740 400 400 250 140 140 SMART SMART SMART SMART SMART SMART SMART SMART SMART SMART ZERO TO 1000 mmwc ZERO TO 1000 mmwc ZERO TO 1600 mmwc ZERO TO 1000mmwc MINUS 100 TO PLUS 100 MINUS 150 TO ZERO MINUS 150 TO ZERO MINUS 150 TO ZERO MINUS 250 TO ZERO MINUS 250 TO ZERO mmwc mmwc mmwc mmwc mmwc mmwc mmwc mmwc mmwc mmwc A A A A A A A A A A 1 1 1 5 1 2 1 1 1 1 167 167 168 167 169 170 170 170 171 171 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003
XX
TT1301 (A,B) TO TT1305 (A,B)
TEMPERATURE TRANSMITTERS
BED TEMPERATURE 960 850 SMART 0 - 1200 C A 10 172 BG059-00-09-0-003
XXI
APG1301 APG1305
AIR PRESSUURE GAUGE

BED PRESSURE COMBUSTION AIR HEADER PRESSURE IN START UP FIRING SYSTEM AIR AIR 600mmwc 1400mmwc 300mmwc 1100mmwc 50 50 42 42 DIAPHARAM DIAPHARAM 0 - 600 0 - 1600 mmwc mmwc 150 150 1 1 228 229 BG059-00-09-0-003 BG059-00-09-3-010 VBE , END CONN. : M20 X 1.5 (M)
XXII
RPC1301 RPC1302 RPC1303
REGULATING POWER CYLINDERS

POWER CYLINDER FOR FD FAN POWER CYLINDER FOR ID FAN POWER CYLINDER FOR PA FAN AIR AIR AIR 1 1 1 081 081 081 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003
sheet 6 of 8
Page 7 of 8
TAG NO
RPC1304
SERVICE
POWER CYLINDER FOR AIR HEATER BYPASS
FLUID
AIR
TYPE
RANGE/ SPAN
UNIT
D/A
DIAL SIZE
QTY.
1
DU No.
081
P & ID No.
BG059-00-09-0-003
REMARKS
XXIII
VARIABLE FREQUENCY DRIVE

10 5 --BG059-00-09-0-003 BG059-00-09-0-003
VFD1401 TO VFD1410 VFD FOR COAL / KUTCH LIGNITE BUNKER VFD1411 TO VFD1415 VFD FOR LIMESTONE BUNKER
XXIV
GB1401 TO GB1410 GB1411 TO GB1415 GB1416
GEAR BOX
GEAR BOX FOR COAL / KUTCH LIGNITE BUNKER GEAR BOX FOR LIMESTONE BUNKER GEAR BOX FOR BED MATERIAL BUNKER 10 5 1 089 090 215 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003
XXV
ZSS1401 TO 1405
ZERO SPEED SWITCH

ZERO SPEED SWITCH FOR DRAG CHAIN FEEDERS 5 093 BG059-00-09-0-003
XXVI
EJ1301 EJ1302 EJ1303 & EJ1304 EJ1401 FBX1401
EXPANSION BELOWS
EXPANSION BELOWS AT FURNACE EXPASION JOINTS BEFORE ECONOMISER EXPASION JOINTS BEFORE AFTER ESP EXPASION JOINTS FOR BEDMATERIAL BUNKER FABRICATED EXPASION BELLOWS FOR SECONDARY AIR LINE 1 1 2 1 1 BG059-00-09-0-003 ENGG. DEPT. TO INDENT BG059-00-09-0-003 ENGG. DEPT. TO INDENT BG059-00-09-0-003 ENGG. DEPT. TO INDENT BG059-00-09-0-003 ENGG. DEPT. TO INDENT BG059-00-09-0-003 ENGG. DEPT. TO INDENT
XXVII
AE1301 AE1302 AE1303
ANALYSERS
O2 ANALYSER NOX/SOX ANALYSER SPM ANALYAER 1 1 1 178 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003
XXVIII
FD1301 ID1301 PA1301
FANS
FD FAN ID FAN PA FAN 1 1 1 BG059-00-09-0-003 CVPL MAKE BG059-00-09-0-003 CVPL MAKE BG059-00-09-0-003 CVPL MAKE
XXIX
MONORAIL1301 MONORAIL1302
CHAIN PULLY BLOCK

MONORAIL FOR FD FAN MONORAIL FOR ID FAN 1 1 218 219 BG059-00-09-0-003 BG059-00-09-0-003
XXX
LIMIT SWITCHES
10 10 5 1 1 1 1 1 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003
ZSC1301 TO OPEN & CLOSE SWITCH FOR POWER ZSC1305,ZSO1301 TO CYLINDER (FD LINES) ZSO1305 ZSC1306TO ZSC1310 ZSO1306TO ZSO1310 OPEN & CLOSE SWITCH FOR POWER CYLINDER (PA LINES)
ZSO1312 TO ZSO1316 OPEN SWITCH FOR SOV AT FD LINE ZSO1317 ZSC1311 ZSC1312 ZSC1313 ZSC1314 OPEN SWITCH FOR SOV AT SECONDARY AIR LINE CLOSE SWITCH FOR FD FAN RPC CLOSE SWITCH FOR ID FAN RPC CLOSE SWITCH FOR PA FAN RPC CLOSE SWITCH FOR AIR HEATER BYPASS RPC
sheet 7 of 8
Page 8 of 8
TAG NO
ZSC1315 ZSC1316 & ZSO1316
SERVICE
CLOSE SWITCH FOR SECONDARY AIR LINE OPEN & CLOSE SWITCH FOR POWER CYLINDER (ID LINES)
FLUID
TYPE
RANGE/ SPAN
UNIT
D/A
DIAL SIZE
QTY.
1 2 5 5
DU No.
P & ID No.
BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-3-009 BG059-00-09-3-009
REMARKS
OPEN SWITCH FOR POWER CYLINDERS AT ZSO1321 TO ZSO1325 BED ASH COOLER AIR LINES ZSC1321 TO ZSC1325 CLOSE SWITCH FOR POWER CYLINDERS AT BED ASH COOLER AIR LINES
XXXI
PD1301 TO PD1305 PD1306 TO PD1310 PD1311 PD1312 PD1315 TO PD1319
POWER CYLINDER
ON/OFF POWER CYLINDERS FOR FD AIR LINE DAMPERS ON/OFF POWER CYLINDERS FOR PA AIR LINE DAMPERS ON/OFF POWER CYLINDERS FOR SECONDARY AIR LINE ON/OFF POWER CYLINDERS AT BEFORE AND AFTER ID FAN. ON/OFF POWER CYLINDERS FOR BED ASH COOLERS 5 5 1 1 5 243 242 243 244 242 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-0-003 BG059-00-09-3-009
XXXII
SCB1301
SOLENOID COIL BOX

SOLENOID COIL BOX FOR POWER CYLINDERS AT FD HEADER OUTLET AIR LINE SOLENOID COIL BOX FOR POWER CYLINDERS AT PA HEADER OUTLET AIR LINE SOLENOID COIL BOX FOR POWER CYLINDERS AT SECONDARY AIR LINE SOLENOID COIL BOX FOR POWER CYLINDERS AT BEFORE AND AFTER ID FAN. SOLENOID COIL BOX FOR POWER CYLINDERS AT BED ASH COOLERS 1 BG059-00-09-0-003
SCB1302
BG059-00-09-0-003
SCB1303
BG059-00-09-0-003
SCB1304
BG059-00-09-0-003
SCB1305
BG059-00-09-3-009
XXXIII
DP0001 & DP0002 DP0501 TO DP0503
PUMPS
RECIPROCATING PUMP FOR LP DOSING TANK RECIPROCATING PUMP FOR HP DOSING TANK NOTES : D/A - DENOTES : DIGITAL / ANALOG SIGNAL VBE - DENOTES : VERTICAL BOTTOM ENTRY. HBE - DENOTES : HORIZONTAL BACK ENTRY. 2 3 127 / 128 BG059-00-09-3-004 097 BG059-00-09-3-004
PREPARE : B A REV. INSTRUMENTS SPECIFICATION REVISED AND DU No`s ARE ADDED INSTRUMENTS ADDED PARTICULARS. SIGN. 31.05.07 27.02.07 DATE CHECKED : APPROVED : DATE : 19.12.2006
sheet 8 of 8
Page 1 of 8
CETHAR VESSELS (P) LIMITED TIRUCHIRAPALLI. INSTRUMENTS LIST

TAG NO SERVICE FLUID
PROJECT
: 2 X 80 TPH SINGLE DRUM WATER TUBE BOILER (FBC). CUSTOMER : M/s. REI AGRO LIMITED.
RANGE/ SPAN DIAL SIZE
DWG. No: BG060-00-09-4-006 RIVISION: B

REMARKS
TYPE
UNIT
D/A
QTY.
DU No.
P & ID No.
I PT2101 PT2201 PT2202 PT2203 II LS2401 LS2402 LS2403& LS2404 III LT2201A, LT2201B, LT2201C ULT2301& ULT2302 IV FT2201 FT2301 V TE2101 TE2201 TE2202 TE2203 TE2204
PRESSURE TRANSMITTERS. FEED LINE PRESSURE STEAM DRUM PRESSURE WATER STEAM 150Kscg 104Kscg 104Kscg 25Kscg 112.3scg 93.58Kscg 86 Kscg 21Kscg 210 315 525 330 200 306 520 330 SMART SMART SMART SMART 0 - 160 0 - 160 0 - 160 0-30 Kg/cm Kg/cm Kg/cm Kg/cm A A A A 1 1 1 1 098 098 098 110 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002
STEAM LINE PRESSURE STEAM PRESSURE TRANSMITTER AT SOOT BLOWER LINE STEAM LEVEL SWITCHES LEVEL SWITCH FOR LIME STONE BUNKER LEVEL SWITCH FOR BED MATERIAL BUNKER BUNKER LEVEL SWITCH LEVEL TRANSMITTERS. STEAM DRUM LEVEL - CONTROL ULTRA SONIC LEVEL TRANSMITTER FLOW TRANSMITTERS. STEAM LINE FLOW AIR FLOW(AERO FOIL) THERMO COUPLES. ECONOMISER OUTLET TEMPERATURE RSH INLET TEMPERATURE RSH OUTLET TEMPERATURE DE - SH. OUTLET TEMPERATURE STEAM LINE TEMPERATURE WATER STEAM STEAM STEAM STEAM STEAM AIR STEAM / WATER
1 1 2
113 113 113
BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003
104 Kscg
93.58 Kscg
315
300
SMART
MINUS 670 TO ZERO
mmwc
3 1
101
BG060-00-09-0-002 BG060-00-09-0-003
104 Kscg 700 mmwc
86 Kscg 600 mmwc
525 50
520 42
ZERO TO 10000 ZERO TO 200
mmwc mmwc
A A
1 1
099 100
BG060-00-09-0-002 BG060-00-09-0-003
104 Kscg 104 Kscg 103.2 Kscg 106 Kscg 106 Kscg
93.58 Kscg 91 Kscg 90 Kscg 89 Kscg 86 Kscg
280 350 525 485 525
262 343 492 470 520
K - DUPLEX K - DUPLEX K - DUPLEX K - DUPLEX K - DUPLEX
0 TO 300 0 TO 400 0 TO 500 0 TO 500 0 TO 600
C C C C C
A A A A A
1 1 1 1 1
151 151 151 151 152
BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 LENGTH : 400 mm END CONN. :1/2" NPT (M) ADJUSTABLE GLAND. LENGTH : 500 mm END CONN. :3/4" NPT (M) BS 10 TABLE D ADJUSTABLE GLAND. LENGTH : 300 mm END CONN. :1/2" NPT (M) ADJUSTABLE GLAND.
TE2301 TE2302A & TE2302B TE2303A & TE2303B TE2304A & TE2304B TE2305A & TE2305B
FD HEADER AIR TEMPERATURE BED TEMP. AT COMPARTMENT - I BED TEMP. AT COMPARTMENT - II BED TEMP. AT COMPARTMENT - III BED TEMP. AT COMPARTMENT - IV
AIR FLUEGAS FLUEGAS FLUEGAS FLUEGAS
700 mmwc -
600 mmwc 800 mmwc 800 mmwc 800 mmwc 800 mmwc
160 950 950 950 950
150 850 850 850 850
K - DUPLEX K - DUPLEX K - DUPLEX K - DUPLEX K - DUPLEX
0 - 1200 0 - 1200 0 - 1200 0 - 1200 0 - 1200
C C C C C
A A A A A
1 3 2 2 2
153 154 154 154 154
BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003
LENGTH : 3000 mm END CONN. :1/2" NPT (M) ADJUSTABLE GLAND.
sheet 1 of 8
Page 2 of 8
TAG NO
SERVICE
FLUID
TYPE
RANGE/ SPAN
UNIT
D/A
DIAL SIZE
QTY.
DU No.
P & ID No.
REMARKS
TE2306A & TE2306B TE2307 TE2308 TE2309 TE2310 TE2311 RTD2301A TO RTD2301B RTD2302A TO RTD2302B RTD2303A TO RTD2303B RTD2304A TO RTD2304B VI TG2201 TG2202 VII PG1101 PG2201 PG2202 PG2203 PG2204 PG2205 DPG2801 DPG2802 VIII I/P2101 & I/P2102
BED TEMP. AT COMPARTMENT - V
FLUEGAS
800 mmwc
950
850
K - DUPLEX
0 - 1200
154
BG060-00-09-0-003
FURNACE TEMPERATURE
FLUE GAS
MINUS MINUS 10 mmwc 5 mmwc MINUS MINUS 125 mmwc 75 mmwc MINUS MINUS 150 mmwc 75 mmwc MINUS 200 MINUS 125 mmwc mmwc MINUS 200 MINUS 125 mmwc mmwc -
900 450 260 200 200 100
740 386 242 148 140 60
K - DUPLEX K - DUPLEX K - DUPLEX K - DUPLEX K - DUPLEX RTD-DUPLEX
0 - 1200 0-500 0-300 0-300 0-300 0 TO 600
C C C C C C
A A A A A A
1 1 1 1 2 2
155 153 153 153 153 156
BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003
LENGTH : 3000 mm END CONN. :1/2" NPT (M) ADJUSTABLE GLAND. LENGTH : 1000 mm END CONN. :3/4" NPT (M) BS 10 TABLE D ADJUSTABLE GLAND.
ECONOMISER INLET TEAMPERATURE FLUE GAS ECONOMISER OUTLET TEMPERATURE FLUE GAS
LENGTH 10 TABLE D
: 500 mm END CONN. :3/4" NPT (M) BS ADJUSTABLE GLAND.
AIRHEATER OUTLET TEMPERATURE FLUEGAS ESPOUTLET TEMPERATURE RTD FOR FD FAN (DE & NDE) FLUEGAS AIR
RTD FOR ID FAN (DE & NDE)
AIR
100
60
RTD-DUPLEX
0 TO 600
156
BG060-00-09-0-003
RTD FOR PA FAN
AIR
100
60
RTD-DUPLEX
0 TO 600
156
BG060-00-09-0-003
LENGTH : 100 mm END CONN. :1/2" NPT (M) ADJUSTABLE GLAND.
RTD FOR ID FAN MOTOR TEMPERATURE GAUGES. STEAM TEMPERATURE AT STEAM LINE
AIR
100
60
RTD-DUPLEX
0 TO 600
156
BG060-00-09-0-003
STEAM
104kscg 104kscg
86Kscg 91Kscg
525 330
520 300
MERCURY - IN - STEEL MERCURY - IN - STEEL
0 - 600 0-400
C C
150 150
1 1
144 144
BG060-00-09-0-002 BG060-00-09-0-002
SOOT BLOWER LINE TEMPERATURE STEAM PRESSURE GAUGES. STEAM LINE PRESSURE - REMOTE STEAM DRUM PRESSURE - LOCAL STEAM DRUM PRESSURE - REMOTE STEAM LINE PRESSURE - LOCAL STEAM LINE PRESSURE - REMOTE SOOT BLOWER LINE PRESSURE STARTUP OIL FIRING LINE DIFF. PRESSURE STARTUP OIL COMMON HEADER I/P CONVERTER. DE-SUPER HEATER STEAM TEMP. CONTROL COMP. AIR COMP. AIR COMP. AIR WATER STEAM STEAM STEAM STEAM STEAM LDO LDO
LENGTH : 400 mm, VBE END CONNECTION : M20 X 1.5 (M) ADJUSTABLE GLAND.
150 kscg 104 Kscg 104 Kscg 104 Kscg 104 Kscg 25 Kscg 8 Kscg 8 Kscg
112.3Kscg 93.58 Kscg 93.58 Kscg 86 Kscg 86 Kscg 22scg 5 Kscg 2 Kscg
250 315 315 525 525 330 50 50
200 306 306 520 520 320 40 40
BOURDON BOURDON BOURDON BOURDON BOURDON BOURDON SEALED BOURDON SEALED BOURDON
0 TO 250 0 TO 250 0 TO 250 0 TO 250 0 TO 250 0 TO 40 0 - 25 0 - 16
Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm
250 250 150 150 150 150 150 150
1 1 1 1 1 1 1 1
149 149 096 096 096 148 159 150
BG059-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-3-010 BG060-00-09-3-010
VBE , END CONN. : M20 X 1.5 (M) VBE , END CONN. : M20 X 1.5 (M) VBE , END CONN. : M20 X 1.5 (M) VBE , END CONN. : M20 X 1.5 (M) VBE , END CONN. : M20 X 1.5 (M) VBE , END CONN. : M20 X 1.5 (M) VBE , END CONN. : M20 X 1.5 (M) VBE , END CONN. : M20 X 1.5 (M)
7 Kscg 7 Kscg 7 Kscg
2 Kscg 2 Kscg 2 Kscg
50 50 50
42 42 42
A A A
2 1 1
BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002
I/P2103A & I/ DRUM LEVEL CONTROL-100% FCV. P2103B I/P2104 DRUM LEVEL CONTROL 30% FCV
sheet 2 of 8
Page 3 of 8
TAG NO
SERVICE
FLUID
TYPE
RANGE/ SPAN
UNIT
D/A
DIAL SIZE
QTY.
DU No.
P & ID No.
REMARKS
I/P2201 I/P2301 I/P2302 I/P2303 I/P2304 IX LG2201 & LG2202 LG2801 X AFR2701A &AFR2701B AFR2702A &AFR2702B AFR2703A &AFR2703B AFR2704A &AFR2704B AFR2705A &AFR2705B AFR2706A &AFR2706B AFR2707A &AFR2707B
SOOT BLOWER PRS
COMP. AIR
7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg
2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg
50 50 50 50 50
42 42 42 42 42
A A A A A
1 1 1 1 1
BG060-00-09-0-002 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003
FD FAN SUCTION DAMPER CONTROL COMP. AIR ID FAN SUCTION DAMPER CONTROL COMP. AIR PA FAN SUCTIONDAMPER AIR HEATER BYPASS RPC LEVEL GAUGES. STEAM DRUM-DIRECT LEVEL GAUGE STARTUP OIL TANK LEVEL GAUGE AIR FILTER CUM REGULATOR AIR FILTER REGULATOR FOR FD FAN COMP. AIR AIR FILTER REGULATOR FOR ID FAN COMP. AIR AIR FILTER REGULATOR FOR PA FAN COMP. AIR AIR FILTER REGULATOR FOR AIR HEATER BYPASS RPC AIR FILTER REGULATOR FOR FEED LINE 100% FCV AIR FILTER REGULATOR FOR FEED LINE BYBASS 100% FCV AIR FILTER REGULATOR FOR FEED LINE 30% FCV COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR COMP. AIR STEAM / WATER OIL COMP. AIR COMP. AIR
104 Kscg 8 Kscg
93.58 Kscg 5 Kscg
315 50
306 42
BICOLOUR MULTIPORT TUBULAR
CC : 670 CC : 800
mm mm
2 1
097 140
BG060-00-09-0-002 BG060-00-09-3-010
7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg 7 Kscg
2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg 2 Kscg
50 50 50 50 50 50 50 50 50 50
42 42 42 42 42 42 42 42 42 42
2 2 2 2 2 2 2 2 2 2
BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002
AFR2708A & AIR FILTER REGULATOR FOR SOOT AFR2708B BLOWER PRV AFR2709A & AIR FILTER REGULATOR FOR AFR2709B TEMPERATURE CONTROL VALVE AIR FILTER REGULATOR FOR AFR2710A & TEMPERATURE CONTROL VALVE AFR2710B BYBASS XI
AIR FILTER REGULATOR CUM LUBRICATOR COMP. AIR COMP. AIR 7 Kscg 7 Kscg 2 Kscg 2 Kscg 50 50 42 42 2 1 BG060-00-09-0-003 BG060-00-09-3-009
AFRL2701 & AFRL FOR SOLENOID COILBOX AFRL2702 AFRL2715 XII PRS2201 XIII ST2201 XIV AFRL FOR SOLENOID COILBOX PRESSURE CONTROL VALVES PRS AT SOOT BLOWER LINE STEAM TRAP
STEAM
95 Kscg
86 Kscg
330
300
081
BG060-00-09-0-002
STEAM TRAP AT SOOT BLOWER LINE STEAM PRESSURE SWITCHES
25 Kscg
22 Kscg
525
525
BG060-00-09-0-002
sheet 3 of 8
Page 4 of 8
TAG NO
SERVICE
FLUID
TYPE
RANGE/ SPAN
UNIT
D/A
DIAL SIZE
QTY.
DU No.
P & ID No.
REMARKS
DPS2201 PSH2301 XV LTM2201
DIFF. PRESSURE SWITCH AT SOOT BLOWER LINE PRESSURE SWITCH HIGH FOR FLUE GAS AT BED MOTORS MOTOR FOR START UP VENT VALVE
STEAM FLUE GAS
25 Kscg MINUS 10 mmwc
21 Kscg MINUS 5 mmwc
330 900
300 740
BELLOWS
0-25
MINUS 25 TO PLUS 25
Kg/cm mmwc
1 1
108 109
BG060-00-09-0-002 BG060-00-09-0-003
STEAM STEAM STEAM AIR AIR FUEL FUEL ASH
1 2 2 1 2 5 15 1 2 126 114 / 115 066 067
BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-3-009 BG060-00-09-3-010
Motorized Valve supplier scope Motorized Valve supplier scope Motorized Valve supplier scope
LTM2202A & MOTOR FOR MSSV LTM2202B LTM2203 & LTM2204 HTM2301 LTM2301 & LTM2302 GM2401 TO GM2405 MOTOR FOR CBD & IBD HT MOTOR FOR FD FAN LT MOTOR FOR PA FAN & ID FAN GEARED MOTOR FOR DRAGCHAIN FEEDER
LTM2401 TO LT MOTOR FOR POCKET FEEDER LTM2415 GM2901 M2801 &M2802 XVI ZT2101 ZT2102 ZT2103A ZT2103B ZT2104 ZT2201 ZT2202 ZT2203 ZT2301 ZT2302 ZT2303 ZT2304 XVII MOTOR FOR BED ASH SCREW FEEDER MOTOR FOR STARTUP OIL PUMP POSITION TRANSMITTER POSITION TRANSMITTER FOR TCV POSITION TRANSMITTER FOR TCV BYBASS POSITION TRANSMITTER FOR FCV101A POSITION TRANSMITTER FOR FCV101B POSITION TRANSMITTER FOR FCV102 POSITION TRANSMITTER FOR CBD LINE POSITION TRANSMITTER FOR IBD LINE POSITION TRANSMITTER FOR START UP VENT LINE POSITION TRANSMITTER FOR FD FAN POSITION TRANSMITTER FOR ID FAN POSITION TRANSMITTER FOR PA FAN POSITION TRANSMITTER FOR AIR HEATER BYPASS RPC FLOW ELEMENT.
AHS VENDOR SCOPE Part of PS unit
210 210 210 210 210 525 525 215 50 50 50 50
200 200 200 200 200 520 520 215 42 42 42 42
1 1 1 1 1 1 1 1 1 1 1 1
BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-002 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003
sheet 4 of 8
Page 5 of 8
TAG NO
SERVICE
FLUID
TYPE
RANGE/ SPAN
UNIT
D/A
DIAL SIZE
QTY.
DU No.
P & ID No.
REMARKS
FE2201 FE2202 XVIII
MSSV ELEMENT SOOT BLOWER STEAM INLET MANIFOLD
STEAM STEAM
103.2 Kscg 108 Kscg
86 Kscg 88 Kscg
525 520
520 515
ZERO TO 10000 0 - 600
mmwc mmwc
A A
1 1
073
BG060-00-09-0-002 BG060-00-09-0-002 CVPL MAKE
3WM2201 TO 3WM FOR LEVEL TRANSMITTER AT 3WM2204 STEAM DRUM 3WM2205 3WM2301 2WM2101 2WM2201 & 2WM2202 XIX DT2301 DT2302 DT2303 DT2304 TO DT2308 DT2309 DT2310 & DT2311 DT2312 DT2313 DT2314 DT2315 XX 3WM FOR FLOW ELEMENT 3WAY VALVE FOR AIR FOIL TRANSMITTER 2WM FOR REMOTE PRESSURE GAUGE. (FEED LINE ) 2WM FOR REMOTE PRESSURE GAUGE. DRAUGHT TRANSMITTERS FD FAN DELIVERY PRESSURE FD HEADER PRESSURE PA HEADER PRESSURE AIR BOX PRESSURE FURNACE PRESSURE BEFORE AND AFTER SUPER HEATER ECONOMISER INLET PRESSURE ECONOMISER OUTLET PRESSURE AIR HEATER OUTLET PRESSURE ESP OUTLET PRESSURE TEMPERATURE TRANSMITTERS 960 850 SMART 0 - 1200 C A AIR AIR AIR AIR FLUE GAS FLUE GAS FLUE GAS FLUE GAS FLUE GAS FLUE GAS 900 mmwc 800 mmwc 50 160 160 160 900 525 525 260 150 150 42 150 150 150 740 400 400 250 140 140 SMART SMART SMART SMART SMART SMART SMART SMART SMART SMART ZERO TO 1000 mmwc ZERO TO 1000 mmwc ZERO TO 1600 mmwc ZERO TO 1000mmwc MINUS 100 TO PLUS 100 MINUS 150 TO ZERO MINUS 150 TO ZERO MINUS 150 TO ZERO MINUS 250 TO ZERO MINUS 250 TO ZERO mmwc mmwc mmwc mmwc mmwc mmwc mmwc mmwc mmwc mmwc A A A A A A A A A A -
4 1 1 1 2 163 163
BG060-00-09-0-002 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-002 BG060-00-09-0-002
1 1 1 5 1 2 1 1 1 1
102 102 103 102 104 105 105 105 106 106
BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003
900 mmwc 800 mmwC 1400 mmwc 1100 mmwc 700mmc MINUS 10 mmwc 500mmwc MINUS 5 mmwc
MINUS 125 MINUS 75 mmwc mmwc MINUS 125 MINUS 75 mmwc mmwc MINUS 150 MINUS 100 mmwc mmwc MINUS 250 MINUS 125 mmwc mmwc MINUS 250 MINUS 125 mmwc mmwc
TT2301 (A,B) TO TT2305 BED TEMPERATURE (A,B) XXI APG2301 APG2305 XXII AIR PRESSUURE GAUGE BED PRESSURE COMBUSTION AIR HEADER PRESSURE IN START UP FIRING SYSTEM REGULATING POWER CYLINDERS
10
107
BG060-00-09-0-003
AIR AIR
600mmwc
300mmwc
50 50
42 42
DIAPHARAM DIAPHARAM
0 - 600 0 - 1600
mmwc mmwc
150 150
1 1
146 147
BG060-00-09-0-003 BG060-00-09-3-010 VBE , END CONN. : M20 X 1.5 (M)
1400mmwc 1100mmwc
sheet 5 of 8
Page 6 of 8
TAG NO
SERVICE
FLUID
TYPE
RANGE/ SPAN
UNIT
D/A
DIAL SIZE
QTY.
DU No.
P & ID No.
REMARKS
RPC2301 RPC2302 RPC2303 RPC2304 XXIII
POWER CYLINDER FOR FD FAN POWER CYLINDER FOR ID FAN POWER CYLINDER FOR PA FAN POWER CYLINDER FOR AIR HEATER BYPASS VARIABLE FREQUENCY DRIVE
AIR AIR AIR AIR
1 1 1 1
061 061 061 061
BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003
VFD2401 TO VFD FOR COAL / KUTCH LIGNITE VFD2410 BUNKER VFD2411 TO VFD FOR LIMESTONE BUNKER VFD2415 XXIV GB2401 TO GB2410 GB2411 TO GB2415 GB2416 XXV GEAR BOX GEAR BOX FOR COAL / KUTCH LIGNITE BUNKER GEAR BOX FOR LIMESTONE BUNKER GEAR BOX FOR BED MATERIAL BUNKER ZERO SPEED SWITCH
10 5
---
BG060-00-09-0-003 BG060-00-09-0-003
10 5 1
065 065 139
BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003
ZSS2401 TO ZERO SPEED SWITCH FOR DRAG ZSS2405 CHAIN FEEDERS XXVI EJ2301 EJ2302 EJ2303 & EJ2304 EJ2401 FBX2401 XXVII AE2301 AE2302 AE2303 XXVIII FD2301 ID2301 MONORAIL PA2301 XXIX EXPANSION BELOWS EXPANSION BELOWS AT FURNACE EXPASION JOINTS BEFORE ECONOMISER EXPASION JOINTS BEFORE AFTER ESP EXPASION JOINTS FOR BEDMATERIAL BUNKER FABRICATED EXPASION BELLOWS FOR SECONDARY AIR LINE ANALYSERS O2 ANALYSER NOX/SOX ANALYSER SPM ANALYAER FANS FD FAN ID FAN PA FAN CHAIN PULLY BLOCK MONORAIL FOR FD FAN
072
BG060-00-09-0-003
1 1 2 1 1
BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003
ENGG. DEPT. TO INDENT ENGG. DEPT. TO INDENT ENGG. DEPT. TO INDENT ENGG. DEPT. TO INDENT ENGG. DEPT. TO INDENT
1 1 1
111
BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003
1 1 1
BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003
CVPL MAKE CVPL MAKE CVPL MAKE
142
BG060-00-09-0-003
sheet 6 of 8
MONORAIL
TAG NO SERVICE FLUID
Page 7 of 8
TYPE
RANGE/ SPAN
UNIT
D/A
DIAL SIZE
QTY.
DU No.
P & ID No.
REMARKS
MONORAIL FOR ID FAN XXX LIMIT SWITCHES
143
BG060-00-09-0-003
ZSC2306 TO 2302 ZSC2310 & OPEN & CLOSE SWITCH FOR POWER ZSO2306 TO CYLINDER (PA LINES) ZSO2310 ZSO2312 TO OPEN SWITCH FOR SOV AT FD LINE ZSO2316 ZSO2317 ZSC2311 ZSC2312 ZSC2313 ZSC2314 ZSC2315 ZSC2316 & ZSO2316 OPEN SWITCH FOR SOV AT SECONDARY AIR LINE CLOSE SWITCH FOR FD FAN RPC CLOSE SWITCH FOR ID FAN RPC CLOSE SWITCH FOR PA FAN RPC CLOSE SWITCH FOR AIR HEATER BYPASS RPC CLOSE SWITCH FOR SECONDARY AIR LINE OPEN & CLOSE SWITCH FOR POWER CYLINDER (ID LINES)
10
BG060-00-09-0-003
5 1 1 1 1 1 1 2 5
BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-3-009
OPEN SWITCH FOR POWER ZSO2321 TO CYLINDERS AT BED ASH COOLER AIR ZSO2325 LINES CLOSE SWITCH FOR POWER ZSC2321 TO CYLINDERS AT BED ASH COOLER AIR ZSC2325 LINES XXXI PD2301 TO PD2305 PD2307 TO PD2310 PD2311 PD2312 PD2315 TO PD2319 XXXII SCB2301 DAMBERS ON/OFF POWER CYLINDERS FOR FD AIR LINE DAMPERS ON/OFF POWER CYLINDERS FOR PA AIR LINE DAMPERS ON/OFF POWER CYLINDERS FOR SECONDARY AIR LINE ON/OFF POWER CYLINDERS AT BEFORE AND AFTER ID FAN. ON/OFF POWER CYLINDERS FOR BED ASH COOLERS SOLENOID COIL BOX SOLENOID COIL BOX FOR POWER CYLINDERS AT FD HEADER OUTLET AIR LINE SOLENOID COIL BOX FOR POWER CYLINDERS AT PA HEADER OUTLET AIR LINE SOLENOID COIL BOX FOR POWER CYLINDERS AT SECONDARY AIR LINE SOLENOID COIL BOX FOR POWER CYLINDERS AT BEFORE AND AFTER ID FAN.
BG060-00-09-3-009
5 5 1 1 5
BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-0-003 BG060-00-09-3-009
CVPL MAKE CVPL MAKE CVPL MAKE CVPL MAKE CVPL MAKE
BG060-00-09-0-003
SCB2302
BG060-00-09-0-003
SCB2303
BG060-00-09-0-003
SCB2304
BG060-00-09-0-003
sheet 7 of 8
Page 8 of 8
TAG NO
SERVICE
FLUID
TYPE
RANGE/ SPAN
UNIT
D/A
DIAL SIZE
QTY.
DU No.
P & ID No.
REMARKS
SCB2305 XXXIII STR2801 STR2802 & STR2803
SOLENOID COIL BOX FOR POWER CYLINDERS AT BED ASH COOLERS STRAINER STRAINER AT STARTUP OIL TANK OUTLET STRAINER BEFORE STARTUP OIL COMMON HEADER NOTES : D/A - DENOTES : DIGITAL / ANALOG SIGNAL VBE - DENOTES : VERTICAL BOTTOM ENTRY. HBE - DENOTES : HORIZONTAL BACK ENTRY. OIL OIL 7 Kscg 7 Kscg 2 Kscg 2 Kscg 50 50 42 42 -
BG060-00-09-3-009
1 2
BG060-00-09-3-010 BG060-00-09-3-010
Part of PS unit Part of PS unit
PREPARE B A REV. INSTRUMENTSSPECIFICATION REVISED AND DU No`s ARE ADDED. INSTRUMENTS ADDED PARTICULARS. SIGN. 31.05.07 27.02.07 DATE CHECKED
: :
APPROVED : DATE : 19.12.2006
sheet 8 of 8
LUBRICATION SCHEDULE
CUSTOMER
CETHAR VESSELS LIMITED, THIRUCHIRAPPALLI - 620 001
M/s. REI AGRO LIMITED 1 X 36 MW CAPTIVE POWER PLANT MBG 059
PROJECT W.O.NO.
INDENT FOR INITIAL FILLING LUBRICANT / GREASE

S.NO 1 2 3 ID FAN FD FAN PA FAN DESCRIPTION PARTS BEARINGS BEARINGS BEARINGS GEAR UNIT 4 DOSING PUMP(HP) BEARINGS 5 6 AIR FILTER REGULATOR WITH LUBRICATOR BOILER FEED PUMP BEARINGS GEAR UNIT 7 DRAG CHAIN FEEDER BEARINGS 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 HT MOTOR FOR BFP MOTOR FOR START UP VENT VALVE MOTOR FOR MSSV HT MOTOT FOR FD FAN LT MOTOR FOR ID & PA FAN BEARINGS BEARINGS BEARINGS BEARINGS BEARINGS LUBRICANT GREASE/SERVO GEM EP2 GREASE/SERVO GEM EP2 GREASE/SERVO GEM EP2 CRANKCASE / OIL SERVO 320 GREASE/SERVO GEM 2 OIL /LIGHT MINERAL OIL / SAE 10 OIL / SERVO PRIME 46 OIL / SERVO MESH (SP 220) GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 OIL / SERVO MESH (SP320) GREASE / SERVO GEM 2 OIL / SERVO MESH (SP 320) GREASE / SERVO GEM 2 OIL / SERVO MESH SP320 GREASE / SERVO GEM 2 OIL / SERVO MESH SP320 GREASE / SERVO GEM 2 OIL / SERVO MESH SP320 GREASE / SERVO GEM 2 QTY 1 1 1 5 5 10 3 INITIAL TOTAL FILLING REQUIREMENT QTY / ITEM 0.63 0.63 0.4 0.5 0.3 0.25 1.25 1.6 5 0.25 3 1 2 1 2 15 2 3 2 1 3 1 2 2 2 1.2 0.25 0.25 1.2 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 1.25 3.6 0.25 0.5 1.2 0.5 3.75 0.5 0.75 0.5 0.25 0.75 0.25 0.5 0.5 0.5 KG KG KG KG KG KG KG KG KG KG KG KG KG KG KG KG HTM0101 TO HTM0103 M1201 M1202A TO M1202B HTM1301 LTM1301 TO LTM1302 LTM1401 TO LTM1415 LTM0001 TO LTM0002 LTM0501 TO LTM0503 M1801 TO M18012 M0201 LTM0101 TO LTM0103 LTM0104 LTM0105 TO LTM0106 LTM0107 TO LTM0108 M1203 TO M1204 0.63 0.63 0.4 2.5 1.5 2.5 3.75 8 UNIT KG KG KG KG KG LTR KG LTR TAG NO.
LT MOTOR FOR POCKET FEEDER BEARINGS MOTOR FOR LP DOSING PUMP MTOR FOR HP DOSING PUMP MOTOR FOR START UP OIL PUMP MOTOR FOR DUMPING PRDS MOTORISED VALVE MOTOR FOR FEED PUMP DELIVERY VALVE MOTOR FOR HP HEATER BYPASS MOTORISED VALVE MOTOR FOR HP HEATER I/L & O/ L MOTORISED VALVE MOTOR FOR BOILER I & II FEED WATER ISO VALVE MOTOR FOR CBD & IBD GEARED MOTOR BEARINGS BEARINGS BEARINGS BEARINGS BEARINGS BEARINGS BEARINGS BEARINGS BEARINGS
GEARED MOTOR FOR DRAG CHAIN FEEDER
GEARED UNIT BEARINGS GEAR UNIT BEARINGS GEAR UNIT BEARINGS GEAR UNIT BEARINGS GEAR UNIT BEARINGS
3.75 5 0.25 0.6 1 0.3 0.6 1 0.3 1.75 2 0.25 1.75 1 0.25
18.75 1.25 0.6 0.3 0.6 0.3 3.5 0.5 1.75 0.25
LTR KG LTR
GM1401 TO GM1405
GEARED MOTOR FOR LP DOSING AGITATOR
GM0001 KG LTR GM0501 KG LTR KG LTR GM1406 KG GM1901 (AHS SUPPLIER SCOPE)
GEARED MOTOR FOR HP DOSING AGITATOR
GEARED MOTOR FOR BED ASH SCREW FEEDER
GEARED MOTOR FOR BED MATERIAL POCKET FEEDER GEAR BOX GEAR BOX FOR COAL / KUTCH LIGNITE BUNKER
GEAR UNIT BEARINGS GEAR UNIT BEARINGS
GEAR BOX FOR LIMESTONE BUNKER
OIL / SERVO MESH SP320 GREASE / SERVO GEM 2 OIL / SERVO MESH SP320 GREASE / SERVO GEM 2
3 10 0.25 3 5 0.25
30 2.5 15 1.25
LTR KG LTR KG
GB1401 TO GB1410
GB1411 TO GB14153
CUSTOMER
CETHAR VESSELS LIMITED, THIRUCHIRAPPALLI - 620 001
M/s. REI AGRO LIMITED 1 X 36 MW CAPTIVE POWER PLANT MBG 060
PROJECT W.O.NO.
INDENT FOR INITIAL FILLING LUBRICANT

S.NO 1 2 3 ID FAN FD FAN PA FAN DESCRIPTION PARTS BEARINGS BEARINGS BEARINGS GEAR UNIT 4 DOSING PUMP(HP) BEARINGS 5 6 AIR FILTER REGULATOR WITH LUBRICATOR BOILER FEED PUMP BEARINGS GEAR UNIT 7 DRAG CHAIN FEEDER BEARINGS 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 HT MOTOR FOR BFP MOTOR FOR START UP VENT VALVE MOTOR FOR MSSV HT MOTOT FOR FD FAN LT MOTOR FOR ID & PA FAN BEARINGS BEARINGS BEARINGS BEARINGS BEARINGS GREASE / SERVOGEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 GREASE / SERVO GEM 2 3 1 2 1 2 15 2 3 2 1 3 1 2 2 2 LUBRICANT GREASE/SERVO GEM EP2 GREASE/SERVO GEM EP2 GREASE/SERVO GEM EP2 CRANKCASE / OIL SERVO 320 GREASE/SERVO GEM 2 OIL /LIGHT MINERAL OIL / SAE 10 OIL / SERVO PRIME 46 OIL / SERVO MESH (SP 220) 5 0.25 1.2 0.25 0.25 1.2 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 1.25 3.6 0.25 0.5 1.2 0.5 3.75 0.5 0.75 0.5 0.25 0.75 0.25 0.5 0.5 0.5 KG KG KG KG KG KG KG KG KG KG KG KG KG KG KG KG HTM0101 TO HTM0103 M1201 M1202A TO M1202B HTM1301 LTM1301 TO LTM1302 LTM1401 TO LTM1415 LTM0001 TO LTM0002 LTM0501 TO LTM0503 M1801 TO M18012 M0201 LTM0101 TO LTM0103 LTM0104 LTM0105 TO LTM0106 LTM0107 TO LTM0108 M1203 TO M1204 QTY 1 1 1 5 5 10 3 INITIAL TOTAL FILLING REQUIREMENT QTY / ITEM 0.63 0.63 0.4 0.5 0.3 0.25 1.25 1.6 0.63 0.63 0.4 2.5 1.5 2.5 3.75 8 UNIT KG KG KG KG KG LTR KG LTR TAG NO.
LT MOTOR FOR POCKET FEEDER BEARINGS MOTOR FOR LP DOSING PUMP MTOR FOR HP DOSING PUMP MOTOR FOR START UP OIL PUMP MOTOR FOR DUMPING PRDS MOTORISED VALVE MOTOR FOR FEED PUMP DELIVERY VALVE MOTOR FOR HP HEATER BYPASS MOTORISED VALVE MOTOR FOR HP HEATER I/L & O/ L MOTORISED VALVE MOTOR FOR BOILER I & II FEED WATER ISO VALVE MOTOR FOR CBD & IBD GEARED MOTOR GEARED MOTOR FOR DRAG CHAIN FEEDER GEARED UNIT BEARINGS GEAR UNIT BEARINGS GEAR UNIT BEARINGS GEAR UNIT BEARINGS GEAR UNIT BEARINGS BEARINGS BEARINGS BEARINGS BEARINGS BEARINGS BEARINGS BEARINGS BEARINGS BEARINGS
OIL / SERVO MESH (SP320) 5 GREASE / SERVO GEM 2 OIL / SERVO MESH (SP 320) 1 GREASE / SERVO GEM 2 OIL / SERVO MESH SP320 1 GREASE / SERVO GEM 2 OIL / SERVO MESH SP320 2 GREASE / SERVO GEM 2 OIL / SERVO MESH SP320 1 GREASE / SERVO GEM 2
3.75 0.25 0.6 0.3 0.6 0.3 1.75 0.25 1.75 0.25
18.75 1.25 0.6 0.3 0.6 0.3 3.5 0.5 1.75 0.25
LTR KG LTR
GM1401 TO GM1405
GEARED MOTOR FOR LP DOSING AGITATOR
GM0001 KG LTR GM0501 KG LTR KG LTR GM1406 KG GM1901 (AHS SUPPLIER SCOPE)
GEARED MOTOR FOR HP DOSING AGITATOR
GEARED MOTOR FOR BED ASH SCREW FEEDER
GEARED MOTOR FOR BED MATERIAL POCKET FEEDER GEAR BOX GEAR BOX FOR COAL / KUTCH LIGNITE BUNKER
GEAR UNIT BEARINGS GEAR UNIT BEARINGS
OIL / SERVO MESH SP320 10 GREASE / SERVO GEM 2 OIL / SERVO MESH SP320 5 GREASE / SERVO GEM 2
3 0.25 3 0.25
30 2.5 15 1.25
LTR KG LTR KG
GB1401 TO GB1410
GEAR BOX FOR LIMESTONE BUNKER
GB1411 TO GB14153
UTILITY SPECIFICATIONS & REQUIREMENT
UTILITY SPECIFICATIONS & REQUIREMENT
AUXILIARY COOLING WATER
COMPRESSED AIR
CHEMICALS
BED MATERIAL, CHARCOAL & KEROSENE
AUXILIARY COOLING WATER AND COMPRESSED AIR REQUIREMENT
AUXILIARY COOLING WATER REQUIREMENT :
SI. No. 01 02.
APPLICATION
QUANTITY in Kg/hr 3600 per pump 7000
BOILER FEED PUMP - 3 No (2W+1S) SWAS TOTAL REQUIREMENT :
10600 Kg/hr
HOLD : BED ASH COOLER COOLING WATER REQUIREMENT COOLING WATER PRESSURE : 4 Kscg TEMPERATURE : 40 C THE CHLORIDE CONTENT IN COOLING WATER MUST BE LESS THAN 35 ppm. COMPRESSED AIR REQUIREMENT: AIR CONSUMPTION PER QTY( m3/hr) PNEUMATIC CONTROL VALVES PNEUMATIC ON OFF AIR CYLINDERS. PNEUMATIC REGULATING POWER CYLINDERS. PNEUMATIC ON OFF SOLINOID VALVES. ELECTRO PNEUMATIC VALVE POSITIONER 14 21 7 6 21 1.2 1.2 1.2 1.2 0.5 TOTAL : MARGIN (50 %) : TOTAL REQUIREMENT : ~ : PRESSURE OIL FREE DEW POINT NOTE : : 7.0 Kscg : 1 PPM : <-20 C TOTAL AIR CONSUMPTION (m3 / hr) 16.8 25.2 8.4 7.2 10.5 68.1 m3/hr 34.05 m3/hr 102.15 m3/hr 105 m3/hr
SI. No. 01. 02. 03. 04. 05.
APPLICATION
QTY
THE COMPRESSED AIR REQUIREMENT GIVEN ONLY FOR BOILER PNEUMATIC INSTRUMENTS SUPPLIED BY CVL.
CHEMICAL REQUIREMENT & SPECIFICATION

FOR HP DOSING SYSTEM: NAME FORMULAE COLOR & CRYSTALLINE FORM SPECIFIC GRAVITY AT 17.5C SOLUBILITY IN 100 PARTS OF COLD WATER 0C OF HOT WATER 100C MIN. QUANTITY TO BE STOCKED FOR LP DOSING SYSTEM: NAME FORMULAE COLOR & CRYSTALLINE FORM SPECIFIC GRAVITY AT 15C MIN. QUANTITY TO BE STOCKED FOR ALKALI BOILOUT: NAME FORMULAE COLOR & CRYSTALLINE FORM SPECIFIC GRAVITY AT 17.5C SOLUBILITY IN 100 PARTS OF COLD WATER 0C OF HOT WATER QUANTITY NO. OF BOILOUT NOTE: THE ABOVE QUANTITY IS TENTATIVE ONLY AND THE SAME SHOULD BE CHECKED AND ADJUSTED DURING BOILER OPERATION. IN THE ABOVE QUANTITY INITIAL FILLING IS NOT CONSIDERED, REQUIREMENT FOR THE SAME IS AS FOLLOWS. I) TRI-SODIUM PHOSPHATE II) HYDRAZINE - 3 Kgs. - 0.25 Kgs. 100C 4.5 77 195 Kgs / BOILOUT 3 7.1 48.5 290 Kgs / BOILOUT 3 TRI-SODIUM PHOSPHATE Na3PO4 WHITE, POWDER 2.537 Na2CO3 WHITE, POWDER 2.533 SODIUM CARBONATE HYDRAZINE N2H4 WHITE, LIQUID 1.011 6 Kgs / MONTH. 4.5 77 90 Kgs / MONTH. TRI-SODIUM PHOSPHATE Na3PO4 WHITE, POWDER 2.537
(TRI-SODIUM PHOSPHATE SHOULD BE DILUTED TO 1% CONCENTRATION)
(HYDRAZINE SHOULD BE DILUTED TO 60% CONCENTRATION)
BED MATERIAL, CHARCOAL, KEROSENE REQUIREMENT

BED MATERIAL REQUIREMENT: Quantity of bed material per startup Quantity of Bed material to be stocked BED MATERIAL SPECIFICATION: Maximum particle size Particles to pass through sieve No. Minimum particle size Particles to stay on sieve No. Particle density Bulk density Chemical composition Alumina Silica Fusion temperature : : : 45% to 35% 55% to 65% 1400C (Min.) : : : : : : : : 18130 54390 Kgs. Kgs. (For 3 Startups)
FOR COAL 2.36 mm 8 0.85 mm 20 2000 Kg/m3 1000 to 1100 Kg/m3
(Bed material shall be from Crushed refractory bricks or from sieved ash). CHARCOAL REQUIREMENT: Quantity of charcoal per startup Quantity of charcoal to be stocked CHARCOAL SPECIFICATION: Charcoal size Calorific value (Charcoal should be sundried) KEROSENE: Quantity of kerosene per startup Quantity of kerosene to be stocked : : 44 Litres. : : 15 to 25 mm LUMPS 6600 Kcal/Kg. : : 400 Kgs. 1200 Kgs. (For 3 Startups)
132 Litres. (For 3 Startups)
GENERAL DESCRIPTION OF BOILER
GENERAL DESCRIPTION OF BOILER
BOILER SYSTEM DESIGN DESCRIPTION
THE STEAM AND WATER SYSTEM
SUPERHEATER SYSTEM
DE-SUPERHEATER
DEAERATOR AND PRDS SYSTEM
AIR AND GAS SYSTEM
FUEL AND ASH SYSTEM
ANALYSERS
DOSING SYSTEM
OTHERS

The "CETHAR FLUIDIX" is a fluidised bed combustion boiler designed for maximum continuous rating of 80,000 kg/hr pressure of 87 ATA at main steam stop valve of boiler with a steam temperature of 520 5C fixing with the following fuels.
1. 100% IMPORTED COAL

2.
70% KUTCH LIGNITE + 30 % IMPORTED COAL
The boiler is designed with superheater temperature control range from 50% to 100% MCR.
CETHAR has designed, manufactured and supplied a single drum water tube boiler with natural circulation and with top support arrangement. The boiler consisting of steam drum, membrane water wall panels, bed coils, convection superheater, radiant
superheater, bed superheater, Economiser, Air heater, Inter connecting pipings, air and gas ductings, fuel feeding system, supporting structure with roof and side cladding,
platforms and staircases etc.
The other equipments like bunker, fans, ESP, HP dosing systems, blow down tanks, start up oil firing, bed material feeding are also supplied along with boiler.
The deaerator, LP dosing system and feed pumps are also supplied with boiler package to supply the required quantity and quality of feed water to boiler.
GENERAL DOWNCOMER & BED COIL
GENERAL DATA SHEET WATERWALL GENERAL OPERATION BLOW DOWN, ASH DEPOSITS, MAINTENANCE TUBE REPAIRS, DATA SHEET STEAM DRUM GENERAL DRUM INTERNALS INSTALLATION DATA SHEET
ECONOMISER GENERAL FEED WATER CONTROL MAINTANANCE DATA SHEET

GENERAL All the water required to produce steam is supplied by the boiler feed water pumps. The feed water passes through the economiser adds only sensible heat to the feed water.
From the drum, water is circulated through the natural circulation circuit. This circuit add latent heat to the water and thus this circuit, may be termed as evaporator circuit. As the steam and water mixture enters the drum from this circuit, the drum internals, separate the steam, from the mixture. The separated water along with the incoming feed water is continuously circulated through this circuit.
The natural circulation circuit is formed by the drum, four downcomers bed evaporator inlet headers, bed evaporator, waterwalls, roof tubes, outlet headers and riser pipes.
The saturated steam from the drum is superheated in the superheater coils, in three stages. The steam passes through the connecting links, convection superheater inlet header, convection connecting link super heater coils, convection superheater outlet header,
between convection superheater outlet and radiant superheater inlet
header, radiant superheater coils, radiant superheater outlet header, connecting link between radiant superheater outlet header and De-superheater, De-superheater, connecting link between De-superheater and bed superheater stage-1 , Bed superheater stage -1 inlet header, bed superheater stage-1coils, bed superheater stage -1&2 intermittent header, bed super heater stage-2 coils, bed super heater stage-2 outlet header, connecting links, bed superheater stage-3 inlet header, bed superheater stage-3 coils, bed superheater stage-3 outlet header.
De-superheater is located in between radiant and bed superheater stage-1, it serves to control the boiler outlet steam temperature.
DOWNCOMER & BED EVAPORATOR
DOWN COMER & BED EVAPORATOR GENERAL The water from drum flows through four down comers to the bottom bed evaporator headers. From this bottom bed evaporator header water flows through the bed evaporator tubes to waterwall bottom ring headers.
Bed evaporator consists of 304 coils assemblies arranged in a inline manner. The inlet headers are located horizontally both left and right side of the boiler. The bed evaporator is completely immersed within the fluidised bed. The bed evaporator is provided to extract heat from fluidised bed and to keep the bed temperature well below the ash fusion temperature.
The bed evaporators outlet headers are connected with front and rear waterwall bottom headers and formed as bottom ring headers for waterwall.
DATA SHEET DOWNCOMER: NO. OFF PIPE SIZE PIPE MATERIAL BED EVAPORATOR: TOP & BOTTOM HEADER PIPE SIZE PIPE MATERIAL : : D273.1 X 25.40 THK. SA 106 GR. B : : : TWO D273.1 X 15.09 THK. SA 106 GR. B TWO D219.1 X 12.7 THK SA 106 GR.B
BED TUBES NO. OFF TUBE SIZE TUBE MATERIAL
: : : :
TYPE-1 190 D 51 X 6.35 THK. SA 210 GR. A1
TYPE-2 114 D 51 X 6.35 THK SA 210 GR. A1
WATERWALL
WATERWALL GENERAL The waterwall, walls and roofs are formed by the tubes rising from the bottom ring headers. The waterwall are made of fin welded tube panels. The front waterwall consists of tubes that rise from the bottom ring header and end in the front roof panels and front roof panels end in the top roof header. The rear wall panel is formed by the tubes that originate from the rear portion of the bottom ring header and rise upto the rear roof tubes and the rear roof tubes end in the roof top header. The rear wall panels are extended into the furnace to form as nose to facilitate to provide convection superheater tubes. In between roof tubes and end of the rear wall nose the tubes are formed without fin to exit the flue gas from furnace. The two side walls are formed from the tubes that rise from the bottom ring headers and they are crowned by the two side waterwall outlet headers. Entire water wall and bed evaporator assembly is suspended from the top using hangers and rockers. From the side waterwall top headers there are three riser pipes, from each header, to carry the steam water mixture to the drum. From the roof panel top header there are four riser pipe to carry the steam water mixture to the drum. The water wall are provided with openings and seal boxes for the coil penetration, Bed material feed chutes, view ports, man hole doors etc. To protect the boiler from the effect of explosions buckstays are used. They are nothing but beams attached to channels welded to the waterwall tubes. The channels from a continuous beam around the wall. The buckstay beams are attached to channels with slip connections. These beams prevent the furnace from blowing inward or outward in the case of furnace puffs or increased negative pressure. Waterwalls serve two functions mainly. They form a gas tight enclosure to contain the hot flue gases. They form the evaporator circuit which generates steam. Natural circulation is established by the density difference between the water in downcomers and water - steam mixtures in waterwalls. The rate of the circulation adjusts itself until an equilibrium is reached such that the difference between the hydrostatic head at the feet of downcomers and the water walls is equal to the sum of pressure drops due to friction and acceleration of the flow medium in the circuit. Circulation will be high at lower pressure and at lower loads. Circulation will be reduced when feed water temperature increases and when drum level is low.
OPERATION INTERNAL DEPOSIT Since the design heat transfer rates in water cooled furnaces are normally high, it is essential that the tubes be kept free from scale formation and copper and iron oxides deposits. This is accomplished by proper boiler water and feed water treatment. Scale formation is the deposition of an insulating film on the water side of the tube wall, which raises the hot face temperature and may result in overheating of the tube section. Boiler water treatment aims to eliminate deposition of scale forming components by substituting non-scale forming components. BLOW DOWN Boiler blowdown is used as a means of controlling boiler water concentrations (solids and alkalinity) and to remove sludge formation. The frequency of blowing down depends upon local conditions, such as; characteristic of the water, nature of feed water treatment and rating of the boiler, etc. In this boiler the continuous blowdown system is sufficient. ASH DEPOSITS The fluidised bed is operated at a temperature which is 850C to 950C less than the deformation temperature of ash. Hence ash fusion and slagging problems are eliminated. MAINTENANCE Routine inspections of furnace wall tubes, drum and headers should be made after breakage and during annual outages. During this, drum should be opened and hand hole should be removed from headers. The condition of the drum internals should be clean and internal surfaces should be inspected for deposits. Any deposits should be removed and headers, drum and tubes flushed out with water. Furnace tubes should be externally for blistering, corrosion, erosion and cracking. For this purpose fire sides of all exposed furnace tubes must first be thoroughly cleaned of ash deposition and manhole doors should be properly closed before firing the boiler.
TUBE REPAIRS A tube section, which has failed, or which must be replaced because of danger of can in most cases easily be replaced. After removing the furnace wall insulation behind failed area, the tube section is removed by cutting across the tube, sufficiently above and below the failure and carefully cutting the web along side the tubes (See note.). The inserting and rewelding a new tube section, the tube ends should be properly prepared for welding. NOTE: The longitudinal cuts must extend beyond the perpendicular cuts sufficiently to welding completely around the periphery of the tube when installing the new section. Webs between tubes must be replaced and made gas tight. It must be recognized that it is impossible to include repair procedure (methods, welding, techniques, etc) to cover all pressure parts and associated structural components of steam generator. It is recommended that this company, local service or erection representative should be consulted for assistance in evaluating and repairing pressure parts damages and / or failures. All repairs should be done by competent and qualified personnel and all welding should be accordance with the recommended rules for repairs of boilers.
DATA SHEET FRONT & REAR WALL BOTTOM RING HEADERS
PIPE SIZE PIPE MATERIAL
: :
D 219.1 X 25.4 THK. SA 106 GR. B
SIDE WATERWALL TOP HEADERS
: :
D 273.1 X 25.4 THK. SA 106 GR. B
ROOF PANEL TOP HEADER
: :
D 273.1 X 25.4 THK. SA 106 GR. B
WATERWALL TUBES
TUBE SIZE TUBE MATERIAL
: :
D 51 X 4.5 THK. SA 210 GR. A1
STEAM DRUM
STEAM DRUM GENERAL The steam drum is of fusion welded type, liberally sized and fitted with high efficiency internals. The steam drum provided with 2 nos manhole door to open inwards. The following nozzles are provided in the steam drum. 01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. 12. 13. 14. 15. LOCAL PRESSURE GAUGE REMOTE PRESSURE GAUGE AIR VENT SAFETY VALVE N2 CAPPING STUB DIRECT LEVEL GAUGES LEVEL TRANSMITTER PRESSURE TRANSMITTER - 1 NO. - 1 NO. - 1 NO. - 2 NOS. - 1 NO. - 2 NOS. - 3 NOS. - 1 NO.
CONTINUOUS BLOWDOWN CONNECTION - 1 NO. INTERMITTENT BLOWDOWN CONNECTION- 1 NO. HP DOSING CONNECTION DOWNCOMER RISER FEED PIPE STEAM OUTLET - 1 NO. - 4 NOS - 10 NOS - 1 NO. - 4 NOS.
The thickness of the drum is arrived based on the requirements as specified under IBR 1950 with latest amendments.
DRUM INTERNALS The boiler drum forms a part of the circulation system of the boiler. It's main functions are a) Providing the necessary space for separation of steam from mixture of steam and water. Housing the equipment needed for purification of steam. Meeting the steam demand fluctuation by its steam storage capacity.
b) c)
The drum internals combine simplicity and efficiency to produce low maintenance cost and high steam quality. The drum is positioned horizontally in front of the boiler. It is fixed on boiler supporting structure. The steam-water mixture, entering the drum from side water wall top headers and roof panel top headers, is collected in the separating chamber formed by the vertical baffle panels through risers. The primary separation of steam and water takes place in the separating chamber. Most of the water drops down after impact and passes around the ends of the panels to mix with the incoming feed water. A portion of the water is drained off through the perforated continuous blow down pipes at this point of high solids concentration. The blow down line is provided with an motor operated angle type blow down with isolation valve. The steam and some water is released over the top ends of the panel and cascades into the top part of the drum. Here the wet steam rises and passes through the drier screens. The water, as it undergoes the tortuous path provided by the screens, gets collected and this water is drained to the waterside of the drum through the four drain pipes. Dry steam leaves the drum through the top four steam outlet nozzles. Drum safety valves are set to open when the drum gets pressurised above limits. Drum level is sensed to control the feed water flow. Drum level is indicated by the local drum water level gauge and by the remote water level indicator. The motorised operated emergency drain (Intermittent blowdown) with isolation valves, is to be used when the drum level shoots up abnormally.
INSTALLATION The following instructions are to be abhered to for the proper functioning of drum. 01. Study the drum internal drawing and learn the purpose of the various internal parts. To prevent mositure from bypassing the screen drier and mixing with dry steam as it leaves the drum, all the joints in the drier assemblies must be absolutely tight. Seal welding, where indicated on the drawing, must be carefully done. All bolts are to have two washers, one under the nut and one under the head. Joints which are bolted only and not seal welded are to be made as tight as possible. 03. The joints in the partition baffles need not be absolutely tight but should be made as tight as possible. Buckles on bent flanges which do not clamp properly should be hammered together between the bolts and corners drifted together. All bolted joints are to be retightened after the initial bolting. Gaskets shall not be used. Joints in feed header are to be absolutely tight. should allow for feed header expansion. U bolts on the feed header
02.
04. 05. 06.
DATA SHEET DRUM INTERNAL DIAMETER THICKNESS OF THE DRUM THICKNESS OF THE DISHED HEAD LENGTH OF THE DRUM MATERIAL OF DRUM PLATE MATERIAL OF DISHED HEAD DESIGN PRESSURE DESIGN TEMPERATURE INTERNALS A) TURBO SEPERATOR: NO. OFF SIZE B) SCREEN BOX: NO. OFF SIZE : : 15 574 X 307 MM : : 17 220 MM : : : : 1371 MM : 90 MM
90 MM (MIN. 76.5 MM) 5500 MM (TAN TO TAN) : : : 314C SA516 GR. 70 SA516 GR. 70 104 Kg/cm(g)
ECONOMISER
ECONOMISER GENERAL The purpose of economiser is to preheat the boiler feed water before it enters the steam drum and to recover some heat from the flue gas leaving the boiler. The inlet and outlet headers are positioned horizontally. It is fed with feed water by a pipe from the feed water control station. There are 51 parallel paths of economiser coils connecting the inlet header to the outlet header. The economiser coils are horizontally arranged and are split into two banks with a gap of 1200 mm in between them. The economiser coils are suspended from the economiser casing top frame through lugs and pins. There is a link connecting the economiser outlet header to the drum. The feed water flow is upward through the economiser, that is, in counterflow to the hot flue gases. Most efficient heat transfer is hereby accomplished. FEED WATER CONTROL The entire boiler water requirement is met by the two boiler feed pumps. Isolation valves are provided at the inlet and outlet of each feed pump. A suction strainer is provided after the inlet isolation valve of each pump, to protect the pump against the damage due to debris in feed water. Balancing leak off arrangement is provided for the pump to reduce the axial thrust on the bearing. goes to the economiser through feed Balancing leak off line is connected to station. The other branch is the deaerator storage tank. The delivery of the pump is split into two branches. One control recirculation branch going to deaerator storage tank through the Auto recirculation valve and inbuilt energy absorber (i.e. the break-down orifice). This arrangement prevents the abnormal temperature rise within the pump by establishing a minimum flow through the pump, whenever the feed water drawn by the boiler is less than the permissible minimum flow through the pump. The two numbers, 1 x 100% feed control valve and 1 x 30% feed control valve provided to regulate the flow of feed water supplied to the boiler. Whenever boiler load less than 30% the water flows through 30% feed control valve and
above 30% water flows through 100% feed control valve. A manual operated isolation valves are installed on both upstream and downstream side of each feed control valves. A pneumatic operated feed control valve 1 x 100% is provided in the bypass line to take care of feed water regulation during the maintenance of feed control valve. A manual operated isolation valve is provided at both upstream and downstream of 1 x 100% bypass control valve. MAINTENANCE Before starting up the boiler, the economiser should be inspected externally and if necessary cleaned. materials is not Especially if the installation is new, accumulation of erection unusual. Large debris should be removed manually followed by
washing the economiser with water. It should be ensured after waterwashing that water droplets from economiser surface are removed by running the FD and ID fans which otherwise will lead to corrosion. The external inspection of the economiser can be made whenever an opportunity is provided or the draft loss through economiser is more than usual, or the heat pick up in the economiser is less than normal.
DATA SHEET ECONOMISER ECONOMISER FEED PIPE: SIZE MATERIAL NO. OFF : : : 168.3 X 14.27 THK. SA 106 GR. B ONE
ECONOMISER INLET HEADER: SIZE MATERIAL NO. OFF ECONOMISER COILS TUBE SIZE : TUBE MATERIAL : LONGITUDINAL PITCH : TRANSVERSE PITCH : FLOW ARRANGEMENT : COIL ARRANGEMENT : TYPE OF SUPPORT : TYPE OF SPACER : 38.1 X 4.06 THK. SA 210 GR. A1 114 100 COUNTER FLOW STAGGERED CLAMP , SUSPENDED FROM ECONOMISER CASING TOP FRAME SCALLOPED - 'U' PLATE : : : 219.1 X 18.26 THK. SA 106 GR. B ONE
ECONOMISER OUTLET HEADER: SIZE MATERIAL NO. OFF : : : 219.1 X 18.26 THK. SA 106 GR. B ONE
ECONOMISER OUTLET LINK: SIZE MATERIAL NO. OFF : : : 168.3 X 10.97 THK. SA 106 GR. B ONE
SUPERHEATER SYSTEM
SUPERHEATER SYSTEM
CONVECTION SUPERHEATER
RADIANT SUPERHEATER
BED SUPERHEATER
BED SUPERHEATER OUTLET LINK
MAIN STEAM PIPE
PROTECTION AND CONTROL
MAINTENANCE
INSPECTION
DATA SHEET
SUPERHEATER SYSTEM
In superheater system, the superheaters are provided in three stages and termed as Convection superheater, Radiant superheater and Bed superheater. CONVECTION SUPERHEATER The dry saturated steam from drum is let into the convection superheater inlet header by means of 4 nos of connecting links. The superheater inlet and outlet headers are located horizontally in top of the water wall headers perpenticular to the boiler axis. The convection sueprheater consists of 45 parallel paths. The superheater is located above rear wall nose portion. The superheater is vertically placed, spaced and cross flow arrangement. The superheater coils with headers are suspended from top using hangers and rockers. RADIANT SUPERHEATER The superheated steam from convection superheater outlet header is let into the radiant superheater inlet header by means of connecting link. The superheater provided as pendent type and the inlet and outlet headers are placed above water wall top headers and suspended from top hangers and rockers coils are placed vertically at the direct radiant zone of furnace just away from rear wall nose construction. The Radiant super heater consists of 45 parallel paths. This superheated steam heated up to 495C. BED SUPERHEATER The superheated steam from radiant superheater outlet is let into the bed superheater inlet header for further temperature raising to the required level through inlet link. The bed superheater arranged are splited as three stages and placed in between bed evaporator tubes in both left and right side by providing inlet, intermittent and outlet headers. All the headers are placed horizontally, parallel to the boiler axis and supported with bed tube bottom headers. The bed superheater tubes are horizontally placed perpendicular to the boiler axis. The bed superheater consists of 25 parallel paths in stage-I, 25 parallel paths in stage-II and 26 parallel paths in stage-III. The bed super heater stage-I and stage-II are connected through intermittent header. The bed super heater stage-II and stage-III are connected through link.
In bed the superheater coils located away from startup compartment to avoid tube failure due to high tube metal temperature while starting of the boiler. The De-superheater is provided on the link that connects the radiant superheater and bed superheater stage-1. De-superheating is done by spraying feed water and mixing it with steam so that the required outlet steam temperature is obtained. Spray control valve is actuated by the signal generated by the temperature sensing element which is mounted on the bed superheater stage-2 outlet steam pipe. BED SUPERHEATER OUTLET LINK The main steam pipe is provided from bed superheater stage-2 outlet header upto main steam stop valve. The main steam pipe accomodates, the following stubs.
01. 02.
SAFETY VALVE STARTUP STEAM VENT (MOTORISED)
- 1 NO. - 1 NO.
03. 04. 05. 06. 07. 08. 09. 10.
PRESSURE TRANSMITTER PRESSURE GAUGE (LOCAL) PRESSURE GAUGE (REMOTE) SAMPLING TEMPERATURE ELEMENT DRAIN AIR VENT AUXILIARY
- 1 NO. - 1 NO. - 1 NO. - 1 NO. - 1 NO. - 1 NO. - 1 NO. - 1 NO. : D 219.1 X 25.4 mm : SA 335 P22
MAIN STEAM PIPE From main steam stop valve outlet steam let to the turbine through main steam pipes. Steam flow measuring nozzle is provided in the main steam pipe with maintaining adequate upstream and down stream pipe length. The adequate no off steam traps provided in the bottom most of the pipes and airvent provided in the top most of the pipes. PROTECTION AND CONTROL As long as there is fire in the furnace adequate protection must be provided for superheater elements. This is especially important during periods when there is no demand for steam, such as start-up and shut down. During these periods, adequate flow through the superheater is assured by means of drains and vents in the headers, links and main steam piping. Superheater is provided with a safety valve. It is set to pop at a lower pressure compared to the low set drum safety valve. Hence when there is load fluctuation or when the steam demand drops suddenly, the flow is established by the lifting of safety valve. During all start ups, care must be taken not to overheat the superheater elements by limiting the inlet gas temperature. MAINTENANCE It is essential that suitable arrangements are made to assure cleanliness of the external and internal surfaces of the superheater at all times. Fly ash accumulations result in unequal gas distribution, inefficient heat transfer and possible localised overheating. The external surfaces of the superheater coils can be inspected using the three access doors provided. Proper feed water treatment and control of steam quality are essential to assure cleanliness of interior surfaces of superheaters. Overloads, fluctuating loads, high water level, foaming, high concentrations etc, all contribute to deposit on interior surfaces. Accumulation of these deposits inside the tube will lead to overheating failures.
Periodic checks of steam pressure drops across the superheater under idendical load conditions usually indicate whether solid deposits are present with in the elements. In the event of failure of one or more elements, it is necessary to determine the cause. The manufacturer may be consulted for repair procedures. INSPECTION The following inspection and maintenance programme, conscientiously following very much to assure continuity of service and to avoid serious and expensive outages. i. ii. iii. The superheater should always be inspected when the boiler is out of service. Check the elements for alignment and any evidence of warping or overheating. condition.
Check supprts, spacers and seal plates for proper location and Replace promptly. Check for erosion of tubes.
iv.
DATA SHEET CONVECTION SUPERHEATER INLET LINK NO. OFF PIPE SIZE MATERIAL : : : FOUR D 114.3 X 8.56 mm SA 106 Gr. B
CONVECTION SUPERHEATER INLET HEADER NO. OFF SIZE MATERIAL : : : ONE D 273.1 X 25.4 mm SA 106 Gr. B
CONVECTION SUPEREHATER COILS NUMBER OF PARALLEL PATHS: NUMBER OF BANKS DISPOSITION TYPE OF HEAT FLOW TUBE SIZE TUBE MATERIAL COIL TYPE TRANSVERSE PITCH LONGITUDINAL PITCH ARRANGEMENT TYPE OF SUPPORT : : : : : : : : : : 45 ONE VERTICAL CROSS D 44.5 X 4.5 MM SA 210 Gr. A1 PENDANT 101 MM 130 MM INLINE ARRANGEMENT U - ROD ATTACHED WITH BATTEND CHANNEL AND SUSPENDED FROM TOP HANGERS AND ROCKERS TYPE OF SPACER : SCALLOPED BAR
CONVECTION SUPERHEATER OUTLET HEADER NO. OFF SIZE MATERIAL : : : ONE D 273.1 X 25.4 mm SA 106 Gr. B
DATA SHEET RADIANT SUPERHEATER INLET LINK NO. OFF PIPE SIZE MATERIAL : : : ONE D 219.1 X 15.09mm SA 106 Gr. B
RADIANT SUPERHEATER INLET HEADER NO. OFF SIZE MATERIAL : : : ONE D 273.1 X 25.4 mm SA 106 Gr. B
RADIANT SUPEREHATER COILS NUMBER OF PARALLEL PATHS: NUMBER OF BANKS DISPOSITION TYPE OF HEAT FLOW TUBE SIZE TUBE MATERIAL COIL TYPE TRANSVERSE PITCH LONGITUDINAL PITCH ARRANGEMENT TYPE OF SUPPORT : : : : : : : : : : 45 ONE VERTICAL CROSS D 44.5 X 4.5 MM SA 213 T11 PENDENT 101 MM 130 MM INLINE ARRANGEMENT U - ROD ATTACHED WITH BATTEND CHANNEL AND SUSPENDED FROM TOP HANGERS AND ROCKERS TYPE OF SPACER : SCALLOPED BAR D 44.5 X 5.0 MM SA 213 T22
RADIANT SUPERHEATER OUTLET HEADER NO. OFF SIZE MATERIAL : : : ONE D 273.1 X 32 mm SA 335 P11
DATA SHEET BED SUPERHEATER INLET LINK NO. OFF PIPE SIZE MATERIAL : : : STAGE-1 ONE D 219.1 X 25.4 mm SA 335 P11 RIGHT SIDE ONE D 273.1 X 32 mm SA 335 P22 STAGE-2 ONE D 273.1 X 25.4 SA 335 P22 LEFT SIDE ONE D 273.1 X 36 mm SA 335 P22
BED SUPERHEATER INLET HEADER NO. OFF SIZE MATERIAL BED SUPEREHATER COILS NUMBER OF PARALLEL PATHS: NUMBER OF BANKS DISPOSITION TYPE OF HEAT FLOW TUBE SIZE TUBE MATERIAL COIL TYPE TRANSVERSE PITCH ARRANGEMENT : : : : : : : : : : :
50 TWO HORIZONTAL CROSS D 44.5 X 5 MM SA 213 T91 U - BEND 100 MM INLINE ARRANGEMENT
25 ONE HORIZONTAL CROSS D 44.5 X 5 MM SA 213 T91 U - BEND 100 MM INLINE ARRANGEMENT
BED SUPERHEATER OUTLET HEADER NO. OFF SIZE MATERIAL MAIN STEAM PIPE SIZE MATERIAL : : D 219.1 X 25.4 mm SA 335 P22 : : : ONE D 273.1 X 32 mm SA 335 P22
DE-SUPERHEATER
DE-SUPERHEATER
GENERAL
CONTROL
MAINTENANCE
DATA SHEET
DE-SUPERHEATER
GENERAL Desuperheater is provided in the link connecting the radiant superheater outlet
header and bed superheater stage-1 inlet header. This is used to maintain the steam temperature at design value. Temperature reduction is accomplished by injecting spray water into the path of the steam, through a nozzles at the entering end of the desuperheater. The spray water is drawn from the feed pump solids. CONTROL A spray control valve linked to an automatic temperature control one number (100% temperature control valve provided to regulate the flow of spray water supplied to de-superheater. A manual operated isolation valve is installed on upstream & downstream of each control valve to permit isolation when required. A pneumatically operated temperature control valve is provided in the bypass line to take care of the spray during maintenance of spray control valve. MAINTENANCE The desuperheater is fitted with a renewable liner to take care of erosion from the spray water stream, thus protecting the main desuperheater shell. Excessive noise from desuperheater usually indicates a worn liner and the service department of this company should be contacted when this or any such abnormal conditions arise. Sufficient clearance should be provided around the desuperheater for replacing liner. discharge line but before the feed control station. It is essential that the spray water be chemically pure and free of suspended and dissolved
DATA SHEET NO. OFF SIZE MATERIAL LINER SIZE LINER MATERIAL NO. OF SPRAY NOZZLES SPRAY NOZZLE MATERIAL SPRAY NOZZLE BODY MATERIAL NUMBER OF HOLES IN SPRAY NOZZLE HOLE SIZE DESH INLET LINK SIZE DESH INLET LINK MATERIAL DESH OUTLET LINK SIZE DESH OUTLET LINK MATERIAL : : : : : : : : : : : : : : ONE D 273.1 X 32 mm SA 335 P11 D 180 X 3.15 mm SA 240 Gr. 304 ONE SA 479 GR. 304 SA 479 GR. 304 ONE D 9 MM D 273.1 X 25.4 mm SA 335 P11 D 273.1X 32 mm SA 335 P11
DEAERATOR & PRDS SYSTEM
DEAERATOR AND PRDS SYSTEM DEAERATOR
GENERAL
DESIGN AND CONSTRUCTION
FEED WATER STORAGE TANK
DEAERATING HEADER
SHELL
TRAY AND SPRAY VALVES
DATA SHEET
DEAERATOR SYSTEM
DEAERATOR AND PRDS SYSTEM

DEAERATOR
GENERAL The deaerator is placed before boiler feed pump in the feed water cycle to remove the dissolved corrosive gases from the feed water which goes to the boiler. The oxygen is reduced to 0.007 cc/litre and carbon di-oxide is reduced to untraceable limits, in the condensate leaving deaerator. It is a direct intimate contact type heat exchanger and is located before suction side of boiler feed pump in thermal cycle. The steam is drawn to heat the condensate which is broken into fine droplets for effective heat and mass transfer of non condensable gases. The deaerator consists of vertical deaerating chamber called header and horizontal feed storage tank. The condensate and make up water enters the deaerating chamber and is sprayed by spray valves. The sprayed water falls through tray stack for heat and mass transfer. The condensate is divided into fine droplets and comes in contact with the steam resulting in release of non condensate gases which are carried by the steam moving upwards. The condensate after leaving deaerating header enters into feed storage tank from where it goes out to boiler feed pumps. Steam enters the feed storage tank and then goes into deaerating header where it gets condensed, some steam alongwith non condensate gases goes out of the equipment. DESIGN AND CONSTRUCTION Steam admitted in storage tank provides a steam blanket over stored condensate and thus eliminates under cooling of condensate and reabsorption of gases by the condensate. The deaerator, feed water storage tank is designed and constructed to International Standard like, HEI, ASME Section VIII Division - 1 etc. The deaerating header is mounted on the feed storage tank for simplified layout and compact arrangement.
FEED WATER STORAGE TANK The shell of the storage tank is fabricated from boiler quality steel plates. The ends are closed with dished ends. Various connections like condensate outlet, steam inlet, drain outlet, relief valve, thermometer pockets, level gauges, high and low level alarms, manhole etc., are provided. DEAERATING HEADER The main parts of the deaerating header are a) b) Shell and dished ends. Tray plates and spray valves.
SHELL The shell of the deaerating header is fabricated from boiler quality steel plates, and is closed with dished end. The shell mounted directly over the feed storage tank. It houses stainless steel trays. Stainless steel spray valves are provided for spraying condensate. It is provided with connections such as condensate inlet, make up water inlet, inspection opening, air vent outlet. TRAY AND SPRAY VALVES The trays and spray valves are fabricated from SS 304.
DATA SHEET 01. 02. TYPE DESIGN DATA DESIGN PRESSURE DESIGN TEMPERATURE TEST PRESSURE TEST TEMPERATURE RADIOGRAPHY : : : : : 6.0 Kg/cm(g) & F.V 250C (DEAERATOR & FST) 9.0 Kg/cm(g) AMBIENT AS PER IBR 1950 WITH LATEST AMENDMENTS AS PER IBR 1950 WITH LATEST AMENDMENTS VERTICAL 1800 MM X 10 MM THK. 3860 MM 7 14 15 TPH HORIZONTAL : : : 2976 MM X 12 MM THK. 13300 MM 59 M^3 : SPRAY CUM TRAY
CORROSION ALLOWANCE 03. DEAERATOR HEADER INSIDE DIA X THK OVERALL LENGTH NUMBER OF TRAYS NUMBER OF SPRAY VALVES SPRAY VALVE CAPACITY 04. FEED WATER STORAGE TANK INSIDE DIA X THK OVERALL LENGTH STORAGE CAPACITY / VOLUME BETWEEN LOW LOW LEVEL & NORMAL LEVEL
: : : : :
05.
MATERIALS DEAERATOR HEADER SHELL AND DISH FEED STORAGE TANK SHELL AND DISH TRAYS NOZZLES FASTENERS FLANGES SPRAY NOZZLE : : : : : : : SA 516 GR. 70 SA 516 GR. 70 SS 240 GR. 304 SA 106 GR. B SA 193 GR.B8 / SA 515 GR.70 SS TP304 / 316
06.
NOZZLES CONDENSATE INLET STEAM INLET : : 1 NO - 8" NB ANSI # 150 RF 1 NO - 8" OD 219.1 X 10.31 : 1 NO - 6" NB OD 273.1 X 12.7 1 NO-INLET 6" ANSI# 150RF OUTLET 10" ANSI # 150RF 1 NO - 3" NB OD 88.9 X 7.62 ANSI # 150 RF
FEED WATER OUTLET
SAFETY RELIEF VALVE INITIAL HEATING STEAM INLET
: :
PRDS SYSTEM
PRDS
GENERAL
CONTROL
DATA SHEET
PRESSURE REDUCING AND DE-SUPERHEATING STATION

GENERAL
We have provided split up PRDS for deaerator initial heating steam supply and Ejector and gland sealing steam supply.
CONTROL
The high pressure and superheated steam drawn from main steam pipe, and the pressure and temperature are reduced by PRDS to the desired value. The steam at the outlets of PRDS is ulitised for deaerator initial heating steam, turbine gland sealing and ejector applications. The spray control valve linked to an automatic control of the flow of spray water supplied to desuperheater. The spray valve is directly mounted in the de-superheater. To reduce the shut off differential pressure in the spray control valve, the feed water
pressure partially reduced in self actuated pressure control valve provide in the upstream of spray control valve.
DEAERATOR INITIAL HEATING STEAM PRDS DATA SHEET

OEPRATING DATA FOR PRDS FLOW AT PRDS OUTLET INLET PRESSURE INLET TEMPERATURE OUTLET PRESSURE OUTLET TEMPERATURE OEPRATING DATA FOR WATER SIDE INLET PRESSURE INLET TEMPERATURE DESIGN DATA FOR STEAM SIDE PRESSURE TEMPERATURE HYDRO TEST PR. FOR PRDS DESIGN DATA FOR WATER SIDE PRESSURE TEMPERATURE HYDRO TEST PR. FOR SPRAY WATER LINES Kg/cm(g) Deg.C Kg/cm(g) 135.00 155 205 Kg/cm(g) Deg.C Kg/cm(g) 93.50 525 141 Kg/cm(g) Deg.C 120 155 120 155 120 155 Kg/hr Kg/cm(g) Deg.C Kg/cm(g) Deg.C MAXIMUM 9168 86 520 8 250 NORMAL 7640 86 520 8 250 MINIMUM 1910 86 520 8 250
EJECTOR AND GLAND SEALING SYSTEM PRDS DATA SHEET

OEPRATING DATA FOR PRDS FLOW AT PRDS OUTLET INLET PRESSURE INLET TEMPERATURE OUTLET PRESSURE OUTLET TEMPERATURE OEPRATING DATA FOR WATER SIDE INLET PRESSURE INLET TEMPERATURE DESIGN DATA FOR STEAM SIDE PRESSURE TEMPERATURE HYDRO TEST PR. FOR PRDS DESIGN DATA FOR WATER SIDE PRESSURE TEMPERATURE HYDRO TEST PR. FOR SPRAY WATER LINES Kg/cm(g) Deg.C Kg/cm(g) 135.00 155 205 Kg/cm(g) Deg.C Kg/cm(g) 93.50 525 141 Kg/cm(g) Deg.C 120 155 120 155 120 155 Kg/hr Kg/cm(g) Deg.C Kg/cm(g) Deg.C MAXIMUM 2760 86 520 26 350 NORMAL 2300 86 520 26 350 MINIMUM 335 86 520 26 350
AIR AND GAS SYSTEM
AIR AND GAS SYSTEM
FD AIR SYSTEM TUBULAR AIR SYSTEM DUCTING SYSTEM PRIMARY AIR SYSTEM FLUE GAS SYSTEM ELECTROSTATIC PRECIPITATOR FANS
AIR AND GAS CIRCUIT

FD AIR SYSTEM All the required air for the boiler operation is supplied by the FD fan. FD fan is provided with inlet regulating damper pneumatically operated. The cold air from the FD fan is let into the air heater. The hot air from the air heater is distributed to the five compartments by means of the air distributor (FD header). This is the air which keeps bed fluidised. This FD header also serves as the suction for primary air fans. The fluidising air to the five compartments can be cut off using the pneumatically operated shut-off dampers provided in the respective compartment air inlet ducts. TUBULAR AIR HEATER Air heater of multi tubular recuperative type is provided for the boiler at the downstream of economiser with flow over the tubes and gas flow through the tubes. Cold air from FD fan let into the air heater in two passes. The regulating pneumatic operated damper is provided in ducting between pass-I inlet and pass-II outlet to control the flue gas exist temperature in low load condition. DUCTING SYSTEM All ducts are of Mild steel suitably stiffened on the outside and designed to withstand the pressures encountered. The ducting system is complete with all required expansion joints, mating flanges, dampers, supports, access doors, platforms insulation etc. All ducts are of welded construction. PRIMARY AIR SYSTEM One no. of PA fan provided in this system. The suction line for PA fan is from the FD header. PA fan inlet provided with pneumatic operated regulating and shut off damper. This helps to control the flow of the fan when required. The PA fan boots up the pressure of incoming hot air so that coal can be pneumatically transported in the bed. The PA fan outlet is connected with PA distribution header.
From this PA header 5 Nos. of ducts connected with branch header with pneumatic operated shutoff dampers. Each branch header has four coal transport air pipes feeding a compartment. The coal transport air to any compartment can be cutoff using pneumatic operated shut off damper. Each fuel transportation line has manual operated shut off dampers to facilitate to take individual line maintenance. FLUE GAS SYSTEM The hot gas generated in bed exchanges the heat with the heat transfer surfaces with in the boiler. The heat is transferred from the flue gases to the water walls, radiant superheater coils and convection superheater coils placed in side of the furnace. The flue gas temperature further drops while passes through economiser coils placed in the outside of furnace. The economiser to air heater gas ducting provides a change in flow direction of the flue gas. This results in seperation of unburnt combustibles and ash from the flue gas. The separated unburnt combustibles and ash are collected in the two hoppers are provided below the economiser and air pre heater and are disposed through suitable ash removal system. The temperature of the flue gas further reduces it passes through the air heater. The combustion air is preheated in the air heater by the flue gas. ELECTROSTATIC PRECIPITATOR Electrostatic Precipitator is the most effective method for removal of solid particles from the flue gases. The Electrostatic Precipitator basically consists of a large steel chamber and the electrodes. High voltage DC supply is applied between the emitting electrode and the collecting electrode. The emitting electrode is connected to the negative terminal. The collecting electrode is connected to the positive terminal and earthed. When flue gases pass through the chamber, because of the high DC voltage applied across the emitting and the collecting electrodes, the solid particles get ionised and are attracted to the collecting electrode Ash drops down in the hoppers, which is then removed and disposed off. The dust concentration in the flue gas is reduced to the requirement by use of the electrostatic precipitator placed after the air heater. The outlet duct of the electrostatic precipitator connected to the inlets of the two ID fans. ID fans are provided with power cylinder operated regulation dampers and power cylinder operated on-off discharge dampers. Manhole doors are provided inlet and outlet duct of economiser and air heater ducts.
FANS One no. of FD fan and one no. of ID fan has designed for 100% MCR capacity and One no. of PA fan has designed for 100% MCR capacity. The fans supplied are complete with coupling, base plates etc. All control vanes/dampers will be supplied complete with the pneumatic actuators and connecting mechanism etc., All the fan impellers are dynamically balanced at works, before despatch.
FUEL & ASH SYSTEM
FUEL SYSTEM
FUEL AND ASH SYSTEM

FUEL SYSTEM
GENERAL
FUEL STORAGE BUNKER
DRAG CHAIN FEEDER
FUEL DISTRIBUTION SYSTEM
FLUIDISED BED PROPER
FUEL AND ASH SYSTEM

FUEL SYSTEM GENERAL The type of firing used in this boiler is under bed feeding. The coal is precrushed and stored in the bunkers. The crushed coal is pneumatically transported into the fluidised bed. The air required for transport of coal is supplied by the primary air fans. There are ten air lock feeders connected with five drag chain feeders of split outlet type to fuel coal to the twenty coal feed lines. The fluidised bed is sectioned into five compartments and each compartment is provided with four side feed points. The fuel input rate can be controlled by the use of variable frequency drives of the rotary air lock feeders. The coal feed lines are provided with sufficient flexibility to clear off choking, if occures. The required air flow can be adjusted using the butterfly dampers provided in the lines. The crushed coal bunkers are provided with gate arrangement with Morris wheel and chain for the purpose of isolation. When the feeders are attended for repair and maintenance. FUEL STORAGE BUNKER The twin bunker is designed to take care combination firing as specified earlier. The bunker having 247 M^3 water volume and having 5 outlet chutes each having rack and pinion gate arrangement with Morris wheel and chain. The adequate size of surge hopper are provided below bunker outlet chutes and same have been mounted above the pocket feeders. The libraly sized non-glogging type pocket feeder are provided to take care of feeding and regulating the required fuel for firing. The variable frequency drives are provided to control fuel feeder speed in order to convey the fuel quantity.
The lime stone bunker having 60 M^3 water volume and having 5 outlet chutes each having rack and pinion gate arrangement with Morris wheel and chain. As like coal feeding system surge hopper, Pocket feeder and VFD drives are provided for Lime stone feeding system to let the lime stone to the common Drag chain feeder. DRAG CHAIN FEEDER The rotary feeder outlet from each bunker is connected with drag chain feeder. The total no. off feeders are 5 Nos. each one number per compartment. Drag chain feeder is provided with constant speed drive. The feeder outlet chute is divided into four chutes and connected with mixing nozzle mounted on the fuel transportation line. FUEL DISTRIBUTING SYSTEM The fuel from the feeding points is pneumatically transported through fuel feed pipe to the fluidised bed. Forced air flow to each of the bed compartments can be isolated independently by dampers. A damper is provided in the air ducting to each bed section. The number of feeding points are Twenty (under bed) and are located in the bed in such a way for uniform fuel distribution. FLUIDISED BED PROPER The Fluidised Bed system is the proven design capable of firing the fuel specified. The nozzle design will permit effective fluidisation at lower loads with shutting down of some compartments. Fluidising nozzles will have suitably sized stem portion extending from the bed plate to the furnace side. The bed air nozzles will be MS body and SS tail and shall be fixed on to the bed plate, by screwing from the bottom side. Necessary ash drain systems will be provided for the bed section as required, for removal of bed ash.
ASH SYSTEM
ASH SYSTEM
GENERAL
BED ASH DRAIN SYSTEM
ASH SYSTEM GENERAL Ash generated from the boiler is collected at four location fluidised bed, hoppers, air heater hopper and electrostatic precipitator hoppers. economiser
The fluidised bed is provided with 2 nos. bottom drains per compartment one for manual and one is provided with bed ash cooler. The bottom ash drains shall be used for emergency purposes and when the bed build up rate is high. Excessive pressure drop in the bed shall be used as an indication to operate the bottom drains of bed. The economiser bottom is provided with an ash hopper with isolation gate arrangement. The over flow pipe provided in the ash hopper with isolation gate arrangement to facilitate the disposal of ash while ash handling system is in maintenance. The air heater bottom is provided with a ash hopper with a isolation gate arrangement. The over flow pipe provided in the ash hopper with isolation gate arrangement for manual ash disposal while ash handling system is in maintenance. The fly ash collected from Economizer, Air Heater & electrostatic precipitator are disposed through proper ash handling system. BED ASH DRAIN SYSTEM This boiler is having five compartments and each compartment is having one no. of ash drain point. The maximum designed ash collection rate per compartment drain pipe is 50 Kg/hr. The ash drain pipe has been connected to the bed ash cooler, Where the bed ash of 900C will be cooled to 175C. Each ash drain pipe will be connected with separate ash coolers and each ash cooler will be having separate ash discharge points and these ash discharge points will be connected to ash handling system. The ash drain will be having a by pass discharge point for any emergency drain. As these emergency drain are not connected with coolers the ash drained through this drain will be having a temperature of 900C' (ie. the actual bed operating temperature).
The bed ash cooler is same as like of FBC system. The atmospheric air has been tapped at the outlet of FD fan and fed through the air nozzles provided in the ash cooler, where the air and bed ash will be mixed and get cooled. The cooled ash has to be collected through the ash handling system and it can be conveyed to storage silo. The hot air from the ash coolers have been connected through ducts to Air heater flue gas outlet. In case of ash cooler maintenance / failure, the ash can be removed manually through the bottom of ash drain pipe gate arrangement. Power cylinder operated shutoff dampers are provided at the air inlet of ash coolers. These dampers can be operated from the DCS panel either manually or automatically. To accomplish the above, individual pressure transmitters are provided in each air box compartments so that whenever the air box pressure is getting increased due to the buildup of bed ash materials, an alarm will be generated to indicate the operator to perform the task manually. The same can be operated automatically considering the programs done in the DCS according to the logics provided. The sequence of cooling of bed ash should be such that ash in alternate compartment is cooled repeatedly. The operation sequence is decided in such a way that only one compartment can be operated at a time. Air inlet in the bed ash coolers is controlled by the power cylinders whose operating time is decided and set in the DCS. The compartment damper (ie. ash cooler air inlet damper) will be opened only for a pre-set time. When the time is elapsed the adjacent compartments damper will be opened. compartment not in operation shall not be considered in the sequence of operation. The
The timing sequence (ie. one cooler to other) can be 5 minutes (maximum) and it should be decided during commissioning of the cooler. Please note that the complete operation depends on ash being generated in the furnace. Normally these coolers operation will be intermittent only.
ANALYSERS
ANALYSERS
STEAM AND WATER ANALYSERS
FLUE GAS ANALYSERS
ANALYSERS
STEAM AND WATER ANALYSERS For continuous monitoring and analysis of samples from water and steam, we have provided the steam and water analysis system for the following locations. 01. 02. 03. 04. FEED WATER BLOW DOWN WATER SATURATED STEAM SUPERHEATED STEAM - pH, CONDUCTIVITY ,SILICA & HYDRAZINE - pH & CONDUCTIVITY - pH & CONDUCTIVITY - pH, CONDUCTIVITY
FLUE GAS ANALYSERS To measure the O2 level in the gas, O2 analyser is provided in the economizer out let via flue gas. To measure the dust concentration in the flue gas SPM analyzer is provided in the chimney.
OTHERS
OTHERS
LP DOSING
HP DOSING
FLASH STEAM RECOVERY SYSTEM
BED MATERIAL / CHARCOAL BUNKER AND FEEDING SYSTEM
BOILER STRUCTURES, ROOF AND SIDE CLADDING
REFRACTORY, INSULATION & CLADDING
DOSING SYSTEM
LP DOSING In LP dosing system, Hydrazine (N2H4) is dosed to feed water at the inlet of feed pumps (or) inlet of feed water tank to scavenge the last traces of dissolved oxygen in feed water. To ensure proper dosing, a residual concentration of Hydrazine (0.02 ppm) is usually maintained in the boiler water. The correct treatment level may vary depending on operating conditions like water characteristics and boiler pressure. DESCRIPTION DM water or condensate is mixed with concentrated Hydrazine using motorised agitator in mixing tank and stored at storage tank prepared chemical is dosed to feed water using reciprocating pump. The flow of reciprocating pump can be varied by adjusting the stroke of the plunger through a scaled knob. At the pump discharge a pressure gauge is provided to read the pump discharge pressure. One no. of pressure relieving valve is provided to safeguard the pump against high pressure. Necessary isolation valves are provided to isolate the pump. One no. of NRV is provided in the pump outlet to prevent the back flow of water to the pump. PROCEDURE When the boiler is under normal operation, chemical is dosed at a particular rate and feed water sample is analysed for residual hydrazine. Based on analysis, increase or decrease the dosing rate to get the required residual hydrazine in the feed water. Once the required residual hydrazine is obtained note the stroke and chemical concentration (Ratio of water / concentrated N2H4) which should not be varied unless there is any change in the feed water quality. HANDLING AND STORAGE: 1. 2. Avoid contact with skin and eyes. Solution if prepared, should be made in a covered tank. Since the solution can absorb oxygen from the atmosphere, not more than one day requirement should be prepared at a time.
HP DOSING In HP dosing system, trisodium phosphate is dosed to steam drum to precipitate the dissolved salts forming hardness. These precipitated sludge is removed through blow down. To ensure proper dosing of phosphate recommended amount of residual phosphate is maintained in the blowdown. The amount of required residual phosphate can be obtained from phosphate curve which depends on the pH value of boiler water. DESCRIPTION DM water is mixed with trisodium phosphate in mixing tank and stored tank. Water is thoroughly mixed with chemicals using motorised agitator. Prepared chemical is dosed to drum using reciprocating pump. The flow of reciprocating pump can be varied by adjusting the stroke of the plunger through a scaled knob. At the pump discharge a pressure gauge is provided to read the pump discharge pressure. One no. of pressure relieving valve is provided to safeguard the pump against high pressure. Necessary isolation valves are provided to isolate the pump. One no. of NRV is provided in the pump outlet to prevent the back flow of water to the pump. PROCEDURE: When the boiler is under normal operation chemical is dosed at a particular rate and boiler blowdown sample is analysed for residual trisodium phosphate. Based on analysis increase or decrease the dosing rate to get the required residual phosphate (PO4). Once the required residual phosphate is obtained note the stroke and chemical concentration (Ratio of water/PO4). Which should not be varied unless there is any change in the feed water quality. HANDLING AND STORAGE: 1. 2. 3. 4. Avoid contact with skin and eyes. Avoid extremes of temperature. Replace caps securely after use. Maximum storage limit is 2 years.
FLASH STEAM RECOVERY SYSTEM Two nos. Blow Down tank will be provided for the continuous and intermittent blowdown. The boiler Continuous Blowdown line will be connected to continuous Blow Down tank and drains from other systems will be connected to the Intermittent Blow Down Tank. The Intermittent Blow Down tank outlet and continuous blowdown tank outlet will be left to the drain system. Required supports, drain valves and necessary piping, etc., have been provided for the tanks. Continuous blowdown tank is a IBR approved pressure part and is used for flash steam recovery. The recovered flash steam will be used for deaerator steam. BED MATERIAL / CHARCOAL BUNKER AND FEEDING SYSTEM We have provided one no. Mild steel bed material bunker having suitable storage volume with supports and feeding chute for feeding the into the bed. Bunker outlet chute will have a pocket feeder and constant speed geared motor to control the flow. BOILER STRUCTURES, ROOF AND SIDE CLADDING The boiler is provided with all required base frame, steel work of sufficient height. The supporting structure for Boiler, Economiser / Airheater are from ground level onwards. RCC firing floor platform is provided by the purchaser. The required structural columns, frame work for the economiser, ducting and piping, equipment are provided with stairs and walkways. In addition, pipe supports, hangers, duct supports, etc., are provided for the complete system covered in this specification.
Necessary roof and side cladding are provided up to the firing floor on all sides of the boiler.
REFRACTORY, INSULATION, CLADDING All other piping, air ducts, flue ducts, equipments etc., are provided with insulating system of adequate thickness. Refractories are provided at the furnace area and at water wall seal boxes.
FLUIDISED BED COMBUSTION
FLUIDISED BED COMBUSTION

FLUIDISED BED When air or gas is passed through an inert bed of solid particles such as sand supported on a fine mesh or grid, the air initially will seek a path of least resistance and pass upward through the sand. With further increase in the velocity, the air bubbes through the bed and the particles attain a state of high turblence. Under such conditions, the bed assumes the appearance of a fluid and exhibits the properties associated with a fluid and hence the name Fluidised Bed. MECHANISM OF FLUIDISED BED COMBUSTION If the sand, in a fluidized state, is heated to the ignition temperature of the fuel and the fuel is injected continuously into the bed, the fuel will burn rapidly and the bed attains a uniform temperature due to effective mixing. This, in short is fluidized bed combustion. While it is essential that temperature of bed should be atleast equal to ignition temperature of fuel and it should never be allowed to approach ash fusion temperature (1050C TO 1150C) to avoid melting of ash. This is achieved by extracting heat from the bed by conductive and convective heat transfer through tubes immersed in the bed. If velocity is too low, fluidization will not occur and if the gas velocity becomes too high, the particles will be entrained in the gas stream and lost. Hence to sustain stable operation of the bed, it must be ensured that gas velocity is maintained between minimum fluidization velocity and particle entrainment velocity. ADVANTAGES OF FBC BOILERS 1. Considerable reduction in boiler size is possible due to high heat transfer rate over a small heat transfer area immersed in the bed. 2. Low combustion temperature of the order of 750C - 900C facilities burning of coal with low ash fusion temperature, prevents NOx formation, reduces high temperature corrosion and erosion, and minimises accumulation of harmful deposits due to low volatilization of alkali components.
3. High sulphur coals can be burnt efficiency without much generation of Sox by feeding limisestone continuously with the fuel. 4. The unit can be designed to burn a variety of fuels including low grade coals like floatation slimes and washery rejects without much sacrifice in operation efficiency, because only about 1% by wt. of carbon content in the bed can sustain the fluidized bed combustion. 5. High turbulence of the bed facilities quick start-up and shut down. 6. Full automation of start-up and operation using simple reliable equipment is possible. 7. Inherent high thermal storage characteristics can easily absorb fluctuations in fuel feed rate. 8. There is reduced possibility of formation of local hot spots on heat transfer surfaces. 9. Though having comparatively low efficiency, fluidized bed coal fired boilers offer the following distinct advantages over pulverized coal fired boilers, especially when using low rank coals:i) High thermal inertia helps to overcome the problems of flame stability. It eliminates the necessity of supplementary oil firing to prevent extinction of flame when moisture and ash content of coal are high. The formation of sticky deposits on the fire side of the tubes because of lowering of ash fusion temperature by sodium components in ash is avoided due to low bed temperature. Lower coal crushing cost due to higher particle size.
ii)
iii)
10. Efficiency of 80% and above can be achieved.
WATER QUALITY REQUIREMENT
WATER QUALITY REQUIREMENT FOR SINGLE DRUM BOILERS DRUM OPERATING PRESSURE (Kg/cm(g)) ABOVE 60
FEED WATER:
SPECIFIC ELECTRICAL CONDUCTIVITY AT 25C MEASURED AFTER CATION EXCHANGER IN THE H+ FORM AND AFTER CO2 REMOVAL. TOTAL IRON TOTAL COPPER TOTAL SILICA OXYGEN HYDRAZINE RESIDUAL pH AT 25C (COPPER ALLOY PRE-BOILER SYSTEM) pH AT 25C (COPPER FREE PRE-BOILER SYSTEM) PERMANGANATE HARDNESS TOTAL CO2 OIL BOILER WATER TOTAL DISSOLVED SOLIDS SPECIFIC ELECTRICAL CONDUCTIVITY AT 25C ppm ms/cm NOT MORE THAN 100 NOT MORE THAN 200 ppm ppm ppm ppm max.
ms/cm ppm ppm ppm ppm ppm ppm
max. max. max. max. max. max.
0.5 0.01 0.01 0.02 0.007 0.01 - 0.02 8.8 - 9.2 9.0 - 9.4 NIL NIL NIL NOT ALLOWED
PHOSPHATE RESIDUAL pH AT 25C SILICA (SEE NOTE : 8)
ppm max.
15 - 25 9.8 - 10.2
ppm
Silica level less than 0.02 ppm in steam leaving the drum.
NOTES:
1. All the measurement of feed water shall be made at high pressure heater outlet or economiser inlet. 2. The recommended pH in feed water can be obtained by dozing ammonia morpholine or any volatile amine. The concentration of volatile chemical in the feed water should not exceed 1 ppm (expressed as ammonia). 3. If the pH of boiler water falls below the recommended range, it increase silica carry over in will considerably
steam and hence suitable lower silica level should be
maintained in boiler water to maintain less than 0.02 ppm in steam leaving the drum. 4. The phosphate and pH are recommended in accordance with co-ordinated phosphate curve to prevent presence of free hydroxide in boiler water. If the recommended pH is consistently obtained phosphate residual can be maintained near lower limits. 5. Water levels in drum should be maintained within limits during all operational modes ie., Start-up, load fluctuation and normal operation. 6. The alignment of drum internal should be checked and ensured to be in order atleast once in every year. 7. It is needless to emphasize that correct sampling, accurate measurements with the use of reliable instruments at adequate intervals and proper logging of reading go a long way in ensuring trouble free operation of boilers. 8. To be controlled on the basis of silica in boiler water and drum pressure and boiler water pH relationship to maintain less than 0.02 ppm in the steam leaving the drum.
WATER TREATMENT
I. SOURCES OF WATER:
Water can be generally classified as: a. Surface water. b. Ground water
a. SURFACE WATER
Surface water comes from streams, ponds, lakes and reservoirs.

b. GROUND WATER
Ground water comes from wells, mines and springs.
II.
IMPURITIES IN WATER:
Impurities in water can be classified into: a) Suspended solids. b) Dissolved solids. c) Dissolved gases. a) SUSPENDED SOLIDS : Clay, silt, Organic matter and micro organisms. b) DISSOLVED SOLIDS. Calcium Salts Magnesium salts Calcium carbonate, calcium bicarbonate, calcium sulphate, calcium chloride and calcium nitrate. Magnesium carbonate, Magnesium bicarbonate, Magnesium sulphate, Magnesium chloride and Magnesium nitrate. Sodium carbonate, Sodium bicarbonate, Sodium sulphate, Sodium chloride and Sodium nitrate.
Sodium salts
Miscellaneous : Dissolved solids
Silica, Iron, Aluminium & Manganese.
Hardness forming salts: Hardness is only due to calcium and magnesium salts.
Carbonate Hardness -
(Temporary hardness)
Calcium Bicarbonate magnesium Bicarbonate (Permanent hardness)
Non-carbonate Hardness : Calcium sulphate Calcium chloride Calcium Nitrate Magnesium sulphate Magnesium chloride Magnesium Nitrate
Silica : Presence of silica in water also gives rise to hard deposits which are as bed as scales. Alkalinity : Alkalinity is due to presence of Bicarbonates Carbonates Hydroxides
M Alkalinity represents Total Alkalinity. P Alkalinity represents Partial Alkalinity. Total Hardness Total Alkalinity a) When H>M H-M When H=M When M>H M-H : H : M Both carbonate and non-carbonate hardness are present Non carbonate hardness (NCH) Only carbonate hardness is present. Only carbonate hardness is present. Sodium bicarbonate.
b) c)
c) DISSOLVED GASES : Oxygen, Carbon-di-oxide and Hydrogen sulphide.
III.
EFFECTS OF IMPURITIES:
A. DISSOLVED SOLIDS AND SUSPENDED SOLIDS: They give rise to scaling and deposition in a given system. They also accelerate corrosion. B. ORGANIC MATTER: This has a greater effect on scale deposition than on corrosion. However, the effect of micro organisms on both deposition and corrosion can be major and must not be overlooked. C. DISSOLVED GASES: They invariably influence the corrosion rate.
IV.
TREATMENT:
Water is purified by External treatment Internal treatment.
EXTERNAL TREATMENT: : For precipitating colloids and setting suspended matter. : To remove suspended matter. : Cold Lime soda process. Hot Lime soda process. Ion Exchange process. Removal of dissolved : Determineralization by Ion Exchange process. Solids Desalination. Electrodialysis. Reverse Osmosis. Clarifiers Filtration Remove of hardness
INTERNAL TREATMENT: A. For Boiler Water Treatment: Water is internally conditioned by the use of chemicals. Chemicals are added to water for the following purposes. 1. 2. 3. 4. 5. 1. Internal softening. Oxygen scavenging. Alkalinity Building. Sludge conditioning. Anti foaming. INTERNAL SOFTENING:
The residual hardness in the feed water should be treated to bring it down to zero. If allowed to concentrate, scales would begin to form. Hardness is taken care of by providing a phosphate treatment. The principle behind it is as follows: Calcium is allowed to react with phosphate and is converted into calcium phosphate which is easily removed by blow down. Phosphate reserves of 30 ppm to 40 ppm is provided in the boiler water. 2. OXYGEN SCAVENGING
Corrosion would be rampant if oxygen in feed water is not removed. This can affect the pre-boiler, boiler and condensate line sections. The removal of oxygen therefore is a must. The concentration of oxygen is dependent on temperatures. Oxygen content is lesser at higher temperatures. Oxygen in water is removed by addition of sodium sulphite. Sodium sulphite reacts with oxygen to form sodium sulphite. We should necessarily provide reserves of sulphite (around 30 ppm) for exigencies. Catalysed sulphite should be used. Hydrazine hydrate can also be used for removal of oxygen. But the speed of reaction is much lesser with hydrazine. Further, it is toxic in nature. However, hydrazine is effective in reducing oxides of copper and iron and is more effective in preventing deposition of corrosion products in feed lines, etc. Hydrazine also helps in removing old corrosion products from boiler internals and helps to maintain a uniform Fe3O4 layer on internal boiler surfaces. Reserves of 0.1 to 0.2 ppm of hydrazine should be maintained.
3.
ALKALINITY:
Alkalinity is necessary for the following reasons : a. To prevent Magnesium to Magnesium Hydroxide sludge which is easily removed by blow down. If Magnesium is allowed to react with phosphate Magnesium phosphate, a thick slimy sludge will be formed, which is as bad as a scale. Therefore OH alkalinity is provided whereby Magnesium preferably reacts with it to form Magnesium hydroxide. To minimize solubility of iron. It keeps silica in solution. i.e, it reacts with silica and forms a complex silicate compound which will remain in solution and will precipitate. NOTE : Excess alkalinity should be avoided as it will give rise to caustic embrittlement. 4. SLUDGE CONDITIONING: Sludge conditioning is a must and must be provided in boiler water. The sludge that is formed should be kept in suspension so that it is removed easily during blow down. If the sludge is not conditioned, it would deposit on the tubes and drums. This will serve as nuclear for scale formation. Sludge conditioning can be achieved by the use of chemical sludge conditioners. 5. ANTIFOAMING: Foaming is said to occur when the steam space in the boiler is partially filled with unbroken steam bubbles. Foaming is caused by impurities in the water preventing the free escape of steam as it rises to the surface or by and oily scum on the surface on the water. This surface scum may be caused by oil, organic matter or any suspended matter in the water. Remedy : 1. 2. 3. To provide an anti foaming agent. Provide enough blow down to avoid excessive concentration of salts. Treatment and filtration of the water to remove solid impurities.
b. c.
Priming : Priming is carrying over of water slugs with the steam. The causes are the same as that of foaming. But it may occur even with perfectly pure feed water itself. a. b. c. The steam space is too small. If the boiler is operated way above its normal capacity. If the water level is carried too high.
Remedy : 1. To avoid priming, all main stop valves on boilers and steam lines should be opened very slowly and water in the boiler should not be carried above its normal level. Boiler design should be corrected to increase the steam space.
2.
Summary : 01. Internal Softening Provide phosphate treatment to take care of residual hardness. (Provide 20-40 ppm of phosphate reserves) Avoid high PO4 Introduce an oxygen scavenger like catalysed sodium sulphite to remove completely dissolved oxygen. Provide 20-30 ppm of sulphite reserves. Provide 200 ppm of OH Alkalinity in boiler water. Sludge should be conditioned with the help of a sludge conditioner. Antifoam should be incorporated in the chemical treatment to take care of foaming. Guard against mud, silt, oil, process contaminants, etc. Provide filteration for raw water if necessary. Control blow down properly to keep sludge accumulation under control and to avoid excessive TDS concentration.
02.
Oxygen Scavenging
03. 04. 05. 06. 07.
Alkalinity Sludge conditioning Antifoam Suspended Solids Blow down
CONVERSION TABLE FOR SPECIFIC CONDUCTANCE TO TDS AT 25C (11F) uS 5 10 15 20 25 30 35 40 50 60 70 80 90 100 110 170 180 190 200 220 240 260 280 TDS 3 6 8 11 14 17 20 23 26 35 40 47 53 59 64 104 110 116 121 136 148 160 173 uS 300 350 400 450 500 550 600 650 700 750 800 850 900 960 1000 1300 1400 1500 1600 1700 1800 1900 2000 TDS 188 218 251 284 320 347 376 402 428 462 495 530 564 623 660 858 923 975 1000 1145 1195 1205 1315 uS 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 8000 8500 9000 9500 10000 12000 14000 16000 TDS 1485 1647 1795 1950 2085 2200 2395 2530 2685 2855 3010 3180 3335 3505 3675 6115 6600 7045 7525 7857 9850 11805 11900
BASED ON CONDUCTANCE OF SODIUM SULPHATE SOLUTIONS
OXYGEN CONTENT AT VARIOUS TEMPERATURES

Oxygen content ppm 4.9 4.4 3.9 3.6 3.0 2.6 Oxygen content ppm 2.4 2.0 ----1.1 0.7 0.3
Temperature Temperature F C 135 145 155 165 175 180 57.2 62.8 68.3 73.9 79.4 82.2
Temperature Temperature F C 185 190 ----200 205 210 85.0 87.8 ----93.3 96.1 98.9
Deaerator pressure Psi 0 2 5 7 10

Max. Oxygen content (ppm)
Temperature F 212 218 227 237 239 0 205 212 221 227 235 0.7 197 204 215 221 230 1.4 188 195 208 215 224 2.2 178 186 200 208 218 2.9 164 175 191 200 211 3.6 148 162 180 190 204 4.3 133 149 169 181 196 5.0 118 134 159 170 185 5.7
WATER TREATMENT SUPPLIER ADDRESSS
M/S. ANCO INDIA CHEMICALS (P) LTD, PLOT NO. 1/1A, U.R. NAGAR EXTENSION, JAWAHARLAL NEHRU ROAD, ANNA NAGAR WEST EXTENSION, CHENNAI 600 101.
M/S. AQUA CONTROLS & SYSTEMS 2/33, D-TYPE SIDCO NAGAR, VILLIVAKKAM, CHENNAI 600 049.
M/S. EFFIMAX ENGINEERS, PLOT NO. : 5107, IST FLOOR, 12TH MAIN ROAD, ANNA NAGAR, CHENNAI 600 040.
M/S. ION EXCHANGE (INDIA) LTD, ION HOUSE, 42, B.N. REDDY ROAD, T. NAGAR, CHENNAI 600 017.
M/S. SURAJ CLEAR WATER SYSTEMS, 12, IIIRD STREET, THIRUMURTHY NAGAR, NUNGAMBAKKAM, CHENNAI 600 034.
METHODS OF WATER ANALYSIS

CONTENTS
1.
SAMPLE COLLECTION - PRECAUTIONS
2.
USE OF INSTRUMENTS GENERAL INSTRUCTIONS.
3.
DETERMINATION OF HARDNESS
4.
DETERMINATION OF P & M ALKALINITY
5.
DETERMINATION OF SULPHITE
6.
DETERMINATION OF DISSOLVED OXYGEN MORE THAN 0.1 PPM
7.
DETERMINATION OF TOTAL DISSOLVED SOLIDS.
8.
DETERMINATION OF OIL
9.
DETERMINATION OF pH
10.
DETERMINATION OF TOTAL SILICA
11.
DETERMINATION OF ORTHOPHOSPHATE

SAMPLE COLLECTION - PRECAUTIONS
Proper sampling procedure is equally important as the actual investigation to ensure reliable measurements. As a matter of principle, water for testing should be sampled by the actual person responsible for the examination or atleast by someone familiar with the plant and suitably instructed. Sampling lines are to be kept continuously flowing. Sampling and cooling water lines should be free from choking and sampling lines to be purged for about 30 minutes everyday as a routine and whenever choking is suspected. To avoid contamination of cooled samples, they are to be collected in dust-free atmosphere. Cooling water contamination of samples is to be prevented. The sampling rate should be of not less than 25 kg/hr and sample temperature shall not exceed about 40C. The container used for collecting samples should be made of polythene or polyethylene. Before collecting samples, rinse the container atleast 3 times. After collecting the samples, rinse the stopper and tightly close the container.
USE OF INSTRUMENTS - GENERAL INSTRUCTIONS

SPECTROPHOTOMETER The following instructions shall be followed to ensure the accuracy of spectrometric
determinations. 1. The spectrophotometer used for colorimetric determinations is to be calibrated atleast once in six months. 2. The temperatures of both sample solution and calibration solution shall be nearly equal to each other. (Preferably within the range 20C to 25C). To obtain this temperature, the sample shall be externally cooled with ice.
3. 4.
Same optical cell is to be used for calibration and measurement. For the determination of the various constituents, individual graphs are to be prepared with standard solutions.
5.
The straight line portion of the curve which represents linearity only is to be used.
6.
Solutions of higher concentrations are to be diluted suitably so that the concentrations can be measured within the linear portion of the graph.
7.
Suppliers other operation instructions shall also be followed.
OTHER INSTRUMENTS The general operating instructions supplied along with instruments shall be followed.
DETERMINATION OF HARDNESS
I. INTRODUCTION 1. TOTAL HARDNESS Calcium and magnesium ions in water are sequestered by the addition of sodium ethylene diamine tetra acetate. The end point of the reaction is detected by means of an indicator, chrome-black Tat an optimum pH of 10.0 10.4 which has a wine red colour in the presence of calcium and magnesium and a blue colour when they are sequestered. 2. CALCIUM HARDNESS Calcium ions in water are sequestered by addition of EDTA. The end point of the reaction is detected by means of an indicator, murexide which is dark purple in the absence of calcium but which with calcium forms a light salmon red complex. The optimum pH range is about 10.4.
II.
PROCEDURE 1. TOTAL HARDNESS a. Pipette 50 ml of the sample into a white procelin casserole. If
necessary adjust to pH7 10 kg using ammonium hydroxide of HCL. b. c. Add 0.5 ml of buffer solution and mix by stirring. (The pH of this solution should be between 10 10.2) Add approximately 0.2 gms of dry chrome black T indicator to produce the required depth of colour. The titration with EDTA should proceed immediately upon addition of the chrome black T. d. If hardness is present the solution will turn red. Standard EDTA solution is added slowly with continuous stirring until the end point is read which is pure blue colour with no reddish tinge remaining. Further addition of EDTA will produce no further colour change. 2. CALCIUM HARDNESS a. b. Pipette 50 ml of the sample into a white porcelain casserole. Add 2 ml of 4% NaOH solution and stir. (The pH of this solution should be above 10.4) c. d. Add approximately 0.2 gms of calcium (Murexide indicator). Add standard EDTA solution slowly with continuous stirring until the colour changes from salmon pink to orchid purple.
CALCULATION 1. 2. 3. III. Total hardness (as ppm CaCO3) Calcium hardness (as ppm CaCO3) = ml std EDTA soln x 20 = ml std EDTA soln x 20
Magnesium hardness (as ppm CaCO3) = Total hardness (as ppm CaCO3) minus calcium hardness (as ppm CaCO3)
REAGENTS 1. Standard calcium chloride solution (1 ml equals 1 mg CaCO3) Dissolve 1.00000 gm of reagent grade calcium carbonate containing less than 0.04% MG (dry at 110C for one hour) in 10 ml 1:1 Hydrochloric acid, without spattering, dilute exactly to one litre and transfer to a clean dry glass stoppered bottle for storage (or use a commercially prepared standard). 2. Buffer solution 350 ml ammonium hydroxide (conc.) + 54 gms ammonium chloride + 20 ml magnesium complex solutions are mixed and made up to one litre with distilled water. Magnesium complex solution is prepared as follows. 4.1 gm of MgO (analar) is mixed with 37.2 gms of EDTA and dissolved in 410 ml of warned distilled water. 3. Calcium Indicator Murexide : Grind 0.2 gm ammonium purpurate (murexide) with 100 gms of sodium chloride to 40 to 50 mesh size. 4. Chrome Black T Indicator Grind 0.2 gms of chrome black T powder with 80 gms of powered Nacl and store in a dark chloride bottle.
5. Standard EDTA solution Weight 4.0 gms of di sodium di hydrogen EDTA di hydrate and dissolve it in 800 ml water. Adjust to pH 10.5 with 5% NaOH. To standardize, pipette 25 ml of standard Cacl2 solution (prepared above) and add ammonium hydroxide (1 : 4) solution to obtain to obtain a pH of 10 to 10.4 add 0.2 gms of chrome-black T indicator. Titrate with EDTA solution according to the procedure above. This EDTA solution should be equivalent to more than 1 mg of CaCO3 per ml. Let V = the volume of standard EDTA solution required to titrate 25 ml of standard CaCl2 solution. Then 25 ml CaCl2 / V (times volume of EDTA to be diluted) = volume to which EDTA must be diluted. Using volumetric pipettes and / or burettes make the required dilution, mix well and restandardize as a check. The use of a factor is also satisfactory. This solution should be stored in polyethylene bottles and restandardized monthly. 6. Sodium hydroxide solution (4%) Dissolve 4.0 gms of NaOH in water and dilute to 100 ml. IV. GLASS WARES 1. Titration apparatus outfit, consisting of automatic zeroing 10 ml burette with reservoir bottle. 2. 3. 4. 50 ml measuring cylinder 1 No. White porcelain casserole with a glass stirrer. Stop cock lubricant.
DETERMINATION OF P&M ALKALINITY

THEORY OF TEST This test is based on the determination of the alkaline content of a sample by titration with a standard acid solution. In this measurement, the end points are taken of change in the colour of organic indicators phenolphthalein (approx. pH 8.3) and methyl orange (approx. pH 4.3) represent definite points to which the alkalinity of the sample has been reduced by the addition of the standard acid solution. APPARATUS REQUIRED 1 Burette, automatic, 25 ml or ordinary 1 Casserole, porcelain 250 ml 1 Cylinder, graduated, 50 ml 1 Stirring rod, glass. CHEMICALS REQUIRED Sulphuric acid, N/50 Phenolphthalein indicator Methyl orange indicator Methyl purple indicator PROCEDURE FOR TEST Measure a clear 50 ml sample of water in the graduate and transfer to the
casserole. Add 4 or 5 drops of phenolphthalein indicator. If the sample is an alkaline water, such as usually is the case with the boiler water, it will turn red. If the sample is a raw or natural water, it usually will remain colourless, Add the standard N/50 sulphuric acid from the burette drop by drop to the sample in the casserole, stirring constantly until the point is reached where on drop removes the last trace of red colour and the sample becomes colourless. Stop and record the total number of ml to this point as the P reading.
Add 4 drops of methyl orange indicator (if no red colour developes on the addition of the phenolphthalein indicator to the original sample, the titration may be started with the methyl orange indicator at this point). Continue adding the acid drop by drop until one drop changes the colour from a yellow to a salmon-pink. Record the final burette reading as the M reading. This is a more difficult end point and some practice may be required. The general tendency is to add too much acid. If too much acid is added, the sample will change from a salmon-pink to definite red. Record the titration to P point and the total titration to the M point as the P and M readings respectively. (Note that the M reading will always be greater then the P reading in as much as the P reading is included in the M reading.) CALCULATION OF RESULTS FORMULA 1000 ppm alkalinity as Ca CO3 = ml N/50 sulphuric acid x -------------ml sample Using a 50 ml sample, the phenolphthalein alkalinity in parts per million as CaCO3 is equal to the ml of N/50 sulphuric acid required for the P reading multiplied by 20. The methyl orange alkalinity is equal to the ml of N/50 sulphuric acid required for the M reading multiplied by 20. LIMITATION OF TEST It is preferable to express the results of the alkalinity determination in terms of P and M alkalinity as above. However, results are sometimes calculated in terms of bicarbonate, carbonate and hydrate on the assumption that titration to the P and point is equivalent to all the hydrate and one half the carbonate alkalinity and that the titration to M is equivalent to the total alkalinity. Many factors such as the presence of phosphate silica, organic and other buffers affect this titration and the calculation of the form of alkalinity present may be in error. Under normal circumstances in plant control, expression of results as P and M alkalinity is entirely satisfactory and is to be preferred from the standpoint of simplicity.
DETERMINATION OF SULPHITE
This method is designed primarily for the routine control of boiler feed waters subject to sulphite treatment. Reductants like sulphite and certain heavy metal ions react similarly to sulphite. Copper catalyzes the oxidation of sulphite on exposure to air especially at warm temperatures. REAGENTS Standard Potassium Lodate Titrant Dissolve 0.566 g KIO3 dried at 120C and 0.5 g NaHCO3 in distilled water and dilute to 100 ml. The equivalent of this titrant is 1.0 mg Na2SO3 per 1.00 ml. Potassium iodide solution 50 g per litre. Dissolve 50 mg of iodate free Kl and 0.5 g of sodium bicarbonate (NaHCO3) in freshly boiled and cooled water and dilute to one litre. Starch indicator. Hydrochloric Acid 1 + 1 PROCEDURE Place 10 ml 1 + 1 HCL in a 250 ml flask. Rapidly add 100 ml sample submerging the pipette tip below the acid surface to minimize air exposure. After adding 1 ml starch indicator solution and 5 ml Kl solution titrate with standard KlO3 titrant to the first appearance of a persistent blue colour. Determine the blank titration by carrying 100 ml distilled water through the complete procedure. SO3 milligrams per litre = (a-b) x 6.35
Na2SO3 milligrams per litre = (a-b) x 10 Where A = milliliters of titration for sample B = milliliters of titration for blank.
APPARATUS REQUIRED 1. 2. 3. 4. 5. 6. 250 CC Erlenmeyer flask 10 CC pipette (for 1 : 1 HCL) 100 ml pipette (for the sample to be measured) 1 ml pipette (for starch indicator) 5 ml pipette (for Kl solutin) 50 ml burette (for KlO3 titrant)
DETERMINATION OF DISSOLVED OXYGEN WATERS CONTAINING MORE THAN 0.10 PPM

I. SAMPLING
IN
INDUSTRIAL
It is important to use air tight connections in all apparatus used for sampling and testing. When sampling hot water a water cooled coil should be introduced into the sampling line. A convenient arrangement for sampling for feed water is shown in the figure. The sample itself should be taken in a 500 ml winkler flask containing a few glass beads, as shown in figure and water should flow through for atleast 10 minutes before taking the actual sample so as to displace all traces of air. Care must be taken to see that air bubbles do not form around the stopper of the winkler flask while sampling. II. 1. REAGENTS REQUIRED Manganous chloride Dissolve 400 gm of Manganous chloride (AR) in one litre. 2. Alkaline iodine Dissolve 600 gm of Potassium Hydroxide and 140 gm of Potassium iodide in one litre of water.
3.
N / 100 Sodium thiosulphate Dissolve 2.482 gm of AR sodium thiosulphate (Na2S2O3 5H2O) in water and make up to one litre. preserve the solution. Add about 1 gm of AR sodium carbonate to
4.
Sulphuric Acid 1 : 1 Add 250 ml of conc. Sulphuric acid to 250 ml of water. Cool and store.
III.
PROCEDURE By means of the funnel fitted to the Winklers flask add 2 ml of the manganous chloride solution and then add 2 ml of the alkaline iodide solution. Mix allow to stand for 10 minutes and then add 2 ml of 1 : 1 H2SO4. Take 250 ml of the sample and titrate the liberated iodine with N/100 thiosulphate solution using starch as indicator. Millilitre of N/100 thiosulphate used for 250 ml sample x 0.224 = ml of oxygen / litre 1 ml of oxygen / litre = 1.430 mg / litre.
IV.
GLASSWARES 1. Winkler flask arrangement as shown in the figure. 2. 2 ml pipette. 3. Burette 50 ml 1 No.
DETERMINATION OF EVAPORATION (T.D.S.) IGNITION RESIDUES AND VOLATILE MATTER

a) Evaporation residues at 105C apparatus required. 1, 2. 3. 4. 5. 6. 200 CC. capacity platinum evaporation dish. 100 CC. 200 CC. pipettes to measure water to be tested. Water bath. Drying over. Dessicator. Ignition furnace.
PROCEDURE 100 CC or possible a greater quantity of the water to be tested (filter if suspended solids are present estimate separately suspended solids content) is evaporated in a platinum dish on a water bath until it is dry after which it is dried down to constant weight in a drying over at 105C. It is weighed after cooling in the dessicator. b) Determining the ignition residues The evaporation residue determined at 105C as described above is ignited in an ignition furnace at 600 25C until constant weight. Cool in the dessicator and weigh. Constant weight shall be considered as attained when the change in weight of the dish plus residue shall be not more than 0.5 mg between two successive operations involving heating, cooling in a dessicator and weighing. c) Determining the volatile matter Record the loss in weight in the previous determination as weight of volatile dissolved matter. CALCULATIONS Total dissolved solids ppm A/W x 1000 Ignition residue ppm B/W x 1000 (A B) Volatile matter ppm ---------- x 1000 W Where, A B (A-B) W = = = = mg of dissolved matter. mg of ignition residue mg of volatile matter (CC) weight of sample used.
DETERMINATION OF OIL INDUSTRIAL WATERS CHLOROFORM EXTRACTABLE MATTER

THEORY OF TEST This test determines the substances which are extractable by chloroform and is not a test specific for oil. Heavy oils, fats and certain other organic compounds will be measured by the test. Following evaporation to dryness of the chloroform extract, the residue is weighed. CHEMICALS REQUIRED Hydrochloric acid (1 : 9) Chloroform, redistilled PROCEDURE FOR TEST Procedure for collecting the sample collect approximately 900 ml of sample in a glass container such as a wide-mouth, 1000 ml Erlenmeyer flask. The sample should be collected directly in the flask and not transferred from another container. Glass stoppers or caps covered with aluminum foil should be used. The flask should be weighed prior to collection of the sample. Procedure for Determination Weigh the flask and its contents to the nearest 1 gram and obtain the weight of the sample by difference. Withdraw a few drops of the sample, determine pH and adjust to between pH 3.0 and 4.0 by hydrochloric acid (1 : 9). Add 100 ml of chloroform to the flask and agitate by means of shaking machine or mechanical stirrer for 15 minutes. After separation, transfer the chloroform layer by a glass siphon to a 500 ml separate funnel. No lubricant should be used on the funnel stopcock. Add 50 ml of chloroform to the flask and repeat agitation for 15 minutes. Then transfer this second portion of chloroform to the separate funnel. Draw off the chloroform layer through a dry, fat-and-oil-free filter paper into a 250 ml breaker. It there is suspended matter at the interface, leave about 2 ml of the chloroform layer the funnel. Add 20 ml portion of fresh chloroform directly to the funnel shake and then withdraw the chloroform, using it as a wash for the filter.
Evaporate the chloroform on a boiling water bath to about 20 ml then transfer quantitatively to a weighted platinum or silica evaporating dish. If the source of the water sample was at or above 212F. Continue evaporation to dryness on the boiling water bath. If the sample was from a source below 212F, again reduce the volume to about 20 ml on the boiling water and then continue evaporation at room temperature. Weigh until constant weight is obtained. CALCULATION OF RESULTS Chloroform extractable matter ppm = 1000 weight increase of evaporating dish, mg x -------------ml sample LIMITATIONS OF TEST With proper technique, an accuracy of 1.0 ppm or 2% which ever is greater can be obtained. The method does not determine lighter hydrocarbons which volatilize under the test conditions. Substances other then oil are included as chloroform extractable matter. While this procedure is based on ASTM method D1178 -54T, that method should be consulted if it is desired to conduct the test in exact conformity to ASTM standards. APPRATUS REQUIRED 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. A well-equipped laboratory Wide mouth 1000 ml Erlenmeyer flask. Balance capable of weighing upto 1 kg with an accuracy of 1 gm. pH meter. 100 ml measuring cylinder. Shaker or mechanical stirrer. 500 ml separating funnel Glass syphon Oil free filter paper 250 ml beaker. Funnel with filter stand. Water path suitable for heating (thermostat) Platinum or silica evaporation dish.
DETERMINATION OF pH VALVE
INTRODUCTION As a yard stick for the concentration of hydrogen ions, the pH value gives an indication of the percentage reaction (alkalinity or acidity) of the water and hence its aggressivity. The pH value is the negative logarithm to the base 10 of the hydrogen ion concentration, expressed as gram ions per litre. The pH value of a given solution depends on the temperature and as a rule it is quoted for 20C. At this temperature the pH value ranges from 0 to about 14. Water with pH=7 has a neutral reaction, while there is an acid reaction at pH<7 and a basic reaction at pH>7. APPARATUS REQUIRED 1. 2. A pH meter with associated glass and reference electrodes. Buffer table of kwown pH.
ELECTROMETRIC DETERMINATION OF pH VALUE With the electrometric method, the pH value is determined from the potential difference between the measuring electrodes immersed in the liquid under test and a reference electrode of known potential for testing water electrode assemblies comprising a glass electrodes and a calomel reference electrode are suited. pH meter is to be operated in accordance with the instruction supplied with it, by its manufacturer. To ensure accurate measurements, air must be prevented from getting to the sample, since pH value may be strongly influenced by atmospheric contaminants. Where water is very pure and the pH value and electrical conductivity are being determined simultaneously, make sure that the pH electrodes are inserted AFTER the conductivity electrodes if the measuring points are connected in series. ELECTRODE TREATMENT New glass electrodes and those that have been stored dry shall be conditioned and maintained as recommended by the manufacturer. If the assembly is in intermittent use, keep the immersed ends of the electrodes in water between measurements. For prolonged storage, glass electrodes may be allowed to become dry, but the junction and filling openings of reference electrodes should be capped to reduce evaporation.
STANDARDISATION OF ASSEMBLY Turn on the instruments, allow it to warm up and bring it to electrical balance in accordance with the manufacturers instructions. Wash the glass and reference electrodes and the sample cap by means of a flowing stream of distilled water from a wash bottle. Note the temperature of the test solutions and adjust the temperature dial of the meter to correspond. Select the two reference buffer solutions, the pHs values of which are close to the anticipated pH of the test solution. (Buffer solutions can be prepared from the buffer tablets following manufacturers instructions). Warm or cool these reference solutions as necessary to match within 2C the temperature of the unknown. Fill the sample cup with the first reference buffer solution, and immerse the electrodes. Engage the operating button, turn the range switch if present to the proper position and rotate the assymmetry potential knob until the reading of the dial corresponds to the known pH of the reference buffer solution. Repeat the above procedure until two successive instrument readings are obtained, without changing the setting of the assymmetry potential knob. Care should be taken to see that the level of the KCI solution in the reference electrode must always be kept within that of the measured solution. To reduce the effects of thermal and electrical hysteresis, the temperature of electrodes, reference buffer solutions and wash water should be kept as close to that of the unknown sample as possible. Wash the electrodes and sample cum three times with water. Place the second reference buffer solutions in the sample cup and measure pH by simply reading the dial. Do not change the setting of assymmetry potential knob. The assembly shall be judged to be operated satisfactorily if the pH reading obtained for the second reference buffer solution agrees with its assigned pH value with in 0.05 unit. In long series of measurements, supplement initial and final standardisations by interim checks. Wash the electrodes by means of a flowing stream from a wash bottle. Place the water sample in a clean glass beaker. Measure the temperature. Insert the electrode and measure pH as before. INSTRUCTIONS pH meter should be checked for its performance using buffer tablets atleast once a shift.
DETERMINATIONS OF TOTAL SILICA IN HIGH PURITY WATER

INTRODUCTION Some boiler stations using ion exchange columns of preboiler water purification have noticed silica concentrations building up in the units and at the same time a soluble silica analysis on water coming from the ion exchange column showed no silica. Analysis for colloidal silica on these same samples showed that the silica was present as a colloidal particle. This technique has been developed as an analytical procedure to accurately determine trace concentrations of silica where all or a part is present in colloidal form. Total silica is determined spectrophotometrically after solubilization by the pressurized bomb method. (Paar oxygen bomb). PROCEDURE 1. Accurately measure 50 ml or a suitable aliquot of the sample into a platinum cup. Add 1 ml of 0.2 N NaOH and close the cup with a platinum cover. Place the closed cup in a paar oxygen bomb containing 100 ml of deionized water and completely assemble the bomb. Nitrogen is added to obtain 30 pounds pressure and let out five times to completely, flush out oxygen in the bomb to prevent bomb corrosion. Pressurize the bomb with nitrogen to 45 psig (maintained for specified period) and place in an oven at 190C for 8 hours. The oven should be placed in a hood since all gaskets in the bomb are made of Teflon. Remove the bomb from the oven, cool and remove the sample from the platinum cup. Silica is determined spectrophotometerically by using the applicable high or low range method.
2. 3.
4.
5.
6.
CALCULATION 1. 2. See silica curve for the spectrophotometer used. Colloidal silica (ppm) = Total silica (ppm) - soluble silica (ppm)
APPARATUS REQUIRED 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 25 ml Pipette 50 ml Pipette for suitable aliquot sample. 10 ml Pipette Platinum cup with cover. Oxygen bomb. 1 ml Pipette (for 0.2 N NaOH solution) 10 ml Pipette (for deionized water) Nitrogen cylinder with pressure regulator opener etc. AIR OVEN to be capable of giving a temp, of 190C for 12 hours continuously. Spectrophotometer at 815 nm.
DETERMINATIONS OF ORTHOPHOSPHATE INDUSTRIAL WATER ASTM : D515-68

INTRODUCTION This method is applicable to the routine determination of orthophosphate in the 2 25 ppm PO4 range in industrial water and is based on the photometric measurement of the yellow colour of the molybdo vanadophosphoric acid produced. The colour intensity is proportional to the orthophosphate concentration in the sample. Highly coloured water such as tannin treated boiler water and high concentration of ferric iron interfere thus requiring preliminary treatment to remove these materials. PROCEDURE 1. To a 125 ml Erlemeyer flask, using a pipette or volumetric flask, add 50 ml. of the clear sample or a liquit there of diluted to 50 ml. with deionized water. The sample must be free of suspended matter to avoid arroneous high results. Filtration using what man no. 42 filter paper has been found to be satisfactory in most cases. Add, using a graduate, 25 ml of ammonium vanadomolybdate solution and mix well by swirling. Allow 10 minutes for colour development and read within 30 minutes on the spectrophotometer at 400 mm. Reagent blank and atleast two phosphate standards should be run along with samples.
2.
3.
4.
CALIBRATION AND STANDARDIZATION 1. Prepare a series of standards to cover the range 0-25 mg/litre (ppm) and prepare calibration curve. REAGENTS 1. Ammonium vanadomolybdate solution Dissove 40 grams of ammonium molybdate tetrahydrate (NH4)6MO7O244H2O) in 400 ml. of water. Dissolve 1.0 gram of ammonium metavanadate in 300 ml of water and add 200 ml concentrated nitric acid (SP. GR. 1.42). Add the first solution to the second solution mix well, and dilute to 1 litre with water in a volumetric flask. 2. Phosphate standard solution (1 ml = 1 mg PO4) Dissolve 1.433 grams of oven dried (4 hours at 105C )C.P. potassium dihydrogen phosphate (KH2PO4) in water and dilute volumetrically to one litre. APPARATUS REQUIRED 1. 2. 125 ml Erlenmeyer flask. 50 ml Pipette 25 ml Pipette 10 ml Pipette
for suitable aliquot sample.
3. 4. 5.
Filter stand with funnel, 42 what man filter paper etc. 25 ml Pipette (for ammonium vanadomolybdate solution) Spectrophotometer at 40 nm.
PROCEDURE FOR HYDROSTATIC TESTING
PROCEDURE FOR HYDROSTATIC TESTING
The system components have been hydrostatically tested to (1-1/2) times the design pressure in the factory. piping should However, the complete system, along with all interconnecting comply with code that might have resulted during shipping and be hydrostatically tested before start-up to
requirements and to check for leaks with water.
handling. The boiler and process lines must be completely vented in order to fill them
The following is a recommended procedure for hydrostatic testing: 1. Open the steam drum vent valve and close steam outlet valve. 2. The boiler safety valve stubs are plugged with end plates and sent as a dummied stub. Hence this end plate have to be cut and removed after hydrotest and the safety valves are to be buttwelded. 3. For subsequent hydro test if any and for every annual hydro testing gag the safety valves in accordance with safety valve manufacturer's recommendations. In lieu of gagging, the safety valves may be removed and replaced with test plugs or blind plates. 4. Isolate pressure switches, gauge glasses or control components which are
not intended to be subjected to a hydrostatic test. 5. Fill the system with treated water in accordance with recommended CVPL's water quality. The temperature of water used shall not be less than 20C and greater than 50C. 6. Once the system is filled and the pressure is approximately 1 kg/cm, close all vents. The pressure may then be increased gradually to the test pressure requirement of the local steam boiler inspecting agency. Do not subject any pressure part to more than 1-1/2 times the design pressure rating of the component.
7. Examine the system for any leaks. If no leaks are visible, hold the system in a pressurised static condition for a period of 1/2 hour to satisfy the code requirements. 8. After that the pressure shall be reduced to maximum allowable working pressure and maintained for sufficient time to permit close visual inspection for leakage of pressure parts. 9. Upon completion of the test, release pressure slowly through a small drain valve. Then fully open the vents and drains when the pressure drops to 1 Kg/cm2(g). Particular care must be given to make sure that parts not normally containing water during operation are drained free of water. The system should be drained fully after hydrostatic testing to prevent freezing, if the unit is installed in a cold weather area, and to minimize corrosion of the metal surfaces. 10. If temporary handhole or manhole gaskets were used for the test, they should be replaced with regular service gaskets before reading the unit for operation. Gaskets should never be reused. Replace gauge glass if necessary and make sure that the gauge cocks are open. Remove all blanks or gags from safety valves and install safety valves, if removed.
PROCEDURE FOR SLOW FIRING
PROCEDURE FOR SLOW FIRING

REFRACTORY DRY OUT:
After the refractory works are finished, the refractory work must be subjected to proper curing and initial heating. These two procedures must be strictly carried out. Otherwise, cracks may occur on the refractory surface. These procedures are explained below.
CURING FOR CASTABLE REFRACTORY:
All the castable are hydraulic setting and need the presence of moisture for setting process, so it is necessary to ensure that the castable does not dry out to exposure or due to heat produced within the mass. It should not be allowed to dry during first 24 hours after it has been placed.
Moist condition has to be maintained by covering the castable with wet gunny sacks or by frequent sprinkling of fine mist of cold water on all exposed surfaces. Sprinkling should be started after the castable has set partially. It is generally advisable to spray water on dense castables every 45 minutes for hours.
INITIAL HEATING FOR CASTABLE REFRACTORY:
Proper attention should be given during initial heat up of castables, as they have considerably lower permeability when compared to brick. It is more difficult for the water to passthrough the castable and escape as the refractory is heated more rapidly. So due to this, high pressure steam is developed inside the brick and this ruptures the lining.
Rapid heating also causes the hot face to dry up and heat up while the rest of castables is still comparatively cool. crack on cold face. This will lead to expansion of hot face and hence develops a
SLOW FIRING PROCEDURE :
Following are to be done before slow firing is started:
a) All the coal nozzles and air nozzles must be fully covered with bed materials.
b) No fans should be operated for the heating purpose. Firing should be done only by natural draught. For this all dampers should be kept open.
c) Sufficient sized fire wood required has to be stocked for the dry out.
The following heat and curing schedule is recommended:
01.
Heat gradually up to 110C and hold at this temperature for six hours.
02.
Then raise the temperature at the rate of 10C per hour up to 550C and hold at this temperature for six hours.
03.
After this, the furnace can be cooled naturally.
Slow firing can be done by burning sized waste wood in the furnace on the bed material. The fuel required shall be computed as if the boiler would be operated to generate the manhole. 20% MCR load. The sized wood can be fed in the furnace through
PROCEDURE FOR ALKALI BOILOUT
PROCEDURE FOR ALKALI BOILOUT

1. Check boiler erection work is completed with all assemblies, valves, fittings and necessary instrumentation. 2. Boiler auxiliaries such as fans, feed pumps should have been trial run and made ready for operation. 3. Check boiler instrumentation and control panel are ready for regular operation. But the following instruments are to be isolated for alkali boilout. I) ii) 4. 5. 6. 7. 8. Flow, pressure and level transmitters. Pressure switches.
Ensure steam drum internals have been fixed in position. Check all the refractory and insulation work are completed. Check all scaffolding, temporary supports, debris are cleared. Ensure slow firing is done as per the slow firing procedure. Check suitable fire fighting equipments such as Co2 or foam type fire
extinguishers, sand buckets, etc, are available at suitable convenient places. 9. 10. Check boiler chemical feeding system is ready for operation. Check sufficient quantity of chemicals are available. Based on the water
volume of the boiler the chemicals required can be estimated. If water volume of the boiler is Q M^3 each chemicals required will be 4 x Q kgs. The same quantity of chemicals will be required for each boil out. 11. For alkali boilout sodium carbonate and trisodium phosphate are used.
12.
Prepare
20% concentrated solution of the
chemicals separately
in a
drum and the solution is charged in to the boiler through the nozzles (either auxiliary steam top nozzle or Air vent nozzle) in to the shell/drum manually by means of funnel. 13. After the addition of chemicals in to the required quantity, the nozzles are covered with the cover flange and fill up water to the normal operating level. 14. Light up the boiler and raise the steam pressure is gradually to 5 ata as per standard operating procedure and maintain the pressure for minimum period of 12 hours. 15. 16. Tighten all glands and flange joints. Raise the firing rate to achieve a boiler loading of nearly of the normal loading rate of the boiler. 17. Samples to be taken every two hours and analysis is to be carried to determine the following: a) b) c) d) e) 18. Ph value Alkalinity Phosphate Oil Silica
Ensure the pre-commissioning activities are carried out as per the commissioning check list.
19.
Ensure
the alkali Boilout is carried out in 3
stages
and fresh chemicals are
changed before each stage.
20.
Ensure the pressure is maintained in the boiler for each stage alkali boilout as follows: DURATION I stage II stage III stage - 5 kg/cm sq. - 7 kg/cm sq. - 10 kg/cm sq. - 12 hours. - 12 hours. - 12 hours.
(Ensure the pressure of the boiler is raised gradually for alkali boilout).
21.
Each stage of boiling can be terminated when the content of oil in the boiler water maintains a steady value. However final reading of oil should be less than 5 ppm.
22.
After termination of boilout procedure, shut down the boiler and allow the unit to cool down gradually.
23.
Drain the boiler after the drum pressure reaches atmospheric pressure. Water jets shall be used to clean the headers.
24.
After complete draining of boiler, clean the complete unit by filling the water and drain it for atleast one time. The handhole pipes of all headers preferably at bottom most point to be cut and inspected for any foreign materials availability and to be cleaned.
25.
After inspection and cleaning reweld the end caps and hydro test the boiler to working pressure.
26.
Now the boiler is ready for steam blowing.
PROCEDURE FOR STEAM BLOWING
PROCEDURE FOR STEAM BLOWING

STEAM BLOWING
Steam blowing is an established practice for the purpose of physically removing any substance which remain deposited in the superheater and associated pipe lines. These substances are mainly scales and loose minerals that might have been entrapped
during manufacture, storage and erection at site.
PRINCIPLE
The principle of steam blowing is to give thermal shock and dislodge the scales. These scales will be subsequently driven out by the dynamic velocity of the expanding steam. Before starting the boiler for steam blowing ensured: the following points are to be
1. Alkali boilout is completed.
2. All the instruments calibration are completed and safety interlocks are in line, except water level interlock which is to be isolated temporarily.
3. NRV and flow nozzle should not be fitted initially and thermowell in steam line is to be removed.
4. All the spring hangers in steam line are loaded properly.
5. Temporary steam line is erected and anchored properly for steam blowing.
6. Target plate fixing arrangement to be kept ready.
7. Required target plates are to be machined and kept ready to fix when required. Target plates shall be of aluminium material.
PROCEDURE :
The method of steam blowing is as below :
1. Operate with one compartment and raise the boiler pressure above 35 kg/cm^2. The bed temperature shall be maintained at about 800-950C.
2. Quickly
open
the main steam stop valve (or
the
temporary blowing valves if
provided). In order to maintain the flow to atmosphere the main steam stop valve is to be kept open till the steam pressure drops down close to 16 kg/cm.
3. Slowly reduce the firing rate and slump the boiler.
The main steam stop valve
shall be closed when the boiler pressure reaches 16 kg/cm . 4. After one hour, the boiler shall be restarted with one compartment and the bed temperature shall be maintained at about 800 - 950C'.
The steam blowing shall be once again started when the pressure reaches 35 kg/cm. By the above procedure, the scale adhering to the contours get cracked due to temperature difference and get removed to subsequent blows.
* SCHEME OF BLOWING
Temporary discharge piping which lead the steam to the atmosphere shall be welded downstream of main steam line must be properly supported and anchored.
OPERATIONAL PRECAUTIONS
1. Normally
the steam blowing operation is the first
occasion to
fire
the unit at
significant rate. The unit must be brought up much slower while all equipments are checked and expansion movements are monitored closely.
2. During blowing, water level in drum gauge glass
may fluctuate
very widely.
Feed regulating station must be checked for proper remote operation. Sufficient quantity of D.M water availability muse be ensured.
3. Flue gas temperature at the inlet of convection 450C.
superheater must be restricted to
4. Temporary discharge piping which should be atleast equal to the diameter of piping to which it is connected must be well supported to withstand reaction forces during steam blowing.
5. Discharge
piping should be so diverted that
personnel
and equipments are not
endangered. The area should be cordoned off.
6. After three free blows, target plate can be fixed.
7. Based on target plate condition as recommended by the turbine supplier blow can be continued or terminated.
8. During blowing sufficient time duration should be given between blows to attain better thermal shock to discharge the scale and other deposits in pressure parts and steam line.
9. After clearing the steam blowing, boiler to be stopped and
steam line to be cooled
to complete the welding of NRV and flow nozzle and thermowell fixing in main steam line.
10. Temporary steam line to be removed and permanent line to be
connected with TG.
11. After completion of the job, the boiler is ready for safety valve floating.
OPERATION ON LOW LOADS
OPERATION ON LOW LOADS
The boiler should not be operated at low loads continuously for long time. If the boiler is run continuously at low loads (<60% MCR load) then due to low quantity of steam flow through the super heater, the super heater tubes may fail. To protect the super heater tube from failure, the boiler should be run at higher loads (>60% load) only and the excess steam over the utilised steam shall be vented continuously through start-up vent.
START UP PROCEDURE FOR OIL BURNER SYSTEM
START UP PROCEDURE FOR OIL BURNER SYSTEM

START UP PROCEDURE:
As this boiler is having start up oil burner system separately to make the start up very convenient.
The total Qty. of charcoal requirement will be approximately 12 - 15% of the qty. of bed material in the start up compartment. As the charcoal addition is done during fluidising condition, the fluidisation will get affected due to the additional weight of charcoal. The drag force required to fluidise the new bed material & charcoal mixture will be more. Hence increasing of air flow by observing the bed condition is a must during charcoal charging. Keeping unnecessarily more air (or) more PA header pressure (ie. above
900 mmwc) may throw the charcoal to the adjacent compartment which will lead to localised clinker formation in the compartment border due to static burning. During this
cold fluidisation study and charcoal charging, the burner combustion air should be kept in open condition to avoid chocking of burner lines.
Start the oil pump and allow the oil to circulate through the return oil line for some time, throttle the oil return line value to increase the oil pressure - 7 to 10 kg/cm2.
Now start the burner one by one as per following procedure.
1. Keep minimum oil and minimum atomising air open.
2. Ignite the burner by swab through the ignition hole.
3. Increase the oil flow and atomising air flow.
4. Observe the flame length and colour. It should be yellowish violet. This is to be achieved by proper adjustment of atomising and combustion air.
In case if flame cut off occurs during start up, immediately that particular burner oil to be stopped and burner light up to be done as per procedure explained above.
All the charcoal which are in fluidised state will get ignited by burner condition for 10 minutes to allow all the charcoal to get fire.
flame.
Keep this
Now decrease the
fluidising air flow little bit to avoid rapid burning of charcoal. Keep this condition for 2 to 5 minutes. Slowly all the bed material will get red hot during this period closely watching of bed condition is a must to avoid quenching of fire in bed and delaying of temp. pick up due to excess air. Now all the bed once it reaches 600C set temperature will increase fastly ,
MCR air flow, for I compartment stop oil pump and
start fuel feeder.
Set optimum feeding and ensure coal catches fire in the start up compartment. Now the bed temperature to be maintained between 850 - 900 C by regulating feeders RPM.
BOILER OPERATING INSTRUCTIONS
BOILER OPERATING INSTRUCTIONS
01.
STARTING OF ALL INDIVIDUAL EQUIPMENTS
02.
STARTING OF BOILER FEED PUMPS
03.
DP STUDY
04.
BED MATERIAL, CHARCOAL & KEROSENE REQUIREMENT
05.
BOILER LIGHT UP
06.
NORMAL OPERATION
07.
NORMAL SHUT DOWN TO COLD
08.
NORMAL SHUT DOWN TO HOT STAND BY
09.
HOT RESTART
STARTING OF ALL INDIVIDUAL EQUIPMENTS
STARTING OF ALL INDIVIDUAL EQUIPMENT
GENERAL
The boiler is provided with interlocks for safe and reliable operation and none of these should be bypassed. The sequence of starting of the equipments is as follows: * 01. 02. 03. 04. Check water level gauge for water in Drum. Start the ID fan. Start the PA fan. Start the FD fan. Start the Fuel feeders.
Similarly while switching off, reverse sequence must be followed. The individual equipment can be started through DCS or from Local Push Button
(LPB). Switch on the power supply to the motor control centre (MCC) panel. The fuses of individual motor controls shall be checked for continuity. Three phase supply of 415 V / 11000 V 50 Hz with allowable before switching on the equipment. percentage of variation shall be ensured
INTERLOCKS
Tiruchirapalli
WRITE UP FOR INTERLOCKS
PROJECT CUSTOMER
: 1 X 36 Mwe CAPTIVE POWER PLANT : M/S. REI AGRO LTD. BOILER NO. REVISION : BG059 :A
SERVICE : 80 TPH SINGLE DRUM WATER TUBE BOILER (FBC)
DOC No. : BG059 -INT-001 SHEET : 01 OF 05
ID FAN MOTOR: (BG059 -00-09-3-035/A)
ID Fan motor can be switched on, only when the following conditions are satisfied. a) b) c) d) e) Normal drum water level ID fan suction damper closed. ID (fan & mot) bearing temperature at drive end not high. ID (fan & mot) bearing temperature at Non drive end not high. Remote selected.
When the ID fan motor comes to the rated speed, it's suction damper can be opened. The ID fan motor shall be wired, such that the motor can from DCS or from Local Push Button (LPBS) . be started / stopped either
The ID fan motor shall be tripped, when the drum level is very high or very low or ID fan motor TOLR is actuated (or) ID (fan & mot) bearing temperature at DE & NDE high.
FD FAN MOTOR: (BG059 -00-09-3-038/A)
FD Fan motor can be switched on, only when the following conditions are satisfied. a) b) c) d) e) PA fan motor running & FD fan suction damper closed. Furnace pressure not high. FD fan bearing temperature at drive end not high. FD fan bearing temperature at Non drive end not high. Remote selected.
When the FD fan motor comes to the rated speed, its suction damper can be opened. The FD fan motor shall be wired, such that the motor can be started / stopped either from DCS or from Local Push Button (LPBS). The FD fan motor shall be tripped, when the PA fan motor is tripped (or) when furnace pressure is high or TOLR is actuated (or) FD fan bearing temperature high.
PA FAN MOTOR: (BG059-00-09-3-050/A)
PA fan motor can be switched on only when the following conditions are satisfied.
Tiruchirapalli
PROJECT CUSTOMER
: 1 X 36 Mwe CAPTIVE POWER PLANT : M/S. REI AGRO LTD.
BOILER NO. REVISION
: BG059 :A
a) b) c) d) e)
ID fan motor running. PA fan suction damper closed. PA fan bearing temperature at drive end not high. PA fan bearing temperature at Non drive end not high. Remote selected.
When PA fan motor comes to the rated speed, its suction damper can be opened. The PA fan motor shall be wired, such that the motor DCS or from LPBs. can be started / stopped either from
The PA fan motor shall be tripped, when the ID fan motor is tripped or PA fan motor TOLR is actuated or PA fan bearing temperature high
PA AIR LINE DAMPERS FOR COMPARTMENT- I TO V (BG059-00-09-3-045)
PA air line dampers has no interlocks and can be opened / closed from DCS only.
FD AIR LINE DAMPERS FOR COMPARTMENT- I TO V (BG059-00-09-3-044)
The FD air line dampers of the respective compartment can be opened from DCS, when FD fan motor running and the PA air line damper of the respective compartment is opened. Closing of FD air line dampers can be done through DCS without any interlocks. AIR BLEED OFF VALVE-I (BG059-00-09-3-046) Air bleed off valve-I will open only when the FD air line damper at compartment-I on closed condition. It will close when FD air line damper at compartment-I on open condition. Similar logic is applicable for air bleed off valve- II, III, IV & V.
NON-INCHING STARTERS (BG059-00-09-3-037 & 064/A)
These motorised valve are suitable for isolation purpose. They have no interlocks and can be switched on either from local or from DCS. Similar logic is applicable for all RDOL NON INCHING starters.
Tiruchirapalli
INCHING STARTERS (BG059-00-09-3-036/A)
PROJECT CUSTOMER
BOILER NO. REVISION
: BG059 :A
These motorized valve are suitable for regulating purpose. They have switched on either from local or from DCS. The position of these valves will be available in DCS. Similar logic is applicable for all RDOL INCHING starters. DRAG CHAIN FEEDERS - I (BG059-00-09-3-042/A)
no interlocks and can be
Drag chain feeders-I can be switched "ON", only when the following conditions are satisfied. a) b) c) d) FD fan motor running. FD air line damper of compartment-I is opened. PA air line damper of compartment-I is opened. Remote selected.
The Drag chain feeders -I motor shall be wired, such that the motor can be started / stopped from DCS or from LPB. The Drag chain feeders-I shall be tripped when the FD fan motor is tripped or FD air line damper compartment is closed (or) PA air line damper of compartment is closed.. Similar logic is applicable for Drag chain feeders II, III, IV & V. DEARATOR OVER FLOW VALVE (BG059-00-09-3-047) It has no interlocks and valve can be opened automatically, when deaerator water level is very high and it will automatically closed, when deaerator water level is normal
SECONDARY AIR SYSTEM DAMPER (BG059-00-09-3-051)
Secondary air system damper has no interlocks and can be opened / closed from DCS only.
Tiruchirapalli
FEED PUMP I (BG059-00-09-3-039/A)
PROJECT CUSTOMER
DOC No. : BG059-INT-001 SHEET : 04 OF 05
Feed pump motor can be switched on, only when the following conditions are satisfied. i) ii) iii) iv) v) Deaerator water level is not very low. DP across suction strainer is not high. Feed pump-I bearing temperature at drive end not high. Feed pump-I bearing temperature at non-drive end not high. Remote selected.
The feed pump motor-I shall be wired such that the motor can be started / stopped either from DCS or from Local push button (LPBS). The feed pump motor-I shall be tripped, when the deaerator level is very low (or) DP suction high (or) bearing temperature high. Similar logic for Feed pump II & III. HP DOSING & LP DOSING AGITATOR, GEAR OIL PUMP I & II, GEARED MOTOR FOR SCREW FEEDER AT BED ASH COOLER, (BG059-00-09-3-049/A) They have no interlocks and can be started / stopped either from DCS or from Local push button (LPBS).
HP DOSING PUMP-I ,II & III (BG059 -00-09-3-040/A)
HP dosing pump-I motor can be switched on, only when the following condition is satisfied. a) HP dosing tank level not low. b) Remote selected. The HP dosing pump-I motor shall be wired, such that the motor can be started / stopped either from DCS or from Local Push Button (LPBS). The HP dosing pump-I motor shall be tripped, when the tank level is low (or) TOLR is actuated.
Tiruchirapalli
PROJECT CUSTOMER
: 1 X 36 Mwe CAPTIVE POWER PLANT : M/S. REI AGRO LTD. BOILER NO. : BG059 :A
SERVICE : 80 TPH SINGLE DRUM WATER TUBE BOILER (FBC) DOC
No. : BG059-INT-001 SHEET : 05 OF 05
REVISION
LP DOSING PUMP-I ,II & III (BG059 -00-09-3-041/A)
LP dosing pump-I motor can be switched on, only when the following condition is satisfied. a) LP dosing tank level not low. b) Remote selected. The LP dosing pump-I motor shall be wired, such that the motor can be started / stopped either from DCS or from Local Push Button (LPBS). The LP dosing pump-I motor shall be tripped, when the tank level is low (or) TOLR is actuated. LIME STONE FEEDERS - I (BG059-00-09-3-043/A) Lime stone feeder-I can be switched "ON", only when the following conditions are satisfied. a) Drag chain feeder-I motor running. b) Remote selected. The Lime stone feeder-I motor shall be wired, such that the motor can be started / stopped from DCS or from LPBS. or from VFD panel. The Lime stone feeder-I shall be tripped when the Drag chain feeder-I motor tripped (or) TOLR is actuated . Similar logic is applicable for Lime stone feeder-II, III, IV & V. POCKET FEEDER - I (BG059-00-09-3-049/A) Pocket feeder-I can be switched "ON", only when the following conditions are satisfied. a) Drag chain feeder-I motor running. b) Remote selected. The Pocket feeder-I motor shall be wired, such that the motor can be started / stopped from DCS or from LPBS. or from VFD panel. The Pocket feeder-I shall be tripped when the Drag chain feeder-I motor tripped (or) TOLR is actuated . Similar logic is applicable for Pocket feeder-II to X.
Tiruchirapalli
PROJECT CUSTOMER
DOC No. SHEET
: BG059-INT-002 : 01 OF 01
BOILER NO. REVISION
: BG059 :A
SOOT BLOWER : (BG059-00-09-3-065 & 066) Following are the Soot Blower provided by as in our boiler: 1-LRSB-1201 - Long Retractable soot blower-I 1-LRSB-1202 - Long Retractable soot blower-II 1-LRSB-1201 comes with Forward and Reverse limit switches, multiple lead timer is required in DCS.
The above soot blowers shall be operated either in auto (or) manual mode as explained below.
MANUAL MODE: The Long retractable soot blower-I at CS heater zone (1-LRSB-1201) should be switched ON, in forward direction. It will operate and it will be switched OFF, when forward limit switch is actuated. Similarly when reverse direction is switched ON, the soot blower will operate and will be switched OFF, when reverse limit switch is actuated. Automatic reversal of soot blower is also done with the provision of a timer. (Timing Adjustable at site). This timer will be actuated as soon as the forward limit switch actuated signal is reed. After, exact time, it automatically switches ON the soot blower and will be switched OFF, when reverse limit switch and actuated. The 1-LRSB-1202 should be manually switched ON and procedure of operation will be as explained before. AUTO MODE: The multiple lead timer will switch on the 1-LRSB-1201 . 1-LRSB-1202 will operate in forward direction followed by time delayed reversal operation. Automatic reversal of soot blower is also done with the provision of a timer. (Timing Adjustable at site). This timer will be actuated as soon as the forward limit switch actuated signal is reed. After, exact time, it automatically switches ON the soot blower and will be switched OFF, when reverse limit switch and actuated. Thus all the soot blowers will work for cyclic mode, based upon the signal from multiple lead timer and sequence of soot blower operation shall be 1-LRSB 1201 as explained above. NOTE: During auto mode of operation the DCS shall be programmed such that, when any one of the soot blower is under maintenance or in non-working condition, then the multi lead timer shall start the next soot blower .
CLICK HERE TO OPEN BOILER INTERLOCK DRAWINGS (BG059)
Tiruchirapalli
PROJECT CUSTOMER
ID FAN MOTOR: (BG060 -00-09-3-030/A)
ID Fan motor can be switched on, only when the following conditions are satisfied.
a) Normal drum water level
b) ID fan suction damper closed. c) ID (fan & mot) bearing temperature at drive end not high. d) ID (fan & mot) bearing temperature at Non drive end not high. e) Remote selected. When the ID fan motor comes to the rated speed, it's suction damper can be opened. The ID fan motor shall be wired, such that the motor can from DCS or from Local Push Button (LPBS) . be started / stopped either
The ID fan motor shall be tripped, when the drum level is very high or very low or ID fan motor TOLR is actuated (or) ID (fan & mot) bearing temperature at DE & NDE high.
FD FAN MOTOR: (BG060 -00-09-3-033/A)
FD Fan motor can be switched on, only when the following conditions are satisfied.
a) PA fan motor running & FD fan suction damper closed.
b) c) d) e)
Furnace pressure not high. FD fan bearing temperature at drive end not high. FD fan bearing temperature at Non drive end not high. Remote selected.
When the FD fan motor comes to the rated speed, its suction damper can be opened. The FD fan motor shall be wired, such that the motor can be started / stopped either from DCS or from Local Push Button (LPBS). The FD fan motor shall be tripped, when the PA fan motor is tripped (or) when furnace pressure is high or TOLR is actuated (or) FD fan bearing temperature high.
PA FAN MOTOR: (BG060-00-09-3-041/A)
PA fan motor can be switched on only when the following conditions are satisfied.
Tiruchirapalli
PROJECT CUSTOMER
BOILER NO. REVISION
: BG060 :A
a) b) c) d) e)
ID fan motor running. PA fan suction damper closed. PA fan bearing temperature at drive end not high. PA fan bearing temperature at Non drive end not high. Remote selected.
When PA fan motor comes to the rated speed, its suction damper can be opened. The PA fan motor shall be wired, such that the motor DCS or from LPBs. can be started / stopped either from
The PA fan motor shall be tripped, when the ID fan motor is tripped or PA fan motor TOLR is actuated or PA fan bearing temperature high
PA AIR LINE DAMPERS FOR COMPARTMENT- I TO V (BG060-00-09-3-037)
PA air line dampers has no interlocks and can be opened / closed from DCS only.
FD AIR LINE DAMPERS FOR COMPARTMENT- I TO V (BG060-00-09-3-036)
The FD air line dampers of the respective compartment can be opened from DCS, when FD fan motor running and the PA air line damper of the respective compartment is opened. Closing of FD air line dampers can be done through DCS without any interlocks. AIR BLEED OFF VALVE-I (BG060-00-09-3-038) Air bleed off valve-I will open only when the FD air line damper at compartment-I on closed condition. It will close when FD air line damper at compartment-I on open condition. Similar logic is applicable for air bleed off valve- II, III, IV & V.
NON-INCHING STARTERS (BG060-00-09-3-032/A)
These motorised valve are suitable for isolation purpose. They have no interlocks and can be switched on either from local or from DCS. Similar logic is applicable for all RDOL NON INCHING starters.
Tiruchirapalli
INCHING STARTERS (BG060-00-09-3-031/A)
PROJECT CUSTOMER
BOILER NO. REVISION
: BG060 :A
These motorized valve are suitable for regulating purpose. They have switched on either from local or from DCS. The position of these valves will be available in DCS. Similar logic is applicable for all RDOL INCHING starters. DRAG CHAIN FEEDERS - I (BG060-00-09-3-034/A)
no interlocks and can be
Drag chain feeders-I can be switched "ON", only when the following conditions are satisfied. a) b) c) d) FD fan motor running. FD air line damper of compartment-I is opened. PA air line damper of compartment-I is opened. Remote selected.
The Drag chain feeders -I motor shall be wired, such that the motor can be started / stopped from DCS or from LPB. The Drag chain feeders-I shall be tripped when the FD fan motor is tripped or FD air line damper compartment is closed (or) PA air line damper of compartment is closed.. Similar logic is applicable for Drag chain feeders II, III, IV & V.
SECONDARY AIR SYSTEM DAMPER (BG060-00-09-3-042)
Secondary air system damper has no interlocks and can be opened / closed from DCS only.
Tiruchirapalli
PROJECT CUSTOMER
DOC No. SHEET
: BG060-INT-001 : 04 OF 05
BOILER NO. REVISION
: BG060 :A
SOOT BLOWER : (BG060-00-09-3-042 & 043) Following are the Soot Blower provided by as in our boiler: 2-LRSB-1201 - Long Retractable soot blower-I 2-LRSB-1202 - Long Retractable soot blower-II 2-LRSB-1201 comes with Forward and Reverse limit switches, multiple lead timer is required in DCS.
The above soot blowers shall be operated either in auto (or) manual mode as explained below.
MANUAL MODE: The Long retractable soot blower-I at CS heater zone (2-LRSB-1201) should be switched ON, in forward direction. It will operate and it will be switched OFF, when forward limit switch is actuated. Similarly when reverse direction is switched ON, the soot blower will operate and will be switched OFF, when reverse limit switch is actuated. Automatic reversal of soot blower is also done with the provision of a timer. (Timing Adjustable at site). This timer will be actuated as soon as the forward limit switch actuated signal is reed. After, exact time, it automatically switches ON the soot blower and will be switched OFF, when reverse limit switch and actuated. The 1-LRSB-1202 should be manually switched ON and procedure of operation will be as explained before. AUTO MODE: The multiple lead timer will switch on the 2-LRSB-1201 . 2-LRSB-1202 will operate in forward direction followed by time delayed reversal operation. Automatic reversal of soot blower is also done with the provision of a timer. (Timing Adjustable at site). This timer will be actuated as soon as the forward limit switch actuated signal is reed. After, exact time, it automatically switches ON the soot blower and will be switched OFF, when reverse limit switch and actuated. Thus all the soot blowers will work for cyclic mode, based upon the signal from multiple lead timer and sequence of soot blower operation shall be 2-LRSB 1201 as explained above. NOTE: During auto mode of operation the DCS shall be programmed such that, when any one of the soot blower is under maintenance or in non-working condition, then the multi lead timer shall start the next soot blower .
Tiruchirapalli
PROJECT CUSTOMER
: 1 X 36 Mwe CAPTIVE POWER PLANT : M/S. REI AGRO LTD. BOILER NO. : BG060 :A
No. : BG060-INT-001 SHEET : 05 OF 05
REVISION
LIME STONE FEEDERS - I (BG060-00-09-3-035/A) Lime stone feeder-I can be switched "ON", only when the following conditions are satisfied. a) Drag chain feeder-I motor running. b) Remote selected. The Lime stone feeder-I motor shall be wired, such that the motor can be started / stopped from DCS or from LPBS. or from VFD panel. The Lime stone feeder-I shall be tripped when the Drag chain feeder-I motor tripped (or) TOLR is actuated . Similar logic is applicable for Lime stone feeder-II, III, IV & V. POCKET FEEDER - I (BG060-00-09-3-039/A) Pocket feeder-I can be switched "ON", only when the following conditions are satisfied. a) Drag chain feeder-I motor running. b) Remote selected. The Pocket feeder-I motor shall be wired, such that the motor can be started / stopped from DCS or from LPBS. or from VFD panel. The Pocket feeder-I shall be tripped when the Drag chain feeder-I motor tripped (or) TOLR is actuated . Similar logic is applicable for Pocket feeder-II to X. GEAR OIL PUMP I & II, GEARED MOTOR FOR SCREW FEEDER AT BED ASH COOLER, (BG060-00-09-3-040/A) They have no interlocks and can be started / stopped either from DCS or from Local push button (LPBS).
CLICK HERE TO OPEN BOILER INTERLOCK DRAWINGS (BG060)
GENERAL
Ensure that the suction valve is open and water is available in the deaerator storage tank. Also ensure that, the discharge valve or the feed control valve including the bypass valve is closed. Then start the feed pump. Do not close the suction valve, when the pump is running. The auto recirculation valve to be opened automatically at the time of starting the pump and the same will be after crossing the pump min. flow. After that outlet valve is to be opened
immediately. Do not run the feed pumps without suction filter. During normal running of boiler the pump can be started / stopped with discharge valve open, since the feed line is under pressurised condition.
DP STUDY
DP STUDY
DP study must be carried out individually for all compartments. In simple terms, DP study is nothing but finding out the pressure drop across distributor plate at different air flows. Follow the steps given below.
DP study shall be done separately for each compartment. dampers of the compartments which are not being studied.
Hence close the FD, PA
Switch on ID fan, PA fan and then FD fan. Open the suction damper of FD fan and set 10 mm air flow in Aerofoil meter. Measure the air box pressure and gas plenum pressure (ID fan damper is to be adjusted to maintain a gas plenum pressure of -5 mmwc at all conditions).
Suppose, FD air flow Air box pressure Gas plenum pressure The pressure drop across DP at 10 mm air flow = 10 mmwc across Aerofoil meter = 75 mmwc = -5 mmwc = 75 + 5 mmwc = 80 mmwc
Thus, the pressure drop across DP can be found out 20, 30, 40, 50, 75, 100 & 125 of air flow.
The pressure drop values should be found out for other compartment too.
The pressure drop values shall be compared. For the same air flow, if a deviation of more than 5 mm between compartments, then it necessary to check the following.
there
is
becomes
The manometer readings may be incorrect. Check for leakage in the tapping locations or Aero foil meter and air box.
pressure
Check for leakage in the impulse lines to manometer/ Draft indicator.
Check for leakage between fuel feed pipe and air box.
Check for broken air nozzles.
The pressure drop values found in DP study, shall be recorded
for
future use. The pressure drop values measured in DP study are used to find out the bed height particular air flow. when the boiler is in running condition i.e. at a pressure drop
Also it is used to establish the practical
across the aero foil meter at the MCR air flow. If the DP drop is subracted from the total drop across the bed and DP, then bed height can be arrived at.
The pressure drop values taken shall be recorded on the following tables for future reference.
DP STUDY READINGS
COMPARTMENT I
PRESSURE DROP ACROSS DISTRIBUTOR SL. NO. 01 02 03 04 05 06 07 08 FD AIR FLOW (MM) GAS PLENUM PRESSURE (MM) PLATE (AIR BOX PRESSURE GAS PLENUM PRESSURE)
COMPARTMENT II
DP STUDY READINGS
COMPARTMENT III
COMPARTMENT IV
61
DP STUDY READINGS COMPARTMENT V

COMPARTMENT VI
62
BED MATERIAL, CHARCOAL & KEROSENE REQUIREMENT
BED MATERIAL, CHARCOAL, KEROSENE REQUIREMENT

BED MATERIAL REQUIREMENT: Quantity of bed material per startup Quantity of Bed material to be stocked BED MATERIAL SPECIFICATION: Maximum particle size Particles to pass through sieve No. Minimum particle size Particles to stay on sieve No. Particle density Bulk density Chemical composition Alumina Silica Fusion temperature : : : 45% to 35% 55% to 65% 1400C (Min.) : : : : : : : : 18130 54390 Kgs. Kgs. (For 3 Startups)
FOR COAL 2.36 mm 8 0.85 mm 20 2000 Kg/m3 1000 to 1100 Kg/m3
(Bed material shall be from Crushed refractory bricks or from sieved ash). CHARCOAL REQUIREMENT: Quantity of charcoal per startup Quantity of charcoal to be stocked CHARCOAL SPECIFICATION: Charcoal size Calorific value (Charcoal should be sundried) KEROSENE: Quantity of kerosene per startup Quantity of kerosene to be stocked : : 44 Litres. : : 15 to 25 mm LUMPS 6600 Kcal/Kg. : : 400 Kgs. 1200 Kgs. (For 3 Startups)
132 Litres. (For 3 Startups)
64
65
USE OF BED MATERIAL The bed material plays a vital role in the fluidised bed combustion process. The bed material is inert and does not undergo any chemical change. The size of the bed The bed material once The normal bed height when material is so selected to meet the fluidisation requirements. heated serves like an ignitor for the incoming fuel.
defluidised is maintained in the range of 300 mm to 400 mm. The bed material also acts as the carrier of heat between the burnt and the heat transfer surface. PROCUREMENT OF BED MATERIAL The bed material shall be procured from refractory supplier. Alternatively, the bed
material can be purchased from the user of a coal fired fluidised bed boiler. The ash drained from the fluidised bed can be screened and used as bed material. IMPORTANCE OF BED MATERIAL QUALITY AND QUANTITY 1. Before programming for a light up, it is necessary that the recommended quantity of bed material is procured according to the specifications. The bed material is to be stocked atleast for 10 start ups. 2. If the bed materials is procured from a refractory supplier, ensure only refractory bricks are crushed to make bed material. Mix up of insulation bricks is not allowed. 3. The fusion temperature of the bed material has to be above 1400C. If the fusion temperature is lower, clinkering will occur in the bed. 4. It is important that the bed material is procured according to the size (Because fine bed
recommended. Oversize particles do not fluidise well and fine powder will fly away. Also the fine powder puts off charcoal fire while start up. material quickly transfer heat to the bed coils).
5. In a coal fired boiler, the ash produced from coal partly accumulates in the bed and the same is drained to maintain a constant recommended bed height in the fluidised bed. This ash drained from the bed can also be screened and the screened ash can be used as bed material. In an agro fuel fired boiler, the bed material will not be generated and hence bed material has to be procured for daily consumption. 6. A coal fired fluidised bed in operation contain good amount of fines and coarse particles. Which are due to varying coal particle size on crushing. Hence for every light up (except hot restart) fresh bed material is to be used. This is essential for a smooth and quick start up. 7. When the bed material is procured from a refractory supplier, the size of the bed material is to be specified up mentioning the upper sieve no. 8 and lower sieve no. 20. The material has to pass through sieve no. 8 and to stay on sieve no. 20. USE AND IMPORTANCE OF CHARCOAL: 1. Charcoal is required for lighting up of the boiler. A fixed quantity of charcoal is burnt in the fluidised bed to raise the bed temperature in the start up compartment. Once the bed temperature is raised further fuel is fed to establish combustion of fuel in the fluidised bed. 2. Charcoal is selected as the start up fuel, mainly, because of its high heat content , rapid burning characteristics and low ignition temperature. 3. Good quality charcoal is a must for easy light up. Ensure charcoal is dry and not already burnt. Heavier charcoal is an indication of good quality. Tamarind wood charcoal is the best because it burns for more time and the about 6600 kcal/kg. 4. Charcoal should be dry for rapid burning. Wet charcoal should not be used in any case. Ensure the charcoal in stock is also dry. calorific value is
5.
The charcoal should not contain powder or bigger lumps. The charcoal shall be sized to 15 - 25 mm. Fine charcoal burns easily and does not contribute much for heating the bed. Bigger lumps would cause clinker formation as the lumps do not easily fluidise.
BED MATERIAL FILLING: * The bed material can be filled by entering the furnace. For compartment. * The bed material below the nozzle level remains static all the time. This is not to be counted as the bed height. * Uniform spreading can be done by admitting fluidising air through the bed. The air should be sufficient enough to * * fluidise bed. start up purpose, the
bed height shall be 200 - 225 mm above the air nozzle top level in the start up
The bed height can be measured physically after putting off the air flow. Alternatively fluidised bed. the bed height can be found out by pressure drop across the
Let us assume, For 100 mm fluidising air flow the distributor plate pressure drop is found to be 150 mm. Let gas plenum pressure Let air box pressure drop across the fluidised bed = -10 mmwc = 484 mmwc
The pressure drop across the fluidized bed and the distributor plate = 491 mmwc
The pressure drop across the distributor plate is 121 mmwc as found in DP study. The pressure drop across the bed = 491 - 121. = 270 mmwc
Since the bulk density of the bed material is 1000 kg/m^3, the pressure drop across the bed in mm is the bed height in mm.
Though the normal operating bed height is 300 - 550 mm, initial bed material filling is done only upto 200-225 mm. This low bed height reduces the charcoal requirement for start up purpose. Also low bed height helps in raising the boiler pressure slowly.
In the case of compartmental start up the bed material shall be filled as explained below:
Fill the bed material to a height of 300 mm in all
compartments. Fluidise
all
the
compartments together provided the fan motor amperes are below the limits. If not possible, fluidise two compartments together for levelling. Then the next compartment can be fluidised separately. The start up compartment is to be fluidised separately. When this is done a portion of the bed material spills to the adjacent compartment and forms a mount along the edge of the compartment. Further bed material is to be added to the start up compartment so that the bed height of 200 - 225 mm is maintained.
BOILER LIGHT-UP
04. BOILER LIGHT-UP: The lighting up of the boiler is to be done with the help of charcoal and kerosene. The light up is to be done only for a single compartment. After stabilising with a single compartment fire is transferred to other compartments as per the procedure explained separately. PREPARATIONS: 01. Inspect the boiler prior to starting and check the following. - All access doors are closed. - All personnel cleared. - All foreign materials are removed from furnace and pressure parts. - Starting equipment and interlocks are in position. - Boiler is filled with DM water above the low level limit. 02. Check the following equipments for adequate lubrication and readiness for service. - Fans and drives. - Feed pumps and drives. - Fuel feeders and controllers. 03. Check dry fuel (0-6) mm is available in the bunker, the gates below the bunker are open and fuel is available at feeder inlet. Check the instrument air is available at the required pressure (of 7 kg/cm2) for instrumentation and control. Check the following valves in the Boiler drum are closed. - Feed control valve and its bypass valve. - Blow down valve. - Main steam stop valve. - Drain valves of water level gauge. 06. Check the following valves are kept open.
04.
05.
- Air vent on top of drum. - Water level gauge, pressure gauge and level transmitter / isolation valves. - Valves before and after the feed control valve in the feed line. - Valves on the feed line connecting to the feed pumps in operation. 07. Check the bed material is filled in the furnace and fluidisation study is complete.
BOILER FILLING: Before starting the filling up, keep the vent on the drum open and close the blow down and drain valves. The filling up is done by running the feed pumps but the rate of flow is controlled by means of feed control valve. During the filling up check the operation of blow down valve and drain valves and then close them. The boiler is filled up completely till water comes through the drum vent and is drained to bring the water level to low level alarm limit. FLUIDISATION STUDY: * * During the fluidisation studies, except for large compartments the fuel transport air need not be introduced as it would disturb the bed. Observe the fluidisation of the start up compartment by varying the air flow gradually. Mark the position of dampers when the bed material begins to fluidise. In the case of pneumatically operated dampers, note the input signal "PSI" from the manual loaders. The on set fluidisation may also be observed by plotting the bed pressure drop against the air flow. Set the air flow at 5 mm P. Measure the air box pressure, P1 mm wc Add the gas plenum pressure P2 to P1 (P1+(P2)) is the pressure drop across the distributor plate and bed. Substact P3 mmwc, which is the pressure drop across DP alone which is measured in DP study. i.e., (P1 + (P2)) - P3 would be the pressure drop across the bed.
* * * *
The pressure drop across the bed is thus obtained for various air flows. The readings may be plotted in a graph as shown. The air flow at which fluidisation starts is noted. This value is to be maintained for the purpose of mixing at the time of startup. Once the fluidisation study is completed, the fans shall be switched off and boiler shall be taken for light up.
The boiler light up is done using charcoal and kerosene as explained below. * * A fixed quantity of dry charcoal is spread uniformly over the start up compartment. A fixed quantity of Kerosene mixed charcoal is spread uniformly over the dry charcoal layer. The fire is initiated using swab. Further by proper air flow control, fire can be spread and the heat released by charcoal is utilised to heat the bed material to a temperature above the ignition temperature of the fuel. In the process of preheating bed material the required fluidisation velocity is maintained in the bed by suitably opening the FD fan inlet damper. Further the fuel feed rate is adjusted to maintain a bed 850C. temperature of 800C to
* *
* *
The charcoal of size below 15 mm shall not be accounted for the above quantity. Keep the ID fan damper open at the time of lighting up. This would reduce the possibility of furnaces puff. Initiate the fire bushing number of swabs. Throw the swabs in such a way that the fire spreads uniformly over the entire furnace. If the spreading of the fire is non uniform sprinkle some kerosene choked charcoal and throw it to the locations where fire is not there. Unless the fire is more or less present over the entire surface, it is advised not to proceed with the light up. Unless the top layer or charcoal gets ignited, further charcoal would not get ignited.
BED TEMPERATURE AND AIR FLOW CONTROL The thermocouples are located in such a way that they are well utilised for start up. The top level bed thermocouple is located at a height to read the temperature just at the burning charcoal layer. The bottom level thermocouple is located to read the bed material temperature at a height of 100 mm from nozzle level. After the introduction of fire, top level thermocouple temperature will go up. It is
very important to increase the air flow gradually in order to increase the top level temperature to 800C. At first the ID fan damper opening alone allows some leakage air. Further opening of FD fan damper will add some more air to increase the bed temperature. Now close ID fan and FD fan inlet dampers. Start ID fan then FD fan. Open ID fan and FD fan inlet dampers step by step to increase the top level temperature to 800C to 850C. Till this period the bottom level thermocouple would not have shown increase in temperature. Once the top level temperature reaches 800 - 850C, The mixing air flow should not
the burning top layer of charcoal shall be mixed with rest of the bed. The mixing is done by increasing the air flow so as to fluidise the bed. be higher than that of the air flow established during the fluidisation study. For this purpose the markings made on damper positions shall be used.If the mixing is done at higher airflow, the burning charcoal will spill into the adjacent compartment. More than the loss of charcoal in the start up compartment, the bed height will reduce in start up compartment. This would lead to defluidisation as the air would tend to bypass at bed heights lower than 100 mm. The duration of mixing shall be between 20 - 30 seconds. the top level temperature would start reducing. temperature would begin to rise. Soon after the mixing is completed the air flow is brought to a minimum. Open the man hole door and visually ensure through mixing has been done. If top layer charcoal has not been disturbed at some places, mixing shall be carried out once again. During the mixing process,
At the same time, bottom level
After ensuring thorough mixing, the air flow shall be brought down to minimum and then shall be increased in steps. raising bed temperature above 600C. Once the bed temperature shoots above 600C, the fuel transport lines are to be The airflow shall be increased gradually so as to raise the bed temperature. The airflow shall be brought up at MCR airflow in process of
dechoked and fuel flow shall be established.
* * *
Switch on the New PA fan. Open the fuel transport air dampers of the start up compartment. Check the suction at the mixing nozzle. If suction is not available, open the respective bottom drain gates of fuel pipes to dechoke, if any. After the choking of fuel feed pipe is cleared close the gates.
In the case of larger compartments it is advisable to
initiate minimum airflow
in fuel pipe lines just before mixing process to avoid choking of the fuel lines. * Adjust the PA fan suction damper, to maintain the header pressure in between 700 to 900 mm of wc. Initiate the fuel flow by switching on the fuel feeders. The fuel flow shall be kept minimum at the beginning. At the time of fuel feed initiation, the charcoal might not have burnt fully. Hence it is most important to initiate fuel feed gradually. Excess fuel feed will increase the bed temperature uncontrollably. Though the
bed temperature can be controlled by increasing the air flow, it is advisable to take care at the time of fuel feed initiation. Stabilise the start up compartment operation with a bed temperature of 850C and with the MCR air flow.
On the waterside watch the drum level. If the level goes down switch on feed pump and regulate the feed control valve. ON/OFF operation of feed pump should be avoided to the extent possible. If the feed pump is auto operated, keep the selector switch in auto mode. Here again regulatethe feed control valve to avoid frequent start/stop of the pump.
Close
the drum vents at 2 kg/cm pressure if the boiler
is provided with
superheater. This is done so that superheater coils are cooled better by more steam flow through them. Ensure the vents, start up vents, drains are open in superheater lines. The condensate in superheater coils and main steam pipe should have been removed earlier. In the case of non drainable sections of superheater coils it is * possible that condensate leads to water hammer. will not be possible to
In cases of powercut during start up after the mixing it the bed
access how much charcoal is burnt out. It is advised to cool throughly and drain material in start up compartment and do a fresh light up.
However, if the powercut had occurred before mixing one may attempt to light up as below:
Sprinkle Kerosene soaked charcoal through man hole evenly compartment. The charcoal quantity shall
over the start up
be the same as that for light up.
* * *
Throw swabs and light up. Follow the same procedure as discussed in a regular light up. If the powercut occurs after mixing and provided the duration is also short, it may be possible to ligh up.
Fluidise the bed minimally. Check the bed temperature. If the bed temperature is more than 400C add dry charcoal to the bed. The charcoal should be thrown uniformly over the entire bed. Observe the rise in temperature. If there is no improvement in bed temperature it is better to cool the bed. Never allow the bed to be static in this method. If the bed is static, clinker formation will start.
START-UP PARAMETERS: Bed height Bed material size Before firing Charcoal (Dry) Charcoal kerosene mixed PA header pressure Before mixing Mixing temperature Mixing air flow Bed temp. before fuel feed Fluidising airflow After mixing PA header pressure Feeder rpm COMPARTMENTAL TRANSFER: The start up with one compartment is recommended for the following reasons. 01. Gradual loading of pressure parts. 02. Reduction of Charcoal for start up. 03. Load variation. The compartment transfer means activating a static furnace adjacent to the activated compartment. (cold) compartment of the : Min. 600C : : mmwc mmwc : : : Kg. mmwc mmwc : 300 mm from Distributor plate : 0.85 - 2.38 mm. : Kg.
: 850C
This is done just by admitting the
fluidising air to the compartment to be activated and mixing the cold material with hot
material of the operating compartment. Before activating a static compartment, the airflow in the fluidising compartment shall be increased to 120% of the MCR air flow, and the fuel feed rate shall be correspondingly increased to maintain the bed temperature at 900C. Now open the compartment air damper of the adjacent compartment which is to be activated. The cold bed material in this compartment would begin to mix up with that of hot bed material in the operating compartment. compartment would begin to rise. The bed temperature in operating compartment will begin to drop. Once this temperature reaches 750C slump the new compartment by closing the air damper. The bed temperature of the operating compartment shall be once again brought up to 900C before another attempt is made. By following the process of mixing the bed material of the compartment activated with that of the activation can be completed. to be The bed temperature in new
operating compartment, on one or many attempts, the The bed temperature of the new compartment shall be
brought to atleast 600C before fuel feeding is commenced. The primary air lines in the new compartment shall be opened and the fuel feeding can be commenced and the bed temperature shall be brought to 800C with MCR fluidising air flow condition. Care shall be taken not to drop the temperature of compartment below 600C in the process of activating adjacent compartment. If by mistake, the temperature of the operating compartment drops below 600C, it becomes necessary to raise the temperature using charcoal. The charcoal should be sprayed over the entire compartment. Charcoal should be mixed with the bed keeping the bed minimally fluidised. The charcoal if burns under static condition, the chance of clinkering is high. operating
NORMAL OPERATION
05. NORMAL OPERATION LOAD CONTROL: The steam generation needs to be matched with that of demand to avoid venting of steam. If the steam drawn from the boiler is less compared to steam generated then the pressure would rise and thus resulting in lifting of safety valve. Frequent lifting of safety valve will damage the safety valve seat. Steam generation can be varied by slumping compartments or by varying the fluidisation air flow or by varying the bed temperature or by varying the bed height. Load variation of 70% to 100% may be obtained by varying the bed temperature. The
bed temperature can be reduced upto 700C and can be increased to 900C based on demand. For this purpose the fuel fed rate needs to be varied. Further turndown is also possible by reducing the fluidisation airflow but not to the extent of defluidisation of the bed. In such cases the air flow through primary air lines should never be reduced. Only the fluidising airflow should be reduced. Further load control is done by slumping the compartments. The compartments can be slumped only from either ends of the bed. In case of two compartments any compartment may be slumped. In case of three compartments only first or third compartment is to be slumped, before the middle compartment is slumped. Slumping of the compartment is to be done as explained here. Bring down the fuel rate to minimum and switch off the feeder. Wait till the bottom bed temperature comes around 850C, and then close the fluidising air damper of the compartment. Then close the fuel transport air line dampers. When the fluidising air through a compartment is cut off, the air through the other compartments would increase. This air flow shall be adjusted by throttling inlet damper of FD fan. Further draft in the furnace shall be adjusted by throtting of ID fan inlet damper. Reactivation of a compartment shall be done in the following sequence. Open the fuel transport airline valves first and ensure the required air pressure is available in the PA fan header. If the line is choked, choke shall be removed by using the drain gates, of the fuel transport lines. Then open the fluidising air damper and set the FD fan inlet damper for the required MCR airflow. If the bed temperature is above 600C fuel feed shall be initiated and the bed temperature shall be brought to the required operating temperature.
In case the temperature of the bed is less than 600C immediately after fluidisation, the compartment shall be started in the manner explained in the compartment transfer method. The load control is graphically depicted in figure 2 for the furnace with three compartments. During one compartment operation, the bed height can not be increased as the bed is not contained on one side. This is applicable to some extent to two compartments operation also maximum variation is possible in all compartments operation as the bed is totally contained in all four sides by the furnace water wall. DYNAMICS IN FLUIDISED BED: The height of the fluidised bed needs to be increased after the activation of all The ash
compartments in order to meet the steam demand. In the case of coal firing, the bed height automatically increases due to generation of ash from coal burning. which is retained in the bed, if not drained, will accumulate to an extend that the air flow through the bed starts coming down below the MCR airflow. The height of bed is not to be allowed to increase beyond the recommended bed height which is about 300 mm to 400 mm. The bed height is indirectly measured by means of air box pressure as explained in the earlier sections. Other than the purpose of maintaining required bed height, the bed drain gates are to be operated for removing higher size particles. When there are deviations from the specified fuel feed size, ie., minus 6 mm, the higher size particles would begin to settle down at the air nozzle level. Similarly when agro fuel is used stones ingress with fuel would lead to setting of stones. The bed drain is to be operated frequently to drain the higher size particles. If the drain is not operated frequently the fluidisation will be upset causing clinker formation. be added frequently in order to In the case of fuels (Agrowaste) which do not generated bed ash, bed material requires to compensate for loss of bed material by attrition and subsequent elutriation. Hence sufficient stock of bed material is to be maintained. ASH REMOVAL: The ash should be drained from all collection points. Failure to remove the ash will result in choking of flue gas path.
BOILER TRIPPING DUE TO POWER CUT: In case of boiler tripping due to power cut or for any other reason, immediately close the inlet dampers of the FD fan and ID fan. In the event of power availability and if the boiler is required to be started immediately switch on the fans. Establish the MCR air flow and start fuel feeding. Otherwise if the boiler is to be boxed up, close the main steam stop valve. Close the compartment dampers also. The boiler can be restarted as explained in the further chapters. (Write up on hot restart). INGRESS OF FOREIGN MATTER IN FUEL: Ingress of cotton waste, waste cloth, coconut shell, mango seed etc., will block the fuel flow from the chute into the feeder. This is indicated by the drop in bed temperature (provided the feed rate of the feeder is not increased). The above mentioned problems can be eliminated if a screen is provided in the fuel handling system. Feeder tripping due to foreign material is a great nuisance and at times it may lead to boiler shut down. In case of coal, it becomes necessary to provide a magnetic separator to separate out the tramp iron from the coal. This not only protects the crusher, but also prevents to damage to the feeder.At times it may so happen that the foreign matter may block the fuel transport line. When there is no airflow in the fuel transport line, the bed material from the bed enters the fuel feed nozzle and leads to choking of the line. The choking should be removed by slumping the bed and by opening the drain gates. Also the foreign matter should be removed from the mixing nozzle opening the plug of the mixing nozzle.
NORMAL OPERATING PARAMETERS (STABILISED CONDITION) Air box pressure (Drain the bed if the pressure is high) Fluidising air flow Primary air header pressure Bed temperature Feeder rpm / vibratory feeder setting Furnace gas plenum pressure Blowdown every : : : : : : : : hrs.
NORMAL SHUT DOWN TO COLD
06.
NORMAL SHUT DOWN TO COLD:
Reduce the fuel feed rate and slow the feeders to empty before stopping them. Maintain the same air flow to cool bed faster. If the steam is not drawn from the boiler, open the airvent to reduce pressure. If it is not necessary to enter the boiler for maintenance, slow rate of pressure and temperature decay is desirable switch off the fans after the bed has cooled down to 500C. Switching off the fans should be in the order of FD and ID fans. If it is desirable to accelerate the cooling process in order to permit entry into the unit for maintenance, the fans could be continued to run at the same flow rate until temperature reaches 100C. During the process maintain normal water level in the boiler. After the bed temperature reached 100C open the blowdown boiler. (The boiler valve and drain the
water temperature must be reduced atleast 90C before draining).
Drain the bed material. This can be done by opening the gates below the drain points collect this bed material, sieve and reuse for subsequent light ups.
NORMAL SHUT DOWN TO HOT STANDBY
07.
NORMAL SHUT DOWN TO HOT STAND BY
If the boiler has to be shut for a relatively short period (minimum of 2 hours) follow the procedure given below.
01. Switch of the fuel feeder, FD, PA & ID fans instantaneously. The PA line dampers and fluidising air dampers need not be closed. But FD & ID fans dampers must be closed.
02. Do not reduce the boiler pressure in line with unit load reduction. When the desired pressure at which the boiler is to be held is reached after the boiler is off the line, the boiler may be up by closing the main steam valve.
03. Keep the water level in sight in the gauge glass and add make up rate as required.
HOT RESTART
08.
HOT RESTART
After a shut down for a brief period, follow the steps given below to re-start the unit.
01.
Open the air vent. Check fluidising air damper and PA damper are "OPEN".
02.
Keeping the ID and FD fan dampers in the closed position.
03.
Start ID, FD and PA fans in quick succession.
04.
Start the fuel feeders with minimum speed.
05.
Gradually open ID and FD fan dampers to maintain air flow D.P. of 30 mm and gas plenum pressure of 10 mm.
06.
Increase the speed of fuel feeders and watch the bed temperature.
07.
If the bed temperature is slowly increasing then increase fuel feed and air flow in line with load requirement.
08.
If the bed temperature is not increasing, stop the fuel feeders.
09.
If the bed temperature is below 600C throw charcoal through access door, till temperature reaches 600C. This has to be carefully done. This may be required if more than one hour has lapsed after shutting down.
10.
If the bed temperature is less than 300C, cool the bed and start the boiler following "normal startup from cold" procedure.
CONTROL LOOPS
CETHAR VESSELS LIMITED Tiruchirapalli
PROJECT CUSTOMER
: 1 X 36 MW CAPTIVE POWER PLANT : M/S. REI AGRO LTD.,
CONTROL LOOP WRITE UP
DOC No. SHEET
: BG059-CL-001 : 01 OF 03
BOILER NO. REVISION
: BG059 :A
THREE ELEMENT DRUM LEVEL CONTROL (This document should be read in conjunction with Drawing No. BG059-00-09-2-025/A) PURPOSE: The main objective of steam drum level control is to maintain constant water level in the steam drum by selecting either Single element control sensed only by drum level parameter for boiler load less than 30% or Three element control sensed by drum level, steam flow & feed flow parameters for boiler load greater than 30%. MEASURED VARIABLES: a. Drum level is measured by three level transmitters (LT-1201A on right side of steam drum and LT-1201B, LT-1201C on left side of steam drum). b. Steam flow is measured by using Steam flow transmitters (FT-1201) across the flow nozzle. c. Feed flow is measured by using feed flow transmitters (FT-0101) across the orifice.
d.
Main Steam line pressure is measured by using a pressure transmitter (PT-1103).
e. Steam temperature is measured by using thermocouples (TE-1101). f. Feed water temperature is measured by using a thermocouple (1-TE-101).
g. Drum pressure is measured by using drum pressure transmitters (PT-1101).
CONTROL PHILOSOPHY: a) The signal of the drum pressure from PT-1101 is used to compensate the drum level signals from three level transmitters (LT-1201A, LT-1201B, LT-1201C) for changes in density. This is accomplished by multiplying the uncorrected drum level signal by a pressure dependent gain. The gain used at any given drum pressure is set by function generator F1 (x). b) The two numbers transmitters (LT-1201B, LT-1201C) located at left side of the steam drum are averaged. Also, the difference between these two transmitters are continuously monitored.
c) If the difference is with in the limit (i.e., with in 3 percentage), then the average signal between the level transmitters are taken and this goes to software selector switch-1.
PROJECT CUSTOMER
DOC No. SHEET
: BG059-CL-001 : 02 OF 03
BOILER NO. REVISION
: BG059 :A
d) If the difference exceeds the limit, then an alarm should be generated as DIFFERENCE IS MORE and DCS should consider the transmitter which shows lower value between them and the software selector switch-1 should be changed to the particular transmitter. e) The output signal from selector switch-1 is average with the level transmitter (LT-1201A) located at right side of the drum. Also, the difference between these two transmitters are continuously monitored. f) If the difference is with in the limit (i.e., with in 5 percentage), then the average signal between the level transmitters are taken and this goes to software selector switch-2.
g) If the difference exceeds the limit, then an alarm should be generated and as DIFFERENCE IS MORE DCS should consider the transmitter which shows lower value between them and the software selector-2 should be changed to the particular transmitter. h) i) The output signal from selector switch-2 is fed to the level indicating controllers (LIC-1201 & LIC1202). The controller performs PI action on the input signal and an output is generated. The output signal from single element controller(LIC-1201) is connected to I/P convertor of 30% flow control valve through Auto/Manual selector block and the mode can be selected auto/manual accordingly. The output signal from three element level controller (LIC-1202) is taken to the summator block through convertor and drum level weightage block. Other input to the summator block is the compensated steam flow signal through steam flow weightage block.
j)
k) This summator combines the steam flow signal with the control output signal from LIC-1202 to produce a variable set point input to the feed water flow controller. l) Another input (PV) to this flow indicating controller is compensated feed water flow signal.
m) The output signal from flow indicating controller is connected to FCV selector switch. The operator can select either FCV-1101A (or) FCV-1101B. n) The FCV selector switch output is connected to smart positioner of both 100% flow control valves through Auto/Manual selector switch and the mode can be selected as auto or manual accordingly. o) The I/P convertor converts the current signal into pneumatic signal and it regulates the feed control valves at required position. p) Position feedback of 30% & 100% feed control valves are taken to DCS and displayed in CRT. q) When single-element control is selected the drum level signal goes to single element controller (LIC-1201). This controller contains a manual transfer station. In manual, the operator can vary the output from the controller to adjust the feed water flow. r) When load is less than 30% of MCR, force a signal to close the 100% flow control valve gradually (FCV-1101A (or) FCV-1101B) & when load is greater than 30% of MCR, force a signal to close the 30% flow control valve (FCV-1101) gradually.
CETHAR VESSELS (P) LIMITED Tiruchirapalli
PROJECT CUSTOMER
DOC No. SHEET
: BG059-CL-001 : 03 OF 03
BOILER NO. REVISION
: BG059 :A
NOTE: 1. The output from both the Single - element controller (LIC-1201) & Three element controller (LIC-1202 & FIC) are connected to respective current to pneumatic converters of control valves through manual transfer switches. When the steam flow signal is less than 30% of MCR load alarm will be generated and operator to transfer the control to Single element control will be in operation through manual transfer switch & when the steam flow signal is greater than 30% of MCR load Three element control will be in operation through manual transfer switch by the operator. 2. Please note that if two transmitters are faulty, alarm is generated in DCS identifying the bad transmitters and the controller goes to manual and operator has the option to select the healthy transmitter and put the loop back into Auto. 3. The drum level low & high signals are derived from individual level transmitters for alarm purpose. These signals should be continuously monitored for control purpose 4. The drum level very high & very low signals should be taken selected process input from the software selector switch-2 and fed to level indicating controllers (LIC-1201 & LIC-1202) for alarm and tripping purpose. 5. Feed flow transmitter signal and steam flow transmitter signals are selected in the similar procedure of the signal selected from drum level transmitters
CETHAR VESSELS LTD. TIRUCHIRAPALLI - 620 001
PROJECT BOILER NO.
M/S. REI AGRO LTD BG059 Date: 10.12.08
DOCUMENT NO. BG059-CURVE-001
FUNCTION-G-CURVES
DRUM LEVEL PRESSURE COMPENSATION (GAIN)

1.8000
1.7000
1.6000
1.5000
1.4000 GAIN
1.3000
1.2000
1.1000
1.0000
0.9000 0 20 40 60 80 100 120 140 DRUM PRESSURE Kg/cm (g)
1.4000 GAIN
1.3000
1.2000
1.1000
1.0000
DRG.NO : BG059-00-09-2-025/A (F1(X))
DRUM PRESSURE Kg/ cm(g) 0 15 30 45 60 90 120 140
GAIN 1.0000 1.1182 1.1886 1.2509 1.3154 1.4383 1.6302 1.7815
Prepared
Date: 10/12/08
Approved Rev. Signature
Date: 10/12/08 Date
Tiruchirapalli
PROJECT CUSTOMER
No. : BG059-CL-002 SHEET : 01 OF 01
BOILER NO.
: BG059 : NIL
REVISION
SUPERHEATED STEAM TEMPERATURE CONTROL (This document should be read in conjunction with Drawing No. BG059-00-09-3-027)
PURPOSE:
The purpose of steam temperature control is to temperature at main steam line.

MEASURED VARIABLES:
maintain constant super heated steam
Main steam line temperature is measured using a thermocouple (TE-1204) CONTROL PHILOSOPHY: a. Cascade type control loop is followed here. b. The main steam temperature signal is compared with the set point provided. c. The output signal from step (b) us goes as cascade set point to next PID block. d. Another (pv) input to this PID block is De-superheater outlet temperature.(TE-1203) e. The output signal from (d) in DCS is fed through Auto/manual block and mode can be selected as auto or manual accordingly. f. The A/M block output is connected to electro pneumatic convertor. g. The Electro pneumatic convertor converts the current signal into a pneumatic signal and it regulates the spray control valve.
Tiruchirapalli
PROJECT CUSTOMER
DOC No. : BG059-CL-003 SHEET : 01 OF 06
BOILER NO. REVISION
: BG059 : NIL
COMBUSTION CONTROL (This document should be read in conjunction with its Drawing No. BG059-00-09-3-034) The objective of the combustion control is to ensure that the air flow into the furnace is proportional to the total amount of fuel entering the furnace at any instant. Normally, air flow will be slightly more than the theoretical air requirement for a given fuel. Too much of air leads to high excess air and higher loss in efficiency. Too less an air leads to insufficient combustion and also leads to clinker formation. Hence the combustion control is very important and it is divided into two parts. 01. 02. Air flow control Fuel flow control
AIR FLOW CONTROL: In this control the air flow is varied corresponding to the variation in steam flow. GENERAL POINTS IN AIR FLOW CONTROL: 1. The combustion control should not be used during boiler startup. 2. Combustion control should be put in Auto mode only after all the compartments are activated atleast once. 3. For combustion control to be in auto mode atleast 2 compartment should be in operation. 4. The air flow Vs steam flow curve will be furnished. From this curve the minimum and maximum air flow for various compartment combinations can be obtained. 5. Whenever the air flow reaches the high and low limits, alarms should be generated. MEASURED VARIABLES: 1. Air flow is sensed through one air flow transmitter (FT-1301) located across the aerofoil at air heater outlet. 2. Steam flow is should through steam flow transmitter (FT-1201) The number of compartments in operation is sensed in DCS using the signal from limit switches (ZSO-1301 to ZSO-1305)
Tiruchirapalli
PROJECT CUSTOMER
BOILER NO. REVISION
: BG059 : NIL
CONTROL PHILOSOPHY: The DCS should perform the following. 1. The no. of compartments in operation has to be checked with help of the digital inputs from the reed switches. Based on the no. of compartments in operation there is a maximum limit (XH) and minimum limit (XL) for the air flow. For example if all three compartments are in operation. The maximum air flow is TPH and minimum air flow is TPH. They are 3 sets of such limits namely XH1, XH2, XH3 & XL1, XL2, XL3. 2. Corresponding to the steam flow there will be air flow value from the air flow Vs steam flow curve. The air flow value will go as the set point to the air flow controller. 3. If this set point is between the maximum and minimum limits for the particular number of compartment in operation, then the controller output will go to the respective final control element i.e., Varying the RPC of FD fan through a auto manual selector block. 4. The air flow set point should go to the high limit (A Max) in case the bed temperature (defined under fuel flow control) goes to 950C. ALL 3 COMPARTMENTS IN OPERATION: a) Supposing the steam drawal is more, then the corresponding set point for air flow also will increase. If the set point crosses the high limit (XH) then the DCS should generate an alarm "STEAM DRAWAL IS MORE" and the air flow is brought to a freeze at the high limit. b) Supposing the steam demand is less, then the corresponding set point for air flow also will decrease. If the set point goes below the low limit (XL), then in DCS should generate an alarm (STEAM DRAWAL IS LESS-SHUT DOWN ANY ONE COMPARTMENT). The following compartment cut off sequence should be done by DCS. I) ii) A signal should trip fuel feeder of one compartment. Consequently the air line damper of that particular compartment has to be closed.
Tiruchirapalli
PROJECT CUSTOMER
BOILER NO. REVISION
: BG059 : NIL
LET US CONSIDER 2 COMPARTMENTS IN OPERATION: a) When the air flow set point corresponding to the steam flow is between the maximum and minimum air flow limits for 2 compartments in operation, then the air flow controller output will operate the final control element, that is the varying the RPC of the FD fan. b) If the steam drawal increases and the corresponding air flow set point reaches the high limit, then alarm starting STEAM DRAWAL IS INCREASED - ACTIVATE A NON OPERATING COMPARTMENT should be generated and the following compartment cut in sequence should be done by DCS. I) The FD air line damper of that compartment should be opened. ii) Ensure that the PA air line damper of that compartment is open. iii) The fuel feeder of that compartment should be started after ensuring that the bed temperature of that compartment is 600C. (This value is for Imported coal only) c) When the air flow set point reaches the low limit then the in DCS should perform the compartment cut off sequence as explained earlier. FUEL FLOW CONTROL: MEASURED VARIABLES: 1. The main steam line pressure is measured using the pressure transmitter (PT-1202) 2. The fuel feeder speed is senses using the VFD-1401 3. Bed temperature of all the compartment are sensed using the thermocouples (TE-1302A to TE-1306B) and the temp transmitter (TT-1301A to TT-1305B) 2 Nos. of thermocouples are provided in each compartment. This bed thermocouple signal is the main criterion for boiler operation. Since we have 2 thermocouple signals, the average value should be considered as the bed temperature. For averaging, erratic signal should not be considered, erratic signal is one of the following. I)Temperature signal of the operating compartment showing less than 600C. II) Open circuit in thermocouple.
III) Temperature difference of more than 50C.
Tiruchirapalli
PROJECT CUSTOMER
BOILER NO. REVISION
: BG059 : NIL
A table containing, various bed temperature ranges for various fuel as below is fed to the fuel feeder selector block. FUEL A1 A2 A3 A4
Imported COAL COAL 840 TO 890C 825 TO 875C 890 TO 940C 875 TO 925C 820 TO 870C 820 TO 870C 940 TO 900C 925 TO 975C 970 TO 920C 970 TO 920C > 990C > 975C > 920C > 920C
30%IMP COAL +70% K.LIGNITE 770 TO 820C 30% COAL +70% K.LIGNITE 770 TO 820C
Following are the various temperature zone, defined in the FBC boiler. 01. LOW BED TEMPERATURE The average bed temperature in the range of 750C to 850C is defined as the low bed temperature. 02. NORMAL BED TEMPERATURE The average bed temperature in the range of 850C to 925C is defined as the normal bed temperature. 03. HIGH BED TEMPERATURE The average bed temperature in the range of 925C to 950C is defined as the high bed temperature. 04. VERY HIGH BED TEMPERATURE The average bed temperature above 950C is defined as very high bed temperature. In DCS shall also have some dead band (between 10C to 20C) between the two temperature zones. The dead band shall be applicable for decreasing trend only. (ie., from very high temperature zone to high temperature zone). CONTROL PHILOSOPHY In the fuel flow control, the speed of the fuel feeder i.e., the fuel feed rate, is controlled based on the steam pressure and the bed temperature.
Tiruchirapalli
PROJECT CUSTOMER
BOILER NO. REVISION
: BG059 : NIL
The steam pressure signal goes to the steam pressure controller which is given a set point for steam pressure. Based on the deviation, this controller generates an output which is given as a cascade set point to the fuel feeder controllers of the individual compartments. The fuel feeder controller output is connected to two nos. of the fuel feeder of the individual compartments through the output selector block & A/M block and each A/M block. The function of the output selector block is as follows : I) NORMAL BED TEMPERATURE
When the bed temperature is normal, the DCS should give output based on the difference in steam pressure signal (output mode A ie., F) as explained above. The output should go to all the running fuel feeders parallaly so as to decrease or increase the fuel feeder speed. II) LOW BED TEMPERATURE
When the bed temperature is low, the DCS should first bring the temperature to normal. This is achieved by incrementing the fuel feed speed (ie. Original fuel feeder speed + some incremental value). The DCS shall have provision for time gap (in terms of minutes) between one increment and the next increment of fuel speed. The actual time will be decided after commissioning the boiler. The 4-20 mA output from fuel feeder VFD will be taken into the DCS and the same should be calibrated to VFD speed. Normally the incremental value can be 10% to start with and provision shall be available in DCS to change the same in future. Once the bed temperature comes to normal zone, the DCS should work based on the steam pressure signal. (Output mode A is F + F). III) HIGH BED TEMPERATURE
When the bed temperature is high, the DCS should first bring the temperature to normal. This is achieved by decrementing the fuel feed speed (ie. Original fuel feeder speed - some decremental value). The decremental value can be 10% to start with and provision shall be available in DCS to change the same in future. The DCS shall have provision for time gap (in terms of minutes) between one increment and the next increment of fuel speed. The actual time will be decided after commissioning the boiler. Once the bed temperature comes to normal zone, the DCS should work based on the steam pressure signal. (Output mode A is F - F).
Tiruchirapalli
PROJECT CUSTOMER
DOC No. : BG059 -CL-003 SHEET : 06 OF 06
BOILER NO. REVISION
: BG059 : NIL
IV)
VERY HIGH BED TEMPERATURE
The fuel feeder of that particular compartment should be tripped. Once the temperature comes to above 750C, the fuel feeder can be switched ON. GENERAL POINTS ON FUEL FLOW CONTROL 01. DCS shall have provision for the following. a) b) The combustion control loop should be by passed during the boiler start-up. For combustion control to be in auto mode minimum two compartments should be in operation.
c) The current output of the fuel feed controllers should be within the specified limits. The upper limit of the current output is fixed by the maximum speed corresponding to the maximum carrying capacity, moisture content and calorific value. The maximum speed of the fuel feeders will be about 10% more than the normal speed required at full load when all the compartments are in operation. The upper and lower limits of the current output will be informed during commissioning and should be possible to change the values at site based on the operating conditions.
02. Speed of fuel feeders can be manually operated from VFD panel also.
03. If the steam pressure is high and correspondingly the fuel feed rate is reduced then the bed temperature will start falling. However if the temperature falls below 800C, even if the pressure is high, fuel feeding is to be increased to maintain bed temperature of >800C and <900C.
Tiruchirapalli
PROJECT CUSTOMER
BOILER NO. REVISION
: BG059 : NIL
AUTOMATIC BED ASH COOLING CONTROL (This document should be read in conjunction with Drawing No. BG059-00-09-4-031) PURPOSE: To cool the hot ash to be specified temperature before discharging. MEASURED VARIABLES: The high ash level in the compartment is sensed by air box pressure transmitter. Each compartment ash drain in connected with individual bed ash coolers. Any compartment's bed ash level can be controlled independently with the help of solenoid operated power cylinder provided. CONTROL PHILOSOPHY: The ash level high signal from any one of the compartment shall initials bed ash cooling. The bed ash cooling shall be either auto or manual. AUTO MODE: The DCS should be programmed in such that if any one of compartments pressure transmitter is high, the control circuit will energize the solenoid operated power cylinder of that particular compartment. This compartment should be opened for a pre-set time. When the time is elapsed the compartment should be closed. Now the DCS should check for the high ash level. It still the ash level is high the next compartment should be opened and this should be continued. It ash level is low, the sequence shall be stopped. Care should be taken such that the compartment which is not running is not opened. MANUAL MODE: The operator by visualising the high alarm signal, can open the compartment and close still the ash level is reduced. NOTE: When any two pressure transmitter show high signal at a time; then the DCS should consider the higher or lower tag nos of pressure transmitter first.
PROJECT CUSTOMER
BOILER NO. REVISION
: BG059 : NIL
RADIANT CHAMBER S.H PRESSURE CONTROL (This document should be read in conjunction with Drawing No. BG059-00-09-3-028) PURPOSE: This control is to maintain Radiant chamber S.H pressure as a achieved by regulating the soot blower pressure reducing valve. MEASURED VARIABLES: The soot blower line pressure is measured by using one soot blower pressure transmitter (PT-1203) CONTROL PHILOSPHY : 1. The current output from the soot blower pressure transmitter (PT-1203) is fed to PIC in controller. This signal is compared with the set point in the controller and the output from the controller varies accordingly 2. The output signal from PIC in the controller is fed to Electro pneumatic convertor constant value. This is
through Auto/manual selector block configured in controller. 3. The Electro pneumatic convertor converts the current signal into a pneumatic signal and it regulates the soot blower pressure reducing valve. 4. The Position of the soot blower line PRS(ZT-1202) pressure control valve will be available in controller through position transmitter provided in soot blower line PRS valve.
Tiruchirapalli
CONTROL LOOP WRITE-UP
PROJECT : 1 X 36 MWe CAPTIVE POWER PLANT CUSTOMER : M/S. REI AGRO LTD.,
DOC No. SHEET : BG059 - CL-006 : 01 OF 01 BOILER NO. : BG059 REVISION : NIL
PA FAN SUCTION DAMPER RPC: (This document should be read in conjunction with Drawing NO: (BG059-00-09-3-030) PURPOSE: To maintain the PA fan delivery pressure by regulating the PA fan suction dampers remote manually. CONTROL PHILOSOPHY: a) Manual loader output is connected to the analog output card.
b) The analog output card is connected to I/P convertor of PA fan suction damper regulating power cylinder c) The position of suction dampers will be also available in DCS.
Tiruchirapalli
PROJECT : 1 X 36 MWe CAPTIVE POWER PLANT CUSTOMER : M/S. REI AGRO LTD.,
AIR HEATER BYPASS DAMPER CONTROL: (This document should be read in conjunction with Drawing NO: BG059-00-09-3-029) PURPOSE: The maintain constant flue gas temperature in ESP inlet. MEASURED VARIABLES: ESP inlet flue gas temperature is measured using a thermocouple (TE-1310) CONTROL PHILOSOPHY:
a) The ESP inlet flue gas temperature signal is fed to the Analog input card. b) The controller performs PID action on the input signal. c) The output signal from step (b) is connected to A/M block and the mode can be selected as auto (or) manual accordingly. d) The A/M block output is connected to I/P convertor from which the air heater bypass damper is controlled. e) Position feed back of air heater bypass damper is taken to DCS and displayed in CRT. f) When the ESP inlet flue gas temperature decreases, the air heater bypass damper closes and when the ESP inlet flue gas temperature increases, the air heater bypass damper opens and thus maintains the temperature.
Tiruchirapalli
PROJECT CUSTOMER
No. : BG059 -CL-008 SHEET : 01 OF 01
BOILER NO. REVISION
: BG059 : NIL
BLOW DOWN LEVEL CONTROL (This document should be read in conjunction with Drawing No. BG059-00-09-3-026) PURPOSE: This control is to maintain CBD tank level as a constant value. This is achieved by regulating the CBD tank level control valve. MEASURED VARIABLES: The CBD tank level is measured by using one CBD tank level transmitter (LT-0004) CONTROL PHILOSPHY : 1. The current output from the CBD tank level transmitter (LT-0004) is fed to PIC in controller. This signal is compared with the set point in the controller and the output from the controller varies accordingly 2. The output signal from PIC in the controller is fed to Electro pneumatic convertor
through Auto/manual selector block configured in controller. 3. The Electro pneumatic convertor converts the current signal into a pneumatic signal and it regulates the CBD tank level control valve. 4. The Position of the CBD tank (ZT-0004) level control valve will be available in controller through position transmitter provided in CBD tank level control valve.
Tiruchirapalli
CONTROL LOOP WRITE UP FURNACE DRAUGHT CONTROL
PROJECT CUSTOMER
BOILER NO. REVISION
: BG059 : NIL
(This document should be read in conjunction with Drawing No. BG059-00-09-3-033)

PURPOSE:
The purpose of furnace pressure control is to maintain the furnace pressure constant at the desired value for all the boiler loads. This is achieved by changing the flow of flue gas by regulating the RPC of ID fan.
MEASURED VARIABLES:
The furnace pressure is measured using a pressure transmitter (DT-1309)

CONTROL PHILOSOPHY:
1. The current output from the furnace pressure transmitter (DT-1309) is fed to the PIC in the DCS. This signal is compared with the set point in DCS and the output from DCS varies accordingly. 2. The output signal from PIC in the DCS is fed to ID fan RPC through Auto/manual selector block provided in PIC and mode can be selected as auto or manual accordingly. 3. The A/M block output is connected to electro pneumatic convertor. 4. When the furnace pressure increase the RPC of ID fan close and when the furnace pressure decrease the RPC of ID fan open.
Tiruchirapalli
PROJECT CUSTOMER
: 1 X 36 Mwe CAPTIVE POWER PLANT : M/S. REI AGRO LTD. BOILER NO. REVISION : BG059/60 : NIL
SERVICE : 2 X 80 TPH SINGLE DRUM WATER TUBE BOILER (FBC)
DOC No. : BG059/60 -CL-001 SHEET : 01 OF 01
DEAERATOR PRESSURE CONTROL (This document should be read in conjunction with Drawing No. BG059-00-09-3-024) PURPOSE: This control is to maintain deaerator pressure as a regulating the deaerator pressure control valve. MEASURED VARIABLES: The deaerator pressure is measured by using one deaerator pressure transmitter (PT-0003) CONTROL PHILOSPHY : 5. The current output from the deaerator pressure transmitter (PT-0003) is fed to PIC in controller. This signal is compared with the set point in the controller and the output from the controller varies accordingly 6. The output signal from PIC in the controller is fed to Electro pneumatic convertor constant value. This is achieved by
through Auto/manual selector block configured in controller.

7.
The Electro pneumatic convertor converts the current signal into a pneumatic signal and it regulates the deaerator pressure control valve.
8.
The Position of the deaerator (ZT-0001) pressure control valve will be available in controller through position transmitter provided in deaerator pressure control valve.
CLICK HERE TO OPEN BOILER CONTROL LOOP DRAWINGS (BG059)
PROJECT CUSTOMER
DOC No. SHEET
: BG060-CL-001 : 01 OF 03
BOILER NO. REVISION
: BG060 :A
THREE ELEMENT DRUM LEVEL CONTROL (This document should be read in conjunction with Drawing No. BG060-00-09-2-021/A) PURPOSE: The main objective of steam drum level control is to maintain constant water level in the steam drum by selecting either Single element control sensed only by drum level parameter for boiler load less than 30% or Three element control sensed by drum level, steam flow & feed flow parameters for boiler load greater than 30%. MEASURED VARIABLES: a. Drum level is measured by three level transmitters (LT-2201A on right side of steam drum and LT-2201B, LT-2201C on left side of steam drum). b. Steam flow is measured by using Steam flow transmitters (FT-2201) across the flow nozzle. c. Feed flow is measured by using feed flow transmitters (FT-0101) across the orifice.
d.
Main Steam line pressure is measured by using a pressure transmitter (PT-2103).
e. Steam temperature is measured by using thermocouples (TE-2101). f. Feed water temperature is measured by using a thermocouple (1-TE-201).
g. Drum pressure is measured by using drum pressure transmitters (PT-2101).
CONTROL PHILOSOPHY: a) The signal of the drum pressure from PT-2101 is used to compensate the drum level signals from three level transmitters (LT-2201A, LT-2201B, LT-2201C) for changes in density. This is accomplished by multiplying the uncorrected drum level signal by a pressure dependent gain. The gain used at any given drum pressure is set by function generator F1 (x). b) The two numbers transmitters (LT-2201B, LT-2201C) located at left side of the steam drum are averaged. Also, the difference between these two transmitters are continuously monitored.
c) If the difference is with in the limit (i.e., with in 3 percentage), then the average signal between the level transmitters are taken and this goes to software selector switch-1.
PROJECT CUSTOMER
DOC No. SHEET
: BG060-CL-001 : 02 OF 03
BOILER NO. REVISION
: BG060 :A
d) If the difference exceeds the limit, then an alarm should be generated as DIFFERENCE IS MORE and DCS should consider the transmitter which shows lower value between them and the software selector switch-1 should be changed to the particular transmitter. e) The output signal from selector switch-1 is average with the level transmitter (LT-2201A) located at right side of the drum. Also, the difference between these two transmitters are continuously monitored. f) If the difference is with in the limit (i.e., with in 5 percentage), then the average signal between the level transmitters are taken and this goes to software selector switch-2.
g) If the difference exceeds the limit, then an alarm should be generated and as DIFFERENCE IS MORE DCS should consider the transmitter which shows lower value between them and the software selector-2 should be changed to the particular transmitter.
h)
The output signal from selector switch-2 is fed to the level indicating controllers (LIC-2201 & LIC2202). The controller performs PI action on the input signal and an output is generated. The output signal from single element controller(LIC-2201) is connected to I/P convertor of 30% flow control valve through Auto/Manual selector block and the mode can be selected auto/manual accordingly. The output signal from three element level controller (LIC-2202) is taken to the summator block through convertor and drum level weightage block. Other input to the summator block is the compensated steam flow signal through steam flow weightage block.
i)
j)
k) This summator combines the steam flow signal with the control output signal from LIC-2202 to produce a variable set point input to the feed water flow controller. l) Another input (PV) to this flow indicating controller is compensated feed water flow signal.
m) The output signal from flow indicating controller is connected to FCV selector switch. The operator can select either FCV-2101A (or) FCV-2101B. n) The FCV selector switch output is connected to smart positioner of both 100% flow control valves through Auto/Manual selector switch and the mode can be selected as auto or manual accordingly. o) The I/P convertor converts the current signal into pneumatic signal and it regulates the feed control valves at required position. p) Position feedback of 30% & 100% feed control valves are taken to DCS and displayed in CRT. q) When single-element control is selected the drum level signal goes to single element controller (LIC-2201). This controller contains a manual transfer station. In manual, the operator can vary the output from the controller to adjust the feed water flow. r) When load is less than 30% of MCR, force a signal to close the 100% flow control valve gradually (FCV-2101A (or) FCV-2101B) & when load is greater than 30% of MCR, force a signal to close the 30% flow control valve (FCV-2101) gradually.
PROJECT CUSTOMER
DOC No. SHEET
: BG060-CL-001 : 03 OF 03
BOILER NO. REVISION
: BG060 :A
NOTE: 1. The output from both the Single - element controller (LIC-2201) & Three element controller (LIC-2202 & FIC) are connected to respective current to pneumatic converters of control valves through manual transfer switches. When the steam flow signal is less than 30% of MCR load alarm will be generated and operator to transfer the control to Single element control will be in operation through manual transfer switch & when the steam flow signal is greater than 30% of MCR load Three element control will be in operation through manual transfer switch by the operator. 2. Please note that if two transmitters are faulty, alarm is generated in DCS identifying the bad transmitters and the controller goes to manual and operator has the option to select the healthy transmitter and put the loop back into Auto. 3. The drum level low & high signals are derived from individual level transmitters for alarm purpose. These signals should be continuously monitored for control purpose 4. The drum level very high & very low signals should be taken selected process input from the software selector switch-2 and fed to level indicating controllers (LIC-2201 & LIC-2202) for alarm and tripping purpose. 5. Feed flow transmitter signal and steam flow transmitter signals are selected in the similar procedure of the signal selected from drum level transmitters
CETHAR VESSELS LTD. TIRUCHIRAPALLI - 620 001
PROJECT BOILER NO.
M/S. REI AGRO LTD BG060 Date: 10.12.08
DOCUMENT NO. BG060-CURVE-001
FUNCTION-G-CURVES
DRUM LEVEL PRESSURE COMPENSATION (GAIN)

1.8000
1.7000
1.6000
1.5000
1.4000 GAIN
1.3000
1.2000
1.1000
1.0000
DRG.NO : BG060-00-09-2-021/A (F1(X))
DRUM PRESSURE Kg/ cm(g)
GAIN Prepared 1.0000 Date: 10/12/08
15
1.1182
Approved
Date: 10/12/08
30
1.1886
45
1.2509
Rev.
Signature
Date
60
1.3154
90
1.4383
120
1.6302
140
1.7815
Tiruchirapalli
PROJECT CUSTOMER
BOILER NO. REVISION
: BG060 : NIL
SUPERHEATED STEAM TEMPERATURE CONTROL (This document should be read in conjunction with Drawing No. BG060-00-09-3-023)
PURPOSE:
The purpose of steam temperature control is to temperature at main steam line.

MEASURED VARIABLES:
maintain constant super heated steam
Main steam line temperature is measured using a thermocouple (TE-2204) CONTROL PHILOSOPHY: a. Cascade type control loop is followed here. b. The main steam temperature signal is compared with the set point provided. c. The output signal from step (b) us goes as cascade set point to next PID block.
d. Another (pv) input to this PID block is De-superheater outlet temperature.(TE-2203)

e. The output signal from (d) in DCS is fed through Auto/manual block and mode can be selected as auto or manual accordingly. f. The A/M block output is connected to electro pneumatic convertor. g. The Electro pneumatic convertor converts the current signal into a pneumatic signal and it regulates the spray control valve.
Tiruchirapalli
PROJECT CUSTOMER
BOILER NO. REVISION
: BG060 : NIL
COMBUSTION CONTROL (This document should be read in conjunction with its Drawing No. BG060-00-09-3-028) The objective of the combustion control is to ensure that the air flow into the furnace is proportional to the total amount of fuel entering the furnace at any instant. Normally, air flow will be slightly more than the theoretical air requirement for a given fuel. Too much of air leads to high excess air and higher loss in efficiency. Too less an air leads to insufficient combustion and also leads to clinker formation. Hence the combustion control is very important and it is divided into two parts. 01. 02. Air flow control Fuel flow control
AIR FLOW CONTROL: In this control the air flow is varied corresponding to the variation in steam flow. GENERAL POINTS IN AIR FLOW CONTROL: 1. The combustion control should not be used during boiler startup. 2. Combustion control should be put in Auto mode only after all the compartments are activated atleast once. 3. For combustion control to be in auto mode atleast 2 compartment should be in operation. 4. The air flow Vs steam flow curve will be furnished. From this curve the minimum and maximum air flow for various compartment combinations can be obtained. 5. Whenever the air flow reaches the high and low limits, alarms should be generated. MEASURED VARIABLES:
1. Air flow is sensed through one air flow transmitter (FT-2301) located across the aerofoil at
air heater outlet. 2. Steam flow is should through steam flow transmitter (FT-2201) 3. The number of compartments in operation is sensed in DCS using the signal from limit switches (ZSO-2301 to ZSO-2305)
Tiruchirapalli
PROJECT CUSTOMER
BOILER NO. REVISION
: BG060 : NIL
CONTROL PHILOSOPHY: The DCS should perform the following. 1. The no. of compartments in operation has to be checked with help of the digital inputs from the reed switches. Based on the no. of compartments in operation there is a maximum limit (XH) and minimum limit (XL) for the air flow. For example if all three compartments are in operation. The maximum air flow is TPH and minimum air flow is TPH. The are 3 sets of such limits namely XH1, XH2, XH3 & XL1, XL2, XL3. 2. Corresponding to the steam flow there will be air flow value from the air flow Vs steam flow curve. The air flow value will go as the set point to the air flow controller. 3. If this set point is between the maximum and minimum limits for the particular number of compartment in operation, then the controller output will go to the respective final control element i.e., Varying the RPC of FD fan through a auto manual selector block. 4. The air flow set point should go to the high limit (A Max) in case the bed temperature (defined under fuel flow control) goes to 950C. ALL 3 COMPARTMENTS IN OPERATION: a) Supposing the steam drawal is more, then the corresponding set point for air flow also will increase. If the set point crosses the high limit (XH) then the DCS should generate an alarm "STEAM DRAWAL IS MORE" and the air flow is brought to a freeze at the high limit. b) Supposing the steam demand is less, then the corresponding set point for air flow also will decrease. If the set point goes below the low limit (XL), then in DCS should generate an alarm (STEAM DRAWAL IS LESS-SHUT DOWN ANY ONE COMPARTMENT). The following compartment cut off sequence should be done by DCS. I) ii) A signal should trip fuel feeder of one compartment. Consequently the air line damper of that particular compartment has to be closed.
Tiruchirapalli
PROJECT CUSTOMER
BOILER NO. REVISION
: BG060 : NIL
LET US CONSIDER 2 COMPARTMENTS IN OPERATION: a) When the air flow set point corresponding to the steam flow is between the maximum and minimum air flow limits for 2 compartments in operation, then the air flow controller output will operate the final control element, that is the varying the RPC of the FD fan. b) If the steam drawal increases and the corresponding air flow set point reaches the high limit, then alarm starting STEAM DRAWAL IS INCREASED - ACTIVATE A NON OPERATING COMPARTMENT should be generated and the following compartment cut in sequence should be done by DCS. I) The FD air line damper of that compartment should be opened. ii) Ensure that the PA air line damper of that compartment is open. iii) The fuel feeder of that compartment should be started after ensuring that the bed temperature of that compartment is 600C. (This value is for Imported coal only) c) When the air flow set point reaches the low limit then the in DCS should perform the compartment cut off sequence as explained earlier. FUEL FLOW CONTROL: MEASURED VARIABLES:
1. The main steam line pressure is measured using the pressure transmitter (PT-2202) 2. The fuel feeder speed is senses using the VFD-2401
3. Bed temperature of all the compartment are sensed using the thermocouples (TE-2302A to TE-2306B) and the temp transmitter (TT-2301A to TT-2305B) 2 Nos. of thermocouples are provided in each compartment. This bed thermocouple signal is the main criterion for boiler operation. Since we have 2 thermocouple signals, the average value should be considered as the bed temperature. For averaging, erratic signal should not be considered, erratic signal is one of the following. I)Temperature signal of the operating compartment showing less than 600C. II) Open circuit in thermocouple. III) Temperature difference of more than 50C.
Tiruchirapalli
PROJECT CUSTOMER
BOILER NO. REVISION
: BG060 : NIL
A table containing, various bed temperature ranges for various fuel as below is fed to the fuel feeder selector block. FUEL
Imported COAL COAL
A1
840 TO 890C 825 TO 875C
A2
890 TO 940C 875 TO 925C 820 TO 870C 820 TO 870C
A3
940 TO 900C 925 TO 975C 970 TO 920C 970 TO 920C
A4
> 990C > 975C > 920C > 920C
30%IMP COAL +70% K.LIGNITE 770 TO 820C 30% COAL +70% K.LIGNITE 770 TO 820C
Following are the various temperature zone, defined in the FBC boiler. 01. LOW BED TEMPERATURE The average bed temperature in the range of 750C to 850C is defined as the low bed temperature. 02. NORMAL BED TEMPERATURE The average bed temperature in the range of 850C to 925C is defined as the normal bed temperature. 03. HIGH BED TEMPERATURE The average bed temperature in the range of 925C to 950C is defined as the high bed temperature. 04. VERY HIGH BED TEMPERATURE The average bed temperature above 950C is defined as very high bed temperature. In DCS shall also have some dead band (between 10C to 20C) between the two temperature zones. The dead band shall be applicable for decreasing trend only. (ie., from very high temperature zone to high temperature zone). CONTROL PHILOSOPHY In the fuel flow control, the speed of the fuel feeder i.e., the fuel feed rate, is controlled based on the steam pressure and the bed temperature.
Tiruchirapalli
PROJECT CUSTOMER
BOILER NO. REVISION
: BG060 : NIL
The steam pressure signal goes to the steam pressure controller which is given a set point for steam pressure. Based on the deviation, this controller generates an output which is given as a cascade set point to the fuel feeder controllers of the individual compartments. The fuel feeder controller output is connected to two nos. of the fuel feeder of the individual compartments through the output selector block & A/M block and each A/M block. The function of the output selector block is as follows : I) NORMAL BED TEMPERATURE
When the bed temperature is normal, the DCS should give output based on the difference in steam pressure signal (output mode A ie., F) as explained above. The output should go to all the running fuel feeders parallaly so as to decrease or increase the fuel feeder speed. II) LOW BED TEMPERATURE
When the bed temperature is low, the DCS should first bring the temperature to normal. This is achieved by incrementing the fuel feed speed (ie. Original fuel feeder speed + some incremental value). The DCS shall have provision for time gap (in terms of minutes) between one increment and the next increment of fuel speed. The actual time will be decided after commissioning the boiler. The 4-20 mA output from fuel feeder VFD will be taken into the DCS and the same should be calibrated to VFD speed. Normally the incremental value can be 10% to start with and provision shall be available in DCS to change the same in future. Once the bed temperature comes to normal zone, the DCS should work based on the steam pressure signal. (Output mode A is F + F). III) HIGH BED TEMPERATURE
When the bed temperature is high, the DCS should first bring the temperature to normal. This is achieved by decrementing the fuel feed speed (ie. Original fuel feeder speed - some decremental value). The decremental value can be 10% to start with and provision shall be available in DCS to change the same in future. The DCS shall have provision for time gap (in terms of minutes) between one increment and the next increment of fuel speed. The actual time will be decided after commissioning the boiler. Once the bed temperature comes to normal zone, the DCS should work based on the steam pressure signal. (Output mode A is F - F).
Tiruchirapalli
PROJECT CUSTOMER
BOILER NO. REVISION
: BG060 : NIL
IV)
VERY HIGH BED TEMPERATURE
The fuel feeder of that particular compartment should be tripped. Once the temperature comes to above 750C, the fuel feeder can be switched ON. GENERAL POINTS ON FUEL FLOW CONTROL 01. DCS shall have provision for the following. a) b) The combustion control loop should be by passed during the boiler start-up. For combustion control to be in auto mode minimum two compartments should be in operation.
c) The current output of the fuel feed controllers should be within the specified limits. The upper limit of the current output is fixed by the maximum speed corresponding to the maximum carrying capacity, moisture content and calorific value. The maximum speed of the fuel feeders will be about 10% more than the normal speed required at full load when all the compartments are in operation. The upper and lower limits of the current output will be informed during commissioning and should be possible to change the values at site based on the operating conditions.
02. Speed of fuel feeders can be manually operated from VFD panel also.
03. If the steam pressure is high and correspondingly the fuel feed rate is reduced then the bed temperature will start falling. However if the temperature falls below 800C, even if the pressure is high, fuel feeding is to be increased to maintain bed temperature of >800C and <900C.
Tiruchirapalli
PROJECT CUSTOMER
BOILER NO. REVISION
: BG060 : NIL
AUTOMATIC BED ASH COOLING CONTROL (This document should be read in conjunction with Drawing No. BG060-00-09-4-029) PURPOSE: To cool the hot ash to be specified temperature before discharging. MEASURED VARIABLES: The high ash level in the compartment is sensed by air box pressure transmitter. Each compartment ash drain in connected with individual bed ash coolers. Any compartment's bed ash level can be controlled independently with the help of solenoid operated power cylinder provided. CONTROL PHILOSOPHY: The ash level high signal from any one of the compartment shall initials bed ash cooling. The bed ash cooling shall be either auto or manual. AUTO MODE: The DCS should be programmed in such that if any one of compartments pressure transmitter is high, the control circuit will energize the solenoid operated power cylinder of that particular compartment. This compartment should be opened for a pre-set time. When the time is elapsed the compartment should be closed. Now the DCS should check for the high ash level. It still the ash level is high the next compartment should be opened and this should be continued. It ash level is low, the sequence shall be stopped. Care should be taken such that the compartment which is not running is not opened. MANUAL MODE: The operator by visualising the high alarm signal, can open the compartment and close still the ash level is reduced. NOTE: When any two pressure transmitter show high signal at a time; then the DCS should consider the higher or lower tag nos of pressure transmitter first.
PROJECT CUSTOMER
BOILER NO. REVISION
: BG060 : NIL
RADIANT CHAMBER S.H PRESSURE CONTROL (This document should be read in conjunction with Drawing No. BG060-00-09-3-024) PURPOSE: This control is to maintain Radiant chamber S.H pressure as a achieved by regulating the soot blower pressure reducing valve. MEASURED VARIABLES: The soot blower line pressure is measured by using one soot blower pressure transmitter (PT-2203) CONTROL PHILOSPHY :
1.
constant value.
This is
The current output from the soot blower pressure transmitter (PT-2203) is fed to PIC in controller. This signal is compared with the set point in the controller and the output from the controller varies accordingly
2.
The output signal
from PIC in the controller is fed to Electro pneumatic convertor
through Auto/manual selector block configured in controller.

3.
The Electro pneumatic convertor converts the current signal into a pneumatic signal and it regulates the soot blower pressure reducing valve.
4.
The Position of the soot blower line PRS(ZT-2202) pressure control valve will be available in controller through position transmitter provided in soot blower line PRS valve.
PROJECT
: 1 X 36 MWe CAPTIVE POWER PLANT
Tiruchirapalli
CONTROL LOOP WRITE-UP PA FAN SUCTION DAMPER RPC:
CUSTOMER : M/S. REI AGRO LTD.,

(This document should be read in conjunction with Drawing NO: (BG060-00-09-3-026) PURPOSE: To maintain the PA fan delivery pressure by regulating the PA fan suction dampers remote manually. CONTROL PHILOSOPHY: a) Manual loader output is connected to the analog output card.
b) The analog output card is connected to I/P convertor of PA fan suction damper regulating power cylinder c) The position of suction dampers will be also available in DCS.
PROJECT
: 1 X 36 MWe CAPTIVE POWER PLANT
Tiruchirapalli
CUSTOMER : M/S. REI AGRO LTD.,

AIR HEATER BYPASS DAMPER CONTROL: (This document should be read in conjunction with Drawing NO: BG060-00-09-3-025) PURPOSE: The maintain constant flue gas temperature in ESP inlet. MEASURED VARIABLES: ESP inlet flue gas temperature is measured using a thermocouple (TE-1310) CONTROL PHILOSOPHY:
a) The ESP inlet flue gas temperature signal is fed to the Analog input card. b) The controller performs PID action on the input signal. c) The output signal from step (b) is connected to A/M block and the mode can be selected as auto (or) manual accordingly. d) The A/M block output is connected to I/P convertor from which the air heater bypass damper is controlled. e) Position feed back of air heater bypass damper is taken to DCS and displayed in CRT. f) When the ESP inlet flue gas temperature decreases, the air heater bypass damper closes and when the ESP inlet flue gas temperature increases, the air heater bypass damper opens and thus maintains the temperature.
Tiruchirapalli
CONTROL LOOP WRITE UP FURNACE DRAUGHT CONTROL
PROJECT CUSTOMER
BOILER NO. REVISION
: BG060 : NIL
(This document should be read in conjunction with Drawing No. BG060-00-09-3-027)

PURPOSE:
The purpose of furnace pressure control is to maintain the furnace pressure constant at the desired value for all the boiler loads. This is achieved by changing the flow of flue gas by regulating the RPC of ID fan.
MEASURED VARIABLES:
The furnace pressure is measured using a pressure transmitter (DT-2309)

CONTROL PHILOSOPHY:
1. The current output from the furnace pressure transmitter (DT-2309) is fed to the PIC in
the DCS. This signal is compared with the set point in DCS and the output from DCS varies accordingly. 2. The output signal from PIC in the DCS is fed to ID fan RPC through Auto/manual selector block provided in PIC and mode can be selected as auto or manual accordingly. 3. The A/M block output is connected to electro pneumatic convertor. 4. When the furnace pressure increase the RPC of ID fan close and when the furnace pressure decrease the RPC of ID fan open.
CLICK HERE TO OPEN BOILER CONTROL LOOP DRAWINGS (BG060)
TROUBLE SHOOTING CHART
TROUBLE SHOOTING CHART

DURING START UP
Sl.NO. TROUBLE CAUSES REMEDY
01.
Start up failures.
Improper Bed material size. Improper charcoal size. Poor Quality of charcoal. Insufficient Qty. of charcoal.
Bed material size has to be between 0.85 mm and 2.36 mm. Charcoal size should be 15-25 mm. Charcoal shall be dry for good quality. Qty. of charcoal shall be 20 kg. per m2 area of bed and kerosene soaked charcoal shall be 10 kg. per m2 area of bed. Bed height should be 200 mm above the air nozzle. Bed height should be 200 mm above the air nozzle. Uniform spreading of charcoal shall be ensured.
Insufficient bed height. Excess bed height. Improper spreading of charcoal.
Improper spreading of fire over the Swab fire initiated should be even. If not throw kerosene soaked top layer of kerosene soaked charcoal at such locations where fire is not present. charcoal. Wrong bed temperature indication. Improper mixing. Thermocouples are to be checked using swab fire before starting Mixing should be done with the predetermined air flow level (Just above MFC level)
Sl.NO.
TROUBLE
CAUSES Improper fuel feeding. P.A. Line choking.
REMEDY Fuel is to be fed only after the bed temperature reaches 600C. Minimum airflow in fuel transport line is to be maintained till the start of fuel feed. Before fuel feed, increase airflow to MCR air flow Dechoking of the lines is possible by opening the line flap damper fully and by opening the corresponding drain gates in the airbox.
02.
Clinker formation during start up over the entire bed.
High bed temperature over the entire Charcoal Quantity shall be as per recommendations. bed. This is due to excess charcoal (or) due to excess fuel feed before High bed temperature can be reduced by controlling fuel feed and charcoal combustion is complete. by increasing the air flow. (or) incomplete mixing. Give the required mixing air flow. Warning: Air flow should be slightly more than MCR level. Otherwise all hot material would go to the adjacent compartment. Low fluidisation velocity after mixing. Wrong temperature indication. Excess fuel feeding. Air flow level can be increased. (MCR air flow level) Checking the thermocouple with swab fire before starting. Fuel feeding should be gradually increased after ensuring that the fuel is catching fire.
03.
Localised Clinker Localised vigorous static burning of Before mixing clinkers may form due to delay in mixing. charcoal before and after mixing : Formation After mixing, clinkers form due to inadequate mixing (i.e. less mixing air flow or less duration of mixing) After proper mixing, clinkers may form if the air flow is not brought to MCR level.
Sl.NO.
TROUBLE
CAUSES
REMEDY
DURING COMPARTMENTAL TRANSFER (FROM COLD CONDITION) The bed temperature of operating compartment drops because of 01. Fire extinguishing Improper method of activation. cold bed material in activated compartment mixing with hot bed in operating material of operating compartment. compartments. Attempting for compartment Slump the activated compartment as soon as the bed temperature in operating compartment drops below 750C. Further attempt transfer in one to two trials. should be made only after bringing the bed temperature of the operating compartment to 900C with 120% MCR air flow. 02. Clinker formation in Operation compartment. Insufficient air flow. After compartmental transfer, the air flow should be once again brought to MCR condition in operating compartment. After tranferning, the fuel feed rate in operating compartment needs to be reduced.
Excess fuel feed.
03.
Bed temperature not rising in activated compartment.
a. Inadequate air flow for disturbing Increase the airflow momentarily if the fan capacity is available and the cold bed material. provided the bed temperature in operating compartment is not low. Alternatively, momentarily close the FD damper of the operating compartment. Long operation with single compartment results in excess bed material ash accumulation in the compartment adjacent to the operating comparment. Drain the bed if necessary.
Sl.NO. 04.
TROUBLE Clinker formation in activated compartment.
CAUSES
REMEDY
Insufficient air flow static bed This can be avoided by maintaining the bed fluidising before fuel promotes vigorous burning of fuel at feed. To disturb the clinker formation momentary mixing may be several locations and thus clinkers adopted at times. form. Excess fuel feed before the bed temperature rises to fuel ignition temperature. Otherwise, fuel accumulated leads to sudden bed temperature rise. Fuel should not be fed before bed temperature rises to fuel ignition temperature (600C for coal; 300C for husk) . Sudden bed temperature rise could be controlled by increasing the air flow or by activating the adjacent cold compartment.
05.
Bed temperature dropping in activated compartment.
Excess fuel feeding when the bed Fuel feeding should be gradually increased, when bed temperature temperature around 600C is 500 - 600C. quenches the fire. Operating at less air flow condition Air flow should be sufficient. MCR air flow is required. leads to CO formation and less heat release and thus bed temperature remains low.
Failure to set fuel transport air flow Minimum air heater pressure of 700 mmwc is required to be set to before attempting activation. prevent PA line choking. The header pressure should be increased to MCR condition before fuel feed. DURING CONTINUOUS OPERATION 01. Bed temperature Insufficient fuel feed rate. Sufficient fuel feed rate is required. dropping. Excess fuel Sufficient fuel feed rate is required. Excess air flow. Sufficient air flow is required (MCR air flow)
06.
PA line choking
Sl.NO.
TROUBLE
CAUSES
REMEDY
Fuel line choking. - Due to wetness of fuel. - Due to entry of foreign materials. Wet fuel should be avoided. To avoid the entry of foreign materials a vibratory screen (or) magnetic separator can be provided in the fuel handling system.
Fuel not being fed from feeder. - Due to high moisture in the fuel, To avoid this, high moisture fuel should not be used. fuel would adhere in the pocket feeders blade, so no fuel would be fed. Excess bed height causes less Bed should be drained once in every shift. pressure below 425 mm of wc). fluidisation. Thermocouple is in loose contact. Bed height is less than 175 mm. 02. High bed temperature. More fuel feed rate. Less air flow. Excess feeding of fuel from feeder. One of the causes may be, broken pocket feeder blades. Due to this more fuel would be fed. Thermocouple to be corrected. Bed height should be increased. Fuel feed rate has to be reduced. Air flow has to be increased slightly (upto MCR air flow level) Rotor requires replacement. (Maintain air box
Sl.NO. 03.
TROUBLE Clinker formation.
CAUSES
REMEDY
High bed temperature due to excess Decreasing the fuel feed rate (or) air flow may be slightly increased. fuel feeding. Low fluidisation velocity. - leads to static burning at places. Bigger size fuel. Air flow can be slightly increased.
Bigger size fuel could be avoided. So correct size fuel could be used (Below 6 mm).
Bigger size fuel would burn partially. So partially burnt fuel would settle in the bed. Sometimes bed temperature would shootup suddenly. This may cause clinker formation. Bed draining not done - due to this To avoid this bed should be drained once for every shift. (Maintain bed height would increase. So, there air box pressure below 425 mm of wc). would be defluidisation. Erentual disturbance fuel feed leads to reduction in bed temperature Erratic disturbance in fuel feeding. - may be due to foreign particles, and thus velocity and the fuel feed is restored if be necessary to tripping the feeder or choking the increase the air flow momentarily. mixing nozzle.
Sl.NO.
TROUBLE
CAUSES
REMEDY
04.
PA line choking.
Foreign material choking the mixing This can be avoided by providing seperator in fuel handling system. nozzle.
vibratory screen or magnetic
05.
Backflow of air Fuel line choking due to one of the Choking is to be removed.. thro bunker gate. above causes. Back firing. ID fan damper has been opened ID fan damper has to be slightly opened. (maintain furnace pressure of minimum - 10 mm of wc). sufficiently. Insufficient air pressure to lift power Sufficient air pressure is to be supplied (pressure 3.5 to 5 kg/cm2 for cylinder. power cylinder action). Ash accumulation in hoppers above Ash should be removed periodically. various drain points. - This would reduce ID fan suction.
06.
07.
Steam production Improper parameters. is less.
Proper parameters should be followed.
DOS AND DONTS
DOS AND DONTS

Sl.NO. DOS DONTS
01.
ECONOMISER
Run the boiler with continuous running of the feed Dont run the boiler with frequent switching ON pump. & OFF of the feed pump. Keep the isolation valves at spare feed pump ---open. Blow down should be given once, daily for level Dont stat the boiler, if the liquid level limitter is transmitter lines. not functioning for high level, low level and trip level. Give frequent blow downs of water level gauge to Dont run the boiler, if the water level gauges free from blockages at both top and bottom are not showing the same water level. points. Allow 10% of 8 - 10 mm size fuel. Dont start the boiler if the fuel size is more than 6 mm ( 8 - 10 mm, over size upto 10% accepted ).
02.
FEED PUMP
03.
LEVEL TRANSMITTER
04.
WATER LEVEL GAUGE
05.
FUEL OVER SIZE
06.
ASH DRAIN POINT (other than bed drain points) FEED WATER & BOILER WATER
During boiler operation check whether there is Dont open the ash drain gates frequently. suction in all the ash drain points.
07.
Analyse the feed water and boiler water daily.
Dont run the boiler if the water quality is not as per the specifications given in the manual.
Sl.NO.
DOS
DONTS
08.
RELAY SETTING (MOTORS)
Set the relay in full load amps of the motor.
Dont start the fans amps.
before setting the relay
09.
GAS PLENUM PRESSURE THREE PHASE SUPPLY
Maintain the gas plenum pressure at minus 5 -------mmwc. Check the continuity of fuses. Dont bypass the fuses with direct wire connection.
10.
11.
CONTINUOUS BACK FIRE
Ensure that ash chutes and ducts are clean from Dont run the boiler with continuous back fire. ash accumulation.
12.
PART LOAD BOILER OPERATION
Change the compartments every shift.
Do not run a particular compartment alone continuousl.
INSPECTION AND MAINTENANCE SCHEDULE
INSPECTION AND MAINTENANCE SCHEDULE

EQUIPMENT FD SYSTEM FD fans & Motors NO. POINTS TO BE CHECKED FREQUENCY REMARKS
1.
Check whether motor bearing temperature is Daily normal. Check whether the motor current is normal. Daily
One set of motor bearings is to be kept as spare. (For coupled fans, one set of fan bearings is to be kept as spare)
2. 3.
Check whether the vibration level and sound level is Daily normal. Ensure that the draught connections are not leaky. Ensure that the manometer water is clean. Ensure that the draft connections are not leaky. Weekly. Weekly. Weekly.
Airfoil meter
1. 2.
Air box draft / mano meter / Draft gauge
1. 2.
Ensure that the manometer water is clean if a Weekly. manomer is provided. Ensure that all the nozzles are in good condition. At every shut 50 nozzles are to be maintained down. as spare.
Air box
1.
2.
Ensure that the nozzles are free from plugging by At every shut Use compressed air for cleaning. coal powder. down. Ensure that the nozzles are free from plugging by If furnace Use compressed air for cleaning. refractory. refractory work was done.
3.
EQUIPMENT
NO. 4.
POINTS TO BE CHECKED Clear the sieved bed compartment in the air box. material from
FREQUENCY each Once in three months/in case of air nozzle breakage.
REMARKS
ID SYSTEM ID fan & Motor 1. Check motor the bearing temperature of the fan and Daily One set of motor and fan bearings is to be maintained as spare.
2. 3.
Check whether the motor current is normal.
Daily
Check whether the vibration and sound level is Daily. normal. Check for erosion / damage. Once in months. six Keep a spare ID fan impeller expected life 1 year.
ID fan impeller
1.
PA SYSTEM PA fan & Motor 1. 2. 3. Check motor bearing temperature. Check whether the motor current is normal. Daily Daily One set of motor and fan bearings are to be maintained as spare.
Check whether the vibration level and sound level Daily. is normal. Inspect the fuel nozzle cap for any damage. Inspect the supporting lugs of coal nozzle cap.
Everyshutdown Everyshutdown
Fuel feed nozzle
1. 2.
Keep 4 nos. of fuel nozzles as spare for replacement.
EQUIPMENT
NO.
POINTS TO BE CHECKED
FREQUENCY
REMARKS
FUEL FEEDING SYSTEM Feeders & Drive 1.
Check the any damage in the feeder due to foreign Weekly material. Chain lubrication. Gear box Lubrication oil level. Change gear box oil, on contamination. Weekly Weekly Weekly
2. 3. 4. FEED WATER SYSTEM Feed pumps 1. 2. 3. 4. Feed water 1.
Check the operation of spare pump. Replace the gland packing. Check for abnormal vibration and sound. Check for suction strainer choking.
Daily If leaking. Daily Daily
Refer O & M Manual. Keep spare gland packings. Keep spare gland packings.
Check for Hardness, pH, O2, oil content and TDS in Daily feed water.
Compare with recommendation given and take corrective measures.
FURNACE Bed thermocouple.
1.
Ensure that all the thermocouple compensating When 40 m length of compensating cables are in good condition and the end thermocouple cable is to be kept as spare. connections are not loose. shows above 1200C. Replace the thermocouple if burnt. During the Keep 4 nos. of spare immediate thermocouples at stock. next shut down bed
2.
EQUIPMENT Refractory wall
NO. 1.
POINTS TO BE CHECKED Repair the cracks in the refractory wall.
Water level gauge BOILER SYSTEM Boiler water
1.
FREQUENCY REMARKS During the Keep required castable refractory immediate and binding mortar in stock. next shut down. Check the water level gauge function by giving a Keep spare glasses and washers blowdown. Every shift. for both water level gauges. Check Alkalinity, pH, phosphate and TDS. Residual SO4 residual Every shift Compare with recommendation given and take corrective actions.
1.
2. 1. Safety valves ASH REMOVAL SYSTEM Ash hoppers 1.
Follow blowdown schedule to bring TDS to limits.
Every shift one
Blow the steam through safety valve by hand Every popping with the lever to avoid seat seizure. month Ensure that ash is being removed and ash flows out Every shift. freely. Inspect and remove sludge accumulation in the bed Every year. coil header.
Bed coil headers.
1.
Blowdown the water through header drain valve At every shut after the fire is put off, but with the boiler under a down. pressure of min. 5 kg/cm2. Valves in feed water, boiler water systems, steam line 1. Inspect for gland leakages and tighten the gland Weekly. nuts. Replace the gland packings. Every year / on major leakage
2.
PRESERVATION OF BOILERS
PRESERVATION OF BOILERS
INTRODUCTION Atmospheric corrosion of ferric materials proceeds rapidly in the presence of oxygen and moisture. The oxides produced are objectionable and can be transported to critical heat transfer areas. Also, through the wall, pit type corrosion can occur. In todays boilers with their numerous complex circuits and bends, it is usually impossible to completely dry a boiler in preparation for storage. Draining all circuits (if drainable) while hot may temporarily dry the surfaces; however, unless dry air can be continuously circulated to eliminate all the water vapour from the unit, recondensation will again result in moist conditions. For this reason, wet lay-up normally offers the most positive method of protection for components in modern boilers. LAY-UP METHOD This method employs filling up the boiler with treated water and keeping the unit pressurized for filling. However, a better method of preserving of boiler would be to have nitrogen blanketting. In this method the boiler is filled with water treated for pH and O2 and sealed with nitrogen at a pressure of 0.35 atg to avoid air ingress. Figure shows the general arrangement of the rig up required for nitrogen blanketting. Nitrogen cylinders can be employed for this purpose. The nitrogen supply can be connected to the drum vent and superheater vent. WET METHOD If the boiler is likely to be out of service for more than a few days, but may be needed for steaming at short notice, all parts, including the economizer and superheater should be completely filled with correctly conditioned water. Non-drainable superheaters should be filled only with condensate quality water treated with volatile chemicals such as hydrazine to 5 Kg /cm(g) feed pump may be used for this purpose. Water conforming to recommended specification furnished in earlier section, is to be used
or ammonia. It is most important that pockets of air are not allowed to remain in the boiler and that there should be no leakage.
When completely filling the boiler with water, sufficient sodium sulphite or hydrazine should be added to combine with the dissolved oxygen and leave an excess of 100 mg/ 1 to 200 mg/1 of sodium sulphite as Na2 SO3 or hydrazine as N2H4. In addition, alkali should be added to ensure that a pH value of 10.0 to 11.5 is maintained. Distribution of these chemicals throughout the bulk of the water should be ensured by filling with a premixed solution, by use of a circulating pump or by heating the boiler when partially filled and then topping up with conditioned water. It is recommended that the aircock on the drum or shell should be connected to a surge tank located at a higher level. This compensates for any volumetric change and ensures a positive pressure thus preventing admission of oxygen to the unit. This tank should be covered and kept dosed with oxygen scavenger and alkali. Alternatively, pressure on the system should be maintained by using a small pump. The oxygen scavenger reserve and the pH value or alkalinity should be checked regularly and additional treatment chemicals added, as necessary and distributed to maintain the treatment levels within the recommended range. Any additional water added to the boiler should contain the appropriate quantities of treatment chemicals. When required for service the boiler should be drained down to normal working level before firing. Phosphate or other conditioning reserves should be re-established as soon as possible. This method of storage is recommended only if there is no likelihood of frost damage occuring. Wet storage is not recommended for periods of longer than 2 or 3 months unless the treated water is circulated regularly in all parts of the boiler including the economizer and superheater. Wet storage tends to promote condensation of atmosphere moisture and hence corrosion in the flue gas side. Where this proves trouble some dry storage is to be preferred.

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CE THAR VESSELS LIMITED

M/s. REI AGRO LIMITED.

CONTRACT DATA SHEET

CONTRACT DATA SHEET

CETHAR VESSELS (P) LIMITED

DWG. No. : BG059-00-09-4-005 REVISION : B

P & I DIAGRAM FOR FEED LINE & STEAM LINE. (VALVES)

CETHAR VESSELS (P) LIMITED

DWG. No. : BG059-00-09-4-005 REVISION : B

STATUTORY APPROVAL (IBR)

CETHAR VESSELS (P) LIMITED

DWG. No. : BG059-00-09-4-005 REVISION : B

STATUTORY APPROVAL (IBR)

ROOT & ISO VALVE FOR BEDCOIL DRAIN

1.45 1.46 1.47 1.48 1.49 1.50

GLOBE GLOBE GLOBE GLOBE 3 WAY GLOBE

1500 1500 1500 1500 250 ATG 1500

YES YES YES YES YES YES

SA182F22 SA105 SS304 SA182F22 SA182 F6 SA182 F22

104 104 104 104 104 104

525 525 525 525 525 525

030 029 113 026 052 026

DRAIN VALVE FOR STEAM LINE

104 104 104 104 104 104 104 104 104 97 97 97

CETHAR VESSELS (P) LIMITED

DWG. No. : BG059-00-09-4-005 REVISION : B

STATUTORY APPROVAL (IBR)

P & I DIAGRAM FOR DEAERATOR & FEED PUMPS.

REF DRG : BG059-00-09-1-001/NIL

CETHAR VESSELS (P) LIMITED

DWG. No. : BG059-00-09-4-005 REVISION : B

STATUTORY APPROVAL (IBR)

CETHAR VESSELS (P) LIMITED

DWG. No. : BG059-00-09-4-005 REVISION : B

STATUTORY APPROVAL (IBR)

REF DRG : BG059-00-09-0-003/NIL

CETHAR VESSELS (P) LIMITED

DWG. No. : BG059-00-09-4-005 REVISION : B

STATUTORY APPROVAL (IBR)

P & I DIAGRAM FOR HP & LP DOSING SYSTEM.

REF DRG : BG059-00-09-3-004/NIL

CETHAR VESSELS (P) LIMITED

DWG. No. : BG059-00-09-4-005 REVISION : B

STATUTORY APPROVAL (IBR)

REF DRG : BG059-00-09-3-008/NIL

P & I DIAGRAM FOR BED ASH COOLING SYSTEM 3.01 V1350

REF DRG : BG059-00-09-3-009/NIL

CETHAR VESSELS (P) LIMITED

DWG. No. : BG059-00-09-4-005 REVISION : B

DESCRIPTION REF DRG : BG059-00-09-3-010/NIL

P & I DIAGRAM FOR STARTUP OIL FIRING SYSTEM

3.01 V1351 TO V1354 3.02 V1355 TO V1358 3.03 V1359

P & I DIAGRAM FOR INSTRUMENTS AIR DISTRIBUTION SYSTEM

REF DRG : BG059-00-09-2-011/NIL

CETHAR VESSELS (P) LIMITED

DWG. No. : BG059-00-09-4-005 REVISION : B

STATUTORY APPROVAL (IBR)

REF DRG : BG059-00-09-1-012/NIL

CETHAR VESSELS (P) LIMITED

DWG. No. : BG059-00-09-4-005 REVISION : B

GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE GLOBE

800 800 800 800 800 800 800 800 800