SUPPLIED TO
THERMAX LIMITED
BOILER & HEATER GROUP
PUNE, INDIA
0
REV
SSC
03.12.2008
PREPARED BY
AA
05.12.2008
CHECKED BY
USU
08.12.2008
APPROVED BY
0
REVISION
DESC. /
REMARK
Contents
Volume 1 Boiler Description ....................................................................................................1
Section A................................................................................................................................2
1 Design Specifications of Steam Generator ....................................................................3
2 Design Code...............................................................................................................3
3 Material Specifications Pressure Parts .....................................................................3
4 Heating Surface Area ..................................................................................................5
5 Fuel ...........................................................................................................................5
6 Fuel Analysis (% By Wt.) .............................................................................................5
6.1 Ultimate Analysis ...............................................................................................5
6.2 Fuel size ...........................................................................................................5
7 Bed Material ...............................................................................................................6
7.1 Bed Material Specifications - Crushed Refractory ................................................6
8 Continuous Blowdown .................................................................................................6
9 Intermittent Blowdown .................................................................................................6
10 Feed Water Recommended Quality ............................................................................6
11 Boiler Water Recommended Quality ...........................................................................7
12 Utilities .....................................................................................................................7
12.1 Electrical Power...............................................................................................7
12.2 Cooling Water..................................................................................................7
12.3 Instrument Air ..................................................................................................8
12.4 Service Air.......................................................................................................8
13 Chemicals for Dosing ................................................................................................8
14 Site Condition ...........................................................................................................8
15 Fans.........................................................................................................................8
16 HP Dozing System ....................................................................................................9
17 Rotary Feeders ....................................................................................................... 10
17.1 Capacity Chart............................................................................................... 10
18 Gauge Glass........................................................................................................... 11
18.1 Drum Level Gauge......................................................................................... 11
18.2 Blow Dowm Tank Level Gauge ....................................................................... 11
19 Safety Valves .......................................................................................................... 11
20 Temperature Profile ................................................................................................ 13
20.1 Gas Temperature ........................................................................................... 13
20.2 Water Temperature ........................................................................................ 13
20.3 Air Temperature ............................................................................................. 13
21 Flue Gas Pressure Profile ........................................................................................ 13
22 Process Flow Diagram............................................................................................. 13
Section B ............................................................................................................................. 14
1 Section Overview ...................................................................................................... 15
2 Feed Water System................................................................................................... 16
2.1 Feed Water Control Station .............................................................................. 16
2.2 Attemperation Control Station........................................................................... 17
3 Boiler Pressure Part Description................................................................................. 17
3.1 Economizer ..................................................................................................... 17
3.2 Steam Drum .................................................................................................... 17
3.3 Water Drum..................................................................................................... 18
3.4 Down Comer Tubes ......................................................................................... 18
3.5 Furnace .......................................................................................................... 19
3.6 Inbed Evaporator ............................................................................................. 20
3.7 Riser Tubes..................................................................................................... 20
3.8 Super Heater................................................................................................... 20
3.9 Attemperator ................................................................................................... 20
3.10 Convection Bank ........................................................................................... 21
4
5
ii
iii
iv
vi
Section A
Section B
Section C
Section-D
Section E
Section A
Topics Covered in this Chapter
Section A
Parameters
Unit
Value
TPH
41
Kg/cm2(g)
66
Deg C
490+/- 5
% MCR
60 100
Deg C
130
Deg C
160
Main Fuel
Indian Coal
Fuel Zizing
Design Code
:
As per IBR
Details
Size In Mm
Shell
Dished End
(SEMI-ELIPSOIDAL)
Material
SA 516 Gr.70
Shell
Water Drum
Dished End
(SEMI-ELIPSOIDAL)
Riser
Tube
SA 210 Gr A1
Section A
Description
Details
Size In Mm
Material
Top Header
SA 106 Gr B
Bottom Header
SA 106 Gr B
Panel Tubes
SA 210 Gr A1
Bend Tube
SA 210 Gr A1
Top Header
SA 106 Gr B
Bottom Header
SA 106 Gr B
Panel Tubes
SA 210 Gr A1
Opening Tubes
SA 210 Gr A1
Top Header
SA 106 Gr B
Bottom Header
SA 106 Gr B
Panel Tubes
SA 210 Gr A1
Opening Tubes
SA 210 Gr A1
Top Header
SA 106 Gr B
Bottom Header
SA 106 Gr B
Panel Tubes
SA 210 Gr A1
Opening Tubes
SA 210 Gr A1
DC1-DC11
100 x Sch 80
SA 106 Gr B
Reducer
SA 234 WPB
Pipe
SA 106 Gr B
90 Elbow
100 x Sch 80
SA 234 WPB
Tube Stub
SA 210 Gr A1
SA 210 Gr A1
SA 210 Gr A1
SA 213 Gr T11
SA 213 Gr T22
Pipe
SA 106 Gr B
Tube
SA 213 T22
Pipe
SA 106 Gr B
Pipe
SA 106 Gr B
Attemperator
Header
SA 106 Gr B
Inbed Coils
Tube
SA 210 Gr A1
Inbed Header
Header
SA 106 Gr B
Tube
SA 210 Gr A1
SA 106 Gr B
Tube
SA 210 Gr A1
RH Panel
Front Panel
LH Panel
Rear Panel
Down comers
Super Heaters
(CSH & RSH)
Super Heaters
(CSH & RSH)
Economiser
Boiler bank
Section A
Coils
Unit
Value
Sq.Mtr
354.0
Sq.Mtr
242.1
Sq.Mtr
688.0
Inbed coils
Sq.Mtr
81.6
Economiser
Sq.Mtr
566.0
Sq.Mtr
1931.7
Fuel
Fuel Type
Fuel Name
Main Fuels
Indian Coal
Start up Fuel
Unit
Indian Coal
Char
Hydrogen
% Wt
2.30
0.42
Carbon
% Wt
37.1
40.30
Nitrogen.
% Wt
0.70
0.17
Oxygen.
% Wt
6.60
2.84
Moisture
% Wt
8.00
3.21
Ash
% Wt
45.0
52.68
Sulphur
% Wt
0.30
0.38
Calorific Value
(GCV)
Kcal/kg
3500
3200
< 6 mm
Up to 30 % (Max.)
< 1mm
100 %
< 3mm
Up to 30 % (Max.)
< 1mm
Char
Section A
Bed Material
Lump Size
Bluk Density
10001100
Chemical Composition
AL2O3 % 35 to 45
SiO2 % 55 to 65
Temperature
>1300 deg C
SIZE
Shape
Chemical Composition
SIO2
5060
AL2O3
FEO
<2.0
TIO2
1.67
MNO
Traces
CAO
0.54
MGO
0.23
P2O5
0.08
NA2O
0.22
K2O
0.45
Continuous Blowdown
Max
3 %/ Hr
Normal
1 %/ Hr
6%
Intermittent Blowdown
Once in 8 Hours
Unit
General Appearance
Total Hardness as CaCO3
Section A
Value
Clear & Colorless
ppm
Nil
Parameters
Unit
Value
Total Fe
ppm
<0.01
Total Cu
ppm
<0.003
Total O2
ppm
<0.007
ppm
Nil.
8.5 9.5
pH Value at 25 Deg C
Total Dissolved Solids
ppm
0.1
Silica as SIO2
ppm
<0.02
Hyderzine residual
ppm
0.02 0.04
Unit
Value
pH at 25 deg C
9.5 10.2
Phosphates PO4
ppm
2- 6
Total Alkalinity
ppm
4 max.
Sodium Sulphite
ppm
Nil
ppm
Nil
p value
mval/kg
0.1
Silica as SiO2
Ppm
Units
Value
12 Utilities
12.1 Electrical Power
Parameters
Frequency
Hz
50 +/- 5%
Type
For Instrumentation (field switches, Level gauge illumination, solenoid valves etc.)
Voltage
110
Frequency
Hz
50
Type
24
Frequency
Hz
NA
Type
DC
Section A
Parameters
Unit
Value
Supply Pressure
Kg/cm2(g)
34
Parameters
Unit
Value
Supply Temperature
Deg C
Ambient
Quality
Duty
Sample Cooling.
Unit
Value
Pressure
Kg/cm2(g)
67
Dew point
Deg C
-40
Temperature
Deg C
Ambient
Parameters
Unit
Value
Pressure
Kg/cm2(g)
Temperature
Deg C
Ambient
Quality
Duty
General purpose
LP Dosing
Hydrazine
14 Site Condition
Kopal, Karnataka
Site Location
Ambient Temperature
Performance
36 C
Maximum
45 C
Minimum
20 C
Electrical Design
60 C
Relative Humidity
60%
Altitude
Seismic coefficient
15 Fans
Duty conditions
Make
Model
Section A
Unit
FD fan
ID Fan
PA Fan
Test Block
Conditions
Test Block
Conditions
Test Block
Conditions
TLT Engineering
TLT Engineering
TLT Engineering
2218 /
16378B -
3166-
758
982
256
FD fan
ID Fan
PA Fan
Duty conditions
Unit
Test Block
Conditions
Test Block
Conditions
Test Block
Conditions
Quantity
Nos.
Clean Air
Flue Gas
Clean Air
Nature of medium
Air /Gas density
Kg/N M3
1.29
1.31
1.29
Volume
Kg/hr
77486
86970
15300
Gas Temperature
at Fan Inlet
Deg C
45
150
45
Absorbed Power /
Rated Fan Power
KW
250
90
50
Differential static
head
mmWc
860
200
760
Fan Speed
Rpm
1480
980
2920
Static Pressure
mmWC
8437
1962
2920
22220 EK/C3
222216 EK/C3
222176 EK/C3
SNH-520
SNH-516
LOE-217
22220 EK/C3
222211 EK/C3
222174 EK/C3
SNH-520
SNH-511
LOE-214
Servogem; EP-2
Servogem; EP-2
Servogem; EP-2
250 KW 4 Pole
90 KW 6Pole
55 KW 2Pole
Siemens Make
Siemens Make
Siemens Make
Flexible Resilient
Flexible Resilient
Flexible Resilient
Size 212A
Size 212A
Size 212A
Wellman MakeI
Wellman MakeI
Wellman MakeI
Free/Fixed
Bearing Housing
Bearing
Lubrication
Motor
Coupling Model
/ Make
16 HP Dozing System
Make : N M Enterprises
Drg no : NMEDS-HP-21 Rev -1
Description
HP
Make
Metachem Pump
Model
MC 2
Type
Reciprocating Plunger
Flow
Discharge Pressure
86 kg/cm2 g
110 kg/cm2 g
Pumps
Section A
Description
HP
Make
Crompton/Siemens
Type
Rating
Make
N M Enterprises
Type
Rating
300 litres
Fluid To Be Handled.
17 Rotary Feeders
Make - Nova Bulk Handlers (P) Ltd.
Refer G.A for Drag Chain Feeder. Drg No : Nova /48/ 0708. 2 sheets
Description
Rotary Feeder
Type
Horizontal
Capacity
Material Used
Indian Coal l
Location
At Bunker Outlet
Length Of Feeder
781mm
2.2 KW with Variable Frequency Drive.
3 HP , 4 Pole
Type of Drive
Rotor Size
Unit
Design
100% MCR
50% MCR
Min
Capicity
Kg/hr
3840
3200
1600
800
7.2
6.0
3.0
1.5
Speed
Through Loading
Capicity Per Unit time per
Revelation
RPM
%
95
Kg/hr/reve
0.00234
Char
Unit
Design
100% MCR
50% MCR
Min
Capicity
Kg/hr
2100
1750
875
438
Section A
10
Char
Unit
RPM
Speed
Through Loading
Design
100% MCR
50% MCR
Min
3.14
2.62
1.31
0.65
95
Kg/hr/reve
0.00234
18 Gauge Glass
18.1 Drum Level Gauge
Description
Details
Make
Tag No.
Type
Location
Steam drum
Operating Pressure
Design Pressure
Hydrotest Pressure
315 BAR
C/C Distance
800 mm
Visibility Range
403 mm
Operating Temp.
Details
Make
Tag No.
LG-550
Type
Location
Operating Pressure
05 kg/cm2 (g)
C/C Distance
500 mm
Visibility Range
360mm
Operating Temp.
19 Safety Valves
Description
Application
Unit
Drum LHS
Drum RHS
Type
Spring Loaded
Make
SH
Size Orifice
1.5/ H/3.0
1.5/ H/3.0
1.5/H /3.0
Set Pressure
Kscg
78.8
80.0
71.8
Section A
11
Description
Drum RHS
SH
Tag No
B7
B8
S4
Model
HC56
W-IBR-SPL
HC56
W-IBR-SPL
HCA58
W-IBR-SPL
19027
19313
13892
1 / BLR
1 / BLR
1 / BLR
Rated Capacity
Quantity
Section A
Unit
Drum LHS
Application
Kg/Hr
12
20 Temperature Profile
20.1 Gas Temperature
At the outlet of furnace
875 Deg C.
445 Deg C.
250Deg C.
160Deg C.
160Deg C.
47 Deg C.
Process return
100 Deg C.
Make up water
32 Deg C.
inlet of FW Pumps
130 Deg C.
130 Deg C.
216Deg C.
45 Deg C.
150 Deg C.
Furnace
40
After Economiser
80
110
After ESP
135
At ID Fan Inlet
135
+5
Section A
13
Section B
Topics Covered in this Chapter
Section Overview
Feed Water System
Boiler Pressure Part Description
Main Steam Piping
Boiler Blow Down System
Air and Gas System
Flue Gas System
Fuel Feeding & Firing System
Chemical Dosing & Sampling System
Section B
14
Section Overview
Section B
GENERAL DESCRIPTION
The main parameters of the boiler are
Maximum Continuous
Rating
41TPH
Steam Pressure
66 kg/cm2
Steam Temperature
490+/- 5 Deg C
Fuel Fired
15
Section B
16
3. Water drum
4. Down comer Tubes
3.1 Economizer
5. Furnace
6. RH & LH Inbed Evaporator
7. Furnace membrane water walls
8. Riser Tubes
9. Saturated steam supply tubes
10. Super heater
11. Attemperator
Section B
17
Section B
18
3.5 Furnace
Furnace is the part of the boiler where the
chemical energy in the fuel is converted into
thermal energy by absorbing the heat produced
through combustion of fuel.
The furnace is
designed for efficient and complete combustion,
with due consideration to the factors that
effect, combustion efficiency like fuel residence
time inside the furnace, temperature and the
turbulence required for complete mixing of fuel
and air..
Following are the distinct advantages of the
furnace design:
Heat transfer is facilitated inside the furnace in
addition to combustion
Practically no maintenance for refractory is
required in case of membrane wall furnace
Due to heat transfer inside the furnace, higher
loading is possible, as part of heat generated,
is already absorbed by the furnace tubes
leaving the flue gas temperature out of furnace
within acceptable limits into super heater zone.
Furnace is constructed with shop fabricated
membrane (water wall) construction. It comprises
of Front panel, Rear panel, L.H panel and R.H
panel. Furnace is 7380 mm long x 5040 mm wide.
3.5.1 Front Wall
(Refer Drg no. P42-1PD 45013, R-1)
Front wall is formed with front header (200NB
x SCH 160) and 63.5 O.D x 4.06 Thick tubes.
One end is connected to the bottom header and
the other end is terminated to the top header.
Front wall tubes receive water from steam drum
through supply pipes. To strengthen the wall
tubes, Buckstays beams are provided all around
the furnace. The buck stay beams are supported
on cleats from the water wall panels and flexibly
interconnected at the corners. The buck stay
beams help to retain the furnace shape within
permissible deviations of furnace pressure.
Corner end connecting links maintain furnace
Section B
P41-1PD45213
&
19
3.9 Attemperator
Section B
20
Section B
Aim
This chapter describes the Boiler Blow down
system for safe draining of high pressure and
temperature steam and water from the boiler
using the Blow down tank.
21
System Description
SOURCE
306
Continuous (depending
on quality of Boiler water)
306
Section B
TEMP. OF
DRAIN C
FREQUENCY OF
USAGE
22
SOURCE
TEMP. OF
DRAIN C
FREQUENCY OF
USAGE
Varying from
70 to 520
Draining of condensate
during start-up and after a
shut down.
~70 - 150
Section B
23
Air System
1.
To minimise the force due to possible
movement of the discharge duct on the fan, as
well as to isolate fan vibrations being passed on
to the duct, the fan is connected to the discharge
duct through bellows type expansion joint (1no)
FD Fan
Air Pre-Heater (APH)
Air ducts
Combustion air to Windbox
Secondary Air OR Over fire air.
Secondary Air For Air Spray Nozzle
Aerofoil
6.2 FD Fan
Figure 2 FD Bearing
Section B
24
6.4 PA Fan
Each Boiler is provided with 2x 100 %. PA fans
driven by electric motor to deliver high-pressure
air, which is used for transportation of fuel to the
Combustor. The suction for the PA fan is taken
after APH second pass.
Section B
25
Section B
26
(TE-102 A B C)
(TE-106)
(TE-107)
Local temperature
indicator after APH
(TI-109)
Section B
(TE-100)
Temperature Indicators
Flue gas temperature
at Air-heater outlet
(TE-109)
(TI-110)
(DG-106)
(DG-108)
(DG-109)
(DG-107)
O2 Analyser
A probe connection to measure the O2 % by O2
Analyser Tag no AP is provided in ID Fan Inlet
duct.
7.3 ID Fan
Figure 3 ID Fan
27
System
DRG
Description
Details
Indian Coal:
mm,
100%< 6
Char: 100%< 3 mm
30% (max) < 1mm.
Iron particles < 0.5% by
wt. Coal:
Non caking type.
Aim
Fuel feeding system is of UNDERBED FEED
type and the fuel is burnt in an ATMOSPHERIC
FLUIDISED BED COMBUSTOR. Fuel is fed
through fuel feed ROTARY FEEDERS with the
help of VFD driven motors into a hot fluid bed
where the combustion takes place.
Fuel bunker
Section B
Details
110 Cu M for Coal
110 Cu M for Char/Coal
Under Bed Feeding
28
8.4
Combustor
Section B
TE-101 A,
TE-102 A
TE-101B
& TE-102E
3rd Compartment
TE-101C &
TE-102C
29
Section B
30
Sample Coolers
There are three sample coolers provided on the
boiler for the Feed water sample, Drum water
sample and Superheated Steam sample.
Section B
31
Section C
Section C
Boiler Start Up
32
11.
ECONOMIZER
1. Verify the internal is clean and all the
manholes are closed with proper sealing
STEAM DRUM
Section C
33
ROTARY FEEDER
ESP
GENERAL
Section C
34
Section C
35
Section C
36
Section C
8.
37
Figure 4
Section C
38
Operational Control
Section C
39
Section C
bed
level
affects
40
Fuel moisture
Section C
41
Bulk Density
Shape
Fusion Temperature
Ensure bed material bulk density is always
between 1000 - 1100 kg/m3. .
Whenever the boiler is to be shutdown, it is
recommended to stabilise the boiler operation
with coal firing prior to slump the bed
ASH HANDLING:
Fly ash handling system shall be started one hour
prior to coal firing.
ESP
Rapping mechanism should be started one hour
prior to start the firing.
Hopper and insulation heater should be switched
on 4hrs prior to charge the ESP.
4hrs.
after attaining the required flue gas
temperature at ESP inlet, the ESP shall be
charged. However in case of disturbance in
normal operation of the boiler, it is advised to
switch off the transformer.
Section C
42
10.
Section C
43
Section C
44
Boiler Shutdown
or
3.
Section C
45
1.
Section C
46
DOS
1. Maintain all instruments and interlocks in good
working condition.
2. Maintain the instrument air free from moisture
and oily matters and the pressure as
recommended.
3. .All dampers must be in smooth operating
condition.
4. Maintain fuel as per the recommendation 1. .
with
furnace
in
Section C
systems
as
per
47
Controls
DRUM LEVEL
Section C
48
Troubleshooting Chart
Section C
49
Section C
50
Highly
Section C
51
Section C
52
11 Boiler Safety
2. Operator error
Causes
Action
2. BFP failure
3. Tube leak
Action
Compare control room indication with gauge
glass level. If the water level falls out of sight due
to momentary failure of water supply system, due
to negligence of the operator, due to momentary
fluctuations that might occur with extraordinary
changes in load, appropriate action should be
taken at once to trip the fuel. Any decision to
continue to operate, even if only for a short time
at a reduced rating would have to be made by
someone in authority who is thoroughly familiar
with the circumstances that led to the emergency
and positively certain that the water level can be
restored immediately without damaging the boiler.
In the absence of such a decision
1. Stop the fuel feeders and Fans immediately.
Shut off the main steam stop valve .
Simultaneously, if feedwater has become
available and the operator is assured that no
pressure part has been damaged
1. Take the feedwater control system into
manual mode
2. Allow the water flow to boiler gradually to
normal water level. (Do not hurry up which
may lead to sudden quenching and tube leak)
if pressure part damage is suspected
3. Reduce the steam pressure gradually
4. Open the drum air vent when the pressure
drops below 2 kg/cm2
steam
discharge
Section C
if
rate,
53
Section C
54
Section C
55
24.
Section C
56
Handling of Furnace
Observation Doors
Ports
and
be
Safety Tips
1. All scaffolding materials are removed and
cleaned.
Safety Precautions
Section C
57
Section C
58
Section-D
Topics Covered in this Chapter
Section Overview
Recommended Maintenance Practice
Conditioned Based Maintenance
Boiler Annual Maintenance and Overhaul
Boiler Preservation Procedure
Tube Failures
Water Chemistry
Welding Procedure Specifications (WPS)
Section Overview
RECOMMENDED MAINTENANCE
PRACTICES
Recommended Maintenance
Practice
Section-D
59
Section-D
60
EQUIPMENT
CHECK
WORK TO BE DONE
leaking ports
Blurred level
Comparison
of
levels
indicated by local level gauge
with that of remote level
indicators in the control room
Maintenance to be planned
to eliminate the source either
immediately or during next
planned shut down (depending on
the source and quantity of leak)
and accessibility for maintenance.
heater
Section-D
61
EQUIPMENT
Purity of instrument air
CHECK
WORK TO BE DONE
are
the
Sluggish
operation
of
fan
suction damper may be due to
stuck linkage, stuck damper,
faulty power cylinder and faulty
positioner.
Sluggish operation
of air register dampers may be
due to stuck air register vanes,
faulty power cylinders and faulty
positioner. Check for possible
cause. Maintenance works have
to be planned.
Maintenance
Operation
Check
List
During
level
indicators
for
proper
Section-D
62
positions
of
dampers
and
BFW pumps
Igniters
Section-D
63
Dosing system
D P Manometer
CHECK
WORK TO BE DONE
Boiler
safety
interlocks,
start permissive, boiler trip
protection.
Plan
for
maintenance
or
re-calibration of defective items if
any noticed, during the shut down
period.
Combustor
/
refractory work.
Burner
CHECK
WORK TO BE DONE
Pressure
gauges,
temperature
gauges,
Pressure/temperature
Switches
Repairs or
necessary
Positioners, actuators
Repairs or adjustments as
necessary as per vendor manuals
to obtain performance as per
Verify
commissioning records.
functioning of proximity switches
where provided. Clean filters of
air regulators. Check functioning
of air regulators. Verify tightness
of air connections.
Section-D
adjustments
as
64
Corrosion
Deposits
Erosion
Tightness
Pittings
Sealings
Baffles
Plugging
Tightness
Holes orientation
Corrosion
Piping
Chemical dosing
Plugging
Tightness
Holes orientation
Corrosion / Pitting
Plugging
Tightness
Hole orientation
Corrosion / pitting
Furnace tubes
Corrosion
(water side)
Scale
Pitting
Metal reduction
Section-D
65
COMPONENT NAME
Furnace tubes
Corrosion
(gas side)
Build up
Blisters
Sagging
Over heating
Fly ash erosion
Sealing
Supports
Cracks
Expansion clearance
Steam impingement
Refractory status
Insulation
Erosion
Erosion
fire side
Corrosion
Build up
Blisters
Sagging
Over heating
Sealing
Cracks
Steam impingement
Refractory status
Corrosion
(steam side)
Erosion
Scale
Pitting
Metal reduction
Flare cracking
Deposits
Section-D
66
COMPONENT NAME
Corrosion
(gas side)
Build up
Sagging
Over heating
Fly ash erosion
Sealing
Supports
Cracks
Exp clearance
Steam impingement
Refractory status
Insulation
Economiser
Corrosion
(water side)
Scale
Pitting
Economiser
Corrosion
(gas side)
Build up
Blisters
Sagging
Over heating
Fly ash erosion
Sealing
Supports
Cracks
Expansion clearance
Steam impingement
Tightness of access
Doors
Refractory
Looseness
Missing pieces
Erosion
Sealing
burner throat
Refractory
Flame impingement on refractory
Refractory holding arrangements.
Baffle tile status
Section-D
67
COMPONENT NAME
Air preheater
Cooling discs.
Gas side plugging/Sealings
Gas side cleanliness
Air side cleanliness
Gas side corrosion
Air side sealing
Drive mechanisms ( if any)
Soot blower status (if any)
Dampers
Blades rigidity
Open/ close positions
Expansion clearance condition of blades
Erosion of blades
Bearing freeness
Lubrications
Damper linkages
Interlock mechanisms.
Section-D
68
COMPONENT NAME
Convection pass
Bent
Bulging
Gas leakages
Access door tightness
Corrosion
Erosion
Cleanliness
Leaks
Visibility
Illumination
Reflectors
Mirrors
Gauge cocks status
Expansion clearance
Section-D
69
COMPONENT NAME
Valves
Erosion
Corrosion
Leakages
Spindle movement
Handle rigidity
Drive mechanisms
Lubrications
Safety valves
Silencer status
Spring stiffness
Drain line status
Drain line rigidity
Discharge pipe rigidity
Expansion clearances
Valve settings
Cleanliness
Leaks
Visibility
Illumination
Gauge cocks status
Internal deposits
Insulation
Erosion
Alignment
Sealing
Section-D
70
COMPONENT NAME
Fuel feed nozzles in the combustor
As per manuals
Dosing pumps
As per manuals
Power cylinders
As per manuals
Deaerator
Combustor
Missing nozzles
Erosion
Plugging
Section-D
71
Section-D
72
Section-D
73
Section-D
74
Mechanical Factors:
4.10 Fans
Section-D
75
6.
Section-D
76
INTRODUCTION
Both the gas and waterside of a boiler should be
protected against corrosion during out of service
periods. It is known that many of the corrosion
problems of boiler and auxiliary equipment have
their inception during storage. Rusting of tube
surfaces, as indicated by the formation of the red
hematite (Fe2O3), not only cause a roughened
tube surface but also results in attack of parent
metal.
The advantages of efficient feedwater and boiler
water treatment during operation may be lost if
the same diligence is not applied to protect heat.
Transfer surfaces during idle periods. Protection
from corrosion during storage becomes vitally
important considering the number of times during
the life of a boiler when it and its auxiliary
equipment are idle.
To minimize the possibility of corrosion, boiler to
be placed into storage must be carefully prepared
for the idle period and closely watched during
the outage. There are two methods available
for storing the unit dry storage and wet storage.
Although the wet storage procedures is preferred
such factors as availability of good quality water,
ambient weather conditions, length of storage
period, auxiliary supply of heat, etc may dictate
that the dry storage procedure is more practical.
Section-D
77
Section-D
78
Section-D
79
TYPE OF SHUTDOWN
SHORT OUTAGES
4 DAYS OR LESS. UNIT NOT DRAINED
SHORT OUTAGES
4 DAYS OR LESS. UNIT IS DRAINED
LONG OUTAGES
LONGER THAN 4 DAYS UPTO 15 DAYS.
UNIT IS DRAINED
LONG OUTAGES
MORE THAN 15 DAYS - UNIT IS DRAINED.
c.
Section-D
80
Tube Failures
Section-D
81
Section-D
82
Section-D
83
CLOCK
POSITION
TUBE
THICKNESS
STUD LENGTH
VISUAL
OBSERVATIONS
DATA COLLECTION BY
Section-D
84
020 66126464
FAX :
020 27479048
WEB SITE :
http://www.thermaxindia.com
EMAIL :
Yashwant1@thermaxindia.com
Uumale@thermaxindia.com
DEAR CUSTOMER,
WE WANT TO HEAR FROM YOU,
WE STRIVE TO CONTINUOUSLY IMPROVE THE QUALITY AND PERFORMANCE OF OUR
PRODUCTS. WE WOULD LIKE TO HEAR FROM YOU, SHOULD YOU EXPERIENCE PROBLEMS
WITH OUR EQUIPMENT OR SHOULD YOU WANT TO SUGESST IMPROVEMENTS,
JUST FILL IN THE INFORMATION NEEDED AT THE ENCLOSED FORMAT AND FAX / POST IT TO
OUR CUSTOMER SERVICE DEPARTMENT TO THE ABOVE MENTIONED ADDRESS.
KINDLY USE ADDITIONAL SHEETS IF REQUIRED.
PLEASE PROVIDE ADEQUATE INFORMATION / DRAWINGS REFERENCE / LOG SHEET
READINGS ETC FOR PROPER ANALYSIS & FEED BACK
WE WILL GLADLY REVIEW YOUR SUGGESTIONS AND REPLY TO YOU WITH IN A REASONABLE
TIME.
WE ARE AT YOUR SERVICES ALWAYS,
U.S. UMALE
DY GENERAL MANAGER (FIELD ENGG.)
Section-D
85
CUSTOMER DETAILS:
COMPANY NAME
COMMUNICATION ADDRESS
TELEPHONE NUMBER
FAX NUMBER
E-MAIL ADDRESS
CONTACT PERSON
OTHER DETAILS (IF ANY)
BOILER DETAILS
BOILER NUMBER :
DATE OF COMMISSIONING;
BOILER CAPACITY MCR
STEAM PRESSURE
STEAM TEMPERATURE
FUEL FIRED
EQUIPMENT DETAILS
S.N
PROBLEM
DETAILS
OBSERVATIONS
CORRECTIVE
ACTIONS TAKEN
COMMENTS /
RECOMMENDATIONS
1.
2.
OTHER INFORMATION:
EXPECTATIONS FROM TBW :
REPLY AWAITED / SERVICE ENGINEER VISIT :
Section-D
86
Water Chemistry
D) IRON:
INTRODUCTION
The natural water contains solid, liquid and
gaseous impurities and therefore, this cannot be
used for the generation of steam in the boilers.
The impurities present in the water should be
removed before its use for steam generation.
The necessity for reducing the corrosive nature
and quantity of dissolved and suspended solids
in feed water has become increasingly important
with the advent of high pressure, critical and
supercritical boilers.
The impurities present in the feed water are
classified as given below
1. Un dissolved and suspended solid materials.
2. Dissolved salts and minerals.
3. Dissolved gases.
4. Other materials (a soil, acid) either in mixed
and unmixed forms.
Section-D
causes
increased
87
Section-D
88
Section-D
89
A. CORROSSIVE CONTROL
SCALE CONTROL
Section-D
90
Mechanical Factors:
Section-D
91
Welding Procedure
Specifications (WPS)
Section-D
92
PREPARATION
1. The area to be patched shall be cleaned to
bare metal.
2. The patch shall be made from tube material
of same type, diameter and thickness, as the
tube being welded
3. The area of the tube to be removed shall be
carefully marked out as close as possible to
contour of the patch. The tube section may
then be removed using an oxyacetylene gas
cutting torch or by mechanical means
4. The weld preparation shall be made as per the
Figure #1. The fit up of the patch weld gap
shall be 2.4 0.8 mm
Welding
1. A welder qualified to the requirements
of ASME shall make the tube and patch
welds in accordance with an approved weld
procedure.
2. The root pass shall be done with GTAW
process. The weld may then be completed
with either SMAW or GTAW process. Some
acceptable weld procedure specifications are
listed in Table below
TESTING
All the tube and patch welding shall be subject
to close visual inspection and 100% radiography
in accordance with the requirements of ASME
section V. The standard for accepting /rejecting is
specified in ASME section I
Completed welds are subject to hydrostatic test
Base Material
Filler Metal
P1 TO P1
ER 70S.2
E7018
P3 TO P3
ER80S.B2
E7018A1
P3 TO P3
Cr Moly To Cr Moly
ER80S.B2
E8018B2L
P4 TO P4
1-1/4 Cr TO 1-1/4 Cr
ER80S.B2
E8018B2L
P5 TO P5
ER90S.B3
E9018B3L
P8 TO P8
Stainless To Stainless
ER308
ER308-16
Section-D
93
Figure 5
Section-D
94
Section-D
2.531
Measure =
Stub OD
Measure =
Stub ID
2.200
Clearance =
Stub
ID
@
Contact
2.231
10% of
0.150 x
2
95
Section-D
96
Section-D
97
Section-D
98
2.531
-2.500
0.031 Clearance
Measure Stub ID =
2.200
Clearance =
0.031
2,231 Stub ID @
Contact
Stub ID @ Contact
=
2,231
10% of 0.150 x 2 =
0.030
2.261 Stub ID after
expanding
Section-D
99
Section-D
100
Tapered plug application for shallow internal CTRB Tube end must be exposed sufficiently for seal welding.
Figure 6
Section-D
101
Figure 7
Section-D
102
Figure 8
Section-D
103
Figure 9
Section-D
104
Figure 10
Section-D
105
Figure 11
Section-D
106
Figure 12
Notes:
T1 is the greater of 1.25 x Nominal tube wall or 3/16
Plug Head O.D = nominal Tube I.d 3/32
Plug length is 1 up thru 3 O.D tube over 3 O.D
Tube use 2 Length
Plug of SA 181 Gr70 preferrred
SA 105 is acceptable.
Section-D
107
Figure 13
Notes:
T1 is the greater of 1.25 x nominal wall or 3/16
Plug diameter = Nominal tube I.D 3/32
Plug length is 1 up thru 4 O.D tube
Plug of SA 181 Gr 70 material preferred
Sa 105 is also accepted
Section-D
108
Figure 14
Section-D
109
Section E
This section holds the Lubrication Schedule and Spare Part List for the AFBC Single Drum
Bed Plate Boiler.
Lubrication Schedule
Lubrication Schedule
Spare Part List
Spare Part List for AFBC Boiler
Section E
110
Volume 2 Drawings
Chapters Covered in this Part
List of Drawings
Volume 2 Drawings
111
List of Drawings
01 G.A. OF Boiler _D11-0PD-07967_3
02 Foundation Plan & Loading Data_D11-1PD-44268_4
03 Boiler Auxillary Foundation Data_D11-1PD-47979_3
04 Pressure Part Assembly _D11-1PD-43038_1
05 Thermal Expansion Diagram_D11-1PD-49076_0
06 P & I D for Steam & Water _D12-1PD-6499P_2
07 P & I D for Fuel Air & Flue Gas System_D12-1PD-6500P_2
08 Fuel Feed Chute Assly_F28-1PD-48091_0
09 Fuel Feed Chute Details_F28-1PD-48092_0
10 Underbed Fuel Feeding System Layout & Details _F59-1PD-46483_0
11 Steam Drum _P21-1PD-43823_1
12 Steam Drum Internal Assly & Details_P21-1PD-43824_0
13 Internal & External Attachment of Steam Drum _P21-3PD-18383_0
14 Water Drum _P31-1PD-43928_1
15 Internal & External Attachment of Water Drum_P31-2PD-40150_0
16 Primary Super Heater Coil _PA1-1PD-45809_1
17 Secondary Super Heater Coil_PA22PD41254_1
18 Economiser Assly _PL4-1PD-45132_0
19 Integrated Economiser Module I, II & III _PL4-2PD-40868_1
20 GA OF Furnace Refractory_R11-1PD-47758_0
Volume 2 Drawings
112
Section
Section
Section
Section
Section
Section
Section
Section
Section
Section
01
02
03
04
05
06
07
08
09
10
113
Section 01
Electrical System Required for Motor Selection
Section 02
2.1 Electrical Motor Selection For FD Fan
2.2 Electrical Motor Selection For PA Fan
2.3 Electrical Motor Selection For ID Fan
Section 03
Instruments Hook Up Diagram
Section 04
Instruments Loop Diagram
Section 05
5.1 Logic Diagram For Drives
5.2 Control Schematic Write up
Section 06
6.1 DCS IO List
6.2 Alarm & Set Point List
Section 07
7.1 Specification for Motorised Actuator
7.2 Instruments Cable & JB Cable Schedule
7.3 Specification For Junction Box
Section 08
8.1 Instruments Specification for Transmitters & Analysers
8.2 Instruments Specification for Gauges & Switches
8.3 Instruments Specification for Valve & Actuator
8.4 Instruments Specification for Sensors
Section 09
9.1 Specification for CBD Valve
9.2 Specification for IBD Valve
9.3 Valve Schedule
9.4 Valve Schedule Add
Volume 3 E & I Specifications
114
Section 10
ACVFD Panel Wiring Diagram
115
Section
Section
Section
Section
Section
Section
Section
Section
Section
Section
01
02
03
04
05
06
07
08
09
10
116
Section 01
Fan TLT Engineering
O & M Manual
ID_FD_PA FAN
Drawings
1. GA DRG FOR FD FAN
2. GA DRG FOR ID FAN
3. GA DRG FOR PA FAN
Section 02
H.P / LP. Dosing System - NM Enterprises
O & M Manual
HP Dosing System Manual
Drawings
1. H.P. Dosing System Drawing
Section 03
Level Gauge Hi Tech Systems (Tyco)
O & M Manual
LEVEL GAUGE MANUAL
Drawings
LEVEL GAUGE DRAWINGS
Section 04
Level Gauge Chemtrol
O & M Manual
LEVEL GAUGE MANUAL
Drawings
LEVEL GAUGE DRAWINGS
Section 05
Tight Shout off Damper Virgo
Manual
Manual
117
Section 06
Kniff Gate Valve Orbinox
O & M Manual
Kniff Gate Valve
Section 07
Process Valve KSB
O & M Manual
Process Valve
Section 08
Safety Valves Tyco Sanmar
O & M Manual
SAFETY VALVES (HC-HCA Manual)
Data Sheet a
Specification Sheets
Drawings
Drawings
Section 09
Motors Siemens
Manual
Motor Manual
Data Sheets
Section 10
Rotary Feeder - Nova Bulk
O & M Manual
Rotary Feeder Manual
Drawings
1. Rotary Feeder GA Sheet 1
2. Rotary Feeder GA Sheet 2
118
Section
Section
Section
Section
Section
Section
Section
Section
Section
Section
01
02
03
04
05
06
07
08
09
10
119
Section 01
Pressure Transmitter Emerson
O & M Manual
PRESSURE TRANSMITTERS (MODEL 3051)
Section 02
Temperature Transmitter Emerson
O & M Manual
TEMPERATURE TRANSMITTERS (MODEL 644H)
Section 03
I/P Converter ABB
O & M Manual
I/P Converter ABB
Section 04
Pressure Switch Switzer
O & M Manual
Pressure Switch Manual
Section 05
5.1 Orifice Plate General Instruments
Calculations & Drawings
Section 06
Pressure Gauge Gages Bourdon
O & M Manual
Pressure Gauge Manual
Section 07
Local Indicator Nishko
Manual
Process Indicator Nichko
120
Section 08
Control Valves MIL
O & M Manual
MIL 21000 SINGLE PORTED TOP GUIDED CONTROL VALVES - MIL_MANUAL
MIL 41000 HEAVY DUTY BALANCED CAGE GUIDED CONTROL VALVES - MIL_MANUAL
MIL37 38 SPRING DIAPHRAGM PNEUMATIC ACTUATOR - MIL_MANUAL
MIL 776 Air Lock Valve MANUAL
8013 Electro pneumatic Valve Positioner - MIL_MANUAL
400 L Electric Position Transmitter- MIL_MANUAL
Data Sheet and Curves
CONTROL VALVE DATA SHEET
Section 09
Power Cylinder Keltron
Manual
Manual
Section 10
ACVFD Drives ABB
Manual
ACS 550 ACVFD Drives ABB Manual
121
122
Index
A
Adequate Bed Temperature........................... 41
Air and Gas System ...................................... 24
Air Ducts ...................................................... 25
Air Pre Heater .........................................24, 43
AirTemperature............................................. 13
Annual Maintenance Check Sheet ................. 65
Ash Drain ..................................................... 30
Attemperation Control Station........................ 17
Attemperator ................................................ 20
B
Balance of Plant Start Up .............................. 42
Bed Ash Alkali Control .................................. 40
Bed Drain System......................................... 30
Bed Level Control ......................................... 40
Bed Material................................................... 6
Bed Slumping Procedures............................. 43
Blowdown Tank ............................................ 23
Boiler Annual Maintenance and
Overhaul .................................................... 72
Boiler Blowdown System ............................... 21
Boiler Emergency Trip................................... 45
Boiler Lay Up Procedures.............................. 80
Boiler Preservation Procedure ....................... 77
Boiler Pressure Part Description .................... 17
Boiler Shutdown ........................................... 45
Boiler Start Up .............................................. 32
Boiler Water Recommended Quality ................ 7
C
Capacity Chart ............................................. 10
Case- II (Bed Ash Temperature < 600C)......... 44
Case- II (Bed Ash Temperature > 600C)......... 44
CBD Drain.................................................... 22
Checks Every Six Months.............................. 64
Checks Every Year ....................................... 64
Chemical Dosing & Sampling System ............ 30
Chemicals for Dosing ...................................... 8
Combustor ................................................... 29
Conditioned Based Maintenance ................... 60
Continuous Blowdown..................................... 6
Controls ....................................................... 48
Convection Bank .......................................... 21
Cooling Water................................................. 7
Crushed Refractory......................................... 6
E
Economizer .................................................. 17
Effects of Impurities ...................................... 88
Electrical Power.............................................. 7
Electrostatic Precipitator................................ 27
Emergency Procedures................................. 53
Expansion Joints .......................................... 73
F
Failure Reporting Formats............................. 85
Fans .........................................................8, 75
FD Fan ........................................................ 24
Feed & Boiler Water Conditioning .............73, 90
Feed Water Control Station ........................... 16
Feed Water Recommended Quality ................. 6
Feed Water System ...................................... 16
Flue Gas System .......................................... 27
Fuel ............................................................... 5
Fuel Analysis.................................................. 5
Fuel and Bed Material Sieve Analysis as
per the Designed Conditions........................ 41
Fuel Bunker.................................................. 28
Fuel Feeding & Firing System........................ 28
Fuel Mix Nozzles .......................................... 29
Fuel Size........................................................ 5
Furnace ....................................................... 19
G
Gas Temperature.......................................... 13
Gauge Glass .................................................11
General Principle of Weld Repairs ................. 94
123
HP Dosing System........................................ 30
HP Dozing System.......................................... 9
R
I
IBD Drain ..................................................... 22
ID Fan ......................................................... 27
Inbed Coil .................................................... 20
Inspection after Cooling ................................ 72
Inspection of Screen, Primary &
Secondary Superheater, Evaporator I/ II &
Economiser ................................................ 73
Instrument Air................................................. 8
Insulation and Cladding................................. 73
Intermittent Blowdown..................................... 6
PA Fan......................................................... 25
Part Load Operation By Bed Slumping ........... 43
pH Value of the Water and its Importance......... 88
Planned Shut Down ...................................... 45
Planning Before Overhaul ............................. 72
Plugging Tubes in Drums & Headers.............. 98
Preservation of Instruments........................... 80
Preservation of Rotating Equipments ............. 80
Pressure Parts ............................................... 3
Preventive Maintenance................................ 59
Preventive Maintenance Program for
Spares ....................................................... 60
Preventive Maintenance Program for
Valve.......................................................... 60
Primary Super Heater ................................... 20
L
Load Operation............................................. 39
W
Walkdown Checklist during Operation ............ 52
Water Chemistry ........................................... 87
Water Temperature ....................................... 13
Weekly Checks............................................. 63
Weld Repair Of Small Cracks in Tube ............ 98
Welding Procedure Specifications.................. 92
Wet Storage Preservation ............................. 78
Window Patch Welding ................................. 93
124
38410 Kg/hr
74 Kg/cm2 (g)
O
130 C
FD
FAN
38410 Kg/hr
73.5 Kg/cm2 (g)
O
216 C
65610 kg/hr
250 OC
-80 mmwg
BOILER +
SUPER HEATER
AIR
PREHEATER
FLUE GAS
65610 kg/hr
160 OC
-105 mmwg
65610 kg/hr
O
160 C
-135 mmwg
FLUE GAS
ESP
ECONOMISER
SEC. AIR
BOILER
12.8
14.53
4.31
4.89
ID
FAN
FLUE GAS
65610 kg/hr
O
C
+5 mmwg
160
FD AIR
COAL
FLUE GAS
COMBUSTOR
6053 kg/hr
FLUE GAS
HEAT TRANSFER
ELEMENTS
CONTINUOUS
BLOW DOWN
410 kg/hr
O
445 C
-40 mmwg
150 C
+650 mmwg
-5 mmwg
65610 kg/hr
45
3000 Kg/hr
74 Kg/cm2 (g)
O
130 C
41410 kg/hr
76 kg/cm2 (g)
O
130 C
60526 kg/hr
FEED WATER
+726 mmwg
ST
O
439 C
AFTER SPRAY
O
366 C
9600 kg/hr
60526 kg/hr
O
150 C
+650 mmwg
10200 kg/hr
O
150 C
PA
FAN
+1400 mmwg
SYMBOL
SERVICE
STEAM LINE
FUEL LINE
AIR LINE
ALT.
NO.
ALTERATION
MADE
DATE
CHKD.BY
DATE
APP.BY
DATE
COAL
UNDERBED
100 %
3500 kcal/kg
8
%
TITLE :-
OC NO:
SCALE
NTS
DESIGNED
CHECKED
APPROVED
PD0161
07.12.07
07.12.07
JRV
07.12.07
JRV
GN
WATER LINE
FLUE GAS
THERMAX LIMITED
PD0161 0033
( SHEET 1 OF 2)
ALT. NO
38310 Kg/hr
74 Kg/cm2 (g)
O
130 C
FD
FAN
38310 Kg/hr
73.5 Kg/cm2 (g)
O
218 C
69240 kg/hr
255 OC
-95 mmwg
BOILER +
SUPER HEATER
50%COAL
5250 kg/hr
50%CHAR
5250 kg/hr
AIR
PREHEATER
FLUE GAS
69240 kg/hr
160 OC
-125 mmwg
69240 kg/hr
O
160 C
-155 mmwg
FLUE GAS
ESP
ECONOMISER
SEC. AIR
BOILER
13.75
15.22
4.38
4.85
STEAM LINE
FUEL LINE
AIR LINE
ALT.
NO.
69240 kg/hr
O
C
+5 mmwg
160
150
PA
FAN
64572 kg/hr
O
150 C
ST
O
445 C
AFTER SPRAY
359 C
715 mmwg
+1410 mmwg
SERVICE
ID
FAN
FLUE GAS
FD AIR
10200 kg/hr
O
150 C
SYMBOL
FLUE GAS
COMBUSTOR
6457 kg/hr
FLUE GAS
HEAT TRANSFER
ELEMENTS
CONTINUOUS
BLOW DOWN
410 kg/hr
O
445 C
-50 mmwg
715 mmwg
-5 mmwg
69240 kg/hr
45
3100 Kg/hr
74 Kg/cm2 (g)
O
130 C
41410 kg/hr
76 kg/cm2 (g)
O
130 C
64572 kg/hr
FEED WATER
+800 mmwg
ALTERATION
MADE
DATE
CHKD.BY
DATE
APP.BY
DATE
TITLE :-
OC NO:
SCALE
NTS
DESIGNED
CHECKED
APPROVED
PD0161
07.12.07
07.12.07
JRV
07.12.07
JRV
GN
WATER LINE
FLUE GAS
THERMAX LIMITED
PD0161 0033
(SHEET 2 OF 2)
ALT. NO