Section A - Design Specification - Final

Section A INDEX EID PARRY (INDIA) LTD.
1. Design Specifications of Steam Generator ............................................................1

2 Design Code ..........................................................................................................1
3 Material Specifications – Pressure Parts ...............................................................2
4 Heat Transfer Area ................................................................................................3
5 Fuel .......................................................................................................................3
6 Fuel Analysis (% By Wt.) ......................................................................................4
6.1 Ultimate Analysis ................................................................................................. 4
6.2 Fuel Size ............................................................................................................. 4
7 Bed Material ..........................................................................................................4
7.1 Bed Material Specifications - Crushed Refractory .................................................... 5
7.2 Sieve Analysis of Bed Material (For Regular Make Up) ............................................. 5
8 Continuous Blowdown ..........................................................................................5
9 Feed Water Recommended Quality .......................................................................6
10 Boiler Blowdown Water Recommended Quality....................................................6
11 Utilities..................................................................................................................7
11.1 Electrical Power ................................................................................................... 7
11.2 Cooling Water ..................................................................................................... 7
11.3 Instrument Air ..................................................................................................... 7
11.4 Service Air........................................................................................................... 8
12 Chemicals for Dosing ............................................................................................8
13 Fans.......................................................................................................................9
14 Boiler Feed Water Pump .....................................................................................10
15 Transfer Pump.....................................................................................................11
16 Screw Pump for Spent Wash ...............................................................................11
17 HP & LP Dozing Pumps........................................................................................12
18 Screw Feeders.....................................................................................................13
18.1 Capacity Chart....................................................................................................13
19 Rotary Air Lock Valve (RAV)................................................................................13
19.1 Capacity Chart....................................................................................................14
20 Gauge Glass ........................................................................................................14
20.1 Drum Level Gauge Glass .....................................................................................14
20.2 Deaerator & Condensate Tank Gauge Glass ..........................................................14
21 Deaerator ............................................................................................................15
22 Safety Valves.......................................................................................................15
23 Relief Valves........................................................................................................15
I
THERMAX LIMITED Project: EID PARRY (INDIA) LIMITED
B&H Group, PUNE, INDIA SIVAGANGA
PROJECT No.: PJ 0041
Number & Type of Boiler : 1 no. Spent wash fired AFBC boiler,
Single Drum, Overbed Fuel Feeding
System, Bottom Supported, Three
Pass, Bed Plate Design.
1. Design Specifications of Steam Generator
PARAMETERS UNIT VALUE

Steam Generation at Main Steam Stop Valve
TPH 22.0
Outlet
Steam Pressure at Main Steam Stop Valve
Kg/cm2(g) 44.0
Outlet
Steam Temperature at the Main Steam Stop 0
C 380 + 5
valve at MCR
Feed Water Temperature at Drum Coil 0
C 135
Heater Inlet
Spent Wash Concentration % of Solid 55
GCV of Spent Wash for Given Concentration Kcal / Kg 1705
Approximate Quantity of support Coal
Kg/hr 2250
Required*
GCV of Coal Kcal / Kg 3800
Start up Fuel - Char Coal mixed with Diesel
Boiler Performance Testing Procedure ASME PTC 4 – 1964
* - The Quantity May Vary According To the Spent Wash Quantity / Concentration
2 Design Code
Pressure Parts : As per IBR 1950with latest amendments
Section A PAGE 1
3 Material Specifications – Pressure Parts
DETAILS SIZE IN MM MATERIAL

DESCRIPTION
Shell 1375 I.D. X 40 THK
Steam Drum Dished End ( Tori SA 516 Gr.70
1375 I.D. X 40 THK
Spherical)
88.9 O.D X 5.49 THK.
114.3 O.D X 6.02 THK
Pipes SA 106 Gr. B
219.1 O.D X 8.18 THK
168.3 O.D X 7.11 THK
Riser
150NB X SCH 40
Elbows 200 NB X SCH 40 SA 234 Gr. WPB
80 NB X SCH 40
100 NB X SCH 40
Top Header 200 NB x SCH 120 SA 106 Gr. B
Bottom Header 200 NB x SCH 160 SA 106 Gr. B
RH Panel
(Pass – 1, 2 & 3) Panel Tubes 50.8 O.D X 4.06 THK SA 210 Gr. A1
Bend Tubes 50.8 O.D X 4.06 THK SA 210 Gr. A1
LH Panel
(Pass – 1, 2 & 3) Panel Tubes 50.8 O.D X 4.06 THK SA 210 Gr. A1
Top Header 219.1 O.D X SCH 120 SA 106 Gr. B
Front Panel
Panel Tubes 63.5 O.D X 4.06 THK SA 210 Gr. A1
Rear Panel
Opening Tubes 63.5 O.D X 4.06 THK SA 210 Gr. A1
Roof Panel Panel Tubes 50.8 O.D X 4.06 THK SA 210 Gr. A1
(Pass – 3)
Intermediate Top Header 200 NB x SCH 120 SA 106 Gr. B
Panel
Section A PAGE 2
DETAILS SIZE IN MM MATERIAL

DESCRIPTION
Top Header 88.9 O.D X 7.62 THK SA 106 Gr. B
Evaporator Tube Bottom Header 76.2 O.D X 5 THK SA 210 Gr. A1
219.1 O.D X 8.18 THK
DC 1 & DC 2 (Pipe) 168.3 O.D X 7.11 THK SA 106 Gr B
88.9 O.D X 7.62 THK
88.9 O.D X 5.49 THK
RDC Tee 200NB X 150 NB X SCH 40 SA 234 Gr. WPB
80 NB X SCH 40
Elbow 150 NB X SCH 40 SA 234 Gr. WPB
Down Comers
200 NB X SCH 40
DC 3 & DC 4 (Pipe) 88.9 O.D X 5.49 THK SA 106 Gr B
219.1 O.D X 8.18 THK
For Screen &
38.1 OD X 3.66 THK SA 210 Gr A1
Evaporator
Elbow 200 NB X SCH 40 SA 234 Gr.WPB

80 NB X SCH 40
Super Heaters
Coils 38.1 O.D x3.66 THK SA 210 Gr A1
(SH – 1 & 2 )
PSH I/L header 114.3 O.D x 13.49 THK SA 106 Gr B
Super Heater PSH O/L header 114.3 O.D x 13.49 THK SA 106 Gr B
(PSH & SSH) SSH I/L header 114.3 O.D x 13.49 THK SA 106 Gr B
SSH O/L header 114.3 O.D x 13.49 THK SA 106 Gr B
Attemperator Header 219.1 X 18.26THK SA 106 Gr B
Economizer Tube 38.1 O.D x 3.66 THK SA 210 Gr A1
4 Heat Transfer Area
ZONE UNIT VALUE

Total Heat Transfer Area Sq. Mtr 2600
5 Fuel
Main Fuel : Spent Wash (SPW), Coal
Start up : Char Coal mixed with Diesel
Section A PAGE 3
6 Fuel Analysis (% By Wt.)

6.1 Ultimate Analysis
COMPOSITION UNIT SPENT WASH COAL ( % BY WT)
Carbon % Wt 20.38 39.9
Hydrogen % Wt 1.97 2.48

Oxygen % Wt 13.30 6.76
Sulphur % Wt 0.56 0.38
Nitrogen % Wt 1.70 0.67
Moisture % Wt 45 10.0
Mineral Matter % Wt 17.11 39.81
Calorific Value (GCV) Kcal/kg 1705 3800
6.2 Fuel Size

Coal:
100 % : < 8 mm
30 % (Max.) : < 3 mm
10% : < 1 mm
Spent Wash:
Concentration : 55 %
7 Bed Material
Required Per start up : 15 Metric Tonnes (Approx.)
Size distribution : 0.84 mm to 2.36 mm (100 %)
For regular makeup
Note:
Bed material size which 100% pass through ASTM Sieve No 10 Commercial Mesh No 12
sq./sq. inch i.e below (2 mm) and retained above ASTM Seive no 24 ( Commercial Mesh
No 24 Squares / Sq. inch) shall be used during cold start-up.
Section A PAGE 4
7.1 Bed Material Specifications - Crushed Refractory

CHEMICAL COMPOSITION PERCENTAGE LIMITS
SIO2 55-60
AL2O3 37-40 , Min 30% required
FEO <2.0
TIO2 1.67
MNO Traces
CAO 0.54
MGO 0.23
P2O5 0.08
NA2O + K2O < 3.0
BULK DENSITY 1100 kg/m3
7.2 Sieve Analysis of Bed Material (For Regular Make Up)

MESH SIZE ( MICRONS ) PERCENTAGE ( PASSING THROUGH )
2360 100
2000 90-95
1190 60-70
840 50-60
600 40-50
420 25-30
297 15-25
Fusion Temperature : > 1300 °C

Shape : Sub Angular / Sperical
8 Continuous Blowdown
Max : 3 % / Hr
Normal : 1 % / Hr
Section A PAGE 5
9 Feed Water Recommended Quality

General Appearance Clear & Colorless
Total Hardness as CaCO3 PPM Commercial Zero
Total Fe PPM 0.02
Total Cu PPM 0.01
Dissolved O2 PPM 0.007
Oil & Organic. PPM Nil
PH Value at 25 Deg C 8.5 – 9.5
Total dissolved Solids PPM <0.1
Silica as SIO2 PPM 0.02
10 Boiler Blowdown Water Recommended Quality

PH at 25 deg C - 9.5- 11.0
Phosphates PO4 PPM < 45
Oil & Organic PPM Nil
Total Dissolved Solids PPM < 2000
Silica as SiO2 PPM <6
Section A PAGE 6
11 Utilities
11.1 Electrical Power
PARAMETERS UNITS VALUE
FOR LT Drives
Voltage V 415 +/- 10%
Frequency Hz 50 +/- 5%
Type AC, 3 Phase, 4 WIRE
FOR INSTRUMENTS
Voltage V 240
Frequency Hz 50
Type Single Phase,2 Wire
FOR FIELD TRANSMITTERS
Voltage V 24
Frequency Hz NA
Type DC
11.2 Cooling Water

Supply Pressure Kg/cm2(g) 4.0
Supply/Return Temperature Deg C 23/33
Quality Soft & Chlorine free
11.3 Instrument Air

Flow SCFM 7
2
Pressure Kg/cm (g) 7.0
Dew point Deg C - 40
Temperature Deg C Ambient
Section A PAGE 7
11.4 Service Air

Pressure Kg/cm2(g) 7.0
Temperature Deg C Ambient
Quality Dry & Oil Free
Duty General purpose
12 Chemicals for Dosing

HP Dosing Tri sodium phosphate
LP Dosing Sodium Sulphite / hydrazine
Section A PAGE 8
13 Fans
FD FAN ID FAN SA FAN
DUTY
UNIT (TEST BLOCK (TEST BLOCK (TEST BLOCK
CONDITIONS
CONDITION) CONDITION) CONDITION)
Make TLT TLT TLT
TYPE 3166 B / 548 2248 B / 872 32572 B / 416
Quantity Nos. 1 1 1
Nature of medium Clean Air Flue Gas Clean Air
Capacity M3/sec 9.39 25.6 4.13
Air/Gas Temperature
Deg C 35 200 35
at Fan Inlet
Absorbed Power /
KW 149 111 39
Rated Fan Power
Fan Speed Rpm 1480 980 1480
Static Pressure Pa 11772 3432 6867
22218 EK/C3 22218 EK/C3 22211 EK/C3

Fixed Bearing/HSG.
SNH-518 SNH-518 SNH-511
22211 EK/C3 22211 EK/C3 22209 EK/C3 SNH-
Free Bearing/HSG.
SNH-511 SNH-511 509
Bearing Lubrication Grease:Servogem-2 Grease:Servogem-2 Grease:Servogem-2
180 KW/ 1492rpm/ 160 KW/ 980rpm/ 55 KW/ 1480rpm/

Motor F/S:355L / F/S:355L / F/S:250M /
Siemens Make Siemens Make Siemens Make
Make: WELLMAN / Make: WELLMAN / Make: WELLMAN /
GBM GBM GBM
Coupling Type : 212A /111 Z Type : 236A/113 Z Type : 158A/109 Z
Resilient Resilient Resilient
(Grid Spring) (Grid Spring) (Grid Spring)
Section A PAGE 9
14 Boiler Feed Water Pump

DESCRIPTION UNITS PARAMETERS
Make Sulzer
Pump Type Ring section centrifugal multistage pump
Model MC 50/11
Quantity 2
Liquid Boiler Feed Water
Temperature Deg C 135
Specific Gravity 0.9305
NPSH Available (Recommended) M 8
Shut off head M 704
3
Rated Flow M /hr 30
Differential Head M 620
Rated Pump speed Rpm 2980
Direction of Rotation CW seen from Coupling End
Bearing Lubrication Ring Oil
Shaft Seal : Type & Size Mechanical Seal/BSTFN
Coupling Flexible spacer type
Siemens,110KW,2980 RPM,
Motor
FRAME:315M
Please refer SULZER vendor operation instruction & maintenance manual for detailed
description of pump.
Section A PAGE 10
15 Transfer Pump
Make Sulzer
Pump Type & Size Centrifugal pump
Model CZ 40 - 315
Quantity 2
Liquid Condensate from process
Temperature Deg C 40
Specific Gravity 1.0
NPSH Available (Recommended) M Above 3.7
Shut off head M 113
Rated Flow M3/hr 27.8
Differential Head M 105
Rated Pump speed Rpm 2980
Bearing Lubrication Oil
Shaft Seal : Type & Size Single Seal/BSTXN (Non API)
Coupling Flexible / Alum
Motor Siemens,30KW,2950 RPM, FRAME:200L
Please refer SULZER vendor operation instruction & maintenance manual for detailed
description of pump.
16 Screw Pump for Spent Wash

Make Tushaco
Pump Type / Quantity T1S-200.1 / 2
Liquid Waste Liquid
Speed rpm 315
Capacity M3/hr 7.78
Pressure Kg/cm2 3.5
Viscosity cP 180
Motor Siemens,3HP,1450 RPM, TEFC
Coupling Lovejoy
Section A PAGE 11
17 HP & LP DOZING PUMPS
DESCRIPTION HP Dosing LP Dosing

Make Metapow Industries Metapow Industries
Drawing No. A – 874 Rev. 2 A – 875 Rev. 2
Capacity 150 LTR 150 LTR
Fluid to be handled Diluted Tri Sodium Diluted Hydrazine Solution
Phosphate solution.
Relief valve set pressure 53 kg/cm2 (g) 5.5 kg/cm2 (g)
PUMPS
Make Metachem Metachem
Model MC – 1 MC – 1
Type Reciprocating Plunger Reciprocating Plunger
Flow 0– 6 LPH by Stroke 0-6 LPH By Stroke
Adjustment Adjustment
Discharge pressure 42 kg/cm2 (g) 4.3 kg/cm2 (g)
MOTOR FOR DOSING PUMPS
Make CGL CGL
0.5HP, 1500 RPM, 3 Ph, AC, 0.5HP, 1500 RPM, 3 Ph, AC,
Type / Rating
415 + 10%V, 50 + 5% Hz 415 + 10%V, 50 + 5% Hz
Sr. No M – 652, 653 M – 552A,553A
MOTOR FOR AGITATOR
Make CGL CGL
0.5HP, 750 RPM, 3 Ph, AC, 0.5HP, 750 RPM, 3 Ph, AC,
Type / Rating
415 + 10%V, 50 + 5% Hz 415 + 10%V, 50 + 5% Hz
Please refer vendor operation instruction & maintenance manual for detailed
description of dosing system.
Section A PAGE 12
18 Screw Feeders
DESCRIPTION DETAILS
Make ACCURATE MATERIAL HANDLERS (P) Ltd.
Drawing No. AHMPL / 05 / 08 – 09 Rev. 2
Capacity See Table Below
Material to be Handled Coal
Type Horizontal
Motor Siemens, 3 HP , 4 pole – AD/ND/100L
Gear Box Inline helical reducer Type,

Size : ACF45L, Ratio : 44.807 : 1
Coupling For Motor to Gear Box Pin Bush BC – 2A, Fenner
Screw Trough Loading 95%
Drive Side Bearing Foot Mounted ( UCF 212) NTN Make
Seal Bearing Flange Mounted ( UCF 212) NTN Make
18.1 Capacity Chart

BULK CAPACITY RPM REQD AT
FUEL CONDITION
DENSITY REQD(Kg/Hr) CAP
Design 1553 15.32
Maximum 1350 13.31
Coal 800
Normal 675 6.7
Minimum 338 3.35
19 Rotary Air Lock Valve (RAV)

DESCRIPTION ROTARY FEEDER
Make Rosmic India
Drawing No. 909001RI51
Capacity See Table Below
Material Handled Hot ash from Spent wash and Indian Coal
Material Size 98.67 % < 1000 Micron
Rotor Speed 20 rpm
Motor Rating 1 HP / 20 RPM
Design Temperature 700 Deg. C
Chain & Sprockets (Transmission & Driven ) ¾ “ pitch, Simplex
Section A PAGE 13
19.1 Capacity Chart

BULK DENSITY (Kg/M3)
CAPACITY
FEEDER FOR POWER /MECH. DESIGN CAPACITY
(Kg/Hr)
TYPE CALCULATION
Normal 1350
RAV 800
Design 6813
20 Gauge Glass
20.1 Drum Level Gauge Glass

DESCRIPTION DETAILS
Make CHEMTROLS SAMIL (I) PVT. Ltd.
Tag No. LI – 301 & LI – 302
Type Transparent Level Gauge
Location Steam Drum
Operating / Design pressure 44 / 54 kg/cm2 (g)
Operating / Design Temperature 257 / 269 Deg. C
Hydrotest pressure 88 Kg/cm2
C/C Distance 800 mm
Visibility 620 mm
20.2 Deaerator & Condensate Tank Gauge Glass

DESCRIPTION DEAERATOR CONDENSATE TANK
Make CHEMTROLS SAMIL (I) PVT. Ltd.
Tag No. LG 101A/B LG 301
Type Reflex Level Gauge
Quantity 2 Nos. 1 Nos.
Operating / Design Pressure 2.2 / 3. 3 kg/cm2 (g) ATM / 2.2 kg/cm2 (g)
Operating / Design Temperature 135 / 150 Deg C 45 / 60 Deg C
Hydrotest pressure 5 kg/cm2 (g) 4 kg/cm2 (g)
C/C Distance 1000 mm 1000 mm
Visible Length 910 mm 820mm
Section A PAGE 14
21 Deaerator
PARAMETER UNITS VALUE
Drawing No. W21-2PJ-43748 Rev. 1
Design & Construction As per IBR
Max. working Pressure / Design Pressure Kg/cm2 3.3
Operating Pressure Kg/cm2 2.2
Hydraulic Test Pressure (At Site) Kg/cm2 4.95
Design / Operating Temperature Deg C 185 / 135
Deaeration Capacity M3/Hr 275
Storage Capacity NWL to LWL M3 10
No. of Trays 2
No. of Sprays 5
22 Safety Valves
DESCRIPTION UNIT DRUM LHS DRUM RHS SH HEADER
Type Spring Loaded /Flanged
Make Tyco Sanmar Ltd
Orifice Size 1.5 – H2 – 3.0
Set Pressure Kg/cm2 (g) 54 55 48
Tag No PSV 301 PSV 302 PSV 401
Model HCI-R-46W– IBR – SPL
Capacity Rated/Reqd Kg/hr 16608/8800 16910/8800 12878/5500
Quantity 1 / BLR 1 / BLR 1 / BLR
23 Relief Valves
DEAERATOR VAPOUR STEAM TO
DESCRIPTION UNIT
TANK DEARATOR
Set Pressure kg/cm2(g) 3.0 3.3
Tag No. PSV 101 PSV 102
Orifice Size 1.5 – H – 3.0
Model JOS-H-E-15-C-IBR-SPL
Section A PAGE 15

Section A - Design Specification - Final

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Section A - Design Specification - Final

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Section A INDEX EID PARRY (INDIA) LTD.

1. Design Specifications of Steam Generator ............................................................1

PARAMETERS UNIT VALUE

3 Material Specifications – Pressure Parts

DETAILS SIZE IN MM MATERIAL

DETAILS SIZE IN MM MATERIAL

Elbow 200 NB X SCH 40 SA 234 Gr.WPB

4 Heat Transfer Area

ZONE UNIT VALUE

6 Fuel Analysis (% By Wt.)

Hydrogen % Wt 1.97 2.48

6.2 Fuel Size

7.1 Bed Material Specifications - Crushed Refractory

7.2 Sieve Analysis of Bed Material (For Regular Make Up)

Fusion Temperature : > 1300 °C

9 Feed Water Recommended Quality

10 Boiler Blowdown Water Recommended Quality

11.2 Cooling Water

11.3 Instrument Air

11.4 Service Air

12 Chemicals for Dosing

22218 EK/C3 22218 EK/C3 22211 EK/C3

180 KW/ 1492rpm/ 160 KW/ 980rpm/ 55 KW/ 1480rpm/

14 Boiler Feed Water Pump

16 Screw Pump for Spent Wash

17 HP & LP DOZING PUMPS

DESCRIPTION HP Dosing LP Dosing

Gear Box Inline helical reducer Type,

18.1 Capacity Chart

19 Rotary Air Lock Valve (RAV)

19.1 Capacity Chart

20.1 Drum Level Gauge Glass

20.2 Deaerator & Condensate Tank Gauge Glass

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