Item Sr. No. 20 TECHNICAL SPECIFICATIONS FOR … FIRED BOILER5000 (Ite… · high pressure jet...

Item Sr. No. 20

TECHNICAL SPECIFICATIONS FOR SUPPLY, INSTALLATION AND COMMISSIONING OF OIL FIRED BOILER

CAPACITY 5000 KG./HR. Completion period. : 6 months

1.0 FUNCTIONAL REQUIREMENT 1.1 General Description :

The oil fired boiler would be required to generate a dry saturated steam for use in various processes in plant. It would cater to considerable varying steam requirements depending on various processes schedules.

2.0 DESIGN REQUIREMENTS 2.1 Capacity and Working Pressure : Capacity, working pressure and quantity for

the boiler should be as per the details given in clause 8.0. 2.2 Dryness of steam : Dryness of steam shall be 98%. The boiler should be designed for adequate size of barrel having necessary internals, etc. 2.3 Type of Boiler :

The boiler should be IBR, smoke tube type and designed for minimum of 3 pass, wet back arrangement for obtaining higher boiler efficiency.

2.4 Fuel : The boiler should be designed to use Furnace oil of net calorific value as given below : Furnace oil - 9650 Kcal/Kg. 2.5 Thermal efficiency :

The thermal efficiency on NCV basis of oil Without HRU at 100% load is 89% and 88% at 50% load. Any tolerance on efficiency to be specified.

2.6 STATUTORY REQUIREMENTS

The boiler should comply with the latest Indian Boiler Regulations (IBR), International Standards Organization (ISO), PCB and other statutory regulations/requirements. The minimum requirement shall be as per the details furnished hereunder.

H:\SARAS\Tender Form\NIT XXXI Tech. specifications\OIL FIRED BOILER5000 (Item No. 20).doc

The electrical equipments, installation should comply with the latest Indian Electricity Regulations, CEIG and the EB regulations of the state in which the boiler is installed. The boiler should be got approved by the supplier from the statutory authorities and any modifications changes if suggested by the authorities shall be carried out by the supplier without any additional cost. IBR certificate shall have to be obtained by the supplier and handed over to the buyer.

3.0 SCOPE OF SUPPLY 3.1 The complete boiler having steam generating arrangement, casing, burners, pumps, controls, instruments, ducting, chimney and all necessary accessories should be supplied. 3.1.2. The main boiler unit shall have pressure parts consisting of fusion welded

shell, flue tubes, tube plates, tubular passes, end plates, reversing chambers, with all associated accessories. The boiler shall also consist of front and back smoke boxes as per latest designs. The furnace should be designed to have optimum volumetric heat release rate for complete combustion. Flame patterns of burner shall be taken into consideration while arriving at the furnace size, which should conform, to the latest IS and statutory regulations. Rear access door if any shall preferably be of bolted type for easy furnace maintenance.

3.1.3 Insulation : All portions of the Boiler not covered by the Boiler casing, are to

be lagged with glass wool mattress 75mm thick & density 120 Kg./mз retained in position with wire mesh.

The boiler shell is then to be covered by GI cladding of 24 SWG thickness duly pre-treated before painting. The temperature of the outer shell should not be more than 10° C of the ambient temp or 50° C which ever is less.

3.2 Feed Water Pumps : Two feed water multi stage vertical type centrifugal pumps to match the

capacity of the boiler (one for duty and one standby) should be supplied with suitable motors. The pump should be capable of handling water at minimum 95° C temperature and pressure up to 10 % higher than maximum discharge pressure generated by the boiler. The pumps should have SS impellers and mechanical seals. The class of motor insulation and number of stages of the pump should be accordingly selected. The motors of the pumps shall be TEFC squirrel cage type having IP 55 class of protection.

The pumps should be supplied with suction strainer, suction isolating valves,

100 mm dia. pressure gauge on delivery side and feed check valves. Feed water piping (MS 'C' class) from the header of feed water service tank located in boiler house to feed water pump and then to boiler should be supplied and installed by the supplier. The Feed water piping after feed pump shall be IBR


approved. A 100 mm dia. temperature indicating gauge should be provided to measure the temperature of feed water.

3.3 Burner : Fully automatic and step less modulating, monoblock design with electronic

compound regulation with Oxygen trim control & touch screen display and high pressure jet spill return burner comprising a nozzle, ignition transformer with electrode, solenoid valve and necessary instruments should be supplied. Should have provision of Trim control on both the fuel i.e. furnace oil and natural gas. The burner also should have provision for oil return and isolating controller to program burner operation for automatic 'cut in' and 'cut out' operation. The noise level should not exceed 90 DBA at 1mtr. distance. The burner should have provisions for oxygen trim system, nozzle shutoff along with other in-built features. The burner motor shall be of TEFC type and having IP 55 class of protection.

3.4 Forced air draught system : The forced air draught system comprising of suitable capacity blower with

driving motor of suitable application and class of protection. The damper positioning for control of inlet air should normally be automatically through the burner modulating servo controlled motor with clutch assembly. Provision to manually lock the damper in low and high positions must be possible. The motor for blower shall be TEFC and having IP 55 class of protection. The motor should be installed with VFD for Oxygen trim from oxygen analyzer.

3.5 Oil pumps and piping : Two oil pumps for pumping heavy grade furnace oil (one for duty and one

standby) along with self-cleaning type duplex oil filter and change over valves. The pumps should be geared type complete with built in pressure regulating device and suitable electric motor. The motors for oil pump shall be TEFC and having IP 55 class of protection.

All the oil piping (mild steel 'C' class heavy duty) from oil service tank in

boiler house to burner and return oil line should also be supplied and installed. The oil pipe line shall be provided with suitable insulation. The supply, installation and commissioning of heat tracing system for the furnace oil line from oil service tank in mezzanine floor to oil pre-heater of boiler is also required and included in the scope of supply and installation without any additional cost.

For the fuel oil pipe approx. length of less than 6 M, 220 V AC heaters of

minimum capacity 2 kW shall be shall be provided for heat tracing. For the fuel oil pipe length of more than 6 M, 220 V AC heaters of minimum capacity of 3 kW shall be used for the heat tracing.


3.6 Oil Pre-heaters : Pressurized oil pre-heaters operating on steam and electricity should be

supplied. The pre-heaters should have immersion type electrical heater and immersion type steam heater with pressurized oil tank having angular safety valve and strainer. The electrical heater should be switched off once the steam starts flowing through the steam coils.

The electrical heater should be provided with thermostats for controlling the

electrical heater to a desired set temperature. The steam heater should be provided with PRV, thermostatic controllers with by pass arrangement and all accessories to control the temperature of the fuel oil to a desired set point. The steam line shall be taken directly from the boiler incorporating all controls as per regulation. The pre heater should also be provided with temperature and pressure gauges to indicate the fuel oil pressure and temperature.

3.7 Auto Blow down System :

(i) Auto blow down system suitable for IBD (Intermittent blow down), line consisting of isolating valves, control valves, non return valve, SS 316 conductivity sensor for monitoring TDS, output to controller, blow-down control valve, up and down IBR steam piping with bypass line and valve and other accessories with built in auto sensor cleaning system. The system should have built in temperature compensation for conversion from conductivity to TDS.

(ii) Monitor the boiler TDS and activate the auto blow down. Auto sensor

calibration feature should be provided. 3.8 Chimney & Ducting : The chimney for the boiler should be of self supporting type, made out of mild

steel sheets of suitable thickness. The steel plates and sections used in construction of the chimney along with other materials such as rivets, bolts, nuts, washers, gaskets including all consumables like welding rods etc., should conform to the relevant IS-6533. The corrosion allowance for thickness of chimney should be considered for minimum of 20 years life. Detail calculation to be submitted with weight of Chimney.

The chimney height shall be as per the Pollution Control Board's regulation.

The design and construction of the chimney shall be conforming to IS:6533 - Part 1 & 2 - 1989. The height of the chimney indicated at clause No. 9.0 is the minimum requirement and it will be the supplier's responsibility to provide the same as per the PCB regulations. The calculation sheets for design of the


chimney and showing section dimensions and various thickness including that of the base is enclosed in the annexure.

3.8.1 While calculating the load on the chimney the following shall be considered : 1) Dead load considering the weights of the chimney shall and permanent

fixtures such as ladders with protection cage, platforms with railings, baffles, helical strakes, flanges, fasteners and all accessories.

2) The imposed load of minimum 300 Kg./Sq.mt. shall be on the sampling

platform. 3) Wind loads in accordance with the provisions contained in IS 875 (part- 3)

1987. The wind load force on the ladders and other fixtures and accessories fixed to the chimney shall also be determined and added to the force on the chimney.

4) Earthquake loads in accordance to IS 1893:1975. The chimney design and the foundation design for the chimney shall be

determined by considering the maximum forces, effects and stress calculated from combination of any of the following combinations.

a) Dead load + wind load. b) Dead load + earthquake load c) Dead load + load due to the lining + imposed load on service platforms

+ wind load. d) Dead load + load due to the lining + imposed load on service platforms

+ earthquake load. 3.8.2 The chimney should consist of all the accessories and the minimum

requirement. Few of them are as follows: a) Base plate with gussets plate (minimum thickness of 8 mm) and base

stool.

b) Inspection door with minimum size of 500 W x 800 W shall be provided. The door shall have handles and all associated accessories. The cutout made on the chimney should have stiffeners of not less than 50 x 50 x 6 mm angles welded on the periphery of the cutout in the chimney.

c) Access ladder with protection cage :

The ladder should start from 3 meter from the base of the chimney and it should be up to the top of the chimney. The ladder shall be supported from the chimney with structural members of not less than 50 x 50 x 6 mm ISA and the ladder rung should be located at a distance of 250mm from the chimney. The ladder rung should be


made of 20 mm dia rod, the width of the rung should be of minimum 400 mm and the ladder step should be at a frequency of 200 mm C/C.

Safety enclousure or cage shall be provided for the ladder. d) Platform for flue gas sampling and inspection : e) Painter's trolley. f) Conical cowl with cowl stays :

The minimum cowl diameter should be 1.5 times the dia of the top of the chimney section.

g) Twin aviation lights and warning lights. Aviation obstruction light fixture shall be made of aluminum alloy

casing with separate galleries to house two 100 watts GLS on BC type bulb holder. The lamp fixture shall have suitable red domes on the galleries and the lamp fixture shall be of reputed make.

Aviation obstruction light-point should be connected from the lighting

circuit available in the boiler plant room with 3 x 2.5 Sq.mm., PVC sheathed, PVC insulated copper cable. The circuit cable shall be run on the rigid steel conduit, and shall be fixed on the chimney surface with suitable saddles and clamps mounted on the epoxy based insulators.

h) Lightning arrester : The lightning arrester should be of GI with minimum 5 prongs, the

lightening arrester should be connected to the two earth stations. The earthing conductor should be of size should not less than GI 25 X 6mm / or of equivalent size and conductor material as approved by the local statutory authorities. The earthing conductor should be mounted on the epoxy based insulators and not directly fixed to the chimney surface. Two earthing conductor should run parallel from the lightening arrester and each connected to the independent earth stations. The earth stations in turn should be interconnected with one another.

i) Flue gas inlet :

Flue gas ducting shall be provided from the boiler to the chimney, it should be made from MS sheet of thickness not less than 3mm and should be provided with baffle plates. The cutout made on the chimney should have stiffeners of not less than 50 x 50 x 6mm angles welded on the periphery of the cutout. The opening made on the chimney for the flue gas duct should be extended by 200 to 300mm and terminated on counter flanges to facilitate connection of the ducting on the chimney.


j) Helical strakes to reduce wind exited oscillations for the top 2/3rd

height of the chimney.

k) Chimney bottom up to 3 M height should be insulated by 50mm white mineral wool followed by cladding with 3mm MS sheet. The mild steel cladding should be of butt welded construction.

l) All MS parts of the chimney shall be given initial surface treatment

including degreasing, de-rusting etc., then a coat of primer shall be applied. The chimney should be finally painted with two coats of suitable heat resistant paint at site.

m) Foundation bolt of adequate length and diameter shall be provided

alongwith the anchoring channel of section ISMC 150 on the bolt base. Template shall be provided suitable for the foundation bolts for casting the chimney foundation.

3.9 Control Panel : 3.9.1 The complete control panel shall be supplied and installed with all

instruments and components such as sequential controller, push buttons, indicating lights, window annunciator, temperature / pressure controller, digital temperature indicators etc. The control panel should be made from 14 Gauge CRCA sheet duly pretreated and painted. It should also have audio alarming system for all the fault condition, which should appear, visually on annunciator window.

Few of the fault conditions are : a) Flame failure :

Flame failure protection should be provided. However, in case of flame failure and accumulation of fuel oil inside the combustion chamber, the audio, visual alarm should be energized.

b) Fuel oil temperature low :

In case fuel oil temp is low, the audio visual alarm should be energized. The interlock should be provided such that, without proper fuel oil temp boiler can not be started.

c) Electrical heater on : The electrical heaters should maintain the temperature of fuel oil,

whenever starts there should be indication on annunciator. d) Steam pressure more than set value :


If the steam pressure goes above the burner cutoff set pressure value, boiler should be stopped and there should be audio-visual signals.

e) High, low and extra low water level should energies the audio-visual

alarm.

The low and extra levels apart from audio-visual alarm should switch off the burner.

The hooter should stop once it is acknowledged, but the annunciator

should keep light 'ON' till the time fault conditions are attended. f) Following controls also should be provided : - The boiler can not be started till the correct fuel inlet conditions like

temperature, pressure and other parameters are met. - There should be control for start up and shut down purge sequences.

- The control also should be provided for burner ignition and modulating.

- To maintain steady steam pressure steam pressure switches to control

the combustion should be provided. - MCB and contractor should be provided with electrical device of

boiler. 3.9.2 The control panel should have suitable incoming and outgoing feeders.

All contactors, switches, starters, HRC fuses, relays, terminals etc., should be neatly mounted and pre-wired in the panel board terminating in suitably rated terminal blocks/epoxy based insulators. All fuses should be HRC link type. The components of the control panel should also selected as follows:

The main incomer to the control panel shall be of suitably rated, TP, 35

KA, MCCB, with shunt coil. Suitable copper terminal extensions shall be made and fixed on epoxy based insulators if required for terminating the incoming power cable to the control panel.

Ammeter and voltmeters shall be provided with selector switches. Resin

cast CT shall be provided for connecting the ammeter and the voltmeter shall have control fuses.

The outgoing feeders shall be of suitably rated TP&N, 440V, panel

mounting type SDU (Switch Disconnected Fuse Unit). Each outgoing feeder shall be located in separate compartment or each feeder shall be surrounded with one another by hylam / FRP sheet of minimum 3mm thickness.


All contactors shall have rated coil voltage of 240 V AC. Individual isolators, fuses, starters, controls etc., shall be provided for each of the outgoing feeders.

Minimum rating of contractor shall be 16 Amps. For star-delta starters

all contractors shall have same rating.

The wiring within the panel shall be done using copper wires. Minimum section of power wiring shall be 4 Sq.mm and that of control cable shall be 1.5 Sq.mm Indicating ferrules at both cable ends shall be provided. Lugs shall be provided for all power and control cable terminations.

Star-Delta starters shall be provided for the motor ratings above 10 HP.

DOL starters shall be provided for the motor ratings of 10 HP and below. However, for feed water pumps DOL starters may be provided irrespective of pump horse power.

Aluminum armored power cables shall be used for the motors.

Minimum size shall be 4 Sq.mm. All cables shall be sized as per the standard practice and as per approval of client

Aluminum earth bus of 25 x 6mm or equivalent area shall be provided

at the bottom of the panel for connecting the earth grid to the panel at two places.

Makes shall be as per the approved makes : 3.9.3 All starters, fuses, isolator, heater ON/OFF push button indicating lamp

etc. shall be mounted in the panel and the same shall be dust and vermin proof.

3.9.4 Indicators, rotary switches etc. shall be provided on top of the panel and

the same shall be at convenient operating height. 3.9.5 The panel shall be completely pre-wired. The electric supply shall be

415 volts, 50Hz AC. 3.9.6 The panel board shall be installed in boiler house as per approved layout. 3.9.7 Necessary isolators near motors shall be provided as per statutory

requirement. 3.9.8 All feeders above 10 HP to be provided with ammeter with selector

switch. 3.9.9 All field wiring (between control panel and field instruments/controls)

shall be in flexible conduits and shall be heat resistant type.


3.10 Painting : All the exposed MS surfaces and boiler shall be thoroughly cleaned with

sand blasting followed by two coats of heat resistance anti corrosive primer followed by two coats of heat resistance paint as given below :

Item Colour All Valves Oxford Blue Front and rear casings Black Platform Black Sheeting Oxford Blue Burner As per manufacturer's Control panel Siemens Grey Feed pump As per manufactur's standard 3.11 Boiler fitting and accessories : The boiler should have all necessary standard mounting and fittings for

safe and efficient operation of the boiler and in accordance with the latest IBR regulations. The boiler shall have all the components as listed below. It will be the supplier's responsibility to indicate any components not listed in this specification but required as per the statutory regulations. Unless otherwise specified the steam valves shall be flanged (flanges as per BS 10 TAB H). All screwed connections shall be BSP.

It will be the supplier's responsibility to provide any components / items

not appearing in the list, nor additionally listed by the bidder in their offer and the same are found to be required as per the statutory regulations. Supplier shall provide such additional components / items within the scope of the work and no additional cost will be considered for the same. All valve should be piston type and Asbestos free packing.

3.11.1 Spring loaded full lift type safety valve having a total discharge rate

exceeding the maximum steam producing capacity of boiler with exhaust pipe to discharge outside the boiler house. -2 Sets.

3.11.2 Access doors (front and rear) - 2

Nos. 3.11.3 Main steam stop valve with counter flanges - 1

No. 3.11.4 Non return valve for main steam with counter flanges - 1 No. 3.11.5 Blow down valve with counter flanges & necessary handles for

operating the valves and necessary pipes and fittings upto blow down pit which will be located outside the boiler house. - 2 Sets


Note : out of the two blow down connections, one shall be fitted with

manual blow down valve, and the other to the auto blow down arrangement. Both outlets are connected to a common pipe which is taken to the blow down pit.

3.11.6 Steam stop valve with counter flanges for auxiliary steam connection

- 1 No. 3.11.7 Steam pressure gauge of minimum size 200mm dia. with siphon tube

and cock. - 1 Set. 3.11.8 Auxiliary steam connection with cock for fixing test pressure gauge and

for removal of air. - 1 Set. 3.11.9 Water level sight glasses with safety shields and isolating cocks.

2 Sets. 3.11.10 High, low and extra low water level alarms with isolating valve and

drain point (screwed) having a drain pipe up to blow down pit. -2 Sets. 3.11.11 Flame observation port/fire view glass of suitable thickness and design

shall be of rotating type with blue tint colour glass/plain glass and the glasses not be exposed to fire. - 2 Nos.

3.11.12 Access ladder service platform and top walkway platform complete with

railings. - 1 Set. 3.11.13 Rigid MS base frame (for boiler & other eqpt) - 1 Lot. 3.11.14 Fusible plug in the furnace tube - 2 Nos. 3.11.15 Pressostats for automatic operation - 1 Set. 3.11.16 Flue gas temperature indicator (digital type) - 1 No. 3.11.17 Steam pressure switch for combustion controls by interlocking with

burner. 3.11.18 Steam temperature indicator. - 1 No. 3.11.19 Water level controller (heavy duty) Mobrey type. - 2 Sets. 3.11.20 Water flow meter magnetic type, suitable to operate up to 100° C and the

maximum boiler pressure. The flow meter should be connected with flanged type isolating valves & accessories at the discharge side of feed water pumps for measurement of water consumption in the boiler. 1 No.

4.0 ERECTION AND COMMISSIONING :


4.1 Scope of Work The scope of work in brief includes unloading, shifting and positioning

of the boiler on foundation, connecting feed water, oil and drain lines, steam line up to main valves and connection to the existing HP steam header, safety valve vent line outside building, blow down lines up to blow down pit, electrical panel installation, power and control supply, installation and termination of all electrical machines upto electric panel, double earthing of the panel and all the equipment, fabrication of ducting as per layout, positioning of the chimney on foundation and making all necessary connections, completing all other associated works.

4.2 The following items in brief shall be supplied and installed by the

supplier as per the battery limits mentioned at 5.0.

a) The steam pipes (HP/LP, vent lines, steam heating pipes for burner pre-heater with PRV and controls, PRS if included in the scope of the work), water pipes, and oil pipes along with pipe fittings for the above.

b) Safety valves, controls, instruments, gauges (dial type and digital

type), valves, sensors and all associated instruments/gadgets.

c) Insulation of steam line and oil pipe lines as per the battery limits and cladding with 24 Gauge aluminum sheet.

d) Asbestos rope insulation of drain lines and safety lines as per

requirement. e) Heat tracing materials for fuel oil pipe line from furnace oil service

tank to the oil pre-heater of boiler. f) All foundation bolts. g) Cables, wires with all interconnections. Earthing materials and laying

of the earthing conductor (on surface, indoor and outdoor trenches including excavation and back fitting of the outdoor trenches.

h) Supply and installation of earth station, 2 Nos. for lightening arrester

complete with earth electrode and associated accessories as per relevant IS, including excavation for the earth pit, back filling, providing CI chamber and the associated concrete masonry work, of pit etc. complete. The Panel board shall be connected to a third earth pit.

i) Necessary bolts, nuts, fittings, consumables, tools and tackles and

labour for the job.


It will be the supplier's responsibility to execute any works, which are neither furnished in the specification, nor additionally listed by the bidder in their offer and the same are found to be required as per the statutory regulations. Supplier shall execute such works within the scope of the ordered price and no additional cost will be considered for the same.

4.3 The boiler should be transported by the supplier after receiving intimation regarding readiness of the foundation. Boiler should be insured, transported and unloaded on foundation by the supplier.

4.4 All mountings, fittings, accessories etc. should be installed, aligned and

piping, electrical connections etc. should be carried out as per the latest engineering practices.

4.5 Chimney and ducting should be fabricated after getting the drawings

approved from the purchaser and concerned Statutory authorities. 4.6 For commissioning and trail run of the boiler, necessary materials for 1st

charge like lubricating oil, grease, and other chemicals, if any, required for commissioning, shall have to be supplied by the supplier. However, fuel, water, shall be supplied by the purchaser.

4.7 After commissioning the boiler the following parameters are to be

established and recorded by the supplier. * Steam generating capacity * Efficiency of the boiler * Dryness fraction of steam, if available * Fuel consumption * Electricity consumption * Water consumption The supplier shall carry out the efficiency test as per BS 845 Part 1. It

will be the supplier's responsibility, to provide all the necessary efficiency monitoring and any other additional instruments required for establishing the design parameters during testing and till the time the results are achieved and accepted by the Purchaser. Efficiency shall be established by indirect method and output by direct method.

Thereafter, the boiler should be on trial run for minimum two months,

during this period training should be imparted to the authorized operating personnel before handing over the boiler to Project Authority.

4.8 The erection and commissioning should be carried out as per general

terms and conditions of erection contract mentioned in the tender. 4.9 The rates with the quantity breakup for essential spares considering

normal operation of the plant for two years shall be provided in the


tender. These rates shall be valid for at least two years from date of commissioning. The purchaser/end user may place the order for spares any time at a later date as desired within the validity.

It may please be noted that, any spares required during startup and

commissioning and trials of the boiler and all its associated equipment, the same shall be deemed to be included in the quoted price of the steam raising plant and shall have to be supplied by the supplier without any extra cost.

5.0 BATTERY LIMITS : a) Feed water The scope of work of the supplier starts from the existing header of feed

water located within the existing boiler house. b) Fuel gas The scope of work of the supplier is up to outlet of flue gas chimney. c) Steam For main steam output, the scope of work ends on the existing HP

steam line header in the boiler house. This connecting pipe of suitable size shall be drawn from the outlet flange of non-return valve fitted after the outlet valve of the boiler. The steam pipe from safety valve discharge shall be taken outside the boiler house and the steam pipe for heating of fuel in the pre-heaters, burner etc., steam outlet shall be taken up to the respective units. All necessary pipe fittings and accessories, valves, strainers, PRV controls etc., as required shall be provided by the supplier.

d) Blow down The scope of work of supplier is to take the piping from each blow down

connection to the separate blow down pits located outside the boiler house. Existing trench to be used.

e) Drains All drains from water level controllers, gauges, press stats, steam pre-

heater, sample cock, mobrey etc. shall be taken outside the boiler house using the existing trenches.

f) Fuel oil The scope of work of the supplier starts from oil service tank outlet valve

(service tank located within the boiler house) to boiler through oil pre


heater and return line from boiler to oil return header, adequately sized. Necessary steam tracing of these pipelines is to be carried out and is included in the scope of the work. Existing trenches are to be used.

g) Electricals The purchasers/client shall provide incoming electrical connection and

earthing to the supplier's boiler control panel. From control panel all power and control cable distribution shall be done by the supplier. Earthing network from boiler control panel/control panel trench to the various equipment is in the scope of the supplier. Existing trenches are to be used.

h) General All necessary bolts/nuts, templates etc. shall be provided by the supplier.

All indoor trenches have already been provided by the client/purchaser and these shall be used for the oil, water, drain and electrical as described above, but necessary steel supports/cable trays etc. for piping/ducting and cabling etc. are in bidder's scope. The supplier shall visit the existing dairy at Raniwara and familiarize himself with the layout of existing trenches within the boiler house, proposed location of chimney, location of feed water and oil service tanks and also the location proposed for the new boiler. The list of drawings to be prepared by supplier and submitted to purchaser for approval is listed elsewhere in the order. Any foundation/structures at the chosen location shall be removed by the client and new foundations as proposed by the supplier shall be provided.

Exclusions a) Boiler house civil work, all foundations, masonry trenches and blow

down pit. b) Feed water service tank, oil service tank. c) Incoming electrical connections to control Panel. 7.0 This is a complete turn key job for supply, installation, testing and

commissioning of steam raising plant. Any items not mentioned in the specification/scope of the work but are required for completion of the work, the same shall be supplied and installed by the boiler supplier without claiming extra payment.

IBR Certification and Boiler firing certificate : The IBR certification and Boiler firing certificate is in the scope of the

supplier. All test certificates and necessary approvals from Boiler, PCB, Electrical Inspectorate etc., shall also be obtained by the boiler supplier and the same is within the scope of the work, Statutory fees paid shall be


reimbursed to the supplier at actual by the Project Authority/Purchaser based on the production of the acknowledged receipt from the Statutory Authorities. The complete IBR documents shall be submitted in duplicate in two neat folders containing the necessary form II, Form III, form IV, As fabricated pressure part drawings, IBR test certificates of all the mountings and accessories in form IIIC for of mountings and accessories coming under IBR.

The operation and maintenance manual in 3 sets shall be submitted. 8.0 Details of the Boiler :- 8.1 The name of the project ................ DAIRY EXPANSION (a) Capacity Continuous water evaporation at the rate of

5000 Kg./hr F&A 100°C (b) Pressure (Maximum operating) 17.5 Kg./Sq.cm at header (designed for 19

Kg./Sq.cm.) (c) Quantity One no. (d) Turn down ratio (minimum) 1:4/1:5 for Gas. (e) Chimney Height As per statutory regulation and the minimum

height of the chimney from the finished floor level should be 39 M.

(f) Chimney quantity One no. (individual chimney) (g) Type of chimney Self supported and mounted outside the boiler

house. (h) Length of flue gas The length of the ducting would be

approximately 20 Mts. and shall be provided from the boiler up to the chimney.

Technical details of the boiler offered to be provided by the supplier

9.1 Boiler General Details 9.11 Type of boiler Horizontal packaged type Steam

Boiler 9.1.2 Model

9.1.3 Wet back/Dry back Wet back 9.1.4 No. of passes. 3 9.2 Steam Generation : 5000 Kg./hr from and at 100°C

water 9.3 Steam Dryness fraction (%) 98 (Dry saturated) 9.4 Steam Pressure 17.5 Kg./cm² 9.4.1 Safety valve set pressure 18 Kg. cm² for 1st safety valve and

18.5 Kg./cm² for 2nd safety valve. 9.4.2 Modulating pressure control range 9.4.3 Burner cut-off pressure switch setting 9.5.1 Boiler Thermal Efficiency : 9.5.2 Boiler efficiency (%) on NCV at

100% load

9.5.3 Boiler efficiency (%) on NCV of fuel at 75% load


9.5.4 Boiler efficiency (%) on NCV of fuel at 50% load

9.5.5 Efficiency Tolerance limits At 100% load At 75% load At 50% load 9.6 Boiler water Concentration Limits 9.6.1 Hardness as CaCo3 (ppm) 9.6.2 Total dissolved solids (ppm) 9.6.3 Suspended solids (ppm) 9.6.4 1. Alkalinity as CaCo3 (ppm) 2. Caustic Alkalinity as CaCo3 (ppm) 9.6.5 pH value 9.6.6 Free CO2 (ppm) 9.6.7 Dissolved oxygen (ppm) 9.6.8 Silica (ppm) 9.6.9 Phosphates as Na3Po4 (ppm) 9.6.10 Sodium sulphite SO3 (ppm) 9.7.1 Connected Electrical Load : No. KW Total KW 9.7.2 Feed water pump 2

(1W + 1 S) 9.7.3 Fuel oil pump 2

(1W + 1 S) 9.7.4 Electrical heater 1 9.7.5 FD fan 1 9.7.6 Any other equipment Total 9.8.1 Fuel Furnace Oil 9.8.3 Electricity (KWH) 9.8.4 Water (Kg./hr) at 30°C 9.9 Boiler Dimension 9.9.1 Overall dimension of boiler (Mtrs.)

L x B x H

9.9.2 Recommended area of boiler house suitable for the new boiler (LxBxH) M

Note : Detailed drawing showing proposed location of boiler with accessories has to be submitted by supplier.

9.10 Mechanical Details of the Boiler 9.10.1 1. Heating surface area (sq.m)

2. Heat release rate Kw/sqm 3. Heating area per sqmt 4. Max. volumetric heat release rate

Kcl/hr./cum 5. Water content when full.

850000 to 900000 Kcal/hr./cum Min. 15.7 cum.


9.10.2 Tubes Seamless tubes to be used. Yes OD x Thickness (mm) Quantity (nos) 9.10.3 Shell Thickness (mm) Size dia (mtrs) Length (mtrs) 9.10.4 Design code and material of

construction

Design code Designed and constructed in accordance with BS 2790 and complies with the IBR regulations 1950 for material, design and construction

Material of construction Shee, furnace, Reversal chamber and

tube plates SA 515-70/IS 2002 Gr. 2

Furnace Access Tube SA 515-70/IS 2002 Gr. 2 Stya bars IBR 1950 Plain and stay tubes -BS 3059 ERW 320 (for 2nd and

3rd pass fire tube) - BS 3059 ERW 360 (for 2nd and 3rd pass fire tube)

Main door, Hand holes, Mud door, lifting lugs

A - 531 CI-1

Pads (valves) SA 515 - 70/IS 2002 Gr 2 Bosses SA 515 - 70/IS 2002 Gr 2 Standpipes SA - 106 GRB 9.10.5 Water content when full (mз) 9.10.6 Steam space (cu.m) 9.10.7 Water content when at working level

(cu.m)

9.11 Feed Water Arrangement 9.11.1 No. of pumps 2 (1 W + 1 S) 9.11.2 Stand by water pumps 1 9.11.3 Type of pump Multistage vertical centrifugal, 9.11.4 Capacity of each pump 9.6 cum @ 190 MWC head 9.11.5 Water flow meter provided Yes Type & make 9.11.6 Maximum water temp. pump and

meter can withstand Deg. C

9.12 Valves in water feed piping (Piston

type)

9.12.1 Stop valve at pump outlet Yes 9.12.2 Non-return valve at pump outlet Yes 9.12.3 Pressure gauge at pump outlet Yes


9.12.4 Pump suction side isolating valve Yes 9.13 Firing arrangement 9.13.1 Burner 9.13.2 Type Automatic modulating Pressure jet.

The burner should be complete unit prewired and includes FD fan, ducting, air/fuel ratio adjusting with independent Servo Motor damper, fuel-oil pump, Electric oil heater, Pressure and temperature gauges, thermostat, spark ignitor, flame surveillance sensor, fuel atomiser, ignition equipment, windbox and control linkages etc. with ECR and oxygen trim. Suitable for FO / Natural Gas.

9.13.3 Make 9.13.4 Turn down ratio 1:4 / 1:5 9.13.5 Alarm Burner trip on flame failure Yes 9.13.6 Alarm Burner trip on extreme low

water level Yes

9.13.7 Alarm Burner trip on low oil pressure Yes 9.13.8 Alarm Burner trip on high steam

pressure Yes

9.13.9 Alarm Burner trip on flue damper closed

9.13.10 Alarm Burner trip on low air temperature

9.14 Heating and pumping units 9.14.1 No. of fuel pumps 2 (1 W + 1 S) 9.14.2 Standby fuel pumps Yes 9.14.3 Type and Duty Gear type continuous 9.14.4 Capacity of each pump burner block 1400 lph @ 25 Kg. / cm² 9.14.5 Electric pre-heater provided Yes 9.14.6 Steam pre-heater provided Yes 9.14.7 Oil temperature gauge provided Yes 9.14.8 Furnace Oil flow meter provided Yes 9.15 FD fan 9.15.1 Quantity (nos) 1 9.15.2 Type Centrifugal 9.15.3 Capacity of each FD fan 5000 cu.m/hr at 350 mm WC static

head 9.16 Flue Gas Disposal 9.16.1 Flue gas opening size on boiler (mm) 9.16.2 Chimney : Dia. at base of the chimney Dia at top of the chimney Number of chimney sections Dia at base of each section Dia at top of each section


Height of each section Total Height of the chimney Plate thick at each sections As per annexure showing chimney

deflection calculations Self supporting type Yes 9.16.3 Flue gas ducting Size (mm) Length (mtrs) Plate thickness (mm) 9.16.4 Flue gas temp. / Stack temp. (deg.c) at

full capacity

9.16.5 Design calculation and drawing of boiler chimney

Chimney design calculation is enclosed. Detailed chimney drawing is to be submitted for approval

9.17 Automatic Water Level Controls 9.17.1 Single element controller type Yes/No

& Qty Yes.

9.17.2 Mobrey Yes/No & Qty Yes 2 Nos (----------------- make) 9.17.3 Alarm and singal provided for Low level Yes, details as given below High level Yes, details as given below Extra Low level Yes, details as given below 9.17.4 Details of water level controls (2

sets)

One dual water level controller gives the following operational signals for on/off operation of feed water pump, first low water and burner shutdown and restart.

- Pump on - Pump off - First low water alarm and burner

shutdown - First low water alarm off and

burner restart Second independent over-riding

control providing an extra low water system lockout as follows

- Second low water alarm and system lockout

Second low water alarm off requiring manual boiler control reset

9.18 Boiler Mountings and Fittings : Qty Size Make 9.18.1 Steam stop valve (flanged) 01 150 9.18.2 Non-return valve (flanged) 01 150 9.18.3 Safety valve (flanged) 02 150 9.18.4 Feed check valve and stop valves 02 50


(flanged) each 9.18.5 Blow down valve (flanged) 01 50 9.18.6 Airvent valve (flanged) 01 50 9.18.7 Water level gauge 02 25 9.18.8 Steam pressure gauge 01 200 9.18.9 Steam flow meter 01 100 Inspector's test connection 01 9.19 Structural 9.19.1 Provision of platform for boiler Shall be provided with boiler 9.19.2 Provision of ladder for boiler Shall be provided with boiler 9.20 Boiler losses in % on NCV basis Dry stack loss Sensible heat loss Moisture in air loss Radiation loss Unaccounted loss TOTAL LOSS = 9.21 Fuel oil heating system (Heat tracing) Electric Heat Tracing 9.22 Makes of bought out items Enclosed 10.0 MAKES OF BOUGHT OUT ITEMS (Mechanical accessories) S. No. Items Makes 1. Steam Piping 1a. M.S.C Class piping (seamless) ISMT/TI/KALYANI/TATA 1b. Cast Iron globe valves BDK/MH BROTHERS/FORES

MARSHALL/ UNIKLINGER 1c. Bronze globe valves as above 1d. Non-return valves as above 1e. Pressure reducing valves, safety

valves, expansion joints and all other steam line accessories and fittings

SPIRAX MARSHALL/ SEMPELL/ FAINGER LESSER

1f. Pressure & Temperature Gauges FORBES MARSHALL/ EQV. 2. Furnace oil piping / air piping 2a. MS C Class pipes (seamless / ERW as

approved) ISMT / IT / KALYANI/ TATA

2b. Cast steel globe / bronze globe / Gun metal gate valve

BDK/MH BROTHERS/FORES MARSHALL/ UNIKLINGER

2c. Pressure gauges FORBES MARSHALL/ EQV. 3 Water piping 3a. GI 'B' class pipe ISMT / IT / KALYANI/TATA 3b. CI globe valve BDK/MH BROTHERS/FORES

MARSHALL/ UNIKLINGER 3c. Gun metal gate valve BDK/MH BROTHERS/FORES

MARSHALL/ UNIKLINGER 3d. Gun metal globe valves / strainers /

non-return valves BDK/MH BROTHERS/FORES MARSHALL/ UNIKLINGER

3e. Water pump SALMSON (FRANCE)/ GRUNDFOSS/ KSB


4 Insulation materials 4a. Expanded polystyrene NA 4b. Glass/ mineral wool LLOYD / MINWOOL 11.0 MAKES OF BOUGHT OUT ITEMS (Electrical Accessories) S. No. Items Makes 1 Power Cable (LT) FINOLEX / POLYCAB 2 Control Cable (LT) FINOLEX / POLYCAB 3 IP - 55 Boxes for Motor Isolators,

Junction boxes & On/Off stations L&T / AQUILINE / SUVAMA

4 All switch gears including Isolators L&T 5 Push Buttons RISHABH/ EQV. 6 LED Indication Lamps L&T/IEC 7 Cable glands COMET / DOWEL 8 Cable lugs / sockets IEC / SHAKTI / SUVAM 9 Electric Motors KEC/ BB/ NGEF/ ABB 12.0 MAKES OF ITEMS OF BOILER COMPONENTS/ACCESSORIES

S. No. Items Description Approved Makes 1 BURNER (to be got approved) 2 FEED WATER PUMP SALMSON (FRANCE)/

GRUNDFOSS/ KSB 3 FUEL OIL PUMP ENTEES / NEELS / SUNTEC/

PRAKASH 4 WATER FLOW METER 5 AUTO BLOW DOWN SPIRAX MARSHALL 6 IBR STEAM VALVES AND

WATER VALVES BDK/MH BROTHERS/FORES MARSHALL/ UNIKLINGER

7 LEVEL INDICATOR AND LEVEL CONTROLLER

MOBREY/MALHOTRA

8 SAFETY VALVES SPIRAX MARSHALL/ SEMPELL/ FAINGER LESSER

13.0 LIST OF SPARES FOR 2 YEARS OF OPERATION (A) SPARES FOR 8 TPH BOILER

DISCRIPTION QTY TOTAL PRICE (RS.) MANHOLE GASKET 2 MUD HOLE GASLET 2 TUBE CLEANING BRUSH 2 MAGNETY SWITCH FOR WATER LEVEL GAUGE

2

S.S. FLOAT, ROD & MAGNET ASSEMBLY

1

BOILER PRESSURE GAUGE 1 FEED WATER PRESSURE GAUGE 1


FUSIBLE PLUG 2 INSPECTOR TEST GAUGE COCK 1 TOUGHENED GLASS FOR FLAME OBSERVATION

2

ELECTRIC HEATER 1 (B) SPARES FOR BURNER

DISCRIPTION QTY TOTAL PRICE (RS.) PHOTOCELL 1 MECHANICAL OIL SEAL OF FEED PUMP

2

SEAL OF FUEL PUMP 2 DIFFUSER PLATE 2 IGNATION ELECTRODE 2 HEATER GASKET 2 BURNER NOZZLE 2 OIL PRESSUR GAUGES 4 BPR VALVE 1 TOTAL = Rs. Note : The above mentioned spares for 2 years of operation have been indicated by

the bidder. This purchase order does not include the prices for these spares. 14.0 LIST OF DRAWINGS TO BE SUBMITTED WITHIN THREE WEEKS

FORM RECEIPT OF ORDER. 1 GA drawing of boiler showing all components with dimension 2 Layout drawing of boiler house with boiler, accessories, trenches etc. 3 Piping layout drawing for drains, feed water and oil within trenches with

support details of piping overground and on trenches 4 Detailed chimney drawing showing details of all sections, fabrication details,

details of platform and other accessories etc. 5 Ducting layout drawing showing plan and elevation and clearances from

nearest lintels/beams if any of existing boiler house. 6 Control panel drawing showing elevation, plan etc., complete with

component schedule, control wiring diagrams showing both field and panel components, single line diagram for power feeders etc.

7 Foundation drawings for boiler and chimney. Special Note :

1. The net efficiency of the boiler should be minimum 89.15% at 100% load at 75% load, 88.4% at 50% load and 88.2% at 33% load, with fuel NCV as 9650 Kcal/Kg.

2. The heat surface area of the boiler would be 110 Sq.mt. or above. 3. Efficiency is the essence of boiler and efficiency depends on Oxygen and CO

in flue gas. The max. O2 to be maintained in Exhaust gas at high fire should be 2% and CO should be less then 100ppm and these values to be assured.


S. No.

Fuel gas component

Abn Required Guaranteed Parameter

1 Flue gas Oxygen % O2 2% High fire. 3% lower fire

Vendor to specify.

2 Carbon Monoxide CO Less than 100ppm Vendor to specify.

3 Stack temperature Deg. C Max. 245 Deg C Vendor to specify.

4. The Burner should have Oxygen Trimming system, suitable for both fuel i.e. furnace oil and natural gas, with digital combustion with individual Servo motors (full automatic) and with monitoring package for display to take advantabe of enhanced efficiency at part loads. FD fan to have VFD. The display should comprise of 02 level, steam pressure, steam temperature, stack losses, blow down quantity, TDS of shall etc. The monitoring system should be supplied with UPS.

5. The O2 analyzer would be Enotech with a guarantee for five years. 6. Single element control system for the drum level would be provided. 7. The boiler mountings & fittings would be as per under :- S. No.

Boiler Mountings & Fittings

Qty. Size Make

1 Steam stop valve 1 100 NB Spirax/BDK/Audco/Unilinger 2 Non return valve 1 100 NB Spirax/BDK/Audco/ Unilinger 3 Safety valve 2 100 NB Finger Lasser 4 Feed check valve and

stop valves 2 50 NB Spirax/BDK/Audco/ Unilinger

5 Blow down valve 1 50 NB Levcon 6 Air vent valve 1 40 NB Spirax/BDK/Audco/ Unilinger 7 Water level guage 2 25/20 Levcon 8 Steam pressure guage 1 200 mm Gluck/Feibig

The other pipes and fittings for water, steam & fuel will also be provided. 8. Considering the varying steam demand the steam and water space should be as

under:- • Water hold up till NWL. – to be specified by tenderer. • Steam space – to be specified by tenderer.

9. The boiler would be provided with Automatic blow-down control system with temperature compensation.

10. The sensor should be incorporated with the self cleaning probe mechanism. 11. The thickness of shall has to be minimum 22mm and the thickness of front and

rear end plate should be 25mm and IBR approved. 12. The operating pressure of the boiler should be 17.5 Kg./cm.sq. and the design

pressure should be 19Kg./cm.sq. 13. The bidder shall supply boiler with seamless tubes with adequate number of

stay tubes. 14. The prices for the boiler and chimney are to be quoted separately. The price

breakup should include Basic price, Excise duty (if any) CST/RST/Taxes & duties, works contract taxes and (or) any other taxes and duties as applicable


in the State of Rajasthan, Erection & Commissioning charges, Transportation and Insurance etc.

15. The scope includes supply, installation, testing and commissioning of new steam generation system & hooking up the same to the existing steam generation system.

16. Tenderer should submit the required technical information as per tender format only.

17. Three earth pit should be required one for chimney, second for control panel and third for instrumentation.

18. The tenderer must have supplied, tested, erected & commissioned at least 5 boilers of such capacity and photocopy of performance certificate from the clients towards the satisfactory performance of the equipment must accompany the technical part of the bid.

19. The tenderer must attach minimum 5 efficiency trial reports duly signed by user of the boiler at different location with O2, excess air, CO and Stack temp. reading at High/med. And low firing of the boiler. These reading should be in line with guaranteed parameters.

20. The bidder should provide minimum 5 references for the successful application of burner trim control system and single element drum level control.

21. On line efficiency monitoring system should be guaranteed for minimum three years, in case of failure free replacement should be provided.

22. On line efficiency monitoring system should provided to demonstrate the following data and also equipped with remote PC communication and should have facility to monitor remotely through web. The minimum data to be provided by such system should be :

a. Real time data display : Oxygen, Stack temp., Steam flow rate, Oil flow rate, water flowrate, Blowdown flowrate and totalized flows of same.

b. Trends – of each parameters and efficiency parameters. c. Patterns d. Diagnostics e. Safety and efficiency Alarms, maintenance schedule information and

alarms. f. Reports – hourly, Shift-wise, daily, monthly and yearly detailed or

summery report. 23. The supplier should provide the following instruments at their cost for

establishing capacity and efficiency of the boilers during trial runs:-

(i) Water meter - Vortex type density compensated. (ii) Steam flow meter - Vortex type density compensated. (iii) Fuel oil meter (iv) CO2 analyzer (v) O2 analyzer

RCDF shall have the option to retain these instruments and supplier needs to quote for these separately for each boiler. 24. Water flow meter and O2 analyzer are in the scope of supply.


25. All tools and tackles required for execution of the work on turn key basis shall be in the bideer’s scope. Any item which is not included in the scope of supply but required for completion and to meet the functional requirements and norms to be complied with the statutory authority shall be without any extra cost.

26. Training : The boiler to be operated for 3 months in presence of bidders representative before hand-over. The raining should be a part during this time covering operation, maintenance, dos and don’ts efficiency and trend monitoring and control. A mock trial should be conducted for all the safety aspects of the boiler.

27. All statutory approvals will have to be obtained by the bidder. However, statutory fee shall be reimbursed by purchaser.


Item Sr. No. 20 TECHNICAL SPECIFICATIONS FOR … FIRED BOILER5000 (Ite… · high pressure jet...

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Transcript of Item Sr. No. 20 TECHNICAL SPECIFICATIONS FOR … FIRED BOILER5000 (Ite… · high pressure jet...