PT. WASKITA KARYA (PERSERO) TBK Offer No.

: EA/VKK/045/2015
JAKARTA March 24, 2015
150/120/IW/mj
Attn : Mr. Ahmad Fahmi Revision 1

QUOTATION
===============
2X EURO COAL MAC COAL FIRED STEAM BOILER 10.5 TPH
Generating saturated steam, each consisting of:

Steam production at F&A 100°C : 10,500 kg/hr

Steam production at 100% MCR : 10,000 kg/hr

Working pressure: 9.50 bar

Design pressure: 10.00 bar
Test pressure: 18.50 bar

Solid fuel: Bituminous Coal

Palm Kernel Shell
Biomass Pellets

Heating surface fire side: 342.4 m2

Heating surface water side: 374.4 m2

Water content: 30.5 cbm

Steam room: 6.5 cbm

Turn down ratio boiler 10:1 Variable speed control by

PLC Siemens S7

1.0 EURO COAL MAC COAL FIRED STEAM BOILER

VKK Standardkessel Type “Condor“

2.0 EURO COAL MAC Valves and Fittings

3.0 Technical Data EURO COAL MAC

4.0 Dimensions & Weights

 Page 2

5.0 1 EURO COAL MAC Chain Grate – including worm gear slip motor
0.12 kW inverter controlled by PLC 4-20mA, with New Air Distribution
System, burning low calorific Bituminous Coal with 5600 kcals and
lower based on As Received (AR), including :

(2 sets) front under grate dampers with 1 Sauter motor PLC controlled,
(2 sets) rear under grate dampers with 1 Sauter motor PLC controlled

6.0 1 Swinging coal chute drive table including worm gear operated by a
rotating chain with a drive of 0.37 kW for even distribution of coal over
the width of the Chain Grate

7.0 1 CFW ID Fan 45 kW with AC variable motor inverter controlled by PLC

8.0 1 CFW FD Fan 11 kW with AC variable motor inverter controlled by PLC

9.0 2 Boiler Feed Pumps type Grundfos CR 15-10, each 11 kW

10.0 1 DWYER Vacuum Control type Photohelic for controlling negative

pressure in the boiler

11.0 1 Over Fire Air System

12.0 1 Water Spray for maintaining moisture in the coal

13.0 1 Reversing Chamber Deashing drop chute for Automatic Fly Ash
Extraction incl. motorized Ash Rotary Discharge Valve size Ø DN 150
with 0.37 kW Motor at the rear of the boiler

14.0 1 Automatic main deashing drop chute with flange for ash and klinker
discharge at the rear of the chaingrate size 400 mm x 600 mm oval type
 Page 3

15.0 1 Flue-Gas Dust Separator Plant Multi Cyclones for Automatic Fly Ash
Extraction incl. motorized Ash Rotary Discharge Valve size Ø DN 150
with 0.37 kW Motor

16.0 Tools

17.0 Supports, Insulation, Alu Sheeting, Refractory and Painting

18.0 Coal Specification:

Total Moisture Content 10% - 14%, Volatile Matter above 40% - 46%,
Ash content 8% - 10% 5600 kcals and lower based on As Received
(AR), coal sizing 20 mm with fines up to max. 25%, with sizing 1- 5 mm,
Sulphur max. 1.2% resulting in optimum combustion, better burn out of
coal, increase of pressure and higher steam output.

19.0 Documentation

20.0 1 GESTRA WATER LEVEL LIMITER AND CONTINUOUS

FEEDWATER REGULATION FOR OPERATION WITHOUT
SUPERVISION (24 H), ACCORDING TO THE GERMAN TRD 604

Make : GESTRA
Type : NRGT 26-1
Flange : DN 100 PN 40

Consisting of :
1 Level control electrode Gestra
Type : NRGT 26-1

1 Level electrode for low water limiting Gestra

Type : NRG 16-11
Amplifier : NRS 1-7b
1 Feed water motorized regulation valve for feed pumps, by-pass
piping with 3 shut off valves and 1 strainer
 Page 4

Make : ARI
Valve : DN 50 PN 16
Function : low water alarm
high water alarm
regulation of control valve movements
shut down of the whole boiler plant in case of
extreme high or low water

1 strainer DN 50 PN 16
3 shut off valves DN 50 PN 16

21.0 1 ADDITIONAL GESTRA WATER LEVEL ELECTRODE FOR

SECOND LOW WATER, ACCORDING TO GERMAN TRD 604
For operation constant supervision for a period of 24 hours according to TRD
604, Make Gestra, consisting of:

1 Level Control Electrode NRG 16-11 Gestra

complete with fitting flange and

1 Switching amplifier NRS 1-7b Gestra

for the function: low water limitation

22.0 1 Set CABLES FROM SWITCHBOARD TO BOILER

INCLUDING WIRING

23.0 1 Set CABLE TRAYS

FOR THE WHOLE PLANT

24.0 1 GESTRA MPA 26 PROGRAM-CONTROLLED PNEUMATICALLY

ACTUATED BLOWDOWN SYSTEM

Suitable for water of 6-24 barg consisting of:

1 diaphragm actuator for the intermittent blowdown valve

(MPA 26) DN 50 PN 40

1 three-way solenoid valve with plug-in programmer

 Page 5

1 programme-controller for the adjustment of time and interval type TA5

25.0 1 OXYGEN-ANALYZER WITH DISPLAY FOR O2 and CO2

Built into the main switchboard with display at Siemens S7 “Touch Screen” HMi
size 12.1″ 4-20 mA adjustable, avoiding over firing of the boiler.

26.0 1 INVENSYS FEED WATER METER WITH DISPLAY DN50 PN40

Built into the main switchboard with display at Siemens S7 “Touch Screen” HMi
size 12.1″ 4-20 mA.

27.0 1 HOPPER LEVEL CONTROL FOR OVERHEAD HOPPER

The boiler will be supplied with a diaphragm level control unit for others to
install in the Coal Hopper which will provide an electrical signal to stop/start
coal screw feeders.

28.0 2 SOOT BLOWERS

The soot blowers are fitted into the reversal chamber of the boiler to clean the
tubes of deposits by the use of steam, manually operated DN 100 connection
at the rear.

29.0 1 RITTAL SWITCHBOARD FREE STANDING INCLUDING PLC

SIEMENS S7 INCLUDING TOUCH SCREEN HMi SIZE 12.1 ″
Made of steel plate, powder coated, mounted at boiler side.

Width 2400 mm, Height 1800 mm and Depth 400 mm.

For automatic operation regulation and control of the combustion system

including of electrical safety requirements and controls associated with the
boiler.
 Page 6

The control panel is manufactured by Rittal-Germany. It contains sealed

doors with lockable inserts, well arranged switches and control devices,
wiring contained in cable ducts with marked connection terminals on
mounting plates. A wiring diagram will be provided.
The panel is fitted with audible and visible alarm signals, doors are equipped
with cooling fans with filter.

Operational data displayed on Touch Screen HMi 12.1″:

· Feedwater Temperature
· Feedwater Flow Rate
· Graphic Trend “Online Program”
· Monitoring Water Flow Rate Fluctuation
· Operation Hour Counter
· Steam Pressure
· Exhaust Gas Temperature

INVERTER PANEL

INVERTER FOR CONTROLLING 1 x ID FAN 45 kW, 1 x FD FAN 11 kW,

1 x CHAINGRATE DRIVE 1.1 kW
 Page 7

Installation together in the main switch board with following advantages:

a) Reduction in kWe
b) Reduction in coal consumption
c) Reduction in exhaust gas temperature
d) Reduction in noise level

PLC Siemens S7
for all automation function for the coal boiler control panel:
- Maintain steam pressure of boiler by controlling the ID Fan, FD Fan and
Stoker Speed according to steam demand.
- Performs the Function of Conventional Relays, Counter and Timers and
Mathematics Formula for Automatic Blowdown Control, Coal Handling
Control, Coal Counter function, Water Feeding, O2 Control, etc.
- Send all boiler parameter such Steam Pressure, Boiler Water Level, Water
Flow Rate, Water Temperature, Flue Gas Temperature to Siemens S7
including Touch Screen HMi size 12.1″ for display and plotting trend data.
- Send the alarm bit to HMi for display as Alarm Messages.

30.0 1 Set SPARES Pcs

Common links 50
Drive links 25
Side links 5
Link rods 5
Guillotine door wire / chain 1

Manhole Gasket for size 405 x 305 1

Handhole Gasket for size 100 x 125 1

31.0 ERECTION, COMMISSIONING & START UP

TOTAL PRICE EX-WORKS ( ITEM 1 – 31) 1 UNIT USD. 409,790.00

TOTAL PRICE EX-WORKS ( ITEM 1 – 31) 2 UNITS USD. 819,580.00

 Page 8

TRANSPORT COSTS
32.0 DELIVERY TO PORT & FOB USD. 13,170.00

33.0 SEA FREIGHT TO JAKARTA USD. 13,620.00

TOTAL TRANSPORT COSTS ( 1 UNIT ) USD. 26,790.00

TOTAL TRANSPORT COSTS ( 2 UNITS ) USD. 53,580.00

IMPORT COSTS

34.0 CUSTOMS CLEARANCE & STEVEDORING USD. 1,150.00

35.0 IMPORT DUTIES USD. 17,200.00

36.0 TRANSPORT TO TUGU EA WAREHOUSE USD. 1,650.00

TOTAL IMPORT COSTS ( 1 UNIT ) USD. 20,000.00

TOTAL IMPORT COSTS ( 2 UNITS ) USD. 40,000.00

SUMMARY

· EX-WORKS (ITEM 1 – 31) 2 UNITS USD. 819,580.00

· TRANSPORT COSTS (ITEM 32 – 33) 2 UNITS USD. 53,580.00
· IMPORT COSTS (ITEM 34 – 36) 2 UNITS USD. 40,000.00

TOTAL PRICE (ITEM 1 TO 36) 2 UNITS USD. 913,160.00

FREE EA WAREHOUSE PLUS 10% PPN
 Page 9

QUOTATION
COAL HANDLING EQUIPMENT
COAL FIRED BOILER 10.5 T/H
**************************************
37.0 FEED HOPPER – 2 Units
Specifications
- Volume : 18 tons
- Material : MS 8 mm, 6 mm
- Support : IWF 300, UNP 150
Angle bar 90 x 90, Angle bar 70 x 70

38.0 FEED HOPPER COVER – 2 Units

Material : MS 6 mm

39.0 SINGLE BUCKET ELEVATOR – 2 Units ( double gear box )

Specifications
- Bucket : 500 kg
- Motor : Brake Motor AEB 4.0 kW, 380 V
- Support : 12,000 mm
- Material : H beam 150, UNP 100, Angle bar 60 x 6
- Level Control : Omron WLNJ

40.0 DUCTING – 2 Sets

Specifications:
- Material : MS 6.0 mm
· From Boiler to Grit Arrestor
· From Grit Arrestor to ID Fan
· From ID Fan to Chimney

41.0 RAILING, LADDER, PLATE FORM FEED HOPPER + BOILER – 2 Sets

Specifications:
- Material : CNP 150, Bordes 3.2 mm
- Support : UNP 100
- Railing : Pipe 1 ¼”, Pipe 1”
- Ladder : Step – 600 x 200 mm
 Page 10

42.0 MAINTENANCE DECK BOILER – 2 Units

Specifications:
- Material : CNP 150, Bordes 3.0 mm
- Support : UNP 100
- Railing : Pipe 1 ¼”, Pipe 1”
- Ladder : Step 600 x 200 mm

43.0 CHIMNEY – 2 Units

Specifications:
- Diameter : 900 mm
- Height : 24,000 mm
- Base plate : Single Plate 25 mm
- Material : T 9,000 – MS t 10 mm
T 7,500 – MS t 8 mm
T 7,500 – MS t 6 mm
- Equipment : ● Heat resistance paint max 300°C, Nippon Paint
● Lightning rod BC 50 – 30.000 mm
● Ladder + Safety Ladder
● Service Platform ½ circle

44.0 WET ASH CONVEYOR COMMON FOR 2 BOILERS – 1 Unit

Specifications:
- Dimension : L 7,875 x W 700 x H 670 mm
- Material : MS 6 mm
- Wet ash support : UNP 100
- Roll carry : Roll 10” x 660 mm – 5 pcs
Roll 3” x 3 pcs – 1 pce
ReRoll 3” x 660 mm – 2 pcs
- Roll pipe : O 650 mm – 4 pcs
- Drain : 2 units – Ball Valve 2”
- Motor : 0.75 kW - Motovario
- Belt : L 600 , 4 Ply
 Page 11

45) QUOTATION
FEED WATER TANK 10M3
**************************************

Volume : 10 m3
Dimension : dia 1.600 x L 5.000 mm x MS 6 mm

Platform 2 units
Size : L 600 x P 3.000 mm, L 600 x P 1.200 mm
Material : CNP 150, Bordes 3 mm

Insulation
Material : Rockwool tomboe 50 mm, denst 80 kg/m3
Aluminum sheet 0.8 mm
Overflow
Material : Piping DN 150

Structural support
Material : IWF 300 – H 4.000 mm, UNP 150

46) QUOTATION
CONDENSATE TANK 5M3
**************************************

Volume : 5 m3
Dimension : dia 1.400 x L 3.000 mm x MS 6 mm

Insulation
Material : Rockwool tomboe 50 mm, denst 90 kg/m3
Aluminum sheet 0.8 mm
 Page 12

47) PIPING
- Feed Tank to Pump Boiler DN 80 x 20 meters
- Pump Boiler – Boiler DN 50 x 6 meters
- Venting Boiler DN 20 x 4 meters
- Safety Valve Boiler DN 100 x 4 meters x 2 units
- Blowdown DN 50 x 3 meters
- Drain Level Gauge DN 25 x 4 meters x 2 units
- Steam Piping DN 200 x 20 meters
- Drain Steam Header DN 25 x 8 meters
- Overloop DN 80 x 5 meters
- Isolation Rockwool 50 meters + Alu 0.6 mm

48) STEAM HEADER DN 300 X 2.500 MM

WITH VALVES & FITTINGS
Flange Nozzle : DN 200 x 5,DN 80 x 1,DN 20 x 1,DN 25x 2
Drain : DN 25 x 1

TOTAL PRICE ( ITEM 37.0 - ITEM 48) USD. 166,800.00

PLUS 10% PPN
 Page 13

49) QUOTATION
SOFTENING PLANT & DEAERATING PLANT
**************************************
49.01 1 FINE FILTER
For removal of dirt particles from water

Process Data:
Volume flow water 10 m3/h
Differential pressure, approx. 0.2….0.5 bar

Filtration grade 100 μm

Ambient Conditions:
Location indoors
Ambient temperature 5…40 ºC

Technical Data :
Allowable gauge pressure min /max 0/10(6) bar
Allowable temperature min/max 0/20(40) ºC

Connections:
Inlet / outlet DN 50 PN 10

Material
Pipelines PVC-U
Filter housing brass

Design:
Filter housing with re-usable filter cartridge. Manual backwash by
opening of a discharge valve at the bottom of the filter housing

Manual valves nominal diameter < DN 50 as ball valve, nominal

diameter > DN 50 as butterfly valve. Each with hand level.

Pre assembled including by pass pipeline with 3 manual valves.

Directive 97/23/EC ( pressure equipment directive ):

Article 3, section 3, sound engineering practice
 Page 14

Main components:
1 filter housing
1 filter cartridge, re-usable
1 set of manual valves
1 by pass line

49.02 1 SOFTENING PLANT ( TWO LINES )

For softening of water, meaning exchange of calcium ions and
magnesium ions with sodium ions.

Ion exchange plant, two lines, 2 x 100% with separate control head,
operating valve and brine valve for each line. Change over operation.
Regeneration with sodium chloride brine, in co flow. Regeneration
triggered by water quantity, as Option by time or quality.

Process Data:
Water volume flow 10 m3/h
Differential pressure at full load, approx 1.2 bar

Total alkaline earths (hardness), outlet 2.0 mmol/l

~ 11 ºdH
~ 200 mg/L CaCO3

Total alkaline earths (hardness) inlet < 0.01 mmol/L

~ <0.05 ºdH
~ < 1 mg/L CaCO3

Resin volume / line 325 L

Exchange capacity / line approx 203 mol Ca2+
~ 1138 ºdH m3
~ 20.3 kg CaCO3
Volume capacity / line, approx 102 m3
Service life at full load, approx 10 h

Salt consumption / regeneration 78 kg NaCI

Influent / regeneration 3.9 m3
Regeneration duration 60…90 min
Total volume brine storage tank 1000 L
 Page 15

Salt storage brine storage tank 278 kg NaCI

Salt storage time at full load, approx 100 h
Motive water volume flow 3 m3/h
Motive water gauge pressure >3 bar

Ambient Conditions:
Location indoors
Ambient temperature 5…40 ºC
Air humidity < 90 %
Potentially explosive atmosphere no

Technical Data:
Allowable gauge pressure, min/max 0/10(6) bar
Allowable temperature, min/max 0/20(50) ºC

Option : Control air volume flow <5 dm3/min

Option : control air gauge pressure 6 bar

Supply voltage 230 V, 50 Hz

Internal control voltage 24 VAC

Dimensions:
Total length, approx. 2400 mm
Total depth, approx. 1000 mm
Total height, approx. 2000 mm

Mass / Weight
Empty mass, approx. 1300 kg
Operating mass, approx. 1950 kg

Connections:
Raw water, inlet DN 50 PN 10
Soft water, outlet DN 50 PN 10
Effluent, outlet DN 25 PN 10

Material :
Pipelines polyvinyl chloride PVC-U
Control heads brass
Pressure vessels glass-reinforced plastic GRP
Brine storage tank polyethylene PE
 Page 16

Instrumentation:
Pressure gauge raw water inlet
Water meter soft water outlet

Design :
Internal piping completely pre assembled, including valves and
instrumentation

Pressure vessel, cylindrical vessel with semi spherical heads, standing

upright on base.

Ion exchange resins as cation exchange resins, strong acid, gel type
polystyrenic.

Control heads as multi way valve, including electric actuator and

internal injector.

Manual valves nominal diameter < DN 50 as ball valve, nominal

diameter > DN 50 as butterfly valve. Each with hand level.

Automated valves nominal diameter < DN 50 as diaphragm valve,

nominal diameter > DN 50 as butterfly valve. Each with pneumatic
actuator, closing by spring load, including local position indicator and
3/2 way solenoid valve.

Local pressure gauges as bourdon tube pressure gauge according to

EN 837-1, accuracy 1, 6 filled with liquid, outer diameter 63 m,
connection location either at the back or at the bottom.

Water meter, multi jet, wet dial, contact type, pulse resolution either 10
L/pulse, 100 L/pulse, or 1000 L/pulse, depending upon plant design.
Reed contact, protection class IP 68.

Micro processor control unit for fully automated operation of the

plant, including regeneration trigger, regeneration process, line change
over. Including 4 line display, operating buttons, LED for operation
and alert conditions. Protection class IP 54.
 Page 17

Directive 97/23/EC ( pressure equipment directive ):

Article 3, section 3, sound engineering practice.

Main components:
2 pressure vessel
2 set filter nozzle
2 set ion exchange resin
2 control head
2 set manual valves
2 set automated valves
1 set local instrumentation
1 water meter
1 internal piping
1 brine storage tank
2 brine valve
1 micro processor control unit

TOTAL PRICE ( ITEM 49.1 – 49.2 ) USD. 14,700.00

PLUS 10% PPN

THERMAL DEAERATOR
Basis of offer :

The quoted plant is designed for the following application:

Application boiler feed water treatment

Task thermal deaeration

Chemical conditioning

Steam Boiler Plant:

- Type of steam boiler shell boiler
- Operating gauge pressure < 20 bar
- Superheater no
- Spray-type desuperheater no
- Steam turbine no
 Page 18

- Steam boiler mass flow, gross 10000 kg/h

- Steam boiler mass flow, net 9025 kg/h
- Condensate return 50 %
- Heating steam absolute pressure 7 bar
- Code(s) reg. water quality EN 12953-10
(TRD 611)
- Mode of operation “high TDS”
- Bfw electrical conductivity > 30 µS/cm
- Projected cycles of concentration > 20
- Projected blow-down rate <5 %

49.03 1 SIEVE TRAY DEAERATOR

For thermal deaeration of boiler feed water.

Process Data:
Boiler feed water mass flow 10500 kg/h
Boiler feed water temperature 105 °C
Boiler feed water absolute pressure (*) 1.2 bar
*hydrostatic pressure not included.

Vent mass flow 38 kg/h

Vent temperature 105 °C
Vent absolute pressure 1.2 bar

Condensate mass flow 4153 kg/h

Condensate temperature 80 °C
Make-up water mass flow 5050 kg/h
Make-up water temperature 25 °C
Heating steam mass flow 975 kg/h
Heating steam temperature 165 °C
Heating steam absolute pressure 7.0 bar
Turndown ratio 20…100 %

Residual oxygen content <0.02 mg/L O2

 Page 19

Technical Data:
Allowable pressure, min./max. 0 / 0.5 bar
Allowable temperature, min./max. 0 / 120 °C
Volume 525 L

Dimensions and Weight:

Outer diameter 700 mm
Cylindrical shell height 1250 mm
Total height, approx. 1570 mm
Wall thickness, shell/heads 4/4 mm

Insulation surface area, approx. 5.4 m2

Insulation not included!

Empty mass, approx. 200 kg

Operating mass, approx. 275 kg
Testing mass, approx. 725 kg

Connections:
Make-up water DN 32 PN 16
Condensate DN 32 PN 16
Vent DN 32 PN 16

Pressure, local G ½”
Pressure, remote G ½”
Feed water tank DN 700

Material:
Shell stainless steel 1.4301
Heads stainless steel 1.4301
Pipe nozzles stainless steel 1.4541
Welding neck flanges stainless steel 1.4541
Sieve tray installations stainless steel 1.4301
Vessel flange carbon steel S235JR

Corrosion protection:
Pickled and passivated. Vessel flange primer 40 µm.
 Page 20

Design:
Cylindrical vessel with torispherical heads, standing upright vessel
flange.
Sieve tray installations welded to the shell.
Length of nozzles 180 mm, supposed for insulation 100 mm thick.
Welding neck flange according to EN 1092-1/11.
Including vessel name plate and lifting lugs.

Directive 97/23/EC (PED):

n/a(PS,max≤0,5 bar)

Design Code:
Sound engineering practice, joint coefficient z=0,7
Corrosion allowance c=0 mm

Accessories:
1 vent orifice DN32 material 1.4301
1 lift check valve DN32 PN16, material CW710R
1 bourdon tube pressure gauge, Ø160 mm, display range 0...1 bar
1 pressure gauge valve ½”, material brass
1 water siphon ½”, material P235GH
1 set of bolts, nuts and gasket for vessel connection
1 counter flange DN 700, material S235JR

49.04 1 ENGINEERING AND ACCESSORIES FOR BOILER FEED WATER

TANK
For secondary deaeration and storing of boiler feed water.
Included: design drawing, accessories. Manufacturing by others.

Technical Data:
Allowable pressure, min./max. 0 / 0.5 bar
Allowable temperature, min./max. 0 / 120 °C
Volume, total 10600 L
Volume, useful 9000 L

Dimensions and Weight:

Outer diameter 1600 mm
Cylindrical shell length 5000 mm
Total length 5520 mm
Total height 2030 mm
 Page 21

Wall thickness, shell/heads 6 / 5 mm

Insulation surface area, approx. 36 m2

Insulation not included!

Empty mass, approx. 1900 kg

Operating mass, approx. 10900 kg
Testing mass, approx. 12500 kg

Connections:
Deaerator DN 700
Heating steam DN 80 PN 16
Boiler feed water DN 80 PN 16
Boiler feed water pump return DN 25 PN 16
Vacuum relief valve DN 80 PN 16
Safety pipe DN 80 PN 16
Drain DN 40 PN 16
Level, local 2xDN 25 PN 16
Temperature, local G ½”
Chemical injection 2xRp ½”
Manway DN 500

Material:
Shell carbon steel S235JR
Heads carbon steel P265GH
Pipe nozzles carbon steel P235GH
Welding neck flanges carbon steel P250GH
Vessel/manway flange carbon steel S235JR
Saddles carbon steel S235JR

Corrosion protection:
Inside without, outside primer 40 µm.

Design:
Cylindrical vessel with tank heads, laying horizontally on two
saddles.
Length of nozzles 180 mm, supposed for insulation 100 mm thick.
Welding neck flange according to EN 1092-1/11.
Steam inlet pipe with vertical inlet, continuing horizontally below the
water level.
Including vessel name plate and lifting lugs.
 Page 22

Directive 97/23/EC (PED):

n/a(PS,max≤0,5bar)

Design Code:
Sound engineering practice, joint coefficient z=0,7
Corrosion allowance c=0mm

Accessories:
4 steam-jet heater 1 ½”, material 1.4541
1 bimetal thermometer, Ø160, display range 0…120°C
1 gate valve DN 80 PN 10, material EN-JL 1040
1 gate valve DN 40 PN 10, material EN-JL 1040

49.05 1 ACCESSORIES FOR SAFETY PIPE

For preventing non-allowable inner pressure increase.
Included: design drawing, accessories. Manufacturing by others.

Technical Data:
Nominal diameter DN 80 PN 16
Filled height 5000 mm

Material:
Pipe carbon steel P235GH
Welding neck flanges carbon steel P250GH

Design:
Safety pipe, open to the atmosphere

Accessories:
2 ball valve ½”, material brass
 Page 23

49.06 1 VACUUM RELIEF VALVE

For preventing non-allowable outer pressure increase.

Technical Data:
Nominal diameter DN 80 PN 16
Cracking pressure 5 mbar
Material:
Body special brass CW 710R
Disc stainless steel 1.4571

Design:
Lift check valve, wafer-type, spring-loaded, soft sealing.

Accessories:
1 pipe elbow 45°, material P235GH
1 counter flange, material P250GH
1 set of bolts, nuts and gaskets

49.07 1 GLASS PIPE LEVEL INDICATOR

For displaying the water level in the boiler feed water tank.
Technical data:
Allowable temp.max 110 (120) °C
Centre distance 1400 mm

Connections:
Process 2xDN 25 PN 16
Material:
Pipe borosilicate glass
Floater PP
Integrated valves stainless steel 1.4404
Connection flanges carbon steel S235JR
Design:
Bypass magnetic level indicator, with magnetic floater, impact
protect cover, integrated isolating valves, integrated drain
valve.
Accessories:
6 level switch, bi-stable
 Page 24

49.08 1 HEATING STEAM CONTROL VALVE

For continuous control of the heating steam flow rate.
Technical Data:
Nominal diameter DN 50 PN 16
Flow coefficient Kvs 16 m3/h
Set point 0.1…0.6 bar

Material:
casing grey cast iron EN-JL 1040

Design:
Pressure reducing valve, with diaphragm actuator, medium
controlled, required no auxiliary energy. Proportional control mode
(P-controller )
Accessories:
1 condensate seal vessel, material P235GH
1 pressure sensing line D6 PN 100, material 1.4571
1 globe valve DN 50 PN 16, material EN-JL1040
1 stainer DN 50 PN 16, material EN-JL 1040

49.09 1 MAKE-UP WATER VALVE

For on / off control of the make-up water flow rate.

Technical Data:
Nominal diameter DN 25 PN 16
Voltage 230 V, 50 Hz
Protection class IP 65

Material:
Body brass

Design:
Solenoid valve, 2/2 way, normally closed
Accessories:
1 by-pass line DN 32 PN 10, material PVC-U
3 ball valve DN32 PN 16, material PVC-U
 Page 25

49.10 1 SAMPLE COOLER

for cooling of boiler feed water samples.
Process Data:
Sample water mass flow 20 kg/h
Sample water inlet temperature 110 °C
Sample water outlet temperature 25 °C

Cooling water mass flow 60 kg/h

Cooling water inlet temperature 20 °C
Cooling water outlet temperature 50 °C

Technical Data:

Shell Side:
Allowable gauge pressure, min./max. 0/10 bar
Allowable temperature, min./max. 0/110 °C
Volume 1.5 L

Tube Side:
Allowable gauge, pressure, min./max. 0/16 bar
Allowable temperature, min./max. 0/200 °C
Volume 0.1 L

Dimensions and Weight:

Outer diameter 88.9 mm
Cylindrical shell height 250 mm
Total height, approx. 500 mm
Total width, approx. 250 mm

Empty mass, approx. 2.0 kg

Operating mass, approx. 4.0 kg

Connections:
Sample water inlet DN 6 PN 100
Sample water outlet DN 6 PN 100
Cooling water inlet Rp ½”
Cooling water outlet R ¾”
 Page 26

Material:
Shell stainless steel 1.4541
Head stainless steel 1.4541
Cooling loop stainless steel 1.4571

Design:
Cylindrical vessel with torispherical heads, standing upright.
Including inner cooling loop, collecting tray, fastening elements.

Directive 97/23/EC (PED):

Article 3, section 3

Design Code:
Sound engineering practice, joint coefficient z=0.7,
corrosion allowance c=0 mm

Accessories:
1 globe valve DN 6 PN 250, material 1.4571
1 ball valve Rp ½”, material 1.4401

49.11 1 SAMPLE COOLER

for cooling of boiler water samples.
Process Data:
Sample water mass flow 20 kg/h
Sample water inlet temperature 200 °C
Sample water outlet temperature 25 °C

Cooling water mass flow 120 kg/h

Cooling water inlet temperature 20 °C
Cooling water outlet temperature 50 °C

Technical Data:

Shell Side:
Allowable gauge pressure, min./max. 0/10 bar
Allowable temperature, min./max. 0/100 °C
Volume 3.0 L
 Page 27

Tube Side:
Allowable gauge, pressure, min./max. 0/40 bar
Allowable temperature, min./max. 0/210 °C
Volume 0.2 L

Dimensions and Weight:

Outer diameter 88.9 mm
Cylindrical shell height 500 mm
Total height, approx. 750 mm
Total width, approx. 250 mm

Empty mass, approx. 2.0 kg

Operating mass, approx. 5.0 kg

Connections:
Sample water inlet DN 6 PN 100
Sample water outlet DN 6 PN 100
Cooling water inlet Rp ½”
Cooling water outlet R ¾”

Material:
Shell, Head stainless steel 1.4541
Cooling loop stainless steel 1.4571

Design:
Cylindrical vessel with torispherical heads, standing upright.
Including inner cooling loop, collecting tray, fastening elements.

Directive 97/23/EC (PED):

Article 3, section 3

Design Code:
Sound engineering practice, joint coefficient z=0.7,
corrosion allowance c=0 mm

Accessories:
1 globe valve DN 6 PN 250, material 1.4571
1 ball valve Rp ½”, material 1.4401
 Page 28

49.12 2 METERING STATION FOR TRISODIUM PHOSPHATE / SODIUM

SULPHITE
for addition of trisodium phosphate or sodium sulphite to the boiler
feed water.
Process Data:
Injection point gauge pressure <10 bar
Injection point temperature ≤ 120 °C
Metering chemical trisodium phosphate Na 3PO4
sodiumsulphite Na 2SO3
Delivery condition powder
Metering condition aqueous solution
Metering concentration 0.1…100 g/L PO4 / SO3
Metering volume flow 0.3…3.6 L/h
Metering mass flow 0.03…360 g/L PO4 / SO3
Storage volume 100 L
Storage time, approx. 24…330 h

Ambient conditions:
Location indoors
Ambient temperature 5…40 °C
Air humidity 0…92 %
Explosive atmosphere no

Design:
Compact metering station. Metering pump including accessories
mounted on top of the metering tank.

1 Metering Pump:
Volume flow 0.3…3.6 L/h
Discharge pressure, max. 16 bar
Allowable temperature, min./max. 0/40 °C
Suction height, max. 6 m H2O
Stroke frequency 180 1/min
Voltage 100…230 V ±10%, 50/60 Hz
Power 15 W
Protection class IP 65
Insulation class F
Material head PP
Material gaskets EPDM
Material casing PPE/GRP
 Page 29

Empty mass 2.9 kg

Solenoid diaphragm metering pump. Stroke frequency normally
adjustable. Recommended stroke frequency interval 30…100%.
Stroke length manually adjustable. Recommended stroke length
interval 30…100%.Including failure alert switch.

1 Metering Tank:
Allowable pressure, min./max. atmospheric
Allowable temperature, min./max. 0/40 °C
Volume 100 L
Outer diameter 500 mm
Total height 760 mm
Material PE
Colour nature
Empty mass 7 kg
Cylindrical vessel, standing upright on flat floor. Top closed. Including
liter scale and handhole with screw cap.

1 Suction Piping with Accessories:

1 suction line Ø6xØ4, material PE soft
1 float-type level switch
1 manual stirrer, material PP

1 Metering Line with Accessories:

1 metering line Ø6xØ4PN 10, material PE soft, length 10 m
1 cooling line Ø8x1, material 1.4571, length 1 m
1 injection valve DN 6 – R ½”, material 1.4571

49.13 1 ENGINEERING AND ACCESSORIES FOR CONDENSATE TANK

For atmosphere storing of condensate.
Included: design drawing, accessories. Manufacturing by others.

Technical Data:
Allowable pressure, min./max. 0 / 0.5 bar
Allowable temperature, min./max. 0 / 110 °C
Volume, total 5200 L
Volume, useful 3900 L
 Page 30

Dimensions and Weight:

Outer diameter 1250 mm
Cylindrical shell length 4000 mm
Total length 4440 mm
Total height 1630 mm
Wall thickness, shell/heads 5/5 mm

Insulation surface area, approx. 24 m2

Insulation not included!

Empty mass, approx. 900 kg

Operating mass, approx. 5600 kg
Testing mass, approx. 6100 kg

Connections:
Condensate inlet DN 40 PN 16
Condensate outlet DN 40 PN 16
vent DN 50 PN 16
overflow DN 40 PN 16
Drain DN 40 PN 16
Level, local 2xDN 25 PN 16
Temperature, local G ½”
Manway DN 500

Material:
Shell carbon steel S235JR
Heads carbon steel P265GH
Pipe nozzles carbon steel P235GH
Welding neck flanges carbon steel P250GH
Vessel/manway flange carbon steel S235JR
Saddles carbon steel S235JR

Corrosion protection:
Inside without, outside primer 40 µm.

Design:
Cylindrical vessel with tank heads, laying horizontally on two
saddles.
Length of nozzles 180 mm, supposed for insulation 100 mm thick.
Welding neck flange according to EN 1092-1/11.
Including vessel name plate and lifting lugs.
 Page 31

Directive 97/23/EC (PED):

n/a(PS,max≤0,5bar)

Design Code:
Sound engineering practice, joint coefficient z=0,7
Corrosion allowance c=0mm

Accessories:
1 bimetal thermometer, Ø160, display range 0…120°C
1 gate valve DN 40 PN 10, material EN-JL 1040

49.14 1 GLASS PIPE LEVEL INDICATOR

For displaying the water level in the condensate water tank

Technical Data:
Allowable temperature, max 110 (120) ºC
Centre distance 1000 mm

Connections:
process 2 x DN 25 PN 16

Material:
Pipe borosilicate glass
Floater PP
Integrated valves stainless steel 1.4404
Connection flanges carbon steel S235JR

Design:
By pass magnetic level indicator. With magnetic floater, impact
protection cover, integrated isolating valves, integrated drain valve.

Accessories:
4 level switch, bi-stable
 Page 32

49.15 1 CONTROL CABINET

For voltage supply and control of electrical plant components.
Incorporated in main panel

Ambient conditions:
Location indoors
Ambient temperature 5…40 ºC
Air humidity < 90 %
Potentially explosive atmosphere no

Technical data:
Main voltage supply 400 V, 50 Hz
Control voltage 24 V DC
Protection class IP 55

Dimensions:
Total length, approx 380 mm
Total depth, approx 210 mm
Total height, approx 600 mm

Mass / weight
Empty mass, approx 80 kg

Material
Enclosure carbon steel
Door carbon steel
Mounting plate carbon stell

Corrosion protection:
Enclosure and doors inside and outside with primer, outside powder
coated, colour light grey (RAL 7035). Mounting plate galvanized.

Design:
Control cabinet, wall mounted, door opening towards the front.

With main switch, M-0-AS switches and change over switches for
electrical equipment with main voltage supply, LED for operation and
phase indication.
 Page 33

Scope of functionality:
- Voltage supply for all internal consumers
- Open loop control for all internal consumers
- Communication with site DCS via terminal strip

TOTAL PRICE ( ITEM 49.03 – 49.15) USD. 39,800.00

PLUS 10% PPN

TOTAL PRICE ( ITEM 49.01 – 49.15) USD. 54,500.00

PLUS 10% PPN
 Page 34

Terms : Free EA Warehouse

Payment : - 30% down payment by T.T.

- 60% by T.T. 4 weeks before shipment
- 10% after commissioning and start up
All payments in favor of:
PT. EUROASIATIC JAYA
PT. Bank Ekonomi Raharja Tbk
Mangga Dua Branch, Ruko Orion No. 21, Blok I,
Jl. Mangga Dua Raya Blok D, Jakarta 14430

USD A/C No. 907-035067-118 (down payment)

(via HSBC New York)
USD A/C No. 907-035067-117 (remaining payment)
(via HSBC New York)
IDR A/C No. 907-035067-075 (for PPN only)
SWIFT EKONIDJA

Delivery : approx. 8 months ex factory after receipt of down

payment, subject unsold.

Packing : Boiler unpacked and uninsulated, Accessories in cases.

Insurance : On Buyer’s account.

Origin : Germany

Warranty : 12 months after commissioning and start-up, however not

later than 18 months B/L’s date, whichever date comes
first, except wear and tear.

Commissioning, : Included.
Start-up & Training Customer will provide accommodation and food (3 meals
per day and sufficient drinking water) for technicians and
engineers to complete the job.
 Page 35

Exclusion : Soil test, boiler house design, foundation and building for
complete system, blowdown pit and overflow basin;
construction, roofing, lighting and materials for complete
system; raw water line (tank(s), piping, accessories.

Pump(s) from raw water area to soft water area; soft water
line (tank(s), piping, accessories and pump(s) from soft
water area to feedwater pumps, main steam line ( piping
and accessories) from boiler main steam valve to steam
header( existing or new); main steam line (piping and
accessories).

Steam header incl. incoming and outgoing valves, pipings,

from steam header (existing or new) to client’s process;
condensate return line, condensate incl. incoming and
outgoing valves (tank(s), piping, accessories and pump(s));
steam traps; boiling out chemicals and caustic soda.

Air compressor and piping or compressed air line

including all accessories for blowdown device pneumatic
diaphragm actuation; ash disposal bins; control room air
conditioner unit; electrical connection power cable up to
control panel including junction box; site facility, working
area, security, lighting and electricity (50 kVA) during
installation and erection; water and coal during start-up
and commissioning.

Complete coal handling and deashing system incl. ducting

and chimney.

Validity : This quotation is valid for 60 days.

PT. EUROASIATIC JAYA

 Page 36

SPECIFICATION

1.0 EURO COAL MAC COAL FIRED STEAM BOILER

VKK STANDARDKESSEL TYPE “CONDOR”

1.01 TECHNICAL SPECIFICATION

Three-pass boiler with dished end plates for the generation of saturated
steam.

Manufacturer : VKK-STANDARDKESSEL
Type : CONDORKESSEL HD 6243

High-pressure steam boiler for the generation of saturated steam according to

the European directives for pressure parts “Druckgeräterichtlinie” DGRL,
PED 97/23/EG, and additionally constructed and calculated according to the
“TRD” (Technical Regulations for Steam Boilers). Designed for chain grate
firings.

The boiler body will be completely electrically welded by proven and acc.
DIN/EN 729-2 qualified welding processes.

All manufacturing and welding processes will be tested and approved by

TÜV (German Technical Supervising Board Controlling), the manufacturing
processes is according to TRD 201. All processes are covered by Quality
Assurance DIN/EN/ISO 9001.

All material will be certificated according to EN 10204.

Pre-qualification and acceptance according to Modul G, including CE-
marking as to EN PED 97/23/EG.

1.02 BOILER SHELL

Cylindrical boiler shell, front and rear end plates executed as dished plates,
symmetrical installed corrugated flame tube as a single furnace, with inside
arranged water-cooled flue gas reversing chamber in wet back design with
the maximum radiant heat transfer from the reversal chamber to the water to
reduce radiation.
 Page 37

SPECIFICATION

The smoke tubes of the second and third flue pass, stay bolts, 3 manholes
with the size 320 x 420, 1 on top, 1 on right side and 1 on left side front
reversing chamber with insulated hinged doors opened by a Henderson roller
hanger for cleaning of the smoke tubes.

Front and rear smoke boxes are fabricated from mild steel plates and fully
welded to the boiler shell and tube plate.

The rear flue gas exhaust chamber is provided with a spy hole at the rear for
observation of the fire with the size of DN 100. A horizontal exhaust gas
outlet for the chimney connection with the size 600 mm x 1000 mm.

1.03 ASH REMOVAL

The ash on the stoker falls into an ash extraction chute at the rear of the grates
where a firebrick wall is constructed to prevent that excessive ash and klinker
will fall into the reversal chamber. The shape of the deashing port is oval with
the size 400 mm x 600 mm. the ash extraction chute passes through the water
portion of the pressure vessel to the submerged ash conveyor.

A second ash extraction of Fly Ash is located at the rear of the boiler to drain
the fly ash automatically via a motorized rotary valve with the size DN 150.

*******
 Page 38

SPECIFICATION

2.0 EURO COAL MAC VALVES AND FITTINGS

- 1 Ari main steam valve connection

- 1 Ari auxiliary main steam valve connection

- 1 Ari feed water valve connection

- 1 Ari air venting valve connection

- 2 Ari safety valves connection

- 1 Manifold pressure controllers

- 2 Igema reflection water level connection

- 1 Gestra level electrode connection

- 1 Gestra level second electrode blind flanged

- 1 Nozzle for conductivity electrode blind flanged

- 1 Desalting valve surface blow down blind flanged

- 1 Gestra blow down valve connection

- 2 Sootblower connection

- 2 Manholes size 305 x 405 mm

- 2 Handholes size 100 x 125 mm

- 3 Top platform brackets for local installation of service platform

( front / center / rear )

- 1 Demister pad preventing water carried over by steam flow

 Page 39

SPECIFICATION

- 1 Ash drop chute oval size 400 mm x 600 mm

- 1 Reversal chamber drop chute for fine ash Ø150 mm

- 2 Support saddles 175 mm as welded structure

- All standpipes height 200 mm

- 4 Lifting lugs on top

- 1 Boiler name plate manufacturer with CE marking with technical datas

- 1 Normal water level indication on pressure part (NWL)

- 1 Fire inspection opening in the rear (spy hole) self closing type with heat
resistant glasses for fire inspection on chaingrate

- 1 Inspection acrylic window under the stoker flap front door

Size : Height 200 mm Width 300 mm built into the lower half circled
front access door (flap mounted on stoker)

- 1 Boiler exhaust gas duct

Dimension inside : width 1000 mm and height 600 mm
Dimension outside : width 1120 mm and height 720 mm

- 1 Rear access door including Refractory

- 1 Coal bed level indicator

- 1 Refractory brickwall half height at the rear of the chaingrate

- 1 Guide rail for the chaingrate welded into the firetube

- 1 Cleaning device include tube brush

- 1 Chaingrate front connection plate

*******
 Page 40

SPECIFICATION

2.0 TECHNICAL DATA EURO COAL MAC

The EURO COAL MAC COAL FIRED STEAM BOILER TYPE “CONDOR
KESSEL HD 6243” is of horizontal three pass wet back design and
constructed in accordance with DIN EN 12.953 part 10, TRD 611 and Vd
TÜV-rules of VKK Standardkessel

Technical Data :

steam output (F & A 100 ºC) : 10,500 kg/hr

steam production (100% MCR) : 10,000 kg/hr
22,046 lb/hr

thermal capacity 5,592,580 kcal/hr

KW output 6,503 kW/hr
Boiler rating 9.809 KW = 1 BHP 663 BHP/hr

working pressure: 9.50 bar

approx. 131 psi

design pressure max. 10.00 bar

approx. 145 psi

test pressure: 18.50 bar

approx. 268 psi

Combustion efficiency 97 – 98 %
Gross thermal efficiency 85 % +/- 2%

exhaust gas temperature 225 °C

heating sqm surface fire side 342.4 m²

heating sqm surface water side 374.4 m²

solid fuel consumption

coal at 5,600 kcals/kg approx. 1,185 kg/hr

feed water temperature 103 °C

*******
 Page 41

SPECIFICATION

3.0 DIMENSIONS & WEIGHTS

3.01 GEOMETRICAL DATA

Total Transport Length 8,720 mm

Total Transport Width 3,630 mm

Total Transport Height 3,775 mm

Boiler Transport Weight excluding chaingrate 29.1 tons

Boiler Transport Weight including chaingrate 36.1 tons

Chain grate transportation weight 7.0 tons

Boiler operating weight NWL 66.6 tons

Boiler operating weight full of water 70.9 tons

Water content at normal water level 30.5 cbm

Steam room 6.5 cbm

Boiler shell outer diameter (uninsulated) 3,400 mm

Boiler shell outer diameter (insulated) 3,600 mm

Boiler shell length 6,840 mm

Boiler length over smoke boxes 7,475 mm

Furnace inside diameter at reversing chamber 1,820 mm

Furnace inside diameter at end plate 1,917 mm

Furnace outside diameter 1,936 mm

Furnace length 5,996 mm

*******
 Page 42

SPECIFICATION

3.02 COMBUSTION DATA

Number of second pass plain tubes 124 pcs

Outside diameter / thickness / length 76.1 x 3.6 – 5996 mm

Number of third pass plain tubes 90 pcs

Outside diameter / thickness / length 76.1 x 3.6 – 6860 mm

Smoke tube heating surface water side 325.2 m2

Smoke tube heating surface fire side 294.4 m2

Furnace heating surface water side 36.5 m2

Furnace heating surface fire side 35.9 m2

Reversing chamber heating surface water side 12.7 m2

Reversing chamber heating surface fire side 12.1 m2

Flue gas volume 29,500 cbm/hr

Coal consumption per hour 1,185 kg/h

Ash produced per hour 100 - 130 kg/h

Exit combustion gas temperature 225 °C

Boiler pressure drop 11.4 mbar

Grit arrestor pressure drop 8.0 mbar

FD air volume 14,775 cbm/hr

FD fan pressure (2500 pascal) 16.5 mbar

ID air volume 29,156 cbm/hr

 Page 43

SPECIFICATION

ID fan pressure (3000 pascal) 17.4 mbar

Chain grate size actual measurement 1652 x 4554 mm

Chain grate size with coal bed 1652 x 3986 mm

Burning area 6.60 m2

Recommended chimney diameter 900 mm

Recommended chimney height 24 m

*********
 Page 44

SPECIFICATION

3.03 BOILER DETAILS

Boiler Shell
Outside diameter 3,400 mm
Length 6,540 mm
Material P295 GH
Thickness 20 mm

Boiler Endplates- front & gear

Outside diameter 3400 mm
Material P295 GH
Thickness 20 mm

Furnace
Type corrugated
Outside diameter 1,936 mm
Length ( total ) 5,996 mm
Material specification P295 GH
Thickness 15 mm

Reversal Chamber
Length ( total ) 650 mm
Outside diameter 2,600 mm
Material specification P295 GH
Shell thickness 16 mm

Flue Pass Convection Tubes 2nd pass 3rd pass

Quantity 124 90 pcs
Outside diameter x Wall thickness 76.1 76.1 x 3.6 mm
Material specification P235 GH

Important remarks:
Material and wall thickness can slightly deviate
During purchase of material a change to thicker wall thickness with same
material quality may occur, as well as changes to thinner wall thickness with
material of higher grate quality.
 Page 45

SPECIFICATION

4.0 EURO COAL MAC – CHAIN GRATE

COMBUSTION AREA 6.60 M2

Size : 1652 x 4554 mm

Combustion area : 6.60 m2

5.01 TECHNICAL DESCRIPTION

The Chaingrate is a compact mechanical combustion grate manufactured as a

rotating chain unit. The Chaingrate is fitted into the fire tube of the boiler
supported by guiding rails which are located at the bottom of the fire tube for
positioning the Chaingrate.

Chaingrates are used in 3 (three) pass fire tube boilers and in furnaces for
thermal oil boilers.

The coal with a uniform sizing of 20 mm, is transported through a coal

storage hopper via the swinging chute to the receiving hopper and is sliding
onto the Chaingrate passing the guillotine door of the hopper.

The hopper incooperates pipe work for spray nozzles to enable the operator
to moisture dry coal prior being fed onto the Chaingrate. The guillotine door
is raised and lowered by means of a hand wheel via a gear reducer to guide
and cut off the coal supply. A coal bed indicator is installed to control the coal
bed depth.

The hopper incooperates a refractory lined cast iron guillotine door which is
supported by cables.

The door incooperates an air channel for an over fire system in the refractory
which allows the air from the FD fan to be sucked over the coal bed to burn
volatile matters for improving the combustion.

A temperature sensor is positioned in the coal feeding area to indicate high

temperature. The measuring point also serves as a warning to possible back
firing of the coal temperature sensor acts as a technical safety device that
triggers water feeding if the readjusted temperature limit is exceeded.

The function of the Chaingrate is to achieve an effective combustion of the

coal and meeting regulations of optimal combustion conditions up to a
complete burn out of coal. The coal together with the combustion air is
 Page 46

SPECIFICATION

entering the coal feeding system at the same time, so that the combustion air
can penetrate the coal layer effectively by drying, degasifying and igniting the
coal.

The primary air has to be guided completely underneath the Chaingrate. To

adjust the air distribution each two pairs of motorized flaps are integrated in
an air box underneath the Chaingrate. The air shutters (in pairs) can be
adjusted independently to each other according to the requirement of the
combustion.

Through the ID fan, the gaseous combustion residues are removed. Ash and
slag are dropped off at the rear of the grate into a water bath and are being
discharged through a submerged ash conveyor.

Coal particles which will fall through the Chaingrate will be taken by the
movement of the Chaingrate to the front side where riddling hoppers collect
the particles.

The Chaingrate having a weight of 7 tons is driven by a 2-stage worm gear

through the stocker drive shaft driven by a motor of 0.25 kW.

5.02 CHAINGRATE FRAME

The Chaingrate consists of two longitudinal guided beams (T profiles), whose

side legs are welded to the bottom base plate. On the top side the stiffness of
the entire frame is achieved by horizontal bracing.

At the left and right front side of the frame, chain guides are installed to
support the feeding hopper and the ignition arch.

On the right hand side of the Chaingrate is a rectangular opening with a

connecting flange to connect the duct of the primary air distribution from the
FD fan.

The air box positioned on the right hand side below the Chaingrate consists of
bended deflector guide plates to achieve a uniform flow of air to the entire
Chaingrate length.

The Chaingrate is equipped with a lifting gear for transport with lifting
equipment.
 Page 47

SPECIFICATION

5.03 COAL FEEDING

From the receiving hopper, the coal is transported through the guillotine door
onto the Chaingrate. The swing chute movements left to right guarantee an
homogenous distribution of coal onto the Chaingrate operated by a rotating
chain for the swing chute drive table. The chain is driven by a gear motor
connected to a 0.37 motor.

The coal is transported through the chain with a controlled coal layer height
to the ignition arch.

The coal cut gate shuts off the coal flow into the ignition arch whenever the
Chaingrate is out of service and is used also used as a shut off security device
in case of possible back fire or a necessary return discharge of the coal.

5.04 FUEL BED CONTROLLER

The fuel bed controller is a welded construction and cladded with refractory.
It serves during operation to adjust the coal layer height on the Chaingrate.
The coal layer height of the fuel can be adjusted by hand wheel via a gear
reducer. The coal layer height is shown on a visible scale outside of the
Chaingrate.

5.05 IGNITION ARCH

The ignition arch in a semi circle casing design is lined with fire resistant
refractory cement. On the side of the ignition arch on the steel, jacket is a spy
hole protected by a closing cap to observe and control the ignition and firing
of the coal during operation. The spy hole cap must always be closed to avoid
false air entering the furnace.

The ignition arch is directly arranged after the fuel bed controller. From the
fire resistant cement the reflected heat is accumulated for drying, degassing
the coal, igniting of the coal volatiles; and to ignite the burning of solid
material. The ignition limit should be adjusted principally 100 mm after the
fuel bed controller.

The full fire develops on the Chaingrate and the complete burn out process
has to be achieved before ash and slag are discharged.
 Page 48

SPECIFICATION

For security reason, use goggles while opening the observation point !!!!!

5.06 CHAINGRATE AND DRIVE SHAFT

The drive shaft is mounted on pillow block bearings. The Plummer block
bearings can be adjusted via setting screws, means the Chaingrate can be
stretched or relieved according to requirement or the movement of the
Chaingrate be corrected.

At the end of the Chaingrate discharge two fixed plain bearings are mounted
for turning off the shaft.

The Chaingrate consists out of various castings, which are assembled to an

endless chain. All links are made out of a high temperature-resistant castings.
The connected bolts are manufactured out of carbon steel.

Every piece and every screw is marked and easy to replace a case of damage.
Three types of links are provided to build up the Chaingrate.

5.07 DRIVE LINKS

Through the drive links, the Chaingrate is pulled by the regulated stoker
drive shaft. The drive links keep the distance of the length of grate.

5.08 COMMON LINKS

The common links of the Chaingrate are used to form the surface of the
Chaingrate and the air nozzles through which the combustion air flows. They
are located between the drive and the common links.

5.09 SIDE LINKS

The side links are forming a flat side surface of the Chaingrate (left and right
side) and secure the side sealing of the Chaingrate and the Carbo-Frax-Blocks.

5.10 LINK RODS

 Page 49

SPECIFICATION

Link rods are used to assemble the Chaingrate and are used at the same time
for disassembly, assembly or replacement of individual damaged links via
pulling out the link rod.

Due to the influence of load, temperature and mechanical strain, the length of
the Chaingrate can change disturbances during operation can result in heavy
running operation or even jamming of the Chaingrate. To avoid this effect,
side guide rails are installed.

During tensioning of the Chaingrate, overstretching must be avoided. To

adjust the drive shaft, the tightening spindles must be turned uniformly on
both sides.

5.11 SIDE SEALING

Carbo-Frax are used to close the gap between chain links, stocker frame and
the fire-tube boiler, avoiding that coal and / or other substances might fall
between chain links and fire-tube boiler.

5.12 FD AIR DUCT

Air duct, blower and motor are included in the scope of our delivery.

5.13 CHAINGRATE DRIVE UNIT

The Chaingrate is equipped with electrical drives. The Chaingrate drive shaft
is driven by a variable speed drive unit (consists of motor with Frequency
Inverter)

Main drive unit of the Chaingrate is manufactured by SEW-Germany

Chaingrate speed
Grate min : 0.8 m/h
Grate max : 6.0 m/h
Motor output : 0.12 KW

Hand driven type of coal gate stop valve and fuel bed controller supplied
with the worm gear unit type H/I, Ratio 50 : 1
 Page 50

SPECIFICATION

6.0 SWINGING COAL CHUTE

Swinging coal chute drive table including worm gear operated by a rotating
chain with a drive of 0.37 kW for even distribution of coal over the width of
the Chain Grate

7.0 1 CFW ID FAN

The Induced Draught Fan (ID Fan) is being used to exhaust the furnace gases
from the combustion air controlled by Dwyer Photohelic to ensure negative
pressure in the boiler.

Technical Data:
Type : AC Variable motor
Flow volume max. : 24,590 m3/hr
Discharge Head max. : 3,000 pascal
Max. temperature gases : 250 ºC
Speed : 1,450 rpm
installed motor power : 45 kW

The whole installation on strong, sturdy robust heavy design, extra heavy
duty pulleys self lubricated with extra strong shaft to prevent any vibrations.

8.0 1 CFW FD FAN

The chaingrate is supplied with an integral mounted Forced Draught Fan
which supplies the air for combustion distributed by the under grate dampers
through the fixed guide vanes. The primary air must pass through the coal
bed without air leaks which will effect combustion and lowering the
efficiency.

The Forced Draught Fan is driven by an AC variable speed motor controlled

by an inverter programmed by PLC and operated under balanced draught
conditions.

Fine adjustments to the fuel bed depth and to the chaingrate speed is done
together by controlling correctly the primary undergrate air. The FD Fans and
the main frame are connected by a suitable duct.
 Page 51

SPECIFICATION

Technical Data :
Type : AC variable motor
Flow volume max. : 15,015 m3/hr
Discharge Head max. : 2,500 pascal
Speed : 1,450 rpm
installed motor power : 11 kW

9.0 2 BOILER FEED PUMPS (ONE AS STANDBY)

Constructed as centrifugal pump mounted on a console, with electric motor,

manometer, valve and including water supply pipings, with electrical
turnover switch Pump 1 / Pump 2 and electrical wiring for each pump, ready
for operation.

The feed pumps are suitable for feed water temperatures of up to 105 grade
C, at suitable gravity height.

Technical Data :
make and type : Grundfos CR 15/10
capacity : 11.6 m3/hr
discharge pressure : 13.2 bar
speed : 2900 rpm
installed motor power : 11 kW
Flange DN

Accessories :
- 1 pressure gauge within pressure line with connecting parts
- 2 stop valves on pressure side DN 50 PN 16
- 2 non return valves on pressure side DN 50 PN 16
- 2 strainers DN 80 PN 16
- 2 butterfly valves DN 80 PN 16
- 1 lot neck flanges, gaskets and screws

9.01 FEED PUMPS PREMOUNTED ON A BASE FRAME

Mounting of two feed water pumps incl. shut off and non return valves on
the steel base frame including charge and discharge pipings (mechanical).
 Page 52

SPECIFICATION

10.0 1 DWYER VACUUM CONTROL TYPE “PHOTOHELIC”

For controlling the negative pressure in the boiler in relation to the amount of
air required for complete combustion.

11.0 1 OVER FIRE AIR SYSTEM

For increasing combustion of volatile matter.

12.0 1 WATER SPRAY

For maintaining moisture in the coal

13.0 AUTOMATIC REVERSING CHAMBER DEASHING

1 Drop Chute Deashing Systems for fly ash at the reversing chamber through
1 Rotary Valve motorized with flange and with 0.37 kW Motor Ø 150.

14.0 1 DEASHING DROP CHUTE

Automatic main deashing drop chute with flange oval type size 400 mm x 600
mm for extracting ash and klinker from the rear of the chaingrate connected
to a water filled wet ash channel.

15.0 FLUE-GAS DUST SEPARATOR PLANT MULTI CYCLONES FOR

AUTOMATIC FLY ASH EXTRACTION INCL. MOTORIZED ASH
ROTARY DISCHARGE VALVE SIZE Ø DN 150 WITH 0.37 KW MOTOR

The dust separating plant reduces the flue gas dust content to approximately
180 - 200 mg/NM3 to the atmosphere depending on coal qualities.

The multi cell cyclones has been designed for removing solid particles in the
gas stream by centrifugal action. Each cell consists of a cylindrical body
having a tangential inlet tube and a conical portion tapering to a hopper. Each
cyclone has a cast integral immersion tube with incombustible coating.
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SPECIFICATION

The particles contained in the gases are subjected to an inward viscous drag
with the larger particles impinging on the cell walls and spiraling to the
collecting hoppers allowing the cleaned flue gas to discharge to the
atmosphere.

The solid particles contained in the collecting hoppers can be removed by the
motorized Ash Rotary Discharge Valve into a drum (container).

16.0 TOOLS
Grate movement handle 1
Driving drift 2
Tube cleaning rod 1
Tube cleaning brushes set
Manhole ring spanner 1

17.0 SUPPORTS, INSULATION, ALU SHEETING, REFRACTORY, AND

PAINTING

17.01 BOILER SUPPORT

As an all welded structure, 2 boiler support saddles designed one as

stationary and one as slide support of the size 175 mm suitable for mounting
an basements on pressure-proof floor.

17.02 JACKING LUGS

Jacking lugs are provided on the boiler saddles to assist in offloading,

positioning and maneuvering the boiler. 2 pcs at the front and 2 pcs at the
rear.

17.03 INSULATION

- boiler body including front and rear wall by rock wool mats
- thickness of shell insulation 100 mm
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SPECIFICATION

17.04 STUCCO ALUMINIUM

- aluminium stucco safety jacket, 1.0 mm thickness

- all sockets and manholes are provided with collars

17.05 CLADDING WITH PLIBRICO

Ignition arch are Guillotine Door with heat resistant high quality refractory
material.

17.06 SHOP PAINTING OF BOILER SHELL

All non-insulated materials are provided with paint. Before painting, the
surface is degreased followed by one layer of heat-resistant anti corrosion
primer with the exception of the insulation jacket.

18.0 COAL SPECIFICATION

Total Moisture Content 10% - 14%, Volatile Matter above 40% - 46%, Ash
content 8% - 10% 5600 kcals and lower based on As Received (AR), coal
sizing 20 mm with fines up to max. 25%, with sizing 1- 5 mm, Sulphur max.
1.2% resulting in optimum combustion, better burn out of coal, increase of
pressure and higher steam output.

19.0 DOCUMENTS
Boiler plates and tubes with works certificates fully electrically computerized
welding, X-rayed and ultrasonic tested according TRD regulations.
Calculations, construction material and wall thickness in accordance with the
German steam boiler code TRD.

Boiler drawings, certificates of material and of the combustion CE marking,

PED of DGRL (97/23 EG Article 3).

Wiring diagrams, acceptance certificates signed by German TÜV (German

Technical Supervising Board).
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SPECIFICATION

Boiler documentations in 2+1 fold consisting of:

- Boiler pressure part - drawing
- Nozzle arrangement - drawing
- Welding details - drawing
- Inspection Certificate of construction
- Pressure testing of all pressure parts
- Material Certificates - Strength Calculation
- Inspection Certificate with test results
- Wiring diagram

All the documentations will be supplied in English language incl. Certificate

of CE-Conformity of the equipment.
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SPECIFICATION

ELECTRICAL LOAD SCHEDULE

10.5 TONS COAL MASTER ELECTRICAL LOADING

SUMMARY MOTOR OUTPUT

1) 1 x I.D. FAN - INVERTER 45.00 KW
2) 1 x F.D. FAN - INVERTER 11.00 KW
3) 1 x CHAINGRATE DRIVE - INVERTER 0.25 KW
4) 1 x FEED PUMP 11.00 KW
5) 2 x ROTARY ASH VALVES @ 0.37 kW 0.74 KW
6) 1 x SWINGING CHUTE 0.37 KW
TOTAL INSTALLED POWER 68.36 KW
OPERATIONAL POWER 28.00 KW
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GENERAL CONDITIONS OF QUOTATION

==================================

Limitation of Supplies:

Our quotation includes all parts and performances as described in the enclosed
specification. Not included in our performances are foundation and building work,
pipe work for sewage, blow-down, blow-off and all other lines, counter-flanges, coal
supply pipes and electric cabling. Steel structures will be painted with one anti-
corrosive prime coat.

Warranty:

We guarantee that output and thermal efficiency rate will be accomplished on the
condition that the firing equipment is apart of our supplies or that the boiler plant
will be set to work and adjusted in the presence of our service personnel.

We guarantee for the quality of material and workmanship for a period of one year
starting from the readiness of the boiler at factory however not longer than 18
months of B/L date whichever date comes first, and replace any parts that are
proved to be defective due to apparent faults of material for workmanship, provided
that the boiler water complies with the conditions as soft water, and that the boiler is
operated and maintained in accordance with our instructions and any defects are
reported to us immediately after their occurrence.

Cost for detachment of personnel to the site is not included in our warranty
performance and will be charged to the customer.

This offer is based on upon General Conditions for Exports.