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MECHANICAL DATA SHEET

REQ NO.

44-LK5100-00-M.17-0010

UTILITY BOILER

DOC NO.

44LK-5100-712/M.04/0022/A4
712 - SG - 1001

PROJECT NO:

44-LK5100

PROJECT LOCATION

MUMBAI REFINERY

ITEM NO.:

PROJECT TITLE

DIESEL HYDROTREATER PROJECT

QUANTITY: ONE

CLIENT

HPCL

SERVICE:

STEAM GENERATION

HSFO

LSFO

DESIGN PARAMETERS

7
8

TYPE OF FUEL :

TYPE OF STEAM REQD :

HSFO

LSFO
SATURATED

FUEL GAS (FIVE CASES)

START UP FUEL :

SUPERHEATED

QUALITY OF STEAM :

10

QTY AT B/L :

Tons/h

SILICA CONTENT :

11

PRESSURE :

kg/cm2 (g)

DRYNESS FRACTION :

12

TEMP :

TDS :

13

PEAK CAPACITY OF BOILER

14

<0.02 mg/ lit


ppm (only for saturated)
ppm

> 8.3
< 0.2 micro siemens/ cm

pH:
Conductivity

MINIMUM POSSIBLE DURATION FOR PEAK CAPACITY

15

RANGE OF LOAD (AS A % OF MCR) DURING WHICH SUPERHEATED STEAM OUTLET TEMP IS MAINTAINED CONSTANT WITHIN ALLOWABLE VARIATION :

16

DESIGN CODES :

17

PERFORMANCE TESTING AS PER PTC 4.1 :

IBR FOR PRESSURE PARTS

IS 6533 FOR CHIMNEY


INDIRECT METHOD

DIRECT METHOD

SCOPE OF SUPPLY

18
19

Fuel Gas

MAIN :

DUCTING AND PIPING :

20

BOILER COMPLETE W/ WATER WALLS, HEADERS,

COLD AIR DUCTING INCLUDING DAMPERS

21

DOWNCOMERS, RISERS, STEAM & MUD DRUMS, FURNACE

HOT AIR DUCTING INCLUDING DAMPERS

22

BOTTOM INCLUDING SEAL PLATES

SUPPORTS FOR ALL DUCTING AS REQUIRED

23

BOILER AND FURNACE REFRACTORY, ALL HEAT INSULATION

OUTLET STEAM PIPING UPTO B/L

24

MATERIALS INCLUDING ALUMINIUM CLADDING

PIPING FOR SATURATED STEAM FOR PURCHASER UPTO B/L

25

ALL BOILER MOUNTINGS AND FITTINGS AS REQUIRED

PIPING FOR STEAM USAGE WITHIN B/L

26

ECONOMIZER WITH SOOT BLOWER

27

NECESSARY INSULATION AND REFRACTORY LINING

28

CS REFRACTORY LINED STACK

29

BLOW DOWN FLASH DRUM AND RCC PIT

30

BFW PIPING BETN DEAERATOR AND F.W CONTROL STATION

STEAM SIDE :

PIPING BETWEEN F.W. CONTROL STATION TO BOILER

31

SUPERHEATER

ATEMPERATOR

D.M. WATER PIPING UPTO CHEMICAL DOSING TANKS

32

PRDS FOR SAT. STEAM REQMT

SILENCER(S)

C.W. PIPING FROM PURCHASER'S ONE POINT SUPPLY AS REQD.

33

PRDS FOR STEAM USAGE ISBL

IBD TANK

SERVICE AIR PIP. FROM PURCH'S ONE POINT SUPPLY AS REQD.

34

PROVISION FOR SAMPLING POINTS FOR STEAM

35
36

SAMPLE COOLER ASSEMBLY

CBD / IBD TANK

I.A. TUBING FROM PURCHER'S ONE POINT SUPPLY AS REQD.


OIL PIPING BETN INTERMEDIATE STORAGE TANK / HSD TANK

WATER SIDE :

37

DEAERATOR

BFW PUMPS (1 W + 1S)

38

DEAERATOR LEVEL CONTROL

HP AND LP CHEMICAL DOSING PACKAGE

39

F.W. CONTROL STATION

BFW EXPORT PUMPS (1 W + 1S)

40

PROVISION FOR SAMPLING POINTS FOR WATER

41

AND BURNER(S)

LP / HP DOSING PIPING FROM PREPARATION TANKS TO USERS

COMBUSTION SIDE :

DRAIN PIPING FOR WATER UPTO DRAIN TRENCH WITH VALVES

42

FUEL OIL DAY TANK

AUTOMATIC ON-OFF CONTROL ON FUEL SUPLY LINE

OIL DRAIN PIPING UPTO OIL SUMP(S) / TRENCH AS AGREED

43

OIL HEATING AND PUMPING UNIT

DUAL FIRED BURNER(S)

CBD / IBD DRAINS UPTO DRAIN TRENCH W/ ISOLATION VALVES

44

STEAM TRACING FOR OIL LINES

INLET GAS TRAIN

ALL CONDENSATE PIPING FROM ELSWHERE IN THE PACKAGE

45

ELEC. TRACING FOR OIL LINES

FUEL GAS KNOCK OUT DRUM

UPTO CBD/ IBD TANK

46

FUEL OIL PREHEATER (ELECTRICAL AND STEAM)

PIPING SUPPORTS, RACKS, HANGERS AS REQUIRED

47

TRACING FOR FUEL GAS KOD OUTLINE

ISOLATION VALVES FOR ALL B/L/ PIPING CONNECTIONS

48

AUTOMATIC BLOCK AND BLEED ARRANGEMENT ON FUEL GAS LINE

PIPING SUPPORTS, RACKS, HANGERS AS REQUIRED

49

FLOWMETER CUM TOTALISER FOR FUEL OIL AND FUEL GAS

ISOLATION VALVES FOR ALL B/L/ PIPING CONNECTIONS

50

LPG CYLINDER ASSEMBLY FOR START UP

51
52

GAS BASED PILOT BURNER


AIR SIDE :

FLUE GAS COMPOSITION DETAILS AT CHIMNEY OUTLET :

53

AIR PREHEATER

I.D. FAN (1W + 1S)

MAX SO2 CONTENT (PPM) :

54

SOOT BLOWERS

F.D. FAN (1W + 1S)

MAX NOx CONTENT (PPM) :

55

SELF SUPP. FLUE GAS STACK W/ FLUE GAS SAMPLING CONNs.

MAX DUST CONTENT (Mg/NM3) :

56

AVIATION LAMP, PAINTER'S TROLLEY, EARTHING CONNECTION,

OXYGEN CONTENT (% BY VOLUME)

57

LIGHTENING ARRESTOR, HEAT INSULATION FROM INSIDE, HEAT

CARBON MONOXIDE CONTENT (% BY VOLUME)

58

RESISTANT PAINTING FROM OUTSIDE, ALUMINIUM CLADDING

CARBON DIOXIDE CONTENT (% BY VOLUME)

59

FLOW INDICATOR FOR AIR FROM FD FAN

MOISTURE CONTENT IN FLUE GASES

60

FLUE GAS ANALYSIS APPRATUS (FOR CO, O2, NOX, SOX)

FLUE GAS TEMPERATURE AT CHIMNEY INLET

61

ANALYSER SHELTER

FLUE GAS TEMPERATURE AT CHIMNEY OUTLET

62

PROVISION FOR SAMPLING OF FLUE GAS

TOTAL FLUE GAS QUANTITY (KG/HR)

GUARANTEED PARAMETERS

63
64

SUPERHEATED STEAM AT B/L :

65

QUANTITY

100

66

PRESSURE

67

TEMPERATURE :

SATURATED STEAM OUTPUT AT B/L :


Tons/h (NOTE-1)

QUANTITY

40

kg/cm2 (g)

360

BOILER EFFICIENCY :

MIN. 90 %

kg/h

F.O. / FUEL GAS CONSUMPTION :

kg/h

PRESSURE

kg/cm2

TOTAL POWER CONSUMP. :

kw

TEMPERATURE :

STEAM PURITY :

68
69 NOTES:
70 1) Boiler net capacity doesnot include boiler internal steam requirements such as deaerator, atomization etc.
71 2) Boiler turndown ratio shall be 25% of MCR.
72 3) Boiler shall be capable of operating with an output of 110% of the MCR rating for a period of minimum 30 minutes in each of 8 hrs shift
73 4) For fuel oil specification and fuel gas specification, refer attached ANNEXURE-1
74 5) Deaerator and DM water supply system shall be designed for no condensate return case.
75 6) Vendor to furnish the filled in datasheet for burners along with the bid.
76 7) Refer attached process datasheet for other details.

Page 1 of 3

SUPERHEATED

MECHANICAL DATA SHEET

REQ NO.

44-LK5100-00-M.17-0010

UTILITY BOILER

DOC NO.

44LK-5100-712/M.04/0022/A4
712 - SG - 1001

PROJECT NO:

44-LK5100

PROJECT LOCATION

MUMBAI REFINERY

ITEM NO.:

PROJECT TITLE

DIESEL HYDROTREATER PROJECT

QUANTITY: ONE

CLIENT

HPCL

SERVICE:

STEAM GENERATION

PERFORMANCE AND OPERATING DATA

1
2 CAPACITY AT STEAM DRUM :

kg/h

3 DRUM OPERATING PRESSURE :

kg/cm2 G

4 FUEL OIL / FUEL GAS CONSUMPTION :

kg/h

5 EFFICIENCY ON NCV :

6 AUX. STEAM CONS. :

kg/h

RELIEF VALVE PRESSURE SETTINGS :

kg/cm2

PSV 1 ON DRUM
BOILER DRUM MOC

PSV 2 ON DRUM

PSV@ STEAM HEADER

SA 387 Grade-11, Class-1 &2

HEAT ACCOUNT :

MCAL

AVERAGE DRAUGHTS :

MMWG

7 BREAKUP :

GROSS OVERALL HEAT PRODUCED

COMBUSTION CHAMBER

8 OIL HEATER

HEAT TRANSFERED TO WATER + STEAM

INLET TO STACK

9 OIL HEATER IN F.O. TANK

HEAT LOSSES DUE TO RADIATION

COMBUSTION AIR QUANTITY :

10 ATOMIZATION STEAM

HEAT LOSSES WITH FLUE GASES

THEORETICAL @ MCR

HEAT LOSSES UNACCOUNTABLE/ MARGINS

EXCESS AIR SUPPLIED

11 FEED WATER PREHEATER

m3/h

12
O

13 TEMPERATURES :

BOILER FEED WATER ANALYSIS :

14 OUTLET STEAM @ MCR

HARDNESS

15 OUTLET STEAM @ LTD

pH VALUE

BOILER WATER CONCENTRATION :


ppm

TOTAL DISSOLVED SOLIDS

Nil ppm

pH @ 25OC

8.5 to 9.5

16 F.W. @ CONTROL VALVE INLET

OXYGEN

0.005 (MAX)

mg/l

SILICA

17 F.W. @ ECONOMIZER INLET

TOTAL IRON

0.01 (MAX)

mg/l

RESIDUAL PHOSPHATE

1.0

18 AIR TO COMB. CHAMBER

TOTAL COPPER

0.003 (MAX)

mg/l

SPECIFIC ELEC. CONDUCTIVITY@25OC

19 GAS @ EXIT OF COMB. CHAMBER

HYDRAZINE (RESIDUAL)

APPROX.

mg/l

BLOW DOWN :

20 FLUE GAS @ ECONOMIZER INLET

SILICA REACTIVE

0.02

APPROX.

mg/l

QUANTITY :

kg/h

21 FLUE GAS @ INLET TO STACK

TSP AS PO4

2.0

APPROX.

mg/l

FREQUENCY :

Per day

22

CATION CONDUCTIVITY @25 DEG C

0.2

23

TDS

NIL

24

MORPHOLINE (RESIDUAL)

ppm
ppm

micro mho / cm COMPOSITION :


TEMPERATURE :
mg/l

CONSTRUCTION PARAMETERS

25
26 HEATING SURFACE AREAS :

m2

VOLUMES :

m3

27 COMBUSTION CHAMBER

VOLUME OF STEAM SPACE FROM NWL TO DRUM TOP

28 SUPERHEATER COILS

WATER HOLDING CAPACITY UPTO NWL

29 ECONOMIZER

WATER VOLUME BETWEEN LOW LEVEL & HIGH LEVEL ON STEAM DRUM

30 AIR PREHEATER

WATER VOLUME BETWEEN LOW LEVEL & LOW LOW LEVEL ON STEAM DRUM

31 DESIGN PRESSURES :

kg/cm2

TIME MEASUREMENTS :

32 DRUM DESIGN PRESSURE

TIME REQUIRED FOR BOILER TO REACH MCR FROM COLD START

33 HEADER DESIGN PRESSURE

BOILER WATER LEVEL BET. LOW LEVEL TO HIGH LEVEL :

34 HEAT AREA LOADING

kcal/m2

hrs.
AT MCR

AT LTD

min.

STEAM DRUM CAPACITY BETWEEN NWL & LLWL :

min.

35
36
37
38

MISCELLENIOUS

39
40

BREAK UP OF POWER CONSUMP. :

41

F.D. FAN

42

I.D. FAN

43

F.O. PUMPS

44

ELEC. HEATER IN TANK

45

BOILER FEED PUMP

kw
kw
kw
kw
kw

L.P. DOSING PUMPS


H.P. DOSING PUMPS
L.P. DOSING AGITATOR
TOTAL POWER CONSUMPTION AT 100% MCR

kw
kw
kw
kw
kw

H.P. DOSING AGITATOR


HEAT TRACING
CONTOL PANEL
AIR COMPRESSOR
EXPORT BFW PUMP

AUXILIARIES

46
47 ECONOMIZER :
48 TYPE :

kw
kw
kw
kw
kw

ELECTRIC OIL PREHEATER

OIL PUMPING AND HEATING UNIT:

BARE TUBE

49 ARRANGEMENT :

FINN TUBE
IN - LINE

INTERMEDIATE OIL STORAGE TANK PROVIDED :


STAGGERED

FUEL OIL DAY TANK DETAILS :

YES

50 NO. OF TUBES :

OD

mm

CAPACITY

m3

51 TOTAL HEAT TRANSFER AREA :

ID

mm

TIME STORAGE

hrs

LENGTH / HT

mm

WEIGHT

kg

52 MOC : TUBES

SA 210 Grade-1 CASING

53 WATER TEMPERATURE AT ECONOMISER INLET

NO

NA

CORROSSION ALLOWANCE :

Min.

mm

54 WATER TEMPERATURE AT ECONOMISER OUTLET


55 ATTEMPEARATOR :
56 TYPE :

HEATING METHOD:
WATER FLOW @ MCR:

kg/h

ELECTRICAL

STEAM

CONN. LOAD:

ELEC. HEATER DETAILS ( Floor Coil ) :

57

NO. OF ELEMENTS:

No. OF BANKS:

58 SUPERHEATERS :

SPARE

SPARE :

59 QUANTITY :
60
61 ARRANGEMENT:
62 MOC

FUEL GAS KOD DETAILS :


PRIMARY

SECONDARY

TERTIARY

OD

mm

CAPACITY

m3

HORIZ / VERT

HORIZ. / VERT.

HORIZ. / VERT.

ID

mm

TIME STORAGE

hrs

LENGTH / HT

mm

WEIGHT

kg

SA 321

63 NO. OF TUBES

CORROSSION ALLOWANCE :

64 HEAT TRANSFER AREAS

Page 2 of 3

mm

Min.

MECHANICAL DATA SHEET

REQ NO.

44-LK5100-00-M.17-0010

UTILITY BOILER

DOC NO.

44LK-5100-712/M.04/0022/A4
712 - SG - 1001

PROJECT NO:

44-LK5100

PROJECT LOCATION

MUMBAI REFINERY

ITEM NO.:

PROJECT TITLE

DIESEL HYDROTREATER PROJECT

QUANTITY: ONE

CLIENT

HPCL

SERVICE:

STEAM GENERATION

PUMPS :

2 CBD / IBD TANK :

TYPE :

CBD

IBD

ROTARY

CAPACITY :

4 OD

mm

DISCHAREGE PRESSURE :

5 ID

mm

SUCTION FILTERS:

6 CORR. ALLOW.

mm

TYPE :

7 LENGTH / HT

mm

DISCHARGE FILTERS:

8 DESIGN PRESSUREkg/cm2

TYPE :

SCREW

RATED

DUPLEX

DUPLEX

MESH SIZE :

Microns

MESH SIZE :

Microns

ELECTRIC OIL PREHEATER (EOPH) :

10 CAPACITY

m3

NO. OF ELEMENTS:

No. OF BANKS

11 WEIGHT

kg

SPARE

SPARE

12

HEATING CAPACITY :

13 AIR PRE-HEATER :

STEAM OIL PREHEATER (SOPH) :

CONN. LOAD:

% OF MCR

14 QUANTITY :

OD

15

Nos.

kg/cm2

9 DESIGN TEMP.

QTY:

m3/h

ID

CORR. ALOWANCE

SHELL DETAILS (mm) :

16 ARRANGEMENT:

HORIZ / VERT

TUBE DETAILS (mm) :

17 MOC

NO. OF TUBES :

18 NO. OF TUBES

STEAM ON :

TUBE SIDE

19 FLUE GAS TEMP ENTERING TO AIR PREHEATER


20 FLUE GAS TEMP LEAVING AIR PREHEATER

ID FAN DETAILS

21 AIR TEMPERATURE ENTERING AIR PREHEATER

FAN MFG NAME

22 AIR TEMPERATURE LEAVING AIR PREHEATER

SIZE

23

TYPE

24 FLUE GAS VELOCOTIES IN M/SEC :

ARRANGEMENT

25 AT FURNACE ZONE

DRIVE MFG NAME

26 AT EVAPORATOR ZONE

RATED KW

27 AT ECONOMISER

RPM

28 AT SUPERHEATER ZONE

INLET CONDITION

29

STATIC PRESSURE @DAMPERS

30 DENOx FACILITY DETAILS :

STATIC PRESSURE@ FAN INLET

31 SLEEVE LOCATION

OUTLET CONDITION
ST.PRESSURE @ DISCHARGE DAMPER

32 TOTAL NO OF SLEEVES
33 AMMONIA ANALYZER LOCATION

STATIC PRESSURE@ FAN OUTLET

34 NOX ANALYZER

BHP REQUIRED @TEMP

35 PLATFORMS AT LOCATION OF TEMP CONNECTION

FAN STATIC EFFICIENCY (%)

36 MAINTANANCE PLATFORM AT INJECTION NOZZLES

FD FAN DETAILS

37 LP STEAM QUANTITY (KG/ HR)

FAN MFG NAME

38 LP STEAM PRESSURE AT BATTERY LIMIT

SIZE

39 LP STEAM TEMPERATURE AT BATTERY LIMIT

TYPE

40 FLUE GAS TEMPERATURE MEASUREMENT

ARRANGEMENT

41 CLEARANCES/APPROVALS FROM IBR

DRIVE MFG NAME

42 CO ANALYZER LOCATION

RATED KW

43 AMMONIA LINE SIZE

RPM

44 LP STEAM LINE SIZE

INLET CONDITION

45

STATIC PRESSURE @DAMPERS

46

STATIC PRESSURE@ FAN INLET

47

OUTLET CONDITION

48

ST.PRESSURE @ DISCHARGE DAMPER

49

STATIC PRESSURE@ FAN OUTLET

50

BHP REQUIRED @TEMP

51

FAN STATIC EFFICIENCY (%)

PREPARED BY

KP

KP

CHECKED BY

PDB

PDB

APPROVED BY

SNG

SNG

DATE

03-11-2008

18-03-2009

REVISION

REFERENCE PDS NO. :


44LK-5100-00/P.04/0613/A4

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SHELL SIDE