CETHAR VESSELS LTD. CFBC GROUP Tiruchirapalli — 620 001. DESIGN BASIS REPORT FOR 2 x 85 TPH CFBC BOILER fe lee 4 | Sonsuitant comments 5 are incorporated. TARUNKUMART | DSARAVANAN | S.LAKSHMANAN SE MANAGER /SDGM A poo ‘4 | Gonsultant comments | JLARUNKUMAR/ | D.SARAVANAN | S.LAKSHMANAN are incorporated SE MANAGER 1SD6M 7, PASA ID fan test block head and flow revised since the customer desires to use ele aares ‘4 _| the same capacity fans | JARUNKUMAR/ | 0.SARAVANAN | S.LAKSHMANAN : ‘supplied for unit-5 SE 7 MANAGER 7'SDGM CFBC boiler. 2, Gas temperature at ‘theater outlet changed. Initial NIL| 15.07.09 A Pe cal | SARUNKUMART | D SARAVANAN | S1LARSHMANAN SE MANAGER /SDGM Re | pate | category Description Prepared Verified ‘Approved CUSTOMER M/s. SHREE CEMENT LTD W. O. No. | MBrio1/102 eppse | PER 210 (2 PROJECT 1X 50 MW CAPTIVE POWER PLANT CONSULTANT M/s. CETHAR CONSULTING ENGINEERS (P) LIMITED LE es DOC, No, BI101-00-25-4-008 Rev:C Date: 05.08.09 U page) J a rir]CETHAR VESSELS LTD. EBC GROUP Tiruchirapalli - 620 001 INTRODUCTION ‘The "CETHAR CFBC" is of single drum, natural recirculation, semi outdoor type, circulating fluidized bed combustion boiler with over bed fuel feeding system designed for continuous rating of 85,000 kg/hr. The parameters of the steam at the outlet of Main steam Stop valve will be of Pressure 89 Kg/cm® (a) and temperature of 520 +5°C. The feed water temperature at inlet of Economiser is 210 ° C. The major fuels fired are either 100% Pet coke or Combination of Pet coke and fly ash (Dominant Fuel) having the GCV of 7936 Keallkg and 4569 Keallkg respectively. The Boiler is also sized for steam generation of 110% (peak rating) for a period of 1/2 hour ina shift \~ In the CETHAR CFBC boiler the hot primary air at high pressure is admitted to the combustor grid through the air nozzles located in the grid. This primary air is used for fluidizing the bed and also provides air for combustion of fuel. The result of increase in gas velocity causes dense mixture of fuel, lime stone and ash to be carried up through the combustion chamber. The ‘secondary air helps to complete the combustion process. The secondary air is introduced at two levels for staged combustion. The flue gas is removed from the combustor by induced draft fan system. Water cooled cyclone separator with vortex finder and loop seal is provided between the combustor and second pass. The unbumt and course materials in the flue gas are separated in the cyclone and returns to the combustor through the loop seal. High pressure air from the seal pot blower is admitted to the loop seal. The loop seal acts as a seal between the ‘combustor and the cyclone and prevents back flow of gases from the combustor to the cyclone. The seal pot blower provides the fluidizing air for the loop seal. The main advantages of our CFBC boilers are ‘Can bum wide range of low grade fuels Improved combustion efficiency due to the improved heat transfer with the increase in residence time. ‘+ Low operating temperature Better sulphur capture with low SOx emission SSO TT Proiect—: 1X 50 MW Captive power Plant Doc. No. - BI101-00-25-4-008CETHAR VESSELS LTD. FBC GROUP ‘Tiruchirapalli ~ 620 001 FUEL ANALYSIS (ULTIMATE): 100% | Fash 54% F Grade 100% Units: 2 100 % 55 % Lignite + (eby | Pet | (225TPD) + . Coat "| Frade Lignite 45 % Fly Ashes | wt) Coke | Pet Coke 46 % Fly Ashes Coa Carbon | ©) | 04.34 | 52.96 38.40 40.53 38.50 Hydrogen | (%) | 266 0.81 140 154 2.80 Nitrogen |G) | 038-] 02 038 aon a7 [Sulphur |) 254 0.33 1.96 050 Moisture | (%) | 200 | 1365 1454 24.00 110.00 “Ash %) | 077 | 2994 42.23 aa [ai69 ‘Oxygen | @) | 191 | 058 271 407___—*[ se - GOV —|ixcalrkg)] 7936 | 4569 3476 3672 3890 Efficiency (Based (%) | 91.50 83.30 85.90 83.00 82.80 87.40 on GCV) | Note: We have designed our boiler for the guarantee condition of 225TPD Fly Ash and balance of Pet coke. The guarantee performance test of the boiler shall be conducted for the guaranteed fuel only. However the boiler can be operated with other fuels as given in the above table and correspondingly steam generative capacities shall be as follows. — ** While LIGNITE firing, the boiler output is 80 TPH. *** While 54% F GRADE COAL + 46% FLY ASH firing, the boiler output is 80TPH. **** While 55% LIGNITE + 45% FLY ASH firing, the boiler output is S0TPH. ***** While 100% F GRADE COAL firing, the boiler output is 81 TPH. The main scope of Boiler package will consist of steam drum, membrane water wall panels, water cooled cyclone, convection superheater (primary & secondary), radiant (wing wall) supetheater, Economiser, primary & secondary Air heater, Boiler feed pumps, Feed control systems, PA, SA & ID fans, Bunker arrangements, fuel feeding system, Electrostatic precipitators, Dosing systems, Continuous and Intermittent Blow down tanks, start up oil firing system, Inter connecting piping, air and gas ducting, , supporting structure with roof and side cladding, platforms and staircases etc. li NT lel Project: 1X SO MW Captive power Plant Doc. No.» B1101-00-25-4-008 wOoNe —° MRIOT/102 Date 98 a 0 Pane - tof tsCETHAR VESSELS LTD. (CFBC GROUP: Tiruchirapalli - 620 001 GENERAL Water required to generate steam is supplied by three boiler feed water pumps (2W+1S). The feed water passes through the HP heater, Economizer via feed control stations which add the sensible heat to the feed water. From there, water is circulated through the natural circulation circuit, This circuit adds latent heat to the water. As the steam and water mixture enters the drum from this circuit, the drum internals separate the steam from the mixture. The separated water along with the incoming feed water is continuously circulated through this natural circulation circuit The natural circulation circuit comprises of steam drum, four down comers, water walls, roof tubes, outlet headers and riser pipes. The saturated steam from the drum is superheated in the superheater coils in three stages. The ‘steam passes through the connecting links to steam cooled wall top header. From top header the steam flows down through side walls and rises through front wall and it passes through cross over duct to steam cooled wall roof header. Further the steam passes through steam cooled rear wall to bottom header, primary super heater coils, primary superheater outlet header, connecting link between primary supetheater outlet header and De superheater, De ‘superheater, connecting link between De superheater and wing wall superheater inlet header, , wing wall superheater coils, wing wall superheater outlet header, connecting link between wing wall super heater outlet header and final superheater inlet header, final superheater coils, final super heater outlet header & final superheater outlet link. ‘STEAM DRUM The steam drum is of fusion welded type, liberally sized and fitted with high efficiency internals. The steam drum is provided with 2 nos manhole door which opens inwards. The following a nozzles are provided in the steam drum. 4, Local pressure gauge =1 no. 2. Remote pressure gauge 1 10, 3. Airvent =2 nos. 4, Safety valve -2 nos, 5. Auxiliary stub =1 no. 6. Direct level gauges +2 nos, 7. Level transmitter =3 nos. 8. Pressure transmitter -1 no, 9. Continuous blow down connection -1 10. 10. Intermittent blow down connection -1 no. 11. Hp dosing connection <1 no, alread ia ——— Project: 1X 50 MW Captive power Plant. Doc.No. - BI101-00-25-4-008 W.O.No, : MBI101/102 Date 05.08.09 Page :4of ixCETHAR VESSELS LTD. FBC GRO! Tinuchirapalli ~ 620 001 12. Down comer -4 nos. 13. Riser 11 nos, 14, Feed pipe +1 no. 15. Steam outlet links 2 nos. The thickness of the drum is arrived based on the calculations and analysis as specified under IBR 1950 with latest amendments. DRUM INTERNALS The boiler drum forms a part of the circulation system of the boiler. It serves the following purposes, a) Providing the necessary space for separation of steam from mixture of steam and water. b) Housing the equipment needed for separation & purification of steam. ©) Meeting the steam demand fluctuation. The drum intemals are designed to have simplicity and efficiency to produce steam of high quality at a very low maintenance cost. The drum is positioned horizontally in front of the boiler. It is fixed on boiler supporting structure. The steam-water mixture entering the drum from side water wall top headers and roof panel top headers is collected in the separating chamber formed by the vertical baffle panels through risers. The primary separation of steam and water takes place in this separating chamber. Most of the water, drops down after impact and passes around the ends of the panels to mix with the incoming feed water. A portion of the water is drained off through the perforated continuous blow down pipes at the point of high solids concentration. The blow down line is provided with a motor operated angle type blow down isolation valve. The steam with little water particles released over the top ends of the panel cascades into the top part of the drum. This wet steam is passed through the drier screens. The water present in this mixture undergoes the tortuous path provided by the screens, gets collected and this water is drained to the waterside of the drum through the four drain pipes. Dry steam leaves the drum through the top two steam outlet nozzles. Drum safety valves are set to open when the drum gets pressurized above the set limits. The neat contolled beans obtbieeelamenh Da enalisaieiiiasilp tintin lO HOFER DE Ret en rioject : 1X S0MW Captive power Plant Doc. No. - BI101-00-25-4-008€ CETHAR VESSELS LTD. FBC GROUP Tiruchirapalli — 620 001 DCS indication, Drum level is indicated by the local drum water level gauge. The motorized operated emergency drain (Intermittent blow down) with isolation valves is also provided to take care while the drum level shoots up abnormally. DATA SHEET — STEAM DRUM INTERNAL DIAMETER 14371 MM. THICKNESS OF THE DRUM 80 MM THICKNESS OF THE DISHED HEAD 80 MM (MIN. 68 MM) LENGTH OF THE DRUM 4570 MM (TAN TO TAN) MATERIAL OF DRUM PLATE : SA516 GR. 70 ~ MATERIAL OF DISHED HEAD SA516 GR. 70 DESIGN PRESSURE 105K g/cm? (g) DESIGN TEMPERATURE 315°C INTERNALS A) TURBO SEPERATOR: NO. OFF 18 SIZE 220 MM B) SCREEN BOX: NO. OFF 13 SIZE 874 X 307 MM DOWN COMER The water from steam drum flows through four down comers. The main two down comers are connected with combustor bottom by taking branches to front wall header, left side wall header, right side wall & rear wall headers. The third down comer is connected with header I, II & III of water cooled cyclone and fourth one to cyclone inlet duct header. $I ETT Project: 1X50 MW Captive power Plant Doc. No. : BI101-00-25-4-008CETHAR VESSELS LTD. FBC GROUP Tiruchirapalli ~ 620 001 ATA SHEET — DOWNCOMER: NO. OFF FOUR PIPE SIZE i) OD 323.9 x 17.48 THK -2 NOS ii) OD 168.3 X 10.97 THK - 1 NO. ill) OD 114.3 X 8.56 THK - 1 NO. PIPE MATERIAL ‘ SA 106 GR. B COMBUSTOR Water walls serve two functions mainly. They form a gas tight enclosure to contain the hot flue gases. In addition they form the evaporator circuit which generates steam. Natural circulation is — _ established by the density difference between the water in down comers and water - steam mixtures in water walls. The rate of the circulation adjusts itself until an equilibrium is reached such that the difference between the hydrostatic head at the feet of down comers and the water wall is equal to the sum of pressure drops due to friction and acceleration of the flow medium in the circuit. Circulation will be high at lower pressure and at lower loads Circulation will be reduced when feed water temperature increases and when drum level is low. Openings are provided in the furnace to allow for the following connections: Solid return inlets from seal pot, Ash outlets, Fuel , Limestone & bed material feed penetrations, Secondary air inlets, Temperature & pressure instrument penetrations, Access openings and Openings for startup bumers. The complete fumace assembly is arranged for natural circulation. The membrane walls incorporate buckstays and tie bars arranged and designed to withstand fumace design pressure. The combustor is top supported and the lower portion is lined with a thin layer of refractory for protection against erosion. Proper refractory profiles are provided for smooth flow of internally recirculation of ash along the panel. Thus erosion is minimized. *Kick-out” tube design is provided to minimize erosion at the refractory tube interface. DATA SHEET - COMBUSTOR ‘Customer: M/s. SHREE CEMENT LTD. Doc. DBR for 2x 85 TPH CFBC Boilers. Sl ail laa Ch en la aCETHAR VESSELS LTD. Tiruchirapalli ~ 620 001 FBC GROUP. COMBUSTOR IZ FRONT AND REAR WALL SIDE WALLS HEIGHT ‘TUBES PITCH FIN WIDTH SIDE WALL TOP & BOTTOM HEADERS PIPE SIZE PIPE MATERIAL, FRONT & REAR WALL BOTTOM HEADERS PIPE SIZE PIPE MATERIAL, ROOF PANEL TOP HEADER PIPE SIZE PIPE MATERIAL WATERWALL TUBES TUBE SIZE ~ TUBE MATERIAL Ec ISER 4442 mm 4442 mm 26300 mm. 76mm 25mm OD 273.1 X 32.00 THK. SA 106 GR.B OD 273.1 X 32.00 THK. SA 106 GR. B OD 273.1 X 32.00THK. SA 106 GR. B OD 51 X4.5 THK. SA210GR.A1 The purpose of Economiser is to preheat the feed water before it enters the steam drum and thus to recover some heat from the fiue gas leaving the boiler. The inlet and outlet headers are po: tioned horizontally. Feed water control station is envisaged to control the feed water flow. There are 45 parallel paths of economiser coils connecting the inlet header to the intermediate headers. From the intermediate header the water rises through hanger tubes to economizer outlet header located above steam cooled wall The economiser coils are horizontally arranged a merreere-epiiiintentouninanienwithnangap=otaisdmaninbeiweennthentnTnenteenemnieetateiiinit a STOTT MOH ERNE RHEE Project: 1X $0 MW Captive power Plant Doc. No. BI101-00-25-4-008CETHAR VESSELS LTD. Tiruchirapalli - 620 001 (FBC GROUP ‘suspended with scalloped plates from the economiser intermediate headers. There is a link connecting the economiser outlet header to the drum. The feed water flow is upward through the economiser, that is, in counterflow to the hot flue gases. Most efficient heat transfer is hereby accomplished = MISER ECONOMISER FEED INLET PIPE: SIZE MATERIAL, NO. OFF ECONOMISER INLET HEADER: SIZE MATERIAL NO. OFF ECONOMISER COILS TUBE SIZE TUBE MATERIAL LONGITUDINAL PITCH TRANSVERSE PITCH FLOW ARRANGEMENT COIL ARRANGEMENT TYPE OF SUPPORT TYPE OF SPACER ECONOMISER INTERMEDIATE HEADER : SIZE MATERIAL, NO. OFF ECONOMISER OUTLET HEADER: SIZE 0D168.3 X 14.27 THK. SA 106 GR. B ONE (0D219.1 X 18.26 THK. SA 106 GR. B ONE, 0038.1 X 3.66 THK SA210GR.A1 76 76 COUNTER FLOW INLINE SCALLOPED PLATE SUSPENDED FROM ECO. INTERMEDIATE HEADERS SCALLOPED - 'U' PLATE OD 168.3 X 18.26 THK. SA 106 GR. B Two 00219.1 X 25.4 THK. ST Project 1X 50 MW Captive power Plant Doc. No. BI101-00-25-4-008CETHAR VESSELS LTD. FBC GROUP Tiruchirapalli ~ 620 001 MATERIAL : SA 106 GR. B NO. OFF : ONE ECONOMISER OUTLET LINK: SIZE OD168.3 X 14.27 THK. MATERIAL SA 106 GR. B NO. OFF ONE, SUPERHEATER SYSTEM The superheater system consists of steam cooled convection pass enclosure walls, primary & final convection superheater and a radiant wing wall superheater located in combustor. The primary & final super heaters are located below the cavity in the convection pass enclosure, PRIMARY CONVECTION SUPERHEATER The saturated steam from steam cooled walll rear wall bottom header passes through primary convection superheater coils to outlet header. WING wat The superheated steam from primary convection superheater outlet header passes through connecting link crossing Desuperheater to wing wall superheater inlet header. From inlet header the steam flows through the vertical coils passing inside combustor to the outlet header. The outlet headers are located above the combustor roof. FINAL CONVECTION SUPERHEATER The superheated steam from wing wall superheater outlet header is let into final convection ‘superheater by means of connecting link. The final convection superheater is located above the primary superheater. The superheated steam heated up to 520 + 5°C is achieved in this zone. PRIMARY CONVECTION SUPI INLET HEADER (OR) REAR SIDE STI COOLED WALL BOTTOM HEADER NO. OFF ONE, Satter iOS — FBR RSE RS ESE Project: 1X 80 MW Captive power Plant Doc.No. - B1101-00-25-4-008CETHAR VESSELS LTD. Tiruchirapalli --620 001 FBC GROUP. SIZE OD 219.1 X 25.4 mm MATERIAL, SA 106 Gr. B PRIMARY CONVECTION SUPERHEATER COILS NUMBER OF STARTS. Two DISPOSITION VERTICAL, TYPE OF HEAT FLOW cROSS TUBE SIZE OD 44.5 X 4.5 MM & OD44.5 X 4.00MM ‘TUBE MATERIAL, SA 210 Gr. A1 &SA213T 11 COIL TYPE CONVECTIVE TRANSVERSE PITCH 104 MM LONGITUDINAL PITCH 89MM ~ ARRANGEMENT INLINE ARRANGEMENT TYPE OF SUPPORT HANGER TUBES PRIMARY CONVECTION SUPERHEATER OUTLET HEADER NO. OFF ONE SIZE OD 273.1 X 32.00 mm THK MATERIAL SA 335 P11 RADIANT (WING WALL) SUPERHEATER INLET LINK NO. OFF ONE PIPE SIZE (OD 219.1X 18.26 mm a MATERIAL, SA 335 P11 RADIANT (WING WALL) SUPERHEATER INLET HEADER NO. OFF SIZE MATERIAL, RADIANT (WING WALL) SUPERHEATER COILS NUMBER OF ASSEMBLY TYPE OF HEAT FLOW ONE OD 273.1 X 25.4 mm SA 335 P11 CROSS SHOOTER DEH OREO AOTC I Project 1X 50 MW Captive power Plant Doc. No. mpii01/102 Nate BI101-00-25-4-008 98 98.100 Page 11 of ®CETHAR VESSELS LTD. Tiruchirapalli - 620 001 FBC GROUP TUBE SIZE TUBE MATERIAL COIL TYPE LONGITUDINAL PITCH ARRANGEMENT OD 38.1 X 4.06 MM THK SA213T11 RADIATIVE 51MM INLINE ARRANGEMENT RADIANT (WING WALL) SUPERHEATER OUTLET HEADER NO. OFF Size MATERIAL ONE, OD 273.1 X 25.4 mm SA 335 P11 FINAL CONVECTION SUPER HEATER INLET HEADER NO. OFF SIZE MATERIAL FINAL CONVECTION SUPER HEATER COILS NUMBER OF STARTS. DISPOSITION TYPE OF HEAT FLOW TUBE SIZE TUBE MATERIAL, COIL TYPE ‘TRANSUERSE PITCH LONGITUDINAL PITCH ARRANGEMENT TYPE OF SUPPORT Fl EATER NO. OFF SIZE MATERIAL, DE-SUPERHEATER ONE OD 273.1 X 25.4 mm SA335 P11 THREE VERTICAL CROSS OD 44.5 X 6.0 MM THK SA213T11 & SA213T22 CONVECTIVE 208 MM 89MM INLINE ARRANGEMENT. HANGER TUBES TT HEADER ONE OD 273.1 X 36.00 MM THK SA 335 P22 De-superheater is provided in the link connecting the primary convection super heater outlet header and radiant wing wall super heater inlet header. This is used to maintain the steam RO Nh SSR ERIE CEN EET TE Project: 1X 50 MW Captive power Plant Doc. No. BI101-00-25-4-008CETHAR VESSELS LTD. Tiruchirapalli ~ 620 001 Temperature reduction is accomplished by injecting spray water into the path of the steam, through a nozzle at the entering end of the desuperheater. The spray water is drawn from the feed pump discharge line but before the feed control station. It is essential that the spray water be chemically pure and free of suspended and dissolved solids. CONTROL PHILOSOPHY A spray control valve linked to an automatic temperature control valve will be provided to regulate the flow of spray water supplied to de-super heater. A motor operated isolation valve ‘on upstream and manual operated isolation valve at downstream of control valve are installed to permit isolation when required. A manual operated regulating valve is provided in the bypass line to take care of the spray during maintenance of spray control valve. DATA SHEET NO. OFF SIZE MATERIAL LINER SIZE LINER MATERIAL NO. OF SPRAY NOZZLES SPRAY NOZZLE MATERIAL SPRAY NOZZLE BODY MATERIAL, NUMBER OF HOLES IN SPRAY NOZZLE HOLE SIZE DESH INLET LINK SIZE DESH INLET LINK MATERIAL DESH OUTLET LINK SIZE DESH OUTLET LINK MATERIAL FINAL SUPERHEATER OUTLET LINK ONE OD 273.1 X 25.4 mm SA335 P11 OD 180 X 3.15 mm SA 240 Gr. 304 ONE SA 479 GR. 304 SA 479 GR. 304 ONE, D15MM OD 219.1 X 18.26 mm SA 335 P11 OD 219.1 X 18.26 mm SA 335 P11 The main steam pipe line is provided from final super heater outlet header up to main steam stop valve. The main steam pipe accommodates the following stubs. W.O.No, ; mi101/102 Date SSS SS Project: 1X $0 MW Captive power Plant Doc. No. BI101-00-25-4-008 05.08.09 Pace: 10fCETHAR VESSELS LTD. FBC GROUP Tiruchirapalli - 620 001 1. SAFETY VALVE = 1 NO. 2. STARTUP STEAM VENT -1NO. (MOTORISED) 3. PRESSURE TRANSMITTER - 1 NO. 4, PRESSURE GAUGE (LOCAL) - 1 NO. 5. PRESSURE GAUGE (REMOTE) = 1NO. 6. SAMPLING - 1NO. 7. TEMPERATURE GAUGE (LOCAL) -1NO. 8. TEMPERATURE ELEMENT -1NO. 9. DRAIN - 1 NO. 10. AIR VENT -1NO. 11. AUXILIARY. -1NO. PIPE SIZE OD 219.1 X 25.4mm PIPE MATERIAL ‘SA 335 P22 SIZE OD 219.1 X 25.40 mm MATERIAL SA 335 P22 MAIN STEAM PIPE From main steam stop valve outlet, the steam is let to the turbine through main steam pipe. ‘Steam flow measuring nozzle is provided in the main steam pipe with adequate upstream and down stream pipe length. Adequate number of steam traps is provided in the bottom most of the pipes and required air vents are also considered as required. FEED WATER SYSTEM The feed water system for boiler comprises of one Common Deaerator cum feed water storage tank and three numbers of Feed water pumps of 100 % MCR capacity, DEAERATOR The Deaerator will supply feed water at 150° cat BMCR. The steam for Deaerator will be taken from 3" extraction of the turbine. Atlowload, to maintain minimum Deaerator Project > 1X 50 MW Captive power Plant Doc.No. : BI101-00-25-4-008CETHAR VESSELS LTD. FBC GROUP ‘Tiruchirapalli — 620 001 outlet temperature, pegging steam will be supplied from main steam header through PRDS station. The deaeration capacity will be provided for 110 % of BMCR. Deaerator will be a direct intimate contact type heat exchanger placed before boiler feed pump in the feed water cycle. The Purpose of Deaerator is to remove dissolved corrosive gases from the feed water before going to the boiler. . The Deaerator consists of vertical deaerating chamber called header and horizontal feed water storage tank. The oxygen is reduced to 0.005 celltre and carbon di-oxide is reduced to untraceable limits, in the feed water leaving Deaerator. The condensate and make up water enters the deaerating chamber and is broken into fine particles by the spray nozzles. The sprayed water falls through tray stack for heat and mass transfer. The condensate is divided into fine droplets and comes in contact with the steam resulting in release of non condensate gases which are carried by the steam moving upwards Part of the steam is condensed in the deaerating chamber while some escapes along with the Non condensible gases whose quantity is negligible. The condensate after leaving deaerating header enters into feed water storage tank and than the feed water is taken by the boiler feed pumps. DESIGN AND CONSTRUCTION Steam admitted in storage tank provides a steam blanket over stored condensate and thus eliminates under cooling of condensate and re absorption of gases by the condensate. The Deaerator/ feed water storage tank is designed and constructed in line with the International Standards such as HEI, ASME Section Vill Division - 1 etc, The deaerating header is mounted on the feed storage tank for simplified layout and compact arrangement. E TANK The common feed water storage tank will be sized to meet 20 minutes requirement (between normal water level and low-low water level) of boiler running at BMCR. The storage vessel will be mounted at suitable height to provide the required NPSH for the feed water pumps. The shell of the storage tank is fabricated from boiler quality steel plates provided with dished ‘ends. Various stubs for condensate outlet, steam inlet, drain outlet, Overflow, dosing inlet and accessories such as relief valve, level gauges, Level control station, Level transmitters, manhole etc., are provided as required Project: 1X SO MW Captive power Plant Doc. No. - BI101-00-25-4-008CETHAR VESSELS LTD. CFBC GROUP Tiruchirapalli ~ 620 001 DEAERATING HEADER The main parts of the deaerating header are a) Shell and b) Tray plates and spray valves ed ends, ‘SHELL The shell is mounted directly over the feed storage tank. It houses stainless steel trays. Stainless steel spray valves are also provided to spray condensate. It is provided with stubs for condensate inlet, make up water inlet, inspection opening, and air vent outlet. ~ I LVES The trays and spray valves are fabricated from SS 304. DATA SHEET 01. TYPE SPRAY CUM TRAY 02. DESIGN DATA DESIGN PRESSURE 5.60 Kg/om*(g) ~ DESIGN TEMPERATURE 250°C (DEAERATOR) HYDRO TEST PRESSURE 8.40 Kg/em*(g) TEST TEMPERATURE AMBIENT RADIOGRAPHY SPOT CORROSION ALLOWANCE, 3.2 mm (As per HEI,ASME section -VIll) DEAERATION CAPACITY 190 M*S/Hr EEO ————— Froject_ —: 1X 50 MW Captive power Plant’ Doc. No. - B1101-00-25-4-008 WwONo. : MBITO1/102 Date: 05.08.09 Pane: 1ofCETHAR VESSELS LTD. Tiruchirapalli - 620 001 03. DEARATOR HEADER INSIDE DIA X THK OVERALL LENGTH NUMBER OF TRAYS NUMBER OF SPRAY NOZZLES SPRAY NOZZLE CAPACITY 04. FEED WATER STORAGE TANK INSIDE DIA X THK OVERALL LENGTH ‘STORAGE CAPACITY / VOLUME BETWEEN LOW LOWLEVEL & NORMAL LEVEL 05. MATERIALS DEAERATOR HEADER SHELL AND DISH FEED STORAGE TANK SHELL AND DISH TRAYS NOZZLES FASTENERS FLANGES. VERTICAL 1900 mm X 10 mm. THK. 4025 mm 16 45 TPH HORIZONTAL 3476 MM X 12 MM THK. 10700 MM 20 MIN. / 65.3 M43 SA 515 GR. 70 SA 515 GR. 70 SA 240 GR. 304 SA 106 GR.B IS 1363 SA 515 GR70 Project: 1X SO MW Captive power Plant Doc. No. BI101-00-25-4-008CETHAR VESSELS LTD. CBC GROUP Tiruchirapalli - 620 001 SPRAY NOZZLE Stainless Steel 06. NOZZLES CONDENSATE INLET 1.No. ~200 NB ‘STEAM INLET 1 No, = 250 NB FEED WATER OUTLET No. ~300 NB SAFETYRELIEFVALVE 1No. ~ 150 NB/ 250 NB (INLETOUTLET) ~ HEATING STEAM INLET 1No. - 80 NB FEI PUMP Three number electrically driven feed pumps will be provided with motorized operated Isolation valves at the delivery of each feed pump. The pumps will be of multistage, ring section, centrifugal type, complete with suction strainer, balancing chamber, necessary valve and instruments. A suction strainer is provided after the inlet manual isolation valve of each pump, to protect the pump against the damage due to debris in feed water. Balancing leak off arrangement is provided for the pump to reduce the axial thrust on the bearing. Balancing leak off line is connected to the Deaerator storage tank. The delivery of the pump is split into two branches. One is auto recirculation Line going to Deaerator storage tank through the Auto recirculation valve and inbuilt energy absorber (i.e. the break-down orifice) for each pump delivery while the other line is going to the common feed water discharge header. The recirculation arrangement prevents abnormal temperature rise within the pump by establishing a minimum flow through the pump, whenever the feed water drawn by the boiler is less than the Permissible minimum flow through the pump. PUMP CAPACITY CALCULATIOI (Considering Worst case) Sacto rnin RCM SrA ET EFORCE Project: 1X 50 MW Captive power Plant Doc.No. - B1101-00-25-4-008 wareynin | MBEAN HAO? own ne ne m0 os€ CETHAR VESSELS LTD. FBC GROUP Tiruchirapalli — 620 001 Boiler MCR flow rate 85 tph Feed water flow at MCR (%110) 93.5 tph Feed water density at 150 °c 916.9 Kg/oum MCR volume flow 102.0 Cumihr Margin 15 % 15.3 Cum/hr Calculated total volume flow 117.3 Cuminr Provided flow rate 117.3 Cumihr PUMP HEAD CALCULATION: (Considering Worst case) Control valve to steam drum A\ Drum safety valve-II pressure 107 kg/cm? (g) Pressure drop in piping 4.0 kg/em? Pressure drop across control valve8orifice 3.0 kg/cm? Pressure drop in Economiser 0.5 kg/m? Static head 2.9 kg/m? Calculated total pressure Boiler feed pump to control valve Pressure drop in HP heater Pressure drop in piping Static head Pressure drop in flow nozzle Calculated Total Pressure Provided Total head (By calculation) FEED WATER CONTROL 144 kg/em? (9) 4.0 kg/cm? 2.5 kg/cm? 0.6 kg/cm? 1.0 kg/em? 119.5. kglcm? (g) 1309 MWC. Two numbers, 1 x 100% pneumatic feed control valve and 1 x 30% pneumatic feed control valves are provided to regulate the flow of feed water supplied to the boiler. Whenever boiler load is less than 30%, the feed flow rate is controlled by 30% feed control valve and when boiler load exceeds 30 % then 100% feed control valve regulates the flow rate. Motorized isolation valves are provided on upstream side of each feed control valve and a manually operated valve are installed on down stream of each control valves. Motorized regulating valve of 100%€ CETHAR VESSELS LTD. EBC GROUP Tiruchirapalli ~ 620 001 capacity is provided in the bypass line to take care of feed water regulation during the maintenance of feed control valve. AIR AND GAS CIRCUIT AIR HEATER Air heater consists of both primary & secondary air heaters adjacent to each other and located at the downstream of economiser in the flue gas path, DUCTING SYSTEM The air ducts will be of 5 mm thickness for both air and gas ducting. All ducts are of Mild stee! suitably stiffened on the outside and designed to withstand the pressures encountered. The ducting system is complete with all required expansion joints, mating flanges, dampers, supports, access doors, platforms insulation etc. All ducts are of welded construction, PRIMARY & SECONDARY AIR SYSTEM All the required air for the boiler operation is supplied by 1 X 100% Primary Air Fan & 1X 100% Secondary Air Fan. The Primary & Secondary air fans are provided with pneumatically operated inlet regulating dampers. The cold air from these fans are let into the tubular air heater. The hot Primary air from the air heater which is used for fluidising is distributed to the ‘combustor through the bottom of the grid through the nozzles. The primary air is also connected to the bed ash coolers for fluidizing the ash. The Secondary air which is primarily the ‘combustion air is distributed through the upper portion of the combustor & also through the fuel feed nozzles and startup bumer air box. FLUE GAS SYSTEM The hot gas generated in bed exchanges the heat with the heat transfer surfaces within the boiler. The heat is transferred from the flue gases to the water walls, wing wall super heater coils and convection super heater coils. The flue gas temperature further drops while passing through economiser coils. The economiser to air heater gas ducting provides a change in flow licaitininitlncallungaienTacncslnicacalleciachimincsbucshoppassspsavideddbelonlne-ceenemice tee ‘Customer: M/s. SHREE CEMENT LTD Doc DBR for 2.x 85 TPH CFBC Boilers, Proect : 1X $0 MW Captive power Plant Doc. No. - RI1M1-90.25-4.0R€ CETHAR VESSELS LTD. (FBC GROUP. ‘Tiruchirapalli — 620 001 and air pre heater and are disposed through suitable ash removal system. The temperature of the flue gas further reduces as it passes through the air heater. The combustion air is reheated in the air heater by the flue gas. WATER COOLED CYCLONE SEPARATOR The flue gas leaving the top of the combustion chamber enter the water cooled cyclone ‘separator located between the combustion chamber and convection pass. Coarser material is ‘separated from the flue gas and retumed to the combustor bed through the loop seal. The flue {gas together with finer fly ash leaves the top of the cyclone and enters the boiler’s convection section. The cyclone itself is made of water cooled tubes and lined on inside with refractory. The top of the cyclone at the outlet is provided with vortex finder to improve the separation efficiency. - LOOP SEAL The ash separated in the hot cyclone separator flows down the to the loop seal. This loop seal acts as a seal between the cyclone and the combustor to prevent the back flow of the flue gases from the combustor to the cyclone separator. The loop seal is made into two compartments called down leg, the line through which ash flows into the loop seal and lift leg through which the ash flows back to the combustor. The ash in the loop seal is fluidized by high pressure air coming through the nozzles located at the bottom and side of the loop seal. This high pressure air is supplied by the seal pot blower. This high pressure air also helps in flow of the ash retumed through the cyclone into the combustor. we ELECTROSTATIC PRECIPITATOR Electrostatic Precipitator is envisaged for removal of solid particles from the flue gases. The Electrostatic Precipitator basically consists number of Collecting and Emitting electrodes enclosed in a MS chamber. High voltage DC supply is_ applied between the emitting electrode and the collecting electrode. The emitting electrode is connected to the negative terminal. The collecting electrode is connected to the positive terminal and earthed. When flue gases pass through the chamber, because of the high DC voltage applied across the emitting and the collecting electrodes, the solid particles get ionized and are attracted to the collecting electrode. Ash drops down in the hoppers during rapping cycle, which is then removed and disposed off Thus effective dust concentration of 50 mg/Nm? is achieved at the outlet of ESP. The outlet duct of the electrostatic precipitator connected to the inlet of the ID fan_ 1D fan will be provided, SSS SS REC EES Se Project: 1X 50 MW Captive power Plant Doc. No. - B1101-00-25-4-008. WONo. : MBI101/102 Date. 05.08.09 Page: 21 of iCETHAR VESSELS LTD. FBC GROUP ‘Tiruchirapalli — 620 001 with power cylinder operated regulation damper at inlet. Manhole doors are provided at the inlet and outlet duct of ESP. uustomer Is, SHREE OEMENT LTD Doc DBR for 2x 85 TPH CFBC Boilers Project: 1X 50 MWW Captive power Plant Doc.No. - BI101-00-25-4-008( CETHAR VESSELS LTD. Tiruchirapalli - 620 001 CFBC chuue Fly Ash SA%F Grate Lk | eUEL 100% Pet 100% 55% Lignite + 45% | 100%F Grate io (@25TPD) + Coale 46 % Fly Coke ignite Fly Ash Coal Pet Coke Ash Fuel quantity for 100% mer | Kgihr | 7080 43181 42569 | 17128 116060 14496 [ as quantity per boiler Kgmnr | 102538 107030 | 103531 | 104035 107072 100428 [Gas density kgm? | 1.261 1.256 1212 | 1.236 123 122 Gas temperature (1) *e 120 125 128 128 128 125 Gas density @T > cane kgm | 0.88 0.88 osz | 0.85 084 084 Gas volume mmisec | 32.37 3487 3507 [33.99 35.41 33.21 ‘Ash content in fuel % 7 29.94 10.00 | 42.23 2754 41.69 ‘Ash quantity kg | 54.66 3046.4 1256.9 | 7293.15 4418.11 6043.38 % OF st colecion bore | 3 % 3 % w Percentage of dust loading Dees % 70 0 70 70 1 | Dustioading@ ESP VL | gmvNm* | 98.63, 57.24 62.30 53.43 $5.06 Dust Loading @ ESP O/L fl asssames mgmvnmr] 0 50 50 $0 50 50 ustomer: M/s. SHREE CEMENTLTD Doc. DBR for 2 x 85 TPH CFBC Boilers. joject —:1 X50 MWCaptive power Plant Doc. No. : BI101-00-25-4-008 O.No. :MBI101/102 Date: 08.08.09 Page :23 0f 38€ CETHAR VESSELS LTD. CFBC GROUP Tiruchirapalli ~ 620 001 FANS. Each one number PA, SA and ID fan will be provided which is designed to cater 100% MCR capacity with adequate margin. The fans supplied are complete with coupling, base plates etc. All control vanes/dampers will be supplied complete with the pneumatic actuators and connecting mechanism etc. The ID fan will be provided with variable frequency drive arrangement for speed control and PA and SA fans will be of constant speed drives. All the fan impellers are dynamically balanced at works, before dispatch. Fans are provided with Lifting and handling provisions for maintenance purpose. TST SSH Ee TTD Doc DBR for 2x 85 TPH CFBC Bollers, Project: 1X 50 MW Captive power Plant Doc. No. : BI101-00-25-4-008 mye ToreCETHAR VESSELS LTD. Tiruchirapalli ~ 620 001 FBC GROUP 100% Pet | Fly Ash (225TPD) + 54% F Grade Coal | °° * Lante + | 100% Fi Units 100 % Lignitet 45% Fly F Grade Coke Pet Coke 48 % Fly Ashe Ashen Coats [2 [NoofFan Nos [1 1 1 1 1 1 3. [ Fan Fiow (cr) Misec | 14.10 15.00 13:70 14.10 1420 13.70 4 PMoR Head Mmwe | 1318 1375 1292 1247 1323 1288 5. [Design Temperature “c. (| 80 50 50 50 50 50 [Density OF air kgm | 1.03 1.03 1.08 1.03 1.03 1.08 7 | Motor Power Kw | 450 450 450 450 450 450 8 | Speea Rpm | 1480 1480 1480 1480 1480 1480 | ‘9 [Test Block Flow Rate | Mr/Sec | 18.85 18.85 18.85 18.85 1885 18.85 |lt0 Test Block Head mmwWec | 1570 1870 1870 1870 1870 4870 1 | Margin on flow % a4 6 3B 4 35 3 42 | Margin on head % 49 a a7 72 aT 58 13 J Type of impelior Back ward Curved - iSlomer : M/s. SHREE CEMENTLTD Doc. DBR for 2x 85 TPH CFBC Boilers ject 1 XSOMWCaplive power Plant ‘Doc. No. : BI101-00-25-4-008 ©.No. : MBII01/102 Date: 05.08.09 Page :250f 38~ CETHAR VESSELS LTD. ceecarour ‘Tiruchirapalli — 620 001 ESIGN BASIS - SA FAN A\ ‘CAPACITY CALCULATION _ 100% 100% Pet | Fly Ash (225TPD) + ‘54% F Grade Coalt | 55% Lignte + Fuel Units 100% Lignitet | F Grade Coke Pet Coke 45% Fly Ash | 4596 Fly Ash Coat No of Fan Nos 1 1 1 1 1 7 Fan Flow (MCR) msec | 10.60 11.0 1020 1050 1070 a MoR Head mmwe 668 720 673 670 err 050 Design Temperature C. 50. 50 50 50 50 0 Density OF Air Kom? 4.03 4.03 1.03 4.03 1903 i ‘Motor Power KW 200 200 200 200 200 Bd Speed pm, 1480 1480 1480 1480 1480 om Test Block Flow Rate wises | 14:11 1441 141 141 1441 14a 7o]| TEST BLOCK HEAD | mm | aaa aa a4 coy aa aaa “ri | Margin on flow 1% 3 2 Er 3 2 7 Margin on head % 3 % Ey a 3 “Type of impeior Back ward Curved ss lustomer: M/s. SHREE CEMENTLTD Doc. DBR for 2x 85 TPH CFBC Boilers. froject 1X 50 MW Captive power Plant Doc. No. BI101-00-25-4-008 O.No. : MBI101/102 Date: : 05.08.09 Page :260f 38‘Tiruchirapalli - 620 001 CETHAR VESSELS LTD. FBC GROUP 0.No. : MBI101/102 foject = 1 X 50 MW Captive power Plant Doc. No. Date: BI101-00-25-4-008 05.08.09, Page 227 0f 38 00% 100% Pet | FlyAsh (205TPD) + F Grade Coalr | 559% Ligne + 1 Fuet Units ast " 100 % Lignite* aa — F Grade coke Pet Coke 46% Fy Ashes | 45% Fy Ashi oar aff No of Fan Nos 1 1 1 1 1 ‘i Fan Flow (MCR) msec | 338 an 363 365 369 aa MCR Head mmwe_ 403 430 412 408 421 baad 5] Design Temperature cc: 120 125 129 126 128 125 6 ff Density OF air Kolm? 0.88 086 082 0.85 0.84 ne 7 If Motor Power Rw 750 350 250 350 250 al] Specs Rom 380 380 380 380 380 aff Test Block Flow Rate meee | 4020 7920 420 7920 4.20 2920 [ff TEST BLOCK HEAD mamwe | 547 a7 oT 37 7peees|eecaata7 “rf Margin on ow % % B 36 3 Seeea|ges “aff Narain on heed % 36 7 3 3 wa self Tipe or imperor Geccward Guved istomer : M/s. SHREE CEMENT LTD Doc DBR for 2 x 85 TPH CFBC Boilers.CETHAR VESSELS LTD. EBC GROUP Tiruchirapalli ~ 620 001 GRATE COAL 100, Cyan imme 95 5 %0 100 0 100 Separator . Fina SH mW 5 a = 5 5 5 Primary S| ~mmwe a5 a5 15 18 1s 15 Eeonomiser [mii ar 30 a a7 Ea 30 aa rie ier 470 186 155 170 170 ESP in 25 25 25 25 25 25 Ducting mmWC 34, 61 S 36 oT. is TOTAL mmc 408 a 300 03 a2 60 PAFAN Aarss fase gc 00 200 seo ooo 200 0 icra rN 220 = 32 Fa i 00 ‘era meter | “mmiWG 3 25 2 2 25 aH mV 70 a 70 70 75 | Sieneor rei 5 2 B Bs 25 | Ducting rev 337 a “4 “1 50 | TOTAL mm azar rr ‘88 iat8 rH a7 SA FAN Furnace eine | we 250 250 250 250 250 250 Air nozzle [mw 272 278 287 274 256 310 ‘ert mn 3 rs 25 zi 2 Fa att rev Es 5 22 0 55 70 siecer ren 20 20 20 20 20 20 Ducting re a8 cS a8 cs oT 35 TOTAL omic 70 err 350 388 73 70 lomer “Mis. SHREE CEMENTLTD Doc: DBR for 2x85 TPH CFBC Boles, bject 1X 50 MW Captive power Plant Doc.No. : BI101-00-25-4-008 No, :MBI101/102 Date: 05.08.09 Page: 28 of 38€ CETHAR VESSELS LTD. ‘CFBC GROUP Tiruchirapalli - 620 001 ‘SEAL POT BLOWER High pressure seal pot blowers of (2 x 100%) are provided. This high pressure seal air is ‘admitted for fluidizing the loop seal through the sides and bottom. This high pressure air acts as a seal to prevent the flow of solid material from the combustor into the retum leg and also to provide for re entry of recirculated bed material into the combustion chamber from the cyclone. The seal pot blower does not have any control damper to regulate the air flow. Air flow distribution to the sides and bottom of the loop seal is accomplished by the manual valves only. ‘One blower will be in service during normal operation and the other blower will be a standby. This standby blower will be put into service in case the blower in service could not deliver the required pressure for sealing. Seal pot blower will be provided with automatic starting of standby blower. During boiler startup the high pressure seal pot blower is started immediately after the ID fan and before starting the SA fan. FUEL AND ASH SYSTEM FUEL SYSTEM GENERAL The type of fuel feeding used in this boiler is over bed feeding. The fuel is precrushed & stored in the bunkers. The fuel bunkers are provided with rod & pin and slide gate arrangement with Morris wheel & ~ chain for the purpose of isolation when the feeders are attended for repair and maintenance. The fuel input rate to drag chain feeder can be controlled by the use of variable frequency driven box feeders. Fuel from box feeders are let into two main drag chain feeders of constant driven speed. From drag chain feeder outlet the fuel is fed through the chutes into front wall of combustor at two inlets. FUEL STORAGE BUNKER Fuel Storage bunker of mild steel construction with suitable stiffeners are considered along with the Boiler package. The water volume of the provided bunker will be 250 m? of two numbers are considered in scope. Customer M/s. SHREE CEMENT LTD Doc DBR for 2x 85 TPH CFEC Boilers Project: 1X 50 MW Captive power Plant Doo. No. : B1101-00-25-4-008 or Sh G1 aCETHAR VESSELS LTD. FBC GROUP ‘Tiruchirapalli — 620 001 DRAG CHAIN FEEDER ‘Two main drag chain feeders are provided for left & right side hopper of bunkers. The fuel to ‘each main drag chain feeders are fed at two inlets from two box feeders located above. Drag chain feeder is provided with constant speed geared motor drives. The lime stone is also fed into main drag chain feeders, LIME STONE BUNKER Boiler will be provided with a lime stone bunker having an effective water volume of 60 m? to feed lime into the furnace for sulphur capture. The lime stone bunker is connected with variable speed pocket feeders for feeding limestone from the hoppers and transporting to drag chain feeder and the same to the fumace. BED MATERIAL BUNKER We have provided one no mild steel bed material bunker having an effective storage volume of 50 m* with supports and direct feeding chute with variable speed pocket feeder for feeding the bed material in to the bed by gravity flow. The Bed material Bunker is provided with gate arrangement for isolation. BED ASH COOLERS ‘Two numbers bed ash coolers of each 50% capacity made up of water cooled tubes is provided for cooling the ash before it is discharged. The bed ash coolers are connected to the combustor through ash duct. These ash transfer ducts are connected with high pressure air from the seal pot blower. This high pressure air helps in free flow of ash from the combustor to the bed ash coolers. The cooling water is circulated through the water cooled tubes in the bed ash coolers for cooling the ash. The gas outlet from the bed ash cooler is connected back to the combustor. Primary air is connected to the cooler through the air box for fluidizing the ash. The cooled ash is discharged through the drain pipe provided with the manual gate. An overflow ash drain line is. also provided with the manual gate to clear the ash incase of ash built-up. ‘An emergency cooling water spray line is also provided in the ash coolers to cool the ash incase of necessity. ASH DISCHARGE SYSTEM Tustomer 7 Ws, SHREE CEMENT LTD. ‘Doe ‘DBR for 2x 65 TPH CFBC Boilers: Project: 1 X 50 MW Captive power Plant Doc. No. : BI101-00-25-4-008 NTCETHAR VESSELS LTD. FBC GROUP Tiruchirapalli ~ 620 001 Ash generated from the boiler is collected at bed ash coolers, hoppers of air heaters & electrostatic precipitator. The fluidized bed ash cooler are provided with one no of bottom drain chute with ash discharge feeders. The air heater | & Il bottom are pro\ arrangement. led with 2 nos. of ash hoppers with isolation gate DOSING SYSTEM LP DOSING In LP dosing system, Hydrazine (N2H4) is dosed to feed water at the inlet of feed pumps (1) inlet of feed water tank to scavenge the last traces of dissolved oxygen in feed water. To ensure proper dosing, a residual concentration of Hydrazine (0.02 ppm) is usually maintained in the boiler water. The correct treatment level may vary depending on ‘operating conditions like water characteristics and boiler pressure. ‘One number LP dosing system will be provided with 2 numbers of reciprocating type dosing Pumps (1W + 1S) for boiler. The system will be provided with necessary valves, fittings and pipe works. HP DOSING In HP dosing system, Trisodium phosphate is dosed to steam drum to precipitate the dissolved salts forming hardness. This precipitated sludge is removed through blow down. To ensure proper dosing of phosphate recommended amount of residual phosphate is ‘maintained in the blow down. The amount of required residual phosphate can be obtained from phosphate curve which depends on the pH value of boiler water. One number HP dosing system will be provided with 3 numbers of reciprocating type dosing Pumps (2W + 1S) for boilers. The system will be provided with necessary valves, fittings and pipe works. T UP OIL FIR TEM The start — up oil firing system is designed for burning light diesel oil (LDO). The system is designed for 40% boiler MCR rating. At 40% MCR steam temperature at MSSV outlet will be around 470°C. Two starts up bumers are provided. a Gusiomer: Wis. SHREE CEMENT LTD Doc : DBR for 2 x 85 TPH CFBC Boilers. Project: 1X 50 MW Captive power Plant Doc.No. _: BI101-00-25-4-008 ——$——S SS ——<——— SSS. OO SooCETHAR VESSELS LTD. FBC GROUP Tiruchirapalli ~ 620 001 The start up oil system comprises LDO tank of capacity 15m°, 2nos. of gear oil pump (1W+1S), suction strainers, compressed air atomized burners, LDO & air piping valve & fitting, instrumentation safety & control system. SWAS ARRANGEMENT This boiler will be provided with SWAS system for boiler feed water, saturated steam, super heated steam, Blow down lines sampling ‘The equipment is designed and assembled to enable conditioning of samples, of boiler water and steam, by reducing the temperature and pressure to a suitable state whereby a continuous ‘sample will be presented for analysis. ~ DESCRIPTION MATERIAL PRESSURE TEMPERATURE ‘SPECIFICATION Ka/em*(a) °c FEED WATER] SA106GRB 132 210 SAMPLING BLOW DOWN] SA106GRB 105 313 SAMPLING. SAT.STEAM SA106 GR B 105 313 | SAMPLING SH.STEAM SAS35P11 86 | 525 ‘SAMPLING. PIPING X In the design of all pipe lines, the sizing of lines will be based on the maximum flow through the line and the allowable pressure drop through the lines including those of control valves, flow elements, strainers, etc., so as to maintain the required pressure at various consumption points. In all the cases, the velocity of flow in the lines will be restricted to a maximum value as per the table below. The thickness calculations for IBR piping will be based on ANSI B31.1 or IBR whichever is more stringent for the design pressure and the allowable stress shall be as per ANSI 831.1 for the selected pipe material at the design temperature. The thickness calculation for Non-IBR pipes shall be as per ANSI B31.1 or IS 1239 / IS 3589 for the design pressure and the allowable stress value for the selected pipe material at the design temperature. Corrosion allowances (0.75 mm for steam piping as per IBR) will be added in “Customer Mis. SHREE CEMENT LTO Doc DBR for 2x65 TPH CFEC Bollers, Project: 1X 80 MW Captive power Plant Doc. No. : BI101-00-25-4-008 —e—————EE———ECETHAR VESSELS LTD. Tiruchirapalli - 620 001 CFBC GROUP addition to tolerance on pipe thickness. Whenever pipe bends are used for larger wall thickness Pipes, the wall thinning factor as per Power Piping design standards ANSI 831.1 will be used ‘and the thickness of pipe bends will be suitably increased. All piping above 65NB size and carrying fluid more than 100°C will be stress analyzed as per ANSI B31.1 power piping code. 4. Steam Lines o ‘Average Velocity in meters / second 7 Description Below 50 | 50 to 150 | 200 mm : mmNB_|_mmNB_| NB above 01. | Saturated steam at 1.1 t0 7.0 kse (9) 1820 | 2035 | 25-45 02._| Saturated steam over 7.0 kse (9) 1525 | 2035 | 30-50 03. | Superheated steam at0to7.0ksc(@) | 20-30 | 25-40 | 30-50 04, | Superheated steam at7.110 35ksc(@) | 20-35 | 30-45 | 3055 05. | Superheated steam at 35.110 70kse(g) | 20-35 | 30-50 | 40-60 06. | Superheated steam over 70 ksc (9) 2035 | 3660 | 50-75 2, Water Lines Feed water suction lines 06 0 4.0 Feed water discharge lines $1.0104.0 Auxiliary cooling water suction 1061015 03. Compressed Air Lines PRESSURE / 65 NB & BELOW | 80NB-150NB | 200 NB & ABOVE o1_|o-2ksC 15-20 20-30 25-35 02_| 2.12-7KSC 15-30 25-40 35-45 03_| >7.0KSC 25-35 30-45, 40-50 MAIN STEAM PIPING The design conditions for the main HP steam line shall be 95. Kg/cm*(a) super heater safety valve set pressure. The pipe shall be designed for the MCR conditions of the Boilers. The ‘material of piping will be alloy steel conforming to ASTM A 335 Gr.P22. ore ee Stee COM TT Boe DER ore x oe Thr Croc Borer Project a 7X50 MW Captive power Plant Doc. No. BI101-00-25-4-008CETHAR VESSELS LTD. CFBC GROUP Tiruchirapalli ~ 620 001 Main steam lines from MSSV will be connected to Turbine inlet. The pipeline will be designed as per IBR. The piping material shall be carbon steel conforming to ASTM A 106 Gr... For sizing of the lines, the velocity of flow will be maintained between1.04 and 4.0 m/sec for BFP discharge Piping BFP discharge pipe sizing calculations are as follows, [ Pr. Temp. | Flow | Pipe size Line De Velocity mi ine Description | acme) | Deg | kate. | mmne | Veli rvs BFP discharge toHP | 135, 1450 | 85,000 | 150 1.68 heater “ HP Heater O/L to Economiser(Through | 135 | 210 | 85,000 | 150 1.81 Feed Control Station) BOILER BLOW DOWN, VENTS, DRAINS, ETC, Blow down piping and the drains from boiler drums, bed coil header, bed super heaters header, Economiser headers etc., will be connected with the blow down tank. The material shall be carbon steel confirming to ASTM A 106 Gr. for the temperature less than 427°C and ASTM A 335 P11 for temperature above 427°C. VALVES The design, material, construction, manufacture, inspection and testing of valves and speciatties ~ will comply with all currently applicable standards, regulations and codes. All drain and vent connections for 40 kg/cm (a) rating will be made up of two (2) valves in series, both of isolating type. All valves and specialties will be located so that they are readily accessible for both operation and maintenance. Motor operated valves will be provided with hand-operated device for operating the valves during power failure. All motor-operated valves shall have open and close limit switches and push-buttons. SSS CE ee CC Project: 1X50 MW Caplive power Plant Doc. No. - BI101-00-25-4-008 MBCETHAR VESSELS LTD. CFBC GROUP Tiruchirapalli 620 001 INSULATION All piping systems having working temperature equal to or more than 60°C will be normally insulated for conserving enthalpy and for personnel protection. The insulating material is selected suitably based on the working temperature of the pipe. It is essential that the material is free from shots, chlorides, oil, sulphur and other impurities and retains its density and thermal conductivity over a reasonably long period, Insulation thickness will be selected that the temperature of its outside jacket remains 60°C with ambient temperature of 42°C considering 1 m/s air velocity, since it is expected that such temperature does not produce bums on human skin within a contact period of 3 seconds. REFRACTORY . GENERAL ‘The boiler will be complete with necessary castable refractories and provided for the following specific areas, Combustor, water cooled cyclone, cross over duct, loop seal, bed ash cooler and all seal boxes for the entry of fuel inlet, bed material, bumer openings, ash retum line and secondary air inlets etc. The refractory lining thickness & specifications are selected for capable of withstanding continuous attack by erosive high velocity particles & temperature surge etc. ‘The grade and thickness of refractory in combustor and cyclone separator are given below. COMBUSTOR LC 60 PLUS SF - 75 mm THK CYCLONE SEPERATOR TARGET ZONE —- ACCMON 90-75 mm THK NON TARGET ZONE - ACCMON 60 - 50 mm THK CYCLONE ROOF = - ACCMON 90 -100 mm THK -INSULYTE - 75mm THK DESIGN TEMPERATURE DIFFERENTIAL - CRITERIA The thickness of wool mattress will be calculated based on a differential temperature of 20°C between ambient (as measures one (1) m from outer casing). This will be applicable, irrespective of ambient temperature. Insulation with cladding will be provided for equipment and ducts where the temperature exceeds 60°C. EXTERNAL INSULATION The machine made mineral wool mattresses will be used as external insulating layer and will have a uniform density of 120 kg/m?. The mineral wool specifications and thermal conductivity figures will be as per 1S:3677. Customer _.M/s. SHREE CEMENT LTD. Doc. DBR for 2x85 TPH CFBC Boilers. Project. 1X 50 MW Captive power Plant Doc. No. - B1101-00-25-4-008 eeeCETHAR VESSELS LTD. FBC GROUP Tiruchirapalli - 620 001 BINDING AND STITCHING WIRE The binding and stitching wire used for fixing the insulation materials will be of GI material and of dia (min. 1.0 mm) — normal 1.219 mm, stitching wire will be of 0.711 mm diameter. QUTER CASING Duets, boiler integral piping and vessels etc will be enclosed with plain aluminium sheet of 24swo The non pressure parts will be enclosed in a 5 mm thick sheet metal casing to prevent air leakage and the top will be covered with plates laid to a fall. The maximum skin temperature of the lagging will not exceed 20°C above ambient when the pipe work, casings and the Economiser, dust collector, flue gas ducting together with all steam and feed water lines will be provided with necessary insulation and clad with aluminium sheeting neatly attached, All drain lines, vent and exhaust lines and all other items at high temperature will be covered with a sufficient thickness of insulation, for personnel safety. The necessary seals, expansion joints, door linings and fire cement and all other items to complete the installation will be included. 01 STRUCTURE: AUXILIARIE! STRUCTURAL STEEL The complete structural steel necessary to support/suspend the various components and equipment, ducts etc will include all auxiliary columns, duct supporting columns, bracing and all equipment structures etc. will be provided. Boiler structure up to firing floor (around +5.5 m level) will be of RCC construction. All structural steel will be designed for horizontal seismic forces as applicable under the latest Revision of IS 1893/75 and wind forces as per latest revision of IS 875/67, whichever govems the design. All structural steel work will be designed as per IS 800 and material specification conforming to 1S 2062 or equivalent. The structure will incorporate necessary lifting beams and hoist blocks required for maintenance of fan PLATFORM, STAIRWAYS AND GRATING ‘A complete system of platforms around boiler, at feed water control station, at main steam outlet header, at fuel feeder floor, etc will be provided and stairways will be provided to enable access to various parts of the boiler. The stairways will be provided on one side of the boiler. Handrails will be provided for all stairways and platforms as per relevant engineering standard and also as Mis. SHREE CEMENT LTD. joc. 1X 50 MW Captive power Plant Doc. No. ‘Customer PrCETHAR VESSELS LTD. FBC GROUP Tiruchirapalli — 620 001 required by Inspector of Factories. Boiler platform width will be 1200mm; steel staircase width will be 860mm. TURE PI = UI ‘STEAM TEMPERATURE PROFILE 3% ‘00% | —sa% |] 35%) st.| pescriprion | 100% | PETCOKE F.crape | 100% | LIGNITE + No. PETCOKE | + 47% COAL + | LicNiTe | 45% FLY FLYASH 46% FLY ASH L ‘ASH | 1 | inlet ofprimary | 20% | sa0% | sao | sa0’e | sao'c | 20% |_| super heater 2 | Outlet of 396°C 400°C 398°C 397°C 399°C 396°C primary super heater 3 | inlet of wingwan | s69°c | 375% | a7s'c | zac | s77°0 | a76c super heater ~ 4 | Outlet of az | 44acc | 4aaec | 445°C | aastc | 44etc wingwall superheater / inlet of inal superheater | 5 |outietoffina | sare | szoc | s20% | sarc | sarc | s20% super heater — 8% | 100% | — 84% 35% ‘SL. | DESCRIPTION 100% PETCOKE F. F-GRADE | 100% | LIGNITE + No. PETCOKE| +47% | GRADE | COAL+ | LIGNITE| 45% FLY FLYASH | COAL | 46% FLY ‘ASH ‘ASH Fumace 5 5 5 ; LC 1 i temperature 862°C 850°C 844°C | 835°C | 818°C 822°C Infet of final i 7 % 2 super heater 819°C 806°C | 800°C | 793°C | 772°C 774°C ‘Outlet of final super heater / 7 ‘ . 3 | Rerneatery, (esec | esac e7ec | 680°C | 681°C super heater ‘Outlet of | primary 4 | superheater/ | 490°C | sooc =| age’c | 4e7°c | asg°c | age°c. inlet of | economizer aie ‘Outlet of 5 | economizer’ |2a8°c | 24o°e | 2se'c | jase) | aaa’ | 238°c ine of aster | ‘Outlet of ¢ 50 ¢ $°¢ °¢ ai loneas sore f1zs'e | 20% free | rere | taste SSE MENTLTD. DBR for 2x85: TPHCFBC Boilers. 1X50 MW Cay Doc. No. ae ne me TotCETHAR VESSELS LTD. FBC GROUP Tiruchirapalli - 620 001 AIR TEMPERATURE PROFILE B3% | 100% 54% 55% SL. | DESCRIPTION | 100% | PETCOKE | F. | F-GRADE| 100% | LIGNITE + No, | PETCOKE| —+47% GRADE | COAL+ | LIGNITE | 45% FLY FLYASH [COAL | 48% FLY ASH | ASH 1 | Inlet of aitheater | 50°C 50°C soc | 50°C 50°C 50°C ‘Outlet of % 5 % 5 m | 2 pve 194°C 195°C t97°c | 198° | t98°¢ | 200% L ~ | | “Customer Ws. SHREE CEMENT LTD Doc DBR for 2x 85 TPH CFBC Boilers, Project: 1X 50 MW Captive power Plant Doc.No. : BI101-00-25-4-008 mi