CHAPTER 1 INTRODUCTION - BOILERS

Steam boiler is equipment, which generates steam from water by transferring heat produced by burning of fuel. Heat energy released from the fuel is transferred to water through boiler parts such as tubes. Steam generated by the boiler is normally used for the following purposes. Power generation: Steam is expanded in a steam engine or steam turbine. Thus mechanical work or electric power is obtained. Heating: Steam is used in winter for air-conditioning of residential and industrial buildings. It is also used to produce hot water. Industrial process: It is used for certain industrial application such as sizing, bleaching etc. in textile industries and for process in some fertilizer plant. In our plant, steam is used for heating process fluids, driving turbines, to run machines or to produce electricity. ESSENTIAL QUALITIES OF GOOD BOILER It should be capable of quick start up. It should meet large load fluctuations. Occupy less floor space. Should afford easy maintenance and inspection. Should possess the capacity of producing maximum steam with minimum fuel consumption. 5* Light and simple construction. 6* Various joints should be accessible for inspection and should be away from direct flame impact. 7* The velocity of water and that of flue gas should be minimum.
0* 1* 2* 3* 4*

Advantages of high pressure steam

8* Increases efficiency (40 - 42 %) of the plant due to higher enthalpy of output

steam. Hence more work output is available from the expansion turbine. 9* Chances of scale formation on the tube walls are very low due to high velocity of feed water.

10*

Fit for meeting variable load quickly.

11* Lightweight tubes with better heating characteristic can be used to reduce the

cost, erection time and space requirement for tube layout. 12* When forced circulation is adopted, there is a great degree of freedom in the layout of furnace and boiler compartments. 13* Danger of over heating and thermal shocks is minimised as all parts are being uniformly heated. BOILER CLASSIFICATION Boilers are classified according to the following criteria. 1 Flow of water and hot gases 2 Method of firing fired boiler 3 Method of water circulation circulation boiler 4 Working pressure pressure boiler High pressure boiler 5 Nature of service 6 Position Inclined boiler 7 Number drums boiler 8 Nature of draught 9 Material of construction Fire tube boiler water tube boiler Internally fired boiler Externally Natural circulation boiler Forced Low pressure boiler Medium Stationary boiler Mobile boiler Horizontal boiler Vertical boiler Single drum boiler Multi drum Natural draught Forced draught Cast Iron boiler Steel boiler

BOILER - MATERIAL OF CONSTRUCTION The type of material used in the boiler depends on its working pressure, load and temperature. Low carbon steel is normally used for most of the water tube boilers working between 500 to 700oF. Medium carbon steel is used up to a temperature of 950oF. For super heater tubes alloy steel, which may contains chromium, molybdenum and nickel is used. Steel may be of ferritic structure or austenitic structure. The most important part of any boiler is a furnace. Fuel is burnt in a furnace to liberate heat energy.

Furnace is a confined space. A furnace therefore must have a suitable enclosure for burning the fuel, an arrangement for regulating the flow of gases, heat receiving surfaces for the absorption of heat for useful purposes and an arrangement for the disposal of residue, if any. The design of boiler furnace depends on the following.
14* 15* 16* 17* 18* 19* 20*

Pressure and temperature Evaporative capacity Type and grade of the fuel used Furnace operating temperature Characteristic of the ash produced, if any Method of fuel firing Nature of load demand

Furnace walls are constructed in three ways.

21* 22* 23*

Refractory walls Hollow refractory walls with an arrangement for air cooling Water walls.

Boilers having smaller evaporative capacity use refractory walls. In our boiler water walls are used. Water walls are installed to absorb the radiant heat. Furnace may be totally or partially water cooled. This wall achieves very high heat transfer of around 200,000 kcal per hour. Various types of fuels like coal, fuel oil, LSHS and Natural gas are commonly used in the boilers depend on availability. In our boiler, HFO and LSHS are used as fuel. Since HFO and LSHS are highly viscous, therefore pre heated to reduce this viscosity and used in the burners for effective combustion. Burner is an arrangement for supplying the correct amount of fuel and air in to the furnace. The burners are so designed as to break up the fuel into minute droplets and project them into the combustion chamber in the form of fine mist. This mist is heated by radiation or turbulent mixing with combustion products. As it mixes with air, the droplets evaporate and burn. During burning chemical reactions are taking place between carbon, hydrogen and Sulphur present in the fuel with oxygen and the heat is liberated. Thus heat transfer is taking place in the furnace walls, bank tubes and in super heater coils while the flue, gas is passing through it. The steam liberated from steam drum is again super heated in the super heater coils. The flue gas coming out from the furnace after super heating is used for preheating feed water in an economizer and to pre heat combustion air in air pre heaters. Finally, the combustion products are vented out to atmosphere through chimney. Some of the boiler related terms are explained here.

BOILER MOUNTINGS Mountings are primarily intended for the safety of the boiler and control of the steam generation process. They are Pressure gauges, Safety valves (2Nos), Water level indicators (2 Nos.), Feed check valve, Steam stop valve, Fusible plug, Blow off cock and Manholes.

SAFETY VALVE Safety valve is a device that lets out the excess steam automatically when the steam pressure in the boiler, steam header or pipeline exceeds the working pressure. A boiler requires minimum two safety valves, because if one gets out of order the other will save the boiler by blowing the excess steam. The total capacity of the safety valves should be equal to the design steam flow of the boiler. In general springloaded safety valve, Lever safety valve, Dead weight safety valve and High steam and low water safety valve are used.

GAUGE GLASS The gauge glass must be provided in boiler drum to check the water level in the drum by direct visibility. It is a vertical hard glass tube. Their upper and lower ends are connected to steam space and water space. This indicates the actual level of water in the boiler. This gauge glass is provided with steel balls inside so that in case of any accidental breakage of gauge glass, steam and water will not gush forth abruptly. Normally boilers are fitted with two gauge glasses because, in case of any accidental breakage of one glass, the other will continue to be in line to show the water level. During normal running the water level in the gauge glass should be observed periodically even though the boiler is equipped with remote water level indicator.

FEED CHECK VALVE Feed check valve is provided to control the feed water flow from the pump to the boiler and to prevent the back flow of water from the boiler to the pump when pump pressure is less than boiler pressure. It is normally placed at the end of pump discharge pipe near the boiler.

BLOW OFF COCK The blow off cock is fitted directly to the boiler shell or to a pipe connected with the boiler. It is used to empty the boiler whenever required, for cleaning and inspection. It also used to drain out any sediment collected in the boiler along with feed water and thus control the TDS in the boiler water. BOILER AUXILIARIES Boiler Auxiliaries are the devices incorporated in the boiler circuit to improve the efficiency and performance of the steam generation plant and to assist in the systematic and adequate operation of the boiler unit for prolonged periods. Air preheater, Economizer, Super heaters, Desuperheaters, Boiler feed pumps, Forced draft and induced draft fans, Mechanical separators, deaerator, drainage expander, chemical dosing system, and Pressure reduction valves are the important auxiliaries used in boilers.

SUPER HEATERS Super heaters are classified based on their type of heat transfer, location, etc. Convective and radiant super heaters are placed in the convection zone. But this type of super heater is not used alone for high-pressure boilers. Because much of heat is lost through flue gas and also it is very difficult to control the furnace exit gas temperature. This super heater may fail on over-heating due to vulnerability during start up, scale deposition, and flame impingement. Platen super heaters absorb both radiant and convection heat. It is mounted on the top of the furnace and partially in the flue gas duct between the Convective and radiant heating surfaces. This type of super heaters absorbs about 50% of total heat. It is an assembly of smooth fined tubes, set into the pattern of a flat-gastight band with inlet and outlet headers. It is arranged either horizontally or vertically with a spacing of 500 - 1000 mm between them.

AIR HEATERS Air heaters are final heat recovery system, located in the fag end of boiler flue gas path. They preheat the incoming furnace air to aid combustion with fuel. Thus,

some fuel is saved which would otherwise be used in heating the air fuel mixture up to its ignition point. But the temperature of the exit flue gas must not be reduced below its dew point. This will cause water to condense, which may combine with sulfur, carbondioxide and carbonmonoxide to form highly corrosive sulfurous and carbonic acids. Regenerative type air heater offers a large surface of contact for heat transfer. It usually consists of a rotor which rotates at about 2 to 3 rpm, and is filled with thin, corrugated metal elements. Hot gases pass through one half of the heater and cold air through the other half. As the rotor turns, the heat storage elements transfer the heat picked up from the hot zone to the incoming air zone. Gas Air heaters in OSB are shell and tube heat exchanger. Air is passed through the shell side and the gas is passed through the tube side for better accessibility of soot cleaning. STEAM DRUM Steam drum is a vessel in which steam is separated from water particles at higher pressures with the aid of baffles and other devices called steam internals. It also provides adequate capacity to store steam. Drum internals It includes all baffles and various devices to effect the separation of steam from steam-water mixture, the various chemical and feedwater admission pipelines and blowdown lines. The steps involved during the process of steam separation and purification in the steam drum are separation, steam washing and steam scrubbing. In separation the moisture is removed by gravity by abrupt change in direction of flow pattern, by centrifugal separation, by using baffles and impact against a plate. BAFFLES The baffles break up the steam-water jets entering the drum. The types are deflector plate, off set deflector plate, slotted deflector plate, V type, Perforated plate, Angle iron deflector, Hydraulic barrage baffle and compartment baffle. Hydraulic barrage is normally used to control excessive foam or spray formation. It creates a successful high velocity screen or curtain through which steam must pass before it exits. As a result the water particles lose their kinetic energy by successive impacts with the curtains, fall off and steam escapes dry. Cyclone separator is an effective device for steam-water separation by creating centrifugal forces. As the mixture enters the cyclone, a rotary motion develops a centrifugal force that destroys the foam bubble,

eliminates spray and separates out solid particles. Baffles used in gas path deflect the hot gases back and forth between the tubes a number of times to enable greater heat absorption by the boiler tubes. They also permit designing for better temperature differences between tubes and gases throughout the boiler. Baffles help in maintaining gas velocity, eliminate dead pockets, ensures proper removal of fly ash deposit and soot and prevent high draft losses. If the furnace baffle breaks, the gas gets short-circuited to one or more passes, causing excessive flue gas temperatures and a loss in efficiency and thus capacity. Over heating and damage might result inthose parts of the boiler designed for low gas temperatures. So during the shutdown, the baffles should be carefully checked for erosion, break or dislocation.

WATER WALLS Water walls consist of relatively close spaced vertical tubes forming the four walls of the furnace. They were originally developed to cool and protect the furnace lining. Depending on the type of boiler, the waterwall heating surface may account for only 10% of the boilers total heating surface, yet represent as much as 50% of the total heat absorption. Water wall performs three basic functions. 1. Protect the insulated walls of the furnace. 2. Absorb heat from the furnace to increase the generating capacity 3. Make the furnace air tight Heat is transferred to the water wall tubes as radiant heat from the zone of highest temperature in the furnace. Water wall headers should not be blown down while the boiler is in service. If blown, normal water circulation will be affected and will cause tube over heating leading to bulge or rupture.

ATOMISATION Atomization is a process of dividing the fuel into fine minute droplets for better combustion. The basic requirement for the efficient combustion of fuel oil are the atomisation of fuel oil into fine particles or droplet and the effective mixing of this

fuel with the correct quantity of combustion air. The various types of atomization are steam atomization, air atomization and mechanical atomisation. For effective atomisation, it is essential that the oil viscosity should be low enough to divide into small particles. Hence heavy oil is normally preheated to reduce the viscosity. Particle size is very important, being the major factor in governing the time taken to burn each oil droplet completely. Combustion commences on the surface of the droplet and burn away the oil as oxygen in the combustion air reaches it. If the droplet is large, longer is the time taken to burn. If longer is the burning time, the burning droplet will travel away form the turbulent mixing zone of the burner throat.

In this stage the burning droplet may be surrounded by gaseous products of combustion and no longer be in contact with combustion air, even though the combustion air is flowing at another part of the flame. The droplet will cease to burn and will form a soot particle. The combustion air, which is travelling in the other side, will pass as excess air and if the quantity is large, it may chill the flame and give high O2 and low CO2 in the flue gas. Steam Atomization In steam atomization, high-pressure steam is used to divide the oil by directing upon a stream of fuel oil. When the steam with high kinetic energy, collides with the jet of fuel oil, it impart its kinetic energy to fuel oil, there by oil gets disintegrated into fine minute droplets of approximately 0.01 mm or even less in diameter. These disintegrated particles are called atomised fuel. Steam atomisation is one of the best ways of ensuring good atomisation. Combustion being a chemical change brought about by heat, this method benefits by the heating effect of the atomising steam on the oil. The relatively low oil pressure required is also an advantage. The steam atomised oil burner uses the energy of expanding steam to atomise the oil. As the steam is released through the gun tip it expands and the oil which comes into contact expands with it to result in fine atomisation of the oil. The angle at which the holes are drilled in the tip will establish the basic spray angle, but this angle will increase as the spray expands. Since it is the expansion of the steam, which aids in atomisation, it is obviously important to supply the correct quantity of steam. The quantity will depend upon the type of fuel and pressures available and will vary with the application. Steam deficiency can cause poor atomisation and an excess of steam is uneconomical. It is important that the atomising steam should be dry. Any condensate in the steam will not expand as it leaves the tip and drops of oil and water mixture will fall out of the flame as small balls of fire. Some superheat in the steam may be desirable to ensure that the atomising steam is dry, but not so much that overheating or gasification of the oil may result. To achieve the best mixing of the oil spray with the combustion air, the steam atomised oil burner gun is normally fitted into an air register. The function of the register is to shape the flame and mix the air and oil spray by adjustment of vanes. In a straight axial airflow, the jets from the tip will burn as individual plumes. If spin or rotation is imparted to the air by the air register vanes, the plumes will tend to merge to give a wider shorter flame. The steam atomised oil burner gives a very stable flame but to shield the root of the flame from high velocities, a diffuser is normally fitted. Varying the oil pressure varies burner

capacity.

Mechanical atomization Mechanical atomisation is also called as pressure atomization. High pressure oil is discharged through a small orifice, often aided by a slotted disk. The disk gives the oil a whirling motion before it passes on through a hole drilled in the nozzle, where atomization occurs. For a given nozzle opening, atomization depends on pressure, and since pressure and flow are related, the best atomization occurs over a fairly narrow range of burner capacities. To follow the boiler load as steam demand goes up or down, a number of burners may be installed and turned on or off, or burner tips with different nozzle openings may be used. AIR REGISTER For efficient combustion of Fuel oil, atomiser and air register are essential. The purpose of the atomiser is to break up the oil into very fine droplets (generally, a dia of 120 microns is acceptable). The function of the air register is to ensure that the flame is stable, and to ensure intimate mixing of air with fuel to promote rapid and complete burning in the space available in the combustion chamber. For better flame stability, low air velocities such as 200 - 300 ft/Mt is recommended. Even for highly turbulent gas flames, the effective flame speed of an oil droplet/air mixture will be less than this. Normally the forward air speed from the register is about 8000 ft/Mt and is therefore necessary to reduce this velocity at some local point to less than the flame speed to ensure the anchor of flame with burner tip. There are various types of registers available; all of them operate by forcing the air stream to form a reversal. This reverse flow carries some small portions of the burning gases back to the root of the flame, thus providing a continuous source of ignition. The simplest method uses a flat baffle or cone. This is still used on many registers today. The disadvantage is that in forming the reversal, the burning gases also carry burning droplets of oil and if these impinge on the baffle, then carbon builds up on the stabilizer. One way to avoid this problem is by seriating the baffle by drilling holes or cutting slots. Care should be taken while doing so, since the baffle becomes less effective as a stabilizer. Another problem is how to prevent the stabilizer from burning away when it is exposed to direct radiation from the flame. The developed type of stabilizer is the axial swirler. This is used very extensively. It does not normally suffer from carbon build up because it is totally aerated. It can however, be damaged by back radiation especially if it is kept shutdown while other burners are in line.

CIRCULATION It is the motion of the working fluid in the evaporating tubes. This motion is effected by head or pressure difference in the working fluid between the downcomer and uptake tubes. The circulation may be natural or forced and the circulation circuit formed by the heated and unheated tubes may be a closed or open hydraulic system. The natural circulation of water sets up in the closed hydraulic system of heated and unheated tubes of the waterwall. It is induced due to a difference in density of water with difference in temperatures. The baffle separates out the heated riser from the unheated downcomer and therefore creates a temperature difference between the two. Saturated water flows down the unheated downcomer and receives heat in the riser whereupon a part of it gets converted into steam. The difference in densities of saturated water in the downcomer and the steam- water mixer in the riser brings about natural circulation. This type of circulation is possible only for the boiler with working pressure less than the critical pressure of water. If the working fluid is forced through the boiler circuits by an external pump, to ensure the circulation, it is called positive or forced circulation. Circulation ratio of the boiler is the ratio of the mass flow rate of circulating water to the rate of steam generation. It usually ranges from 4 to 30 for natural circulation boilers and 3 to 10 for forced circulation boilers. Circulation ratio for once through boiler is unity.

CAUSES OF TUBE FAILURE IN WATER TUBE BOILERS

24* 25* 26* 27* 28* 29* 30* 31* 32*

Solid deposits inside the tubes Low water level in the boiler Corrosion Slagging of gas passages High concentration of heat in some tube areas Stress corrosion Flame impingement Poor circulation of water inside the boiler External corrosion and erosion by soot blowers due to improper location.

COMBUSTION SAFEGUARD AND CONTROLS Gas explosion in the boiler results from the presence of unburned fuel and its delayed ignition. Furnace explosion is of the primary and secondary types. The unburned fuel in the furnace may distill large volume of gas during a period of interrupted ignition. If this gas does not ignite properly, it may fill in the furnace and succeeding passes. This continued ignition delay might cause dilution of unburned fuel and exhaustion of volatile content in the furnace. Hence major part of the volatile gas fills in the succeeding passes. If the diluted gas in the furnace get ignited, results explosion of minor intensity. The blast flame may then ignite the gas in the succeeding passes resulting more violent explosion. The following are the necessary conditions to create furnace explosion.
33* 34* 35*

Accumulation of unburned fuel Air and fuel in the explosive mixture A source of ignition such as a hot furnace walls, improper ignition timing, faulty torch and dangerous burner cut-in or cut-off procedure.

Main causes of furnace explosion

36* 37* 38* 39* 40* 41* 42* 43* 44*

Flame failure due to entering of liquid in the fuel system. Insufficient purging before lighting the first burner. Human error Faulty automatic fuel regulation system. Fuel shut off valve leakage. Unbalanced fuel air ratio. Faulty fuel supply system. Loss of furnace draught. Faulty burner igniter.

Precaution needed to prevent furnace explosion Check the operation of the boiler periodically. If the burner goes out accidentally shut off the fuel supply and thoroughly purge the furnace. Find the cause and take remedial action before lighting up the burners. 47* Check the interlock for air and fuel system periodically. 48* Never allow an unstable flame condition to continue. 49* Keep the temperature and pressure of preheated air in correct level. 50* Maintain proper air flow.
45* 46*

HOT END CORROSION Sodium, vanadium and sulfur are main contaminants present in the fuel oil. Even small amount of the above constituents may cause slag deposits and corrosion. During and after the combustion they react and form oxides, sulfates, and vanadates. A fuel having less than about 100 ppm of vanadium is considered a low vanadium fuel and above 200 ppm it is considered as high vanadium. Sodium and vanadium contamination causes corrosion and slag difficulties only when temperatures are at or above their melting points. When both sodium and vanadium are present, the tendency to cause corrosion is greater than when either is present alone. At this temperature the particles of these compounds stick to the metal, forming slag and causing corrosion. If the temperature is low, they pass through the boiler as fly ash. Normally this problem occurs when the steam temperature is more than 538 C or higher. There is no practical way to reduce the vanadium content in heavy fuel.

COLD END CORROSION When sulfur in the fuel burns, it forms sulfur dioxide which is relatively harmless. However, small quantities of the SO2 are further oxidized to SO3 as a result of the catalytic effects of vanadium in the fuel itself and iron oxide. Presence of even very small quantities of SO3 has a large effect on the dew point (temperature below which condensation of moisture takes place). So the SO3 present in the flue gas forms sulfuric acid with the water leading to corrosion problem. This type of corrosion normally occurs in air pre-heater installed just before the flue gas exit to the stack or induced draft fans. The usual method employed to minimize air preheater corrosion is to maintain the exit fluegas temperature above the dew point range or to reduce sulphur in fuel oil.

WATER CAPACITY If a boiler has large water capacity, it will function smoothly and better when the load is relatively steady or varying slowly. Water tube boilers are more responsive to a rapid load change when compare with fire tube boilers, as it has lesser water

holding capacity.

HEATING SURFACE It is the surface area of boiler tubes exposed to the hot gases of combustion in the furnace in order to transfer heat to the working fluid to generate steam. The types of heating surface are Radiant heating surface, Convective heating surface, and Radiant-Convective heating surface.

SCRUBBING The wet steam is passed between closely spaced corrugated plates or screens that collect the water droplets carried by steam. The mass of water collected on the screens is dripped by gravity to the water below in side the boiler drum. It eliminates most of the water droplets added to steam from spray and splatter. Also, it breaks up and eliminates dry foam.

CHAPTER 2 STATUTORY REQUIREMENT

The following statutory Regulation acts and Rules govern the Industrial boilers 1. Indian Boiler Regulation 2. Indian Boiler Act. 3. Madras Boiler Operation Engineers Rule. 4. Madras Boiler Attendants Rule. The Indian Boiler Regulation and the Indian Boiler Act are common for the whole of India except the state of Jammu and Kashmir. They deal generally with materials of construction, type of construction, workmanship, design of Boiler and its components, Registration of Boilers, Inspection and testing. The Boiler Operation Engineers and Boiler Attendants Rule are local regulations of the state Government and they vary from state to state. These rules take care of the Safety Aspects while the boiler is in operation and specify the requirement of welltrained personnel for operation of the boiler. An abstract of these statutory requirements is furnished below. BOILER According to the Indian Boiler Act 1923, a boiler is a closed pressure vessel with capacity exceeding 22.75 liters used for generating steam under pressure. It includes all the mountings fitted to such vessels, which remain wholly or partly under pressure when steam is shut off. Every boiler shall be provided atleast with the following. Two safety valves, one of which may be a high steam and low water type safety valve. In no case should the bore of the seat of the valve be less then 19 mm. 52* Two water-level indicators. 53* A steam pressure gauge. 54* A steam stop-valve. 55* One feed system (When the heating surface exceeds 200 Sq.ft, two dependent feed apparatus, each such apparatus shall have a capacity of not less than the maximum continuous rating of the boiler.)
51*

56* 57*

A blow-down cock or valve. A fusible plug when boiler has internal furnaces.

An attachment for Inspectors test gauges. A manhole, where size and construction permit, and such manholes or sight holes are necessary for effective cleaning of the boiler. 60* In case of boilers fitted with integral super heaters, an additional safety valve shall be fitted at the end of the superheater outlet header.
58* 59*

ECONOMIZERS Economizers are any part of the feed pipe that is wholly or partly exposed to the action of flue gas for the purpose of recovery of waste heat. The design conditions shall be such that the maximum outlet temperature of water shall be atleast 40 F below the saturated steam temperature in the boiler drum, if the working pressure is greater than 120 ft of head of water. The following valves and mountings shall be provided for the economizers. Relief valve: A valve, which will prevent increase of pressure beyond a predetermined limit, shall be fitted to every economizer. Economizers with pressure parts of cast iron and arranged in groups of tiers connected by circulating piping shall have a relief valve fixed on each group or tier. Relief valves should have a minimum diameter of 2". 62* Pressure gauge. 63* Air release valve 64* Blow off drain valve. 65* Non return valve in feed line. 66* Explosion doors.
61*

FEED PIPE This is the pipe or connected fitting wholly or partly under pressure through which feed water passes directly to a boiler. STEAM PIPE Steam pipe is the pipe through which steam passes at a pressure of more than 3.5ksc from a boiler to a prime mover. Such pipe should exceed 254mm in ID.

CHAPTER 3 PLANT DESCRIPTION

The off site boilers are two in numbers designed to meet the total steam demand of Urea plant, partial steam requirement (45 ksc) of Ammonia Plant and to cater the needs of Phase II plants when self steam is not adequate for them. The Boilers are supplied by M/s BHEL Trichy and were commissioned in the year 1974. The Boilers are designed for a thermal efficiency of 87%. The Boilers are of medium pressure 45 kscg with exit steam temperature 382 oC. They consists of two drums, fuel oil fired and pressurized furnace type with a design capacity of 60 T/hr as normal continuous rating and a maximum rating of 85 T/hr. Originally both the Boilers were run with electrical power driven. This resulted in tripping of both the Boilers during power failure and leads to non-availability of 45 ksc steam to Ammonia plant. So in 1982 the following equipments were changed to turbine driven so as to run Boiler I (west) even during power failure. 1. Forced Draft fan A 2. Boiler Feed water pumps A & B 3. Heavy fuel oil pump A (North) Initially the Boilers were designed to use Heavy fuel oil as fuel and LDO during start up. Later on when the Government insisted on using Low Sulphur Heavy stock (LSHS), the oil system has been suitably modified to accommodate LSHS also as fuel. Three Nos, of LSHS pumps were added to unload LSHS from trucks and HFO day tank is traced with Electric coils. Steam tracing is given to LSHS handling lines. HFO requires atomization to use as fuel. For initial condition, steam will not be available for preheating and atomization of fuel. OSB is designed to generate steam with LDO during initial startup and then switch over to HFO. The temperature profile of boiler is so designed to use LDO as start up fuel and hence care must be taken to control the temperature raise of boiler parts during start up.

BOILER SPECIFICATION 13' --20' 60 32' 2 1/2" Front wall firing Furnace width Furnace depth Diameter of steam drum Diameter of bank tube Distance between steam and Diameter of water wall tube

VU 60

---

F 13' 20' 60" 2 1/2" 32' mud drum 3" Total Number of tubes in a Boiler Furnace front wall tubes 39 Furnace side wall tubes 68 x 2 =136 Front screen wall tubes 20 Rear screen wall tubes 19 Boiler side wall tubes 17 x 2 = 34 Boiler bank tubes

14 x 39= 546 Boiler rear wall tubes 41 TOTAL 835

BOILER PERFORMANCE DATA Maximum evaporation : Super heater outlet temperature : 382oC Super heater outlet pressure : 45ksc Boiler drum pressure : Super heater pressure drop : Boiler efficiency Feed water temperature : Fuel firing rate (HFO / LSHS) : 6.350tph Excess air leaving boiler bank : 15% 105C 5ksc : 87% 50ksc 85tph

Gas leaving boiler bank : Gas temperature leaving boiler bank : 346oC Gas temperature leaving air heaters : 182oC Ambient air temperature : Humidity : 60% Air temperature to gas air heater : 60oC Air temperature leaving gas air heater : 260oC Air leaving air heaters : Number of burners / boilers : HFO burner capacity : HFO pressure at burner : LDO burner capacity : LDO pressure at burner : Atomising steam pressure at burner : 8.45ksc LPG supply pressure for ignitors : 2.2ksc Air pressure for ignitors : HFO temperature at the burner : 105oC Water holding capacity of the boiler : 38.5M3 Water holding capacity of the SH coil : 0.9017M3 Steam air heater capacity 1.0ksc 35ksc 500kg/hr 10.2ksc 1650kg/hr 4 99.8TPH 30oC 106tph

: PRESSURE DROP Steam air heater

1950kg/hr

: Air heater - airside : Air ducts 67 Wind box mmwc 111

36

mmwc

mmwc : :

152 mmwc Boiler and super heater : Gas ducts : 46 mmwc Air heater - gas side : TOTAL : 585 mmwc HEATING SURFACE AREA Furnace : 400 M Boiler bank M Super heater : Gas air heater : M
2 2 2

137

mmwc

36

mmwc

: 170

1500 M2 3100

WATER WALL The furnace walls are constructed by 76.1 mm OD tubes on 101.6mm centres between the tubes. The space between the tubes were closed by 25 mm wide fins which are shop welded to the tubes, thereby forming gas tight seal. Except the boiler side walls, all walls were shop fabrictated panels, which were welded together in the field. The boiler side walls consist of prefinned tubes which were welded together during field assembly, to ensure gas tight envelope. The tube connecting water wall header and the drums were rolled into the drums at one end and at the other end, they were welded to header. Furnace openings such as peephole doors, soot blowers, and burners were provided by suitable bending of the tubes. The fins interrupted in these areas were sealed with castable refractory. Castable refractory is also applied between the two rows of roof tubes near the upper drum and at the gas baffles. The furnace floor tubes are covered with firebrick tiles, which are placed loosely on top of the bottom tubes with sufficient expansion clearance between the tiles. The outside of the furnace and boiler walls are covered with ribbed Aluminium casing. The space between the casing and the wall tubes was filled with laminated mineral wool blankets, reinforced on both sides by wire mesh. The blankets were fastened to the walls by means of impaling pins, which were welded to the tube fins. STEAM DRUM The Boiler is equipped with a large steam drum to provide adequate steam storage capacity and to minimise water level fluctuations in case of sudden changes in steam demand. The drum internals are so designed for better efficiency, simplicity, low maintenance costs and high steam quality. The steam and water mixture entering the drum from the riser tubes, furnace wall tubes and front boiler tubes is collected in the steam drum chamber formed by the vertical baffle panels. Here the primary separation of the steam and water takes place. Most of the water drops down after impact on these panels and passes around the ends of the panels to mix with the incoming feed water before entering the rear boiler tubes. A portion of water having high solid concentration at this separation point is tapped off through the perforated continuous blowdown pipe to control the solids concentration in the boiler water. The steam and little amount of water released from the top ends of the panels, come to the main part of the drum. From here the wet steam rises and passes through the primary screens, where further separation of water takes place.

Then the steam enters the screen dryer, consisting of several layers of screens, and all the entrained moisture is completely removed, The water thus separated is returned to the waterside of the drum through the drainpipes. Dry steam leaves the drum through the top outlet nozzle. Hence during boiler inspection the following things are checked. All the joints in the dryer assembly must be absolutely tight to prevent moisture mixing with the dry steam by bypassing the top screen dryer when it leaves the drum. All bolts are to have two washers one under the nut and one under the head. Joints, which are not seal welded, are to be bolted tightly as possible. 68* The joints in the partition baffles need not be absolutely tight but should be made as tight as possible. 69* Gasket shall not be used. 70* Joints in feed piping are to be absolutely tight. Expansion joints located well below the water level in the feed piping are not to be made tight. Anchor for feed pipe must be properly installed to prevent twisting of the sleeve in the feed nozzle.
67*

MUD DRUM It is a cylindrical vessel similar to steam drum. It is fixed directly below the steam drum. The two drums are connected by bank tubes. The bottom most two rows in the mud drum are connected with furnace front wall panel tubes and side wall panel bottom header connecting tubes. The main purpose of this drum is to increase the boiler holding capacity, thus minimise the load fluctuation during upset in the steam drawl system. As it is located at the bottom most part of the boiler, it is used as the sludge trap. Main blow down line taken from this drum is used to drain the boiler water during shut down and during normal run to control TDS in the boiler water by blow down. Phosphate solution is injected in this drum for effective mixing and better reaction. SUPER HEATER The super heater is located directly in front of the boiler tube bank. It consists of a single pendant composed of 27 assemblies and spaced on 140-mm centres across the furnace width. Each assembly consists of 1 3/4" OD tubes arranged in vertical loops. Saturated dry steam is led from 60" steam drum to the 8 5/8" pendant super heater inlet header via 10 Nos of 108 mm connecting tubes. Steam passes through the

pendant super heater to the 273 mm OD high temperature pendant super heater outlet header. Superheated steam leaves the outlet header through the main steam line connected at the centre to it. One coil is bent and used as steam cooled spacer to keep the super heater coil loops in their position. The superheater coil loops are connected to the steam-cooled spacer by cleat arrangement. As long as there is fire in the furnace, adequate protection must be provided for the superheaters. This is especially important during the periods such as start up and shut down when there is no steam demand. During these periods, adequate flow through the super heater coil should be ensured by means of SH header drains and starting vent. A safety valve at the superheater outlet header is provided to protect when steam demand suddenly and unexpectedly drops. This safety valve lift pressure is set lower than that of the drum safety valves, so that steam flow through the superheater coils is assured. DESUPER HEATER The purpose of the desuperheater is to reduce the exit steam temperature when necessary and to maintain it within the limits. Desuperheater is located in each boiler on the main steam line at the outlet header of superheater. It is fitted with a spray tube located horizontally to maintain uniform distribution of water at extremely low flow. The spray occurs due to differential pressure between injecting water and steam. A control valve (TC 55) controls the flow of spray water to the desuperheater. A bypass valve is provided to use in case of emergency, or when the control valve is under maintenance. It is essential that the spray water should be chemically pure and free of solids in order to prevent both chemical deposition and carry-over in the steam lines. A tapping is taken from the discharge of feed water pumps and connected to the upstream of the control valve for this purpose. The desuper heater is fitted with a renewable liner to take care of wear and erosion, thus protecting the main desuperheater shell. Excessive noise within the desuperheater indicates a worn liner. Sufficient clearances is provided around the desuper heater for replacing the liner. The water flow to the desuperheater is 1600 kg/hr as per design. The steam temperature varies with the load. It raises as the load increases and falls as the load decreases. At constant load, abnormal super heat temperature may be caused due to the following reasons.

71* 72*

Too high excess air Too low feed water temperature

73* 74* 75*

Slagged up furnace Secondary combustion Improper operation of automatic steam temperature indication and control equipment.

Super heated steam temperature may be maintaining less in the normal condition due to the following reasons.
76* 77* 78* 79* 80*

Too low excess air Too high feed water temperature Excessive external deposits on super heater tubes Excessive moisture carry over from the boiler Improper operation of temperature control system

DEAERATOR The DM water along with Urea condensate and steam air heater condensate enters the top of the Deaerator and sprayed into the heating zone with the help of spray cones. Here the uncondensed steam escaping from the Deaeration zone comes into contact with the water spray and gets condensed, resulting in preheating of water. Then the water enters the deaerating zone where 0.3 kscg low pressure steam is bubbled through it. This causes stripping action to remove dissolved oxygen which escapes with the steam. The deaerated water collects at the bottom storage zone which is also used as a reservoir for the feed pumps. Feed water temperature is maintained at 105oC. Sodium sulphite is injected in the deaerated water at the feed water suction line to remove the remaining traces of oxygen. The sodium sulphite removes the traces of oxygen by its chemical reaction with oxygen. The reaction is as follows. 2 Na2 So3 + O2

2 Na

So4

FEED WATER PUMPS The hot feed water reaches the feed water pump suction through a strainer of 60#. The pump is a seven stage, centrifugal high pressure (75 kscg) and runs at 2950rpm. Each stage has an impeller with suction and discharge provision. The water from the pump suction enters I stage impeller suction side and its discharge is routed to II stage impeller suction again. Thus water is pressurised in 7 stages to the pressure of 75 kscg. Since the suction pressure is 1.5 kscg and discharge pressure is 75 kscg,

axial force is likely to act on the shaft pushing it towards the low-pressure suction side. To counter this force, an inbuilt balancing arrangement

is provided in the pump. A small quantity of high pressure water is taken from the delivery, its pressure is reduced (suction pressure + 0.5 ksc) and allowed to act on the balancing disc which is connected to the shaft but enclosed in the balancing chamber. It is designed in such a way that equal amount of axial force is imparted to the shaft but in opposite direction so that both the forces get nullified. Originally, there were three motor driven pumps in which two meant for service and one for standby. After revamping of west boiler to steam driven, two pumps were converted to turbine driven. The pump supplies feed water to the steam drum through a flow control valve FCV 01 and feed check valve. MINIMUM FLOW RECIRCULATION When the water off take to the boiler drum decreases, the power requirement of the pump does not decrease proportionally, and remains relatively large even at zero discharge. This absorbed power is converted into heat and the water within the pump gets heated up and may form cavitation. In order to avoid the cavitation problem, minimum recirculation flow is usually maintained by an automatic leak off valve. The closing of the auto bypass valve plug is governed by the weight of the non return valve cone, which is mounted vertically in-between the pump discharge nozzle and the discharge valve. The position of the non return valve cone and the auto bypass valve plug will depend on the flow passing around the cone. When the off take from the pump decreases, the valve cone sinks closer to its seat and at zero discharge (closed discharge) the conical passage is completely closed. In the mean time, the auto bypass valve plug opens and allow the minimum recirculation flow to the deaerator. Similarly when the off take from the pump increases, the bypass valve plug opening decreases. When the flow is more the minimum recirculation flow it gets closed completely. A manual bypass valve with an orifice is also provided to give minimum flow during start up condition. This valve is normally closed after establishing the sufficient flow (more than 35 TPH) through the pump. OIL SUPPLY UNIT Each turbine driven pump has an oil reservoir to feed oil to the bearings and also to the control circuit in the turbine. A gear oil pump is incorporated in the gearbox supply oil from the reservoir through cooler and filter with necessary pressure, into the control circuit. For lubrication purpose the same oil is used after reducing the pressure through a throttle unit. During start up, an auxiliary turbo oil pump

incorporated in the turbine is used to supply lub oil. It is kept in line until the main gear oil pump supplies adequate quantity and there after this pump is kept stopped. It also serves as a cooling oil pump after the turbine is kept stopped. The oil supplied by the main pump is cooled in the oil cooler. The two thermometers fixed in upstream and downstream of the cooler indicate the cooling effect. Lube oil line is tapped off from the main line at the downstream of the oil filter. The oil pressure and quantity required for regulating system and lube oil circuit is regulated by means of the lube oil throttle. The excess oil supplied by the gear pump, over flows through an over flow valve to the sump to maintain the control oil system pressure. RAPID CLOSING DEVICE The rapid closing safety device is provided after the front bearing of the turbine shaft to prevent over speed. When the shaft rotates at the maximum admissible speed, the rapid closing bolt move outward by centrifugal force, hits and releases the pawl of the rapid closing relay. This results in opening of slide valve by a spring pressing downward. Hence the oil before the power piston of the servo motor flows off through the relay and the rapid closing valve is closed by spring power. At the same time, to speed up this action, the oil to the servomotor is also shut off by this relay. To shut down the turbine suddenly, the emergency relay can be disengaged manually by operating the release bolt.

REGULATION OF SPEED The speed of the turbine is maintained constant by means of a cantilever spring speed governor, which hydraulically operates the regulating, and rapid closing valve. The allowable speed variation of turbine is 10% below and 5% above the normal speed. However for effecting the rapid closing test, the turbine speed is raised up to the maximum admissible level by turning the hand wheel of the speed-adjusting device and confirmed for proper action. LOW LUBE OIL PRESSURE TRIP DEVICE Sufficient Lube oil pressure is ensured to protect the bearings. When the pressure is normal, the lube oil trip device cone screwed to the diaphram acts against the spring pressed on the valve seat. If the lube oil pressure falls below 0.5 ksc, the spring lifts

the cone from its seat. Therefore, the impulse oil acting on the servomotor and the trip valve is by passed to the sump and close the chest valve. HFO TANK Fuel oil used in OSB is received from Ammonia plant and is stored in HFO day tank. The capacity of OSB tank is 265 M3. It is surrounded by a dyke wall in all the sides to curtain fire oil spillage if any. Oil from this tank is pumped by a screw pump through a suction strainer to remove any suspended impurities. There are two pumps in which one is turbine driven and the stand by is motor driven. (Turbine live steam pressure 11 ksc and back pressure 3 ksc) Then the oil is preheated to 110 oC in an oil heater (shell and tube type - shell side oil and tube side steam) using 11ksc steam. A pressure control valve (PC 30) is provided in the local return oil line, to control the oil pressure by diverting the excess oil to the tank. The preheated oil is filtered in the delivery filter and atomised with 11 ksc steam at the gun tip before burning at the burner. In 1983, the plant has been modified to accommodate LSHS also as fuel. Since the LSHS oil has high pour point, the HFO day tank was externally traced with electrical heaters and the oil lines and instrument connections were steam traced. Three Nos. of LSHS unloading pumps were installed for LSHS unloading from the tanker. The HFO pressure control valve located in the upstream of oil heater was shifted to its downstream, to maintain temperature of oil in the tank. . OIL HEATER The oil preheater is a shell and tube (U tube type) heat exchanger. Oil flows through the shell side and steam at 11 ksc, used as heating medium, flows in the tubes. A spring loaded safety valve is provided on the shell to protect it from excess oil pressure. Oil temperature is controlled by TCV 30. To avoid failure of tube sheet or bolted flange joints during startup, the cold oil circulation is established first and then the temperature is to be gradually raised to allow expansion in the bolted flange joints. This preheated oil is then supplied to the burners. BURNERS LDO burner is used for cold start up. It is a pressure atomising type. Oil under pressure is supplied to the gun and enters the atomiser tip through slots tangentially to the periphery of whirling chamber. This causes high pressure drop. This pressure

drop is converted to velocity causing the oil to enter whirling chamber tangential at very high speed. This establishing a rapid rotation to the oil in the whirling chamber and passes through tip orifice and flies apart under the influence of centrifugal force. This forms uniform hollow conical spray. The fineness of spray depends solely on the speed of the oil rotation in the whirling chamber, and the pressure determines quantity of oil forced through the tip orifice. Burner capacity is controlled by regulating the oil pressure. Decreasing the oil pressure reduces the speed of oil rotation in the whirling chamber. Thus burner capacity is reduced. HFO is used in load carrying burners. These burners are steam-atomizing type. Steam and oil are carried separately to the burner tip. Both are mixed together at the tip and the oil gets atomised due to the expansion of steam. Burner is fixed in a wind box through which combustion air is supplied. The burner gun can be moved in the wind box in the axial direction and thus the position of the gun tip in the burner throat is set according to the atomising angle. BURNER ARRANGEMENT

The output of the gun is regulated with in the limit between 100% to 23% by means of a control valve (FC 36) provided in the oil line. Further reduction of output is effected by shutting down the burner. Burner 1 and 2 can be lined up with both LDO

and HFO. Interlock is available to line up any one the above at a time. Normally LDO is lined in burner 1 and 2 during start up and switched over to HFO after raising sufficient pressure and temperature. OIL SPECIFICATION DESCRIPTION HSD Density at 15 oC 0.854 o at 80 C Kinematic Viscosity at 37 oC 2.5~15.7 150 o at 50 C 110 at 120 C 13.4 at 104 C 16.8 Flash point 66 105 Pour point Sulphur by weight 1 Vanadium 25 Sodium ppm % 1.75 ppm
o o o o

Unit LSHS gm/cc HFO 0.818 0.958 gm/cc 0.921 CST 2~7.5 CST

LDO

75 CST 9.4 CST C 174 C 65 1.8 3.5

38

40 LCV 10180 Sediments by wt. max Ash volume 0.006 % 0.018 % 0.015 0.06 kcal/kg 10660

AIR SYSTEM Atmospheric air is sucked into the system through a Forced draft fan and delivers at 750 mm WC. The fan is provided with vane control arrangement at the suction to vary the airflow to the furnace. Its design capacity is 29.1 NM 3/ Sec. The air is first preheated in a fin type heater called steam air heater where 11 ksc steam is used as heating medium. Then it enters the Gas Air Heaters (GAH) on the shell side. If the air is, send to Gas air heater without pre-heating at lower temperature, this may reduce the exit flue gas temperature leading to cold end corrosion. The gas air heaters are recovering the heat from the flue gas coming out of the furnace. It is a two-pass shell and tube type heater with vertically placed tubes made of carton steel. In the first pass, the hot flue gas enters the GAH from the top passes through the tubes and reaches the bottom. In the second pass the gases enter from the bottom and leave out from the top to the chimney. In both the heaters the combustion air from the FD fan passes through the shell side, picks up heat from the flue gas and attains a temperature of 252oC. The hot air reaches the burner front through the wind box where a venturi flow meter (FC 21) is provided and finally flows into the combustion chamber through the air registers provided in the

burner assembly. Two retractable type soot blowers are provided in each GAH just over the top tube sheet. During soot blowing operation, they travel along the length of the air heater, blowing steam downward through the nozzles. An additional soot blower No 6 is provided just below the bottom tube sheet of GAH cold with the blowing nozzles facing upwards. Due to frequent choking problem experienced in GAH cold, the tube diameter was increased from 40 mm to 50 mm in both the boilers. While preheating the combustion air, the flue gas is cooled to 170 oC from 346 oC. A minimum of 170 oC is maintained in the flue gas to prevent the cold end corrosion. The Sulphur in the fuel oil, on combustion will form acid gases such as So 2 and SO3 (due to the presence of Vanadium impurity.). At low temperatures these acid gases in presence of moisture (available in atmospheric air) will form dilute acid and that will attack the tubes. Therefore, care must be taken that the temperature at stack outlet is maintained well above the condensation point of SO2 and SO3. Hot gas air heater has 4144 tubes in 56 rows with each row having 74 tubes. The cold air heater has 3060 tubes.

PREDICTED PERFORMANCE

UNIT
50% MCR FD fan delivery Before GAH After GAH Wind box Combustion chamber Boiler Exit Air before GAH Air after GAH Gas before Super heater Gas after Super heater Gas at boiler exit Gas at GAH exit

100% MCR 25% MCR mmwc 585 410 mmwc 530 380 mmwc 420 320 mmwc 370 280 mmwc 220 130 mmwc 85 55 mmwc 60 70 mmwc 260 250 mmwc 1182 1092 mmwc 985 930 mmwc 346 320 mmwc 182 170

75% MCR 260 245 220 205 55 20 81 235 990 635 295 160 180 175 168 165 15 6 92 220 840 710 270 148

CHAPTER 17 INTERNAL TREATMENT

The performance of a boiler in a long run generally depends on the quality of the feed water. Strict adherence to the quality will eliminate maintenance and reduces the downtime. The recommended feed water analysis are: pH Conductivity P alkalinity M alkalinity Silica Total Hardness : : 50 micromho/cm : 0.5 ppm : 1.0 ppm : : Nil 7.5 to 8.5

0.2 ppm

Our water treatment plant is designed to produce DM water to meet the above quality. This DM water is subjected to Deaeration in the deaerator for the removal of dissolved oxygen. Rigid control of feed water and operating variables avoid scale formation and corrosion of water and steam contacted surfaces of the boiler. This is very important in low-pressure boilers and becomes increasingly magnified at intermediate and higher-pressure operation. Corrosion of metal surfaces in contact with water and steam constitutes the major maintenance expenses. The condensate and feed water must be free of dissolved corrosive gases and the pH of the water must be properly adjusted to prevent the attack of metal surfaces. The oxygen content in the feed water must be reduced to low levels by effective Deaeration. Make up condensate from storage tanks should not be added directly to the feed water system without Deaeration. It is important to maintain a chemical-reducing environment in the boiler water and chemicals such as Hydrazine, sodium sulfite is added to achieve this effectively. The pH of the feed water must be controlled to prevent the dis-solution of the Iron and copper alloys in the pre boiler system. They form corrosive products when introduced into the boiler and will contribute to the corrosion of boiler steam generating surfaces. Oxides of Iron and copper diffuse and thus the boiler water to the heated surfaces cause locally high concentrations of boiler water salines that result in the attack of the tube metal. The pick up of metals from pre boiler surfaces can be minimised by the addition of volatile alkaline chemicals that raise the pH of the feed water. The caustic based pH system, the co-ordinated phosphate. pH control and the volatile treatment method have all been successfully applied. However, the latter two methods of control are preferred in higher-pressure boilers. Volatile treatment protects deposition in super heaters and turbines turbines may result from

intermittent carry over. The disadvantage is rapid changes in boiler water pH values. Close control of solids in the boiler water must be established to prevent carry over of boiler water into the steam. The presence of oil, grease, high alkalinity, or other foam products including solids cannot be tolerated. For this on line analytical instruments are provided and must be counter checked with lab analysis. OXYGEN REMOVAL Sodium sulphite and Hydrazine are the most commonly used chemicals for removal of oxygen in boilers. HYDRAZINE This has the following inherent advantages: 1. Remove all dissolved solids in the boiler water. 2. The degree of volatilization of Hydrazine increases with the temperature of boiler water. This makes it available in the condensate system for removal of any oxygen that may be present in the condensate system. 3. Hydrazine also protects iron and copper surfaces and they became less susceptible to corrosion by passivation. Conversion of ferric iron to ferrous iron and cupric copper to cuprous form takes place on the metal surfaces in the preboiler, boiler and after boiler systems. This is of special significance as some ferrous form oxide is more easily dispersed than ferric oxide. Any iron that finds its way to the boiler is kept in a more soluble loose binding state, allowing it to be easily removed from the system by blow down. Though Hydrazine has the above advantages, it is not used in OSB because its reaction with oxygen and metals at lower temperatures is sluggish. Because of its high volatility, any interruption in dosing will lead to the sudden fall of pH of the boiler water. SODIUM SULFITE Sodium sulfite is used in OSB as oxygen scavenger for removal of oxygen effectively in low temperatures. During preparation, excessive agitation of the chemical solution must be avoided to prevent intake of air into the solution. This will reduce the active sulphite available for the reaction in boiler. This chemical should

be kept in a dry places. 5 to 10 ppm of sulphite is maintained in boiler water for effective removal of oxygen. Higher concentration will increase the TDS and hence not recommended. Sulphite solution is injected in boiler water at pump suction and controlled by a variable stroke pump. The preparation tank is provided with and agitator and DM water make up for solution preparation. Based on lab analysis and boiler load the stroke of this pump is adjusted. PHOSPHATE TREATMENT This is a common system being used for several decades. This process converts hardness salts to a readily controlled and removable form. In hydroxide atmosphere, phosphate combines with calcium hardness salts yielding a sludge known as hydroxyapatite. This sludge is with drawn by blowdown if the boiler working pressure is 800 psi or below. If adequate silica is present in the water, this phosphate forms serpentine. In low-pressure boiler, the residual phosphate is maintained around 20 to 30 ppm in the hydroxide alkalinity range of 200 to 400 ppm. But there are some disadvantages. It adds to the total suspended solid content. If boiler make up water contains any contamination like oil or organic matter; the suspended solid will combine with this and adheres to heat transfer surfaces resulting in over heating and tube failure. COORDINATED PHOSPHATE CONTROL Coordinated phosphate control is based on balance between pH and phosphate concentration to control caustic corrosion. It is designed to prevent the existence of free hydrate alkalinity by maintaining boiler water pH in such a way that sodium to phosphate ratio is less than 3 and all alkalinity is tied up by phosphate. ROLE OF SILICA The presence of silica in low-pressure boilers can play vital function. Even minimum amount of silica will precipitate magnesium as serpentine. But two high silica residual can produce as adherent silica scale. It volatilize above 600 psi and passing over with steam and forms troublesome deposits on turbine blades. The extend of silica carry over depends on operating pressure and silica concentration. Boiler carry over is an another phenomenon in which solids leave from boiler water with steam. This carry over affects internal boiler treatment more than vapourising of silica. This carry over can deposit on valves, boiler feed pump, condensate return system, and

feed water heaters.

This carry over results from four basic causes. 1. Priming: It is the surging of boiler water into the steam outlet. Normal causes for this priming are poor control of steam drum level during load fluctuations, spouting of submerged raisers and water swelling due to erratic combustion. 2. Poor design and installation of drum internals or damage in steam separators. 3. Heavy misting or fogging occurrence when steam departs from the water surface due to damaged or inefficient steam separators. 4. Foaming: It is the most common mechanism of carry over due to excessive alkalinity, presence of oil or any organic matter and process contamination. Injecting anti foam agents can prevent this. In our boiler DM water and condensate is used as boiler feed water in deaerator. As water boils, the dissolved solids are retained in water and are removed continuously by CBD. In case of any abnormal raise in concentration IBD is given. The CBD is continuously analysed in our side and periodically by lab to ascertain the effectiveness of treatment. BOILER WATER TREATMENT CHEMICAL APPLICATIONS REMARKS Sodium Hydroxide Increase Alkalinity. Raise pH. Precipitate Magnesium. pH control improves by the formation of calcium precipitate. Sodium carbonate Increase Alkalinity and pH. Precipitate calcium in Carbonate form. Cheaper. More easily handled than caustic. Some carbonate breaks down to release CO2 with steam. Sodium phosphate Precipitate calcium as Hydroxyapatite. Reaction requires sufficiently high alkalinity and pH. Sodium Aluminate Precipitate calcium and magnesium Forms a flocculent sludge. Chelants (EDTA, NTA ) Control scale by forming heat stable soluble complex with calcium and magnesium. Prevents precipitation of scale forming compound on metal surfaces. May dissociate at high pressures. Use O2 free water. Tannins Starch Lignin derivatives Carboxymethyl cellulose Prevent feed water line deposits. Coat on scale crystal and produce sludge.. Often used as protective colloids with soda ash, phosphate. Distort scale growth. Inhibit caustic embrittlement. This does not adhere as readily to heat transfer

surfaces Polymers Copolymers Disperse sludge. Distort crystal structure of calcium deposits. Prevent fouling by corrosive products. Distortion of crystal structure of precipitates prevents their adherence to metal surfaces. Sodium sulphite Prevent O2 corrosion by forming sodium sulphate. May deposit at high temperatures and pressures forming H2S. Catalysed form gives faster action. Hydrazine andsubstitutes Prevent O2 corrosion React with residual O2 and form N2 and water. Filming Amines(Octadecylamine) Control return line corrosion by forming protective film. Protect against O2 and CO2 attack. Small and continuous feed maintains effective film. Neutralising Amines (Cyc- lohexamne) Control return line corrosion by adjusting condensate pH. Protection given by neutralisation of carbonic acid from CO2. Sodium Nitrate Inhibit caustic embrittlement Used where water has embrittling characteristics. Antifoams (Plolyglycols, Silicones, Polyamides. Reduce foaming tendency of high solids boiler water. Usually added with other chemicals for scale control and sludge dispersion.

CHAPTER 18 REFRACTORY AND INSULATION

Proper refractory and insulation minimises heat loss and avoids heating of boiler external parts. The combustion chamber is a membrane wall construction and hence less refractory work is involved. The bottom of the furnace is lined inside with fire bricks. For ceiling, burner regions and baffles, castable refractories are used for lining. The outer side of the combustion chamber and the pent house are insulated with mineral wool mattress. The super heater tubes and header inside the pent house are insulated with calcium silicate slabs and segments. The hot lines, valves and fittings are insulated with mineral wool mattress. SPECIFICATION OF REFRACTORY AND INSULATION MATERIALS Sl No Description Kgs/M3 1 Fire brick 2 Fire day marter 3 Fire brick ( Sillimanite quality) 4 Sillimanite binding mortar 5 Castable refractory 6 Insulating binding martar 7 Slag wool mattress 8 Calcium silicate pipe sections 9 Calcium silicate mouldable insulation CARE ON REFRACTORY WORK 1. The entire refractory work is subjected to considerable thermal stresses during boiler operation. Sudden application of heat or cooling introduces severe stresses. The following precautions eliminate damages to the refractory work. 2. Avoid sudden cooling of the furnace after a shutdown. A cooling rate of 20 oC to 30 oC per hour is recommended. This means fan must be stopped after the shutdown of boiler. Ventilation of the furnace by natural draft is permissible only after 6 hrs of shutdown. Forced cooling can be started only after 16 hrs. 3. Quick heating of furnace may be avoided. Boiler starting procedure is usually a reliable guide to achieve this Specification IS 8/67 IS 195/63 2 HD CSN 726112 KI CSN 726112 KI As per BHEL spec BPS 516002 As per BHEL spec BS 3658 part 2 BS 3958 part 2 Density 2000 2000 2200 2200 2200 500 150 320 320

4. The brickwork to be thoroughly examined during shutdown for cracks, loosening of bricks, expansion of joints, chipping off, spilling etc. Periodical inspection to be done during operation through observation holes. Whenever defects are noted, they should be attended at the earliest depending on the seriousness of the defect. Abnormal heating of outside metal sheet covering of the boiler is usually a good indication of damaged refractory in that area. 5. The inspection doors, peepholes etc should be kept closed properly. They are entry points for cold air and this cold air can damage the brickwork by localised cooling.

CURING AND DRYING OF REFRACTORY WORK Curing of refractory is essential. It retains the moisture for a minimum period in order to ensure the proper hydration of the binder. Initial setting occurs with in two hours. Castable refractory should be cured for 24 hr. Refractory is to be kept wetted by protecting with damp sacking or plastic sheet with out touching the refractory or by using dry coating with organic based sealing compound. Water sprinkling also can be used if the area is easy to approach. This method is continued for a period of 20 to 24 hr. after 4 or 5hr. Of construction. After this the surface from direct sunlight atleast for about 48 hr. Natural air drying for castables after curing will actually cause slight increase in strength. Normally the refractory is air dried for 24 hr. after removal of the framework and then heat dried by starting the boiler for 12hr. between 50oC and 100oC. Temperature increase is to be limited to a maximum of 50 oC per hour. Uniform drying is the basic requirement for longer life of the refractory. The purpose of the drying is to remove moisture to soothe out the internal strains in individual parts of brick setting and also to allow thermal expansion. The soothing out operation is to be continuous. Maximum rate of allowable temperature by using oil burner is as follows. 1.Average raise in temperature should be 10 oC /hr up to 200 oC 2.Average raise in temperature should be 20 oC /hr from 200 oC to 600 oC. 3.Average raise in temperature should be 50 oC /hr above 600 oC

PROCEDURE FOR REFRACTORY CURING Refractory curing is to be carried out carefully keeping Gas air heater inlet temperature as reference. The operation is to be done as per the following chart. TIME INLET Hrs tempoC 00.00 35 oC 01.00 50 oC 02.00 65 oC 02.00 TO 07.00 (5 hrs) 07.00 TO 12.00 (5 hrs) 12.00 TO 15.00 (3 hrs) 15.00 TO 18.00 corresponding to 45 ksc GUIDE LINES To control temperature, firing is to be stopped and restarted as and when required. 82* LDO pressure may be maintained at minimum pressure required for good flame condition. 83* Simultaneously start up vent may be throttled to increase pressure and thereby GAH inlet temperature. 84* During the above period charge all steam headers and deaerator and check and attend all steam leaks. 85* After steam blowing, safety valves are to be floated. For this again change to LDO firing if required.
81*

GAH

Maintain 65 oC Increase at the rate of 25 oC to 200 oC Maintain at 200 oC Reach maximum temperature exit pressure

CHAPTER 19 BOILER HYDROSTATIC TEST

The hydrostatic test is conducted to ensure the pressure tightness of steam and water circuit of the boiler. It is important to note that the hydrostatic test should be so planned that period between the hydrostatic test and the start up of the boiler should be as short as possible, so as to minimise the corrosive effect of residual moisture which may be present in the boiler. PREPARATION FOR HYDROSTATIC TEST 1. 2. 3. 4. 5. 6. 7. 8. 9. Change drum pressure gauge and exit steam pressure gauge with standard one. Drop all the safety valves and blind drum end flanges. Check steam and mud drum manholes are in closed condition. Close all the isolation valves connected to pressure parts such as drain, sample lines, instrument lines, gauge glass etc. Open starting vent, and drum vent. Open boiler filling valve at drain header. Open both blow off mud drum valves at drain header. Close all other valves. Ensure the availability of Feed water pump and sufficient quantity of water in deaerator.

PROCEDURE 1. Start feed water pump C. 2. Open FC 01 A or B, and its u/s and d/s isolation valves by 1 to 2 turns. 3. Open boiler filling valve near feed check valve by 2 to 3 turns and fill the boiler (allow 10 t0 15 T of water) through drain header. 4. Close the drum vent when water comes through it. Allow the water to fill super heater coils and exit steam line up to main steam stop valve. 5. Close the starting vent when water comes through it. Now boiler pressure started raising.

6. Raise the boiler pressure at a rate not exceeding 10 ksc per minute by adjusting the drum vent and boiler filling valve near feed check valve. 7. If any significant leakage is observed while raising the pressure, stop further raise of pressure. If necessary reduce the pressure or even drain the boiler to attend such leakage. 8. Raise the boiler pressure up to 1.5 times of normal operating pressure. Close the valves and stop the pump. (Note: At this pressure boiler should not be held for more than ten consecutive minutes.) 9. Watch for pressure drop. The hydrotest is considered successful if the boiler withstands the pressure with out any appreciable leakage (drop is with in), or under deflection or distortion of its pressure parts during the above period. 10.Bring down the pressure at the rate of 5 ksc per minute max to working pressure and carry out further checks if required. 11.When the pressure has dropped to 2 ksc open the starting vent and allow the pressure to drop to zero. 12.Drain the water up to its working level. Note: For running boiler allowable drop rate is1 ksc per minute For new boiler allowable drop rate is 0 ksc per minute

CHAPTER 20 BOILER PRESERVATION

The internal surfaces of boilers are prone to corrosion by leftover water after operation or by atmospheric oxygen when they are out of service. Hence boiler preservation is required to protect the internal surfaces from corrosion. There are two types of preservation called wet and dry preservation. Wet method of preservation is recommended for boilers, which are kept ready for stand-by service and may be required for sudden demands of operation. This method is also recommended for large boiler units with multiple circuits where water is very difficult to drain and dry out thoroughly.

EXTERNAL PRESERVATION
86*

The external as well as internal surfaces of all pressure parts and metallic surface should be cleaned thoroughly by adapting relevant cleaning standards. The whole boiler pressure parts surfaces as well as the gas side surfaces of the air heater should be thoroughly washed with alkaline water. Alkaline water is used to remove sulphur, since sulphur is soluble in caustic alkali. Boiler is to be filled with deaerator water and then lighted. Boiler pressure to be raised to 7 ksc and to be maintained in this pressure till alkali water is getting dried. This may require intermittent firing. After this drying close the gas exit damper near chimney to avoid entry of fresh air. Inspect the boiler surface (external surface) periodically to guard against the corrosion.

87*

88*

WET PRESERVATION
89*

The boiler should be filled with feed water to normal working level at a pH of 10.5 to 11. Hydrazine is to be dosed with water to about 200 PPM. Boiler to be fired to ensure uniform concentration of boiler water throughout the unit and to eliminate dissolved oxygen from water.

90*

91*

The boiler pressure to be stepped down gradually and the water level to be raised as high as it is permitted for safe operation while delivering steam to the line. Then shutdown the boiler and allow for natural cooling. After complete depressurisation, the boiler is to be filled with deaerated water till water comes out through the starting vent. Analyse the boiler water frequently. If the hydrazine concentration in water is below 50ppm, the water in the drum should be lowered to the normal operating level and an appropriate quantity of chemicals should be dosed to bring back 200 PPM of Hydrazine or 300 to 400 PPM of Sodium sulphite. The boiler should be steamed to circulate chemicals to uniform concentration.

92*

93*

DRY PRESERVATION
94* 95* 96* 97* 98* 99*

Fill the boiler up to working level and light up. Increase the boiler pressure to 7 ksc and discontinue the firing. Cool down the boiler and drain completely. Open all the drains and drum manholes. Direct the hot air from the portable blower and drum and super heater coils. After thorough drying, keep the trays containing silica gel or activated alumina inside the drum. Close the pressure parts to air tight to avoid air entering. Inspect the boiler once a month and replace the desiccant if necessary. Pure nitrogen can also be used for dry preservation.

100* 101* 102*

CHAPTER 12 SOOT BLOWING

Soot blowing is performed to remove the soot deposits from the boiler inner heat transfer surfaces by the use of high velocity steam or air. The soot is formed as a result of incomplete combustion of fuel. When deposited over heat transfer areas, they decrease the heat transfer rate due to their poor conducting nature. 15-ksc steam is utilised for soot blowing in our boiler. 6 Nos. of soot blowers are provided in each boiler at different locations and they are of three different types. Soot blower 1 is a rotary cum retractable type provided in the super heater coil zone. The second and third are rotary type provided in the downcomer and riser regions respectively. The fourth and fifth are retractable type located on the top of the tube sheet of each of the two gas air heaters. The last one is also retractable type placed at the bottom tube sheet of GAH cold. The nozzles of these two blowers are positioned so as to face the GAH tube holes to avoid chocks in the GAH tubes from soot. PREVENTING PUFFS AND EXPLOSIONS DURING SOOT BLOWING. 1. During soot blowing, the boiler should be operated at or near its maximum design load. When soot blowers are operated at lower loads, clouds of soot may be blown to the gas stream to form explosive mixtures, which may be ignited by the heat from furnace walls, or by smoldering soot fires. 2. Soot blowing operation at low boiler load with a pulsating colder furnace may also result in some of the unburned combustibles escaping from the furnace and collecting in pockets in back passes. 3. Agitation and ignition of these gas pockets will cause puffs or explosions. All tube surfaces and gas passes, therefore, should be blown with the gas flow at or near maximum to purge the boiler of these possible explosion causes. 4. Burners should be checked during soot blowing for stability. High and stable burning rates also prevent flames from being blown out by small puffs or agitation of the gas flow common to soot blowing. A high burning rate assures a lower oxygen content in flue gases, which eliminate puffs and explosions. 5. The furnace draft is increased by increasing the airflow to take care of the increased flue gas volume due to the soot blowing operation. Increased furnace draft helps to purge combustible gas pockets as well as improves cleaning by moving soot particles through gas passes rather than redepositing them on the

adjacent surfaces.

6. The normal sequence of soot blowing is to follow the gas flow through the boiler. The first blower to be operated should be the nearest to the burners and then each unit in turn along the gas passes to complete the cleaning cycle. This method thoroughly cleans the entire unit by moving along the passes rather than blowing them loose and redepositing on adjacent surfaces. It may be desirable to reverse this procedure when soot deposits are unusually heavy to avoid puffs and explosions in the back passes. Blowers should then be operated in reverse order from rear to front and again to rear. This procedure may be desirable during periods of low load operation. 7. The steam used must be dry and free from water particles as otherwise the wetness may erode the boiler parts and also the wet steam may dissolve acidic constituents and corrode the parts. If the soot blower got strucked inside the flue gas path, it is to be brought outside as quickly as possible to avoid bending of tubes. It is preferable to operate the soot blowers once in a shift. SOOT BLOWING PROCEDURE 1. 2. 3. 4. Ensure proper lubrication is available in all gearboxes of soot blowers. Open all the drain valves in soot blower steam system. Open upstream isolation valve of PCV 02. Open PCV 02 slowly, and pressurise the system to 2ksc. Warm up the lines in this pressure for 10 mts. Allow condensate to drain freely. Check the temperature of the steam neat soot blower 6. It must be around 220 oC. 5. Throttle all the drain valves to minimum opening. 6. Pressurise the system to 12 ksc. by opening PCV 02 and put it on auto. 7. Increase the furnace draft by increasing the airflow by about 2 NM3/sec. 8. Operate the blowers in the numerical sequence as shown in the soot blower panel one after another. (Ensure the blower 2 and 3 are rotating in the direction of flue gas path.) 9. When entire blowing sequence has been completed close the PCV and isolate the steam. 10.Open all drains and depressurise the system. 11.Normalise the furnace draft.

CHAPTER 22 EQUIPMENT DETAILS

STEAM AND MUD DRUM STEAM DRUM 1598 mm 1524 mm 42 mm 74 mm 5700 mm 4500 mm 58 mm 515 Gr 70 One One 3 Nos MUD DRUM 956 mm 714 mm 45 mm 25 mm 5216 mm 4500 mm ASTMA 515 Gr 70

Outer diameter Inner diameter Top thickness Bottom thickness Total length LOS Dished end thickness Material Primary screen Secondary screen Drain pipe WATER WALLS

Water wall fine width Pitch of the water wall tube Water wall header connecting tubes at the bottom SUPER HEATERS Number of coil assemblies Type Number of loops per assembly Tube size Material of construction Inlet header size Outlet header size

25 mm 101.6 mm 18 tubes

27 Pendent vertical lube Four 44.5 mm or 1 3/4" 2 loops - SA 210 Gr Al Next 2 loops SA 213 Gr T11 219.1mm dia x 16 tubes 273 mm dia x 32 tubes

GAS AIR HEATER

HOTGASAIR HEATER COLD GAS AIR HEATER

Make Total tubes Size Length Material SAFETY VALVES

M/s BHEL 74x56= 4144 40 mm dia 3.0 M ERW

M/s BHEL 90x34=3060 50 mm dia 3.0 M ERW or Carton A steel

Size Reset inch ksc 1. Drum west 53.0 2. Drum east 54.5 3. Super heater 49.0 4. 20 ata header 22.5 5. Soot blower header 21.0 ---6. 50/11 ksc header 12.7 ---7. Deaerator ( 3 Nos ) 1.24 ---8. 11/3 ksc header (HP) 13.80 ---9. 11/3 ksc header (LP) 4.50 ---10 BFW A exhaust line 15.0 ---11 BFW B exhaust line 15.0 ---12 BFW C exhaust line 15.0 ---ksc 2 50.8 2 42.5 2 47.0 5 ---2 2 8 4 -----------

Capacity Tph

Lift

46.3 30.7 32.4 20.0 10.0 6.2 7.0

13 HFO turbine exhaust 4.00 ---FD FAN Fan classification Fan operation Medium handled Design rating Discharge head Max temperature of medium handled Specific weight of medium Fan speed Direction of rotation Blade type Type of flow control FD FAN A TURBINE Supplier Type Inlet steam pressure Inlet steam temperature Outlet steam pressure Outlet steam temperature Turbine output Turbine working speed Trip speed Turbine oil

---

Radial single inlet and single width Horizontal Atmospheric air 29.1 m3 / second 750 mmwc 27C 11 1.1 kg / M 3 980 rpm Clock wise Backward curved plate Inlet vane control

M/s KKK West Germany Back pressure 45 kscg 382 C 10.8 kscg 278 C 320 KW 988 rpm 1087 rpm Turbine oil 57

DEAERATOR Type Heater portion Storage portion Maximum treating capacity Minimum treating capacity Mechanical type with low pressure steam as stripping medium 2700 mm dia x 1050 mm HOS 3000 mm dia x 10000 mm LOS 220000 Kg / hr 55000 kg / hr

Temperature of treated water 105 C Total storage capacity 60 M3 Maximum working pressure 0.3 kscg Dissolved Oxygen in treated water 0.005 to 0.007 ppm Steam requirement 10% of DM water and 5% of condensate treated Number of spray cones in the dome 21 Vacuum breaker One

BOILER FEED WATER PUMP PUMP Number of pumps Suction pressure Delivery pressure Temperature of liquid handled Speed Capacity Drive motor TURBINE Type of turbine Supplier Inlet steam pressure Outlet steam pressure Outlet steam temperature Turbine output Working speed Trip speed Steam consumption Turbine relief valve set pressure Back pressure M/s KKK west Germany 45 kscg 11 kscg 278 C 280 KW / 308 KW max 2950 rpm 3245 rpm 6.44 TPH 17 kscg 3 1.5 kscg 70 kscg 105 C 2950 rpm 105 T / hr 300 KW / 3300 V / 60A

HFO TANK Liquid handled Liquid temperature Make Material of construction Capacity Heavy fuel oil or LSHS 90 C M/s Vijay tanks MS vertical tank 265 KL

Height 6.5 M

HFO PUMP "A" PUMP Make Type Capacity Delivery pressure Viscosity of liquid handled PUMP A TURBINE Make Live steam pressure Exhaust steam pressure Steam consumption Casing relief valve pressure Turbine speed Trip speed Reduction gear Gear box oil Normal output Maximum output Turbine lub oil HFO PUMP "B" Make Type Supplier Viscosity of liquid handled Suction strainer mesh size Discharge pressure Capacity Speed Suction Power transmission Motor FUEL OIL HEATER Hamworthy - 8 AA series Screw pump M/s Wesman 120 CST at 80 C 0.5 mm 16 kscg 300 lit / min 1450 rpm Flooded Direct coupling 1460 rpm, 18.5 KW, 440 V KKK West Germany 10.8 kscg 3 kscg 0.88 TPH 4 kscg 4500 rpm 5175 rpm 3:01 SP 57 20 KW 25 KW SP 57 Tushaco Screw pump 300 lit / min 16 kscg 75 CST

Number of heaters Rated output Working pressure Exit oil temperature Heating steam pressure Heating steam temperature Maximum steam flow Type Shell side fluid Tube side fluid Material of construction Safety valve set pressure

2 14000 kg / hr 16 kscg 110 C 11.5 kscg 200 C 850 kgs / hr Shell and tube Oil Steam CS tube and MS shell 20 kscg

LDO TANK Liquid handled Liquid temperature Make Material of construction Capacity LDO PUMP Make Type Viscosity handled Suction Discharge pressure Capacity Speed Power Motor Swiss Make Screw pump 2.5 E - 15 CST Flooded 40 kscg 120 lit / min 2900 rpm 17.8 HP 440 V / 15 KW / 2900 rpm Light diesel oil Atmospheric temperature M/s Alkan Engineering Ltd. MS Horizontal tank 65 KL

SOOT BLOWERS Rotary cum rotary Retractable Type 1. No.of SB per boiler 2 3 2. Nozzle size 2 x 3/4" 18x3/8" 3. Blowing pressure in PSIG 125 4. Blowing rate in kg/hr 12650 5. Blowing time for each in mts 1/3 6. Speed of travel in ft/mt 7. Steam consumption per unit (kgs) 70 8. Operation period per unit (mts) 2/3 664 4.4 3.7 3.24 6.5 6.5 427 12250 3.56 19x3/8" 175 150 7200

Retractable type type 1

ROTARY CUM RETRACTABLE SOOT BLOWERS Make Copes Vulcan Type Long rotary & retractable Model Number LR-IE Traverse Speed 1.63 M/min Rotary speed 5.2 rpm Head size

15mm Rotary gear ratio 28:1 Sprocket teeth 20 Cluster teeth 28: 5 Diameter 80mm Traverse gear ratio Sprocket teeth 14 Steam pressure 10.5ksc Inner lance tube material Outer lance tube material Droop 60 at free end downwards Direction of rotation clock wise Motor details Kirloskar make Traverse : 415V, 1.1 A, 0.37 KW Rotary : 415V, 0.45 KW

155:1

SS CS Anti

CHEMICAL PREPARATION TANK

PHOSPHATETANK SULPHITE TANK

Size 600mm x 900 mm Volume Make Exchange India Ltd Material with Epoxy coating Solution Concen DOSING PUMPS Type Plunger diameter Capacity litres/min Maximum working pressure Lub oil 100 Power transmission Motor details rpm, 415 V, 0.37KW. LSHS UNLOADING PUMP

1000mm x 1200 mm 942.9 litres 254.6 litres M/s Ion Exchange India Ltd MS tank with Epoxy coating 0.5% in alkaline medium

M/s MS 0.5 %

Ion tank

Plunger type 15.9mm 21.8 70 ksc SS 81 & SS Belt drive 0.5 HP, 1500

Make pump Type ( R-100-SLSJ data corporation) Motor details Bijilee Ltd. 415V, 11A, 50 HZ, 5.5 KW 445 rpm, Stg - C - 74A.

Tushaco Screw pump Make: Bhara

STEAM CONDENSATE PUMP Make (Akay Industries) Operating temperature Discharge head Material of construction Capacity Bearing 6306, Thrust - 3305, Motor details 415V, 4.5A,2.2 KW,2940 rpm. Chen 70C 30 M SS 10 T/hr Radial NGEF, Flo

INSTRUMENT AIR COMPRESSOR Make Khosla-Crepelle Type Reciprocating compressor Number of stages stages, Double acting. RPM 750 I stage pressure 2.2 ksc II stage delivery pressure Suction temperature II stage suction temperature After cooler temperature Capacity 550 M3/hr at 10 ksc pressure. Material of construction Power transmission Cooling water pressure Lub oil pressure 2.0 ksc Two

6.5 ksc 33C 50C 40 ~ 45 C Cast Iron body. Belt driven. 2.5 ksc

Cooling water pressure low trip 0.8 ksc Lub oil pressure low trip Unloading pressure Loading pressure ksc Motor details NGEF, 415V, 130A, 75KW, 1485 rpm.

0.8 ksc 8.0 ksc 6.0

INSTRUMENT AIR DRYER Make Mirch - Mirex Ltd. Flow rate 1000 M3/hr Working pressure ~ 10 ksc. Dew point of air 40C Dryer cycle 16 hrs. Desiccant Silica gel (550 kg each) Heater 24 KW Heater temperature thermostat set Vessel top temperature during regen 100C Power circuit 440 V Control circuit 230 V 7

160C ~ 200C

BURNER ASSEMBLY Primary swirler mm , SS 533.5

Secondary air swirler , MS MS ring with mortor packed Secondary air side vent throat Burner mouth 627 mm Burner mouth outer Flame length 6 M Swirler diameter mm HFO gun capacity LDO gun capacity kg/hr LPG gas pressure for burner STEAM AIR HEATER Heating medium ksc steam Steam consumption No of tubes in a bundle No of bundles 2 Total number of tubes Type Fins radiator type Material of construction Make

597 477 570 mm 692 mm mm

mm

601 1650 kg/hr 500 1.2 ksc

9.0 1950 kg/hr 28 x 2 = 56 112 MS