BOILER SYSTEM

The boiler consisting of steam drum, membrane water wall panels,bed evaporator coils,convection superheater, radiant 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, 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 All the water required to produce steam is supplied by the two 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 seperated water along with the incoming feed water is continuously circulated through this circuit. The natural circulation circuit is formed by the drum, downcomers, bed evaporator headers, bed evaporator, waterwalls, roof tubes, outlet headers and riser pipes. The saturated steam from the drum is superheated in the superheater coils, in 2 stages. The steam passes through the connecting links, convection superheater inlet header, convection superheater coils, convection superheater outlet header, connecting link between convection superheater outlet and De-super heater , De-superhaeter, connecting link between De-superheater and radiant super heater inlet header and radiant superheater inlet header. Radiant super heater coils, radiant superheater outlet header. De-superheater is located inbetween convection and radiant superheater, it serves to control the boiler outlet steam temperature.

STEAM DRUM The steam drum is of fusion welded type, liberaly 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 AUXILIARY STUB DIRECT LEVEL GAUGES LEVEL TRANSMITTER PRESSURE TRANSMITTER - 1 NO. - 1 NO. - 1 NO. - 2 NOS. - 1 NO. - 2 NOS. - 2 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.

DOWN COMER & BED COILS The water from drum flows through six downcomers 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 coil assemblies are 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.

WATERWALL 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 bottom support . From the side waterwall top headers there are riser pipes, from each header, to carry the steam water mixture to the drum. From the roof panel top header there are two 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. 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. ECONOMISER 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. The economiser coils are horizontally arranged and are split into two banks with a gap of 1200 mm in between them. The economiser 4

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.

SUPERHEATER SYSTEM
In superheater system, the superheaters are provided in 2 stages and termed as Convection superheater, and Radiant superheater . CONVECTION SUPERHEATER The dry saturated steam from drum is let into the convection super heater inlet header by means of 4 nos of connecting links. The super heater inlet and outlet headers are located horizontally in top of the water wall headers perpenticular to the boiler axis. The convection super header consists of 35 parallel paths. The super heater is located above rear wall nose portion. The super heater is vertically placed, spaced and cross flow arrangement. The super heater coils with headers are suspended from top using hangers and rockers. Convection heat transfer area is arrived based on the following mentioned formulae. Q = U.A.LMTD Q Heat transfer rate Kcal/hr U Overall heat transfer coefficient Kcal/ hr-m^2.C LMTD- Log mean temp. difference, C Heat balance is done for both heated side and heating side by using the following equation: Q = m.Cp (T2 T1) m mass flow, kg/hr Cp sp. Heat, Kcal/kgC T- Tempearture, C

RADIANT SUPERHEATER The superheated steam from convection super heater outlet header is let into the radiant super heater inlet header by means of connecting link. The super heater provided as pentant 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 De-super heater is provided on the link that connects the convection super heater and radiant super heater. 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 radiant super heater outlet steam pipe.

RADIANT SUPERHEATER OUTLET LINK The main steam pipe is provided from radiant super heater outlet link upto main steam stop valve. The main steam pipe accomodates, the following stubs. 01. 02. SAFETY VALVE STARTUP STEAM VENT (MOTORISED) 03. 04. 05. 06. 07. 08. 09. 10. 11. PRESSURE TRANSMITTER PRESSURE GAUGE (LOCAL) PRESSURE GAUGE (REMOTE) SAMPLING TEMPERATURE GAUGE (LOCAL) TEMPERATURE ELEMENT DRAIN AIR VENT AUXILIARY 6 - 1 NO. - 1 NO. - 1 NO. - 1 NO. - 1 NO. - 1 NO. - 1 NO. - 1 NO. - 1 NO. - 1 NO. - 1 NO.

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.

DE-SUPERHEATER
Desuperheater is provided in the link connecting the convection superheater outlet header and radiant superheater 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 discharge line but before the feed control station. It is essential that the spray water be chemically pure and free of suspended and dissolved solids. CONTROL A spray control valve linked to an automatic temperature control one number temperature control valve will be provided to regulate the flow of spray water supplied to de-superheater. A manual operated isolation valve is installed on upstream and downstream of control valve to permit isolation when required. A motor operated regulating valve is provided in the bypass line to take care of the spray during maintenance of spray control valve.

FEED WATER SYSTEM

The feed water system for both boiler comprises one common deaerator deaerator-cumfeed water storage tank, two numbers of Feed water pumps of 100 % MCR capacity of boiler. DEAERATOR The deaerator is provided to supply feed water at 126 Deg.C at BMCR. The steam for deaearator will be supplied by Turbine extraction. At low load to maintain minimum deaearator outlet temperature, pegging steam will be supplied from main steam line through PRDS station. 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 0.005 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. 8

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 feed water storage tank will be sized to meet 20 minutes requirement (between normal water level and low-low water level) of boiler running at BMCR. The storage vessel will be mounted at suitable height to provide the required NPSH for the feed water pumps. 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, dosing inlet, 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. FEED WATER PUMP Two number electrically driven feed pumps will be provided with manual operated Isolation valves provided at the outlet of each feed pump. The pumps will be of multistage, ring section, centrifugal type, complete with suction strainer, balancing chamber and necessary valve and instruments A suction strainer is provided after the inlet manual isolation valve of each pump, to protect the pump against the 9

damage due to debris in feed water. Balancing leak off arrangement is provided for the pump to reduce the axial thrust on the bearing. Balancing leak off line is connected to the deaerator storage tank. The delivery of the pump is split into two branches. One goes to the economiser through Common feed water discharge header to supply the water to economizer through feed control station. And the other branch is 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. FEED WATER CONTROL The one number, 1 x 100% feed control valve provided to regulate the flow of feed water supplied to the boiler. water flows through 100% feed control valve. manualy operated isolation valves are installed on upstream side and down stream side of control valve. manual operated regulating valve is provided in the bypass line to take care of feed water regulation during the maintenance of feed control valve.

AIR AND GAS CIRCUIT

FD AIR SYSTEM All the required air for the boiler operation is supplied by one number FD fan. FD fan is provided with pneumatically operated inlet regulating damper. The cold air from the FD fan is let into the tubular air heater. The hot air from the air heater is distributed to the 4 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. AIR HEATER Air heater of multi tubular recuperative type is provided for the boiler at the downstream of economiser with gas flow through the tubes and air flow over the tubes. Cold air from FD fan let into the air heater in two passes.

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DUCTING SYSTEM 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 number of PA fan will be provided with pneumatic operated regulation damper at inlert. Suction line of PA fan is from the FD header. The PA fan bootsup 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 4 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 cutt-off using pneumatic operated shutt off dampers. Each fuel transportation line has manual operated shutt 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 transfered from the flue gases to the water walls, radiant super heater coils and convection super heater 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 un-burnt combustibles and ash from the flue gas. The separated un-burnt combustibles and ash are collected in the two hoppers provided below the economiser and two hoppers provided below 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.

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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 inlet of the ID fan. ID fan will be provided with power cylinder operated regulation damper at inlet. Manhole doors are provided inlet and outlet duct of economiser and air heater ducts.

FANS Each one number FD, ID and PA fans will be provide and each designed for 100% MCR capacity with adequate margin. 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., The ID fan will be provided with variable frequency drive arrangement for speed control and FD and PA fans will be of constant speed drives. All the fan impellers are dynamically balanced at works, before despatch.

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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 4 drag chain feeders of split outlet type to deliver the fuel coal to the 16 coal feed lines.

The fluidised bed is sectioned into 4 compartments and each compartment is provided with four fuel feed points. The fuel input rate can be controlled by the use of variable frequency drives of the drag chain 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 coal bunkers will be provided with gate arrangement with morries wheel and chain for the purpose of isolation. When the feeders are attended for repair and maintanance.

FUEL STORAGE BUNKER Each boiler provide with separate bunkers with mild steel construction with suitable stiffeners. The bunker will be provided for ------ M^3 water volume. The bunker is having 4 outlet chutes. DRAG CHAIN FEEDER The outlet from bunker is connected with drag chain feeder. The total no. off feeders are 4 nos. each one number per compartment. Drag chain feeder is provided with variable frequency drives to control fuel feeder 13

speed inorder to convey the fuel quantity feeder outlet chute is devided 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 16 (underbed) 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 SS and 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 generated from the boiler is collected at five 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 and air heater bottom will be provide with each 2 nos of ash hoppers 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 fly ash collected from Economiser, Air heater and Eelectrostatic precipitator will be disposed through pneumatic Dense phase ash handling system to FLY ASH SILO.

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BED ASH DRAIN SYSTEM This boiler is having five compartments and each compartment is having one no. of ash drain point. The ash drain pipe has been connected to the bed ash cooler, Where the bed ash of 900C will be cooled to 175-200C. 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 .

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. One number LP dosing system will be provided with 2 numbers of reciprocating type dosing pumps(1W + 1S) for boiler. The system will be provided with necessary valves, fittings and pipe works. 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. One number LP dosing system will be provided with 2 numbers of reciprocating type dosing pumps(2W + 1S) for boiler. The system will be provided with necessary valves, fittings and pipe works.

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START UP OIL BURNER SYSTEM Char coal assisted startup oil firing is provided for this boilers to make the start up very convenient. One number common LDO oil tank will be provided for 400 m capacity which is common for two boilers. One number common pumping and straining unit will be provided for 120 LPH capacity which is common for two boilers. Four numbers startup burners will be provided for each boilers. Each burners having capacity of 20 LPH throughputs. SAMPLE COOLER ARRANGEMENT This boilers will be provided with sample cooler system for boiler feed water, Saturated steam, super heated steam, Blow down water lines samples. The requirement is designed and assembled to enable conditioning of samples, of boilers water and steam, by reducing the temperature and pressure to a suitable state whereby a continuous sample will be presented on to on-line analysers, and a manual sample may be drawn off as required. The sample conditioning and analysers will be provided for the following.

PIPING
In

the design of all pipe lines, the sizing of lines will be based on the maximum flow through the line and the allowable pressure drop through the lines including those of control valves, flow elements, strainers, etc., so as to maintain the required pressure at various consumption points. In all the cases, the velocity of flow in the lines will be restricted to a maximum value as per the table below. The thickness calculations for IBR piping will be based on ANSI B31.1 or IBR whichever is more stringent for the design pressure and the allowable stress shall be as per ANSI B31.1 for the selected pipe material at the design temperature. The thickness calculation for Non-IBR pipes shall be as per ANSI B31.1 or IS 1239 / IS 3589 for the design pressure and the allowable stress value for the selected pipe material at the design temperature. Corrosion allowances (0.75 mm for steam piping as per IBR) will be added in addition to tolerance on pipe thickness. Whenever pipe bends are used for larger wall thickness pipes, the wall thinning factor as per Power Piping design 16

standards ANSI B31.1 will be used and the thickness of pipe bends will be suitably increased. The Material of Construction for various Piping, Valves & Fittings shall be as per attached document, Piping Material Specification Summary. All piping above 65NB size and carrying fluid more than 100C will be stress analysed as per ANSI B31.1 power piping code.
01.

Steam Lines Average Velocity in metres / second Below 50 50 to 150 200 mm NB mm NB mm NB above

01. 02. 03. 04. 05. 06.

Saturated steam at 1.1 to 7.0 ksc (g) Saturated steam over 7.0 ksc (g) Superheated steam at 0 to 7.0 ksc (g) Superheated steam at 7.1 to 35 ksc (g) Superheated steam at 35.1 to 70 ksc (g) Superheated steam over 70 ksc (g)

15.20 15-25 20-30 20-35 20-35 20-35

20-35 20-35 25-40 30-45 30-50 35-60

25-45 30-50 30-50 30-55 40-60 50-75

02.

Water Lines Feed water suction lines Feed water discharge lines Auxiliary cooling water suction 0.6 to 1.0 1.0 to 4.0 0.6 to 1.5

03. Compressed Air Lines 65 NB AND AND BELOW 150 NB ABOVE 80 NB 200 NB

Pipe Size below 50 mm Pipe Size 50 to 150 mm Pipe Size 20 mm & Up

0-2.0 ksc(g) 2.1-7.0 ksc (g) Over 7.0 ksc(g)

15-20 15-30 25-35

20-30 25-40 30-45

25-35 35-45 40-50

BOILER BLOW DOWN, VENTS, DRAINS, ETC.

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Blow down piping and the drains from boiler drums, bed coil header, bed super heaters header, economizer headers etc., will be connected with the blow down tank. The material shall be carbon steel confirming to ASTM A 106 Gr.B for the temperature less than 427C and ASTM A 375 P11 for temperature above 427C.

VALVES

The design, material, construction, manufacture, inspection and testing of valves and specialities will comply with all currently applicable standards, regulations and codes. All drain and vent connections for 40 kg/cm(a) rating will be made up of two (2) valves in series, both of isolating type. All valves and specialities will be located so that they are readily accessible for both operation and maintenance. Motor operated valves will be provided with hand-operated device for operating the valves during power failure. All motor-operated valves shall have open and close limit switches and push-buttons.

INSULATION

All piping systems having working temperature equal to or more than 60C will be normally insulated for conserving enthalpy and for personnel protection. The insulating material is selected suitably based on the working temperature of the pipe. It is essential that the material is free from shots, chlorides, oil, sulphur and other impurities and retains its density and thermal conductivity over a reasonably long period. Insulation thickness will be so selected that the temperature of its outside jacket remains 60C with ambient temperature of 40C considering 1 m/s air velocity, since it is expected that such temperature does not produce burns on human skin within a contact period of 3 seconds.

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REFRACTORY AND INSULATION GENERAL

The boiler will be complete with all the necessary castable refractory and refractory bricks and blocks as required for the furnaces with all the necessary insulating blocks, bricks and mattresses and all the requisite fixings, holders and other attachments. The refractory and insulation materials will comply with the relevant Indian standards.

DESIGN TEMPERATURE DIFFERENTIAL CRITERIA

The thickness of wool mattress will be calculated based on a differential temperature of 20C between ambient (as measures one (1) m from outer casing). This will be applicable, irrespective of ambient temperature. Insulation with cladding will be provided for equipment and ducts where the temperature exceeds 60C.

EXTERNAL INSULATION

The machine made mineral wool mattresses will be used as external insulating layer and will have a uniform density of 150 kg/m^3. The mineral wool specifications and thermal conductivity figures will be as per IS:3677.

BINDING AND STITCHING WIRE

The binding and stitching wire used for fixing the insulation materials will be of GI material and of dia (min. 1.0 mm) normal 1.219 mm, stitching wire will be of 0.711 mm diameter.

ANTI-CORROSIVE PAINTING FOR OUTER CASING

For the inner side of outer casing sheets, two coats of anti-corrosive black Bituminous paint, as per IS:159, will be applied before the outer casing is installed.

OUTER CASING

The main boiler section (furnace and bank tubes) will be enclosed with corrugated aluminium sheet casing of 0.711 mm thick. The ducts, boiler integral piping and vessels etc will be enclosed with plain aluminium sheet of 24 swg. The non membrance pressure parts will be enclosed in a 4 mm thick sheet metal casing to prevent air leakage and the top will be covered with plates laid to a fall. The maximum 19

skin temperature of the lagging will not exceed 20C above ambient when the pipework, casings and the economizer, dust collector, flue gas ducting together with all steam and feed water lines will be provided with necessary insulation and clad with aluminium sheeting neatly attached. Removable insulated boxes will be provided for valves and provision should made for easy removal of the insulation at flanges, without affecting the general pipework insulation. All drain lines, vent and exhaust lines and all other items at high temperature will be covered with a sufficient thickness of insulation, for personnel safety. The necessary seals, expansion joints, door linings and firie cement and all other items to complete the installation will be included.

BOILER STRUCTURES AND AUXILIARIES STRUCTURAL STEEL

The complete structural steel necessary to support/suspend the various components and equipment, ducts etc will include all auxiliary columns, duct supporting columns, bracing and all equipment structures etc. will be provided. Boiler structure upto firing floor will be of RCC construction. All structural steel will be designed for horizontal seismic forces as applicable under the latest Revision of IS 1893/75 and wind forces as per latest revision of IS 875/67, whichever governs the design. All structural steel work will be designed as per IS 800 and material specification conforming to IS 226/68, IS 2062/62 or equivalent. The structure will incorporate necessary lifting beams and hoist blocks required for maintenance of fans, pumps etc. Boiler roof will be coloured sheet.
PLATFORM, STAIRWAYS AND GRATING

A complete system of platforms around boiler, at feed water control station, at main steam outlet header, at fuel feeder floor, etc will be provided and stairways will be provided to enable access to various parts of the boiler. The stairways will be provided on one side of the boiler. Handrails will be provided for all stairways and platforms as per relevant engineering standard and also as required by Inspector of Factories. Boiler platform & stair case width will be minimum 900 mm except for the firing floor. Floor width will be 1500 mm.

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