Vous êtes sur la page 1sur 2881

INDEX

VOLUME DESCRIPTION VOLUME DESCRIPTION


BOILER Pages Pages
1 (a) Boiler Operation and Maintenance  PLANT AUXILIARIES
PLANT AUXILIARIES Compressor 137
3 (a)
BFP 56 Cooling tower 94
Deaerator 25 PLANT CONTROL AND INSTRUMENTATION
ARC Valve 16 Control valves and positioner 275
4 (a)
DM tank 12 Transformer 26
2 (a) Dosing pump 17 PLANT CONTROL AND INSTRUMENTATION
Butterfly valves 9 Electromagnetic flow meter 24
Safety valves 6 Flow Elements 33
Sample coolers 33 Gauges 3
WTP  PLC 37
4 (b)
PLANT AUXILIARIES Pressure Switch 1
Silencer 13 RTD and thermocouple 77
HP and LP valves 16 UPS 117
Level Gauge 6 RF type level switch 17
RAVs 16 PLANT CONTROL & INSTRUMENTATION
Slide gates 5 4 (c) Transmitters 347
2 (b)
Manual Hoist 44
Fire Fighting System 14 PLANT CONTROL & INSTRUMENTATION
AC and Ventilation system 38 4 (d) VFD drives-1 
EOT cranes 31 4 (d) VFD drives-2 
Rapping mechanism 12 PLANT ELECTRICAL SYSTEM
PLANT AUXILIARIES 5 (a) HT switchgear 4
2 (c) Miscellaneous pumps 3 PLANT ELECTRICAL SYSTEM
PLANT AUXILIARIES 5 (b) LT switch gear 32
2 (d) Hot gas generator and auxiliaries -1 73 Battery charger 7
5 (c)
2 (d) Hot gas generator and auxiliaries -2  CGL Motor 16
BOILER OPERATION
AND
MAINTENANCE MANUAL
CONTENTS

SECTION DESCRIPTION PAGE NO.

A Overall Plant Description

1 Plant Introduction

2 Site Specific Design Data

3 Mechanical Equipment Description Summary

4 Electrical Equipment Description Summary

5 Control and Instrumentation Equipment Description Summary

6 Anticipated Performance Data Sheet

7 Control Philosophy

B Plant Startup and Shutdown Procedure

C Construction Features

D Recommended Water Quality

E Boiler and Auxiliary Control and Protection Concept

F Maintenance Practices

G( Boiler Preservation

H) Commissioning Procedure

* Lubrication Schedule

J+ Attachment

1 Boiler GA

2 Boiler P&ID
A.OVERALL PLANT DESCRIPTION
A.1 PLANT INTRODUCTION
In ever growing industrialization of developed and developing nations, electric power generation through Waste heat
Recovery boilers have played very important role over more than two decades now. Waste Heat Gases from Cement Plant
are being utilized for steam generation. Utilization of Waste heat gases from the Cement Plant contributes to Green
Power as this reduces the use of the Natural Resources and it contributes to save the earth and the reduce the growing
Pollution in the industries due to emission of SOx, NOx etc. This aspect has been attracting more and more attention of
governments as well as people and the main focus is now on generation of steam with environmentally friendly system of
firing in boilers, without the use of natural resources.
In Cement manufacturing (dry process), nearly 40% of the total input heat is rejected as the waste heat from the exit
gases of the pre-heater (PH) and Air quenching clinker cooler (AQC). This waste heat has various applications within the
cement plant such as drying of Raw materials/Fuel, preheating the combustion air to Kiln etc. Even after utilizing the heat
for above application, there is still waste heat available in the PH & AQC circuit which can be effectively utilized for power
generation.
Considering the potential of waste heat available from the exhaust gases of pre-heater & from the hot air available from
cooler vent, M/s Parasakti Cement Industries Ltd have installed a Waste Heat Recovery (WHR) based captive power plant
in their existing cement plant at Jetipalam Distt Guntur AP. And as there is no CPP within the premises of Plant, HAG
option have been added in the AQC Boiler heat input to get some additional power benefit.

"WHR Boiler" offers valuable solution to reduce ill effects of pollution. Salient advantages of this system are:
a) Effective utilization of the Waste Heat Gases from Cement plant.
b) Contribution to Green Power.
c) No Use of Natural Resources for Power Generation.
d) Increase in Life and efficiency of the pollution control equipment’s in Cement Plant.

The WHR boilers are user friendly and needs only the control of the Dampers for diversion of the gases into the steam
generators.

The advantages of WHR boiler are such as:


¾ Simple and reliable arrangement.
¾ Easy in Operation.
¾ Low Operating cost.
¾ No Fuel required
¾ Low Generation Cost
¾ Low Maintenance required
A.2 SITE SPECIFIC DESIGN DATA (PH & AQC)

2 No x WHRB Natural Recirculation, Water Tube, Single drum, Vertical Orientation with bottom Entry for AQC & Vertical
Orientation with top entry in case of PH.

Waste Heat Recovery Boiler on Cement Plant


UNIT VALUE
PARAMETERS
Total Boiler’s Rating [MCR] (PH & AQC) HP Steam Kg/hr 29200
HP Steam Pressure @ Super heater – 2 Outlet (AQC Boiler) Kg/cm²(g) 14.5
HP Steam Temperature @ Super heater -2 Outlet (AQC Boiler) °C 390±5
AQC Boiler LP steam quantity Kg/hr 1800
LP Steam Pressure @ LP Super heater Outlet (AQC Boiler) Kg/cm²(g) 2.5
LP Steam Temperature @ LP Super heater Outlet (AQC Boiler) °C 195
PH Boiler LP steam quantity Kg/hr 3200
LP Steam Pressure @ LP Super heater Outlet (PH Boiler) Kg/cm²(g) 2.5
LP Steam Temperature @ LP Super heater Outlet (AQC Boiler) °C 195

Design Code
Boiler Pressure Parts IBR

Boiler Piping ASME B31.1 approved by IBR

Flue Gas Data (For PH Boiler)


PARAMETERS UNITS VALUE

Flue gas flow Nm³/Hr 1,62,925


Inlet Temperature Deg C 320
Outlet Temperature Deg C 180 ± 5
Flue gas inlet pressure at Tapping point mmWC -590
Flue Gas Composition :-
CO2 % Volume 30.5
H2 O % Volume 0.8
N2 % Volume 64.7
O2 % Volume 4
Dust Loading gm/Nm3 103
Flue Gas Temperature Profile (PH- Boiler)

Sr. Component Deg C.


Boiler inlet 320
1
2 HP Super heater Outlet 308
3 HP Evaporator outlet 212
4 LP Super heater Outlet 200
5 LP Evaporator Outlet 180 + 5

Flue Gas Data (For AQC- Boiler)

PARAMETERS UNITS VALUE

Flue gas flow (Cooler Exhaust) Nm³/Hr 1,42,000

Flue Gas Temperature ( Cooler Exhaust) Deg C 305

Flue Gas Flow ( HAG Outlet) Nm³/Hr 1,53,200

AQC Boiler Inlet Temperature °C Deg C 440


Outlet Temperature °C Deg C 90 ± 5

Flue gas pressure at Tapping point (Cooler Exhaust) mmWC -20

Flue gas pressure at HAG Inlet (Deduster Outlet) mmWC -35

Flue gas pressure at AQC Boiler Inlet (HAG Outlet) mmWC -55

Flue Gas Composition :-


H2 O % Vol 0.00
N2 % Vol 79.00
O2 % Vol 21.00
Dust Loading gm/Nm3 30
Flue Gas Temperature Profile (AQC-Boiler)
Sr. Component Deg C

1 Boiler inlet 440

2 HP Super heater 2 Outlet 400


3 HP Super heater 1 Outlet 373
4 HP Evaporator outlet 212
5 LP Super heater outlet 211
6 Economizer outlet 171
7 LP Evaporator Outlet 151
8 Condensate Pre-heater outlet 90 ± 5

Flue gas Pressure profile


Sr. Component AQC PH
mmWc mmWc
1 Flue gas Pressure at Tapping point -20 -590

2 Flue gas Pressure at outlet Tapping -170 - 670

3 Pressure drop across I/L & O/L Tapping 150 80

Water & Steam Temperature profile for AQC & PH Boiler


Sr. Component Units AQC PH
1 Inlet of Condensate Pre-heater Deg C 48 Not Applicable
2 Outlet of Condensate Pre-heater Deg C 118 Not Applicable
3 Inlet of Economizer Deg C 126 Not Applicable
4 Outlet of Economizer Deg C 193 Not Applicable
5 HP Drum Temp Deg C 193 193
6 Inlet of Primary Super heater HP Deg C 201 201
7 Outlet of Primary Super heater HP Deg C 340 300
8 HP Steam Temperature at Mixing Header Deg C 320
9 Inlet of Final HP Super heater Deg C 320 Not Applicable
10 Outlet of Final HP Super heater Deg C 390 Not Applicable
11 LP Drum Temp Deg C 127 127
12 LP Super heater Outlet Temp Deg C 195 195
Water & Steam Pressure profile

Sr. Component (Pressure) AQC Boiler PH Boiler


Kg/cm² (g) Kg/cm² (g)

1 Inlet of Condensate Pre heater 5.0 Not Applicable


2 Outlet of Condensate Pre-heater 3.0 Not Applicable

3 Deaerator Operating Pressure 1.44

4 Economizer outlet 19 Not Applicable

5 HP Steam drum operating pressure


6 HP Super heater I inlet
7 HP Super heater I outlet 15.4 15.5
8 Mixing Header 15.5
9 HP Super heater II inlet 15.5 Not Applicable
10 HP Super heater II outlet (MSSV) 14.5 Not Applicable
11 LP Steam Drum Operating pressure
12 LP Super heater Inlet pressure
13 LP Super heater Outlet pressure 2.5 2.5
Electrical power
PARAMETERS UNITS VALUE
For LT motors (UPTO AND INCLUDING 200 KW)
Voltage V 415±10%
Frequency Hz 50+5%
For HT motors (above 200 KW)
Voltage V 11000
Frequency Hz 50
For Instrumentation (field switches, Level gauge illumination, solenoid valves etc.)
Voltage V 230±10%
Frequency Hz 50+%
For Control Instruments
Voltage V 110±10%

COOLING WATER FOR BOILER AUXILIARIES


PARAMETERS UNIT VALUE
Pressure Kg/cm²(g) 4
Temperature Deg C 42°C Max, 33°CMin
Quality Raw water

INSTRUMENT AIR
PARAMETERS UNIT VALUE
Pressure Kg/cm²(g) 6-7
Dew point Deg c -20
Quality — As per ISO 8573-1

CHEMICALS FOR DOSING


HP Dosing at Steam Drum (LP & HP Both) Tri Sodium Phosphate
DETAIL SPECIFICATION OF PRESSURE PARTS AND EQUIPMENTS FOR AQC BOILER

HP STEAM DRUM
S. No DESCRIPTION UNITS VALUE
1 Design code --- IBR 1950 with latest amendments
2 Design pressure kg/cm²(g) 17
3 Design temperature Deg C 208
4 Hydro test pressure kg/cm²(g) 25.5
5 Length mm 5000
6 Inner diameter mm 1200
7 Thickness mm 18
8 Type of Dished End --- Tori spherical
9 Thickness of Dished end mm 18
10 Material of construction --- SA 516 Gr. 70
11 Quantity --- One
12 Corrosion allowance --- IBR 1950 with latest amendments

13 Internals --- Demister Pad & Baffles


14 Quantity of safety valves --- 2

LP STEAM DRUM
S. No DESCRIPTION UNITS VALUE
1 Design code --- IBR 1950 with latest amendments
2 Design pressure kg/cm²(g) 5
3 Design temperature Deg C 158
4 Hydro test pressure kg/cm²(g) 7.5
5 Length mm 4000
6 Inner diameter mm 1200
7 Thickness mm 8
8 Type of Dished End --- Tori spherical
9 Thickness of Dished end mm 8
10 Material of construction --- SA 516 Gr. 70
11 Quantity --- One
12 Corrosion allowance --- IBR 1950 with latest amendments

13 Internals --- Demister Pad & Baffles


14 Quantity of safety valves --- 2
HP PRIMARY SUPER HEATER
S. No DESCRIPTION UNITS VALUE
1 Design code --- IBR 1950 with latest amendments
2 Design pressure kg/cm²(g) 17
3 Hydro test pressure kg/cm²(g) 25.5
4 Design temperature Deg C 369
5 Tube Type --- FINNED
6 Total Heat transfer area (Thermal) m² 119 – TUBES , 1017- FINS
7 Type configuration --- INLINE
8 Tube outer diameter mm 44.5
9 Tube thickness mm 3.25
10 No. of Tubes (Wide x Deep) --- 42 X 4
12 Effective Tube Length mm 8000
13 MOC of tubes --- SA 210 GR A1
14 MOC of headers --- SA 106 GR B
15 Type of Fin --- SPIRAL
16 Fin Dimensions (Height x Thk x Fins per m) mm x mm 12.7 X 1.3 X 156

HP FINAL SUPERHEATER
S. No DESCRIPTION UNITS VALUE
1 Design code --- IBR 1950 with latest amendments
2 Design pressure kg/cm²(g) 17
3 Hydro test pressure kg/cm²(g) 25.5
4 Design temperature Deg C 414
5 Tube Type --- FINNED
6 Total Heat transfer area (Thermal) m² 398 – TUBES , 2009- FINS
7 Type configuration --- INLINE
8 Tube outer diameter mm 44.5
9 Tube thickness mm 3.25
10 No. of Tubes (Wide x Deep) --- 42 X 4
12 Effective Tube Length mm 7900
13 MOC of tubes --- SA 210 GR A1
14 MOC of headers --- SA 106 GR B
15 Type of Fin --- SPIRAL
16 Fin Dimensions (Height x Thk x Fins per m) mm x mm 12.7 X 1.3 X 156

HP EVAPORATOR
S. No DESCRIPTION UNITS VALUE
1 Design code --- IBR 1950 with latest amendments
2 Design pressure kg/cm²(g) 17
3 Hydro test pressure kg/cm²(g) 25.5
4 Design temperature Deg C 236
5 Tube Type --- FINNED
6 Total Heat transfer area (Thermal) m² 1108 – TUBE, 5102- FIN
7 Type configuration --- STAGGERED
8 Tube outer diameter mm 50.8
9 Tube thickness mm STRAIGHT TUBES- 3.25, BENDS – 3.6
10 No. of Tubes (Wide x Deep) per Module --- 38 X 4
12 No. of Modules --- 2
133 Effective Tube Length mm 8000
14 MOC of tubes --- SA 210 GR A1
15 MOC of headers --- SA 106 GR B
16 Type of Fin --- SPIRAL
17 Fin Dimensions (Height x Thk x Fins per m) mm x mm 12.7 X 1.3 X 156

ECONOMIZER
S. No DESCRIPTION UNITS VALUE
1 Design code --- IBR 1950 with latest amendments
2 Design pressure kg/cm²(g) 32.5
3 Hydro test pressure kg/cm²(g) 48.8
4 Design temperature Deg C 267
5 Tube Type --- FINNED
6 Total Heat transfer area (Thermal) m² 541 – TUBES, 3045- FINS
7 Type configuration --- STAGGERED
8 Tube outer diameter mm 31.8
9 Tube thickness mm 3.25
10 No. of Tubes (Wide x Deep) per Module --- 46 X 7

12 No. of Modules --- 2


133 Effective Tube Length mm 8000
14 MOC of tubes ---
15 MOC of headers --- SA 106 GR B
16 Type of Fin --- SPIRAL
17 Fin Dimensions (Height x Thick x Fins per m) mm x mm 12.7 X 1.3 X 156

CONDENSATE PREHEATER
S. No DESCRIPTION UNITS VALUE
1 Design code --- IBR 1950 WITH LATEST AMENDMENTS
2 Design pressure kg/cm²(g) 17
3 Hydro test pressure kg/cm²(g) 25.5
4 Design temperature Deg C 236
5 Tube Type --- FINNED
6 Total Heat transfer area (Thermal) m² 775 – TUBES , 4350 FINS
7 Type configuration --- STAGGRED
8 Tube outer diameter mm 31.8
9 Tube thickness mm 3.25
10 No. of Tubes (Wide x Deep) per Module --- 46 X 10
12 No. of Modules --- 2
133 Effective Tube Length mm 8000
14 MOC of tubes --- SA 210 GR A1
15 MOC of headers --- SA 106 GR B
16 Type of Fin --- SPIRAL
17 Fin Dimensions (Height x Thick x Fins per m) mm x mm 12.7 X 1.3 X 156

LP EVAPORATOR
S. No DESCRIPTION UNITS VALUE
1 Design code --- IBR 1950 with latest amendments
2 Design pressure kg/cm²(g) 5
3 Hydro test pressure kg/cm²(g) 7.5
4 Design temperature Deg C 186
5 Tube Type --- FINNED
6 Total Heat transfer area (Thermal) m² 428 – TUBES ,2040- FINS
7 Type configuration --- STAGGERED
8 Tube outer diameter mm 50.8
9 Tube thickness mm 3.25
10 No. of Tubes (Wide x Deep) per Module --- 38 X 2
12 No. of Modules --- 2
133 Effective Tube Length mm 8000
14 MOC of tubes --- SA 210 GR A1
15 MOC of headers --- SA 106 GR B
16 Type of Fin --- SPIRAL
17 Fin Dimensions (Height x Thick x Fins per m) mm x mm 12.7 X 1.3 X 156

LP SUPERHEATER
S. No DESCRIPTION UNITS VALUE
1 Design code --- IBR 1950 with latest amendments

2 Design pressure kg/cm²(g) 5


3 Hydro test pressure kg/cm²(g) 7.5
4 Design temperature Deg C 219
5 Tube Type --- FINNED
6 Total Heat transfer area (Thermal) m² 41 – TUBES ,109- FINS
7 Type configuration --- STAGGERED
8 Tube outer diameter mm 31.8
9 Tube thickness mm 3.25
10 No. of Tubes (Wide x Deep) per Module --- 46 X 1
12 No. of Modules --- 1
133 Effective Tube Length mm 8000
14 MOC of tubes --- SA 210 GR A1
15 MOC of headers --- SA 106 GR B
16 Type of Fin --- SPIRAL
17 Fin Dimensions (Height x thk x Fins per m) mm x mm 12.7 X 1.3 X78

Safety Valves
DESCRIPTION
UNITS HP DRUM HP DRUM HP SH 1 OUTLET HP SH 2 OUTLET
/APPLICATION

Type --- Spring loaded Spring loaded Spring loaded Spring loaded

Make --- Fainger Lesser Fainger Lesser Fainger Lesser Fainger Lesser
Medium --- Saturated Steam Saturated Steam Superheated Steam Superheated Steam

WHRS-AQC2HP- WHRS-AQC2HP- WHRS-AQC2HP- WHRS-AQC2HP-


Tag No. -
MAS-SV-001 MAS-SV-002 MAS-SV-004 MAS-SV-003

Working Pressure Kg/cm² 15.3 15.3 15.1 14.5

SET PRESSURE Kg/cm² 18 19 17.5 17

Relieving Capacity TPH 7.62 8.02 3.9 36.47

QUANTITY --- One One One One

DESCRIPTION UNITS LP DRUM LP DRUM LP SH OUTLET ECO

Type --- Spring loaded Spring loaded Spring loaded Spring Loaded

Make --- Fainger Lesser Fainger Lesser Fainger Lesser Fainger Lesser

Medium --- Saturated Steam Saturated Steam Superheated Steam Feed Water

WHRS-AQC2LP- WHRS-AQC2LP- WHRS-AQC2LP- WHRS-AQC2HP-


Tag No. -
MAS-SV-001 MAS-SV-002 MAS-SV-003 FDW-SV-001
Working Pressure Kg/cm² 2.5 2.5 2.45 23

SET PRESSURE Kg/cm² 4 5 3.5 32

Relieving Capacity TPH 0.72 0.93 0.66 34.6

QUANTITY --- One One One One

LEVEL INDICATOR FOR STEAM DRUM


S. No DESCRIPTION UNITS DETAILS
1 Make --- V Automat & Inst. Ltd
2 Type --- Transparent Level gauge
3 Location --- Steam Drum
4 Operating pressure.(HP/LP) kg/cm²(g) 15.5 / 2.5
5 Design Pressure (HP/LP) kg/cm²(g) 19 / 5
6 C/C distance (HP/LP) mm 686 / 686
7 Operating temp. (HP/LP) Deg C 202 / 138
8 Design temp (HP/LP) Deg C 215 / 160
BLOW DOWN TANK
S. No DESCRIPTION DETAILS
1 Design code IBR 1950 with latest amendments
2 Design pressure 1.5 kg/cm²(g)
3 Design Metal Temperature 128 Deg C
4 Hydro test pressure 2.25 kg/cm²(g)
5 Shell Height 2000 mm
6 Shell ID 1200 mm
7 Shell thickness 8 mm
8 Type of ends TORISPHERICAL
9 Material of construction SA 516 GR 70
10 Type of Level gauge

LEVEL GAUGE FOR BLOW DOWN TANK


S. No DESCRIPTION UNITS DETAILS
1 Make --- V Automat & Inst. Ltd
2 Type --- Tubular Type
3 Location --- Blow-down Tank
4 Operating pressure. kg/cm²(g) Atmospheric
5 Design Pressure kg/cm²(g) 1.5
6 Hydro test pressure kg/cm²(g) 2.25
7 C/C distance mm 1000
8 Operating temp. Deg C 100
9 Design temp Deg C 150

HP DOSING SYSTEM
S. No DESCRIPTION UNITS DETAILS
1 Make -- Flow Control Pumps & Systems

2 Major parts --- Storage tank – 1 no (Common for AQC HP &


LP), Stirrer – 1 no., Dosing pumps – 2 nos.
Storage tank Details
1 Size of storage tank mm x mm x mm Dia.750 X 890 H X 3thk
2 Tank capacity liters 300
3 MOC of tank --- MSRL
Dosing pump Details
1 Pump make/Model --- FLOW CONTROL MAKE FCP 5011

2 Pump capacity lph 0-5


3 Pump discharge Pressure kg/cm²(g) 30
4 Pump type --- Positive Displacement

Agitator details
1 Type of operation --- Slow Speed Motorized AGI, Propeller Type
Motor details
1 Motor for Pump --- 0.5 hp/1440 rpm/415V/50Hz
2 Motor for Agitator --- 0.5 hp/ 1440 rpm/415V/50Hz

INSULATION & Al. CLADDING


S. No DESCRIPTION VALUE
1 Type LRB Mineral Wool

2 Density 100-150 kg/m³

3 AL Cladding 20 SWG

DETAIL SPECIFICATION OF PR. PARTS AND EQUIPMENTS FOR PH BOILER

1. STEAM DRUM
S. No DESCRIPTION UNITS VALUE
1 Design code --- IBR 1950 with latest amendments
2 Design pressure kg/cm²(g) 17
3 Design temperature Deg C 208
4 Hydro test pressure kg/cm²(g) 25.5
5 Length mm 5000
6 Inner diameter mm 1300
7 Thickness mm 18
8 Type of Dished End --- Tori spherical
9 Thickness of Dished end mm 18
10 Material of construction --- SA 516 Gr. 70
11 Quantity --- One
12 Corrosion allowance --- IBR 1950 with latest amendments
13 Internals --- Demister Pad & Baffles
14 Quantity of safety valves --- 2

2. SUPER HEATER
S. No DESCRIPTION UNITS VALUE
1 Design code --- IBR 1950 with latest amendments
2 Design pressure kg/cm²(g) 17
3 Hydro test pressure kg/cm²(g) 25.5
4 Design temperature Deg C 317
5 Tube Type --- Bare
6 Total Heat transfer area (Thermal) m² 921
7 Type configuration --- Inline
8 Tube outer diameter mm 38.1
9 Tube thickness mm 3.25
10 No. of Tubes (Wide x Deep) --- 58 x 6
12 Effective Tube Length mm 10700
13 MOC of tubes --- SA 210 GR A1
14 MOC of headers --- SA 106 GR B

3. EVAPORATOR
S. No DESCRIPTION UNITS VALUE
1 Design code --- IBR 1950 with latest amendments
2 Design pressure kg/cm²(g) 17
3 Hydro test pressure kg/cm²(g) 25.5
4 Design temperature Deg C 236
5 Tube Type --- Bare
6 Total Heat transfer area (Thermal) m² 8428
7 Type configuration --- Inline
8 Tube outer diameter mm 50.8
9 Tube thickness mm 3.25
10 No. of Tubes(Wide x Deep) for Module 1 to 4 --- 58 x 4
113 Effective Tube Length mm 10700
12 MOC of tubes --- SA 210 GR A1
13 MOC of headers --- SA 106 GR B

4. SAFETY VALVES
DESCRIPTION
UNITS HP DRUM HP DRUM HP SH 1 OUTLET
/APPLICATION
Type --- Spring loaded Spring loaded Spring loaded

Make --- Fainger Lesser Fainger Lesser Fainger Lesser

Medium --- Saturated Steam Saturated Steam Superheated Steam

Tag No. - WHRS-PH2HP-SV-001 WHRS-PH2HP-SV-002 WHRS-PH2HP-SV-003


Working Pressure Kg/cm² 15.9 15.9 15.7

SET PRESSURE Kg/cm² 18 19 17.5

Relieving Capacity TPH 7.62 8.0 2.56

QUANTITY --- One One One

5. LEVEL INDICATOR FOR STEAM DRUM


S. No DESCRIPTION UNITS DETAILS
1 Make --- V Automat & Inst. Ltd

2 Type --- Transparent Level gauge


3 Location --- Steam Drum
4 Operating pressure. kg/cm²(g)
5 Design Pressure kg/cm²(g)
7 C/C distance mm
8 Operating temp. Deg C
9 Design temp Deg C

6. BLOW DOWN TANK


S. No DESCRIPTION VALUE
1 Design code IBR 1950 with latest amendments
2 Design pressure 1.5 kg/cm²(g)
3 Design Metal Temperature 135 Deg C
4 Hydro test pressure 2.25 kg/cm²(g)
5 Shell Height 2000 mm
6 Shell ID 1200 mm
7 Shell thickness 8 mm
8 Type of ends Tori spherical
9 Material of construction SA 516 GR 70
10 Type of Level gauge Transparent Type

7. LEVEL GAUGE FOR BLOW DOWN TANK


S. No DESCRIPTION UNITS DETAILS
1 Make --- V Automat & Inst. Ltd

2 Type --- Tubular Type


3 Location --- PH Blow down tank
4 Operating pressure. kg/cm²(g) Atmospheric
5 Design Pressure kg/cm²(g) 1.5
7 C/C distance mm 1000
8 Operating temp. Deg C 100
9 Design temp Deg C 150
8. HP DOSING SYSTEM
S. No DESCRIPTION UNITS DETAILS
1 Make -- Flow Control Make

2 Major parts --- Storage tank – 1 no (Common for AQC HP &


LP), Stirrer – 1 no., Dosing pumps – 2 nos.
Storage tank Details
1 Size of storage tank mm x mm x mm Dia.750 X 890 H X 3thk
2 Tank capacity liters 300
3 MOC of tank --- MSRL
Dosing pump Details
1 Pump make/Model --- FLOW CONTROL MAKE FCP 5011

2 Pump capacity LPH 0-5


3 Pump discharge Pressure kg/cm²(g) 30
4 Pump type --- Positive Displacement
Agitator details
1 Type of operation --- Slow Speed Motorized AGI, Propeller Type
Motor details
1 Motor for Pump --- 0.5 hp/1440 rpm/415V/50Hz
2 Motor for Agitator --- 0.5 hp/ 1440 rpm/415V/50Hz

9. Insulation
Sr. Description Value
1 Type LRB Mineral Wool

2 Density 100-150 kg/m³

3 Al. Cladding 20 SWG

Mechanical Equipment Description Summary


Technical data sheet:

A. Chain Conveyor – AQC Boiler

Location AQC BOILER


Quantity 05
Make TURBOVENT
Design Capacity 10 TPH
Width Single Strand DCC 250 X 500mm
Conveying speed 0.1077 m/sec
Control
Bulk Density (Clinker Dust) 1.1 T/m3
Input Coupling
Gear Box Geared Motor -1.1Kw 19rpm

A. Screw Conveyor – PH Boiler

Location PH BOILER
Quantity 01
Make TURBOVENT
Design Capacity 20 TPH
Width U-trough, horizontal, 450mm Dia
Conveying speed 26 rpm
Control
Bulk Density (Raw meal Dust) 0.85 T/m3
Input Coupling
Gear Box Geared Motor -3.7Kw 26 rpm

B. Boiler HP feed pump


Make KSB Pumps
Quantity 02 (01 W + 01 S)
Rated Flow 41.3 m3/hr
Rated differential head 290 m
Feed water temperature 126 Deg C
Bearing lubrication Antifriction Bearing & Plain Bearing
Coupling type Gear Type Spacer Coupling
Flow Control

C. Make-Up Water Deaerator & FW Storage Tank

Make EAS
Quantity One
Deaeration Capacity 38.8 TPH
Storage tank volume 8 m3
Storage tank usable volume (NWL to LLWL) 6.3 m3
Design pressure 3.5 kg/cm2 (g) & full vacuum
Design temperature 200 Deg C
D. DM water storage tank

Make Rostfrei Steels


Quantity one
Capacity 100m3
Storage tank volume 109.40 KL
Storage tank usable volume (NWL to LLWL) 87 KL
Design pressure Atmospheric
Design temperature Ambient

G. Silencer – Details & drawings enclosed

H. Boiler anticipated parameters –Enclosed

I. Rotary airlock valves - Drawings

J. Schedule of Valves (Format Attached below) – enclosed

Class
S.N. Valve Tag No. Type Size NB Opn. End. Conn. Body mtl. Qty. per Boiler
Rating

K. Schedule of electrical equipment (Format attached below) – enclosed load list


Motor Motor Voltage
Qty Operatio
Equipment Rating speed level Feeder Type Remark
n
W S (KW) (rpm) Volt

L. Hot gas generator data sheet. – enclosed

M. RAVs. – Details Enclosed

N. Cooling Water Make up pump


Make Mather & Platt - WIlo
Quantity 02 Nos (1W + 1S) TYPE – Vertical
Rated Flow 60 m3/hr
Rated differential head 65 m
Feed water temperature Ambient
Bearing lubrication Anti friction bearings
Coupling type Pin & Bush Coupling

O. Raw water transfer pump


Make Kirloskar Brothers Ltd
Quantity 02 (1 W + 1S)
Rated Flow 6.5m3/hr
Rated differential head 55m WC
Feed water temperature Ambient
Bearing lubrication
Coupling type

P. Fire hydrant pumps


Make Mather & Platt (WILO)
Quantity 01 No’s Main Electric driven Pump / 01 No’s Jockey Pump / 01 No’s Diesel Engine driven pump
Rated Flow Main & Diesel driven – 171 m3/hr Jockey Pump – 10.8 m3/hr
Rated differential head Main & Diesel driven – 88m, Jockey Pump – 88m
Feed water temperature 32 Deg C
Bearing lubrication
Coupling type Spacer Type Coupling

Q.DM Transfer pumps


Make Wilo – Vertical Pump
Quantity 02 No. (1W + 1S)
Rated Flow 4 m3/hr
Rated differential head 35m
Feed water temperature 10 Deg C
Bearing lubrication Anti Friction Bearings
Coupling type

R. Cooling Tower. Details Enclosed


S.ACW Pumps
Make Mather & Platt – Wilo Brand
Quantity 02 No’s (1 W + 1S)
Rated Flow 200 m3/hr
Rated differential head 45 m
Feed water temperature 32 Deg C
Bearing lubrication Antifriction Bearings
Coupling type Spacer type coupling

T. MCW Pumps
Make Mather & Platt
Quantity 02 No.s (1W + 1S)
Rated Flow 2310 m3/hr
Rated differential head 30 m
Feed water temperature 32 Deg C
Bearing lubrication Anti Friction bearings
Coupling type Flexible Pin Bush type coupling

U.CT fans – Enclosed with cooling tower details

V. Side stream filter – Capacity 125m3/hr

A.3 CONTROL PHILOSOPHY

Instrumentation and control philosophy of WHR boiler incorporates control loops, which are mostly common with other
conventional boiler control systems. Broadly total scheme can be split into:

1. Boiler Protection
2. Boiler Interlock
3. Auto Control

BOILER PROTECTION

During cold or hot startup of the boiler as also normal operation of the unit, certain parameters e.g. drum level; final steam
temperature, Flue Gas temperature etc. are monitored on continuous basis and ensures that unit will be pulled out of service in
cases of deviations beyond set limits. The unit will be restarted only after normal values are established.
BOILER INTERLOCK

In order to start the boiler smoothly, safely and in a desired sequence, certain interlocks are provided. The contacts / sources to
achieve sequential start are drawn from MCC, transmitters, actuators etc. The unit can also be shut down safely as per desired
sequence and same contacts will mostly be useful in normal shut down sequence.

AUTO CONTROLS

The steam generator is normally expected to maintain operating parameters at desired levels from approximately 60% MCR to
100% MCR by tuning the standard control loops as described below:

THREE-ELEMENT CONTROL

The drum level control is executed as conventional three-element control system and designed to keep the level in the boiler
drum constant at all load conditions. For steam flow up to 30% of the MCR flow, drum level control is executed as a single
element control. For steam flow above 30% of the MCR flow, drum level control is executed as a three-element control.
The three elements of this control system are steam flow, drum level and feed water flow. Temperature correction is applied for
feed water flow; temperature & pressure compensation is applied for steam flow; pressure correction is applied for drum level.
Load changes, i.e. changes in steam flow rate as steam is drawn by the turbine, are feed forwarded to the boiler drum level
controller as disturbance variables.
The set point signal for the feed water flow control comes from the drum level controller. Feed water controller output then
adjusts the feed flow to maintain the desired drum level. When the desired drum level is maintained the feed water flow and
steam flow will generally match. But, feed water flow will be slightly higher because of continuous blow down.

Level transmitters generate following alarms: LOW-LOW, LOW, HIGH, and HIGH-HIGH. The maximum and minimum levels in the
boiler drum are monitored. As soon as water level in the drum drops below LOW-LOW level, boiler must be tripped. An emergency
blow down is provided in case the drum level goes to HIGH-HIGH for restoring the normal water level.
Three (3) drum level transmitters are used for drum level measurement. Drum level reading is obtained by taking median value of
readings for the respective transmitters on the drum. From three separate level transmitters high, high-high, low, low-low alarms
and trip signals are generated and 2 out of 3 Logic will be used for tripping of Boiler and High and Low Alarm.
FLUE GAS PRESSURE CONTROL
Three (3) pressure transmitters are used to measure the Flue Gas pressure (usually measured at a point at the tapping, Boiler
inlet & Outlet) with the inlet value being used for control. The three pressure inputs will be monitored to provide an alarm signal,
whereas Inlet Flue Gas pressure drop gives a trip signal to the boiler as the induced draught is very high at boiler inlet -650mmW
C. If flue gas pressure at PH boiler inlet beyond -700mmWC Boiler will trip.
Similar is the case in AQC boiler where the induced draught is maintained by the ID fan at the Clinker ESP Outlet. If flue gas
pressure at boiler inlet beyond -75 mmWC Boiler will trip.
If an excessive deviation occurs between the measured values of pressure and the desired value then the auto/manual station
will be taken to manual control, & Open Command to bypass damper will be given.

STEAM TEMPERATURE CONTROL


Final Super heater steam temperature is controlled by the modulation of spray water control valves to the two stages of
attemperation. Attemperator is located between Mixing Header & SH2 of AQC Boiler
SH2 outlet steam temperature is used as a measured value to SH2 outlet controller with desired value being manually set.
Output of this controller being the set point of SH2 inlet steam temperature controller via a high selector relay which compares
the output to the saturation temperature limit derived from the drum pressure signal.
SH2 inlet steam temperature is used as the measured value to the SH2 inlet steam temperature controller. The controller output
is supplied to the Attemperator spray valve.
As the load increases, the quantity of water spray also increases. In the event of only one spray nozzle, it is likely that at higher
water flow, atomization of water may not be proper, which may adversely affect on life of Attemperator. However, dual-spray
nozzle system incorporated in WHR boiler ensures fine spray of water, within specific limits through each nozzle, to achieve quick
evaporation.

FLUE GAS FLOW CONTROL


Flue gas flow inside the boiler is regulated by the By Pass Regulation Damper in both cases of PH & AQC Boiler.
If there is any deviation in boiler parameters as given in the trip list, It gives a command of boiler trip, which is actually opening of
the bypass damper for control of the flue gas flow in the boiler. If after opening of Bypass damper due to certain value parameters
such as Flue Gas temperature, Drum Level, Main Steam Temperature etc. normalizes, the Bypass Damper is again closed as per
requirement, normalizing the boiler operation.
In case of AQC Boiler HAG Operation has to be bypassed by the HAG Bypass Multi-louver damper in case of any abnormality/
variation in Kiln operation.
B. BOILER OPERATION
B. BOILER OPERATION
Section Overview
This section describes the start up, shut down procedures of the WHRB. WHRB operation logics, Maintenance practices & safety
are also described here.

Topics Covered
1. Pre-requisites to be Attended Before Start up
2. Boiler Start Up
3. Boiler Shutdown
4. Paralleling WHRB To The Plant steam Mains
5. Cooling of Shutdown WHRB & Its Preservation
6. Do’s and Don’ts
7. WHRB Log Sheet
8. Emergency Procedures
9. Alarms and Tripping
10. Operation Logic
11. Troubleshooting Chart

1. PRE-REQUISITES TO BE ATTENDED BEFORE START UP

¾ All pre-commissioning activities like Refractory dry out of AQC Boiler Inlet Duct, Alkali Boil Out, Hydro test of the complete
system, Safety Valve floating check and steam blowing of pipe lines should have been completed prior to startup of boiler
for continuous operation
¾ All instruments should be taken on line and checked for proper functioning. Switch on power supply to MCC and control
panel. Ensure all the safety interlocks are in operation and functioning. Necessary personal protection equipment and
field safety gear should be kept in place.
¾ Provide all manholes and hand-holes with proper gaskets. Use sealant for proper holding of gaskets.
¾ Flush all piping like feed water piping, drain lines, CBD piping etc with water to ensure no clogging in pipelines.
¾ Open isolation valves for level transmitters & level gauge for steam drum. Run the feed Water pump with minimum
opening of flow control valve. Fill the system with fresh boiler feed water up to common below normal water level. Close
the manual valve at pump discharge and stop the pump.
¾ Check system for any leaks or mal-functioning equipment.
¾ Reduce the water level by operating blow-down valve and check the operation of level low alarms from transmitter are
functioning properly. Also check readings on level transmitter and level gauges are matching.
¾ Keep water level 2 inches below the normal operating level.
¾ Adjust valves for boiler operation according to VALVE SETTINGS.
¾ Check electrical and pneumatic motorized operation of valves.
¾ Ensure flow and pressure of instrument air and cooling water is as per requirement.

Feed Water Supply


Primarily before allowing the flue gases to the Waste Heat Boiler, a thorough check should be made of all feed water supply
equipment to insure a continuous and adequate supply of treated and de-aerated feed water to the boiler.
The feed water quality should be maintained as per norms.
Refer concerned chapter for recommended water chemistry.

Valve Settings

Valves Line Up
As the boiler is to be operated mainly from the DCS from the control room (except for some venting / draining during filling /
charging etc. which are done locally) the valve line up has to be prepared accordingly on field.
Root valves of all Instruments (Pressure gauges, Pressure transmitters, Flow transmitters, DP transmitters etc.,) must be kept open
and their drains if any are to be kept closed. They are not separately listed:

Super Heater
¾ Open the vents on the inlet and outlet header of Super Heater and should be closed after the boiler pressure had reach
5 Kg/cm²
Economizers
¾ Keep the air vents open on the outlet headers of the Economizer these valves to be closed after water is filled up to the
vents.
¾ Keep the drain valves on the headers open for boiler water filling, these valves to be closed after boiler water filling.

Blow Down Tank


¾ Verify that the inlet cocks of level gauge are open and its drain valve is closed.
¾ Verify that the above valves to the blow down tank are open & closed.

Steam Drum
¾ Verify that Inlet valves of Level Transmitters, are opened and their drain valves closed.
¾ Verify that root valves of pressure transmitter’s pressure gauges are open.
¾ Open Air Vent valves.
¾ Verify that drains from level Indicator and level gauges closed.
¾ Verify that the valve on HP dosing to Drum are open.
¾ Verify the CBD regulating valve is closed.
¾ Verify that valves on sample line from CBD line to sample cooler are open.
¾ Open the valves on the saturated steam sample line to sample coolers

Steam Line from Super Heater Outlet to the Main steam header
¾ Verify that root valves of pressure gauges and pressure transmitters, are open.
¾ Verify that up-stream / down-stream isolating valves of steam flow transmitters are open.
¾ Drain valves from the steam line, is open.
¾ Verify from DCS that the pneumatically operated Start-up vent valves is open
¾ Keep close the MSSV.

Filling Water in Boiler


¾ For filling water in a cold boiler, cold water from the boiler filling line is preferred. The following procedure is for
filling from the boiler filling line.
¾ During this filling, for assurance of correct steam drum water level, post an attendant at the drum level to monitor
the local gauges and to communicate to the control room when a level of -150mm is reached
¾ Open the boiler filling line valve.
¾ Water rises to the steam drum through the Economizer. It may take about some minutes to fill water to the required
level. As level of water reaches – 150mm on (confirmation by the attendant), water filling can be discontinued by
Close filling water line valve.
Lineup the Feed Regulating Stations
Note
For line up a cold boiler, cold water from the boiler filling line, initial fill pumps be used for first fill. Regular boiler feeding may not be
required for some time after line up. Feed lines are lined up such that any of the Feed Regulating stations can be taken into service
from DCS.
¾ Verify that drain valves on feed line at boiler inlet are closed.
¾ Verify that the root valves of all the instruments are open.
¾ Isolation valve of the Pressure indicator is open.
¾ Isolation valve of the Flow element are open.
¾ Verify that both the 100% flow control valve is in the closed (0%) position in the DCS.

100% Feed Control Station


¾ Verify that the manually operated inlet isolating valve of the feed regulating station is open.
¾ Close the drain valves before the regulating valve control valve.
¾ Verify that the outlet manual isolating valve from the feed station, are open.
Attemperation Control Station
¾ Close the drain valves before the regulating valve control valve.
¾ Verify that the outlet manual isolating valve, are open.

Feed Line to Economizer


¾ Verify that the line drains are closed.
¾ Verify that valve (Economizer Bypass valve) is closed.

B 2.1.5.0 See the following valves are closed positively


¾ Feed water regulating & Attemperation control valves are closed and are in manual control.
¾ All blow-down and drain valves on boiler.
¾ Main steam stop valve.
¾ Drain valves for instruments.

Open the following valves:


¾ All steam drum vents
¾ Economizer vent valve.
¾ All instrument and control connection to the boiler Super heater header vents, drains, startup vent, and main steam line
drains.

Filling with Water


The filling line is provided to the steam drum with an isolation valve & an NRV. The valve is provided for the isolation at DM inlet.
Fill the boiler to about 2 inches below normal water level on the level gauge, thus allowing room for expansion of water with heating
and pressure rise. Only boiler quality feed water should be used for filling. It is desirable to fill the boiler with de-aerated feed
water. Filling with hot water is permissible provided water is added slowly and flow does not exceed capacity of de-aerating
heater. Strains set up in the waste heat recovery boiler from hot water filling are minor compared to strains induced from heating
cold water rapidly. When filling with water, drum vent should be opened to permit escape of steam or air. All the respective valves
on the startup vent piping are to be kept open.

Heating Up
Once the boiler has been filled with water, the flue gas may be taken into the boiler. The flue gas temperature and the steam drum
pressure are to be controlled as mentioned in the Start-up curve attached.

¾ Minimum 1/3rd of steam generation to be vented to assist circulation of boiler and to control superheated steam
temperature. At any point of time during startup the super heater steam temperature should not exceed the temperature
mentioned in the curve. Flue gas temperature at boiler inlet to be kept below 300 °C until the steam circulation in the
super heater is established. Prior to placing a super heater in service, the super heater headers vents and drum vents and
main steam line drain should be opened to clear all water, condensate and entrained air. These drain & vents should all
remain open until the steam pressure reaches about 4 to 5 Kg/cm2 g and a definite flow of steam through the super
heater have been noted. At this time, the steam drum vents should be closed.

¾ As the steam pressure reaches 60% of operating pressure open the main steam stop valve gradually and allow heating up of
steam piping approximately for 30-45 min till the Battery limit isolation valve to the main steam header. This will help
draining of condensate through the steam drain line and attaining operating temperature of piping. After attaining the
required temperature & pressure gradually open the main steam stop valve fully and close the startup vent valve.

¾ During all the above steps, maintain normal water level in the steam drum. Initially, the controls should be on manual mode
only and once the steam supply to the process is started, change the controls in auto mode and monitor continuously.

2. BOILER START UP

This chapter describes the boiler start up procedures as applicable for the following boiler conditions:
¾ Startup of a cold boiler
¾ Startup of a warm / Hot boiler
NOTE
1. Procedures explained in this chapter apply for startup of the boiler already commissioned Commissioning a new boiler
calls for several additional requirements.
It is assumed that operators are fully familiar with the design and construction features described in the earlier section.
2. Owner is encouraged to evolve standard operating procedures (SOP) based on the framework and recommendations
that are explained in the subsections below
¾ The SOPs have to be well understood by operating personnel for safe and reliable operation.
¾ The preparations for a boiler start up so far described can be summarized as below:
¾ Walk down checks of the boiler, economizer & all pipelines.
¾ System/ valves line up of the boiler & economizer, feed water system, steam line and drain lines.
¾ Filling the boiler with feed water and normalizing the drum level.

Cold Start up Procedure:


In general, super heaters are located in areas of high temperatures and as a result, the danger of oxidizing or burning the super
heater tubes always exists. Thus, like it is important to maintain the water in the boiler, it is equally important to maintain steam
flow through a super heater and at a rate sufficient to absorb and carry away the heat surrounding the super heater. The rate of
steam flow must compensate for the rate of heat input to the super heater. It is not only true during periods of normal operation
but also during startup and shutdown periods. Bearing these in mind, the following procedure is described for cold start up.
Allow the flue gases to pass through the Boiler for gradual heating up of the Boiler system. Initially the flue gas temperature at
the Boiler inlet shall be < 300 °C.
Flue gas temperature at boiler inlet to be kept below 300°C until the steam circulation in the super heater is established. Prior to
placing a super heater in service, the super heater headers vents and drum vents should be opened to clear all water, condensate
and entrained air. These vents and drains, should all remain open until the steam pressure reaches about 4 to 5 Kg/cm2 g and a
definite flow of steam through the super heater have been noted. At this time, the steam drum vents should be closed.
It is necessary to leave the super heater vent open until the unit is on line and a definite steam flow is obtained through the
super heater tubes. It is essential that steam should flow through the super heater at all times when it is subjected to high gas
temperature
Please follow the pressure rising curve for determining the rate of increasing the steam drum pressure.
Gradually reduce the water level in the drum during warming up period to normal water level by blowing down the boiler as
required to maintain the water level in the gauge glass. This is to drain the water level swelling during heating up.
While the boiler is heating up make frequent checks of the boiler expansion movements. In case of any abnormalities, stop flue
gas flow and carry out remedial action.
Check the boiler water concentration and constituents as frequently as required to maintain proper boiler water concentration by
blow down.

As the drum pressure increases, progressively throttle the final super heater outlet header startup vent. Do not close startup vent
completely until steam flow through the main steam line is established.
As the steam pressure reaches 60% of operating pressure crack open the main steam stop valve gradually and allow heating up of
steam piping approximately for 30-45 min. This will help attaining operating temperature of piping. After attaining the required
temperature & pressure gradually fully open the main steam stop valve and close the startup vent valve.
During all the above steps, maintain normal water level in the steam drum. Initially, the controls should be on manual mode only
and once the steam supply to the process is started, change the controls in auto mode and monitor continuously.

Note

It is advised to avoid frequent startup and stoppage, as this will lead to thermal cyclic loading of the boiler and premature
failures

Hot Startup Procedure:

Restarting the boiler after banked condition again requires controlled flue gas flow rate so as to prevent the super heater from
overheating. This procedure is applicable for starting of boiler after a short stop. The conditions should apply:
¾ Drum pressure must be > or equal to 8 Kg/cm2 (g). Drum water level should be at normal water level.
¾ The main steam stop valve will be in closed condition. Open the startup vent valve to minimum venting and monitor
super heater outlet steam temperature.
¾ Admit approximately 10% of the flue gas for a period of 30 minutes. Keep a close watch on the super heater outlet
steam temperature adjust start-up vent valve as required.
¾ Open main steam drain valves & removes condensate and crack open main steam stop valve and warm up the
steam line leading to turbine.
¾ Now gradually increase the flue gas flow and increase the steam drum pressure as per the pressure rising curve.
Adjust the flue gas quantity and / or start-up vent valve opening as required.
¾ As the steam pressure reaches operating parameter, fully open main steam stop valve & charge steam to turbine.
Gradually close the startup vent.
¾ Take all the controls on auto mode and check for stable operation.

Note

It is advised to avoid frequent startup and stoppage, as this will lead to thermal cyclic loading of the boiler and premature
failures.

5.4 Operator Action Required During Boiler Cold Start up


¾ Ensuring permissible rate of heat input to WHRB during start up
¾ Operator can also check the local exhaust gas and temperature indications
¾ Monitor Drum metal temperatures.
¾ Monitor the water level in the drum. As the temperature reaches about 90°C, a huge swelling of water level in the
drum takes place. The operator anticipates this and controls the level by opening the CBD valve
¾ Initially, checking the local level gauges makes a careful assessment of water level in the drum
¾ Observe the air vent on drum. Air gets expelled and steady steam starts coming out of the air vents
¾ Observe drum pressure at DCS by Pressure transmitter , as also local pressure gauges
¾ When drum pressure shows 2kg/cm², drum air vents can be closed when the steam pressure builds up to 3–5
kg/cm², super heater drain valves are to be closed.
¾ When the swelling phase of drum water level is over and the level shows a decreasing trend, the feed control can be
taken into service by opening isolating valves it can be positioned as required manually to maintain drum level.
¾ Ensure CBD, feed water and super-heated steam samples are flowing to the coolers and the pH, conductivity
meters are in operation. Verify pH and conductivity is within permissive values.
¾ Allow the WHRB steam pressure and temperature to build up to rated temperature and pressure by suitably
adjusting start up vent valve.
¾ When steady feeding is established through the feed control valve, the same can be taken on auto mode, by
switching into auto mode.
¾ If sluggish, continue manual operation of for some more time before trying again.
¾ Monitor the steam drum water level.
¾ Monitor the parameters, which can cause a WHRB trip.
3. BOILER SHUT DOWN

Normal Shutdown Procedure


The following procedure for normal shutdown is based on the assumption that the unit is operating at full load on automatic control
and the unit should be brought to zero pressure and cool the boiler completely.
Gradually reduce the load on the unit reducing the flue gas flow rate in line with decreasing steam flow Allow the pressure drop
with the reduction in load to accelerate cooling. Steam temperature control may be left on automatic until the point is reached
where better control can be obtained on manual.
Open the startup vent gradually and close the main steam stop valve.
Open the bye pass damper
This operation should be carefully done in order to prevent any stoppage of the cement kiln as draught is disturbed during
operation of bypass damper.
Close the boiler outlet duct isolation damper after getting the open limit feedback from the bypass damper. Then Close the boiler
inlet duct isolation damper after getting the close limit feedback from the outlet damper. Reduce the boiler steam pressure. As
the boiler pressure drops below 5 Kg/cm2, open steam drum vent. In Case of PH Boiler the Seal Air fans to be started in case any
maintenance to be taken with the Kiln in Operation to have 100% isolation for Man safe entry to the Boiler.
Immediately after the boiler is off line, after 5 kg/cm2 wide open the super heater vents and drains.
After the boiler is completely depressurized, then the cooling process can be initiated in order to permit entry into the unit for
maintenance, proceed as follows: Purge the unit cools the unit by opens the entire manhole. Maintain water level at normal.
Stop chemical dosing pumps.
During long shut down of the boiler, Feed water pump can be shut down only after stabilizing drum level.
If the boiler is to be emptied the boiler water temperature should be reduced to at least 70°C before draining.)
Open the manhole when the flue gas temperature is below 50°C.

Emergency Shutdown Procedure.


¾ Open the startup vent gradually and close the main steam stop valve.
¾ Open the bye pass damper in sequence as stated above of the cement kiln
¾ Close the Boiler Outlet Damper and after getting close feedback from the boiler outlet damper, close the Boiler inlet
damper.
¾ Sequence of the damper opening should be only as stated above as any mal-operation of sequence may lead to
boiler or duct imploding as high negative draught is there in the PH side.
¾ In case of AQC Boiler HAG operation has also to be bypassed and need to shut off the HAG by the philosophy as
indicated in HAG OEM Manual
During Black - Out Procedure Condition
¾ During the Blackout condition
¾ Close the MSSV and open the startup vent to minimum position just for protecting the super heater (ensure to
avoid overshooting of main steam temp).
¾ The BFP should start within 3-min with the help of emergency power supply and manually maintain the water level in
the steam drum.
¾ Emergency power supply has to be provided to the MSSV, Startup vent and by pass duct damper. The steam drum
pressure and the level have to be manually maintained.

4. PARELLALING WHRB TO PLANT STEAM MAINS


Paralleling WHRB to the Plant steam Mains
Paralleling WHRB to the steam mains of the plant is an important operation to be carefully done without affecting the
temperature of steam in the plant. In this case the sequence of introducing steam into turbine will be in the following sequence:-

First Line up AQC Boiler and start rolling the turbine with HP steam. Till then warm up vent of LP steam injection line at the turbine
is to be in open condition.
Once the Turbine attains full speed & the generator is synchronized with the Grid, introduce the LP steam through the LP Injection
line at Turbine inlet and close the warm up vent.
After this process Paralleling PH Boiler steam to the Mixing header at AQC Boiler Primary Super heater is an important activity for
which below pre-requisites are required

The pre requisites for this operation are:


¾ Building the steam pressure in PH Boiler to a pressure slightly more than AQC Boiler Primary HP Steam super
heater outlet pressure/mixing header pressure
¾ With the buildup of required steam pressure and temperature in PH Boiler O/L, the main steam stop valve can
be opened slowly heating up the line with the drains till AQC mixing header open.
¾ Once the Line is heated up and temperature at mixing header normalizes, Initiate a full open command for
MSSV, and allow the steam to completely go through the mixing header & close all the drains slowly.
¾ Reduce the opening of the startup vent valve to about 15%. This valve can be completely closed later (once
boiler is connected to plant completely.)
¾ Observe steam temperatures after SH. If main steam temperature at turbine inlet starts coming down then
open the Turbine inlet warm up vent for some time till the temperature normalizes.
¾ Observe the feed control station. When steam flow exceeds 25%, full load control station comes into service
(based on operator selection)
5. BOILER COOLING DOWN
Cooling down of boiler:
This chapter describes the methods of cooling a shutdown WHRB and the steps to be followed for the same.
System Description
WHRB after shut down has to be cooled carefully. If the cooling rate is accelerated, thermal stresses develop in the thick
components such as the steam drum, Economizer, Evaporator, Super Heater headers, etc.
A WHRB is shut down either for keeping it in reserve as a stand by unit or for maintenance and inspection. The purpose of the
shutdown determines the method of cooling to be adopted.

Natural Cooling
The WHRB after a shutdown is allowed to cool slowly in a ‘boxed up condition’. The following valves are also closed.
¾ MSSV valve
¾ HP dosing to Drum
¾ CBD from Drum
¾ Sample line of WHRB water, saturated steam & SH Steams to SWAS System
The WHRB cools slowly, loosing its heat by radiation to the environment. Till the steam drum pressure drops to 2 kg/cm² (g),
permissible water level is maintained in the drum (+150mm to – 250mm) by intermittent feeding. After the steam drum pressure
falls below 2 kg/cm² (g) maintaining water level in the drum is not essential.
When the steam drum pressure is less than 2 kg/cm2 (g), the access doors in the WHRB are kept open to create a natural draft
through the WHRB to the chimney. WHRB cools to an accessible level in about two-three days.

Forced Cooling
If the WHRB has to be made available for inspection or repair and the shut down time has to be reduced to a minimum, forced
cooling of the WHRB is done.
After the shutdown of the WHRB, the HP dosing, CBD and sample cooler valves are closed as for natural cooling. Water level in
the drum is also maintained between permissible levels till the steam drum pressure falls to 2kg/ cm2 (g) For 8 hours after the
shutdown, the WHRB is allowed to cool naturally in the boxed up condition.
After 8 hours, access doors on WHRB are opened to allow air flow through the WHRB to the stack.
Controlled opening of the startup valve also speeds up the de-pressurization of steam in the WHRB. De-pressurization rate is not
to exceed 10 kg/cm2 per hour.
6. DOS AND DON’TS

Do’s
¾ Startup of boilers should be done only after Kiln Operation is stable
¾ Drum level should be monitored and maintained accordingly.
¾ By pass damper open command should go immediately when the drum level is Low Low. Bypass damper should be
opened slowly in co-ordination with Cement plant Operation team without disturbing the cement plant operation.
¾ Cold filling of the Boiler with DM Water and maintain drum level –100mm before cold start.
¾ Ensure that the dust conveying system of Cement Plant is running.
¾ Opening of drum vent, super heater vent, startup vent, evaporator vent before startup of the boilers.
¾ Each Hammering system should be operated periodically/continuously based on flue gas parameters
¾ Receive permission from Cement Plant Kiln operation people before operating the boiler dampers
¾ Damper Opening & Closing Sequence should be as per the logic.
¾ Check for the Opening of slide gates below Boiler Hopper atleast once in shift, also ensure dust is getting conveyed
through the dust conveyors by visually checking through conveyor man hole. If no dust is found in the conveyors investigate
for the correctness of Hopper level switch. Opening of the Emergency slide gate on the Boiler Hopper can also be initiated
to check the dust level in the hopper
¾ Close drum vent when drum pressure reaches 2 kg/cm²
¾ During kiln operation if there is any urgency to open the bypass damper the logic of opening the bye pass damper should
be in co-ordination with cement plant operation team without disturbing the cement plant
¾ Bypass Damper opening should be done on fan draught behavior during operation and then decide the timing.
¾ If Kiln Main drive only stops and the ID fan doesn’t trip. We can continue the boiler operation for at least 30 minutes, if
cement plant operation team allows the same.
¾ This sometimes is not acceptable to kiln operation people as kiln starts cooling down which are not a healthy condition for
them during restart due to which boiler trip has to be incorporated with Kiln & ID fan tripping with some delay.
¾ Proper co-ordination has to be there between the kiln operation people and power plant operation people, both have to
understand well each other’s problems is the only key to run this waste heat recovery power plant.
¾ After the boiler comes into normal operation the complete boiler has to be checked for false air ingress if any which has to
be arrested especially in case of PH Boiler as high negative draught is there.

Don’ts
¾ Don’t close or open the bye pass damper immediately.
¾ Damper interlocks shall never be bypassed
¾ Don’t start the boiler without permission of the Kiln Operation People
¾ Don’t start the boiler without ensuring the water filling in the condensate pre heater of AQC boiler
Most Important is the sequence of dampers during boiler box up and boiler Lined up process Sequence should be as below:-
x During Boiler Lineup:
As Boiler Inlet & Outlet Dampers are ON/OFF type dampers, Open Limit of the Inlet & both HAG & Bypass damper
should only permit the opening of the Outlet damper & Open Limit for Inlet Damper, Outlet damper & HAG Bypass
damper should only permit the Bypass damper to be closed slowly which is a regulating type damper. Below 5%
feedback & closed limit of the Bypass damper should only indicate the full closing of the bypass damper. When the
Inlet, Outlet & HAG bypass damper are fully opened, by pass damper can be operated (Close/Open) if required for
cement plant operation.
Bypass damper physical verification should be done from inside while calibrating with the manual pointer provided by
the vendor outside the damper for intermittent calibrations to be done for feedback errors during operation.
x During boiler box up :
Vice versa sequence of Line up. Extreme care has to be taken while opening the bye pass damper. Bypass Damper
opening should be done in co-ordination with cement plant operation team with disturbing the cement plant Operation
& based on fan draught behavior during operation and then decide the timing. Also open limit should come at DCS only
above 95% opening of the damper. Then only permission shall go for closing the outlet damper and after that the inlet
damper. But permission interlocks shall be in the same manner. As said above. This is for the safety of the boiler & the
cement plant
Sometimes a condition comes when we want to box up the boiler, but kiln operation people don’t allow opening the
bypass damper. This only occurs when the kiln operation is not in proper conditions that time the induced draught of
the fan which is in DCS picture plays a major role and damper can be opened with proper co-ordination with Kiln
Operation desk.

7. EMERGENCY PROCEDURES
Emergency Procedures

This Section Describes the Causes and Action during emergency condition.

Low Water Level

Causes

¾ Feed water control system failure.


¾ BFP failure
¾ Tube leak
Action
Compare control room indication with gauge glass level. If the water level falls out of sight due to momentary failure of water
supply system, due to negligence of the operator, due to momentary fluctuations that might occur with extraordinary changes in
load, appropriate action should be taken at once. Any decision to continue to operate, even if only for a short time at a reduced
rating would have to be made by someone in authority who is thoroughly familiar with the circumstances that led to the
emergency and positively certain that the water level can be restored immediately without damaging the boiler.
In the absence of such a decision shut off steam flow and divert the gas from the bypass duct.
Simultaneously, if feed water has become available and the operator is assured that no pressure part has been damaged
¾ Take the feed water control system into manual mode.
¾ Allow the water flow to boiler gradually to normal water level. (Do not hurry up which may lead to sudden
quenching and tube leak) if pressure part damage is suspected
¾ Reduce the steam pressure gradually
¾ Open the drum air vent when the pressure drops below 2 kg/cm2
¾ Cool the boiler so as to examine the extent of damage
¾ Drain the boiler after cooling
¾ If any tube rupture and bulging is observed rectify the same
¾ After the repairs conduct Hydro test
¾ Determine the cause of low water level.

High Water Level


Causes
¾ Feed water control malfunction
¾ Operator error
¾ Instrument air supply failure
¾ Foaming

Action
¾ Take the drum level control loop into manual mode
¾ Reduce the water level immediately by operating the continuous blow down to maintain the drum level
¾ Reduce the steam discharge rate, if necessary
¾ Start the stand by compressor if required.
Tube Failure
Operating the boiler with a known tube leak is not recommended. Steam or water escaping from a small leak at
pressure can cut other tubes by impingement and set up a chain reaction of tube failures. Large leaks can be
dangerous. The boiler water may be lost, boiler casing can get damaged.
Small leaks can sometime be detected by the loss of water in the cycle or system. A loss of boiler water or by the noise
made by the leak if a leak is suspected the boiler should be shut down as soon as possible by following the normal
shutdown procedure.
After the exact location of the leak or leaks is located, the leaks may be repaired by replacing the failed tube or by
splicing in a new section of tube, conforming to relevant ASME code. An investigation of the tube failure is very
important so that the condition causing the tube failure can be eliminated and future failures can be prevented. This
investigation should include a careful visual inspection of the failed tube and in some cases a lab analysis. It is
recommended that every effort be made to find the cause of tube failures before operation is resumed.

ALARM & TRIP LIST

BOILER ALARM & TRIP LIST (PH Boiler)

PROJECT- 1 X 6.85 MW Cement WHRS Project

CUSTOMER-PARASAKTI CEMENT INDUSTRIES LTD. AP

Alarm*/Trip** Values
Sr.no. Description Low High Remarks
Low* High*
Low** High** Unit
(Alarm) (Alarm)
(Trip) (Trip)
1 Kiln Trip - - - - Both PH & AQC Boiler will Trip

2 PH Fan Trip - - - - Boiler Trip

Boiler Trip at High High & Low


Low and Alarm At High & Low
3 HP & LP Drum Level -200 -300 +100 +150 mmWC
Values ( 2 out of 3
Logic)

4 HP Drum Pressure 13 - 18 - kg/cm²(g) Alarm at Low and High


Alarm at Low and High &
5 Main Steam Temp 280 - 330 350 Deg C Boiler trip at High High (2 out
of 3 Logic)

6 HP Main steam pressure 14 - 17.5 - kg/cm² Alarm at Low and High

Cement plant dust transport Alarm & Boiler Conveyor Trip


7 - - - - -
trip ( After Boiler Conveyors) in sequence

8 Flue Gas Inlet temp 280 - 360 380 Deg C Boiler Trip at High High

9 Flue Gas Outlet Temp - - 220 - Deg C Alarm at High

10 Boiler Inlet Flue Gas Pressure -650 - - - mmWC Alarm at Low

11 DCF 1 Trip - - - - - Alarm & Boiler RAV’s Trip


DCF 1Zero Speed Switch
- - - - - Alarm
13 Alarm
DCF 2 Zero Speed Switch
- - - - - Alarm
14 Alarm
RAV # 1 Zero Speed Switch - - - - - Alarm & RAV-1 Trip
15 Alarm
RAV # 2 Zero Speed Switch - - - - - Alarm & RAV-2 Trip
16 Alarm
17 RAV # 1 Trip - - - - - Alarm
18 RAV # 2 Trip - - - - - Alarm
Boiler Dust Hopper # 1 Level
- - - - Level
19 HI Alarm & Boiler Trip Command
Boiler Dust Hopper # 2 Level after 15 Minutes Delay
- - - - Level
20 HI
26 BD tank level high - - - - mmWC Alarm

27 HP Dozing Tank Level Low - - - - Level Alarm


28 HP Dozing Tank Level Low Low - - - - Level HP Dozing Pump Trip
29 Hammering System # 1 - - - - - Alarm
30 Hammering System # 2 - - - - - Alarm

31 Hammering System # 3 - - - - - Alarm

32 Hammering System # 4 - - - - - Alarm


33 Hammering System # 5 - - - - - Alarm
34 Hammering System # 6 - - - - - Alarm
35 Hammering System # 7 - - - - - Alarm
36 Hammering System # 8 - - - - - Alarm
37 Hammering System # 9 - - - - - Alarm
38 Hammering System # 10 - - - - - Alarm
33 MS line MSSV Open Torque - - - - - Alarm
34 MS line MSSV Close Torque - - - - - Alarm
PH steam Stop Valve Open
- - - - - Alarm
56 Torque
PH steam Stop Valve Close
- - - - - Alarm
57 Torque
Upstream isolation of PH
- - - - - Alarm
58 Main FCV Open Torque
Upstream isolation of PH
- - - - - Alarm
59 Main FCV Close Torque
Upstream isolation of PH - - - - - Alarm
60 bypass FCV Open Torque
Upstream isolation of PH - - - - - Alarm
61 bypass FCV Close Torque
Main Steam Line Drain Close
- - - - - Alarm
67 Torque
MS start up vent regulation
- - - - - Alarm
68 Open Torque
MS start up vent regulation
- - - - - Alarm
69 Close Torque
PH drum EBD regulation Open
- - - - - Alarm
70 Torque
PH drum EBD regulation
- - - - - Alarm
71 Close Torque
PH drum CBD regulation
- - - - - Alarm
72 Open Torque
PH drum CBD regulation
- - - - - Alarm
73 Close Torque
Inlet Flue Gas Damper Open
- - - - - Alarm
75 Torque
Inlet Flue Gas Damper Close
- - - - - Alarm
76 Torque
Outlet Flue Gas Damper Open
- - - - - Alarm
77 Torque
Outlet Flue Gas Damper Close
- - - - - Alarm
78 Torque
Bypass Flue Gas Damper
- - - - - Alarm
79 Open Torque
Bypass Flue Gas Damper
- - - - - Alarm
80 Close Torque
BOILER ALARM & TRIP LIST (AQC Boiler)

PROJECT- 1 X 6.85 MW Cement WHRS Project

CUSTOMER- PARASAKTI CEMENT INDUSTRIES LTD. AP

Alarm*/Trip** Values
Sr.no. Description Low High Remarks
Low* High*
Low** High** Unit
(Alarm) (Alarm)
(Trip) (Trip)
Boiler Trip at High high &
Low Low , Alarm at High
1 HP/LP Drum Level -200 -300 +100 +150 mmWC
& Low Values (2 out of 3
Logic)
Alarm Only at High and
2 HP / LP Drum Pressure 14 - 17.5 - kg/cm²(g)
Low

Main Steam Temp ( SH-2


3 350 - 410 - Deg C Alarm at Low and High
Outlet)

Main steam pressure ( SH-2 Alarm Only at High and


4 13 - 16.5 - Kg/cm²(g)
Outlet) Low

5 Clinker ESP Fan Trip - - - - Boiler Trip

Cement plant clinker dust


6 - - - -
transport trip Alarm

7 Flue Gas Inlet temp 375 - 460 480 Deg C Boiler Trip at High High

8 Flue Gas Outlet Temp - - 150 - Deg C Alarm at High

9 Boiler Inlet Flue Gas Pressure -60 -75 - - mmWC Boiler Trip at Low Low

10 DCF # 1 Trip - - - - Alarm

11 DCF # 2 Trip - - - - Alarm


DCF # 1 Zero Speed Switch
12 - - - - - Alarm
Alarm
Alarm
DCF # 2 Zero Speed Switch
13 - - - - -
Alarm

14 RAV # 1 Trip - - - - Alarm


15 RAV # 2 Trip - - - - Alarm
16 RAV # 3 Trip - - - - Alarm
RAV #1 Zero Speed Switch
- - - - - Alarm
19 Alarm
RAV # 2 Zero Speed Switch
- - - - - Alarm
20 Alarm
RAV # 3 Zero Speed Switch
- - - - - Alarm
21 Alarm
24 BD tank level mmWC Alarm
25 Boiler Dust Hopper # 1 Level Hi - - - - Level
Alarm at High & Boiler
26 Boiler Dust Hopper # 2 Level Hi - - - - Level trip with a delay of 15
min
27 Boiler Dust Hopper # 3 Level Hi - - - - Level
28 Boiler Dust Hopper # 4 Level Hi - - - - Level
Alarm at High
Boiler Dust Hopper # 5 Level & Boiler trip immediately
- - - - Level
29 Hi
30 HP Dozing Tank Level - - - - Level Alarm
31 HP Dozing Tank Level - - - - Level HP Dozing Pump Trip
Economizer Outlet
- - 200 - Deg C Alarm
32 Temperature
33 CPH Outlet Temperature - - 135 - Deg C Alarm
AQC-1 steam Stop Valve Open
- - - - - Alarm
34 Torque
AQC-1 steam Stop Valve Close
- - - - - Alarm
35 Torque
Upstream isolation of AQC
- - - - - Alarm
36 Boiler Main FCV Open Torque
Upstream isolation of AQC
- - - - - Alarm
37 Boiler Main FCV Close Torque
Upstream isolation of AQC
- - - - - Alarm
38 Boiler bypass FCV Open Torque
Upstream isolation of AQC
- - - - - Alarm
39 Boiler bypass FCV Close Torque
AQC Boiler Steam Line Drain
- - - - - Alarm
40 Open Torque
AQC Boiler Steam Line Drain
- - - - - Alarm
41 Close Torque
AQC Boiler steam startup vent
- - - - - Alarm
42 regulation Open Torque
AQC Boiler steam startup vent
- - - - - Alarm
43 regulation Close Torque
AQC Boiler drum EBD
- - - - - Alarm
44 regulation Open Torque
AQC Boiler drum EBD
- - - - - Alarm
45 regulation Close Torque
AQC Boiler drum CBD
- - - - - Alarm
46 regulation Open Torque
AQC Boiler drum CBD
- - - - - Alarm
47 regulation Close Torque
48 Mid Tap Damper Open Torque - - - - - Alarm
49 Mid Tap Damper Close Torque - - - - - Alarm
50 End Tap Damper Open Torque - - - - - Alarm
51 End Tap Damper Close Torque - - - - - Alarm
52 Inlet Damper Open Torque - - - - - Alarm
53 Inlet Damper Close Torque - - - - - Alarm
54 Outlet Damper Open Torque - - - - - Alarm
55 Outlet Damper Close Torque - - - - - Alarm
56 By Pass Damper Open Torque - - - - - Alarm
57 By Pass Damper Close Torque - - - - - Alarm
Attemperator spray water line
58 - - - - - Alarm
isolation Open Torque
Attemperator spray water line
59 - - - - - Alarm
isolation Close Torque
Near Attemperator Spray
60 - - - - - Alarm
Nozzle Open Torque
Near Attemperator Spray - - - - - Alarm
61 Nozzle Close Torque
Main Steam Line Drain Open - - - - - Alarm
62 Torque
OPERATION LOGIC
PH BOILER OPERATION LOGIC

HAMMERING SYSTEM START PERMISIVES


Rapping Hammer system Start permissive will be ok if all the following conditions are satisfied.
1. Drive Ready to start
2. CV 01 running
3. Field Stop ok
4. Remote selected
5. No Trip condition persists
6. In case of CV-02 tripping, CV-01 will trip and due to this RAV’s of both side hoppers will trip resulting in tripping of the
Hammering system (Grouping to be done accordingly.)

HAMMERING SYSTEM TRIP CONDITIONS


Rapping Hammer System will trip if any one of the following signal present
1. with a delay of 15 minutes after CV01 Tripping / RAV 1 & 2 tripping
2. Zero Speed activated
3. Drive not ready
4. Field stop not ok
5. Remote not selected
6. Sequence stop operated
7. RAV 1 OR 2 not running.
Note: Conveyors, RAV’s to be grouped for Hammering system operation

RAPPING HAMMER SYSTEMS START/STOP (REMOTE/SEQUENTIAL OPERATION)


Rapping Hammer system will start if the following conditions are satisfied.
1. Rapping Hammer system start permissive ok
2. NO Stop/Trip condition persists.
3. {(Remote selected AND Remote Start PB operated) OR (Sequence Start command From Sequence Logic)}
4. CV02, CV01, RAV 1 & 2 running

Rapping Hammer system will stop if any one of the following signal present
1. Remote Stop PB operated
2. No Trip condition persists
3. Rapping Hammer system fail to start/trip
SEQUENCE COMMAND FROM SEQUENCE LOGIC
When Boiler Dust Transportation system On, Rapping Hammer system Enable, Sequence selected and Sequence Start command
given and following things will happen
1. Sequence selected and Sequence Running Indication will be on
2. Hammering system Enable
3. First Row Rapping Hammer system 1 & 2 will be on 2sec after and remain on for 5 minutes
4.5 min. after 2nd Row Rapping Hammer system 3 & 4 will be on 2 sec after and remain on for 5 min. In the same
sequence 3rd row (5 & 6), 4th Row (7 & 8) & 5th Row (9 &10)
7. 1st row Hammering system again will be on 30 min after the complete hammering system completes its one cycle
operation.

Rapping Hammer system sequence will stop if


1. Boiler Dust Transportation system not on
2. Sequence Stop PB operated
3. Sequence tripping with CV-01
Note: All hammering systems are designed to run continuously/Intermittently in sequence as mentioned above if required based
on flue gas parameters & site conditions.
SKIPPING OF ANY RAPPING HAMMER OPERATION DURING SEQUENTIAL OPERATION
To skip any Rapping Hammer system operation that particular Rapping system is to be disabled. This can be done by operating
that Rapping Hammer Enable PB twice.

REMOTE/SEQUENCE SELECTION
Remote will be selected when Remote select PB is operated and reset when Sequence selects PB is operated.
Sequence will be selected when Sequence select PB is operated and reset when Remote select PB is operated.

BOILER READY TO START


Boiler will be ready to start if the following signals are
1. DCF running. Cement Plant Dust transport running
2. PH Fan running.
3. Kiln running
4. Drum Level not high
5. Drum level not low.
BOIER TRIP CONDITION
Boiler will trip if any one of the following signal present
1. DCF not running / Cement Plant Dust Transport trip.
2. PH Fan not running.
3. Kiln not running
4. Drum Level very high
5. Drum level very low.

BOILER INLET TANDEM DAMPER OPEN PERMISIVES

Inlet Damper open permissive will be ok if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Damper not closing
4. Field Stop ok
5. Remote selected. Provision for Manual Operation should also be there.
6. Boiler Ready to start
7. Damper not full open
8. Opening Torque not high
9. {(Remote selected AND Remote Start PB operated) OR (Sequence Start command from Sequence Logic)}
10. By Pass Damper open feedback persists.
11. Seal Air Fan of Inlet Tandem Damper not running.

BOILER INLET TANDEM DAMPER CLOSE PERMISIVES

Inlet Damper close permissive will be ok if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Damper not opening
4. Field Stop ok
5. Remote selected Provision for Manual Operation should also be there
6. Closing Torque not high
7. Damper not full open
8. Close Feedback of outlet damper & open feedback of Bye pass damper persists.
9. Seal Air Fan of Boiler Inlet Tandem Damper not running. (Seal Air Fan to be started only after full close limit of Boiler
Inlet Tandem damper is attained).
INLET DAMPER OPEN/CLOSE (REMOTE/SEQUENTIAL OPERATION)

Inlet Damper will open if the following conditions are satisfied.


1. Inlet Damper open permissive ok
2. {(Remote selected AND Remote Open PB operated AND Boiler Ready to start) OR
(Sequence selected AND Sequence Open command from Sequence Logic)}

Inlet Damper will close if the following conditions are satisfied


1. Inlet Damper close permissive ok
2. {(Remote selected AND Remote Close PB operated AND Outlet Damper Full close) OR
(Sequence selected AND Sequence Close command from Sequence Logic)}

BOILER OUTLET TANDEM DAMPER OPEN PERMISIVES

Outlet Damper open permissive will be ok if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Damper not closing
4. Field Stop ok
5. Remote selected Provision for Manual Operation should also be there
6. Boiler Inlet Damper Full open
7. Damper not full open
8. Opening Torque not high
9. {(Remote selected AND Remote Start PB operated) OR (Sequence Start command
From Sequence Logic)}
10. Inlet Damper open feedback persists.
11. Seal Air Fan for Boiler Outlet Tandem Damper not running.

BOILER OUTLET TANDEM DAMPER CLOSE PERMISIVES

Outlet Damper close permissive will be ok if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Damper not opening
4. Field Stop ok
5. Remote selected Provision for Manual Operation should also be there.
6. Closing Torque not high
7. Damper not full open.
8. By Pass Damper open feedback persists
9. Seal Air Fan of Boiler Outlet Tandem Damper not running. (Seal Air Fan to be started only after full close limit of Boiler
Outlet Tandem damper is attained).

OUTLET DAMPER OPEN/CLOSE (REMOTE/SEQUENTIAL OPERATION)

Outlet Damper will open if the following conditions are satisfied.


1. Outlet Damper open permissive ok
2. {(Remote selected AND Remote Open PB operated AND Boiler Ready to start) OR
(Sequence selected AND Sequence Open command from Sequence Logic)}

Outlet Damper will close if the following conditions are satisfied


1. Outlet Damper close permissive ok
2. {(Remote selected AND Remote Close PB operated AND Bypass Damper Full open) OR
(Sequence selected AND Sequence Close command from Sequence Logic)}

BOILER BYPASS DAMPER OPEN PERMISIVES

Bypass Damper open permissive will be ok if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Damper not closing
4. Field Stop ok
5. Remote selected Provision for Manual Operation should also be there
6. Damper not full open
7. Opening Torque not high
8. {(Remote selected AND Remote Start PB operated) OR (Sequence Start command from Sequence Logic)}
9. Inlet and Outlet damper open feedback persists
10. PH Fan Running
11. Flue Gas inlet temp high > 480°C
BOILER BYPASS DAMPER CLOSE PERMISIVES

Bypass Damper close permissive will be ok if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Damper not opening
4. Field Stop ok
5. Remote selected Provision for Manual Operation should also be there
6. Closing Torque not high
7. Damper not full open
8. Inlet and Outlet damper open feedback persists.

BYPASS DAMPER OPEN/CLOSE (REMOTE/SEQUENTIAL OPERATION)

Bypass Damper will open if the following conditions are satisfied.


1. By Pass damper Open Permissive ok
2. {(Remote selected AND Remote Open PB operated) OR (Sequence selected AND Sequence
Open command from Sequence Logic)}
3. PH Fan Running Bypass Damper will close if the following conditions are satisfied
1. By Pass Damper close permissive ok.
2. {(Remote selected AND Remote Close PB operated AND Boiler Ready to start) OR
(Sequence selected AND Sequence Close command from Sequence Logic)}

SEQUENTIAL OPERATION OF INLET/OUTLET DAMPER OPENING AND BYPASS DAMPER CLOSING FROM SEQUENCE LOGIC

When Damper Sequence selected AND No Boiler Trip signal present AND Damper Sequence Start PB (Opening) operated
following things will happen
1. Inlet Damper open command will be generated.
2. After getting .Inlet Damper full open feedback from Field Outlet Damper will start opening
3. After getting Outlet Damper full open feedback from Field Bypass Damper will start closing

Closing the Boiler Bypass damper during Boiler Cold Start should be done slowly and manually to protect the Boiler Pressure
parts.
SEQUENTIAL OPERATION OF INLET/OUTLET DAMPER CLOSING AND BYPASS DAMPER OPENING FROM SEQUENCE LOGIC

When Damper Sequence selected AND Damper Sequence Stop PB (Closing) operated OR Boiler Trip signal present following
things will happen
1. Bypass Damper will start opening
And % opening to be closely done in coordination with Cement Plant Operation team without disturbing the cement plant
operation & based on Boiler Start up conditions (Hot/Cold)
2. After getting bypass Damper full open feedback from Field Outlet Damper will start closing after getting Outlet Damper
full close feedback from Field Inlet Damper will start Closing.

RAV 1& 2 START/STOP LOGIC

RAV1 &2 will start if the following conditions are satisfied


1. RAV1&2 fail to start/trip signal not present.
2. Field Stop ok
3. Remote selected
4. Motor not Trip
5. No Fault signal present
6. Chain Feeder 1 running
7. MCC Ready to Start
8. Stop command not operated from DCS
9. Start command given from DCS

RAV1 & 2 will stop if any one of the following signals is present
1. RAV1 & 2 Fail to start/trip signal present.
2. Zero Speed Switch not okay
3. Field Stop not ok
4. Remote not selected
5. Motor Trip
6. Chain Feeder 1 not running
7. MCC not Ready to Start
8. Stop command not operated from DCS
CHAIN FEEDER START/STOP LOGIC

Chain Feeder will start if the following conditions are satisfied


1. Chain Feeder Fail to start/trip signal not present.
2. Field Stop ok
3. Remote selected
4. Motor not Trip
5. No Fault signal present
6. Cement Plant Dust Conveyor (Raw Meal Silo Feed Elevator) running
7. MCC Ready to Start
8. Stop command not operated from DCS
9. Start command given from DCS

Chain Feeder will stop if any one of the following signals is present
1. Chain Feeder Fail to start/trip signal present.
2. Field Stop not ok
3. Remote not selected
4. Motor Trip
5. Cement Plant Dust Conveyor (Raw Meal Silo Feed Elevator) not running
6. MCC not Ready to Start
7. Stop command not operated from DCS

MOTORISED ISOLATION VALVE BEFORE MAIN/BYPASS FEED CONTROL VALVE OPEN/CLOSE LOGIC

Motorized Isolation valve will open if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not closing
4. Field Stop ok
5. Remote selected
6. Main/Bypass Feed Control Valve full closed
7. Valve not full open
8. Opening Torque not high
9. (Remote selected AND Remote Open PB operated)

Motorize Isolation Valve will close if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not opening
4. Field Stop ok
5. Remote selected
6. Closing Torque not high
7. Valve not full open
9. (Remote selected AND Remote Close PB operated)

STEAM HEADER DRAIN VALVE OPEN/CLOSE LOGIC

Motorized Drain valve will open if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not closing
4. Field Stop ok
5. Remote selected
6. Valve not full open
7. Opening Torque not high
8. (Remote selected AND Remote Open PB operated)

Motorize Drain Valve will close if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not opening
4. Field Stop ok
5. Remote selected
6. Closing Torque not high
7. Valve not full open
8. (Remote selected AND Remote Close PB operated)
PH 1 STEAM STOP VALVE OPEN/CLOSE LOGIC

Motorized Stop valve will open if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not closing
4. Remote selected
5. Valve not full open
6. Opening Torque not high
7. Bypass valve full open
8. (Remote selected AND Remote Open PB operated)

Motorize Stop Valve will close if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not opening
4. Remote selected
5. Closing Torque not high
6. Valve not full open
7. {(Remote selected AND Remote Close PB operated)

MAIN STEAM STOP VALVE OPEN/CLOSE LOGIC

Motorized Stop valve will open if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not closing
4. Remote selected
5. Valve not full open
6. Opening Torque not high
7. Bypass valve full open
8. (Remote selected AND Remote Open PB operated)
Motorized Stop Valve will close if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not opening
4. Remote selected
5. Closing Torque not high
6. Valve not full open

EBD VALVE OPEN/CLOSE LOGIC


EBD valve will open if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not closing
4. Remote selected
5. Valve not full open
6. Opening Torque not high
7. (Remote selected AND Remote Open PB operated)

EBD Valve will close if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not opening
4. Remote selected
5. Closing Torque not high
6. Valve not full open
7. {(Remote selected AND Remote Close PB operated)

CBD VALVE OPEN/CLOSE LOGIC

CBD valve will open if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not closing
4. Remote selected
5. Valve not full open
6. Opening Torque not high
7. (Remote selected AND Remote Open PB operated)

CBD Valve will close if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not opening
4. Remote selected
5. Closing Torque not high
6. Valve not full open
7. {(Remote selected AND Remote Close PB operated)

START UP VENT VALVE OPEN/CLOSE LOGIC

Startup vent valve will open if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not closing
4. Remote selected
5. Valve not full open
6. Opening Torque not high
7. (Remote selected AND Remote Open PB operated)

Startup vent Valve will close if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not opening
4. Remote selected
5. Closing Torque not high
6. Valve not full open
7. {(Remote selected AND Remote Close PB operated)
HP DOSING PUMP 1/2 START/STOP LOGIC
HP Dosing Pump 1/2 will start if the following conditions are satisfied
1. Pump 1/2 Fail to start/trip signal not present.
2. Field Stop ok
3. Remote selected
4. Motor not Trip
5. No Fault signal present
6. Level not Low
7. MCC Ready to Start
8. Stop command not operated from DCS
9. Start command given from DCS

Pump 1/2 will stop if any one of the following signals is present
1. Pump 1/2 Fail to start/trip
2. Field Stop not ok
3. Remote not selected
4. Motor Trip
5. Level Very Low
6. MCC not Ready to Start
7. Stop command operate from DCS

HP DOSING TANK STIRRER START/STOP LOGIC

HP Dosing Tank Stirrer will start if the following conditions are satisfied
1. Stirrer Fail to start/trip signal not present.
2. Field Stop ok
3. Remote selected
4. Motor not Trip
5. No Fault signal present
6. Level not Low
7. MCC Ready to Start
8. Stop command not operated from DCS
9. Start command given from DCS

HP Dosing Tank Stirrer will stop if any one of the following signals is present
1. Stirrer Fail to start/trip.
2. Field Stop not ok
3. Remote not selected
4. Motor Trip
5. Level Very Low
6. MCC not Ready to Start
7. Stop command operated from DCS

ATTEMPERATOR SPRAY NOZZEL VALVE OPEN/CLOSE LOGIC


Nozzle valve will open if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not closing
4. Field Stop ok
5. Remote selected
6. Spray Water Flow > 0.5T/HR
7. Valve not full open
8. Block Valve Full Open
9. Opening Torque not high
10. (Remote selected AND Remote Open PB operated)

Nozzle Valve will close if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not opening
4. Field Stop ok
5. Remote selected
6. Closing Torque not high
7. Valve not full open
8. {(Remote selected AND Remote Close PB operated) OR (Turbine Tripped)}

ATTEMPERATOR SPRAY BLOCK VALVE OPEN/CLOSE LOGIC

Nozzle valve will open if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not closing
4. Field Stop ok
5. Remote selected
6. Steam Flow > 7T/HR
7. Valve not full open
8. Opening Torque not high
9. (Remote selected AND Remote Open PB operated)

Nozzle Valve will close if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not opening
4. Field Stop ok
5. Remote selected
6. Closing Torque not high
7. Valve not full open
8. {(Remote selected AND Remote Close PB operated) OR (Turbine Tripped)}

FAULT SIGNAL LOGIC FOR BI-DIRECTIONAL MOTOR ON/OFF TYPE


Fault signal will be generated if any one of the following signal is present.
1. Motor Trip
2. Field Stop not ok
3. Fail to Open
4. Fail to Close
5. Stop command operate from DCS

FAULT SIGNAL LOGIC FOR BI-DIRECTIONAL MOTOR INCHING TYPE


Fault signal will be generated if any one of the following signal is present.
1. Motor Trip
2. Field Stop not ok
3. Stop command operate from DCS

FAULT SIGNAL LOGIC FOR UNI-DIRECTIONAL MOTOR


Fault signal will be generated if any one of the following signal is present
1. Motor Fail to start/trip
2. Field Stop not ok
3. Remote not selected
4. Motor Trip
5. MCC not Ready to Start
6. Stop command operate from DCS

B 11.2.0.0 AQC BOILER OPERATION LOGIC

BOILER READY TO START


Boiler will be ready to start if the following signals are
1. DCF 1 & 2 running
2. ID Fan running.
3. Kiln running
4. Clinker ESP Fan running
5. Cement Clinker Dust Conveying System on
6. Drum Level not high
7. Drum level not low.

BOILER TRIP CONDITION


Boiler will trip if any one of the following signal present
1. DCF 2 not running
2. ID Fan not running.
3. Kiln not running
4. Clinker Dust Conveying System not running
5. Clinker ESP Fan not running
6. Drum Level very high
7. Drum level very low.

BOILER INLET DAMPER OPEN PERMISIVES


Inlet Damper open permissive will be ok if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Damper not closing
4. Field Stop ok
5. Remote selected
6. Boiler Ready to start
7. Damper not full open
8. Opening Torque not high
9. {(Remote selected AND Remote Start PB operated) OR (Sequence Start command from
Sequence Logic)}
10. Open Feedback of bypass damper & close feedback of outlet damper persists.

BOILER INLET DAMPER CLOSE PERMISIVES


Inlet Damper close permissive will be ok if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Damper not opening
4. Field Stop ok
5. Remote selected Provision for Manual Operation should be there.
6. Closing Torque not high
7. Damper not full open
8. Open Feedback of by Pass damper & close feedback of outlet damper persists

INLET DAMPER OPEN/CLOSE (REMOTE/SEQUENTIAL OPERATION)

Inlet Damper will open if the following conditions are satisfied.


1. Inlet Damper open permissive ok
2. {(Remote selected AND Remote Open PB operated AND Boiler Ready to start) OR
(Sequence selected AND Sequence Open command from Sequence Logic)}

Inlet Damper will close if the following conditions are satisfied


1. Inlet Damper close permissive ok
2. {(Remote selected AND Remote Close PB operated AND END TAP Damper full close) OR
(Sequence selected AND Sequence Close command from Sequence Logic)}

BOILER OUTLET DAMPER OPEN PERMISIVES


Outlet Damper open permissive will be ok if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Damper not closing
4. Field Stop ok
5. Remote selected Provision for Manual Operation should be there
6. Boiler Inlet Damper Full open
7. Damper not full open
8. Opening Torque not high
10. {(Remote selected AND Remote Start PB operated) OR (Sequence Start command From Sequence Logic)}
11. By pass damper full open

BOILER OUTLET DAMPER CLOSE PERMISIVES


Outlet Damper close permissive will be ok if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Damper not opening
4. Field Stop ok
5. Remote selected Provision for Manual Operation should be there
6. Closing Torque not high
7. Damper not full open
8. By pass damper full open

OUTLET DAMPER OPEN/CLOSE (REMOTE/SEQUENTIAL OPERATION)


Outlet Damper will open if the following conditions are satisfied.
1. Outlet Damper open permissive ok
2. {(Remote selected AND Remote Open PB operated AND Boiler Ready to start) OR
(Sequence selected AND Sequence Open command from Sequence Logic)}

Outlet Damper will close if the following conditions are satisfied


1. Outlet Damper close permissive ok
2. {(Remote selected AND Remote Close PB operated) OR (Sequence selected AND
Sequence Close command from Sequence Logic)}

BOILER BYPASS DAMPER OPEN PERMISIVES


Bypass Damper open permissive will be ok if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Damper not closing
4. Field Stop ok
5. Remote selected Provision for Manual Operation should be there
6. Damper not full open
7. Opening Torque not high
8. Outlet, Inlet Damper full open
9. {(Remote selected AND Remote Start PB operated) OR (Sequence Start command from Sequence Logic)}

BOILER BYPASS DAMPER CLOSE PERMISIVES


Bypass Damper close permissive will be ok if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Damper not opening
4. Field Stop ok
5. Remote selected
6. Closing Torque not high
7. Damper not full open
8. Inlet & Outlet damper full open Feed Back Persists.

BYPASS DAMPER OPEN/CLOSE (REMOTE/SEQUENTIAL OPERATION)


Bypass Damper will open if the following conditions are satisfied.
1. By Pass Damper open permissive ok
2. {(Remote selected AND Remote Open PB operated) OR (Sequence selected AND Sequence open command from
Sequence Logic)}

Bypass Damper will close if the following conditions are satisfied


1. By Pass Damper close permissive ok
2. {(Remote selected AND Remote Close PB operated AND Boiler Ready to start) OR
(Sequence selected AND Sequence Close command from Sequence Logic)}

SEQUENTIAL OPERATION OF /END TAP/HAG BYPASS/OUTLET DAMPER OPENING AND BYPASS DAMPER CLOSING FROM
SEQUENCE LOGIC

Boiler Line up Process


When Damper Sequence selected AND No Boiler Trip signal present AND Damper Sequence Start PB (Opening) operated
following things will happen
1. END TAP Damper open command will be generated
2. After getting END TAP Damper full open feedback from Field HAG BYPASS Damper will start Opening
3. After getting HAG BYPASS Damper full open feedback from Field OUTLET Damper will start Opening
4. After getting Outlet Damper full open feedback from Field Bypass Damper will start closing
This Operation should take sufficient time to take the boiler inline during cold startup, whereas during hot start it can be closed
within 30 minutes.

SEQUENTIAL OPERATION OF INLET/OUTLET DAMPER CLOSING AND BYPASS DAMPER OPENING FROM SEQUENCE LOGIC
BOILER BOX UP PROCEDURE

When Damper Sequence selected AND Damper Sequence Stop PB (Closing) operated OR Boiler Trip signal present following
things will happen
1. By pass Damper will start opening.
This Damper can be opened quickly in co-ordination with Cement Process as the negative draught is very less and does
not cause any disturbance to Cement Plant Operation
2. After getting .Bypass Damper full open feedback from Field Outlet Damper will start Closing
3. After getting .Outlet Damper full close feedback from Field END TAP Damper will start Closing

BY PASS DAMPER OPERATION WHEN BOILER INLET GAS TEMP >450 DEGC
When Boiler Inlet Gas Temperature >460 Deg C and <480 Deg C By Pass Damper will open up to 50% and when the Temperature
>480 Deg C By Pass Damper will open 100%.
By Pass Damper will start closing when Boiler Inlet Temperature is < 435 Deg C.

CHAIN FEEDER 1 START/STOP LOGIC


Chain Feeder 1 will start if the following conditions are satisfied
1. Chain Feeder 1 Fail to start/trip signal not present.
2. Field Stop ok
3. Remote selected
4. Motor not Trip
5. No Fault signal present
6. Chain Feeder 2 running
7. MCC Ready to Start
8. Stop command not operated from DCS
9. Start command given from DCS
10. Zero Speed Switch Okay.

Chain Feeder 1 will stop if any one of the following signals is present
1. Chain Feeder Fail to start/trip signal present.
2. Field Stop not ok
3. Remote not selected Remote should be selected after starting of the equipment manually.
4. Motor Trip
5. Chain Feeder 2 not running
6. MCC not Ready to Start
7. Stop command not operated from DCS
8. Zero Speed Switch Not Okay / Alarm

CHAIN FEEDER 2 START/STOP LOGIC


Chain Feeder2 will start if the following conditions are satisfied
1. Chain Feeder 2 Fail to start/trip signal not present.
2. Field Stop ok
3. Remote selected Remote should be selected after starting of the equipment manually.
4. Motor not Trip
5. No Fault signal present
6. Cement Plant Clinker Dust Conveyor running
7. MCC Ready to Start
8. Stop command not operated from DCS
9. Start command given from DCS

Chain Feeder 2 will stop if any one of the following signals is present
1. Chain Feeder 2 Fail to start/trip signal present.
2. Field Stop not ok
3 Remote not selected Remote should be selected after starting of the equipment manually.
4. Motor Trip
5. Cement Plant Clinker Dust Transport not running
6. MCC not Ready to Start
7. Stop command not operated from DCS

STEAM HEADER DRAIN VALVE OPEN/CLOSE LOGIC


Motorized Drain valve will open if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not closing
4. Field Stop ok
5. Remote selected
6. Valve not full open
7. Opening Torque not high
8. (Remote selected AND Remote Open PB operated)

Motorize Drain Valve will close if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not opening
4. Field Stop ok
5. Remote selected
6. Closing Torque not high
7. Valve not full open
9. (Remote selected AND Remote Close PB operated)

AQC BOILER STEAM STOP VALVE OPEN/CLOSE LOGIC


Motorized Stop valve will open if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not closing
4. Remote selected
5. Valve not full open
6. Opening Torque not high
7. Bypass valve full open
8. (Remote selected AND Remote Open PB operated)

Motorize Stop Valve will close if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not opening
4. Remote selected
5. Closing Torque not high
6. Valve not full open
7. {(Remote selected AND Remote Close PB operated)
EBD VALVE OPEN/CLOSE LOGIC
EBD valve will open if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not closing
4. Remote selected
5. Valve not full open
6. Opening Torque not high
7. (Remote selected AND Remote Open PB operated)

EBD Valve will close if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not opening
4. Remote selected
5. Closing Torque not high
6. Valve not full open
7. {(Remote selected AND Remote Close PB operated)

CBD VALVE OPEN/CLOSE LOGIC


CBD valve will open if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not closing
4. Remote selected
5. Valve not full open
6. Opening Torque not high
7. (Remote selected AND Remote Open PB operated)

CBD Valve will close if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not opening
4. Remote selected
5. Closing Torque not high
6. Valve not full open
7. {(Remote selected AND Remote Close PB operated)
START UP VENT VALVE OPEN/CLOSE LOGIC
Start up vent valve will open if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not closing
4. Remote selected
5. Valve not full open
6. Opening Torque not high
7. (Remote selected AND Remote Open PB operated)

Start up vent Valve will close if all the following conditions are satisfied.
1. Drive Ready to start
2. No Fault signal present
3. Valve not opening
4. Remote selected
5. Closing Torque not high
6. Valve not full open
7. {(Remote selected AND Remote Close PB operated)

HP DOSING PUMP 1/2 START/STOP LOGIC


HP Dosing Pump 1/2 will start if the following conditions are satisfied
1. Pump 1/2 Fail to start/trip signal not present.
2. Field Stop ok
3. Remote selected
4. Motor not Trip
5. No Fault signal present
6. Level not Low
7. MCC Ready to Start
8. Stop command not operated from DCS
9. Start command given from DCS

Pump 1/2 will stop if any one of the following signals is present
1. Pump 1/2 Fail to start/trip
2. Field Stop not ok
3. Remote not selected
4. Motor Trip
5. Level Very Low
6. MCC not Ready to Start
7. Stop command operate from DCS

HP DOSING TANK STIRRER START/STOP LOGIC


HP Dosing Tank Stirrer will start if the following conditions are satisfied
1. Stirrer Fail to start/trip signal not present.
2. Field Stop ok
3. Remote selected
4. Motor not Trip
5. No Fault signal present
6. Level not Low
7. MCC Ready to Start
8. Stop command not operated from DCS
9. Start command given from DCS

HP Dosing Tank Stirrer will stop if any one of the following signals is present
1. Stirrer Fail to start/trip.
2. Field Stop not ok
3. Remote not selected
4. Motor Trip
5. Level Very Low
6. MCC not Ready to Start
7. Stop command operated from DCS

FAULT SIGNAL LOGIC FOR BI-DIRECTIONAL MOTOR ON/OFF TYPE


Fault signal will be generated if any one of the following signal is present.
1. Motor Trip
2. Field Stop not ok
3. Fail to Open
4. Fail to Close
5. Stop command operate from DCS

FAULT SIGNAL LOGIC FOR BI-DIRECTIONAL MOTOR INCHING TYPE

Fault signal will be generated if any one of the following signal is present.
1. Motor Trip
2. Field Stop not ok
3. Stop command operate from DCS

FAULT SIGNAL LOGIC FOR UNI-DIRECTIONAL MOTOR


Fault signal will be generated if any one of the following signal is present
1. Motor Fail to start/trip
2. Field Stop not ok
3. Remote not selected
4. Motor Trip
5. MCC not Ready to Start.
6. Stop command operate from DCS.
C.CONSTRUCTION FEATURES
TITLE: WATER & STEAM CIRCUIT

FEED WATER SYSTEM

The water and steam system covered in this chapter describes the components of the WHRB which transfer heat from the exhaust
gas of the Kiln to the feed water flowing from the feed water main to convert it to steam of 14.5 Kg/cm² (g) at a temperature of
390 °C in case of HP & 2.5 Kg/cm² (g) at a temperature of 195 °C in case of LP .The components in the serial order of water flow
of path are
¾ Condensate Pre-heater
¾ Deaerator
¾ Boiler feed water Pump (Common for LP & HP System both)

FOR HP STEAM
¾ Economizer module AQC
¾ HP Boiler Feed Control Station
¾ HP Evaporators and drum natural circulation of PH and AQC Boiler
¾ HP Super heater 1 of AQC and PH Boiler
¾ Mixing Header
¾ HP Super heater 2 of AQC Boiler
¾ Final HP steam to Turbine

FOR LP STEAM
¾ LP Boiler Feed Control Station (Tapping from existing HP Feed Water line with a PRV)
¾ LP Evaporators and drum natural circulation of PH & AQC Boiler
¾ LP Super heater of PH & AQC Boiler
¾ Final LP steam to Turbine LP Injection Point

CONDENSATE PRE HEATER (CPH)


Condensate Preheater (CPH) assembly is envisaged in AQC Boiler in last module assembly placed at the top in flue gas path
before Clinker ESP & stack. Condensate Preheater is envisaged to recover available heat from the flue gas before discharging to
the atmosphere. The recovered heat increases the temperature of Condensate entering the Deaerator, thus overall efficiency of
the boiler is increased.
The CPH modules consist of a top and bottom header and helically wound Solid Fins tubes.
The CPH assembly is fully drainable by the drain valve provided on the inlet header. To expel air from the CPH during charging and
while draining air vent valves are provided on the outlet header.
Condensate inlet piping to the CPH is provided with following:
¾ Temperature Element for remote temperature indication.
¾ Pressure gauge for local pressure indication.
¾ Temperature gauge for local temperature indication.
¾ Flow Nozzle is provided to measure and provide signal to control valve located at the inlet of Condensate Preheater to
open / close. The amount of flow passing through control valve is depended on amount of steam generated in the Boiler.
Condensate water outlet piping from CPH is provided with following:
¾ A Temperature indicator after the tapping of the recirculation line.
¾ Pressure transmitter is provided for remote pressure indication and a pressure gauge for local indication.
Condensate water system is also having the bypass arrangement.

DEAERATOR (Common for Plant)


Deaerator supplies de-aerated water to PH & AQC boilers. Hot condensate from AQC Boiler Condensate Pre-heater flows back
into the Deaerator and also there is make up water connection for catering the losses.
Deaeration removes the corrosive gases such as dissolved oxygen and free carbon dioxide from the condensate water. This
ensures protection of the feed water lines, steam lines, boiler tubes and other pressure parts of the boiler against corrosion and
pitting thus saves boiler re-tubing and expensive plant shutdowns. Further as the temperature of feed water is raised to Deaerator
operating temperature of 126°C and then fed to the economizer to increase overall boiler thermal efficiency.
Deaeration is done by heating the condensate with steam vigorously scrubbing the water with this steam removes the last traces
of dissolved oxygen2 and brings down well below the recommended level in feed water.
The Deaerator in which make up water & condensate is heated to its boiling temperature at the operating pressure by steam. At
boiling point all the dissolved gases such as Oxygen, Carbon Dioxide, Etc. are liberated as solubility of gases decreases with
increase in temperature.
Steam rises from the bottom of Storage Tank, heating the water and rises through the interconnection pipe. Oxygen, Carbon
dioxide and other dissolved gases are vented out along with vent steam through the vent nozzle. Vent pipe has a globe valve to
throttle or restrict the flow of venting steam.
The dissolved Oxygen level in the feed water by mechanical Deaeration can be brought to 0.007 ppm. If oxygen level is not
maintained in Deaerator, the dissolved oxygen can be further scavenged by the reaction with chemicals such as Hydrazine. By
chemical scavenging the dissolved Oxygen level can be maintained to 0.007 ppm. Chemical is dosed in the storage section of
the Deaerator through a header, which is connected to the dosing system through a pipe with an isolation valve. The dosing of the
particular chemical is done in predetermined quantity and concentration.
Storage tank is supported by two saddle supports. One saddle is fixed and another is sliding to take care of thermal expansion.
Platforms and ladders are provided for tank for O & M feasibility.

Feed Water Pumping Station


The de-aerated water from the Deaerator storage tank is pumped into the boiler through feed water pumps (BFWP). Two feed
water pumps are commonly provided for both for HP & LP system (1W + 1S). The feed water pumps (2 x 100%) are multistage
Centrifugal Pumps. Electrical motors drive the pumps. Feed water pumps associated system:
Suction piping Common suction header for both the pumps is connected from the Deaerator outlet piping, providing necessary
NPSH. Each pump on suction side is provided with an isolation valve, strainer & local pressure indication.
Differential pressure switch across the strainer is provided to generate the diff. pressure Hi & Hi-Hi alarm signal in the DCS.
•Discharge piping of each pump on discharge side is connected to discharge header, which supplies feed water to the 2 HP
boiler drums through the Economizers located in AQC Boiler. Whereas in case of LP system, the a tapping with a pressure
regulating valve from the common Feed water pump discharge header & directly supplies the feed water to the both LP drums in
PH & AQC Boiler at the required pressure.
•The pressure transmitter installed on the header generates the discharge pressure low alarm signal to enable / caution for
starting the stand by pump.

Note (Please refer vendor pump manual for safe operation & maintenance of the BFWP)
•Auto Re-circulation valve (ARC): The automatic pump recirculation valves protect centrifugal pumps from possible damages
caused by thermal and hydraulic overloads at low load operations by means of an automatic controlled bypass flow which
corresponds with the required minimum flow of the pump. This protects the pump from cavitation due to churning effect.
•The cooling system is provided for the common Boiler feed water pump bearings .

Refer P&ID for Deaerator & BFP system (PB-33376-1)

Feed Control Station


WHRB, when it is in operation, must be kept continuously supplied with feed water to maintain normal level in the drum.
Feed water is obtained at the inlet of feed water control station from the Economizer Outlet of AQC Boiler after the feed water
pump at a temperature of 193 ºC.
There are two feed control stations (2 x 100%) for both AQC & PH boiler (HP) & separate feed control stations (2 X 100%) for LP
systems in both PH & AQC Boiler, out of which at least one of each must be in service in each case when the related WHRB is
operational.
2x100% feed controls is used during startups and is capable of feeding the boiler only when the steam flows from WHRB. A
feature of above 100% level control valves is that it enables the regulation of feed water to the WHRB to be on auto mode from
the very start of WHRB.
The following are installed in the common inlet line from the Plant feed main to the two feed regulation Stations.
¾ Pressure indicator to indicate feed water pressure
¾ Flow nozzle with impulse connections with 2 out of 3 flow transmitter.
The flow transmitters provide feed flow signal to the feed Indicating controller.
There are separate feed control stations (2 X100 %) for both PH & AQC boiler (HP) & 2 X100% for LP Circuit applicable for both
PH & AQC Boiler. The feed regulating stations are now described.

100% valve of Feed Regulation Station


The 100% feed regulating valve is used during Startup of the WHRB.
The valve can be operated either on auto or manual made. The positioning of on auto is controlled only by the level signal from
the Drum, which is acceptable at loads
Valve is a globe type control valve pneumatically actuated by a spring opposed diaphragm actuator. The characteristic of the
valve is linear, with equal increase in flow for equal valve opening. On loss of control air, the valve opens full. There is no manual
override for controlling the valve.
The valve is arranged between a motorized operated inlet Isolating valve and a manually operated outlet Isolating valve. The valve
is normally kept open. In Inlet of the both the valves a drain connection is provided with isolation valve. The drains normally
remain closed and opened only to drain the line when control valve has to be opened for inspection/maintenance.
The valve can be positioned on manual mode from the DCS to provide the required quantity of water to maintain normal water
level. In the auto mode the level indicating controller positions the valve.
Level transmitters continuously monitor the steam drum water level. A signal from two out of three of these transmitters feed a
level signal to through a 2/3 drum level micro. These level signals are compensated for drum steam pressure. The set point of the
controller is 0 (i.e. normal level, 50%). When is switched on the auto mode, the controller compares the level signal with the set
point and generates an error signal if there is a deviation and positions the valve through the positioner to correct the deviation
and its automatic control are adequate during WHRB startups & low steam flows, when rapid changes of drum level (except
during swelling) is not envisaged. The operation of control valves can be sluggish and cannot respond to rapid water level
changes due to large load changes.
The inlet, outlet and drain arrangements are similar to the low load control valve described earlier.
Valve is a full load feed regulating valve for maintaining drum water level and is pneumatically operated by a spring opposed
diaphragm actuator. The valve opens full on loss of control air and has no manual over ride. The valve is positioned by the flow
indicating controller.
It is a three element controller, which takes into account not only the drum level, but also the steam flow from WHRB and the
current feed water flow, to correctly position the feed regulating valve.

The drum level signal, compensated for drum pressure, is received in controller. A linearized steam flow signal, compensated for
steam pressure is also received in.
The drum level which is a measured variable signal is computed with the anticipatory signal of steam flow in and a resultant error
signal is fed to feed indicating controller compares the level error signal with the feed flow signal it receives from flow
transmitters and computes a control current signal based on its set point (usually normal level) . The valve position is transmitted
to the DCS. On the DCS, current drum level, steam flow, feed flow & the feed control valve position can be monitored.
The three element control adopted for the 100% flow control valves takes into account the drum level, steam flow and feed water
flow for positioning of both the control valve

Attemperation line
Attemperation control station consists of globe type pneumatically actuated control valve to control spray water flow to the
Attemperator. The control valve is provided with isolation valves and a bypass control valve with the isolation valves to prevent
back flow of steam a NRV is provided in the line.
The main steam temperature signal is received from the measured process variable is compared with the fled set point (SP) in the
temperature controller block and a control signal is generated. The control output signal (CV) from the controller will position the
Attemperator control valves through a current-pneumatic converter. Action of the control valve is Air/ Signal fail to open.

Attemperation station is located in between Super heater 1 & Super heater 2 of AQC Boiler.

Boiler Pressure Part Description


Various pressure parts are grouped as follows:
Economizer (Common for both PH & AQC Boiler)
Steams drum (Both LP & HP)
Evaporator (LP & HP Circuit both)
Super heater (LP & HP Circuit both)

Economizer (Common for both PH & AQC Boiler)


The Economizer located on the third last stages of the exhaust gas path of the AQC Boiler.
Finned tube Economizer is located in the boiler to recover economically feasible heat from the flue gas before discharging to the
atmosphere. The recovered heat increases the temperature of feed water entering the steam drum. The direction of feed water
flow (inside the tubes) and flue gas (outside the tubes) are parallel flow to avoid steaming in Economizer. Flue gas flows vertically
through the Economizer. Feed water from the Boiler Feed Water Pump enters the Inlet header of the Economizer.
The coils are arranged between inlet and outlet headers. The economizers are fully drainable by the drain valves provided on the
inlet headers to expel air from the economizers during filling of the boiler, air vents with valves have been provided on the outlet
header. Manholes are provided on the in/out duct casing for cleaning and inspection of the Economizer surfaces.
There are two modules of Economizer; during operation, feed water from BFP outlet flows to the Economizer- inlet header and
through the coils absorbing heat from the flue gas to economizer-outlet header then it flows to the steam drum via the feed
control station.
Economizer is provided with air vent and drains. ECO is hung from the top by Rod Hangers and anchor support with provision for
downward thermal expansion.
The drain valves are used for draining the ECO tubes when the WHRB is not in service, if required for maintenance
Feed water, after picking up heat from the Economizer, enters the HP Drum of both PH & AQC Boilers through the feed control
stations.
Feed water from Eco outlet header of AQC Boiler, one branch of feed pipe is connected to AQC Boiler HP drum through the AQC
Boiler HP feed control station and another branch is connected to PH Boiler HP drum through PH Boiler feed control station.

Temperature Indication
¾ Temperature Indication is meant for indicating feed water temperatures before & after Economizer.
A temperature transmitter provides indication in DCS.

Pressure Indication
¾ Pressure Indication is meant for indicating feed water pressure after Economizer.

Steam Drum
The Steam Drum is a welded cylindrical vessel. For PH Boiler the LP & HP steam drum is supported by the main down comers and
the down comers are placed on the WHRB structure with slide bearing. The slide bearing will permit the horizontal thermal
expansion of the drum. For AQC Boiler the HP & LP steam drums are supported on two saddle supports, one is fixed to main
structure & the other support is bolted with slotted hole to permit the thermal expansion of the drum. The drum is insulated by
bonded mineral wool mats. Two manholes are provided at either end to access the drum. The drum is closed tight at either end
cover plates bolted against the manhole rim by two holding bars.
A gasket is fitted between the cover plate and the mating machined surfaces in the dished ends. The cover plates swing inside,
for convenience during opening.
Steam Drum is fitted with several components to perform important functions, which are listed below:
Steam Drum receives feed water from the Economizer outlet through feed pipes and distributes the feed water along the length of
the drum by a perforated pipe to maintain a near constant level (Normal water level) for continuous supply to the evaporators
through down comer pipes. While flowing through the evaporator panels, by absorbing heat from the cement kiln exhaust gas, the
hot water gets converted to water / steam mixture and flows back to the steam Drum through riser tubes.
Steam drum receives the water – steam mixture from the evaporator tubes through the riser tubes, the water – steam mixture in
the steam drum separated by Baffle plates which is a primary steam separator. Further saturated steam flows through the
Secondary steam separator Demister pad installed at the outlet of the steam drum to separate traces of water particles and to
ensure steam purity. Water which is heavier is separated from steam and trickle down to mix with the water in the steam drum.
Saturated dry steam collects at the top of the drum and distributed to the Super heater.

Conditioning of Boiler Water


Due to continuous evaporation of boiler water in the drum, minor impurities present in the feed water, concentrate to high
impermissible levels in the boiler water. Rise in hardness of water (conductivity), content of chlorides, silica etc., have to be kept
to a minimum to prevent scale formation or deposits, in the evaporator tubes and drum.
Sample of Boiler water is collected from the continuous blow down line through the sample coolers and are to be tested in
laboratory. If the analysis indicate high conductivity (chlorides, silica etc.,), small pre-determined amount of water is
continuously drained from the steam drum through the continuous Blow down valve. Motorized Blow down valve (Globe valve) is
provided for controlling the flow to reduce their concentration to permissible levels in the steam drum.
Tri-Sodium phosphate is dosed into steam in the boiler drum to maintain a phosphate concentration of maximum 34 ppm and
pH of 9.0 to 11.2. The Phosphate has the capacity to convert hardness producing insoluble calcium/ magnesium salts to soluble
sodium salts, which are drained through the blow down. A typical reaction can be as follows

3 CaSO4 + 2 Na3 PO4 →Ca3 (PO4)2↓ + 3Na2 SO4

The dozed phosphate also provides desired alkalinity to the boiler water. An alkaline pH minimizes the possibilities of corrosion.
Dosing of phosphate to the Boiler water is to be done in a manner that it quickly mixes with the whole of Boiler water. To enable
this, a perforated 25NB pipe has been laid along the length of the steam drum and connected to the HP chemical dosing system
through line with an isolation valve and a non-return valve.
The following facilities have been provided in the steam Drum for the above operations:
Level Gauges, Level Indicators, Level Transmitters Level Sensing Instruments
Level sensing instruments are tapped off from the front & rear sides of the steam drum near the hemispherical dished ends. Level
Indicators & LEVEL TRANSMITTERS:-Three level transmitters are installed on the steam drum. Signal from the two of these
transmitters & level indicator are taken for three element control and the level transmitters signal is used for drum level control
as process variable .
Maintaining the normal water level in the steam drum is one of the important parameters, to monitor and control this, elaborate
provisions for level instrumentation has been made on the Steam Drum.
¾ Pressure Indicators
¾ Pressure indicators are provided for local indication
¾ Pressure Transmitters
¾ Pressure transmitter is installed on the steam drum to provide remote indication of steam drum pressure.

The reading of the steam drum water level by the level transmitters is affected by the drum pressure. Transmitters through
isolating valves mounted on the steam drum, provide a pressure compensation signal to the drum level control macro, so that
drum level signals represent true level neutralizing variations due to pressure changes. They also provide steam drum pressure
signal to DCS.

Drum Safety Valves


To protect the boiler and the personnel against the consequences of abnormal pressure increase caused by sudden load
fluctuations, closure of steam valves etc., two spring loaded mechanical safety valves have been fitted on the steam drum. On
increase of the steam pressure beyond the set value of the Safety Valve’s the valves open automatically to relieve the steam to
atmosphere. There are silencers on each safety valve to reduce the noise levels within the specified levels. The safety valve closes
when the drum pressure falls to the reset pressure of the valve. The relieving capacity of all the Safety Valves together with safety
valve on steam super-heater outlet line is designed in such a manner that even at maximum fluctuating of the Boiler, the valves
are capable to relieve the total generation of steam thus safeguarding the boiler.
Do not operate the WHRB with safety valves gagged. Passing safety valves must be attended during the next planned shutdown.

Air Vent
An air vent, with one isolation valves is provided at the outlet line of the steam drum to vent out air during initial boiler filling &
cold start-up and while de- pressurization/ shutting down the boiler to prevent the drum from going into vacuum pressure due to
condensation. While boiler cold start up, the air vent is kept open till the steam drum pressure reaches 2 kg/cm2 (g) and similarly
it is opened when the drum pressure falls to 2 kg/cm2 (g) during shutdown

Dosing and Blow down Connections


A Continuous Blow down (CBD) connection and a Chemical Dosing connection are provided on the steam drum for conditioning
of the Boiler Water.

Continuous Blow Down


Due to continuous evaporation of boiler water in the drum, minor impurities present in the feed water concentrate to high
impermissible levels in the boiler water. Rise in hardness of water, phosphates, content of chlorides, silica etc., have to be kept
to a minimum to prevent scale formation or deposits in the boiler evaporation tubes, drums, super-heater, steam piping and the
downstream equipment. Sample of boiler water is collected through a sample cooler and the sample is analyzed by an online
conductivity analyzer. Based on measured value of conductivity, determined amount of water is continuously drained from the
boiler drum through the Continuous Blow down (CBD) line by a motorized CBD valve to reduce the concentration of impurities
and to maintain within the permissible levels.
A 25 NB pipe with its one end open is provided below the steam drum, this line is connected to blow down tank. Blow down tank
consist of Level transmitter which gives signals to level control valve provided at the outlet of Blow down tank to maintain the BD
tank levels.

Evaporators (for both HP & LP circuits)


The HP Evaporator is located after the super heater coils in the flue gas path for both PH & AQC Boilers. Finned tube evaporators
for AQC Boiler and bare tube evaporators for PH Boiler are provided. The latent heat required for converting saturated water to
saturated steam is taken from flue gasses and mixture of saturated steam and water will enters to the steam drum. The direction
of steam and water mixture (inside the tubes) and flue gas (outside the tubes) are parallel in AQC Boiler whereas cross flow in PH
Boiler. Flue gas flows vertically through the Evaporators in both PH & AQC boilers. Saturated Water from the drum enters to the
Inlet header of the Evaporators. The coils are arranged between inlet and outlet headers. The evaporators are drainable.
Manholes are provided on the in/out duct casing for cleaning and inspection of the HP evaporator surfaces.
There are four modules of HP evaporator & single module of LP evaporator in PH Boiler & single module each of HP & LP
evaporator in AQC Boiler; during operation, the saturated water from the drum is supplied to the evaporator coils through inlet
header where the water absorbs latent heat from the flue gases and again flows back to steam drum through outlet header. Or in
other words the Evaporators convert saturated boiler water received from the Drum through down comer pipes into a steam water
mixture, by absorption of latent heat from the Kiln exhaust gas.
The steam water mixture is led back to the drum from the evaporators through riser pipes. The Evaporators are hung from the top
in the flue path by rod hangers in AQC and PH boiler Evaporator is supported on boiler cage, with provision for thermal expansion
downward & in the sides.
In the steam drum, the steam water mixture flows through the separators where water & steam are separated and saturated
steam is collected in the steam header and flows to the Primary Super heater. Separated water mixes with boiler water to flow
through the Evaporator circuit again.

Super Heaters (Both HP & LP Circuit)


Saturated Steam collected at the outlet of PH HP steam drum flow through the Primary super heater section to convert saturated
steam into superheated steam by heat absorption from flue gasses. This superheated steam further collected in mixing header
located at the outlet of AQC boiler Primary Super heater.
Similarly saturated steam collected at the outlet of AQC Boiler HP Steam drum flow through the Primary super heater section to
convert saturated steam into superheated steam by adding degree of superheat.
Both AQC and PH Boiler Superheated steam collected at Mixing header and Total superheated steam further superheated in AQC
Boiler Final HP super heater through Attemperator control station. Attemperator control station is envisaged to maintain the final
super heater steam temperature going to Turbine.
Super heaters are made of modules, each consisting of an inlet header and an outlet header, with coils between the headers.
Super heater modules are hung from their top headers with provision for thermal expansion down wards.
The direction of steam (inside the tubes) and flue gas (outside the tubes) for both AQC and PH Boiler HP Super heater are counter
flow for optimum heat transfer.
Continuous and sufficient flow of the steam through the Super heater ensures the metal temperature of the coils does not exceed
the design value.
HP Final Super Heater inlet header (being the bottom most point in AQC) is provided with drain. Air vents is provided on the outlet
header of the HP final super heater. The air vents are opened before line up of the boiler. They are closed at a drum pressure of 2
to 5 Kg/cm²
Similarly saturated steam collected at the outlet of both PH & AQC Boiler LP Steam drum flow through the single LP super heater
section in both PH & AQC Boilers to convert saturated steam into superheated steam by adding degree of superheat and finally
injected in the Turbine through the LP injection point.
Attemperator
An Attemperator is provided after the mixing header of AQC boiler to maintain the final HP steam temperature. Spray is controlled
by quantity of feed water from the outlet of BFP header into the Attemperator through a pneumatic control globe valve which
controls the HP SH2 outlet temperature.
The spray water is taped from the feed water piping before the feed water control station at the BFP outlet header. Attemperation
control station consists of globe type pneumatically actuated control valve to control spray water to the Attemperator. The control
valve is provided with isolation valves and a bypass control valve with the isolation valves. To prevent back flow of steam a NRV is
provided in the line.

STEAM TEMPERATURE CONTROL LOOP


Steam temperature control is designed to maintain the Final HP steam temperature at 390° C. As the heat pickup in the Super
heater increases with load; the spray water quantity will increase.
The final steam temperature is measured and transmitted by the transmitter to the controller in DCS. The measured value is
compared to the fixed set point in the controller and a control output signal is generated, which is sent to position the
temperature control valve.

Main Steam Piping


The SH steam line connecting the outlet header of Super heater to the plant mainly comprising of:
• PRESSURE & TEMPERATURE MEASUREMENTS Pressure indicators with one isolation valves are provided for local pressure
indication.
Pressure transmitters installed on the steam line provide the main steam pressure signal to DCS. Pressure signals are taken as
the process variable for the pressure indicating controller. Steam pressure very high and Very low alarm is generated from the
signal and is indicated in DCS.
Temperature elements with transmitter are provided on the main steam line to measure and transmit the steam temperature to
DCS. Temperature signal is taken as the process variable for the temperature indicating controller.

ELECTRICALLY OPERATED MAIN STEAM STOP VALVE


This valve isolates the WHRB from the plant / Common steam header. Main steam stop valve is provided to isolate the boiler
from the plant during shutdown and during start-up until the operating parameters are attained. During regular operation of the
boiler, this valve is kept fully open supplying steam from the boiler to the plant mains. For line charging till TG Inlet

SAFETY VALVE,
This is a spring loaded, valve set at 15 Kg/cm²; pressure to protect the boiler against over pressures. The safety valve is similar to
Drum safety valves described earlier. The exhaust of the safety valve is piped to a silencer to reduce the noise levels when the safety
valve is operating. The silencer is mounted on a separate structure on top of the WHRB.
START UP VENT VALVE
Startup vent is an electrically operated regulating valve. The startup vent valve is to be kept open while start up. The valve is
normally set to open when there is load upset at a pressure higher than normal operating header pressure and below the super
heater safety valve set pressure. This valve is expected to relieve the excess pressure. For this purpose, pressure controller which
takes pressure impulses from the main line, commands start up vent valve to open the valve. The exhaust of is connected through
a silencer to reduce noise levels during its operation.

FLOW NOZZLE
Flow nozzle is installed on the steam line to provide impulse to upstream & downstream pressure readings to steam flow
transmitter. Flow nozzle is connected after the main steam stop valve.
Total 2 Flow nozzles provided in main steam line for AQC Boiler at HP Primary Super heater outlet and another flow nozzle at the
outlet of HP Final Super heater. Where, in PH Boiler, one Flow nozzle is provided at the outlet of HP Primary Super heater.
Similarly one flow nozzle is provided at the Outlet of LP super heater in both PH & AQC Boilers.

NRV As the plant steam supply is from more than one boiler, to prevent back flow of steam from the steam mains to the boiler,
when the boiler trips or when the boiler pressure is lower than that of the steam mains, a non-return valve has been provided before
the main steam stop valve.

STEAM LINE DRAIN


A motorized drain valve is provided at the inlet of MSSV. Other steam line drains consist of the manually operated valve .The
manually operated valve is kept opened during connecting to the main steam header.

SAMPLE CONNECTION
To analyze the super-heated steam quality, a sample line is taped off from the main steam line with an isolation valves and
connected to the Sample Coolers.

Operational Control
This section explains the major operational control points described in this chapter.

Steam Drum
Maintain feed water, boiler water quality, and chemical concentration as prescribed.
Maintain water level in the steam drum within permissible low and high levels. The protection system envisages boiler trip at very
low levels, which should not be bypassed.
Maintain drum level gauges in good working condition. Operators may verify the level transmitter reading with the level gauge once
a day.
THERMAL STRESSES IN DRUMS DURING START UP AND SHUT DOWN
Steam Drum is a large cylindrical shell. Before line up of a boiler, the inner and outer surfaces of the drum are at the same
temperature. When boiler is lined up, the inner surface gets heated up first by the water (and then by steam) and transmits heat
to the outer surface of drum. The heat transfer is by conduction and is a bit slow. For short time after line up, there can be
differences of temperature between steam and water surfaces of the drum. Such a difference can set up thermal stresses, which
are not desirable, and an alarm sounds gives at DCS. To minimize the thermal stresses, the operator must restrict the flue gas flow
rate when starting the WHRB by modulating the bypass control damper.

SWELLING
During WHRB startup, as the Boiler water temperature reaches 90°C, there is an increase of water level caused by increase in the
volume of hot water. Such swelling, if not controlled, can cause a High Level trip. To avoid this, initial filling is normally restricted to
low level (say – 100 to 150 mm) and the smart Operator anticipates a swell and uses the BD to drain and control the level.
Do not operate the WHRB with safety valves gagged.
Passing safety valves must be attended during the next planned shutdown.

Super Heaters

Super heaters must be drained after shut down and cooling of the boiler. They must also be kept open before a cold start up till 5
2
kg/cm pressure is built up. During hot charging they are opened for a few minutes.
Superheat steam temperatures at exit of Super Heater main steam temperatures must be monitored to see there is no excessive
heat pick up. Compare these figures with predicted performance values. High steam temperatures may mean high metal
temperatures.

General
2
Boiler water can be drained after a shut down only after depressurizing to 2 kg/cm and after cooling to 80 °C
Draining of Boiler water must preferably be done through the blow down tank.
If a tube failure is detected, it is advisable to plan for an early shut down. It may be possible to quickly repair the failed tube and
return to service. If the shutdown is in-ordinately delayed, there are possibilities of larger secondary damages, which may prolong
the shutdown, required for repairs.
Manually operated valves must be closed hand tight only. Use of levers on hand wheels is not desired.

Drum Metal Temperature Monitoring


When a WHRB is started after filling water to normal level, initially drum metal temperatures on the steam side and water side may
show considerable difference due to slow convective heat transfer across the drum metal and difference of heat inputs across the
water washed & steam washed parts of the drum. The temperature difference, if it exceeds 50°C, may set up abnormal thermal
stresses. Thermo well provision is given to measure the metal temperature in case of abnormal stresses occur.
Steam and Water System Technical Performance Data

WHRB Design Pressure: Maximum Working Pressure Kg/Cm² (g)

Set pressure and capacity of safety valves


Tag No Set Pressure kg/cm² (g)
WHRS-AQC2HP-MAS-SV-001 18
WHRS-AQC2HP-MAS-SV-002 19
WHRS-AQC2HP-MAS-SV-004 17.5
WHRS-AQC2HP-MAS-SV-003 17
WHRS-AQC2HP-FDW-SV-001 32
WHRS-AQC2LP-MAS-SV-001 4
WHRS-AQC2LP-MAS-SV-002 5
WHRS-AQC2LP-MAS-SV-003 3.5
WHRS-PH2HP-MAS-SV-001 18
WHRS- PH2HP-MAS-SV-002 19
WHRS- PH2HP-MAS-SV-003 17.5

Do not operate the WHRB with safety valves gagged.


Passing safety valves must be attended during the next planned shutdown.

Boiler Blow down System


This section describes the WHRB blow down system for safe draining of high pressure / High temperature steam and water from
the boiler using the blow down tank.

System Description
The P & I. Diagram of the water and steam system shows the various drains from the WHRB. Large quantities of steam or high
pressure / temperature water are not to be drained through open canals for the following reasons:
a) Such draining will cause splashing of high volumes of steam, which can be a nuisance by the noise it creates, and also it
affects the visibility around the draining area.

b) High temperatures of these drains can cause Scalding injuries to workmen who may come in contact with it.
c) The force and temperature of these drains will erode the linings of the drain canals.
d) Low-pressure steam, which can be recovered, if required, is wasted.
HIGH PRESSURE / HIGH TEMPERATURE STEAM AND WATER DRAINS (HP & LP)
S. No. Source Valve Nos. Temp of drain °C Frequency of usage

1. Continuous blow CBD with isolation 193 °C (HP Steam) Continuous, quantity depending on
down valve 127 °C (LP Steam) quality of boiler water
2. Intermittent / IBD with isolation 193 °C (HP Steam) During high level in steam drum and
emergency blow valve 127 °C (LP Steam) quality of boiler water
down

CBD Drain
Continuous blow down (CBD) is connected to the blow down tank. A motorized operated inching type valve is provided on CBD
line. Isolation valves at upstream are provided.

IBD / EBD Drain


Intermittent blow down (IBD) is connected to the blow down tank. A motorized operated inching type valve is provided on IBD
line. Isolation valves at upstream are provided.

Other Drains
The drains indicated in the P & ID are connected to the blow down tank. The blow down tank is capable of separating steam from
the drain water. The drains are connected tangentially in the upper half of the drum, to direct the drain fluid circumferentially
around the inner wall of the tank, to aid separation of steam and water by their differences in densities. A vent line of the tank is
provided open to atmosphere.
It can be seen that drains have been provided in the feed water line and connected to the drain canal. As these drains are either
for operation to drain these lines after isolation or for short time during charging, their connections to the open canal is not
expected to pose a problem.
¾ All level control station drain
¾ All pressure control station drain
¾ Steam drum level indicator.
¾ Steam drum safety valve drains
¾ Sample coolers let off drain.
¾ All equipment / pressure part drains
Continuous & Intermittent Blow down Control
CBD & IBD control involves the following operations:
Obtain a sample of boiler water from the steam drum to the Sample Coolers.
Analyze the sample for conductivity, hardness, NaCL, Silica, Fe, etc., and working out a rate of draining of boiler water to
maintain the concentrations as suggested in Boiler water quality.
Motorized opening / closing positioning the CBD valve is to be decided depending on the water quality. Motorized opening /
closing positioning the IBD valve is to be decided depending on the Steam drum high level and water quality.
Repeating the sampling, analysis and repositioning the CBD & IBD valve after certain Interval is necessary to maintain the
required Boiler water quality. This system of motorized control requires the services of collection of samples from sample coolers,
a chemist and a laboratory round the clock.
The arrangements provided for CBD control is:
A perforated pipe, laid along the water space in the steam drum connects through a stub to the continuous blow down line.
CBD & IBD line from drum connects to the blow down tank.
A tap off from the CBD line is taken to the sample coolers for intermittent analysis of boiler water conductivity and also for a grab
sample sampling of CBD / Boiler water is done in sample coolers of the sampling package.
This sample coolers package provides analysis of the following samples to provide comprehensive information of quality of
steam and water of WHRB.

¾ Samples of boiler water (CBD) from the steam drum of WHRB.


¾ While all the samples above are analyzed for conductivity by separate analyzers, the CBD samples are analyzed in
addition for pH also.
¾ Care of other sample coolers is identical. Valve is normally kept open to maintain small continuous flow of boiler
water to the blow down tank. This is required to ensure the sample at any time to the sample coolers is truly
representative of the sample being analyzed. This continuous flow also ensures that these lines do not get chocked
for want of adequate flow.
An isolating valve to the sample coolers is kept open. The sample coolers are used for grab sampling for doing the analysis of the
boiler & Blow down water and maintaining the boiler water quality.
Tri-sodium phosphate dosing to Boiler water is to maintain its phosphate content at 35 to 40 PPM. The tri-sodium phosphate at
the suggested levels maintains the alkalinity of the boiler water (pH 9.0 to 10.5) and also converts the harmful, insoluble calcium
and magnesium salts which form the residual hardness of boiler water, to benign soluble, sodium salts, in the form of a soft
sludge, to be drained by the CBD.
Phosphate dosing, prevents corrosion of the water washed parts of the steam drum and the Evaporator tubes, by adjusting the
speed or the stroke of the pump provided as described below. Excess as well as reduced phosphate levels in Boiler water should
be avoided. (The phosphate dosing is also sometimes called as "HP dosing" as the pump used develops high pressure to dose
against the boiler drum pressure).
Chemical Dosing & Sampling System

HP Dosing System
The equipment, which are of stainless steel, provided for phosphate dosing (“HP dosing”), are shown in P & I diagram and consists
of:
¾ A common mixing tank of 300 liters for preparation of tri-sodium phosphate solution.
¾ Two dosing pumps (with one stand by) dedicatedly for both HP & LP Boiler systems
DM Water source for preparation of the phosphate solution as well as for flushing
Generally Tri sodium phosphate is dozed through HP Dozing system to take care of the ingress of hardness salts and to increase the
boiler water pH.

Mixing Tank
The Mixing tank of 300 liters is a MSRL covered cylindrical vessel, with a level indicating gauge glass , DM water inlet line (with a
manual isolating valve) , an over flow drain line. A drain line with a manual-isolating valve, a dissolving basket for placing
required quantity of tri-sodium phosphate powder for preparation of the solution is provided. A solution inlet connection to the
pumps with a manual isolating valves, a motor operated stirrer is also fitted for preparation of chemical solutions. The level of the
mixing tank is monitored by level switch. Availability of a minimum level is a required permissive condition for starting or
continued service of a dosing pump.

Sr. Requirement Dosing % Dosage Specific Flow rate Chemical Qty. at 100%
No. Concentration ppm gravity (lit/hr) conc. (kg/day)

1 AQC Boiler
Tri sodium 0.5-5% 28 -- 20 0.50
Phosphate
2 PH Boiler
Tri sodium 0.5-5% 28 -- 20 0.55
Phosphate

Phosphate Dosing Pump


Two phosphate dosing pumps 0-5LPH and 30kg/cm²(g) pressure for HP Boiler & 0-5 LPH and 12 kg/cm²(g) pressure for LP
Boiler have been provided, out of which one is for service at a time, and the other is a standby. The pumps are plunger operated
reciprocating, positive displacement type. The stroke of the plunger can be altered for manual adjustment of flow to suit feed
water requirement. The vendor manual of the pump and gearbox is provided for full information on construction and parts detail.
Each pump is connected to a common discharge line with the following valve arrangement:
An inlet, valve with a "Y" strainer, Y strainer traps dirt or other solid particles in its basket. The Y strainer is to be cleaned once a
month, after stopping the pump and closing its inlet and outlet isolating valves.
On the discharge side of the pump, a pressure gauge and an outlet isolating valve is fitted before the common discharge line. A
safety relief valve has also been fitted on the discharge line to relieve any over pressures in case of closure of valves on the
discharge line. The outlet of the relief valve is returned to the mixing tank. The relief valve must be tested for its operation at the
set pressure at least once a year. The pump must not be operated with the relief valve continuously operating. (Cause of relief
valve operation must be found and rectified).
The common discharge line is connected to the HP dosing line of the steam drum through an NRV and an isolating valve. The
isolating valve is verified open before boiler line up and normally remains open all the time. Phosphate dosing is through a
perforated pipe along the full length of the water space in the drum.
Availability of a minimum level in the mixing tank is a pre-condition for starting or running of the dosing pumps. Out of the two
pumps, one pump is selected for service and the other is in reserve (DCS macro, Local panel). The pumps are interlocked such
that when a working pump trips, the reserve pump starts automatically.
A phosphate pump is placed immediately in service after the WHRB start up in the following manner:
Boiler water sample is analyzed and phosphate content is determined.
The pump is prepared by opening the outlet valve from the mixing tank, opening the inlet and the two outlet valves of the pump.
Two minutes are allowed after opening the inlet valve for the pump to get filled with phosphate solution. The pump is started by
switching on the motor. The pressure gauge is observed. It should show a reading, higher than the steam drum pressure. A Safety
Valve is provided on the pump discharge line for safety as this is a positive displacement reciprocating pump.
Any abnormal noise from the pump, motor or gearbox is noted. The safety relief valve should not also be operating. If there are no
abnormalities the pump is allowed to run.
Every four hours, the phosphate content in the boiler water is checked by laboratory sample analysis and also by the pH meter.
The pump speed stroke is increased or decreased to maintain the phosphate content within 8 to 10 PPM by continuous pump
operation.
The phosphate solution level is observed in the mixing tank by the level gauge. If the level falls to 25% of the gauge glass level,
additional solution is prepared as stated above. Low level switches are also provided in the tank for safety of the pumps.

FLUSHING THE PHOSPHATE PUMP AND THE LINES WITH WATER DURING LONG STOPPAGE OF THE WHRB:
If the WHRB is to be stopped for more than a few days for servicing or maintenance, the phosphate pumps and the line are
flushed with water to keep them clean in the following manner. (Flushing) line is connected from the tank solution preparation
DM waterline to the inlet line of the pumps. The pump which was in service earlier is run, for about 30 minutes to one hour. DM
Water flushes the phosphate solution from the pump and the lines to the steam drum and cleans them. The pump is stopped. The
outlet valve from the mixing tank, is not opened till the boiler is again lined up and a phosphate pump is required in service. At
that time the isolating valve on the DM line is closed.
NOTE: Do not operate the Stirrer of the HP dosing pump when the HP tank is dry or not filled with water or the dosing solution.
The dry operation of the stirrer can lead to failure of the stirrer (misalignment of the stirrer).
LP dozing system is provided in the common Deaerator for Hydrazine to scavenge the last traces of the dissolved Oxygen in feed
water.

The vendor manual of both the systems is provided for full information on construction and parts detail.

Maintaining Quality of Steam


Good Quality steam is obtained if the following requirements are met:
Proper assembly of baffles, demister pad in the steam drum as per erection instructions (checked before commissioning of the
Boiler) Boiler feed water as per norms as suggested.
(Monitor the feed water conductivity & PH analyzers) and Control of Boiler water quality as suggested.
Monitor the saturation steam & main steam conductivity Increase of saturation steam conductivity may be a warning for check of
drum internals or maintaining high water levels in steam drum. It should be understood that if the quality of Boiler feed water
deteriorates; the steam quality is directly affected. After several years of service, during a boiler over haul, baffles and demister
are checked for damage or erosion holes, which may bypass steam from the separation devices. Steam which bypasses the
separation devices carry with it moisture, with it salt contaminants to steam.
Higher than permissible levels of Silica in boiler water will result in Silica carry over in steam.

Operational Control
The water chemistry for determining low levels of impurities in water calls for special instruments, special analytical procedures
and an experienced chemist. These should be available from the time of commissioning the boiler.
In a chemical process plant, in spite of the best available demineralization facilities the boiler feed water may occasionally get
contaminated by return condenses from the system. A procedure to systematically check the return condensates (particularly for
contamination by Fe, Chlorides and Oil) must be established and contaminated condensates must be discarded.
Phosphate & Hydrazine dosing must be adjusted for continuous operation.
List of points in the Sample coolers for both PH & AQC boilers is given in the page below

TITLE: FLUE GAS SYSTEM


FLUE GAS SYSTEM
This chapter describes the Cement kiln exhaust flow through the WHRB, insulation and casing of WHRB and the Stack, various
sealing air connections are also indicated.
System Description
The steam drum & WHRB pressure part panels are supported on column structures. Insulation & steel casing is applied enclosing
the coils to provide a gas tight passage for the exhaust gas from the Cement kiln. The casing is covered fully with insulation and
aluminum cladding. The insulation is held by strips and the screws as shown in the respective drawing. Exhaust gas from the
Cement kiln enters the WHRB through ducting. The following are the instruments in the flue gas system.
¾ Flue Gas Pressure & Temperature at the tapping Point
¾ Flue Gas Pressure & temperature at Deduster Outlet
¾ Flue Gas Pressure & temperature at Boiler Inlet
¾ Flue Gas pressure & Temperature at Boiler Outlet
¾ Flue Gas Temperature at various intermediate stages.
¾ Boiler /Deduster Hopper Dust Level switches.
¾ Zero speed switches on the dust conveying equipment’s such as Drag Chain & RAV
¾ Damper Actuators for operating various dampers.

Operational Control
The anticipated performance figures both steam / water and gas side has been given in following section. The operator shall
familiarize himself with these figures. Elaborate instrumentation has been provided to measure each of these factors. Alarms
also have been provided to alert the operator in case of deviations for several of these readings Operator attention is needed
particularly for the following - Kiln Exhaust Gas (Boiler inlet) temperature -Gas side temperature drop, pressure drop
Steam/Water side heat pick up across pressure parts like,
– Super heater 1 & 2
– Evaporator coils
– ECO
– CPH
Evaluating these figures the operator should decide the need for hammering in case of PH Boiler (Or other checks during
a shutdown).
– Healthiness of aviation warning lamps is to be check periodically.

Flue Gas Flow can be monitored by spot flue measurement methods at the locations provided in ducts for flue gas flow
measurement. For reference values, refer Boiler Data sheet mentioned above in this manual.
The accuracy of the flow measurement will be based on instrument error, measurement errors & the upstream and downstream
corrections at the measuring points.

HAMMERING SYSTEM FOR PH BOILER


The exhaust gases from the Pre-heater which are entering the PH boiler contain high dust concentration. Moreover the operating
conditions in the cement plants requires design of waste heat recovery boilers which should be able to withstand the problem of
heavy coating formation, as the raw meal dust tends to adhere to the heat exchanging surfaces, resulting in drastic reduction of
capacity. As such the characteristics of the dust in the waste gases with regard to particle size, stickiness, abrasiveness has to be
taken into account while designing the boiler heating surfaces.
Heating surfaces of PH boiler are exposed to sticky dust coming along with the incoming gases from the Pre-heater. This dust
settles on the heating surface and reduces the overall heat transfer coefficient. Hence the heat transfer reduces. So provision of
proper dust removal system becomes essential for the PH boilers. The PH boilers are designed with horizontal tubes arrangement
and these tubes are continuously or periodically cleaned by mechanical hammering / rapping.
A rapping device is a special facility provided for boiler cleaning. By rapping the fouled convection heating surfaces, the bank
tubes are subjected to vibrations so that the deposited dust falls off. For PH boilers the rapping system (01 No.s each side) is
provided on each pressure part bundles of the boiler to have hammering. The hammering systems are provided on both L H and R
H sides of each boiler pressure part bundle from top to bottom of the vertical PH Boiler so that effective cleaning of all the tubes
in the entire cross section of the boiler is possible.
The rapping system consists of the drive motor, helical gear box, chain & sprocket arrangement with chain, the hammers
installed on the horizontal shaft. The shaft is rotating at a speed of 2.3 rpm. When the shaft rotates, the hammers installed on the
shaft hit the ends of the bottom part which results in vibrations to the tubes which are interconnected to each other. Due to
vibrations the dust accumulated over the tubes is dislodged and falls down. Depending on the nature / characteristics of the dust
in the gas, the rapping system is to be operated continuously or periodically.

PROCESS & PLANT STRUCTURE

Plant consists of two WHR Boilers installed behind cement plant. AQC boiler consists of LP & HP sections and PH boiler also
consists of both HP & LP sections.
Flue Gas Circuit
PH Boiler Circuit
PH BOILER is located in the circuit in between the PH outlet string and the existing PH Fan. The PH Boiler is designed to cool the
flue gasses from 320°C to 180°C to maintain required Flue Gas temperature at the inlet of Raw Mill after the PH Fan.
There are 2 Isolation ON / OFF Tandem type damper is located at boiler entry and exit to facilitate PH Boiler operation and
maintenance. These dampers are provided with seal air fans for volumetric isolation of the boiler during maintenance with the
Cement Plant in operation.
One By Pass Multi louver Damper located in the PH down comer duct to regulate the Flue gas flow to PH Boiler.
During the operation hot flue gasses are diverted to PH Boiler by opening inlet & outlet damper and start closing the bypass
regulating damper slowly. By pass regulating damper is to divert the flue gases through the PH Boiler and also to maintain the
Cement plant in stable operating conditions. After Cement plant is in stable condition with PH Boiler in operation the Total Flue
Gas Draught required is maintained by existing PH Fan itself.
In case, if temperature required at outlet of PH Fan is high, which might be required when there is high moisture content in Raw
Meal during rainy season, open by pass damper slightly so that partial hot gasses from PH outlet string will mix with cold PH
Boiler outlet gasses and maintain required temperature at the outlet of the PH Fan, which is connected to the Inlet of the Raw
Mill.
The direction of flue gas flow is Vertical (Top to Bottom) in case of PH Boiler. Dedicated Hammering system is provided (2 No’s in
each bundle of pressure parts) to remove of the sticky dust which is carried with the flue gases and sticks to Boiler pressure parts
due to its nature during operation. These are supposed to be removed to have a proper heat transfer across the pressure parts
surfaces.

Please Refer PB-33381-2 (Flue Gas P & ID for PH Boiler) for better understanding.

AQC Boiler Circuit


AQC boiler is located in circuit in between the Clinker Air Quenching cooler and the clinker ESP. End Tapping is envisaged for
Maximum heat recovery from existing Waste gases with a coal fired Hot Air Generator in the circuit. The AQC Boiler is designed to
cool the gasses from 440°C to 90°C so that maximum heat recovery from flue gasses is possible. The Boiler exhaust gasses will
deliver to Chimney through clinker ESP & ESP Fan.
Isolation ON/OFF Butterfly dampers are located at Deduster inlet (End Tap), at the Inlet of HAG, whereas at the outlet of HAG
there is Guillotine type hoisting damper to facilitate HAG Operation and maintenance.
One No Bypass Multi Louver Damper is located between existing End Tap (Cooler Exhaust) and Clinker ESP to regulate flue gas
flow to AQC Boiler. Also there is a Multi-louver damper to bypass the Hot Air Generator/to regulate Dilution gases through Hot Air
Generator
The Pre dust collector is provided before the Hot Air Generator to remove higher particles of abrasive dust coming from Cooler
End tap ducting so that dust loading at HAG/AQC Boiler inlet can reduce.
During operation Hot Flue gases are diverted from Cooler Exhaust (End Tap) to AQC Boiler by opening De-duster inlet and HAG
Bypass & Boiler Outlet damper. After that close Bypass Regulating damper to divert hot flue gases to Boiler and also to maintain
the cement plant in stable operating condition. After lining up the Boiler Operation cycle for the HAG Starts as per the logic, once
the HAG is in line the governing point will be the HAG outlet Temperature which will regulate the dilution gases by the Pneumatic
Multi-louver damper at HAG Inlet. The dilution gases for the Hot Air Generator is nothing but the Cooler Exhaust gases, which is
routed through HAG to dilute the high temperature gases generated by coal firing and obtain the required Flue Gas parameters at
the AQC Boiler Inlet. After Cement plant is in stable condition with AQC Boiler in operation the total Flue Gas Draught required is
maintained by existing Clinker ESP Fan itself.
The Mechanical Design Flue gas temperature allowed through AQC End Tap is 450 °C, whereas process design temperature is
305 Deg C. The process temperature at the Outlet of HAG is 440°C. If Flue gas temperature is more than 440 °C the Dilution air
quantity is increased by opening the Pneumatic Multi-louver damper at the Inlet of HAG & if it is still more & when it goes more
than 450 °C then open the fresh air damper to allow the ambient air to dilute the Flue Gases and maintain the temperature
within limit.
Even if the inlet temperature is not reduced and goes above 475°C then open the bypass damper fully and box up the boiler to
safeguard the Boiler pressure Parts from high gas temperature.
The direction of flue gas flow is Vertical in AQC Boiler (Bottom entry & Top Exhaust)
Pre Dust Collector
One (1) No. of Integrated Pre-dust collector before AQC Boiler is envisaged. Pre-dust collector installed to remove the heavier
dust particles from the gases coming from Mid Tapping so that relatively clean gases pass through the AQC boiler. Baffles are
placed inside the pre dust collector for better gas distribution throughout the Pre dust collector so that higher particles of dust
can be retained in the dust collector due to gravity.

Following are the Properties of dust considered for design of Pre dust collector.
¾ Dust Concentration : 40 gm/ Nm³
¾ Bulk Density of dust : 1300 Kg/ Nm³3
¾ Temperature of dust : 305 deg c
¾ Diameter of particle size : μ 100 & μ 200

Following are the results at the hopper outlet of Pre dust collector.

Sr.no Particle Particle Inlet Dust Outlet Dust Diameter Distribution


Diameter(μ) distribution Mass flow Mass flow wise wise
rate(Kg/s) rate(Kg/s) separation separation
Efficiency (%) Efficiency (%)
1 100 0.8 0.84 50.29 40.23
1.67
2 200 0.2 1.41 84.33 16.87
3 Total Dust Separation Efficiency (%) 57.10

Please Refer PB-33380-2 (Flue Gas P & ID for AQC Boiler) for better understanding.
Feed Water, Evaporation, Superheated Steam and Condensate Circuit
Feed Water Circuit
Feed Water Circuit comprising of Deaerator cum Storage Tank, BFW Pumps (Same pumps Dedicated for both HP & LP Circuits),
and Common Economizer (Only in AQC Boiler) and Attemperator station.
Feed water from Deaerator outlet at 126 deg C is fed through HP BFW pumps to Common Economizer for HP Circuit, whereas in
case of LP Circuit feed water from Deaerator outlet at 126 Deg C is fed by taking a tapping from the HP BFP outlet header with a
pressure regulating valve directly to the LP drum (for both PH & AQC Boiler). HP Economizer for both AQC and PH Boiler located in
AQC Boiler to recover more heat from Flue gases and preheat Feed water from 126 deg C to 183 deg C and maintains proper
approach to avoid steaming in Economizer. Further feed water enters to AQC Boiler HP steam drum through AQC Boiler Feed
Control station to facilitate proper level in steam drum through 3 Element Drum level controls.
Feed water for PH Boiler is taken by tapping at the inlet of Feed control station. Further feed water enters to PH Boiler drum
through PH Boiler Feed control station to facilitate proper level in PH HP steam drum through 3 Element drum level control.
Fluctuations in the feed water circuit because of flue gas flow / temp fluctuations taken care by Feed control station through 3
Element drum level control.
Evaporation Circuit
Saturated Water from Steam drum enters to Evaporator through inlet headers and get converted into saturated steam by
absorbing required latent heat from Flue gases and return back to steam drum. We have provided two stage Steam separators
one is baffle plate arrangement which is primary steam separator and another Demister pad which is second stage steam
separator to ensure required 99.99% saturated steam purity coming out from the steam drum.
Independent Evaporator circuit is provided for AQC (LP & HP Evaporator & both Steam Drum) and PH Boiler (LP & HP Evaporator
& both Steam Drum).

Superheated Steam Circuit


Saturated Steam collected at the outlet of AQC steam drum flow through the primary HP super heater section to convert
saturated steam into superheated steam by heat absorption from flue gasses. This superheated steam further collected in mixing
header located at the outlet of in AQC boiler Primary Super heater.
Similarly saturated steam collected at the outlet of PH Boiler Steam drum flow through the Single super heater section to convert
saturated steam into superheated steam by adding degree of superheat.
Both AQC and PH Boiler HP Superheated steam collected at mixing header at the outlet of AQC Boiler Primary Super Heater and
Total superheated steam further superheated in AQC Boiler Final super heater through Attemperator control station.
Attemperator control station is envisaged to maintain the Final Super heater steam Temperature going to Turbine.
Where as in case of LP circuit the LP saturated steam collected from the PH & AQC LP drum is routed through LP super heater
sections of both PH & AQC Boilers (located at the outlet of HP Evaporator section in both PH & AQC Boiler flue gas path) directly
to Turbine LP Injection Point.
Auxiliary steam for Deaerator is taken from Main LP Steam Line to steam turbine.

Condensate Circuit (Common for PH & AQC Boilers)


Condensate after expansion in the Steam Turbine gets cooled by releasing latent heat to the cooling water in the water cooled
condenser and gets collected in the hot well at the bottom of Water cooled condenser.
The collected Condensate from the hot well pumped to Condensate Pre-heater located in AQC boiler through Condensate
Extraction pump to recover maximum available heat from flue gases and gets heated up to 118 deg C. Further the heated
Condensate gets collected in the Deaerator to remove dissolved oxygen. This is to facilitate maximum heat recovery and reduce
de-aeration steam consumption.
No separate Condensate Pre-heater is envisaged in PH Boiler.

For HAG operation kindly refer Vendor manual for HAG Operation & Maintenance
(M/s Fives Combustion)
D.WATER CHEMISTRY
D. WATER QUALITY RECOMENDATIONS

Water Quality Recommendations


This chapter describes the standards for the boiler feed water and boiler water for corrosion and scale free operation of the WHRB and
for obtaining pure steam. Methods of control of boiler water are also explained.

NOTE
This chapter must be read in conjunction with the following vendor manuals.
HP dosing system -
Suggested quality of boiler feed water (and Attemperator water) fed to the WHRB is given in following table:

FEEDWATER

S.NO. DESCRIPTION UNITS VALUE

1 General Appearance --- Clear & Colorless


2 PH at 25 Deg C --- 8.5 - 9.5
3 Total Iron as Fe ppm < 0.01ppm
4 Total Copper ppm < 0.003 ppm
5 Oxygen cc/ltr < 0.007
6 Conductivity at 25°C after cation exchanger and CO2 removal ms/cm < 0.5
7 Free CO2 Nil
8 Silica ppm < 0.02 ppm
9 Hardness as CaCO3 ppm Nil
10 Oil ppm Nil
11 KMnO4 Ppm Nil
12 Total Carbonic acid ppm Nil

NOTE
¾ Alkaline levels of feed water minimizes corrosion of steel
¾ Chlorides, Silica, Iron, Copper, Organic matter etc., present in the feed water concentrate further in Boiler water. Their
higher concentration calls for increased blow down (CBD) of boiler water causing loss of useful heat.
¾ Silica in boiler water vaporizes to SiO2 and escapes through steam
¾ Copper present in water, deposits on the inner surfaces of evaporator tubes and is harmful
¾ Chlorides in boiler water depress the pH level and render boiler water acidic and may cause accelerated corrosion.
¾ Oxygen in boiler water promotes corrosion of boiler tubes
¾ Oil present in feed water deposit on tubes and interferes with heat transfer.
DRUM WATER
S.NO. DESCRIPTION UNITS VALUE
1 pH --- 9.0 to 10.0
2 Total Dissolved solids / Conductivity ms/cm < 50
3 Silica ppm <1.2
4 “p” Value mval/kg 0.1
5 Sodium Phosphate as PO4 mg/kg 2-6

Minor permissible contaminants present in the WHRB feed water concentrate to high levels in boiler water due to continuous
evaporation in the Steam drum - evaporator circuits. Two controls are exercised on Boiler water to avoid corrosion of WHRB
tubes and the drum water - washed surfaces.
Tri-sodium phosphate dozing to convert the hardness producing insoluble calcium, magnesium salts to soluble sodium salts
which can be drained by CBD and to maintain the alkalinity levels of boiler water.

NOTE: The drum water quality should be continuously monitored and suitable adjustment in blow down to be made to maintain
the drum water as per above recommendations.
E. BOILER AND ITS AUXILIARY PROTECTION
AND INTERLOCK CONCEPTS
E. BOILER AND ITS AUXILIARY PROTECTION AND INTERLOCK CONCEPTS

Boiler Protection
This chapter lists out various protections provided in the WHRB.
As the system protections and interlocks have been described in the preceding chapters along with the description of equipment,
a listing of these protections will only be made with brief notes on their significance. Testing of these interlocks & protections is
to be done before the first startup of WHRB and at suitable intervals subsequently.

Safety Valve on Steam Drum & Super heater


To protect the boiler safety valves have been provided with set pressures and blow down capacities as indicated below.
Tag No Capacity (TPH) Set Pressure kg / cm² (g)
WHRS-AQC2HP-MAS-SV-001 18 7.6
WHRS-AQC2HP-MAS-SV-002 19 8
WHRS-AQC2HP-MAS-SV-004 17.5 3.9
WHRS-AQC2HP-MAS-SV-003 17 36.5
WHRS-AQC2HP-FDW-SV-001 32 34.6
WHRS-AQC2LP-MAS-SV-001 4 0.73
WHRS-AQC2LP-MAS-SV-002 5 0.94
WHRS-AQC2LP-MAS-SV-003 3.5 0.66
WHRS-PH2HP-MAS-SV-001 18 7.6
WHRS- PH2HP-MAS-SV-002 19 8

Interlocks
Interlocks provided for various systems ensure safe and sequential operation at any point of operation which includes start up,
shut down and emergency conditions. Kindly refer the Section A for the detailed description of the Alarms & Interlocks
Description.

Boiler Protection
Operational Control
The interlocks are to be tested before commissioning. Repeat tests are advised once a year. Any malfunction noted during
operation has to be attended early. (Kindly refer the Logic Write up section for details of interlocks)
Automatic Control
To describe the automatic controls provided for operation of the WHRB.
Drum Level Control
It includes:
¾ Three Element Control
¾ High and low level alarm

THREE ELEMENT CONTROL


In the three element control, the feed water control valves are positioned after comparing the steam flow and feed flow signals
suitably corrected for the drum level signal.
The operator can select feed control station to be on duty.
The controller receives the steam flow signal and compares it with the current feed flow signal. Any variation in these is compared
with the two out of three, pressure compensated, level signal from the steam drum and a final error signal is computed by the
controller from its operator selected set point. From the final error signal, a correction signal is sent to position the selected feed
control valves. Such a control is termed as a three element control and maintains the steam drum water level, taking into account
steam flow and water flow
The controller provides the following alarms for both HP & LP Drums:
¾ Drum level Low alarm (- 200 mmWC)
¾ Drum level Low Low alarm (TRIP) (- 300 mmWC)
¾ Drum level High alarm (+50 mmWC)
¾ Drum level Hi Hi alarm (+150 mmWC)

Automatic controls have been provided for smooth, strain free and high efficiency operation of the WHRB. These controllers are
set during commissioning. Any mal operations of these controllers must be corrected to keep the controllers on auto mode all the
time. Adjustments of controllers, checking of pressure, temperature and flow transmitters must be attended by a qualified
instrument Engineer or technician.

BOILER INLET
¾ Temperature transmitter for remote indication in DCS.
¾ These temperature transmitters measure the temperature of exhaust gas. This is provided to safeguard the Super heater
and Evaporator panels.

BOILER INLET & OUTLET PRESSURE


¾ Pressure transmitters at Boiler Inlet & Outlet for pressure drop across the WHRB.
BEFORE & AFTER SUPERHEATERS
¾ Temperature Element for DCS indication of the temperature of the flue gas at the inlet & Outlet of both super
heaters.
BEFORE & AFTER EVAPORATOR
¾ Temperature Element for DCS indication of the temperature of the flue gas at the inlet & Outlet of the
evaporator.
AFTER ECONOMISER
¾ Temperature Element for DCS indication of the temperature of the flue gas at the outlet of the Economizer.
AFTER CONDENSATE PREHEATER
¾ Temperature indicator for remote indication of temperature at inlet to the Bag House.
'F. MAINTENANCE PRACTICES
G. MAINTENANCE PRACTICES

Section Overview
This section describes the various maintenance practices, overhauling, and preservation techniques. Also discussed are failures
and repair techniques.
This section covers the following
1. Recommended maintenance practices
2. Preventive maintenance program
3. Condition based maintenance
4. Maintenance check list for daily, weekly, monthly and annual inspection
5. Shutdown and cooling the boiler
6. Inspection after cooling

1. Recommended Maintenance Practices


Systematic maintenance is essential to keep the boiler and its auxiliaries in good condition and to obtain reliable operation of
the boiler with high availability and plant load factor. Effective maintenance aims at timely inspection of parts to repair or replace
defective components and to prevent their failure when the boiler is in service.

Maintenance can be classified as -


¾ Preventive maintenance – mostly condition based
¾ Annual Boiler overhauls to clean and inspect pressure parts.
The shutdown period of the overhaul is also utilized to attend to systems and parts which cannot be attended during short
shutdowns or when the boiler is in operation
The vendor manuals of the fans, motors, control valves with their positioner and actuators, instruments and controls, power
cylinders etc., prescribe certain minimum maintenance requirements which are to be carried out in one of the above two
maintenance categories.
It is suggested to maintain a defect register in the control room to register all the items, which need maintenance.

2. Preventive Maintenance
The objective of the preventive maintenance program is to obtain trouble free service from the component till the next
maintenance.
Vendor manual for various equipments suggest inspection periods, checks to be done and recommended spares. The true
objective of the maintenance program can only be realized, if a master plan of maintenance of all the components is prepared as
per vendor instructions.
Full benefits of maintenance can be obtained only if proper parts are used. Mandatory spare part list covers most of the spares
required. It may be found that in the first two years of operation due to variations of site conditions, some additional spares not
included are also required. Action has to be initiated to procure such spares.
Some equipment has 100% reserve standby units. (Feed water pumps etc.). Maintenance of such equipment’s can be organized
even when the boiler is in service, although some minimum risk is involved. Equipment such as igniters, scanners have
replacement spares which can be utilized when the working equipment are to be maintained without affecting the boiler
operation. The prepared master plan for maintenance should be periodically reviewed during the first three years of the boiler
operation.

It may be found that due to varying site conditions, the frequencies and quantum of work scheduled as per vendor manuals are
either too much or too less. Based on site experience, the frequencies and work schedules can be modified.

A scientific method of preparation of the preventive maintenance schedules is to make them condition based. In condition based
maintenance, the equipment and components of the plant are inspected daily, weekly monthly etc., as per a suggested schedule
by the local operators and deteriorating conditions if any observed are reported. Suggested inspection program is given in this
section. Based on operator reports of such inspection, maintenance works are planned for the next available planned shutdown.
Mandatory inspections prescribed by the vendors are also taken care of, irrespective of the equipment condition.

Preventive Maintenance Program for Valve


A preventive maintenance program for valves once in two years can be done with one or more of the following works:
¾ Dismantle the bonnet, clean the trim and valve seat, lapping them if necessary.
¾ Cleaning the valve stem and re-lubrication of the operating threads
¾ Renewing the bonnet joint, and assembling the trim on the valve seat
¾ Renewing the gland packing
¾ Renewing the valve flange joint, if necessary

Preventive Maintenance Program for Spares


It may be found that in the first two years of operation due to variations of site conditions, some additional spares are also
required. Action has to initiate to procure such spares.
The prepared master plan for maintenance should be periodically reviewed during the first three years of the boiler operation.
It may be found that due to varying site conditions, the frequencies and quantum of work scheduled as per vendor manuals are
either too much or too less. Based on site experience, the frequencies and work schedules can be modified
A scientific method of preparation of the preventive maintenance schedule is to make them condition based.
In condition based maintenance, the equipment and components of the plant are inspected daily, weekly, monthly etc. as per
suggested schedule by the local operators and the deteriorating conditions if any observed are reported. Suggested inspection
program is given in this chapter. Based on operator reports of such inspection, maintenance works are planned for the next
available planned shutdown. Mandatory inspections prescribed by the vendors are also taken care of, irrespective of the
equipment condition.

3. Conditioned Based Maintenance


The schedule of daily, weekly and monthly inspections given in the following pages do not require a boiler shutdown and in fact
can only be done when the boiler is in service. Three and six monthly inspections are done utilizing an available planned
shutdown approximately in the specified time period.

Objective of these inspections is to ensure that:


¾ The components are in trouble free condition.
¾ To carry out any minor repairs or adjustments this can be done with the boiler in service.
¾ To plan for repair of such items, this cannot be attended when the boiler is in service, during the next available
shutdown.
¾ To collect a database to determine optimum service life of the systems and components before maintenance if
required.
¾ The schedule can be expanded, curtailed or modified based on experience in the first two years of operation.

4. Daily Checks
To be done once a day by the local operator during his walk down checks. Such walk down checks is to be encouraged to be done in
each shift by the local operators. Only those operational checks which require maintenance work for correction have been
included.

EQUIPMENT CHECK WORK TO BE DONE


Local level gauges on steam ¾ Check illumination is proper. ¾ Replace fused bulbs.
drum ¾ Leaking valve glands. ¾ Isolate level gauge and tighten
¾ leaking ports leaking glands.
¾ Blurred level ¾ Replace leaking ports.
¾ Steam wash mica as suggested
by vendor (not to be done
¾ too frequently)
Comparison of levels Compare the levels after verifying there are no ¾ If there are serious discrepancies
indicated by local level gauge leaks from valves, glands etc. of the level calibration of the remote level
with that of remote level gauge and indicators. Report discrepancies. indicators has to be planned
indicators in the control room immediately.
Traces of water, oil spots on Such spots are indicative of valve leaks, ¾ Maintenance to be planned to
boiler floor, buck stay beams, instrument tapping leaks etc., Trace the eliminate the source either
boiler cladding etc. source of leak. immediately or during next
planned shutdown (depending on the
source and quantity of leak) and
accessibility for maintenance.
Lubricating oil levels of Fans, & Check adequacy of oil level. ¾ Top up if required (immediately)
feed pumps bearings, dosing ¾ If leakage through oil seals,
pump gear box etc. gaskets drain plugs etc. Are noticed
plan for maintenance during next
planned shutdown.

Fans, BFW pumps dozing •Check bearing temperatures. ¾ If higher than normal bearing
pumps •Check for Vibration Levels temperatures are noticed check for
cause proper oil level, correct grade
and quality of oil or grease, abnormal
sound or vibration.
¾ If bearing temperatures are very high,
start the reserve equipment and plan
for a maintenance checks.
¾ If vibrations are above the
satisfactory limits. Check for
mechanical looseness and start the
reserve equipment and plan for a
Drum and super heater Check for passing of safety valves ¾ Hand pop the affected safety valve one
safety valves. (noise or wisp of steam through silencer) or two times to
clear any dirt sticking to
the valve seats
¾ Lightly tap on the stem of
the safety valves.
¾ If these measures do not
succeed, if request for check
of the safety valve during next
Purity of instrument air Check by visual observation that the ¾ Oil and moisture in the instrument air is
instrument air is oil and moisture free. likely to clog the positioner of
(Oil and moisture content can also be pneumatic controllers / solenoids
checked by laboratory examination as per and make their operation sluggish or
standards) unreliable.
¾ Open drain valves of air receivers for
short time to drain condensate if any.
¾ If these measures are not successful,
inform the Maintenance group.

Steam or water leakages from ¾ Loose valve gland ¾ Tighten the gland nuts.
valves and from flange joints ¾ Loosened bolts of flange joint If the leakage not gets arrested, plan
and / or failed gasket. for maintenance
during shut down.
¾ Tighten the bolts. If the
gasket failed then plan for the
maintenance during shut down
Boiler cladding, air duct or flue Check for hot spots ¾ Hot spots may be due to leakage of flue
gas duct. gas or hot air. Source of leakage has
to be located after selective removal of
insulation (to be planned for the next
planned shutdown)

Daily Maintenance
Maintenance Check List during Operation
¾ Check the correctness of HP & LP water level in the control desk with direct level glass
¾ Check the level indicators for proper illumination.
¾ Check for unusual noises for steam / water leakage.
¾ Check for unusual noises for from pumps.
¾ Check for vibration in rotary equipment’s.
¾ Check for unusual traces of water on floor, buck stays or casings
¾ Check for valve & gland leakages.
¾ Check for air / gas leakages from ducts and flue.
¾ Check for hot spots, bulging etc. on casings, ducts etc.
¾ Check the positions of dampers and cleanliness
¾ Check for safety valve steam leakages.
¾ Check the bearings for lubrication and cooling water systems.
¾ Check all alarm annunciations with respect to set points.
¾ Check for water, oil along with instrument air
¾ Check the field instruments for its proper indications.
¾ Check the stack for any unusual smoke conditions.

Monthly Checks
Fans, Dosing pumps, With the vibration analyzer record vibration, By monthly recording of data, establish a
sound levels and measure bearing data base for deciding the overhaul time of
temperature Note the pressure, flow of air, the equipment. An overhaul once in two or
suction damper opening, (Capacity of the three years may be adequate. Database will
FD Fan) pressure (seal air blowers, HP dosing help in deciding the time frame. Sharp
pump) increase in vibration levels bearing
temperatures or sound levels may call of
early scheduling of overhauls.
BFW pumps Check for coupling alignment between By monthly recording of data, establish a
motor and pump. Check the impeller is not database for deciding the overhaul time of
rubbing with pump body. Check operation the equipment. An overhaul once in two or
of NRV at pump discharge. three years may be adequate. Database will
help in deciding the time frame. Sharp
increase in vibration levels bearing
temperatures or sound levels may call of
early scheduling of overhauls.
Safety valve operation Increase the boiler pressure and check the If necessary do the adjustments.
operation of valves.
Feed water tank / internals Deposits of foreign particles Clean with normal water
Dosing system Cleanliness of dosing tank, operation of Clean dosing tank with normal water, Adjust
pressure relief valve, lubrication oil level in relief valve ,if required Fill lubrication oil , if
pump. required

D P Manometer Choking of impulse tubes Liquid level in Clean impulse tube with air Keep liquid level
manometer at zero
Level switch for steam drum Close the steam out let valve and gas by If switch or alarm is not working, do the
water level very low pass damper. Open blow down valve and rectification work.
check for level switch very low alarm.
Checks Every Six Months

During a planned shutdown of the boiler, the following checks can


be done.
EQUIPMENT CHECK WORK TO BE DONE
Boiler safety interlocks, start Coinciding with a planned shutdown of Plan for maintenance or re-calibration
permissive, boiler trip protection. boiler, carry out the checks to identify of defective items if any noticed, during
malfunctioning or sluggish pressure, the shutdown period.
temperature switches, solenoid operated
valves, positioner, proximity switches, actuators
etc.,

Checks Every Year

(See also jobs listed under Boiler overhaul)


EQUIPMENT CHECK WORK TO BE DONE
Pressure temperature, Flow level, Utilizing the boiler annual shut down for Carry out any maintenance
differential pressure controllers overhaul, recalibrate all pressure, temperature, replacement or adjustment needed to
flow, level and d/p controllers as per vendor secure initial calibration values as per
manuals commissioning records
Pressure gauges, temperature Recalibrate, Verify functioning of Repairs or adjustments as necessary
gauges, Pressure/temperature pressure/temperature switches as per design
Switches
Positioner, actuators Verify functioning of positioner and actuators Repairs or adjustments as necessary as
by feeding current inputs to positioner and per vendor manuals to obtain
measuring the air pressure output of the performance as per commissioning
positioner and opening closing of actuators records. Verify functioning of proximity
switches where provided. Clean filters
of air regulators. Check functioning of
air regulators. Verify tightness of air
connections.
Annual Maintenance Check Sheet
COMPONENT NAME INSPECTION REQD FOR
Drums (water side ) ¾ Corrosion
¾ Scale / deposits
¾ Pitting
¾ Metal reduction
¾ Manhole seat
¾ Process / instrument tapping’s
¾ Internal cleanliness
Feed water pipe in steam drum. ¾ Plugging
¾ Tightness
¾ Holes orientation
¾ Corrosion
¾ Piping
Chemical dosing ¾ Plugging

Pipe in steam drum ¾ Tightness


¾ Holes orientation
¾ Corrosion / Pitting

Continuous blow down ¾ Plugging

Pipe in steam Drum ¾ Tightness


¾ Hole orientation
¾ Corrosion / pitting
Boiler tubes (water side) ¾ Corrosion
¾ Scale
¾ Pitting
¾ Metal reduction
Boiler tubes (gas side) ¾ Corrosion
¾ Build up
¾ Blisters
¾ Sagging
¾ Over heating
¾ Erosion
¾ Sealing
¾ Supports
¾ Cracks
¾ Expansion clearance
¾ Steam impingement
¾ Insulation
Evaporator coils – flue gas side ¾ Erosion
¾ Corrosion
¾ Build up
¾ Blisters
¾ Sagging
¾ Over heating
¾ Sealing
¾ Cracks
¾ Steam impingement
Super heater (steam side) ¾ Corrosion
¾ Erosion
¾ Scale
¾ Pitting
¾ Metal reduction
¾ Flare cracking
¾ Deposits
Super heaters (gas side) ¾ Corrosion
¾ Build up
¾ Sagging
¾ Over heating
¾ Erosion
¾ Sealing
¾ Supports
¾ Cracks
¾ Exp clearance
¾ Steam impingement
¾ Insulation
Economizer ¾ Corrosion
(water side) ¾ Scale
¾ Pitting
Economizer ¾ Corrosion
(gas side) ¾ Build up
¾ Blisters
¾ Sagging
¾ Over heating
¾ Erosion
¾ Sealing
¾ Supports
¾ Cracks
¾ Expansion clearance
¾ Steam impingement
¾ Tightness of access
¾ Doors
Refractory ¾ Looseness
¾ Missing pieces
¾ Erosion
¾ Sealing
¾ Refractory
¾ Flame impingement on refractory
¾ Refractory holding arrangements.
¾ Corrosion
¾ Damper operating
¾ Mechanisms
Dampers ¾ Flaps rigidity
¾ Open/ close positions
¾ Expansion clearance condition of flaps
¾ Erosion of flaps
¾ Bearing freeness
¾ Lubrications
¾ Damper linkages
¾ Interlock mechanisms.

Remote level gauges ¾ Cleanliness


¾ Leaks
¾ Visibility
¾ Illumination
¾ Gauge cocks status
¾ Internal deposits
¾ Insulation
¾ Liquid status (if any)

Dosing pumps ¾ As per manuals


Power cylinders ¾ As per manuals
Convection pass ¾ Erosion and material accumulation.
¾ Signs of gas channeling.
¾ Tubes for erosion patterns.
¾ Economizer support beams for erosion.
¾ Lower water wall headers for erosion / cracks.
¾ Seal at economizer and super heater
piping penetration.
¾ All penetration for erosion.
¾ Super heater supports
¾ Riser roof
¾ For penetrations
¾ Sealing and cracks.
¾ Walls for erosion at the top of the tube
¾ Thermocouples and pressure taps for erosion /
corrosion.
¾ Pressure taps for plugs
¾ All penetration for sealing and erosion.
¾ All penetration and plates for warpage or damage.
Casing ¾ Bent
¾ Bulging
¾ Gas leakages
¾ Access door tightness
¾ Corrosion
¾ Erosion
Water level gauges ¾ Cleanliness
¾ Leaks
¾ Visibility
¾ Illumination
¾ Reflectors
¾ Mirrors
¾ Gauge cocks status
¾ Expansion clearance
¾ Internal deposits
¾ Insulation
¾ High/low water alarms/tripping
Valves ¾ Erosion
¾ Corrosion
¾ Leakages
¾ Spindle movement
¾ Handle rigidity
¾ Drive mechanisms
¾ Lubrications

Safety valves ¾ Valve nozzle conditions


¾ Disc seat conditions
¾ Corrosion of internals
¾ Pitting
¾ Cracks
¾ Valve spring status
¾ Spring stiffness
¾ Corrosion of spring
Silencer status ¾ Spring stiffness
¾ Drain line status
¾ Drain line rigidity
¾ Discharge pipe rigidity
¾ Expansion clearances
¾ Valve settings
Boiler Annual Maintenance and Overhaul
In addition to the check and inspections listed under preventive maintenance, the boiler requires an annual shut down of about
10 to 15 days for cleaning, inspection ad overhaul of boiler pressure parts. The shutdown period is restricted to a minimum by
deploying adequate resources. If required, engineering department of TKII can assist the customer in carrying out the boiler
overhaul.
The annual shutdown is utilized for cleaning and inspection of the pressure parts and to collect data on the wear pattern of boiler,
super heater and economizer pressure parts. The shutdown opportunity is also utilized for overhaul of safety valves, regulating
and isolating valves and components, which cannot be attended when the boiler is in service. (The valve overhauls need not be
done every year).

Planning Before Overhaul


¾ Prepare a list of jobs to be done during the overhaul based on earlier inspection reports and the jobs listed below.
¾ Ensure availability of spares required for the proposed jobs.
¾ Ensure tools, tackles, scaffolding materials required for the job.
¾ Ensure availability of manpower required for the job (Own sources, contract labor etc) supervision services of TKII is also
available for carrying out annual overhauls and inspections.

5. Shutdown and Cooling the Boiler


¾ Shutdown the boiler in a planned manner.
¾ Doesn’t force cool the boiler
¾ Open all access and inspection doors.

Inspection after Cooling


¾ Carry out a preliminary inspection after cooling to check cleanliness and sign of deposition on pressure parts and needs
any cleaning.
¾ Open the access doors of the either sides of the drum.
¾ Allow the drum to ventilate for about 8 hours. If necessary a fan cooler can be fitted over temporary stand to force air
through the drum.
¾ From the time the drum manholes are opened till they are closed after inspection, the area around the drum must be
cordoned to restrict entry only to specifically authorized personnel.
¾ The names of persons who are entering the drum for inspection, along with tools they carry must be entered in a register.
Persons coming out of the drum after inspection should be asked to account for the material they carried into the drum.
This precaution is to prevent accidental dropping of foreign material through the water wall tubes, which may block
water circulation through them and can cause tube failures.
¾ Carry out a preliminary inspection of the drum to check for deposits on the water side of the drum.
¾ Using nylon brushes, the deposits (which are normally soft) are cleaned, collected on trays and disposed of outside the
drum. Washing down the deposits to the boiler tubes is not recommended.
¾ In case of excessive deposits, the chemist is asked to analyze the nature of the deposits. In case of excessive deposits, a
review of phosphate concentrations (higher than 10ppm) and boiler water quality control (high conductivity) may be
made to reduce the deposit in the next year of operation.

After cleaning the following examinations can be made.


¾ Examine the boiler drum metal for scale, pitting, corrosion and metal wastage. (Drum thickness is measured at a few
selected spots using ultrasonic instruments and compared to design thickness).
¾ Inspect fastenings of the baffles, cyclones, and demisters to see that they are intact, without corrosion pitting or holes.
Eroded or corroded drum internals can be patched by welding. No welding however is permitted on the drum metal. The
cyclones and demisters can be examined in position. They need not be dismantled. Reasonable water tightness of the
baffles and cyclones are to be ensured.
¾ Examine that feed water pipe is intact with flange connections tight and discharge exit correctly oriented.
¾ Examine that the continuous blow down pipe and dosing pipes is not plugged or corroded their supports are normal;
their holes have been correctly oriented.
¾ Examine that there are no cracks in the stub welding s of the drum.
¾ After the inspection, clean the manhole seats and provide new gaskets. Sometimes the boiler inspector may like to
inspect the steam drum. After this inspection and after verifying that all men and material have been removed from the
drum, close the manholes and bolt them tight.

Expansion Joints
Examine the expansion joints. Eroded / corroded parts can be patched by welding. When severe erosion is noticed (after several
years of service) the expansion joints are to be replaced. Collapse or stretching of the expansion joints is usually due to forces
exerted by the connecting ducts. Readjustment of duct supports will solve the problem and will assist the expansion joints to
regain their original dimensions.

Insulation and Cladding


x Verify insulation as per drawings and correct wherever necessary.
x Inspect cladding for damages due pitting, hotspots, dislocation etc. Repaired as necessary.

Other Equipment
Overhaul of fans, pumps, fuel feeders, control valves, actuators etc., is scheduled as per vendor instructions and condition
monitoring described under preventive maintenance
FEED & BOILER WATER CONDITIONING

1. INTRODUCTION
The successful use of boiler is dependent on proper water conditioning and treatment. The quality of water must have accurate
for trouble free operation of boiler.
The water as available to industry is not suitable for boiler use. A complete pre-treatment and internal chemical treatment is
necessary to make raw water suitable for boiler feed.
The objective of the water treatment is:
¾ Eliminate scaling - deposition in boiler which cause tube over heating leading to accidents.
¾ Control corrosion of boiler system, which cause failure of boiler tubes, leading to unscheduled shutdowns.
¾ Reduce carryover of water with steam, which is the cause of deposition on super heater/turbine blades, leading to the
expensive failures.
¾ To maintain peak boiler efficiency by keeping complete boiler water system clean

In order to meet above objectives, it is necessary to maintain certain chemical conditions in boiler condense and feed water
systems. A brief review of important factors is given in this section to assist those taking charges of new boiler equipment. It is not
possible to cover the subject fully, therefore; it is recommended that the care and control of water quality be entrusted to water
treatment specialist.

2. NEED FOR WATER TREATMENT

A. CORROSSIVE CONTROL
Water is corrosive to boiler metal. Typically corrosion due to water will reduce thickness of tube @ 1 mm/year. Thus the life and
safety of boiler entirely depends on the rate of corrosion of boiler metal. In order to protect boiler from corrosion, pre-treatment is
done to remove excessive corrosion ions like chloride, sulphate etc. However, further chemical conditioning is required to protect
boiler and auxiliary systems from corrosion.
Tri sodium phosphate, caustic, ammonia and amines are used as corrosion inhibitors. These chemicals form a protective film
over metal surface and reduce corrosion. It is necessary to maintain prescribed concentration of these chemicals in boiler water
systems continuously.

B.OXYGEN CORROSION INHIBITOR:


Oxygen is present in dissolved form in water. At high temperature, oxygen reacts with metal to cause pitting corrosion. Thus
prevention of oxygen leads to pin holes in economizer, steam drums and steam tubes.
Most of the oxygen is removed externally by Deaerator and preheating of feed water. However, traces of residual oxygen must be
removed by chemical conditioning.
Sodium sulfite, hydrazine and amines are recommended for oxygen removal. These chemicals react with residual oxygen making
it inactive and protect metal against pitting corrosion. Catalyzed oxygen scavengers are used for quick reaction.

C.SCALE / DEPOSIT CONTROL:


Raw water contains dissolved solids, hardness salts and suspended matters.
External treatment is used to remove such impurities.
¾ Clarification - To remove suspended matters.
¾ Filtration - To remove residual turbidity
¾ Softening - To remove hardness salts

De-alkaliser - To remove hardness salts and excessive alkalinity


x Demineralization - To remove residual salts and silica
x Mixed bed - To remove residual salts and silica from DM water.
A combination of above equipments is used to remove undesirable impurities in raw water.

SCALE CONTROL
Hardness salts in feed water cause formation in boiler. Under temperature and pressure inside the boiler and due to
concentration, hardness salts precipitate in tubes as calcium carbonate, calcium sulphate and Ca/Mg silicate scales.External
treatment like softening, demineralization or de-alkalization removes most of the hardness salts from boiler feed water. However,
malfunctioning of this equipment, occasional bypassing of the softener/DM plant or contamination of condensate or feed water
with raw water often led to ingress of hardness in the boiler.
All hardness salt precipitate inside boiler leading to hard scale formation on tubes. Such scale has lower conductivity causing
increase in metal temperature, leading to bursting of tubes in extreme conditions.
Therefore, inspire of elaborate external treatment, internal chemical conditioning is always recommended as additional safety.
Following chemical methods are used for internal treatment.

PHOSPHATE CONDITIONING
Tri-sodium phosphate is commonly used. Hardness salts react with tri-sodium phosphate to form calcium phosphate precipitate.
This precipitates above pH of 9.5 colloidal in nature and therefore do not allow for form hard scale of carbonate and silicates. The
precipitated hardness salts are then removed through blow down as sludge and boiler tubes are kept scale free.
Tri-sodium phosphate, apart from acting as hardness conditioning agent, also is a good corrosion inhibitor.
The recommended concentration in boiler water is given in Vendor Manuals
Note 1: TSP will act as hardness conditioner, only when boiler pH is above 9.5. Below 9.5 pH TSP may cause hard scale formation
of Ca3 (PO) 2. Therefore, coordinated or congruent phosphate treatment is recommended. The water treatment experts can advise
you right treatment after studying your water quality and operation conditions.

E. TURBINE / SUPERHEATER DEPOSITION CONTROL:


The solids in boiler feed water get concentrated in boiler. The concentration of solids in boiler is decided blow down and feed
water quality. The carryover of boiler water with steam depends on;

Mechanical Factors:
¾ Boiler load - Higher the load, lower is the steam purity
¾ Water level in boiler - Higher the water level in drum, lower is steam purity.
¾ Load Variation - Sudden increase in load reduce steam purity for short time.
¾ Separation efficiency - Higher efficiency, better is steam purity.

Chemical Factors:
¾ TDS - Higher TDS in boiler, lower is steam purity.
¾ Total Alkalinity - Higher alkalinity as % of TDS lower is steam purity
¾ Organics - Higher the organic contamination, lower is steam purity.
¾ Foaming - Higher the foaming character of water, Lower is steam purity.
The water carried over with steam due to above reasons is exactly similar in quality to blow-down or boiler water. In super
heater or in turbines, water evaporates, leaving dissolved and suspended matter as scales or deposits.
Thus severity of scaling and fouling of super heater and turbine depends on boiler water quality and steam purity.
Maintaining boiler water quality as per norms and maximum steam purity is the only way to prevent deposition due to
carryover of water with steam.

F.SILICA DEPOSIT CONTROL:


Silica is volatile under high temperature and pressure inside boiler. In turbines, the evaporated silica precipitates during
pressure and temperature reduction and form hard scales.
Maximum allowable concentration of silica depends on water analysis. Expert’s best decide the maximum permissible
concentration after striding the operating parameters.
G. CONDENSATE CORROSION CONTROL:
The carbon dioxide is present in boiler feed water in dissolved and combined from as carbonate. Under boiler pressure and
temperature it is liberated and carried over with steam as CO2 gas. This gas re dissolves in steam condensate to form carbonic
acid.
CO2 + H2O = H2CO3

H. MAINTENANCE OF PEAK EFFICIENCY:


Corrosion, scaling, fouling carryover and condensate corrosion can cause unscheduled shutdown, accidents and deterioration of
system efficiency. Therefore for trouble free operation and maintenance peak operation efficiency, a combination of various
internal chemical treatments is essential along with a good control over boiler water quality.
Maintaining boiler water quality by using commodity chemicals likes TSP, Hydrazine, and Sodium sulphate. However, it is
recommended that the care and control of water chemistry be entrusted to specialist.
(G. BOILER PRESERVATION PROCEDURE
INTRODUCTION
Both the gas and waterside of a boiler should be protected against corrosion during out of service periods. It is known that many
of the corrosion problems of boiler and auxiliary equipment have their inception during storage. Rusting of tube surfaces, as
indicated by the formation of the red hematite (Fe2O3), not only cause a roughened tube surface but also results in attack of
parent metal. The advantages of efficient feed water and boiler water treatment during operation may be lost if the same
diligence is not applied to protect heat. Transfer surfaces during idle periods. Protection from corrosion during storage becomes
vitally important considering the number of times during the life of a boiler when it and its auxiliary equipment are idle.
To minimize the possibility of corrosion, boiler to be placed into storage must be carefully prepared for the idle period and closely
watched during the outage. There are two methods available for storing the unit dry storage and wet storage. Although the wet
storage procedures is preferred such factors as availability of good quality water, ambient weather conditions, length of storage
period, auxiliary supply of heat, etc may dictate that the dry storage procedure is more practical.

Definition of Water Quality


Some cleaning procedures, hydrostatic testing and storage require water of higher quality than others. For the purpose of
economy and convenience the lowest water quality consistent with requirements is specified in these various procedures. The
terms that identify the different water qualities along with their definitions are list below: Station service water - Water normally
used for drinking, fire protection, etc.
Softened water - Filtered, sodium zeolite softened water with total hardness less than 1 ppm.
Two- bed demineralized water - Water then has been passed through Cation and anion ion exchanges in series.
Mixed bed demineralized water - Water that has been passed through a mixed bed demineralizer. Water from an evaporator is
considered to be of equal quality.
Treated demineralized water - Mixed bed demineralized water that has 200 ppm of hydrazine and enough ammonia added to
give final concentration of 10 ppm (or a pH of 10.0). In this procedure, condensate is considered to be treated demineralized
water.

Dry Storage Preservation


When it is known that a boiler is to be idle for a considerable length of time and that a brief period will be allowed for preparation to
return it to service, the dry storage method is recommended.
In this method the unit is emptied, thoroughly cleaned internally and externally dried, and then closed up tight to exclude both
moisture and air. Trays of lime, silica gel, or other moisture absorbent may be placed in the drums to draw off the moisture in the
air trapped by the closing up of the boiler.

The following general procedure is recommended when placing a unit into dry storage.

1. Admit Flue Gas to the boiler according to the normal start-up procedure and establish up to 3.5-kg/cm² (g) drum pressure.
Stop firing. Secure the boiler and when the pressure decays to 1.3 kg/cm² (g), immediately drain the boiler and headers
under air. As soon as possible, open the drums to allow air to circulate for drying of all internal surfaces.
This step is included for a unit that has been in service and is to be placed into storage. For a unit that has never been in service,
start with Step 2.

3. If the unit is full of water and cold, drain the unit under air. All non-drainable boiler tubes should be blown with
compressed air. If an external source of heat is available such as a steam coil air heater, portable heaters, etc., operate
these heaters to assist in drying the internal boiler surfaces.

Install trays (of non-porous construction and capable of passing through the drum manhole) containing the
moisture absorbent (silica gel is preferred) into the drums. Insert the trays into the drum being certain that none of the
absorbent comes into contact with the metal surface of the drum. To insure against an overflow of corrosive liquid after
the moisture has been absorbed, the trays should not be more than ½ full of dry absorbent. The amount of absorbent
can vary but the recommended minimum is one Kg of absorbent per 1000 Kg per hour steam flow capacity of the unit.

Open the isolation valve for nitrogen connection, on the steam drum, close all other vents and drains and pressurize the
boiler to 0.3 to 0.6 kg/cm2(g) with nitrogen. The amount of nitrogen required will vary according to the volume of the
unit.

With the boiler pressurized, alternately open all boiler drains to purge air from the unit until pressure decays to zero. It may be
necessary to repeat this process several times to reduce the amount of oxygen left in the unit to a minimum.

The unit should now be stored under 0.3 to 0.6-kg/cm² (g) nitrogen pressure maintained at the steam drum. To maintain the
nitrogen pressure, all connections and valves should be blanked or tightly closed. Check gas pressure daily to ensure
protection.

We would recommend that periodic inspection of the unit be performed every 3 months to assure that no corrosive action is
taking place and to replenish the absorbent as required. Since air will enter the unit during this inspection, it will be necessary to
repeat Steps 3 & 4 to expel the air.

The unit should be properly tagged and the appropriate warning signs attached noting that the boiler is stored under nitrogen
pressure and that complete exhaustion of the nitrogen must occur before anyone enters the drum. Before entering drums test to
prove that the oxygen concentration is at least 19.5%.

The above procedure is intended to include the economizer.

Wet Storage Preservation

The advantage of employing the wet storage procedure is that the unit is stored completely wet with the recommended levels of
chemicals to eliminate a wet-dry interface where possible corrosion can occur. It is suggested that volatile chemicals be used to
avoid increasing the level of dissolved solids in the water to be used for storage.

In preparing a unit for wet storage, the following procedure is recommended.

1. The unit should be filled with deaerated, Demineralized water treated with 200 ppm hydrazine (N2H4) for oxygen removal
and sufficient ammonia (NH3) in order to attain a pH of 10 (for demineralized water, this will require approximately 10 ppm
ammonia).

2. We strongly recommend pre-mixing of the chemicals with the water to insure a uniform mixture entering the boiler. This can
be accomplished by the blend-fill method. The blend-fill method consists of blending the chemicals with the demineralized
water at a continuous rate such that a uniform mixture is entering the boiler. Simply introducing the chemicals through the
drum after establishing water level will not insure adequate dispersion of chemicals to all internal surfaces, unless sufficient
heat is delivered to the furnace (i.e. firing the boiler) to induce natural circulation throughout the boiler.

3. Fill the unit with the treated demineralized water to the normal centerline of the steam drum. Stop filling further.
4. Back-fill the with treated Demineralized water until a rise in steam drum level is noted.
Continue filling until water exits from the steam drum vents. After filling, all connections should be blanked or tightly closed.
A source of low-pressure nitrogen should be connected at the steam drum to maintain 0.3 to 0.6 Bar G to prevent air from
entering the unit during the storage period.

The unit should be properly tagged and the appropriate warning signs attached noting that the boiler is stored under
nitrogen pressure and that complete exhaustion of the nitrogen must occur before anyone enters the drum. Before entering
drums test to prove that the oxygen concentration is at least 19.5%.

If storage continues into winter, ambient temperatures below the freezing point of water create a real hazard to the boiler
pressure parts and it will be necessary to provide a means of keeping the unit warm to avoid damage.
At some later date when the unit is to be placed into service, the boiler can be drained to normal start-up water level and placed
into operation.
In some cases, an expansion tank or surge tank (such as a 55-gallon drum) above the steam drum elevation may be required to
accommodate volume changes due to temperature changes. This tank is equipped with a tight cover and sight glass and contains
properly treated water. The tank should be connected to an available opening, such as a vent line at the top of the steam drum in
order to create a hydrostatic head. This tank will provide a ready, visual check of water level or in leakage during lay up.
A source of low-pressure nitrogen should be connected to the surge tank to maintain 0.3 to 0.6 Bar G to prevent air from entering
the unit during the storage period.
The treated demineralized water should be analyzed weekly, and when necessary, sufficient chemicals should be added through
the chemical feed line, to establish the proper levels recommended. Samples of the treated water can be taken at the continuous
blow down line or any suitable drain connection.
No unit should be stored wet when there is any possibilities of a temperature drop to the freezing point unless sufficient heat can
be provided to the unit to eliminate the danger of water freezing and subsequent damage to pressure parts.
Nitrogen Blanket
Nitrogen can be introduced at the following locations
¾ Through the steam drum
¾ Through the main steam line
The nitrogen required to seal the drainable components may be supplied from a permanent nitrogen system or portable tanks
located near the vent elevations. Due to differences in plant layout, the owner should choose his own method of piping the
nitrogen, either from their permanent system or from portable tanks, to the vent (or drain) locations listed.

The unit should be properly tagged and the appropriate warning signs attached noting that the boiler is stored under nitrogen
pressure and that complete exhaustion of the nitrogen must occur before anyone enters the drum.
Before entering drums test to prove that the oxygen concentration is at least 19.5 %

Hot Draining
If the WHRB shut down is for a short period of less than seven days and during that period maintenance work on pressure parts
have to be undertaken, the WHRB can be preserved by hot draining
The shut down WHRB is allowed to depressurize up to 2kg/cm2 (g) pressure on the drum. Water level is maintained up to
prescribed levels till that time.
When the steam drum pressure drops to 1.5 kg/cm2 (g), the air vents of the steam drum, Super heaters, economizer are opened
and the WHRB is drained through the economizer, evaporator (or only the sections required) by opening the required drain valves.
When all the water is drained, the residual heat of the water wall, economizer, Super Heater and steam drum, Flash dries most of
the moisture present on the tube surfaces. As the pressure parts remain dry, corrosion is prevented. This method of preservation
however is not effective for more than a week.

Alkaline Water Dozed With Hydrazine


If a WHRB has to be preserved for long periods (two months or more) an effective method of preservation is to fill the WHRB,
Super Heater and economizer with water treated with ammonia to a pH of 10.5 and dozed with 200 PPM or more hydrazine.
This water is completely filled in the water and steam space of the WHRB and a pressure of 5 kg/cm2 (g) is maintained in the
drum by a pump.
This method is effective but requires additional equipment such as a tank, and a pump with a connection to one of the drain
headers.
All the possible methods of preservation of a shut down WHRB, the nitrogen blanketing method is simple and suitable for the
type of preservation, which may be ordinarily required.
Preservation of Pressure Parts of WHRB during Long shutdown
During WHRB shut downs exceeding a few days, the external surfaces of the pressure parts of especially in a chemical plant
environment, may come under corrosive attacks by moisture, SO2, SO3 vapors etc
Keeping inspection doors tightly closed (when no inspection is being planned) may minimize such corrosion.
Water lancing with hot water or mild alkaline water once a month may wash out the corrosive components from the external
surfaces of the pressure parts.

TYPE OF PROCEDURE
SHORT OUTAGES Maintain the same hydrazine and ammonia concentration as present during normal operation. Establish 0.3 to
4 DAYS OR LESS. UNIT NOT 0.6 kg/cm² (g) nitrogen cap on the steam drum
DRAINED
SHORT OUTAGES Drain and open only those sections which require repair. Isolate remainder of the unit under 0.3 to 0.6 Bar
4 DAYS OR LESS. UNIT IS nitrogen pressure where possible. Maintain the same nitrogen and ammonia concentration for water remaining in
DRAINED the cycle

LONG OUTAGES Fill the boiler with water having 200 ppm of hydrazine and 10 ppm of ammonia to maintain pH 10.
LONGER THAN 4 DAYS UPTO Establish nitrogen cap of 0.3 to 0.6 kg/cm² (g), over the steam drum.
15 DAYS. UNIT IS DRAINED

LONG OUTAGES Dry storage of boiler with nitrogen alone is preferred procedure. Nitrogen cap of 0.3 to 0.6 kg/cm² (g), to be
MORE THAN 15 DAYS - UNIT IS maintained on the steam drum. Installed silica gel tray in the steam drum to soak moisture if any present in the drum
DRAINED. atmosphere

Preservation of Rotating Equipments


Put the rotating equipment in service once in every 48 hours or at least once in a week

1. If the equipment is going to be under long shutdown

a. Fill bearing block full of oil to preserve the bearing and rotate the Fan/Pump Shaft by 90° once in every 48 hours (If
bearing housing is oil lubricated)

b. Rotate the fan / pump shaft by 90° once in 48 hours (for bearing housings with grease)

c. Cover the bearing block & uncovered portion of shaft with plastic sheets to prevent dust/water ingress

d. Ensure no dust/water accumulates on the rotating equipment.


Preservation of Instruments

1. Cover all field instruments with plastic sheets

2. Power up the panel instruments and check the operation

3. Keep the control room dust and moisture free

4. Operate control valves, power cylinders once a week and check operation.

5. Operate quick shutoff valves frequently (Twice a week)


)H. COMMISSIONING PROCEDURE
Alkali Boil Out Procedure
For

1 x 6.85 MW CEMENT WHRS PROJECT

At

PARASHAKTI CEMENT INDUSTRIES LTD,


ANDHRA PRADESH

thyssenkrupp Industries India Pvt. Ltd.


Pimpri, Pune – 411018.
Date : 17.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parashakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

ALKALI BOIL OUT PROCEDURE

CONTENTS

SR. NO. DESCRIPTION

SECTIONS

1.
ABSTRACT

2. OBJECTIVES

3. PRE-REQUISTIES

4. CHECK LIST

5. REQUIRED CHEMICALS

6. SAFETY PRECAUTIONS

7. PROCEDURE

8. COMPLETION CRITERIA

9. ALKALI BOIL OUT SCHEDULE

10. HOT RINSING

Prepared By :
Checked By : Approved by:
Page 2 of 16 Boiler Commissioning – Project Management
Date : 17.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parashakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

ALKALI BOIL OUT PROCEDURE

1. ABSTRACT

Alkali Boil out Procedure (ABO) is Common for AQC-HP, AQC-LP, PH-HP AND PH-LP circuit.
For PH Boiler LP Circuit boiling pressure & TSP Concentration need to be changed.

2. OBJECTIVE

The cleaning of internal surfaces of boiler water circuit is essential to ensure that during normal operation of
steam generation, steam is free from impurities/foreign particles such as lubricants, oil, rust, sand, metal
fragments and assorted debris which are harmful for steam consumers e.g. steam turbine. This is achieved by
boiling out/circulating alkaline solutions through water circuit of boiler.

1. PRE-REQUISITES

1. Duct refractory Drying out procedure is completed. (If applicable)

2. Deaerator commissioning is completed & should be filled with adequate quantity of feed water.

3. Feed water line flushing is completed.

4. BFP is commissioned and ready.(WHRS-DEA-FDW-BFP-001/002/003)

DM plant is ready and adequate amount of DM water must be available (min. three times filling
5.
required)

6. Initial filling pump ready and available.(WHRS-DMS-DM-IFP-001)

7.

Prepared By :
Checked By : Approved by:
Page 3 of 16 Boiler Commissioning – Project Management
Date : 17.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parashakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

ALKALI BOIL OUT PROCEDURE

Neutralizing pit is available along with adequate quantity of neutralizer.

Feed control station motorised and control valve is ready and operation checked from DCS.

Tag Details:

AQC-(Tag no. WHRS-AQC-FDW-MOV-001, WHRS-AQC-FDW-MOV-002, WHRS-AQC-FDW-FCV-001,


WHRS-AQC-FDW-FCV-002)

PH-1-HP-(Tag no. WHRS-PH1HP-FDW-MOV-001, WHRS- PH1HP –FDW-MOV-002, WHRS- PH1HP -


8. FDW-FCV-001, WHRS- PH1HP -FDW-FCV-002)

PH-1-LP-(Tag no. WHRS-PH1LP-FDW-MOV-001, WHRS- PH1LP –FDW-MOV-002, WHRS- PH1LP -


FDW-FCV-001, WHRS- PH1LP -FDW-FCV-002)

PH-2-HP-(Tag no. WHRS-PH2HP-FDW-MOV-001, WHRS- PH2HP –FDW-MOV-002, WHRS- PH1HP -


FDW-FCV-001, WHRS- PH2HP -FDW-FCV-002)

PH-2-LP-(Tag no. WHRS-PH2LP-FDW-MOV-001, WHRS- PH2LP –FDW-MOV-002, WHRS- PH2LP-


FDW-FCV-001, WHRS- PH2LP -FDW-FCV-002)

IBD tank pre-commissioning is completed and IBD tank to Blow down sump drain line must be
9.
completed.

10. Drum level gauge installation is completed along with drain line up to safe location.

Boiler insulation of pressure parts, Drum, penthouse, Risers, interconnecting piping, cross over
11.
duct, Economiser casing is completed.

12. Air and flue gas all temperature and pressure readings are available in DCS.

13. Boiler expansion indicators are installed.

14.
Water and steam circuit all temperature, pressure readings to be made available in DCS. During

Prepared By :
Checked By : Approved by:
Page 4 of 16 Boiler Commissioning – Project Management
Date : 17.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parashakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

ALKALI BOIL OUT PROCEDURE

Alkali Boil Out one number of drum level transmitter to be taken in line and made available in DCS.

15. Feed water line all spring support are floated and temporary supports removed.

Main steam line up to MSSV all supports is erected. All spring support floated and temporary
16.
supports removed.

17. In drum safety valve and MS line safety valves Hydrostatic plug is installed.

18. Temporary ducting installed for RDO removed along with dummy.

19. Inlet, Outlet and Bypass dampers ready to operate

Sampling point must be erected between water wall drain station and its outlet isolation valve to
20.
IBD tank.

Ensure plant laboratory is ready and below mentioned testing instruments and requisite chemicals
is available for testing.

x PH
21.
x Oil & grease
x Turbidity
x Phosphate ( upto 5000ppm)
x M alkalinity & P alkalinity

Prepared By :
Checked By : Approved by:
Page 5 of 16 Boiler Commissioning – Project Management
Date : 17.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parashakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

ALKALI BOIL OUT PROCEDURE

2. CHECK LIST BEFORE COMMENCEMENT OF ALKALI BOIL OUT

1. All temporary supports have been removed and boiler is free for expansion.

2. Alkali chemical available and shifted to drum level.

3. Drum one side manhole is boxed up and another side is open and boiler drum gasket is available.

4. Boiler water filling is completed (level below 150mm of drum centre line).

5. Start up vent valve and its isolation both valves must be in close condition.

6. All super heaters drains are in open condition.

EBD (Emergency blow down) & CBD (Continues blow down) valves in closed condition.

AQC HP-(Tag no. WHRS-AQC2-HP-FDW-MOV-001, WHRS-AQC2-HP-FDW-MOV-002, WHRS-AQC2-


HP-FDW-GT-009, WHRS-AQC2-HP-FDW-GT-010, WHRS-AQC2-HP-FDW-FCV-001A, WHRS-AQC2-
HP-FDW-FCV-001B)

AQC LP-(Tag no. WHRS-AQC2-LP-FDW-MOV-001, WHRS-AQC2-LP-FDW-MOV-002, WHRS-AQC2-


LP-FDW-GT-003, WHRS-AQC2-LP-FDW-GT-004, WHRS-AQC2-LP-FDW-FCV-001A, WHRS-AQC2-LP-
7.
FDW-FCV-001B)

PH-HP-(Tag no. WHRS-PH2-LP-FDW-MOV-001, WHRS-PH2-LP-FDW-MOV-002, WHRS-PH2-LP-


FDW-FCV-001A, WHRS-PH2-LP-FDW-FCV-001B, WHRS-PH2-LP-FDW-GT-002, WHRS-PH2-LP-FDW-
GT-003)

PH-LP-(Tag no. WHRS-LP2-LP-FDW-MOV-001, WHRS-LP2-LP-FDW-MOV-002, WHRS-LP2-LP-FDW-


FCV-001A, WHRS-LP2-LP-FDW-FCV-001B, WHRS-LP2-LP-FDW-GT-002, WHRS-LP2-LP-FDW-GT-
003)

Prepared By :
Checked By : Approved by:
Page 6 of 16 Boiler Commissioning – Project Management
Date : 17.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parashakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

ALKALI BOIL OUT PROCEDURE

8. Down comers drain valves in closed condition.

9. Pressure gauges on drum and main steam line are installed and taken in line.

Mixing drum (plastic) for chemical (size -200litrs quantity 2 numbers and bucket or container of
10.
capacity 5 litres must be available on drum level).

11. Fire extinguisher and Fire tender is available.

Drum vents must be in open condition.

AQC HP - (Tags no. WHRS-AQC2-HP-MAS-GB-005)


12.
AQC LP- (Tags no. WHRS-AQC2-LP-MAS-GB-005)
PH HP- (Tags no. WHRS-PH2-HP-MAS-GB-005)
PH LP- (Tags no. WHRS-PH2-LP-MAS-GB-005)

13. Stirrer for mixing of TSP in water is available.

Prepared By :
Checked By : Approved by:
Page 7 of 16 Boiler Commissioning – Project Management
Date : 17.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parashakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

ALKALI BOIL OUT PROCEDURE

3. REQUIRED CHEMICAL:
Boiler water holding capacity (upto drum centerline)-
x AQC HP Boiler- ~27 m3
x AQC LP Boiler- ~8 m3
x PH Boiler- ~93 m3

Sl.No Chemical Quantity Required

AQC HP Boiler- 135 kg


1. Crystalline Tri-sodium phosphate (Na3Po4,12H2O)
AQC LP Boiler- 4 kg
PH Boiler- 465 kg

2. Detergent Total 6 Kg and 2 kg each for each Boiler Drum

Adequate quantity of lime (Soda ash) for neutralizing is required.

Calculation of required Chemical quantity:

Total quantity of chemical required: (Water holding capacity (m3) × required ppm)/1000

Quantity of chemicals is decided to maintain initial phosphate concentration 5000 ppm in boiler along with

the chemical total 3 kg normal good quality detergent/Washing powder to be added in boiler drum for

foaming purpose only.

Water holding capacity (up to steam drum centre line) ~

Prepared By :
Checked By : Approved by:
Page 8 of 16 Boiler Commissioning – Project Management
Date : 17.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parashakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

ALKALI BOIL OUT PROCEDURE

4. SAFETY PRECAUTION

Before commencement of Alkali boil out please ensure below mentioned safety pre-cautions are available.

x Good quality rubber hand gloves for handling Tri-sodium phosphate.

x Safety goggles for eyes. ( for chemical handling)

x Emergency eye wash station at drum elevation and near drainage station.

x Fire fighting system is ready and adequate quantity of fire extinguisher is available.

x Adequate illumination is available.

x Neutralizing pit is ready and adequate quantity of lime (Soda ash) is available for neutralizing.

x Ensure while giving blow down bottom header area a properly cordoned off with warning tapes

Prepared By :
Checked By : Approved by:
Page 9 of 16 Boiler Commissioning – Project Management
Date : 17.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parashakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

ALKALI BOIL OUT PROCEDURE

5. PROCEDURE :

After ensuring the above said checklist, alkali boil out out can be started and according to start up procedure
mentioned below.

5.1 Boiler Filling


i) Start boiler initial filling pump and charge boiler initial filling line.
ii) Boiler initial filling to be done from initial filling provided at Boiler Feed water line
iii) Before initial filling the boiler ensure below mentioned valves are in closed condition

Sr. No. Description

1. EBD line valves

2. CBD line valves

3. Drainage station to IBD tank drain line valve

iv) LEVEL-water to be filled below 150mm below the bottom of drum. Level to be visually ensured from other side which
is open.

Prepared By :
Checked By : Approved by:
Page 10 of 16 Boiler Commissioning – Project Management
Date : 17.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parashakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

ALKALI BOIL OUT PROCEDURE

5.2 Boiler Light Up:


.
AQC
.
Fill the boiler tubes and headers with Fresh DM Water up till the level below the steam drum.
Open the steam drum man hole from one side.
Prepare for boiler light up; open the, Boiler Inlet and Outlet damper completely to 100 % and start warming up the
boiler till the water temperature reaches 60-70degc.
PH
Fill the boiler tubes and headers with Fresh DM Water up till the level below the steam drum.
Open the steam drum man hole from one side.
Prepare for boiler light up; open the, Boiler Inlet and Outlet damper completely to 100 % and start warming up the
boiler till the water temperature reaches 60-70degc.

5.3 Filling the chemical in boiler drum:

When drum water temperature reaches above 60-80 deg c .Take water from boiler drum into mixing drum and

dissolve required chemicals thoroughly into the solution tank. Mix the chemical properly in the tank by normal

stirrer and after mixing transfers the solution into the drum via manhole. Do not pour the solution in empty boiler

drum. Repeat the steps and by this method dose the total quantity of Na3Po4, 12H2O into boiler drum. After

mixing the chemical into boiler drum dosed the detergent into boiler drum and box up drum manhole.

5.4 Boiler Pressure raising :

Start closing the bypass damper (HA/LA-05-FLG-DMPR-001) slowly. Let the gases to pass through boiler and
heat up the boiler pressure parts.
By controlling the bypass damper take the system pressure to maximum 8-10 kg/cm² and for LP drum 1.5

Prepared By :
Checked By : Approved by:
Page 11 of 16 Boiler Commissioning – Project Management
Date : 17.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parashakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

ALKALI BOIL OUT PROCEDURE

kg/cm2 pressure to be maintained.


Sl.No Boiler Pressure raising during ABO
1. AQC HP Boiler 8 kg/cm2
2. AQC LP Boiler 1.5 kg/cm2
3. PH Boiler 8 kg/cm2

Keep the system stable for 4 hours, then start opening the drain valves one by one for few seconds.
Check the quality of the blow down water. After every 2 hours blow down shall be given from bottom ring headers.
No. of blow down will depend on blow down water quality which needs to be checked during every blow down.
When the oil & grease content comes below 5 ppm. Alkali Boil Out to be stopped and boiler should be boxed up
immediately and left for natural cooling.
Keep it replenished with DM water and keeps draining the system and samples to be taken and checked.
Continue with the hot rinsing and draining process. After rinsing when the blow down water quality is as same as
the feed water quality,

5.5 Blow down sampling:

After completion of blow down from each header, crack open all drain line valves and collect sample from sampling point
located at drain line from drainage station to IBD tank & tested for.

x Phosphate concentration
x Alkalinity (Both M-alkalinity and P-alkalinity)
x Oil & Grease
x Turbidity
x PH & Conductivity

Prepared By :
Checked By : Approved by:
Page 12 of 16 Boiler Commissioning – Project Management
Date : 17.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parashakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

ALKALI BOIL OUT PROCEDURE

5.6 Drum level:


During blow down drum level will drop .Make up drum level by BFP through Feed water line and
maintained water level in approx 3-4 ports of drum level gauge.

6. COMPLETION CRITERIA

When oil and grease in blow down water will comes below 5 ppm HAG should be off and close both the I/L, O/L
dampers, left the boiler for natural cooling.

When pressure decreases around 6 kg/cm2 all drain lines including CBD and IBD valves shall be opened

simultaneously for hot blow down of boiler. During hot blow down process sample shall be collected and checked

of the parameters stated above.

7. ALKALI BOIL OUT SCHEDULE :

Sr. No. Temperature range Time


1. Boiler initial filling
2. Water rising upto 80- 90 deg C
3. Chemical mixing in boiler drum and drum box up 4 hours
4. Pressure rising up to 12 kg/cm2 3 hours
Holding time at 12 kg/cm2 4 hours
5. First blow down at 12 kg/cm2 After 4 hours of attaining 12
kg/cm2
Consecutive blow downs at 12 kg/cm2 At every 2 hours interval till oil and
6. grease decreases below 5 ppm in
blow down
7. Boiler hot blow down At 4 kg/cm2

Prepared By :
Checked By : Approved by:
Page 13 of 16 Boiler Commissioning – Project Management
Date : 17.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parashakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

ALKALI BOIL OUT PROCEDURE

8. HOT RINSING:
OBJECTIVE

It is essential to carry out hot rinsing process after alkali boil out to remove residue phosphate, oil and grease from
boiler and also to ensure boiler blow down water quality matches with feed DM water.

PRE-REQUISITES

1. Alkali Boil out completed.


2. Post alkali boil out hot draining completed.
3. Boiler is cooled after alkali boil out and below screen temperature is below 70 degc.
4. Sufficient quantity of DM water available.
5. DM transfer pump is ready and available.

6. Neutralizing pit is available along with adequate quantity of neutralizer.

CHECK LIST

14. Furnace temperature is below 70 degc.

15. Drum, superheater vent is in open condition


16. Drum level gauge glass indication is available.
17. DM lab is available with all required testing chemicals
18. Mainsteam stop valve and by-pass valve is in closed condition
19. All superheater drains are in close condition

20. EBD valves and CBD valves are in closed condition.

Prepared By :
Checked By : Approved by:
Page 14 of 16 Boiler Commissioning – Project Management
Date : 17.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parashakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

ALKALI BOIL OUT PROCEDURE

PROCEDURE:

After ensuring the above said checklist, hot rinsing process can be started

¾ Start boiler initial filling pump and charge boiler initial filling line up to boiler drain header inlet .
¾ Start boiler filling from boiler feed water line.
¾ Fill DM water up to drum centre line.
¾ After filling water up to drum centre line stop DM transfer pump/initial fill pump
¾ While filling boiler take DM water sample and test at lab for
a. PH
b. Oil and grease
c. Turbidity
d. Phosphate
e. M-alkalinity and P-alkalinity
¾ During blow down collect water sample and test below mentioned parameters at laboratory.
a. PH
b. Oil and grease
c. Turbidity
d. Phosphate
e. M-alkalinity and P-alkalinity

¾ Hot rinsing procedure will continue till boiler blow down water quality matches with feed DM water quality.
¾ After completion of Hot rinsing Process Header Cleaning and Flushing to be carried out. For Header Cleaning and
Flushing Header stubs along with Drain to be cut (List of headers to be provided at site) and Flushing with Normal
temperature DM water (Preferably from DM transfer pump) to be carried out.

Prepared By :
Checked By : Approved by:
Page 15 of 16 Boiler Commissioning – Project Management
Date : 17.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parashakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

ALKALI BOIL OUT PROCEDURE

SAFETY PRECAUTION
x Before commencement of Hot rinsing process please ensure blow down sump is properly barricaded with
proper caution tag.
x While collecting samples all required PPE’s must be worn.

Prepared By :
Checked By : Approved by:
Page 16 of 16 Boiler Commissioning – Project Management
STEAM BLOWING PROCEDURE
For

1 x 6.85 MW CEMENT WHRS PROJECT

At

PARASAKTI CEMENT INDUSTRIES LTD, ANDHRA


PRADESH

thyssenkrupp Industries India Pvt. Ltd.


Pimpri, Pune – 411018.
Date : 18.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parasakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

STEAM BLOWING PROCEDURE

SR. NO. DESCRIPTION

SECTIONS

1. OBJECTIVES

2. PRINCIPLE

3. PRE-REQUISTIES

4. STEAM BLOWING CHECK LIST

5. PROCEDURE

6. COMPLETION CRITERIA

7. POST STEAM BLOWING ACTIVITY

Prepared By : Boiler Commissioning-Project


Page 2 of 10
Checked By : Approved by: Management
Date : 18.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parasakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

STEAM BLOWING PROCEDURE

1. OBJECTIVE
The purpose of the steam blowing is to clean the super heater circuits and main steam line of any foreign material, mill
scale ,loose weld, dirt etc which may otherwise lead to damage of turbine blades, valves etc.

2. PRINCIPLE
Steam blowing is carried out in which, boiler pressure is raised to 12 Kg/cm2 and released through a quick opening
valve and steam blowing done till the Drum pressure drops from 12 Kg/cm2 to 8 Kg/cm2.
During steam blowing steam drum metal temperature changes has to monitor on continuous basis. Maximum
allowable thermal shock for drum material is 40 °C.
If allowable thermal shock reaches 40 °C, then operator has to close temporary blowing valve. Generally the pressure
drop from 12 Kg/cm2 to 8 Kg/cm2 happens in between 3-5 minutes and with 4 kg/cm2 pressure drop Drum metal
temperature does not drops more than 40 °C.
Repetitive heating and cooling of steam pipes with the help of high momentum of expanding steam dislodge the
rust/scales from pipe work.

3. PRE-REQUISITES

A. Services Required
1. Availability of Power Supply (H.T/L.T/220 VDC/ 110 V AC), Instrument / Service Air etc.
2. Availability of Lab facility for boiler water parameters inspection. Boiler water samples to be collected from IBD
drain line as SWAS will not be taken in line during Steam Blowing. Charging of SWAS system during Steam Blow will
leads to choking of Cooler internal tubes, Strainers etc.
Boiler Water samples to be collected for Checking pH, Conductivity and Silica.
3. Ensure adequate amount of DM water and fuel must be available.

Prepared By : Boiler Commissioning-Project


Page 3 of 10
Checked By : Approved by: Management
Date : 18.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parasakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

STEAM BLOWING PROCEDURE

B. Safety Precautions
1. Required quantities of PPE’s such as helmets, Temperature resistant hand gloves, Ear Mufflers etc. are available.
First aid kit box available in control room
2. Service water shall be made available near the activity area.
3. Required stair cases or platform or approaches etc with hand rails to temporary valves are made available.
4. Required barricades to be made to prevent personnel from coming into contact with temporary piping.
5. Required number of sign boards (Mentioning PPE requirements) to be put into position at selected locations to
indicate the ongoing process of steam blowing. Steam Exit Area must be cleared from personnel (not required for
Steam Blow operation) before giving Blow.

C. Emergency Procedures
1. The group consisting of personnel, which is carrying out steam blowing should be aware of procedures to be
followed in case of accidents involving injury to personnel.
2. The group should be aware of operating procedures of portable fire extinguishers to be used for quenching minor
fires.
3. The group should be aware that if any abnormality is observed in the permanent and temporary system during the
steam blowing operation, the operation should be immediately terminated and appropriate action taken to
address the issue.

D. Readiness of The Following To Be Ensured

Sr Description Checked
no.

1 Alkali boil out and post boil out activities like Hot rinsing, Header flushing completed

2 Post Welding, Inspection of header stubs and hydro test completed

3 Temporary exhaust piping erection completed along with all supports

Prepared By : Boiler Commissioning-Project


Page 4 of 10
Checked By : Approved by: Management
Date : 18.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parasakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

STEAM BLOWING PROCEDURE

3 Target plate and its fixing device are ready

4 Ensure hydrostatic test of pipe work is completed

5 Pressure and temperature gauges in temporary pipe are installed

ESP air load test completed, Hopper heaters, insulation heaters, Rapping systems are
7
Commissioned

8 All oxygen analyzers and CO analyzer (if provided) commissioned and reading available in DCS

Hydrostatic plugs from safety valves removed and safety valves (WHRS-AQC2HP-MAS-SV-001,
9 WHRS-AQC2HP-MAS-SV-002, WHRS-AQC2HP-MAS-SV-003, WHRS-AQC2LP-MAS-SV-001,
WHRS-AQC2LP-MAS-SV-002, and WHRS-AQC2LP-MAS-SV-003) assembled.

Main steam line from boiler outlet to exhaust all supports erected and spring supports Cold
10
setting completed

11 HP dosing system is commissioned and ready

Feed water pipe, de-super-heater pipe and Deaerator pipe have been flushed by water.
12
Desuperheater and Deaerator system is ready.

13 All man holes are closed.

Ensure Deaerator (WHRS-DEA-FDW-DEA-001, WHRS-DEA-FDW-BFP-001, WHRS-DEA-FDW-BFP-


14 002) BFP and DM transfer pumps (WHRS-DMS-DM-DM-DMTP-001 and WHRS-DMS-DM-DM-
DMTP-002) are ready

15 HGG in ready condition (WHRS-AQC2-FLG-HGG-001)

Steam must be exhausted outside turbine hall area which is cordoned off and notice displayed
16
prominently.

17 Fire fighting system is ready and commissioned.

Prepared By : Boiler Commissioning-Project


Page 5 of 10
Checked By : Approved by: Management
Date : 18.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parasakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

STEAM BLOWING PROCEDURE

4. STEAM BLOWING CHECK LIST

Sr.
Description Checked
No.

Main Steam Stop valve (WHRS-AQC2HP-MAS-MOV-001WHRS-AQC2LP-MAS-MOV-001,),


1 MSSV bypass (WHRS-AQC2HP-MAS-MOV-001A, WHRS-AQC2LP-MAS-MOV-001A) operation
checked from DCS.

2 MS line from boiler O/L to exhaust all spring support checked.

3 Steam blowing line from temporary blowing valve to atmosphere erected with all supports.

4 Target plate fixing arrangement done and is accessible in all exhaust line to atmosphere.

6 Trial of Temporary Sacrificing MOV, Warm up vent MOV completed from DCS

Trial of Chain Conveyor and RAV (WHRS-AQC2-FLG-RAV-001, WHRS-AQC2-FLG-RAV-002,


7 WHRS-AQC2-FLG-RAV-003, WHRS-AQC2-FLG-RAV-004, WHRS-PH2-FLG-RAV-001, WHRS-
PH2-FLG-RAV-002) completed from DCS

Deaerator pegging Steam PRDS line not connected to deaerator and end kept open for
8
venting to atmosphere for flushing at Deaerator end

Drum level transmitter


(WHRS-AQC2HP-FDW-LT-001A, WHRS-AQC2HP-FDW-LT-001B, WHRS-AQC2HP-FDW-LT-
001C, WHRS-AQC2LP-FDW-LT-001A, WHRS-AQC2LP-FDW-LT-001B, WHRS-AQC2LP-FDW-
LT-001C, WHRS-PH2HP-FDW-LT-001A, WHRS-PH2HP-FDW-LT-001B, WHRS-PH2HP-FDW-LT-
001C, WHRS-PH2LP-FDW-LT-001A, WHRS-PH2LP-FDW-LT-001B, WHRS-PH2LP-FDW-LT-
9
001C)
Drum pressure transmitter
(WHRS-AQC2HP-MAS-PT-001, WHRS-AQC2HP-MAS-PT-002, WHRS-AQC2LP-MAS-PT-001,
WHRS-AQC2LP-MAS-PT-002, WHRS-PH2HP-MAS-PT-001A, and WHRS-PH2HP-MAS-PT-
001B) s are ready for commission.

10 Expansion indicators installed in boiler

11 Tri-Sodium phosphate dosing pump is available for HP Dosing.

Prepared By : Boiler Commissioning-Project


Page 6 of 10
Checked By : Approved by: Management
Date : 18.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parasakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

STEAM BLOWING PROCEDURE

12 All required pressure and temperature indications are available in DCS.

Start up vent (WHRS-AQC2HP-MAS-MOV-002, WHRS-AQC2HP-MAS-GT-001, WHRS-PH2HP-


13 MAS-MOV-002, WHRS-PH2LP-MAS-GT-001) commissioned and MS line temperature
readings are available in DCS and PTs are ready to commission.

All Steam traps of Main Steam line Drains are not installed before Steam Blowing as
14
accumulation of dirt, Scales at upstream of Trap will leads to damage trap internals

Note: steam blowing should be started after ensuring all the system readiness mentioned above.

SEQUENCE OF STEAM BLOWING:

For this plant structure steam blowing can be completed in two stages.

1) Steam Blowing of AQC Boiler (HP & LP Circuits at the same time) up to TG Inlet.

Temporary blowing line along with a temporary blowing sacrificing valve to be erected at TG inlet before ESV with all
permanent support and its inspection completed.
Blowing to be done up to TG inlet for both HP & LP circuits to be carried out at alternatively. First HP side blow to be given
after reaching desired temp and pressure (by puffing method). After HP side blow is completed, after 5 min, start LP side
blow (continuous method) for about 10-15 min (time of blow should be decide on the drum parameters at site only).

Prepared By : Boiler Commissioning-Project


Page 7 of 10
Checked By : Approved by: Management
Date : 18.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parasakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

STEAM BLOWING PROCEDURE

2) Steam Blowing of PH Boiler (Only HP Circuit) till AQC mixing header.

Temporary blowing line along with a temporary blowing sacrificing valve to be erected at AQC mixing header inlet at the PH
main steam line with all permanent support and inspection completed.
Blowing to be done up to Mixing header Inlet. After ensuring cleanliness of target plate, temporary line to be removed and
PH main steam line to be connected with AQC mixing header.

Prepared By : Boiler Commissioning-Project


Page 8 of 10
Checked By : Approved by: Management
Date : 18.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parasakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

STEAM BLOWING PROCEDURE

5. PROCEDURE
Start up procedure for steam blowing

Take air compressors & ACW system in line, start the HP BFP and LP BFP and charge the line up to Feed Control Station
(FCS).
Follow below mentioned start up procedure of boiler for steam blowing;

a. Fill the HP & LP Drum (In Case of AQC Boiler) & HP Drum (In Case of PH Boiler) maintaining level at (-100mmWC), with
initial filling line. Open by Flue gas by pass damper, then inlet and outlet damper.

b. Start Closing the Flue Gas By-pass damper to regulate the Flue gases through the boiler slowly increasing the drum
pressure.

c. Close the Drum vent after 2 kg/cm2 (g) pressure is attained in the drum. When drum pressure reach 5 kg/cm2 (g),
close the super heater drains and MS line drain.

d. Watch the Drum level and line up the BFP and Feed control station

e. Slowly increase the steam pressure by closing the Flue Gas by-pass damper and charge the Main steam line up to
sacrificing valve by opening the Boiler MSSV slowly after steam pressure reaches 8 kg/cm2 (g). Open the start-up vent
valve and adjust opening to increase the Main Steam temperature as per requirement. Before charging the main steam
line till TG inlet ensure that all line drains and warm up vent before TG Inlet is opened.

f. When required steam temperature (above 225 °C for AQC Boiler (HP) and above 200 °C for PH Boiler) and pressure
of about (12-14) kg/cm2 (g) is attained before the Sacrificing valve, close the Warm up vent ,start up vent and the
line drains , FCV. Open the Flue Gas Bypass damper of the Boiler and give an open command to the sacrificing valve
and blow off the steam from the temporary blow off line till the steam pressure drops down to 4 kg/cm2 (g) -5 kg/cm2
( puffing method).

g. After Closing the Sacrificing valve Immediately open feed control valve and start taking feed water into Boiler, and
close feed control valve at drum level (-100mmWC).

h. After HP side blow is completed and water is taken in Boiler. Wait for 10 min to normalize and start giving LP side blow
continuously when pressure is 1.5 -2.5 kg/cm2 (g) for 10-15 min. (Blowing time should be decide on site based on the
drum level parameter) Flue gas flow rate to be regulated to maintain the pressure during blow ( continuous method).

I. After completion of blowing, check all the Main Steam line supports in field. If found normal give blows by
Following the same procedure keeping minimum 1.5 - 2 hour gap between 2 consecutive Blows, Continue the
Same procedure of HP and LP blow till target plate is cleared.

j. The steam blowing process should continue until target plate is declared cleared by TG OEM.

k. ESV flange up to turbine inlet which is not blown out in steam blowing to be acid pickled. (Depends upon
arrangement)

Prepared By : Boiler Commissioning-Project


Page 9 of 10
Checked By : Approved by: Management
Date : 18.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parasakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03

STEAM BLOWING PROCEDURE

6. COMPLETION CRITERIA
The steam blowing can be declared complete only after ensuring cleanliness of target plates mounted in the temporary
exhaust pipe. It is recommended to install the target plate after completing few blows in each stage. Since the highest
velocity of the steam is at the centre, the effectiveness of steam blowing is identified by knowing the absolute pitting on

the target plate in the central zone, i.e. the area covered by ¾ th of the diameter.
Note: For acceptance criteria of steam blowing Turbine OEM recommended acceptable limits to be followed.

7. POST STEAM BLOWING ACTIVITY


1. Removal of temporary blowing piping
2. Installation of Main steam Flow nozzles
3. Final walk down Checking for all Main steam piping supports
4. Termination of Deaerator pegging steam PRDS piping to deaerator
5. Parallelity checking for Main steam piping with STG ESV
6. Fixing of Steam traps at Main steam drain line.
7. Boiler Drum and Main steam safety valve floating and setting.

Prepared By : Boiler Commissioning-Project


Page 10 of 10
Checked By : Approved by: Management
*.LUBRICATION SCHEDULE
LUBRICATION SCHEDULE
WHR BASED POWER PLANT
PARASAKTI CEMENT INDUSTRIES LTD.
2M.0040

Grade of Quantity per TOTAL


Equipment KW Part to be Equipment Code / Lubrication Interval Lubricant Lubricants Name
Equipment Tag Number Lubricant Equipment QUANTITY Remarks
rating / Pole Lubricated Qty. Standards Hours Type & Makes
(Make) (Kg/Liters) (Kg/Liters)
HGG
OIL

WHRS-AQC2HP-HGG-P-001 Fluid to be Continues when pump under


NA BEARING 2 - Self lubricating Fluid to be pumped - - Bearing is lubricated by the fluid to be pumped
WHRS-AQC2HP-HGG-P-002 pumped operation

GREASE
WHRS-AQC2HP-HGG-M-001 /
0.75KW BEARING 2 NA NA Greased for life NA NA Greased for life NA No need to lubricate Greased for life
WHRS-AQC2HP-HGG-M-002

NA - BEARING 13 EP-3 NA Once every 3months Grease As Standard available at site ̴ 200grm 2.5kg

1. Initial Filling 300 grm/Bearing


NA - BEARING 2 EP-2 or EP-3 NA 300 grm/bearing Grease MOBIL: HXP 222. 300 grm 600 grm 2. After 1600 hrs Refilling 40 grm/Bearing
3. Replacement after 10000 hrs

WHRS-AQC2HP-HGG-M-003
30KW BEARING 2 NA NA Greased for life NA NA Greased for life NA No need to lubricate Greased for life
WHRS-AQC2HP-HGG-M-004

NA - DE & NDE Bearing 1 LGEP-2 NA Every 900 Hrs Grease Standard 10grm 20grm

1.5KW (DC) WHRS-AQC2HP-HGG-M-005 BEARING 1 NA NA Greased for life NA NA Greased for life NA No need to lubricate Greased for life

First fill for 240 hrs


WHRS-AQC2HP-HGG-RB-001 Blowers are supplied with NO Oil .
NA Gear case 2 SP-320 NA Then Oil Indian Oil 650ml every time 1300 ml
WHRS-AQC2HP-HGG-RB-002 Please fill Oil before 1st Start
Every 1440 Hrs replacement

WHRS-AQC2HP-HGG-M-006
18.5KW BEARING 2 NA NA Greased for life NA NA Greased for life NA No need to lubricate Greased for life
WHRS-AQC2HP-HGG-M-007

NA - Shaft Bearing 1 EP-3 NA Once Every Month Grease Standard 15-20 grm 15-20 grm

NA - NA 1 NA NA Greased for life NA NA Greased for life NA No need to lubricate Greased for life

1. Castrol Hipress or Alpha617


2. BP : CABOL75 or AMOCAM
NA - Gearbox 1 NA NA Every 10000 hrs refilling Oil 3 Ltr 3 Ltr
3.ESSO: Enclo120 or Gervil EP-3
4. IOC : Servomesh40 or Servosystem533

1. Castrol : Spherol Gr.Ap-3


2. BP : Mobilux Gr.3
NA - Motor 1 NA NA Every 10000 hrs refilling Grease 50 grm 50 grm Only 2/3 of rearing area to be filled to avoid Overheating
3. ESSO : Multipurpose Gr-2
4. IOC : Alvania Gr-3

1. Castrol : Spherol Gr.Ap-3


2. BP : Mobilux Gr.3
NA - Pulleys 1 NA NA Every 2 weeks Grease 300 grm 300 grm Full completely with additional packing
3. ESSO : Multipurpose Gr-2
4. IOC : Alvania Gr-3

1. Castrol : Spherol Gr.Ap-3


Belt tensioning and Oil weekly on ends 2. BP : Mobilux Gr.3
NA - 1 NA NA Grease 150 grm 150 grm Full completely with additional packing
Steering Device Grease every 2 weeks 3. ESSO : Multipurpose Gr-2
4. IOC : Alvania Gr-3
1. Castrol : Spherol Gr.Ap-3
2. BP : Mobilux Gr.3
NA - Belt steering Idler 1 NA NA Every 2 weeks Grease 300 grm 300 grm Full completely with additional packing
3. ESSO : Multipurpose Gr-2
4. IOC : Alvania Gr-3
1. Castrol : Spherol Gr.Ap-3
2. BP : Mobilux Gr.3
NA - Tension Spindles 1 NA NA Every 6 Month Grease 300 grm 300 grm Clean the spindles from Dirt and ready the grease
3. ESSO : Multipurpose Gr-2
4. IOC : Alvania Gr-3
1. Castrol : Spherol Gr.Ap-3
Open threads of 2. BP : Mobilux Gr.3
NA - 1 NA NA Every 6 Month Grease 100 grm 100 grm
fasteners 3. ESSO : Multipurpose Gr-2
4. IOC : Alvania Gr-3

NA - Gear box 1 NA NA Replace after Every 1,00,000 hrs Oil Servomesh 40 or Servosystem 553 2.5 Ltr 2.5 Ltr

NA - Damper shaft 5 EP-2 or EP-3 NA Check Every 2 weeks Grease Standard 10-15 grm / shaft 50 grm

WTP
GREASE

After 40000 hrs we


15 KW/2 EFSSPL-TKII-P-10.8-88-03 Bearing 1 NA NA 40000 NA NA have change the NA
bearing

After 40000 hrs we


75/2 EFSSPL-TKII-P-171-88-02 Bearing 1 NA NA 40000 NA NA have change the NA
bearing

After 40000 hrs we


102 HP/1800 EFSSPL-TKII-P-171-88-01 Bearing 1 NA NA 40000 NA NA have change the NA
bearing

EOT CRANE
OIL

MAIN HOIST GEAR


3.7 kw/8 pole 1 NO SP, 220/320 SPLASH TYPE CASTROL ALHA,SP, 220,320 50 LTS 50 LTS
BOX HR-500+150

AUXILLARY HOIST
11 kw/6 pole 1 NO SP, 220/320 SPLASH TYPE CASTROL ALHA,SP, 220,320 15 LTS 15 LTS
GEAR BOX HB-400

CROSS TRAVAL
0.75 kw/6 pole 1 NO SP, 220/320 SPLASH TYPE CASTROL ALHA,SP, 220,320 4 LTS 4 LTS
GEAR BOX VC-320

LONG TRAVAL
0.75 kw/6 pole 2 NO SP, 220/320 SPLASH TYPE CASTROL ALHA,SP, 220,320 15 LTS (EACH) 30 LTS
GEAR BOX HC-350

D i S
Dosing System'
t '

0.5LPH , 30 After 450 hours of operation or Indroll Lubricants / Caltex Alpha ZN 817/ Indion Oil 250 GRMS/PER
2003-B-00930 Pump internal parts 4 nos Gear Oil 460 460 Gear Oil 1000 GRM
Kg/cm2 every 3 months wichever is earlier Corporation Servomesh 50 PUMP

0.5 LPH , 30 After 450 hours of operation or Indroll Lubricants / Caltex Alpha ZN 817/ Indion Oil 250 GRMS/PER
2003-B-00930 Pump internal parts 4 nos Gear Oil 460 460 Gear Oil 1000 GRM
Kg/cm2 every 3 months wichever is earlier Corporation Servomesh 50 PUMP

0-10 LPH, 6 After 450 hours of operation or Indroll Lubricants / Caltex Alpha ZN 817/ Indion Oil 250 GRMS/PER
2003-B-00930 Pump internal parts 2 nos Gear Oil 460 460 Gear Oil 500 GRM
Kg/cm2 every 3 months wichever is earlier Corporation Servomesh 50 PUMP

Miscellaneous Pumps
GREASE

After 40000 hrs we


1250 KW/6 WHRS-CWS-MCW-MCWP-001/002 Bearing 2 NA NA 40000 NA NA have to change the NA
bearing

After 40000 hrs we


37/4 WHRS-CWS-ACW-ACWP-001/002 Bearing 2 NA NA 40000 NA NA have to change the NA
bearing

After 40000 hrs we


18.5/2 WHRS-CWS-ACW-ACWP-001/002 Bearing 2 NA NA 40000 NA NA have to change the NA
bearing

After 40000 hrs we


15 KW/2 Bearing 1 NA NA 40000 NA NA have to change the NA
bearing

After 40000 hrs we


1.1 KW/2 Bearing 2 NA NA 40000 NA NA have to change the NA
bearing

Compressor
OIL

Sigma Fluid S- 40 litre for 2 No


25 KW Air Screw Element 2 6000 Oil 20 Litre/compressor
570 Compressor

GREASE

Anti-friction
800 Gram for 2
25 KW Motor Bearing 2 bearing grease 2000 Grease 400 Gram/Motor
Motors
Unirex N3 4

Cooling Tower
OIL

ISO VG-100; Change oil after 6 months or after


Hydraulic
GEAR BOX 3 IOLSERVO 3000 hours of operation whichever Oil 1 Litre/unit 3 Liters
Mineral Oil
SYSTEM 100 is earlier.

ISO VG-100;
Hoist 1 Hydraulic Oil IOLSERVO After 4 months Oil 1 Litre/unit 1 Liter
SYSTEM 100

Hammering System
OIL

after 24 months
ISO
GEAR BOX 14 Mineral Oil from date of Oil Shell/Kluber 4.5 Litre/unit 63 Liters
VG 220
supply

2500 to 3000
Chain & Sprocket 14 Mineral Oil SAE 30 Oil Servo/Castrol/Mobil 1.25 Litre/unit 17.5 Liters
hours of operation

RAV
OIL

Indian Oil/HP ISO


GEAR BOX 4 5000-8000hrs Oil Indian Oil/HP 1.25 Litre/unit 5 Liters
Grade 220 VG 220

Indian Oil/HP ISO


GEAR BOX 3 5000-8000hrs Oil Indian Oil/HP 3.75 Litre/unit 11.25 Liters
Grade 220 VG 220

GREASE

Indian Oil/HP
Bearing 8 EP-3, Grease 2000-2500hrs Grease Indian Oil/HP 0.05 kg/unit 0.4 kg
Grade 220

Indian Oil/HP
Bearing 6 EP-3, Grease 2000-2500hrs Grease Indian Oil/HP 0.075 kg/unit 0.45 kg
Grade 220

Slide Gates
GREASE

Threaded portion after 4000-5000


12 Indian Oil/HP EP-3, Grease Grease Indian Oil/HP 0.3 kg/unit 3.6 kg
for MSG Screw Rod hrs from first fill
++J. ATTACHMENTS
BOILER GA DIAGRAM



 








BOILER P&ID
SILENCER
RAV
VALVE SCHEDULE
Project : 1 x 6MW/7MW WHRS Project Doc. No. 2003-B-00944-0 Rev.2
Client : PARASAKTI CEMENT INDUSTRIES LTD., AP BOILER VALVE SCHEDULE Date: 03-11-2017
WO No. : 2M.0040
Mech. Mech.
Operating Operating Operating
Type of Design Design Body Total Special Requirement /
Sr.No. Item/Location Piping NB mm Pressure Temp Flow H / M End Conn. Class** IBR (Yes/No) Tag Numbers BW Schedule
Valve Pressure Temp MOC Qty Remark
(kg/cm2 (g)) deg. C (TPH)
(kg/cm2 (g)) deg. C
GATE VALVES
P&ID FOR DEAERATOR & BFP (PB-33376-1 Rev.A)
1 Upstream Isloation for PCV on Deaerator Aux. Steam Line Deaerator Steam Piping GATE 100 3 190 3 190 0.5 H BW 150 WCB 1 YES WHRS-DEA-AUX-GT-001 SCH.40
2 Downstream Isloation for PCV on Deaerator Steam Line Deaerator Steam Piping GATE 100 3 190 2.8 190 0.5 H BW 150 WCB 1 YES WHRS-DEA-AUX-GT-002 SCH.40
3 Isolation in steam line at Deaerator inlet Deaerator Steam Piping GATE 100 3 190 2.8 190 0.5 H BW 150 WCB 1 YES WHRS-DEA-AUX-GT-003 SCH.40
4 Intial Warm Up Line for Deaerator Storage Tank Deaerator Steam Piping GATE 80 3 190 M BW 150 WCB 1 YES WHRS-DEA-AUX-MOV-001 SCH.40
5 Condensate from GSC Condensate Piping GATE 80 15 80 10 60 35 H BW 150 WCB 1 YES WHRS-DEA-CDS-GT-001 SCH.40
6 Condensate from GSC to AQC-CPH inlet Header Condensate Piping GATE 80 15 80 10 60 35 H BW 150 WCB 1 YES WHRS-DEA-CDS-GT-002 SCH.40
7 CPH Bypass Valve Condensate Piping GATE 80 15 150 10 120 35 H BW 300 WCB 1 YES WHRS-DEA-CDS-GT-004 SCH.40
8 Isolation valve in condensate line near Deaerator Condensate Piping GATE 80 15 150 10 120 35 H BW 300 WCB 1 YES WHRS-DEA-CDS-GT-005 SCH.40
9 Deaerator outlet Line isolation (Locked Open) Feed Water Piping GATE 150 4 150 2 126 35 H BW 150 WCB 1 YES Locked Open Valve WHRS-DEA-01-FDW-GT-001 SCH.40
10 BFP-1 suction side isolation Feed Water Piping GATE 150 4 150 2 126 35 H BW 150 WCB 1 YES With Limit Swithces WHRS-DEA-01-FDW-GT-002 SCH.40
11 BFP-1 - Discharge side Isolation Valve Feed Water Piping GATE 80 35 150 28 126 35 M BW 300 WCB 1 YES WHRS-DEA-FDW-MOV-001 SCH.40

12 BFP-1 - Isolation for Minimum Recirculation Line near ARC Valve Feed Water Piping GATE 40 35 150 H SW 800 A105 1 YES Locked Open Valve WHRS-DEA-FDW-GT-004

13 BFP-1 - Isolation for Minimum Recirculation Line near Deaerator Feed Water Piping GATE 40 35 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GT-007
14 BFP-2 suction side isolation Feed Water Piping GATE 150 4 150 2 126 35 H BW 150 WCB 1 YES With Limit Swithces WHRS-DEA-FDW-GT-003 SCH.40
15 BFP-2 - Discharge side Isolation Valve Feed Water Piping GATE 80 35 150 28 126 35 M BW 300 WCB 1 YES WHRS-DEA-FDW-MOV-002 SCH.40

16 BFP-2 - Isolation for Minimum Recirculation Line near ARC Valve Feed Water Piping GATE 40 35 150 H SW 800 A105 1 YES Locked Open Valve WHRS-DEA-FDW-GT-005

17 BFP-2 - Isolation for Minimum Recirculation Line near Deaerator Feed Water Piping GATE 40 35 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GT-006

P&ID FOR WATER & STEAM (AQC) (PB-33377-1 Rev.A)


BFP Outlet to AQC - Feed Water isolation Valve upstream of attemperator
18 HP Feed Water Piping GATE 80 35 150 28 126 35 H BW 300 WCB 1 YES WHRS-AQC2HP-FDW-GT-001 SCH.40
tapping
19 Initial filling Line to HP Feed Water Line DM Water Piping GATE 40 10 50 H SW 800 A105 1 NO WHRS-AQC2HP-FDW-GT-002
20 Feedwater tapping to PH LP Section LP Feed Water Piping GATE 40 35 150 28 126 3.2 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GT-003
21 Feedwater tapping to AQC LP Section LP Feed Water Piping GATE 40 35 150 28 126 1.8 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GT-004
Feedwater Line to AQC - isolation Valve downstream of Attemperator
22 HP Feed Water Piping GATE 80 35 150 28 126 29.2 H BW 300 WCB 1 YES WHRS-AQC2HP-FDW-GT-005 SCH.40
tapping
23 AQC ECO bypass to HP drum of PH line isolation HP Feed Water Piping GATE 50 35 150 28 126 11.8 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GT-007
24 Isolation for Feed Water to PH Boiler (Economiser outlet) HP Feed Water Piping GATE 50 35 200 28 190 11.8 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GT-008
25 Upstream Isolation for HP side Main FCV (0-100%) HP Feed Water Piping GATE 80 35 200 28 190 17.4 M BW 300 WCB 1 YES WHRS-AQC2HP-FDW-MOV-001 SCH.40
26 Upstream Isolation for HP side Bypass FCV (0-100%) HP Feed Water Piping GATE 80 35 200 28 190 17.4 M BW 300 WCB 1 YES WHRS-AQC2HP-FDW-MOV-002 SCH.40
27 Downstream Isolation for HP side Main FCV (0-100%) HP Feed Water Piping GATE 80 35 200 28 190 17.4 H BW 300 WCB 1 YES WHRS-AQC2HP-FDW-GT-009 SCH.40
28 Downstream Isolation for HP side Bypass FCV (0-100%) HP Feed Water Piping GATE 80 35 200 28 190 17.4 H BW 300 WCB 1 YES WHRS-AQC2HP-FDW-GT-010 SCH.40
29 Isolation valve in feed water line at HP steam drum inlet HP Feed Water Piping GATE 80 35 200 28 190 17.4 H BW 300 WCB 1 YES WHRS-AQC2HP-FDW-GT-011 SCH.40
30 Hydrotest Connection to HP Steam Drum of AQC DM Water Piping GATE 25 35 50 H SW 800 A105 1 NO WHRS-AQC2HP-FDW-GT-010
31 Upstream Isolation of Emergency Blow Down Valve Blow Down Piping GATE 40 18 210 H SW 800 A105 1 YES WHRS-AQC2HP-BDS-GT-002
32 Upstream Isolation of Continuous Blow Down Valve Blow Down Piping GATE 25 18 210 H SW 800 A105 1 YES WHRS-AQC2HP-BDS-GT-001
33 Main attemperator line isolation Spray Water Piping GATE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GT-006
34 Upstream isolation for Attemperator TCV Spray Water Piping GATE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GT-013
35 Downstream isolation for Attemperator TCV Spray Water Piping GATE 25 18 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GT-014
36 HP Main Steam Startup vent isolation HP Main Steam piping GATE 100 18 400 H BW 300 WCB 1 YES WHRS-AQC2HP-MAS-GT-001 SCH.40
37 PH HP Steam - HP FSH Bypass Isolation HP Main Steam piping GATE 150 18 310 H BW 300 WCB 1 YES WHRS-AQC2HP-MAS-GT-002 SCH.40
With integral motorized
38 HP Main Steam Stop Valve HP Main Steam piping GATE 300 18 400 14.5 390 29.2 M BW 300 WCB 1 YES bypass valve (Inching WHRS-AQC2HP-MAS-MOV-001 SCH.40
type)
39 Initial filling Line to Feed Water Line of AQC LP Steam drum DM Water Piping GATE 25 8.5 50 H SW 800 A105 1 NO WHRS-AQC2LP-FDW-GT-001
40 Upstream Isolation for LP side Main FCV (0-100%) LP Feed Water Piping GATE 40 35 150 28 126 1.8 M SW 800 A105 1 YES WHRS-AQC2LP-FDW-MOV-001
41 Upstream Isolation for LP side Bypass FCV (0-100%) LP Feed Water Piping GATE 40 35 150 28 126 1.8 M SW 800 A105 1 YES WHRS-AQC2LP-FDW-MOV-002
42 Downstream Isolation for LP side Main FCV (0-100%) LP Feed Water Piping GATE 40 7 150 3.5 126 1.8 H SW 800 A105 1 YES WHRS-AQC2LP-FDW-GT-002
43 Downstream Isolation for LP side Bypass FCV (0-100%) LP Feed Water Piping GATE 40 7 150 3.5 126 1.8 H SW 800 A105 1 YES WHRS-AQC2LP-FDW-GT-003
44 Isolation valve in feed water line at LP steam drum inlet LP Feed Water Piping GATE 40 7 150 3.5 126 1.8 H SW 800 A105 1 YES WHRS-AQC2LP-FDW-GT-004

Page 2 of 13
Project : 1 x 6MW/7MW WHRS Project Doc. No. 2003-B-00944-0 Rev.2
Client : PARASAKTI CEMENT INDUSTRIES LTD., AP BOILER VALVE SCHEDULE Date: 03-11-2017
WO No. : 2M.0040
Mech. Mech.
Operating Operating Operating
Type of Design Design Body Total Special Requirement /
Sr.No. Item/Location Piping NB mm Pressure Temp Flow H / M End Conn. Class** IBR (Yes/No) Tag Numbers BW Schedule
Valve Pressure Temp MOC Qty Remark
(kg/cm2 (g)) deg. C (TPH)
(kg/cm2 (g)) deg. C
45 Hydrotest Connection to LP Steam Drum of AQC DM Water Piping GATE 25 8.5 50 H SW 800 A105 1 NO WHRS-AQC2LP-FDW-GT-005
46 Upstream Isolation of Emergency Blow Down Valve-LP Drum Blow Down Piping GATE 40 4 150 H SW 800 A105 1 YES WHRS-AQC2LP-BDS-GT-002
47 Upstream Isolation of Continuous Blow Down Valve-LP drum Blow Down Piping GATE 25 4 150 H SW 800 A105 1 YES WHRS-AQC2LP-BDS-GT-001
48 LP Main Steam Startup vent isolation LP Main Steam piping GATE 50 5 210 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GT-001
With integral motorized
49 LP Main Steam Stop Valve LP Main Steam piping GATE 150 5 210 2.5 195 1.8 M BW 150 WCB 1 YES bypass valve (Inching WHRS-AQC2LP-MAS-MOV-001 SCH.40
type)
P&ID FOR WATER & STEAM (PH) (PB-33378-1 Rev.A)
50 Initial filling Line to PH HP Feed Water Line DM Water Piping GATE 50 8.5 50 8.5 50 H SW 800 A105 1 NO WHRS-PH2HP-FDW-GT-001

51 Feedwater to PH HP drum- Upstream Isolation for Main FCV (0-100%) PH Boiler Feed water GATE 50 35 200 28 190 11.8 M SW 800 A105 1 YES WHRS-PH2HP-FDW-MOV-001

52 Feedwater to PH HP drum- Upstream Isolation for Bypass FCV (0-100%) PH Boiler Feed water GATE 50 35 200 28 190 11.8 M SW 800 A105 1 YES WHRS-PH2HP-FDW-MOV-002

53 Feedwater to PH HP drum- Downstream Isolation for Main FCV (0-100%) PH Boiler Feed water GATE 50 35 200 28 190 11.8 H SW 800 A105 1 YES WHRS-PH2HP-FDW-GT-002

54 FW to PH HP drum- Downstream Isolation for Bypass FCV (0-100%) PH Boiler Feed water GATE 50 35 200 28 190 11.8 H SW 800 A105 1 YES WHRS-PH2HP-FDW-GT-003

55 Isolation valve on Feedwater Line at inlet of PH HP Drum PH Boiler Feed water GATE 50 35 200 28 190 11.8 H SW 800 A105 1 YES WHRS-PH2HP-FDW-GT-004
56 Hydrotest Connection to PH HP Steam Drum DM Water Piping GATE 25 35 50 H SW 800 A105 1 NO WHRS-PH2HP-FDW-GT-005

57 Upstream Isolation of Emergency Blow Down Valve - PH HP Drum Blow Down Piping GATE 40 18 210 H SW 800 A105 1 YES WHRS-PH2HP-BDS-GT-002

58 Upstream Isolation of Continuous Blow Down Valve - PH HP Drum Blow Down Piping GATE 25 18 210 H SW 800 A105 1 YES WHRS-PH2HP-BDS-GT-001

59 PH HP Main Steam Startup vent isolation PH Main Steam piping GATE 65 18 310 H BW 300 WCB 1 YES WHRS-PH2HP-MAS-GT-001 SCH.40
With integral motorized
60 PH HP Main Steam Stop Valve PH Main Steam piping GATE 150 18 310 15.4 300 11.8 M BW 300 WCB 1 YES bypass valve (Inching WHRS-PH2HP-MAS-MOV-001 SCH.40
type)
61 Initial filling Line to PH LP Feed Water Line DM Water Piping GATE 50 8.5 50 H SW 800 A105 1 NO WHRS-PH2LP-FDW-GT-001

62 Feedwater to PH LP drum- Upstream Isolation for Main FCV (0-100%) PH Boiler Feed water GATE 40 35 150 28 126 3.2 M SW 800 A105 1 YES WHRS-PH2LP-FDW-MOV-001

63 Feedwater to PH LP drum- Upstream Isolation for Bypass FCV (0-100%) PH Boiler Feed water GATE 40 35 150 28 126 3.2 M SW 800 A105 1 YES WHRS-PH2LP-FDW-MOV-002

64 Feedwater to PH LP drum- Downstream Isolation for Main FCV (0-100%) PH Boiler Feed water GATE 40 7 150 3.5 126 3.2 H SW 800 A105 1 YES WHRS-PH2LP-FDW-GT-002

65 FW to PH LP drum- Downstream Isolation for Bypass FCV (0-100%) PH Boiler Feed water GATE 40 7 150 3.5 126 3.2 H SW 800 A105 1 YES WHRS-PH2LP-FDW-GT-003

66 Isolation valve on Feedwater Line at inlet of PH LP Drum PH Boiler Feed water GATE 40 7 150 3.5 126 3.2 H SW 800 A105 1 YES WHRS-PH2LP-FDW-GT-004
67 Hydrotest Connection to PH LP Steam Drum DM Water Piping GATE 25 7 150 H SW 800 A105 1 NO WHRS-PH2LP-FDW-GT-005

68 Upstream Isolation of Emergency Blow Down Valve - PH LP Drum Blow Down Piping GATE 40 7 150 H SW 800 A105 1 YES WHRS-PH2LP-BDS-GT-002

69 Upstream Isolation of Continuous Blow Down Valve - PH LP Drum Blow Down Piping GATE 25 7 150 H SW 800 A105 1 YES WHRS-PH2LP-BDS-GT-001

70 PH LP Main Steam Startup vent isolation PH Main Steam piping GATE 80 5 210 H BW 300 WCB 1 YES WHRS-PH2LP-MAS-GT-001 SCH.40
With integral motorized
71 PH LP Main Steam Stop Valve PH Main Steam piping GATE 150 5 210 2.5 195 3.1 M BW 300 WCB 1 YES bypass valve (Inching WHRS-PH2LP-MAS-MOV-001 SCH.40
type)
P&ID FOR PLANT STEAM SYSTEM (PB-33379-2 Rev.A)
72 HP Main Steam - isolation for Tapping to Ejector HP Main Steam piping GATE 50 16 400 H SW 800 A105 1 YES WHRS-PSSHP-MAS-GT-002

73 HP Main Steam - isolation for Tapping to Gland Sealing HP Main Steam piping GATE 40 16 400 H SW 800 A105 1 YES WHRS-PSSHP-MAS-GT-001

74 HP Main Steam - isolation for Steam Blowing vent Vent Piping GATE 300 16 400 M BW 300 WCB 1 YES WHRS-PSSHP-MAS-MOV-002 SCH.40
75 Upstream isolation for warmup vent -HP steam line Vent Piping GATE 80 16 400 H BW 300 WCB 1 YES WHRS-PSSHP-MAS-GT-003 SCH.40

76 LP Main Steam - isolation for Tapping to Dearator LP Main Steam piping GATE 100 4.5 210 H BW 150 WCB 1 YES WHRS-PSSLP-MAS-GT-002 SCH.40

77 LP Main Steam - isolation for Steam Blowing vent Vent Piping GATE 200 16 400 M BW 300 WCB 1 YES WHRS-PSSLP-MAS-MOV-002 SCH.40
78 Upstream isolation for warmup vent -LP steam line Vent Piping GATE 80 16 400 H BW 300 WCB 1 YES WHRS-PSSLP-MAS-GT-003 SCH.40

P&ID FOR DM WATER SYSTEM (PB-33383-2 Rev.A)


79 Drain valve for DM water Tank DM Water Tank GATE 80 2 50 H FE 150 WCB 1 NO WHRS-DMS-DM-GT-010
80 DM water Tank outlet isolation valve DM Water Piping GATE 100 2 50 H FE 150 WCB 1 NO WHRS-DMS-DM-GT-001

Page 3 of 13
Project : 1 x 6MW/7MW WHRS Project Doc. No. 2003-B-00944-0 Rev.2
Client : PARASAKTI CEMENT INDUSTRIES LTD., AP BOILER VALVE SCHEDULE Date: 03-11-2017
WO No. : 2M.0040
Mech. Mech.
Operating Operating Operating
Type of Design Design Body Total Special Requirement /
Sr.No. Item/Location Piping NB mm Pressure Temp Flow H / M End Conn. Class** IBR (Yes/No) Tag Numbers BW Schedule
Valve Pressure Temp MOC Qty Remark
(kg/cm2 (g)) deg. C (TPH)
(kg/cm2 (g)) deg. C
WHRS-DMS-DM-GT-002,
81 DM water Transfer pumps - 1 & 2 - Upstream isolation DM Water Piping GATE 50 2 50 H SW 800 A105 2 NO
WHRS-DMS-DM-GT-003
WHRS-DMS-DM-GT-004,
82 DM water Transfer pumps - 1 & 2 - Downstream isolation DM Water Piping GATE 40 5 50 H SW 800 A105 2 NO
WHRS-DMS-DM-GT-005
WHRS-DMS-DM-GT-006,
83 DM water to Hotwell - upstream & Downstream isolation for LCV DM Water Piping GATE 40 5 50 H SW 800 A105 2 NO
WHRS-DMS-DM-GT-007
84 Initial Fill pump - Upstream isolation Initial Fill Piping GATE 100 2 50 H FE 150 WCB 1 NO WHRS-DMS-DM-GT-008
85 Initial Fill pump - downstream isolation Initial Fill Piping GATE 80 11 50 H FE 150 WCB 1 NO WHRS-DMS-DM-GT-010
Total 88
GLOBE VALVES
P&ID FOR DEAERATOR & BFP (PB-33376-1 Rev.A)
86 Bypass valve for PCV on Deaerator Steam Line Deaerator Steam Piping GLOBE 100 3 190 2.5 195 0.5 H BW 150 WCB 1 YES WHRS-DEA-AUX-GB-013 SCH.40
WHRS-DEA-AUX-GB-001,
87 Upstream Drain for PCV on DeA Steam Line (Main & Bypass) Drain Piping GLOBE 25 3 190 H SW 800 A105 2 YES
WHRS-DEA-AUX-GB-003
WHRS-DEA-AUX-GB-002,
88 Downstream Drain for PCV on DeA Steam Line Drain Piping GLOBE 25 3 190 H SW 800 A105 2 YES
WHRS-DEA-AUX-GB-004
WHRS-DEA-AUX-GB-006,
89 Isolation for PG & PT on DeA Steam Line dowstream of Desuperheater Deaerator Steam Piping GLOBE 25 3 190 H SW 800 A105 2 YES
WHRS-DEA-AUX-GB-007
WHRS-DEA-AUX-GB-008,
90 Isolation for FT on DeA Steam Line dowstream of Desuperheater Deaerator Steam Piping GLOBE 15 3 190 H SW 800 A105 2 YES
WHRS-DEA-AUX-GB-009
WHRS-DEA-AUX-GB-010,
Ustream, Downstream & Bypass Isolations for Steam Trap on DeA
91 Deaerator Steam Piping GLOBE 25 3 190 H SW 800 A105 3 YES WHRS-DEA-AUX-GB-011,
Steam Line
WHRS-DEA-AUX-GB-012
92 Upstream Isolation on Initial Fill Line to Dearator Initial Filling Piping GLOBE 50 10 50 M SW 800 A105 1 NO WHRS-DEA-DMS-MOV-001
93 Isolation valves for Pressure gauge on Deaerator Storage Tank Deaerator Storage Tank GLOBE 25 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-001
WHRS-DEA-FDW-GB-002,
94 Isolation valves for Pressure transmitter on Deaerator Storage Tank Deaerator Storage Tank GLOBE 25 4 150 H SW 800 A105 2 YES
WHRS-DEA-FDW-GB-003
95 Drain valve in Condensate line from GSC to AQC-CPH inlet Header Drain Piping GLOBE 25 15 80 H SW 800 A105 1 YES WHRS-DEA-CDS-GB-001
Condensate from GSC to AQC-CPH inlet Header - Isolation for pressure
96 Condensate Piping GLOBE 25 15 80 H SW 800 A105 1 YES WHRS-DEA-CDS-GB-002
gauge
97 Vent Isolation on AQC-CPH inlet Header Condensate Piping GLOBE 25 15 80 H SW 800 A105 1 YES WHRS-DEA-CDS-GB-003
98 Drain Isolation on Outlet Header of AQC-CPH Condensate Piping GLOBE 25 15 150 H SW 800 A105 1 YES WHRS-DEA-CDS-GB-004
99 Isolation for PT in AQC-CPH outlet to Deaerator line Condensate Piping GLOBE 25 15 150 H SW 800 A105 1 YES WHRS-DEA-CDS-GB-005
100 Isolation valve at AQC-CPH outlet Condensate Piping GLOBE 80 15 150 H BW 300 WCB 1 YES WHRS-DEA-CDS-GB-006 SCH.40
101 Deaerator Drain Line - to Flash Tank Deaerator Drain GLOBE 50 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-029
Drain isolation valves-upstream & down stream of Solenoid Valve in DeA WHRS-DEA-FDW-GB-027,
102 Deaerator Overflow GLOBE 25 4 150 H SW 800 A105 2 YES
over flow line WHRS-DEA-FDW-GB-028
103 Deaerator storage tank open drain valve Drain Piping GLOBE 50 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-026

104 Deaerator Line to BFP Suction Header- Isolation for Sample Cooler Feed Water Piping GLOBE 20 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-030

WHRS-DEA-FDW-GB-031,
105 BFP-1 - Isolation for DP on Strainer Feed Water Piping GLOBE 25 4 150 H SW 800 A105 2 YES
WHRS-DEA-FDW-GB-032
106 BFP-1 - Drain Valve on suction side Drain Piping GLOBE 25 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-033
107 BFP-1 - Suction Side PG Isolation Drain Piping GLOBE 25 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-034
108 BFP-1 - Discharge Side PG Isolation Drain Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-035
109 BFP-1 - Discharge Side PSLL Isolation Drain Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-036
WHRS-DEA-FDW-GB-037,
110 BFP-2 - Isolation for DP on Strainer Feed Water Piping GLOBE 25 4 150 H SW 800 A105 2 YES
WHRS-DEA-FDW-GB-038
111 BFP-2 - Drain Valve on suction side Drain Piping GLOBE 25 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-039
112 BFP-2 - Suction Side PG Isolation Drain Piping GLOBE 25 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-040
113 BFP-2 - Discharge Side PG Isolation Drain Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-041
114 BFP-2 - Discharge Side PSLL Isolation Drain Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-042
115 BFP Common Suction Header Drain Drain Piping GLOBE 25 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-043
116 BFP Common Discharge Header Drain Drain Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-044
117 BFP Common Discharge Header- PT isolation Feed Water Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-045
118 BFP-1 - Isolation for PG in Balance Leak-off Line Feed Water Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-046
119 BFP-2 - Isolation for PG in Balance Leak-off Line Feed Water Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-047
120 BFP-1 - Isolation for PG in Min. recirculation Line Feed Water Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-048
121 BFP-2 - Isolation for PG in Min. recirculation Line Feed Water Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-049

Page 4 of 13
Project : 1 x 6MW/7MW WHRS Project Doc. No. 2003-B-00944-0 Rev.2
Client : PARASAKTI CEMENT INDUSTRIES LTD., AP BOILER VALVE SCHEDULE Date: 03-11-2017
WO No. : 2M.0040
Mech. Mech.
Operating Operating Operating
Type of Design Design Body Total Special Requirement /
Sr.No. Item/Location Piping NB mm Pressure Temp Flow H / M End Conn. Class** IBR (Yes/No) Tag Numbers BW Schedule
Valve Pressure Temp MOC Qty Remark
(kg/cm2 (g)) deg. C (TPH)
(kg/cm2 (g)) deg. C
122 BFP-1 - Isolation for Balancing Leakoff Line near Deaerator Feed Water Piping GLOBE 40 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-051
123 BFP-2 - Isolation for Balancing Leakoff Line near Deaerator Feed Water Piping GLOBE 40 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-050
WHRS-DEA-FDW-GB-018,
WHRS-DEA-FDW-GB-019,
124 Isolation for Level Transmitters on Deaerator Deaerator GLOBE 25 4 150 H SW 800 A105 4 YES
WHRS-DEA-FDW-GB-020,
WHRS-DEA-FDW-GB-021
P&ID FOR WATER & STEAM (AQC) (PB-33377-1 Rev.A)
125 BFP Outlet to AQC - Drain upstream of Main Attemperator Line Drain Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-001

126 Vent on Economiser inlet Header Vent Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-002
127 Drain on Economiser outlet Header Drain Piping GLOBE 25 35 200 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-003
128 Isolation for PT downstream of ECO. HP Feed Water Piping GLOBE 25 35 200 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-004
WHRS-AQC2HP-FDW-GB-005,
WHRS-AQC2HP-FDW-GB-006,
129 Isolation for FT upstream of FCS for AQC HP section. HP Feed Water Piping GLOBE 15 35 200 H SW 800 A105 4 YES
WHRS-AQC2HP-FDW-GB-007,
WHRS-AQC2HP-FDW-GB-008
WHRS-AQC2HP-FDW-GB-009,
WHRS-AQC2HP-FDW-GB-010,
130 Drain valves for FCS of AQC HP section. Drain Piping GLOBE 25 35 200 H SW 800 A105 4 YES
WHRS-AQC2HP-FDW-GB-011,
WHRS-AQC2HP-FDW-GB-012
131 FCS to HP Steam Drum - isolation for PG HP Feed Water Piping GLOBE 25 35 200 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-013
WHRS-AQC2HP-FDW-GB-014,
WHRS-AQC2HP-FDW-GB-015,
132 Root Valves for level gauge on HP Steam Drum Feed Water Piping GLOBE 25 20 210 H SW 800 A105 4 YES
WHRS-AQC2HP-FDW-GB-023,
WHRS-AQC2HP-FDW-GB-024
WHRS-AQC2HP-FDW-GB-016,
133 Drain Valves for level gauge on HP Steam Drum Feed Water Piping GLOBE 15 20 210 H SW 800 A105 2 YES
WHRS-AQC2HP-FDW-GB-025
WHRS-AQC2HP-FDW-GB-017,
WHRS-AQC2HP-FDW-GB-018,
WHRS-AQC2HP-FDW-GB-019,
134 Root Valves for level transmitter on HP Steam Drum Feed Water Piping GLOBE 25 20 210 H SW 800 A105 6 YES
WHRS-AQC2HP-FDW-GB-020,
WHRS-AQC2HP-FDW-GB-021,
WHRS-AQC2HP-FDW-GB-022
135 Root Valves for pressure gauge on HP Steam Drum Feed Water Piping GLOBE 25 20 210 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-003
WHRS-AQC2HP-MAS-GB-001,
136 Root Valves for pressure transmitter on HP Steam Drum Feed Water Piping GLOBE 25 20 210 H SW 800 A105 2 YES
WHRS-AQC2HP-MAS-GB-002
137 N2 Capping Line for HP steam Drum N2 Capping GLOBE 25 20 210 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-004
138 Emergency Blowdown Valve - HP Side Blow Down Piping GLOBE 40 20 210 M* SW 800 A105 1 YES Inching Duty WHRS-AQC2HP-BDS-MOV-002
139 Emergency Blowdown Bypass Valve - HP Side Blow Down Piping GLOBE 40 20 210 H SW 800 A105 1 YES WHRS-AQC2HP-BDS-GB-004
140 Downstream Isolation of Emergency Blow Down Valve - HP Side Blow Down Piping GLOBE 40 20 210 H SW 800 A105 1 YES WHRS-AQC2HP-BDS-GB-005
141 Continuous Blowdown Sample cooler Tapping - HP Side Blow Down Piping GLOBE 20 20 210 H SW 800 A105 1 YES WHRS-AQC2HP-BDS-GB-001
142 Continuous Blowdown Valve - HP Side Blow Down Piping GLOBE 25 20 210 M* SW 800 A105 1 YES Inching Duty WHRS-AQC2HP-BDS-MOV-001
143 Continuous Blowdown Bypass Valve - HP Side Blow Down Piping GLOBE 25 20 210 H SW 800 A105 1 YES WHRS-AQC2HP-BDS-GB-002

144 Downstream Isolation of Continuous Blow Down Valve - HP Side Blow Down Piping GLOBE 25 20 210 H SW 800 A105 1 YES WHRS-AQC2HP-BDS-GB-003

145 Isolation in for PG in spray water line attemperator Spray Water Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-026
146 Drain in spray water line to attemperator Drain Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-027
147 Upstream Drain for Attemperator TCV (Main & Bypass) Spray Water Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-029
148 Attemperator TCV line bypass valve Spray Water Piping GLOBE 40 35 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-034
149 Downstream of Attemperator TCV - PG isolation Spray Water Piping GLOBE 25 20 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-030
WHRS-AQC2HP-FDW-GB-031,
150 Downstream of Attemperator TCV - FT isolation Spray Water Piping GLOBE 15 20 150 H SW 800 A105 2 YES
WHRS-AQC2HP-FDW-GB-032
151 Motorised valve in spray water line at attemperator inlet Spray Water Piping GLOBE 40 20 150 M SW 800 A105 1 YES WHRS-AQC2HP-FDW-MOV-003
152 Vent on HP Saturated Steam Line HP Steam piping GLOBE 25 18 210 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-005
153 HP Saturated Steam Sample Cooler Tapping HP Steam piping GLOBE 20 18 210 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-006
154 Drain Valve on HP Evap Inlet Header Drain Piping GLOBE 25 20 210 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-033
155 Vent Valve on HP PSH Inlet Header Vent Piping GLOBE 25 18 210 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-007
156 Drain Valve on HP PSH Outlet Header Drain Piping GLOBE 25 16.5 350 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-008

157 Isolation Valves for Pressure gauge downstream of HP PSH outlet header HP Steam piping GLOBE 25 16.5 350 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-009
Isolation Valves for Pressure transmitter downstream of HP PSH outlet
158 HP Steam piping GLOBE 25 16.5 350 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-010
header
Page 5 of 13
Project : 1 x 6MW/7MW WHRS Project Doc. No. 2003-B-00944-0 Rev.2
Client : PARASAKTI CEMENT INDUSTRIES LTD., AP BOILER VALVE SCHEDULE Date: 03-11-2017
WO No. : 2M.0040
Mech. Mech.
Operating Operating Operating
Type of Design Design Body Total Special Requirement /
Sr.No. Item/Location Piping NB mm Pressure Temp Flow H / M End Conn. Class** IBR (Yes/No) Tag Numbers BW Schedule
Valve Pressure Temp MOC Qty Remark
(kg/cm2 (g)) deg. C (TPH)
(kg/cm2 (g)) deg. C

WHRS-AQC2HP-MAS-GB-025,
158A Drain & Vent valves on SH Mixing Header HP Steam piping GLOBE 25 16.5 350 H SW 800 A105 2 YES
WHRS-AQC2HP-MAS-GB-026

159 Vent Valve on HP FSH Inlet Header Vent Piping GLOBE 25 16.5 350 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-011
160 Drain Valve on HP FSH Outlet Header Drain Piping GLOBE 25 16 400 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-012
161 Vent Valve on HP Main Steam Line HP Main Steam Piping GLOBE 25 16 400 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-013
162 Isolation Valves for Pressure gauge on HP Main Steam Line HP Main Steam Piping GLOBE 25 16 400 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-014
WHRS-AQC2HP-MAS-GB-015,
163 Isolation Valves for Pressure transmitter on HP Main Steam Line HP Main Steam Piping GLOBE 25 16 400 H SW 800 A105 2 YES
WHRS-AQC2HP-MAS-GB-016
164 Drain Valve on HP Main Steam Line Drain Piping GLOBE 25 16 400 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-017
165 HP Main Steam Sample Cooler Tapping isolation HP Main Steam Piping GLOBE 20 16 400 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-018
Inching Duty
166 HP Main Steam Startup vent isolation HP Main Steam piping GLOBE 100 16 400 M* BW 300 WCB 1 YES (Operating Time <15 WHRS-AQC2HP-MAS-MOV-002 SCH.40
Sec)
WHRS-AQC2HP-MAS-GB-019,
WHRS-AQC2HP-MAS-GB-020,
167 Isolation Valves for Flow transmitter on HP Main Steam Line HP Main Steam Piping GLOBE 15 16 400 H SW 800 A105 4 YES
WHRS-AQC2HP-MAS-GB-021,
WHRS-AQC2HP-MAS-GB-022
168 HP steam from PH2 boiler to AQC PH Outlet - Vent Valve Vent Piping GLOBE 25 18 310 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-023
169 HP steam from PH2 boiler to AQC PH Outlet HP Main Steam Piping GLOBE 150 18 310 H BW 300 WCB 1 YES WHRS-AQC2HP-MAS-GB-024 SCH.40
WHRS-AQC2LP-FDW-GB-001,
WHRS-AQC2LP-FDW-GB-002,
170 FW to AQC LP Drum - FT isolation LP Feed Water Piping GLOBE 15 35 150 H SW 800 A105 4 YES
WHRS-AQC2LP-FDW-GB-003,
WHRS-AQC2LP-FDW-GB-004
171 FW to AQC LP Drum - PG isolation LP Feed Water Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2LP-FDW-GB-023
WHRS-AQC2LP-FDW-GB-005,
WHRS-AQC2LP-FDW-GB-006,
172 Drain valves for FCS of AQC LP section. LP Feed Water Piping GLOBE 25 35 150 H SW 800 A105 4 YES
WHRS-AQC2LP-FDW-GB-007,
WHRS-AQC2LP-FDW-GB-008
173 FW to AQC LP Drum downstream of FCS - PG isolation LP Feed Water Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2LP-FDW-GB-022
WHRS-AQC2LP-FDW-GB-009,
WHRS-AQC2LP-FDW-GB-010,
174 Root Valves for level gauge on LP Steam Drum LP Steam Drum GLOBE 25 6 150 H SW 800 A105 4 YES
WHRS-AQC2LP-FDW-GB-018,
WHRS-AQC2LP-FDW-GB-019
WHRS-AQC2LP-FDW-GB-011,
175 Drain valves for level gauge on LP Steam Drum LP Steam Drum GLOBE 15 6 150 H SW 800 A105 2 YES
WHRS-AQC2LP-FDW-GB-020
WHRS-AQC2LP-FDW-GB-012,
WHRS-AQC2LP-FDW-GB-013,
WHRS-AQC2LP-FDW-GB-014,
176 Root Valves for level transmitter on LP Steam Drum LP Steam Drum GLOBE 25 6 150 H SW 800 A105 6 YES
WHRS-AQC2LP-FDW-GB-015, WHRS-
AQC2LP-FDW-GB-016,
WHRS-AQC2LP-FDW-GB-017
177 Root Valves for pressure gauge on LP Steam Drum LP Steam Drum GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-003
WHRS-AQC2LP-MAS-GB-001,
178 Root Valves for pressure transmitter on LP Steam Drum LP Steam Drum GLOBE 25 6 150 H SW 800 A105 2 YES
WHRS-AQC2LP-MAS-GB-002,
179 N2 Capping Line for LP steam Drum N2 Capping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-004
180 Emergency Blowdown Valve - LP Side Blow Down Piping GLOBE 40 6 150 M* SW 800 A105 1 YES Inching Duty WHRS-AQC2LP-BDS-MOV-002
181 Emergency Blowdown Bypass Valve - LP Side Blow Down Piping GLOBE 40 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-BDS-GB-004
182 Downstream Isolation of Emergency Blow Down Valve - LP Side Blow Down Piping GLOBE 40 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-BDS-GB-005
183 Continuous Blowdown Sample cooler Tapping - LP Side Blow Down Piping GLOBE 20 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-BDS-GB-001
184 Continuous Blowdown Valve - LP Side Blow Down Piping GLOBE 25 6 150 M* SW 800 A105 1 YES Inching Duty WHRS-AQC2LP-BDS-MOV-001
185 Continuous Blowdown Bypass Valve - LP Side Blow Down Piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-BDS-GB-002

186 Downstream Isolation of Continuous Blow Down Valve - LP Side Blow Down Piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-BDS-GB-003

187 Vent on LP Saturated Steam Line LP Steam piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-005
188 LP Saturated Steam Sample Cooler Tapping LP Steam piping GLOBE 20 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-006
189 Drain Valve on LP Evap Inlet Header Drain Piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-021
190 Vent Valve on LP SH Inlet Header Vent Piping GLOBE 25 4.5 150 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-007
191 Drain Valve on LP SH Outlet Header Drain Piping GLOBE 25 4.5 210 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-008
192 Vent Valve on LP Main Steam Line to Turbine Vent Piping GLOBE 25 4.5 210 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-009

Page 6 of 13
Project : 1 x 6MW/7MW WHRS Project Doc. No. 2003-B-00944-0 Rev.2
Client : PARASAKTI CEMENT INDUSTRIES LTD., AP BOILER VALVE SCHEDULE Date: 03-11-2017
WO No. : 2M.0040
Mech. Mech.
Operating Operating Operating
Type of Design Design Body Total Special Requirement /
Sr.No. Item/Location Piping NB mm Pressure Temp Flow H / M End Conn. Class** IBR (Yes/No) Tag Numbers BW Schedule
Valve Pressure Temp MOC Qty Remark
(kg/cm2 (g)) deg. C (TPH)
(kg/cm2 (g)) deg. C
WHRS-AQC2LP-MAS-GB-010,
193 Isolation Valves for Pressure measurement on LP Main Steam Line LP Main Steam Piping GLOBE 25 4.5 210 H SW 800 A105 3 YES WHRS-AQC2LP-MAS-GB-011,
WHRS-AQC2LP-MAS-GB-012
194 Drain Valve on LP Main Steam Line Drain Piping GLOBE 25 4.5 200 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-013
195 LP Main Steam Sample Cooler Tapping isolation LP Main Steam Piping GLOBE 20 4.5 210 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-014
Inching Duty
196 LP Main Steam Startup vent isolation LP Main Steam piping GLOBE 50 4.5 210 M* SW 800 A105 1 YES (Operating Time <15 WHRS-AQC2LP-MAS-MOV-002
Sec)
WHRS-AQC2LP-MAS-GB-015,
WHRS-AQC2LP-MAS-GB-016,
197 Isolation Valves for Flow transmitter on LP Main Steam Line LP Main Steam Piping GLOBE 15 4.5 210 H SW 800 A105 4 YES
WHRS-AQC2LP-MAS-GB-017,
WHRS-AQC2LP-MAS-GB-018
WHRS-AQC2-BDS-GB-001,
198 Root Valves for LG isolation on BD Tank - AQC Blowdown Piping GLOBE 25 1 110 H SW 800 A105 2 YES
WHRS-AQC2-BDS-GB-002
199 BD Tank Outlet valve - AQC Blowdown Piping GLOBE 50 1 110 H SW 800 A105 1 YES WHRS-AQC2-BDS-GB-003
P&ID FOR WATER & STEAM (PH) (PB-31669-2 Rev.B)
200 Isolation for PG on Feedwater line to PH HP FCS Drain Piping GLOBE 25 35 200 H SW 800 A105 1 YES WHRS-PH2HP-FDW-GB-024
201 Drain valve on PH HP Feed Water Line Drain Piping GLOBE 25 35 200 H SW 800 A105 1 YES WHRS-PH2HP-FDW-GB-001
WHRS-PH2HP-FDW-GB-002,
WHRS-PH2HP-FDW-GB-003,
202 Feedwater to PH HP drum - FT isolation PH Boiler Feed water GLOBE 15 35 200 H SW 800 A105 4 YES
WHRS-PH2HP-FDW-GB-004,
WHRS-PH2HP-FDW-GB-005
WHRS-PH2HP-FDW-GB-006,
Upstream & downstream Drain valves for FCS for Feedwater to PH HP WHRS-PH2HP-FDW-GB-007
203 Drain Piping GLOBE 25 35 200 H SW 800 A105 4 YES
drum WHRS-PH2HP-FDW-GB-008,
WHRS-PH2HP-FDW-GB-009
204 Isolation for PG downstream of PH HP FCS Drain Piping GLOBE 25 35 200 H SW 800 A105 1 YES WHRS-PH2HP-FDW-GB-023
WHRS-PH2HP-FDW-GB-010,
WHRS-PH2HP-FDW-GB-011,
205 Root Valves for level gauge on PH HP Steam Drum PH Steam Drum GLOBE 25 18 210 H SW 800 A105 4 YES
WHRS-PH2HP-FDW-GB-019,
WHRS-PH2HP-FDW-GB-020
WHRS-PH2HP-FDW-GB-012,
206 Drain Valves for level gauge on PH HP Steam Drum Drain piping GLOBE 15 18 210 H SW 800 A105 2 YES
WHRS-PH2HP-FDW-GB-021
WHRS-PH2HP-FDW-GB-013,
WHRS-PH2HP-FDW-GB-014,
WHRS-PH2HP-FDW-GB-015,
207 Root Valves & drains for level transmitter on PH HP Steam Drum PH Steam Drum GLOBE 25 18 210 H SW 800 A105 6 YES
WHRS-PH2HP-FDW-GB-016,
WHRS-PH2HP-FDW-GB-017,
WHRS-PH2HP-FDW-GB-018
208 Root Valves for pressure gauge on PH HP Steam Drum PH Steam Drum GLOBE 25 18 210 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-003
WHRS-PH2HP-MAS-GB-001,
209 Root Valves pressure transmitters on PH HP Steam Drum PH Steam Drum GLOBE 25 18 210 H SW 800 A105 2 YES
WHRS-PH2HP-MAS-GB-002
210 N2 Capping Line for PH HP Steam Drum N2 Capping GLOBE 25 18 210 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-004
211 Emergency Blowdown Valve - PH HP Drum Blow Down Piping GLOBE 40 18 210 M* SW 800 A105 1 YES Inching Duty WHRS-PH2HP-BDS-MOV-002
212 Emergency Blowdown Bypass Valve - PH HP Drum Blow Down Piping GLOBE 40 18 210 H SW 800 A105 1 YES WHRS-PH2HP-BDS-GB-004

213 Downstream Isolation of Emergency Blow Down Valve - PH HP Drum Blow Down Piping GLOBE 40 18 210 H SW 800 A105 1 YES WHRS-PH2HP-BDS-GB-005

214 Isolation for blowdown Sample cooler of PH HP Drum Blow Down Piping GLOBE 20 18 210 H SW 800 A105 1 YES WHRS-PH2HP-BDS-GB-001
215 Continuous Blowdown Valve - PH HP Drum Blow Down Piping GLOBE 25 18 210 M* SW 800 A105 1 YES Inching Duty WHRS-PH2HP-BDS-MOV-001
216 Continuous Blowdown Bypass Valve - PH HP Drum Blow Down Piping GLOBE 25 18 210 H SW 800 A105 1 YES WHRS-PH2HP-BDS-GB-002

217 Downstream Isolation of Continuous Blow Down Valve - PH HP Drum Blow Down Piping GLOBE 25 18 210 H SW 800 A105 1 YES WHRS-PH2HP-BDS-GB-003

218 Vent on PH HP Saturated Steam Line PH Steam piping GLOBE 25 18 210 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-005
219 PH HP Saturated Steam Sample Cooler line PH Steam piping GLOBE 20 18 210 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-006
220 Drain Valve on PH HP Superheater Inlet Header Drain Piping GLOBE 25 18 210 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-007
221 Vent Valve on PH HP Superheater Outlet Header Vent Piping GLOBE 25 16 310 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-008
222 Vent Valve on PH HP Main Steam Line to Turbine Vent Piping GLOBE 25 16 310 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-009
223 Isolation Valves for Pressure gauge on PH HP Main Steam Line PH Main Steam Piping GLOBE 25 16 310 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-010
WHRS-PH2HP-MAS-GB-011,
224 Isolation Valves for Pressure transmitter on PH HP Main Steam Line PH Main Steam Piping GLOBE 25 16 310 H SW 800 A105 2 YES
WHRS-PH2HP-MAS-GB-012
225 Drain Valve on PH HP Main Steam Line Drain Piping GLOBE 25 16 310 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-013
226 PH HP Main Steam Sample Cooler Tapping isolation PH Main Steam Piping GLOBE 20 16 310 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-014

Page 7 of 13
Project : 1 x 6MW/7MW WHRS Project Doc. No. 2003-B-00944-0 Rev.2
Client : PARASAKTI CEMENT INDUSTRIES LTD., AP BOILER VALVE SCHEDULE Date: 03-11-2017
WO No. : 2M.0040
Mech. Mech.
Operating Operating Operating
Type of Design Design Body Total Special Requirement /
Sr.No. Item/Location Piping NB mm Pressure Temp Flow H / M End Conn. Class** IBR (Yes/No) Tag Numbers BW Schedule
Valve Pressure Temp MOC Qty Remark
(kg/cm2 (g)) deg. C (TPH)
(kg/cm2 (g)) deg. C
Inching Duty
227 PH HP Main Steam Startup vent isolation PH Main Steam Piping GLOBE 65 16 310 M* BW 300 WCB 1 YES (Operating Time <15 WHRS-PH2HP-MAS-MOV-002 SCH.40
Sec)
WHRS-PH2HP-MAS-GB-015,
WHRS-PH2HP-MAS-GB-016,
228 Isolation Valves for Flow transmitter on PH HP Main Steam Line PH Main Steam Piping GLOBE 15 16 310 H SW 800 A105 4 YES
WHRS-PH2HP-MAS-GB-017,
WHRS-PH2HP-MAS-GB-018
WHRS-PH2HP-FDW-GB-022,
229 Drain Valve on PH HP Evap Inlet Header Drain Piping GLOBE 50 18 200 H SW 800 A105 2 YES
WHRS-PH2HP-FDW-GB-0XX
WHRS-PH2HP-BDS-GB-001,
230 Root Valves for LG isolation on BD Tank -PH HP Blowdown Tank GLOBE 25 2.5 120 H SW 800 A105 2 YES
WHRS-PH2HP-BDS-GB-002
231 BD Tank Outlet valve - PH Blowdown Piping GLOBE 50 2.5 120 H SW 800 A105 1 YES WHRS-PH2HP-BDS-GB-006
232 Isolation for PG on Feedwater line to PH LP FCS Drain Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-PH2LP-FDW-GB-024
233 Drain valve on PH LP Feed Water Line Drain Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-PH2LP-FDW-GB-001
WHRS-PH2LP-FDW-GB-002,
WHRS-PH2LP-FDW-GB-003,
234 Feedwater to PH LP drum - FT isolation PH Boiler Feed water GLOBE 15 35 150 H SW 800 A105 4 YES
WHRS-PH2LP-FDW-GB-004,
WHRS-PH2LP-FDW-GB-005
WHRS-PH2LP-FDW-GB-006,
Upstream & downstream Drain valves for FCS for Feedwater to PH LP WHRS-PH2LP-FDW-GB-007
235 Drain Piping GLOBE 25 35 150 H SW 800 A105 4 YES
drum WHRS-PH2LP-FDW-GB-008,
WHRS-PH2LP-FDW-GB-009
236 Isolation for PG downstream of PH LP FCS Drain Piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-PH2LP-FDW-GB-023
WHRS-PH2LP-FDW-GB-010,
WHRS-PH2LP-FDW-GB-011,
237 Root Valves for level gauge on PH LP Steam Drum PH Steam Drum GLOBE 25 6 150 H SW 800 A105 4 YES
WHRS-PH2LP-FDW-GB-019,
WHRS-PH2LP-FDW-GB-020
WHRS-PH2LP-FDW-GB-012,
238 Drain Valves for level gauge on PH LP Steam Drum Drain piping GLOBE 15 6 150 H SW 800 A105 2 YES
WHRS-PH2LP-FDW-GB-021
WHRS-PH2LP-FDW-GB-013,
WHRS-PH2LP-FDW-GB-014,
WHRS-PH2LP-FDW-GB-015,
239 Root Valves for level transmitter on PH LP Steam Drum PH Steam Drum GLOBE 25 6 150 H SW 800 A105 6 YES
WHRS-PH2LP-FDW-GB-016,
WHRS-PH2LP-FDW-GB-017,
WHRS-PH2LP-FDW-GB-018
240 Root Valves for pressure gauge on PH LP Steam Drum PH Steam Drum GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-003
WHRS-PH2LP-MAS-GB-001,
241 Root Valves pressure transmitters on PH LP Steam Drum PH Steam Drum GLOBE 25 6 150 H SW 800 A105 2 YES
WHRS-PH2LP-MAS-GB-002
242 N2 Capping Line for PH LP Steam Drum N2 Capping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-004
243 Emergency Blowdown Valve - PH LP Drum Blow Down Piping GLOBE 40 6 150 M* SW 800 A105 1 YES Inching Duty WHRS-PH2LP-BDS-MOV-002
244 Emergency Blowdown Bypass Valve - PH LP Drum Blow Down Piping GLOBE 40 6 150 H SW 800 A105 1 YES WHRS-PH2LP-BDS-GB-004

245 Downstream Isolation of Emergency Blow Down Valve - PH LP Drum Blow Down Piping GLOBE 40 6 150 H SW 800 A105 1 YES WHRS-PH2LP-BDS-GB-005

246 Isolation for blowdown Sample cooler of PH LP Drum Blow Down Piping GLOBE 20 6 150 H SW 800 A105 1 YES WHRS-PH2LP-BDS-GB-001
247 Continuous Blowdown Valve - PH LP Drum Blow Down Piping GLOBE 25 6 150 M* SW 800 A105 1 YES Inching Duty WHRS-PH2LP-BDS-MOV-001
248 Continuous Blowdown Bypass Valve - PH LP Drum Blow Down Piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-PH2LP-BDS-GB-002

249 Downstream Isolation of Continuous Blow Down Valve - PH LP Drum Blow Down Piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-PH2LP-BDS-GB-003

250 Vent on PH LP Saturated Steam Line PH Steam piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-005
251 PH LP Saturated Steam Sample Cooler line PH Steam piping GLOBE 20 6 150 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-006
252 Drain Valve on PH LP Superheater Inlet Header Drain Piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-007
253 Vent Valve on PH LP Superheater Outlet Header Vent Piping GLOBE 25 4.5 210 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-008
254 Vent Valve on PH LP Main Steam Line to Turbine Vent Piping GLOBE 25 4.5 210 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-009
255 Isolation Valves for Pressure gauge on PH LP Main Steam Line PH Main Steam Piping GLOBE 25 4.5 210 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-010
WHRS-PH2LP-MAS-GB-011,
256 Isolation Valves for Pressure transmitter on PH LP Main Steam Line PH Main Steam Piping GLOBE 25 4.5 210 H SW 800 A105 2 YES
WHRS-PH2LP-MAS-GB-012
257 Drain Valve on PH LP Main Steam Line Drain Piping GLOBE 25 4.5 210 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-013
258 PH LP Main Steam Sample Cooler Tapping isolation PH Main Steam Piping GLOBE 20 4.5 210 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-014

Inching Duty
259 PH LP Main Steam Startup vent isolation PH Main Steam Piping GLOBE 80 4.5 210 M* BW 300 WCB 1 YES (Operating Time <15 WHRS-PH2LP-MAS-MOV-002 SCH.40
Sec)

Page 8 of 13
Project : 1 x 6MW/7MW WHRS Project Doc. No. 2003-B-00944-0 Rev.2
Client : PARASAKTI CEMENT INDUSTRIES LTD., AP BOILER VALVE SCHEDULE Date: 03-11-2017
WO No. : 2M.0040
Mech. Mech.
Operating Operating Operating
Type of Design Design Body Total Special Requirement /
Sr.No. Item/Location Piping NB mm Pressure Temp Flow H / M End Conn. Class** IBR (Yes/No) Tag Numbers BW Schedule
Valve Pressure Temp MOC Qty Remark
(kg/cm2 (g)) deg. C (TPH)
(kg/cm2 (g)) deg. C
WHRS-PH2LP-MAS-GB-015,
WHRS-PH2LP-MAS-GB-016,
260 Isolation Valves for Flow transmitter on PH LP Main Steam Line PH Main Steam Piping GLOBE 15 4.5 210 H SW 800 A105 4 YES
WHRS-PH2LP-MAS-GB-017,
WHRS-PH2LP-MAS-GB-018
WHRS-PH2LP-FDW-GB-022,
261 Drain Valve on PH LP Evap Inlet Header Drain Piping GLOBE 50 6 150 H SW 800 A105 2 YES
WHRS-PH2LP-FDW-GB-0XX
P&ID FOR PLANT STEAM SYSTEM (PB-31670-2 Rev.B)
262 Vent Valve on HP Main Steam Line to Turbine Vent Piping GLOBE 25 16 400 H SW 800 A105 1 YES WHRS-PSSHP-MAS-GB-001
WHRS-PSSHP-MAS-GB-002,
263 Drain Valve on HP Main Steam Line to Turbine Drain Piping GLOBE 25 16 400 H SW 800 A105 2 YES
WHRS-PSSHP-MAS-GB-003
Upstream and downstream Isolation valves for steam trap in HP main WHRS-PSSHP-MAS-GB-004,
264 Drain Piping GLOBE 25 16 400 H SW 800 A105 2 YES
steam line drain near Turbine (Drain-8) WHRS-PSSHP-MAS-GB-005
265 Bypass Isolation valve for steam trap in HP main steam line near T Drain Piping GLOBE 25 16 400 H SW 800 A105 1 YES WHRS-PSSHP-MAS-GB-006
266 Warmup vent valve -HP steam line Vent Piping GLOBE 80 16 400 M* BW 300 WCB 1 YES Inching Duty WHRS-PSSHP-MAS-MOV-001 SCH.40
267 Drain for Warmup vent in HP Steam line at Turbine inlet Drain Piping GLOBE 25 16 400 H SW 800 A105 1 YES WHRS-PSSHP-MAS-GB-007
268 Vent Valve on LP Main Steam Line to Turbine Vent Piping GLOBE 25 4.5 210 H SW 800 A105 1 YES WHRS-PSSLP-MAS-GB-001
WHRS-PSSLP-MAS-GB-002,
269 Drain Valve on LP Main Steam Line to Turbine Drain Piping GLOBE 25 4.5 210 H SW 800 A105 2 YES
WHRS-PSSLP-MAS-GB-005
270 Warmup vent in LP Steam line at Turbine inlet Vent Piping GLOBE 80 4.5 210 M* BW 150 WCB 1 YES Inching Duty WHRS-PSSLP-MAS-MOV-001 SCH.40
271 Drain for Warmup vent in LP Steam line at Turbine inlet Drain Piping GLOBE 25 4.5 210 H SW 800 A105 1 YES WHRS-PSSLP-MAS-GB-006
P&ID FOR RAW WATER SYSTEM (PB-31673-3 Rev.B)
WHRS-RWS-RW-GB-001,
272 Isolation for Flow Transmitter on WTP Inlet C.T. Makeup Piping GLOBE 15 8 50 H SW 800 A105 2 NO
WHRS-RWS-RW-GB-002
WHRS-RWS-RW-GB-003,
273 Isolation for Flow Transmitter on WTP Outlet C.T. Makeup Piping GLOBE 15 8 50 H SW 800 A105 2 NO
WHRS-RWS-RW-GB-004
P&ID FOR DM WATER SYSTEM (PB-31674-2 Rev.B)
WHRS-DMS-DM-GB-001,
274 DM water Transfer pumps - 1 & 2 - Isolation for PG on discharge side DM Water Piping GLOBE 25 5 50 H SW 800 A105 2 NO
WHRS-DMS-DM-GB-002
275 DM water Discharge Line - Isolation for PSL DM Water Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-003
276 DM water Discharge Line - Isolation for PT DM Water Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-004
277 DM water Minimum recirculation line - Upstream of RO DM Water Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-005

278 DM water Minimum recirculation line - Isolation valve near Tank DM Water Piping GLOBE 25 3 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-0XX

279 DM water isolation for HP Dosing of AQC & PH Boiler DM Water Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-006
WHRS-DMS-DM-GB-007,
280 DM water to Hotwell - LCV upsteam & Downstream drain valves DM Water Piping GLOBE 25 5 50 H SW 800 A105 2 NO
WHRS-DMS-DM-GB-008
281 DM water to Hotwell - LCV bypass Valve DM Water Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-014
282 DM water isolation for LP Dosing DM Water Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-009
283 Initial Fill Pump - Isolation for PG on discharge side Initial Filling Piping GLOBE 25 11 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-010

284 Initial Fill Pump - Isolation for PSL on discharge side Initial Filling Piping GLOBE 25 11 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-011
285 Initial Fill Line - isolation for AQC WHRB Initial Filling Piping GLOBE 50 11 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-012
286 Initial Fill Line - isolation for PH WHRB Initial Filling Piping GLOBE 50 11 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-013
287 Initial Fill Line - isolation for Deaerator Initial Filling Piping GLOBE 50 11 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-015
P&ID FOR COOLING WATER SYSTEM (PB-31675-1 Rev.B)
WHRS-RWS-RW-GB-005,
288 Isolation valves FT on Raw water line to CT Forebay Raw Water Piping GLOBE 15 8 50 H SW 800 A105 2 NO
WHRS-RWS-RW-GB-006
WHRS-RWS-RW-GB-001,
289 Upstream & Downstream Drains for CT Make-up LCV Raw Water Piping GLOBE 25 8 50 H SW 800 A105 2 NO
WHRS-RWS-RW-GB-002
290 Bypass valve for CT Make-up LCV Raw Water Piping GLOBE 125 8 50 H FE 150 WCB 1 NO WHRS-RWS-RW-GB-003
WHRS-CWS-MCW-GB-001,
291 MCW Pump A & B - Upstream drains Drain Piping GLOBE 25 2 50 H SW 800 A105 2 NO
WHRS-CWS-MCW-GB-007
WHRS-CWS-MCW-GB-002,
WHRS-CWS-MCW-GB-003,
292 MCW Pump A & B - Isolation Valves for DP Across Suction Strainer MCW Piping GLOBE 25 2 50 H SW 800 A105 4 NO
WHRS-CWS-MCW-GB-008,
WHRS-CWS-MCW-GB-009
WHRS-CWS-MCW-GB-004,
293 MCW Pump A & B - Isolation Valves for Suction side PG MCW Piping GLOBE 25 2 50 H SW 800 A105 2 NO
WHRS-CWS-MCW-GB-010
WHRS-CWS-MCW-GB-005,
294 MCW Pump A & B - Isolation Valves for Discharge side PSL MCW Piping GLOBE 25 5 50 H SW 800 A105 2 NO
WHRS-CWS-MCW-GB-011
WHRS-CWS-MCW-GB-006,
295 MCW Pump A & B - Discharge side vent valves Vent Piping GLOBE 25 5 50 H SW 800 A105 2 NO
WHRS-CWS-MCW-GB-012

Page 9 of 13
Project : 1 x 6MW/7MW WHRS Project Doc. No. 2003-B-00944-0 Rev.2
Client : PARASAKTI CEMENT INDUSTRIES LTD., AP BOILER VALVE SCHEDULE Date: 03-11-2017
WO No. : 2M.0040
Mech. Mech.
Operating Operating Operating
Type of Design Design Body Total Special Requirement /
Sr.No. Item/Location Piping NB mm Pressure Temp Flow H / M End Conn. Class** IBR (Yes/No) Tag Numbers BW Schedule
Valve Pressure Temp MOC Qty Remark
(kg/cm2 (g)) deg. C (TPH)
(kg/cm2 (g)) deg. C
296 MCW Pump A & B - Isolation for PG on Discharge Header MCW Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-CWS-MCW-GB-014

297 MCW Pump A & B - Isolation for PSL on Discharge Header MCW Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-CWS-MCW-GB-013
WHRS-CWS-ACW-GB-001,
298 ACW Pump A & B - Upstream drains Drain Piping GLOBE 25 2 50 H SW 800 A105 2 NO
WHRS-CWS-ACW-GB-007
WHRS-CWS-ACW-GB-002,
WHRS-CWS-ACW-GB-003,
299 ACW Pump A & B - Isolation Valves for DP Across Suction Strainer ACW Piping GLOBE 25 2 50 H SW 800 A105 4 NO
WHRS-CWS-ACW-GB-008,
WHRS-CWS-ACW-GB-009
WHRS-CWS-ACW-GB-004,
300 ACW Pump A & B - Isolation Valves for Suction side PG ACW Piping GLOBE 25 2 50 H SW 800 A105 2 NO
WHRS-CWS-ACW-GB-010
WHRS-CWS-ACW-GB-005,
301 ACW Pump A & B - Isolation Valves for Discharge side PSL ACW Piping GLOBE 25 7 50 H SW 800 A105 2 NO
WHRS-CWS-ACW-GB-011
WHRS-CWS-ACW-GB-006,
302 ACW Pump A & B - Discharge side vent valves Vent Piping GLOBE 25 7 50 H SW 800 A105 2 NO
WHRS-CWS-ACW-GB-012
303 ACW Pump A & B - Isolation for PG on Discharge Header ACW Piping GLOBE 25 7 50 H SW 800 A105 1 NO WHRS-CWS-ACW-GB-014
304 ACW Pump A & B - Isolation for PSL on Discharge Header ACW Piping GLOBE 25 7 50 H SW 800 A105 1 NO WHRS-CWS-ACW-GB-013
305 ACW Pump A & B - Drain Valve on Discharge Header Drain Piping GLOBE 25 7 50 H SW 800 A105 1 NO WHRS-CWS-ACW-GB-015
306 MCW Line to CW Supply Header - PT isolation MCW Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-CWS-MCW-GB-015
307 MCW Supply Header - PG isolation MCW Supply Header GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-CWS-MCW-GB-022
WHRS-CWS-MCW-GB-018,
WHRS-CWS-MCW-GB-019,
308 Isolation valves for DPT between MCW Supply & Return Lines MCW Piping GLOBE 25 5 50 H SW 800 A105 4 NO
WHRS-CWS-MCW-GB-020,
WHRS-CWS-MCW-GB-021
309 MCW Return Header - PG isolation MCW Return Header GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-CWS-MCW-GB-023
WHRS-CWS-MCW-GB-016,
310 MCW Line to MCW Return Line - FT isolation MCW Piping GLOBE 15 5 50 H SW 800 A105 2 NO
WHRS-CWS-MCW-GB-017
311 MCW Return Line Drain Drain Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-CWS-MCW-GB-024
312 MCW Return Line Vent Vent Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-CWS-MCW-GB-025
313 MCW Return Line - PT Isolation MCW Return Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-CWS-MCW-GB-026
WHRS-CWS-ACW-GB-016,
314 ACW Supply Line - Isolation for FT ACW Piping GLOBE 15 7 50 H SW 800 A105 2 NO
WHRS-CWS-ACW-GB-017
WHRS-CWS-ACW-GB-018,
315 ACW Supply Line - Upstream Isolation for BFP 1 & 2 ACW Piping GLOBE 50 7 50 H SW 800 A105 3 NO WHRS-CWS-ACW-GB-020,
WHRS-CWS-ACW-GB-021
316 ACW Supply Line - Upstream Isolation for BFPs - PG isolation ACW Piping GLOBE 25 7 50 H SW 800 A105 1 NO WHRS-CWS-ACW-GB-019
WHRS-CWS-ACW-GB-022,
317 ACW Return Line - Downstream Isolation for BFP 1 & 2 ACW Piping GLOBE 50 7 50 H SW 800 A105 3 NO WHRS-CWS-ACW-GB-023,
WHRS-CWS-ACW-GB-024
WHRS-CWS-ACW-GB-026,
318 PG isolation for supply & return lines of Sample coolers ACW Piping GLOBE 25 7 50 H SW 800 A105 2 NO
WHRS-CWS-ACW-GB-027
319 Isolation for AQC & PH BD tank quenching line ACW Piping GLOBE 25 7 50 H SW 800 A105 1 NO WHRS-CWS-ACW-GB-029
Total 368
NON-RETURN VALVES
P&ID FOR DEAERATOR & BFP (PB-31667-1 Rev.B)
320 Upstream of Deaerator on DeA Steam Line DeA Steam Piping NRV 100 3 190 2.5 195 0.5 - BW 150 WCB 1 YES WHRS-DEA-AUX-NR-001 SCH.40
321 NRV in Intial Warm Up Line for Deaerator Storage Tank DeA Steam Piping NRV 80 3 190 - BW 150 WCB 1 YES WHRS-DEA-AUX-NR-002 SCH.40
322 NRV on Initial Fill Line to Dearator DM Water Piping NRV 50 10 50 - SW 800 A105 1 NO WHRS-DEA-DMS-NR-001
323 AQC-CPH outlet to Deaerator inlet Condensate Piping NRV 80 15 150 10 120 35 - BW 300 WCB 1 YES WHRS-DEA-CDS-NR-001 SCH.40
324 BFP-1 - Discharge side NRV Feed Water Piping NRV 80 35 150 28 126 35 - BW 300 WCB 1 YES WHRS-DEA-FDW-NR-002 SCH.40

325 BFP-1 - NRV on Minimum Recirculation Line near Deaerator Feed Water Piping NRV 40 25 150 - SW 800 A105 1 YES WHRS-DEA-FDW-NR-007

326 BFP-2 - Discharge side NRV Feed Water Piping NRV 80 35 150 28 126 35 - BW 300 WCB 1 YES WHRS-DEA-FDW-NR-003 SCH.40

327 BFP-2 - NRV on Minimum Recirculation Line near Deaerator Feed Water Piping NRV 40 25 150 - SW 800 A105 1 YES WHRS-DEA-FDW-NR-006

328 BFP-1 - NRV on Balancing Leakoff Line near Deaerator Feed Water Piping NRV 40 25 150 - SW 800 A105 1 YES WHRS-DEA-FDW-NR-004
329 BFP-2 - NRV on Balancing Leakoff Line near Deaerator Feed Water Piping NRV 40 25 150 - SW 800 A105 1 YES WHRS-DEA-FDW-NR-005
P&ID FOR WATER & STEAM (AQC) (PB-33377-1 Rev.A)
330 BFP Outlet to AQC - NRV upstream of Main Attemperator Line HP Feed Water Piping NRV 80 35 150 28 126 29.2 - BW 300 WCB 1 YES WHRS-AQC2HP-FDW-NR-001 SCH.40

331 Initial filling Line to HP Feed Water Line DM Water Piping NRV 40 8.5 50 - SW 800 A105 1 NO WHRS-AQC2HP-FDW-NR-002

Page 10 of 13
Project : 1 x 6MW/7MW WHRS Project Doc. No. 2003-B-00944-0 Rev.2
Client : PARASAKTI CEMENT INDUSTRIES LTD., AP BOILER VALVE SCHEDULE Date: 03-11-2017
WO No. : 2M.0040
Mech. Mech.
Operating Operating Operating
Type of Design Design Body Total Special Requirement /
Sr.No. Item/Location Piping NB mm Pressure Temp Flow H / M End Conn. Class** IBR (Yes/No) Tag Numbers BW Schedule
Valve Pressure Temp MOC Qty Remark
(kg/cm2 (g)) deg. C (TPH)
(kg/cm2 (g)) deg. C
332 FCS to HP Steam Drum - NRV on feedwater Line HP Feed Water Piping NRV 80 35 200 28 190 29.2 - BW 800 WCB 1 YES WHRS-AQC2HP-FDW-NR-003 SCH.40

333 Hydrotest Connection to HP Steam Drum of AQC DM Water Piping NRV 25 35 200 - SW 800 A105 1 NO WHRS-AQC2HP-FDW-NR-004
334 NRV in spray water line (at tapping) Spray Water Piping NRV 40 35 150 - SW 800 A105 1 YES WHRS-AQC2HP-FDW-NR-005
335 NRV in spray water line (downstreamof TCV) Spray Water Piping NRV 40 18 150 - SW 800 A105 1 YES WHRS-AQC2HP-FDW-NR-006

335 A NRV downstream of HP PSH outlet to Mixing header AQC Steam piping NRV 200 18 350 15.4 340 17.4 - BW 300 WCB 1 YES WHRS-AQC2HP-MAS-NR-003 SCH.40

336 HP Main Steam NRV Downstream of Main Steam Stop Valve HP Main Steam piping NRV 300 16 400 14.5 390 29.2 - BW 300 WCB 1 YES WHRS-AQC2HP-MAS-NR-001 SCH.40

337 FW to AQC LP Drum - Feed Water NRV LP Feed Water Piping NRV 40 35 150 28 126 1.8 - SW 800 A105 1 YES WHRS-AQC2LP-FDW-NR-004

338 Initial filling Line to LP Feed Water Line DM Water Piping NRV 25 8.5 50 - SW 800 A105 1 NO WHRS-AQC2LP-FDW-NR-001

339 FCS to LP Steam Drum - NRV on feedwater Line LP Feed Water Piping NRV 40 7 150 3.5 126 1.8 - SW 800 A105 1 YES WHRS-AQC2LP-FDW-NR-002

340 Hydrotest Connection to LP Steam Drum of AQC DM Water Piping NRV 25 9 150 - SW 800 A105 1 NO WHRS-AQC2LP-FDW-NR-003

341 LP Main Steam NRV Downstream of Main Steam Stop Valve LP Main Steam piping NRV 150 4.5 210 2.5 195 1.8 - BW 150 WCB 1 YES WHRS-AQC2LP-MAS-NR-001 SCH.40

342 HP Main Steam from PH to steam Mixing Header in AQC boiler PH Main Steam piping NRV 150 18 300 15.4 300 11.8 - BW 300 WCB 1 YES WHRS-AQC2HP-MAS-NR-002 SCH.40

P&ID FOR WATER & STEAM (PH) (PB-31669-2 Rev.B)


343 Initial filling Line to PH HP Feed Water Line DM Water Piping NRV 50 8.5 50 - SW 800 A105 1 NO WHRS-PH2HP-FDW-NR-001

344 FCS to PH HP Steam Drum- NRV on feedwater Line PH Boiler Feed water NRV 50 35 200 28 190 11.8 - SW 800 A105 1 YES WHRS-PH2HP-FDW-NR-002

345 Hydrotest Connection to PH HP Steam Drum DM Water Piping NRV 25 35 200 - SW 800 A105 1 NO WHRS-PH2HP-FDW-NR-003

346 PH LP Main Steam NRV Downstream of Main Steam Stop Valve PH Main Steam piping NRV 150 16 300 14.5 300 11.8 - BW 300 WCB 1 YES WHRS-PH2HP-MAS-NR-001 SCH.40

347 Initial filling Line to PH LP Feed Water Line DM Water Piping NRV 50 8.5 50 - SW 800 A105 1 NO WHRS-PH2LP-FDW-NR-001

348 FCS to PH LP Steam Drum- NRV on feedwater Line PH Boiler Feed water NRV 40 7 150 3.5 126 3.2 - SW 800 A105 1 YES WHRS-PH2LP-FDW-NR-002

349 Hydrotest Connection to PH LP Steam Drum DM Water Piping NRV 25 9 150 - SW 800 A105 1 NO WHRS-PH2LP-FDW-NR-003

350 PH LP Main Steam NRV Downstream of Main Steam Stop Valve PH Main Steam piping NRV 150 4.5 210 2.5 195 3.2 - BW 300 WCB 1 YES WHRS-PH2LP-MAS-NR-001 SCH.40

P&ID FOR DM WATER SYSTEM (PB-31674-2 Rev.B)


WHRS-DMS-DM-NR-001,
351 DM water Transfer pumps - 1 & 2 - Downstream NRVs DM Water Piping NRV 40 5 50 - SW 800 A105 2 NO
WHRS-DMS-DM-NR-002
352 Initial Fill Pump Downstream NRV Initial Filling Piping NRV 80 11 50 - FE 150 WCB 1 NO WHRS-DMS-DM-NR-003
P&ID FOR COOLING WATER SYSTEM (PB-31675-1 Rev.B)
C.I. IS.-
WHRS-CWS-MCW-NR-001,
353 MCW Pump A & B - Discharge side NRVs MCW Piping NRV OD 616 5 50 - FE 150 210 FG 0 NO Wafer Type
WHRS-CWS-MCW-NR-002
260
C.I. IS.-
WHRS-CWS-ACW-NR-001,
354 ACW Pump A & B - Discharge side NRVs ACW Piping NRV 200 7 50 - FE 150 210 FG 0 NO Wafer Type
WHRS-CWS-ACW-NR-002
260
P&ID FOR INSTRUMENT AIR SYSTEM (PB-31676-3 Rev.B)
WHRS-CMP-IST-NR-001,
355 Instrument Air Line - NRVs downstream of Fine Filter Instrument Air Piping NRV 40 9 50 - SW 800 A105 2 NO
WHRS-CMP-IST-NR-002
Total 37
Grand Total 493
Notes
1 All motorised valves are with integral actuator
2 IBR certificate is required for all IBR valves as mentioned in above list

Prepared
DRJ
By:
Checked BOILER VALVE SCHEDULE
RNN
By:

Page 11 of 13
Project : 1 x 6MW/7MW WHRS Project Doc. No.
Client : PARASAKTI CEMENT INDUSTRIES LTD., AP COMMISSIONING SPARES LIST Date: 18-05-2016
WO No. : 2M0037 P&ID Ref:
Design Design
Type of Body Qty. per Special Requirement /
Sr.No. Item/Location Fluid Piping NB mm Pressure Temp H / M End Conn. Class** IBR Tag Numbers
Valve MOC Boiler Remark
(ATA) deg. C

GATE VALVES
1 Commissioning spares GATE 25 H SW 800 A105 2 Yes Commissioning spares
2 Commissioning spares GATE 40 H SW 800 A105 3 Yes Commissioning spares
3 Commissioning spares GATE 50 H SW 800 A105 2 Yes Commissioning spares
4 Commissioning spares GATE 80 H BW 300 WCB 2 Yes Commissioning spares
5 Commissioning spares GATE 150 H FE 150 WCB 0 Yes Commissioning spares
Total 9
GLOBE VALVES
1 Commissioning spares GLOBE 15 H SW 800 A105 1 No Commissioning spares
2 Commissioning spares GLOBE 15 H SW 800 A105 5 Yes Commissioning spares
3 Commissioning spares GLOBE 20 H SW 800 A105 2 Yes Commissioning spares
4 Commissioning spares GLOBE 25 H SW 800 A105 20 Yes Commissioning spares
5 Commissioning spares GLOBE 25 H SW 800 A105 10 No Commissioning spares
6 Commissioning spares GLOBE 40 H SW 800 A105 2 Yes Commissioning spares
6 Commissioning spares GLOBE 50 H SW 800 A105 5 No Commissioning spares
Total 45
NON-RETURN VALVES
1 Commissioning spares NRV 25 - SW 800 A105 1 Yes Commissioning spares
2 Commissioning spares NRV 25 - SW 800 A105 1 No Commissioning spares
3 Commissioning spares NRV 40 - SW 800 A105 1 Yes Commissioning spares
4 Commissioning spares NRV 40 - SW 800 A105 1 No Commissioning spares
Total 4
BALL VALVES
1 Commissioning spares BALL 25 H SW 800 A105 0 No Commissioning spares
2 Commissioning spares BALL 40 H SW 800 A105 0 No Commissioning spares
Total 0
Grand Total 58
Notes
1

Prepared By: DRJ


COMMISSIONING SPARES LIST
Checked By: RNN Approved By:
ELECTRICAL LOAD LIST
Client: Parasakti Cements Ltd, Telangana ELECTRICAL LOAD LIST - R3 Doc. No:
Project: 1x7MW WHRS Project Date: April 18,2017
thyssenkrupp Industries India Pvt. Ltd.

Client : Parasakti Cement Industries Ltd, AP


ELECTRICAL LOAD LIST Doc No: 2003-E-0147-0, Rev-02
Project : 1 X 6.875 Mw WHRS Project
thyssenkrupp Industries India Pvt.Ltd Date : 10-01-2018

Intermitte Total Total Total Remark


No. of
Rating in Connected Load Standby Type of
RPM nt Load in Continuous Standby Intermittent Scope P-Priliminary Remark
Sl. kW Load in kW Factor Load in kW Working Starter
Load Description Total Working Standby kW Load in kW Load in kW F- Finalized
No. Load in kW
9 = (5 - 7 - 8)
1 2 3 4 5=1*4 6 7=3*4 8 10 11 12
*6
I. Boiler
IA. Boiler MCC- AQC -2
1 RAV 4 4 0 0.750 3.00 0.90 0.00 0.00 2.70 0.00 0.00 DOL TKII Vendor F WHRS-AQC2-FLG-RAV-001, 002, 003 AND 004
2 HP Dosing Pump for HP AQC 2 1 1 0.370 1440 0.74 0.90 0.37 0.00 0.33 0.33 0.00 DOL TKII Vendor F
3 HP Dosing Pump for LP AQC 2 1 1 0.370 1440 0.74 0.90 0.37 0.00 0.33 0.33 0.00 DOL TKII Vendor F
4 Stirrers 1 0 1 0.370 1440 0.37 0.90 0.37 0.00 0.00 0.00 0.33 DOL TKII Vendor F
5 Drag Chain Conveyor 1A, 2, 3, 4 4 4 0 1.100 4.40 0.90 0.00 0.00 3.96 0.00 0.99 DOL Client F
Based on Confirmation from Client
6 Drag Chain Conveyor -1 1 1 0 1.500 1.50 0.90 0.00 0.00 1.35 0.00 1.35 DOL Client F

Actuators for Valves-HP


Tag : WHRS-AQC2HP-MAS-MOV-001
7 Main steam Stop Valve 1 1 0 3.3 3.30 0.90 0.00 3.30 0.00 0.00 2.97 RDOL(NI) TKII Vendor F
Act. No. K300F14A
Tag : WHRS-AQC2HP-MAS-MOV-001A
7A Integral Bypass for Main steam Stop Valve 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A
Tag : WHRS-AQC2HP-MAS-MOV-002
8 Steam start up vent valve 1 1 0 1.8 1.80 0.90 0.00 1.80 0.00 0.00 1.62 RDOL(I) TKII Vendor F
Act. No. KM150F10A
Tag : WHRS-AQC2HP-FDW-MOV-001 / 002
9 FCV upstream isolation valves 2 1 1 0.18 0.36 0.90 0.18 0.16 0.00 0.16 0.16 RDOL(NI) TKII Vendor F
Act. No. K30F10A
Tag : WHRS-AQC2HP-BDS-MOV-002
10 EBD regulation 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A
Tag : WHRS-AQC2HP-BDS-MOV-001
11 CBD regulation 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A
Tag : WHRS-AQC2HP-FDW-MOV-001
12 Attemperator Spray Nozzle 1 1 0 0.18 0.18 0.90 0.00 0.18 0.00 0.00 0.16 RDOL(NI) TKII Vendor F
Act. No. K30F10A
Actuators for Valves-LP
Tag : WHRS-AQC2LP-MAS-MOV-001
13 Main steam Stop Valve 1 1 0 0.18 0.18 0.90 0.00 0.18 0.00 0.00 0.16 RDOL(NI) TKII Vendor F
Act. No. K30F10A
Tag : WHRS-AQC2LP-MAS-MOV-001A
13A Integral Bypass for Main steam Stop Valve 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A
Tag : WHRS-AQC2LP-MAS-MOV-002
14 Steam start up vent valve 1 1 0 0.23 0.23 0.90 0.00 0.23 0.00 0.00 0.21 RDOL(I) TKII Vendor F
Act. No. KM30F10A
Tag : WHRS-AQC2LP-FDW-MOV-001 / 002
15 FCV upstream isolation valves 2 1 1 0.09 0.18 0.90 0.09 0.08 0.00 0.08 0.08 RDOL(NI) TKII Vendor F
Act. No. K30F10A
Tag : WHRS-AQC2LP-BDS-MOV-002
16 EBD regulation 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A
Tag : WHRS-AQC2LP-BDS-MOV-001
17 CBD regulation 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A

Actuators for Dampers


18 Isolation Damper at boiler inlet (End tap) (Butterfly 1 1 0 1.100 1.10 0.90 0.00 1.10 0.00 0.00 0.99 RDOL(NI) Client F
19 Isolation Damper at boiler outlet (Butterfly damper) 1 1 0 0.550 0.55 0.90 0.00 0.55 0.00 0.00 0.50 RDOL(NI) Client F Based on confirmation from Client
20 Fresh air damper at Cooler inlet (Multi louvre type) 1 1 0 0.120 0.12 0.90 0.00 0.12 0.00 0.00 0.11 RDOL(I) Client F
By pass Regulating Dampers (Modulating with inching)
21 1 1 0 1.100 1.10 0.90 0.00 1.10 0.00 0.00 0.99 RDOL(I) Client F Emergency power required
for AQC Boiler (Multi louvre type)
22 Isolation Damper at deduster inlet 0 0 0 0.000 0.00 0.90 0.00 0.00 0.00 0.00 0.00 RDOL(NI) Client F
23 HAG Inlet Damper (Butterfly damper) 1 1 0 1.100 1.10 0.90 0.00 1.10 0.00 0.00 0.99 RDOL(NI) Client F Based on confirmation from Client
24 HAG Bypass Damper (Multi louvre type) 1 1 0 1.100 1.10 0.90 0.00 1.10 0.00 0.00 0.99 RDOL(I) Client F
25 HAG Outlet Damper (Hoisting Damper) 1 1 0 1.100 1.10 0.90 0.00 1.10 0.00 0.00 0.99 RDOL(NI) tkII Vendor P
26 Coffee Pot Damper 1 1 0 0.550 0.55 0.90 0.00 0.00 0.50 0.00 0.00 RDOL(NI) tkII Vendor P

IB. Boiler MCC- PH 2


1 RAV 2 2 0 1.500 3.00 0.90 0.00 0.00 2.70 0.00 0.00 DOL TKII Vendor F
2 HP Dosing Pump 2 1 1 0.370 1440 0.74 0.90 0.37 0.00 0.33 0.33 0.00 DOL TKII Vendor F
3 Stirrers 1 0 1 0.370 1440 0.37 0.90 0.37 0.00 0.00 0.00 0.33 DOL TKII Vendor F
4 Screw Conveyor 1 1 0 3.700 3.70 0.90 0.00 0.00 3.33 0.00 3.33 DOL Client F

Actuators for Valves- HP


Tag : WHRS-PH2HP-MAS-MOV-001
4 Main steam Stop Valve 1 1 0 0.45 0.45 0.90 0.00 0.45 0.00 0.00 0.41 RDOL(NI) TKII Vendor F
Act. No. K60F10A
Tag : WHRS-PH2HP-MAS-MOV-001A
4A Integral Bypass for Main steam Stop Valve 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A
Tag : WHRS-PH2HP-MAS-MOV-002
5 Steam start up vent valve 1 1 0 0.25 0.25 0.90 0.00 0.25 0.00 0.00 0.23 RDOL(I) TKII Vendor F
Act. No. KM60F10A
Tag : WHRS-PH2HP-FDW-MOV-001 / 002
6 FCV upstream isolation valves 2 1 1 0.09 0.18 0.90 0.09 0.08 0.00 0.08 0.08 RDOL(NI) TKII Vendor F
Act. No. K30F10A
Tag : WHRS-PH2HP-BDS-MOV-002
7 EBD regulation 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A
Tag : WHRS-PH2HP-BDS-MOV-001
8 CBD regulation 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A
Actuators for Valves-LP

Sheet 1 of 4
Client: Parasakti Cements Ltd, Telangana ELECTRICAL LOAD LIST - R3 Doc. No:
Project: 1x7MW WHRS Project Date: April 18,2017
thyssenkrupp Industries India Pvt. Ltd.

Intermitte Total Total Total Remark


No. of
Rating in Connected Load Standby Type of
RPM nt Load in Continuous Standby Intermittent Scope P-Priliminary Remark
Sl. kW Load in kW Factor Load in kW Working Starter
Load Description Total Working Standby kW Load in kW Load in kW F- Finalized
No. Load in kW
9 = (5 - 7 - 8)
1 2 3 4 5=1*4 6 7=3*4 8 10 11 12
*6
Tag : WHRS-PH2LP-MAS-MOV-001
9 Main steam Stop Valve 1 1 0 0.45 0.45 0.90 0.00 0.45 0.00 0.00 0.41 RDOL(NI) TKII Vendor F
Act. No. K60F10A
Tag : WHRS-PH2LP-MAS-MOV-001A
9A Integral Bypass for Main steam Stop Valve 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A
Tag : WHRS-PH2LP-MAS-MOV-002
10 Steam start up vent valve 1 1 0 0.25 0.25 0.90 0.00 0.25 0.00 0.00 0.23 RDOL(I) TKII Vendor F
Act. No. KM60F10A
Tag : WHRS-PH2LP-FDW-MOV-001
11 FCV upstream isolation valves 2 1 1 0.09 0.18 0.90 0.09 0.08 0.00 0.08 0.08 RDOL(NI) TKII Vendor F
Act. No. K30F10A
Tag : WHRS-PH2LP-BDS-MOV-002
12 EBD regulation 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A
Tag : WHRS-PH2LP-BDS-MOV-001
13 CBD regulation 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A

Actuators for Dampers


9 IsolationTandem Dampers at inlet for PH Boiler 1 1 0 1.1 1.10 0.90 0.00 1.10 0.00 0.00 0.99 RDOL(NI) Client F
10 Isolation Tandem Dampers at outlet for PH Boiler 1 1 0 1.1 1.10 0.90 0.00 1.10 0.00 0.00 0.99 RDOL(NI) Client F Based on Client Confirmation
Seal Air fan for Tandem damper at inlet and outlet of
11 2 0 2 3.7 7.40 0.90 7.40 7.40 0.00 6.66 6.66 RDOL(NI) Client F
PH Boiler
By pass Regulating Dampers (Modulating with inching)
12 1 1 0 1.10 1.10 0.90 0.00 1.10 0.00 0.00 0.99 RDOL(I) Client F Emergency power required
for PH Boiler (Multi louvre type)
13 Motors for Hammering Unit 14 14 0 1.5 21.00 0.90 0.00 0.00 18.90 0.00 0.00 DOL TKII F

II STG MCC
IIA Plant Steam Valves
1 MS line to TG inlet drain - HP 0 0 0 0 0.00 0.90 0.00 0.00 0.00 0.00 0.00 RDOL(NI) TKII Vendor P
2 MS line to TG inlet drain - LP 0 0 0 0 0.00 0.90 0.00 0.00 0.00 0.00 0.00 RDOL(NI) TKII Vendor P
Tag : WHRS-PSSHP-MAS-MOV-001
3 warm up vent - HP 1 1 0 0.25 0.25 0.90 0.00 0.25 0.00 0.00 0.23 RDOL(I) TKII Vendor F
Act. No. KM60F10A
Tag : WHRS-PSSLP-MAS-MOV-001
4 warm up vent - LP 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A
Tag : WHRS-PSSHP-MAS-MOV-002
5 Sacrificing valve for HP MS line 1 1 0 3.3 3.30 0.90 0.00 3.30 0.00 0.00 2.97 RDOL(NI) TKII Vendor F
Act. No. K300F14A
Tag : WHRS-PSSLP-MAS-MOV-002
6 Sacrificing valve for LP MS line 1 1 0 1.7 1.70 0.90 0.00 1.70 0.00 0.00 1.53 RDOL(NI) TKII Vendor F
Act. No. K300F14A
Tag : WHRS-DEA-FDW-MOV-001 / 002
7 HP BFP outlet isolation 2 1 1 0.18 0.36 0.90 0.18 0.16 0.00 0.16 0.16 RDOL(NI) TKII Vendor F
Act. No. K30F10A
Tag : WHRS-DEA-AUX-MOV-001
8 Initial warm up line / pegging steam line 1 1 0 0.18 0.18 0.90 0.00 0.18 0.00 0.00 0.16 RDOL(NI) TKII Vendor F
Act. No. K30F10A
Tag : WHRS-DEA-DMS-MOV-001
9 Isolation valve for Initial filling line to Dea Tank inlet 1 1 0 0.09 0.09 0.90 0.00 0.09 0.00 0.00 0.08 RDOL(NI) TKII Vendor F
Act. No. K30F10A
10 Boiler feed pumps -HP 2 1 0 55 2980 110.00 0.90 0.00 0.00 99.00 0.00 0.00 Supply TKII F VFD
11 LP Dosing Pump 2 1 1 0.370 0.74 0.90 0.37 0.00 0.33 0.33 0.00 DOL TKII Vendor F
12 Stirrers 1 1 0 0.370 0.37 0.90 0.00 0.00 0.33 0.00 0.00 DOL TKII Vendor F

IIB STG Auxiliaries


1 Condensate Extraction pump 2 1 1 37.0 74.00 0.80 37.00 0.00 29.60 29.60 0.00 DOL Client F WHRS-STG-TGD-MT-001 / 002
2 Main Oil pump 0 0 0 0.0 0 0.00 0.80 0.00 0.00 0.00 0.00 0.00 DOL Client P Shaft Driven
3 Auxiliary Oil pump 1 1 0 11.0 11.00 0.80 0.00 11.00 0.00 0.00 8.80 DOL Client F WHRS-STG-LOC-MT-001
4 Oil Vapour Extraction Pump Oil Mist Seperator 2 1 1 0.7 2800 1.40 0.80 0.70 0.70 0.00 0.56 0.56 DOL Client F WHRS-STG-LOC-MT-002 / 003
Soft Starter Panel
5 Barring Gear Motor 1 1 0 15 15.00 0.80 0.00 15.00 0.00 0.00 12.00 DOL Client F
WHRS-STG-LOC-MT-004
6 GVC Blower Motor 2 1 1 2.2 2876 4.40 0.88 2.20 2.20 0.00 1.94 1.94 DOL Client F WHRS-STG-AUX-MT-001 / 002
7 Control oil Pump 2 1 1 7.5 1467 15.00 0.80 7.50 0.00 6.00 6.00 0.00 DOL Client F WHRS-STG-COC-MT-001 / 002
8 Lube oil purifier / Centrifuge 1 1 0 0.75 0.75 0.70 0.00 0.00 0.53 0.00 0.00 Client F
Supply
9 Lube Oil Purifier heater 2 2 0 12.0 24.00 1.00 0.00 0.00 24.00 0.00 0.00 Client P
10 Lube oil tank heaters 4 4 0 3.0 12.00 1.00 0.00 0.00 12.00 0.00 0.00 DOL Client P
11 Generator space heaters (230 V, 1 phase) 2 2 0 1.0 2.00 1.00 0.00 0.00 2.00 0.00 0.00 Supply Client F 16A DP MCB with power contactor from TG MCC panel
12 Exiter space heaters (230 V, 1 phase) 1 1 0 0.2 0.20 1.00 0.00 0.00 0.20 0.00 0.00 Supply Client F with generator Breaker On interlock for auto start/stop.
13 Spare 1 Supply Client
14 Spare feeder for AOP 1 1 0 11 11.00 0.80 0.00 0.00 0.00 0.00 0.00 DOL Client P
15 Spare feeder for OVE 1 1 0 1.3 1.30 0.80 0.00 0.00 0.00 0.00 0.00 DOL Client P
16 Spare for Barring gear motor 1 1 0 15 15.00 0.80 0.00 0.00 0.00 0.00 0.00 DOL Client P
16A Main steam line to STG isloation 1 1 0 4 4.00 0.80 0.00 0.00 0.00 0.00 0.00 RDOL Client F WHRS-STG-MAS-MOV-001
16B Main steam line to STG isloation - Bypass 1 1 0 0.06 0.06 0.80 0.00 0.00 0.00 0.00 0.00 RDOL Client F WHRS-STG-MAS-MOV-001A
16C Injection line to STG isloation 1 1 0 1 1.10 0.80 0.00 0.00 0.00 0.00 0.00 RDOL Client F WHRS-STG-MAS-MOV-002
16D Injection line to STG isloation - Bypass 1 1 0 0.06 0.06 0.80 0.00 0.00 0.00 0.00 0.00 RDOL Client F WHRS-STG-MAS-MOV-002A

230V (AC SUPPLY) Panel Auxilliary Supply


IIC
requirements
1 Generator relay & metering panel 1 1 0 1.500 1.50 0.00 0.00 0.00 0.00 0.00 SUPPLY Client F
2 Generator Synchronizing panel 1 1 0 1.500 1.50 0.00 0.00 0.00 0.00 0.00 SUPPLY Client F
3 Generator LASCPT Panel 1 1 0 1.500 1.50 0.00 0.00 0.00 0.00 0.00 SUPPLY Client F
4 Generator NGR Panel 1 1 0 1.500 1.50 0.00 0.00 0.00 0.00 0.00 SUPPLY Client F
5 Generator AVR Panel 1 1 0 1.500 1.50 0.00 0.00 0.00 0.00 0.00 SUPPLY Client F
6 Turbine Supervisory panel 1 1 0 1.500 1.50 0.00 0.00 0.00 0.00 0.00 SUPPLY Client F

Sheet 2 of 4
Client: Parasakti Cements Ltd, Telangana ELECTRICAL LOAD LIST - R3 Doc. No:
Project: 1x7MW WHRS Project Date: April 18,2017
thyssenkrupp Industries India Pvt. Ltd.

Intermitte Total Total Total Remark


No. of
Rating in Connected Load Standby Type of
RPM nt Load in Continuous Standby Intermittent Scope P-Priliminary Remark
Sl. kW Load in kW Factor Load in kW Working Starter
Load Description Total Working Standby kW Load in kW Load in kW F- Finalized
No. Load in kW
9 = (5 - 7 - 8)
1 2 3 4 5=1*4 6 7=3*4 8 10 11 12
*6
7 Generator water leakage detector 1 1 0 1.500 1.50 0.00 0.00 0.00 0.00 0.00 SUPPLY Client F
8 Barring Gear Starter panel 1 1 0 1.500 1.50 0.00 0.00 0.00 0.00 0.00 SUPPLY Client P
9 DC starter panel 1 1 0 1.500 1.50 0.00 1.50 0.00 0.00 0.00 SUPPLY Client F
10 Spare feeder 1 1 1 0 1.500 1.50 0.00 1.50 0.00 0.00 0.00 SUPPLY P
11 Spare feeder 2 1 1 0 1.500 1.50 0.00 1.50 0.00 0.00 0.00 SUPPLY P
12 Spare feeder 3 1 1 0 1.500 1.50 0.00 1.50 0.00 0.00 0.00 SUPPLY P
13 Turbine Gauge Panel 1 1 0 1.500 1.50 0.00 1.50 0.00 0.00 0.00 SUPPLY F

IID 110V DC SUPPLY


1 Emergency Oil Pump (DC) 1 1 0 2.200 1500 2.20 0.80 0.00 2.20 0.00 0.00 1.76 DC Starter Client F Emergency power required
2 Panel auxilliary supply requirements
3 Generator relay & metering panel 1.000
4 Generator Synchronizing panel 1.000
5 Generator AVR Panel 1.000
6 Turbine Supervisory panel 1.000
16 Amp DP MCB
6A NGR Panel 1.000
7 Spare feeder 1 1.000
8 Spare feeder 2 1.000
9 Spare feeder 3 1.000

IIE 230V (AC UPS POWER SUPPLY)


1 Continuous wattage 1 1 0 1.237 1.24 0.80 0.00 0.00 0.99 0.00 0.00 SUPPLY Client P
2 wattage for 60 min 1 1 0 1.243 1.24 1.80 0.00 1.00 0.44 0.00 1.80 SUPPLY Client P
3 wattage for 1 min 1 1 0 1.267 1.27 2.80 0.00 1.00 0.75 0.00 2.80 SUPPLY Client P
4 Panel auxilliary supply requirements
5 Generator relay & metering panel 0.500
6 Generator Synchronizing panel 0.500
7 Turbine Supervisory panel 0.750
16 Amp DP MCB
8 Spare feeder 1 0.500
9 Spare feeder 2 0.500
10 Spare feeder 3 0.500
0.750
IIF EMERGENCY POWER (415 V)
1 DC System 1 1 0 10.0 10.00 0.90 0.00 10.00 0.00 0.00 9.00 Supply TKII Vendor P
2 UPS system 1 1 0 10.0 10.00 0.90 0.00 10.00 0.00 0.00 9.00 Supply TKII Vendor P E&I to confirm
3 Emergency lighting 1 1 0 5.0 5.00 0.90 0.00 5.00 0.00 0.00 4.50 Supply TKII Vendor P

III AC & Ventilation MCC


1 Packaged AC Unit fot Control Room & MCC Room 4 3 1 25.500 102.00 0.95 25.50 0.00 72.68 24.23 0.00 Supply TKII Vendor P
2 Split A/C unit - WTP 3 3 0 4.500 13.50 0.88 0.00 0.00 11.88 0.00 0.00 Supply TKII Vendor P
3 Air Washer - supply air fans 2 2 0 11.000 22.00 0.85 0.00 0.00 18.79 0.00 0.00 S/D TKII Vendor P
4 Air Washer pumps 2 1 1 0.750 1.50 0.44 0.75 0.00 0.33 0.33 0.00 DOL TKII Vendor P
5 AVF Motor 4 4 0 0.180 1.00 0.88 0.00 0.00 0.88 0.00 0.00 DOL TKII Vendor P
6 Exhaust fans - Cable Cellar 3 3 0 1.100 3.30 0.49 0.00 0.00 1.60 0.00 0.00 DOL TKII Vendor P
7 Exhaust fans - Compressor Room 1 1 0 0.370 0.37 0.25 0.00 0.00 0.09 0.00 0.00 DOL TKII Vendor P
8 Exhaust fans - BFP area 1 1 0 0.370 0.37 0.25 0.00 0.00 0.09 0.00 0.00 DOL TKII Vendor P
9 Exhaust fans - Battery Room 1 1 0 0.050 0.05 1.00 0.00 0.00 0.05 0.00 0.00 DOL TKII Vendor P Single Phase
10 Exhaust fans - WTP Room 2 2 0 0.750 1.50 0.34 0.00 0.00 0.51 0.00 0.00 DOL TKII Vendor P

IV EOT
1 EOT Crane 1 1 0 15.000 15 0.90 0.00 15 0 0.00 32.00 SUPPLY TKII Vendor P

V Cooling Tower & DM water


1 CT Fans 3 2 1 37.000 111.0 0.84 37.00 0.00 62.16 31.08 0.00 SUPPLY TKII F VFD suitable drive
2 ACW Pumps 2 1 1 45.000 90.0 0.90 45.00 0.00 40.50 40.50 0.00 DOL TKII F
3 MCW Pumps 2 1 1 250.000 500.0 0.90 250.00 0.00 225.00 225.00 0.00 SUPPLY TKII F VFD
4 DM Water transfer pumps 2 1 1 1.100 2.2 0.90 1.10 0.00 0.99 0.99 0.00 DOL TKII F
5 CT make up pumps 2 1 1 18.500 37.0 0.90 18.50 0.00 16.65 16.65 0.00 DOL TKII F
Tag : WHRS-CWS-MCW-BF-003 / 004
6 MCW oump discharge butterfly valves 2 1 1 0.550 1.1 0.90 0.55 0.55 0.00 0.50 0.50 RDOL(I) TKII Vendor F
Act. No. SA6E90 + GS100.2
Tag : WHRS-CWS-ACW-BF-003 / 004
7 ACW oump discharge butterfly valves 2 1 1 0.060 0.1 0.90 0.06 0.06 0.00 0.05 0.05 RDOL(I) TKII Vendor F
Act. No. SA3E22 + GS63.2
8 Boiler Initial filling pumps 1 1 0 15.000 15 0.90 0.00 0 13.5 0.00 0.00 DOL TKII F

VI Compressor
1 Instrument air compressor+Dryer 2 1 1 25.000 50 1.08 0.00 25.000 27.1 0.00 27.10 SUPPLY TKII Vendor F Service factor 1.08

VII Water Treatment Plant


1 Raw Water Pumps 2 1 1 3.7 7.4 0.85 3.70 0 3.145 3.15 0.00 DOL TKII Vendor F
2 MB Blower 2 1 1 1.5 3 0.85 1.50 0 1.275 1.28 0.00 DOL TKII Vendor F
3 UF Backwash Pump 2 1 1 2.2 4.4 0.85 2.20 0 1.87 1.87 0.00 DOL TKII Vendor F
4 RO Feed Pump 2 1 1 1.1 2.2 0.85 1.10 0 0.935 0.94 0.00 DOL TKII Vendor F
5 RO HPP 2 1 1 3.7 7.4 0.85 3.70 0 3.145 3.15 0.00 DOL TKII Vendor F
6 Blower for Degasser 2 1 1 0.37 0.74 0.85 0.37 0 0.3145 0.31 0.00 DOL TKII Vendor F

Sheet 3 of 4
Client: Parasakti Cements Ltd, Telangana ELECTRICAL LOAD LIST - R3 Doc. No:
Project: 1x7MW WHRS Project Date: April 18,2017
thyssenkrupp Industries India Pvt. Ltd.

Intermitte Total Total Total Remark


No. of
Rating in Connected Load Standby Type of
RPM nt Load in Continuous Standby Intermittent Scope P-Priliminary Remark
Sl. kW Load in kW Factor Load in kW Working Starter
Load Description Total Working Standby kW Load in kW Load in kW F- Finalized
No. Load in kW
9 = (5 - 7 - 8)
1 2 3 4 5=1*4 6 7=3*4 8 10 11 12
*6
7 DG Water transfer Pump (DM Feed Pump) 2 1 1 1.1 2.2 0.85 1.10 0 0.935 0.94 0.00 DOL TKII Vendor F
8 SSF Feed Pump 1 1 0 11 11 0.85 0.00 0 9.35 0.00 0.00 DOL TKII Vendor F
9 Blower for SSF 1 1 0 10 10 0.85 0.00 0 8.5 0.00 0.00 DOL TKII Vendor F
10 RO CIP Pimp 1 1 0 2.2 2.2 0.85 0.00 1.5 0.595 0.00 1.28 SUPPLY TKII Vendor F
11 ALUM DOSING TANK Aggitator 1 1 0 0.37 0.37 1.00 0.00 0 0.37 0.00 0.00 SUPPLY TKII Vendor F Single Phase
12 ALAKLI DOSING TANK Aggitator 1 1 0 0.37 0.37 1.00 0.00 0 0.37 0.00 0.00 SUPPLY TKII Vendor F Single Phase
13 ALAKLI DOSING TANK Aggitator (2) 1 1 0 0.37 0.37 1.00 0.00 0 0.37 0.00 0.00 SUPPLY TKII Vendor F Single Phase
14 NaOCl Dosing Pumps 2 1 1 0.1 0.2 1.00 0.10 0 0.1 0.10 0.00 SUPPLY TKII Vendor F Single Phase
15 Alum Dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
16 Actuator for UF Valves (6) 5 5 0 0 0 1.00 0.00 0 0 0.00 0.00 SUPPLY TKII Vendor P 24 V Supply from PLC
17 UF dosing pumps (1) 2 1 1 0.1 0.2 1.00 0.10 0 0.1 0.10 0.00 SUPPLY TKII Vendor F Single Phase
18 UF dosing pumps (2) 2 1 1 0.1 0.2 1.00 0.10 0 0.1 0.10 0.00 SUPPLY TKII Vendor F Single Phase
19 Acid dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
20 SMBS Dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
21 Antiscalent dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
22 RO Dump Valve actuator 1 1 0 0 0 1.00 0.00 0 0 0.00 0.00 SUPPLY TKII Vendor P
24 V Supply from PLC
23 RO flushing valve actuator 1 1 0 0 0 1.00 0.00 0 0 0.00 0.00 SUPPLY TKII Vendor P
24 PH dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor P Single Phase
25 H2S04 Dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
26 Corrosion inhibitor Dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
27 Disperent dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
28 Scale inhibitor dosing pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
29 NaoCL Dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase

VIII Fire Fightening System (Raw Water Tank Area)


1 Electrical Motor driven Main Hydrant Pump 1 1 0 90 90 0.72 0.00 90.00 0.00 0.00 64.80 SUPPLY TKII Vendor P
2 Electrical Motor driven Jockey Pump 1 1 0 7.5 7.50 0.68 0.00 7.50 0.00 0.00 5.10 SUPPLY TKII Vendor P

IX Hot Gas Generator MCC- for AQC Boiler


1 Combustion Air Fan 2 1 1 30.000 60.00 0.80 30.00 0.00 24.00 24.00 0.00 VFD TKII Vendor F VFD by tkII
2 Coal Conveying Air Fan 2 1 1 18.500 37.00 0.80 18.50 0.00 14.80 14.80 0.00 DOL TKII Vendor F
3 Emergency Cooling Air Fan 1 1 0 1.500 1.50 0.80 0.00 0.00 1.20 0.00 1.20 DOL TKII Vendor F Emergency power req
4 Coal Conveying system 1 1 0 5.500 5.50 0.80 0.00 0.00 4.40 0.00 4.40 VFD TKII Vendor F VFD by tkII
5 Solenoid Valves 8 8 0 0.018 0.14 0.80 0.00 0.14 0.00 0.00 0.01 DOL TKII Vendor F
6 RAV 1 1 0 0.750 0.75 0.80 0.00 0.00 0.60 0.00 0.60 RDOL TKII Vendor F
7 LDO oil pumps 2 1 1 0.750 1.50 0.80 0.75 0.00 0.60 0.60 0.60 DOL TKII Vendor F
8 Local Control Panel 1.000 SUPPLY F
9 For 1 No. HEI 0.500 SUPPLY P
10 For 1 No flame Scanner 20 VA SUPPLY P
11 For 1 No. Flow meter 10VA SUPPLY P

Actuators for Dampers in HAG


12 Isolation damper at burner inlet in coal conveying line 0 0 0 0 0.00 0.80 0.00 0.00 0.00 0.00 0.00 RDOL(NI) TKII Vendor P
13 Isolation damper at Comb Air fan outlet 0 0 0 0 0.00 0.80 0.00 0.00 0.00 0.00 0.00 RDOL(NI) TKII Vendor P
14 Isolation damper at Dilution Air fan inlet & outlet 2 2 0 0 0.00 0.80 0.00 0.00 0.00 0.00 0.00 RDOL(I) TKII Vendor P Emergency power required
15 Isolation damper at Emergency cooling fan outlet 0 0 0 0 0.00 0.80 0.00 0.00 0.00 0.00 0.00 RDOL(NI) TKII Vendor P
Isolation damper at Hot Air Generator outlet - hoisting
16 0 0 0 0 0.00 0.80 0.00 0.00 0.00 0.00 0.00 RDOL(NI) TKII Vendor P
damper
Isolation damper at Hot Air Generator outlet -coffee pot
17 0 0 0 0 0.00 0.80 0.00 0.00 0.00 0.00 0.00 RDOL(NI) TKII Vendor P CONSIDERED IN ACTUATORS FOR DAMPERS
damper
18 Electromagnet for coffee pot damper 1 1 0 0.2 0.20 0.80 0.00 0.20 0.00 0.00 0.16 RDOL(NI) TKII Vendor F
780.87
Notes on Starter Scheme:
1. Inching / Non-Inching starter requirement for motorised valves will be confirmed during drawing review stage.
F : Motor Ratings are final
Note : Reference for Electrical Load List of WTP, HAG & STG enclosed along with this load list
P : Motor Ratings are Preliminary

DOL - DIRECT ON LINE STARTER


DOL(**) - DIRECT ON LINE STARTER FOR SINGLE PHASE 220V SUPPLY
SUPPLY - SUPPLY FEEDER
RDOL - REVERSIBLE DIRECT ON LINE STARTER
RDOL(I) - REVERSIBLE DIRECT ON LINE STARTER (Inching Duty)
RDOL(NI) - REVERSIBLE DIRECT ON LINE STARTER (Non-Inching Duty)
O/G - SIMPLE FUSE / OUTGOING FEEDER
2. Above mentioned load list is tentative.
3. All motorised actuators are with integral starters
4. The above Electrical load list is Preliminary & is updated/revised based on vendor inputs.

Sheet 4 of 4
BURNER DATA SHEET
BURNER DATA SHEET DOCUMENT NO. FCS-BDS-01

Company Name FIVES COMBUSTION SYSTEM PVT LTD

Project Name Project Engineer HARDIK SONI (HS)

ThyssenKrupp Industries
Purchaser FCS Project No. 2017.3610
India Pvt. Ltd.,

End User A/c PARASHAKTI CEMENT Rev No. 0

P10117217/JB1001 Dated
Purchase Order No. Date 24.08.2017
25.01.2017

0 24.08.17 Initial Issue NM HS DP


Rev. No. Date Description Prepared By Checked By Approved BY

1/4
ThyssenKrupp Industries
CLIENT DOC NO. FCS-BDS-01
India Pvt. Ltd.,

PROJECT REV NO. 0

FCS JOB 2017.3610 DATE 24.08.2017

A HOT GAS GENERATOR


Sr. No. Description Unit Value
A1 Qty. of HGG No(s). One
A2 Application To generate hot gases to generate steam WHRU Boiler
A3 HGG orientation Vertical
A4 Type of Burner - GRC Burner :Coal Fired with LDO/HSD for startup
A5 Fuel Fired
A5.1 Main Pulverized Coal
A5.2 For Startup LDO/HSD
A6 Register Draft Loss mmWC <250
A7 Turn Down For Pulversised Coal - 1:3
A8 Turn Down Ratio Oil 1:3
A9 Heat Release Rate per HGG Mkcal/hr 8.4 (With Coal)
A10 HGG Outlet Temperature deg.C 440 - 450

Kindly note dilution air ports pressure drop is calculated based


A11 Hot Air Pressure at HGG Outlet mm WC on 20 mmwc.The HAG outlet pressure shall be maintained to
have negative draft in your system.

A12 HGG Outlet Hot Gas Flow at 440-450 Deg Cel Kg/hr 198000

A13 Coal Flow Rate Kg/hr 1500


A14 Gross calorifice Value of Coal Kcal/kg 5600
A15 Coal particle size Micron <100
A16 Firing capacity with LDO fuel Mkcal/hr 2.52
A17 Gross Calorific Value of LDO/HSD Kcal/kg 10000
A18 Combustion Air Flow Rate Kg/hr 15500
A19 Combustion Air Temp Deg C 40

Dilution air req. flow per burner from Cooler Vent to


A20 Kg/hr 181100
HGG

A21 Dilution Air Temp from Cooler Deg C 305

Dilution Air Pressure @ inlet of HGG dilution air


A22 mmWC (-20)
nozzle from cooler from Cooler Vent to HGG

A23 Coal Conveying Air required per burner Kg/hr 970


A24 Emergency Cooling Air Flow Rate Kg/hr 4700
A25 Emergency Cooling at Pressure mmWC 50

B For LDO/HSD
B1 Temperature of fuel at burner inlet Deg C 40
B2 Viscosity of @ 40 Deg cel cSt 2.5-15.7
B3 Specific gravity @ 15 Deg Cel 0.88
B4 density Kg/m3 880
B5 Pressure at Burner Inlet Kg/cm2(g) ~10
B6 Oil Flow Rate at Burner Kg/hr 252
B7 Oil Pressure at Piperack Inlet Kg/cm2(g) ~12
B8 Oil Flow Rate at Pump Outlet Kg/hr 302
B9 Oil Pressure at Pump Outlet Kg/cm2(g) 15

2/4
ThyssenKrupp Industries
CLIENT DOC NO. FCS-BDS-01
India Pvt. Ltd.,

PROJECT REV NO. 0

FCS JOB 2017.3610 DATE 24.08.2017

C Atomising Air @ Pipe Rack Inlet

C1 Pressure Kg/cm2(g) 4

C2 Temp. Deg.C 40

C3 Flow Rate Kg/hr 50

D Instrument Air @ Pipe Rack Inlet

D1 Pressure Kg/cm2(g) 6-7

D2 Temp. Deg.C 40

D3 Flow Rate Kg/hr 65

E Pilot Type

E1 Type of Ignition System - High Energy Igniter (HEI)

F Power Supply

F1 Instrument / Panel Power VAC 220

F2 Solenoid Voltage VAC 220

F3 Motor Supply VAC 415

F4 Non UPS Utilty Suuply VAC 230

F5 Variation In Volatge +/- 10%

F6 Variation In Frequency +/- 5 %

G Coal Composition

Pulverized Coal % RAW COAL

G1 Ultimate Analysis Wt%

G1.1 Carbon % 57.75

G1.2 Hydrogen % 3.96

G1.3 Nitrogen % 1.12

G1.4 Sulphur % 0.08

G1.5 Oxygen % 12.09

G1.6 Moisture % 1.5

G1.7 Ash % 23.5

G2 Proximate Analysis %

G2.1 Fixed Carbon % 40-50

G2.2 Volatile Matter % 25-35

G2.3 Coal Ash % 15-25

G2.4 Coal Moisture % 7-12- Raw Coal 1.5-5 - Fine coal

3/4
ThyssenKrupp Industries
CLIENT DOC NO. FCS-BDS-01
India Pvt. Ltd.,

PROJECT REV NO. 0

FCS JOB 2017.3610 DATE 24.08.2017

H SITE DATA

H1 Ambient temperature

H1.1 Maximum dry bulb temperature °C 50

H1.2 Minimum dry bulb temperature °C 20

H1.3 Mean dry bulb temperature °C 32

H1.4 Wet bulb temperature °C 28


H2 Plan design temperature °C 35
H3 Electrical equipment design temperature °C 50
H4 Wind Speed m/s 44
H5 Relative Humidity (Performance) % 70
H6 Area Classification Safe and Non Hazardous
H7 Area classification of LDO tank area (tank instruments Hazardous, IIA / IIB, T3
H8 Maximum noise level dBA <85 @ 1.0 mtrs distance
H9 Seismic Zone Zone - II
H10 Site elevation 106 mtrs above MSL
H11 Average Rainfall mm 850
H12 Plant Location Jetti palem, Rentachintala, Guntur Dt., Andhra Pradesh, India

I PERFORMANCE GUARANTEE ARAMETER


I1 Performance Parameter Value
I1.1 Hot gas generator heat release capacity < 8.4 Mkcal/hr – with Coal
I1.2 Hot gas generator outlet temperature 440-450 °C + 1%
I1.3 Fuel flow rate each hot gas generator 1500 kg/hr
I1.4 Turndown 1:3

I2 Note
I2.1 1. Measurement / instrument error of 1% shall be allowed.

HGG outlet temperature guaranteed above is average temperature during performance test duration if equipment is operated at
I2.2 design capacity and combustion air and cooler air is regulated as required to achieve this temperature. The temperature shall be
measured further away from HGG, preferably at the inlet of mill, so that temperature measured is more stable.

For capacity measurement, fuel flow rate will be measured. The fuel calorific value (LHV) considered by us for this capacity rating
I2.3 is 5600 kcal/kg during performance testing of HGG, you/your client shall provide us with calorific value details/ ultimate analysis of
fuel for our reference.

4/4
COOLING TOWER
PLANT AUXILIARIES
BOILER FEED PUMP (BFP)


  
  



 

 

  
 
  
  
 
 

 
  !"
#
$ % &
  "

'
 "
(
 )!
!!#
# %
  
!
  *
* + *
, "(
   !,
- 

 

 -
. /

0%
 .
1 +

 (2
 .
  
3
 .
  %!
  .
 

   1


 4

 1
     1
 

   !
% & 1
$ % &
  "

'
(
   !!
 1
# )


 % & 1
* ! 
,  (
   
 !

5!
 
  '!



 
 

 $
$ 
  $
$  4

 #
$ 5
!


 #
$$ 4

  5
%   #
$#    *
$#   &
 *
$#  + 
  (
 %
  ,
  !

 "
 -
# 
 .
* "

   ! .
*  !(
  
4
  .
*     1
*   &
   1
*  + 
  (
 %
   1
*$  
 "
 


 

*# ')

  4 
  
** !0  $
*,    #
*-  
  '  ,
% 

&' .
, 4
   ! .
,  !
  .
, +
   
 "
 
,$ % &
   "
(
  
 6& 
,# 8
  ' $
,* 

     #
,*   &
  #
,*  + 
  (
 %
  #
,, +
  
 *
,- %!
  ,
,. 
5   -
,1 '

  '9 !(
 ! 
4
 : .
(  )
$1
* +
, 

, -  ' $
. / 0   $$
    $*
 !+
  $,
 !!

  $,
    /
 1  
$-
 
 (
 
E$1#1 $-
  
 (
 
E*#7-111 #1
 
 (
 
E # #


 

 
6
0 
5!
 6
+ 
 040
 !7( (
4(&
 
!!  
(

+ 
  4
 0  
&! 
80  3
!
9!
  0!!:



;  





  !!

 40
<=
>
7  !


>
; 
 



 
40
>
(  

0!0 
 !!

?5@+@A%5B6'+A5>A?'>@A65B'>A>"A5

) 
   !!
 !7
 
74 0

 

? 'A6%@'AA>BA65BA5A>%>BA>'5'C6A?

) !
 
!!
!7!!

6@'>A5%5+ ?;6AA>>'>@A65B%B'>@A6B >'5B


6BD@'?B""+>A5A>>2@6 +>BA

%
  !!(


0

 0 0
 




A 



+  !
 !!!!
 A 
+  

!
4 

(
 


 
 
7!

7  0  


A 0!
7
E7
!
 
 4 ( ! 
 !!0






+ 70
<


A !!  4!
   !
 !

(

 


4

<6!
40! 
<3 


>


; 
!

 
6!!7!
  0!




!
7
!


+>@'6B6BA'@+>BA@ 6>";6AA> @+ 75@">


%6'A>">5'>%5++665B6B5A> @+ >A

 $

A !!3
!!(
 ! 
4
 
 
 4

7  

4&!
 9 

 !4

:4 (111!
(!7 4

 
 (
4

!! 0 
4
 7 
 

 4
 

!
7( 0  5 >'A6B6BA'@%A65B+B@7 

 0 

7
  4 
!
4
3




 

2 
6 !!
 
!!
! 
4 4
4! 7 


 !  4  


4 (9   04 
 
:

! + ! +

!
4
4! 

64!!!! 4! 7  



 !  
4 


4 (



 
            
  
 


! ! !

! 4! 



 

2 )  1 / 3  4  1 5


+  
 9" ! 0:




  
; 

 9; :

+2 $4!


  
& 
9!! 0:

1

+

#1
1

1
#1+

F
B) 
&
#/



 &

+2  $ 


 

"
$
A 
4
 

4 4 (
 ) 
&  0
   (!
44 (
 ! 7
  
!!
G G   
E  4H- 1

  
 7   4

 (
 
! !! 0


!




 

)


!03
!4
 (
 /
4( 
4 
A


 074 
 !

!4(47!&! 
 &
! !!
   



 0A
 &


)(

(& 
"!

7 


( 11I

A 7  (
 !
(
 )

 B 011I4( 


 44! 
 %
4 
 

!(

) 
A  (
 !!

 (

) A 4
!
(
  !7(
 (  47



 9'
:

) 
   !! 4
 &! 4!
 8&
 4 
3
 

9!! 0#1/#1/ 1A &! :
  
 
  4!! 8&
 4 
!

$ !
4 
 !&!
 
4 &
#   !! 
0  (

11$!7
 8&
 
4 !
     4
*  
4 44! 9( :40
 3
&

 ) 
&7%%&J'6B<<5+ J5''5%&
J%5B>KA') J3
 9'
 :
,  (
 
 $,  !
 !  
- A
 
4 
   
.  ! 47
 
    (!
7
07
 

  
 
/
7  %7  
!!
G G 
  
E/ 1
1  
!! 0
4 

!



$
 

2   1  )  3 


A !!4
 0
(   !4(  

 ! /
 0 (  !
 
  !
 

% &

 
 

9
:4 (



; 
 

  !!& (0  


 
  
(
 !



 !!
 
 
 

9/! :

!
  4(
 
! !
  4(
 
!

A /
 
 

4( (  !
 /11$

2  6    1 - 1  3    7 





 ! !!7 & 
=


60
 




4 7
 
 !! & 





 6    1 -

) ;
 G
) >  4
 0(
 9
&
:
) "
 !  !
 
) ! 7
4
 07 
(
) % & 


L


( 7  
   40
 

 ) & 



) BG
4 0& 

 
 4/
) ;
 G
) @
!7  4
 0(
 9
&

:%0
 
 !
 
!
) 
!
  


#
 

2    )


B !!  !
 !
!
 

A 

  4(
 !!
  !( !!A !
!  
4!!0 !!  4 !!(
 


 0

A !!4 (
 
!
!
 A 
 4 !
!  4     
!!EE 

;

 )  ) 7
  0!

 
A  /!
 !
!(&  440
4 

!0/  !!

2# +
  

A !
!
   0   (  !!( 4
48/
 
  

'  

0!
 !
!
 
(

 
 

 !!
/

"

G 
B
  +
B
  "B



  0

  
EE A 


  EE 4
! 0

"B
+0

E 0 +/

/ +E

/70E

 


(
  7 (G
/M 
E !   !!/

0M 
E 
  !!/

EM
 
  !!/


+/7+0+E

 


(
  7 (G
+/M 
E /
!   !!/

+0M 
E /

  !!/

+EM 
 EE /


"BM 
 
N
  EE 


*
 

2%    )


6  
 !!(
4  0 
!
!
 4 (!7(
 
 !!
 
 /
( !!!
 7 !!  4
(  4!  (
  (
 
A !!  4( 
(0

 !


A /


4  !!EE  ( 
!

   (
 4/40 (
 
!


0 /

"(
  !! 4! 


,
 

2(      /





 (
 
7  0 7  4 (   
 7!
!
 
( 
 47  
!

3 0
 04
  
!

7

0


 


7 !
4  
EE 7! 
  !!
A  )
   
 
  4 
 )

 !
!
 !/
!  
40 
 
A !!
 
/; !


"

   N"

  (
 7

!!

A 
 


40





 661$N66*

3



+ (
  1#
;

 1 #

@!"B11 4"B11

 

 


 

# / # /

$ $

 
  N
!
!
 


 %

$ !
EE 
# "

 !
  9!)  :



,
.
1 1
N


#
1
 


-
11.
1
N


 #
1
O

%
 
(
 !

 9/! :


-
 

2* 8'  

A 
E 
 /

0
9 
 
3
74 
3
:
 (
 
 
! 

2 .  + 9 


+

 (
 
40
)
 
 6

!

0!!!5!
 6


2 5 /:
A  ( 
0
 4 
3

  /#N6 4 
3


4&
 
 7 ! 4 
3
4 1#4

  
! !!
 7 !

4 !
 !
/ #I/ !!
  !

6 4 


3

 4&
 
      4 
3


/17 
  4
E
 
E  


$$> 
 (
 
 


2   
0  

!   !!4
(
 !
  


.
 

  

 

  
) 
1 

  

') &
64!
4  40  !
 6 




(  !!
 0

 !


2 /&
% &4
 !
  4

!! 0 3
3

 4


! A 
 !!
/
 4
 


2 1  
% &  6 !&!!7  !&
 ! 0
A 
 4/N 
 4
(
   !&
 7

 

2 )  )  

   6

C!
 !!

4!A  ) 
 


4 0! 0!  /

0
 &  (

2  6    1 -   )  


A 


  ( !!% &
40(

  
!!  


 0

; $ 0 )  440! 


!
 


2 ) 7

  6

6


 &!  #  
 
7  (
 
 &4!

 >  !


 
!

 A !
 
  !
 44 
  0
 
/
 


 % & 
!
!
 
)
$ % &  
# % &!
 
 

 3
!
* 6 

 
7 & 


(
  !!!

40(

  !!  


 0A 


 ( !!

; $ 0
  )  440! 

A4

G (!

 4
75!
 6

+ A4



1
 

  

2# 
 (!

 
P

: 6

 !

 5!  ) 


 

 (
(
  !!9: 0

 
   
 

  ( 0! 
   4
 3
0!
 !! 
  !% & ! 
 

40

 !
L
  /

4: B 5!




 (
 !!9:

 % & ! 


 

40

 !L

 /

2% 
: B !


 (
  
 &
  
( 0


 6

  ) 


 
  
 


4&!

4 

4:  

 %   ) 


 
  


 (
  
7 & 
( 0
%   )
 
 
7

 (!! 0
 ( !!
 
(7&
!) 



 6N!   (!


7 !!4

 (

4 0  
E
 



  

  
2  3
 1 < 
A !! 0 0 
A !!0

  !
 
 
   9Q #1 !0:4


 
'
 
 

 9 ) 

7(
 '
 
 
 :

% & 3
03
0 4
 !
  4

!


A 
 !!
/

A ! 4
  
 0/4
!40#1R%74
  /-1R%

A  ) 


 !! 0

!
 !


  

 
  

% & 
!!7 !!
  !
!

A 

  EE  !!  43
!!(
 !
   
 
4   !N!
 7
! !  & 

% &
 
3
 (!

A /!

4 
4(
  !
1R%;

 



  4&

40!!  4! 



 0 ((&&!
 !
   & 
 
0 /

0




  

2 - 
 
A /
 !

 7!
 0 ( 4 
 




40 !



 
  
!!

'!




 

4 9* :( 4
 
7(
 
 
0!7 

9* $:(
 
(
  

  7(
 
 0!

A 4  (
4&7
   /
7(
 #!
A &
4 

(
   
 !

 7
 



 4 



"
  
  !!7 4 
 
(7 4


( 

7(
 


40 



 (
 !
 & 

4 

A !
 #4( (& 

4 7! 
/
!

4 ( 4 
 
 7(  




  

40#( 

7 !!  4
!! 4 
 
  4(

!
  0 A
 ( !!
*  * $ *  * $

#
1

'!



 '!







 


 


2 5 

A  9 1:



 0 

(! 
4
 9,1:A 
&!
 /
  4

40 4 
9*1*1 :
)

 
  
4 0
 4 
 
 
4 
 

  (!7 
 ! (!
40
 

 9$ :! & 
3

  4
  
 9#11:

4
 
EA 
 !!
/
.11.
. $1.
,1 ,1
$1 $ .111 .11- #*1
.11 * 1 .$11 #11 $1- $ 
.#1 ,1
#*1
$# ,1
*- * 1 .11  1 #$ $111# . #*1
*-
.

# * #1#1 $111* *1 .11,


$111$ $1, #1, #11
*- .11$
* # #1 .$1 .11* .11# *$$ 1
$111, $1* $1#
.11, 
$1,
*$
.11#
$1#
) "2 ) 
 ) "2 ) 
 ) "2 ) 

$# ! $1. 
 
 ,1 &+ ) 
*1 % $1 
 
 ,1  &+ ) 
1   $ 
 
 .111 (
 1  4 4  $  40
 
 .11  /4 9  :
#11 
  
 #1#1  '

 
 .11$ /4 9  :
#11  
  
 #1, !  
 .11# / ! 
#$ A 4
  
 # #1 !  .11* / ! 
* 
  # * %
   .11, / ! 
,1 
   #* 1   !
 .11- / ! 
$111$   & #*1   !
 .11. / ! 
$111#   & #*1   !
 .11 / ! 
$111*   & * 1  

 . C! 
$111,   & * 1  6
 .$1 /&!(
$1# 
 
 *- %  
 .$11 <
 0
$1* 
 
 *$  5
  
  .#1 !

$1, 
 
 *$$ 4

 

$1- 
 
 *- 


$
 


2 /&

4
 G
'
 
 4


3
A 
 !!
/N4

% 

2 <
 1
00 
65 C$*7)A""6B###


3



2 /&  


 < 


  411 !


5
  0 -7111 07(
 
 

% &



  
9*-:

/&

A 4
 
 ) 4
40
A  4

 
 9*$$:




! 
 

3 4



A 0
  
 4
  
 9#1:

 0
40
  
9*-: 40
 
 9$ :!0
 & 4( 
4
  
 A 4
  
 
440(
  !  
9.1:






!!
 !

5
 

%  


)  $

@(!  9.1:A(   


9*-: 

  
 !  ! 
 
 ( 
   



!!
 
 !
 
 4(   

9
:A 
 
   
(
 
!
4& 0

!
 !

(!  
 
 
  !7 &
(   
  
 
 &A 
   (0





A 
     (04
4 (       !
  
 4(7
    (04! 00


#
 


2 1  

2 2 1 6  11 58



 4/
 

(
 8&4( 
 4/ 
 9$#:

 9*#:7(
  !

8&
 7( 3


A 
    /
   95":

40$!&
 

 
  
 0
 
 4/!40
 4/




;  ! !!


 
3

!1#R%8&
 

0

!!
 !4(1#R%#1R%
  8&
0
9,>N,:7
!!
 !4#1R%

 
 
  
09,> N, :

)6  11 58

 (0(!&
 
 !& 
 4/!7!4 0 
!&
 
   4&!




6
!/
 #47


)!


 
!&
 
 
!74


 
 4/A !
 !  
4 #14

% 0  !&


 !  !
  
(
  04
 
6 !&
 
 


 0!   

 !&
 !(
    !
 4/ A 


 
!&
 
   440!!/.1R7
 
  +& 
3   
 4/ !

 
 
4/ 

7 !&
 
   4!
 0(
    ! 
A  & 
  
40  0@ 
  &  
   09
&(:( !!

!
!!




A 
 4/  
!
 0(
 !!

!
A  & 
  44(


N 

 !&
 
EG
&

!
E B'
 
N4/9:
$1#1 $ 1/1/-#1
*#-1 $  / /111
11 $  / /11
 # $  / /11


*
 


2 2    
9 %
 (
 + 
  !!!
!4:

6 
  7 
 
&! 
 (/
   !
4( 
  
  
0 
 A 
  


 
4( 44
  ( 
 A !

 



     
!

4

0    

 


 40  4

  

  
!!40 

  

   

+ 
   (N>   
E&4
!
A  
 
 74 A 
  (
4



+ 
  
E(
49
:"$1#19

:"*#-1

"11" #(
 

E+ 
  

 /&N0!+ 
  
 
 ! 7! 
!

 
 (
 + 
  


,
  !

 "

  !

 "

;
 P


 

 7&  !!

 !(
!! 04(
 
 0

A 
 
  
 


 
  
!
 04
 A !!
   (4
!A !!

 4
! 

%
 
3

!
!4 
  !!!4
 A 4
  
!! 0
! 
!! 0!  4



'!
  "
 !
  ! 
"
  /

0!
!
 0

' !&
 7
 !!
 !&

% &!!
 !
 7&(
 
 9

=
=: (0  
 (
 
 

 
4 0


-
# 


# 

#2 
  ) 9& !:

#2 )  ) & 

 

  !
  4  
 !!


 


 @(

4 >4
 
  /4 9.11 :>4
 9*:
$ @( 4
  9# *:     4 4
 9 1:


 9#1#1 :
# '! 9# #1:!
 9.#1:
* '(9.111:& 4
  
 9#$:7( !
9$#:

  4 



, @(
/
  !!4
  
 9#11:
- '!!4
  
 9#11:
. '!4
   9,1:74

 
 9*$$:4 40
 
 
9$ :
1 '44
   9,1:
 @(9. 11N1$:9.1 1N1$:

  
 7
 (4
  
 9#11 :
  A& !  
 9#1,:

6! 44
 !
 47
00
!&
(
 !% & 
 4
   9,1:
4
  
 9#1:; 

!

 4
     44 

6 

 9



!
4  4
   :7 (8
 4
 

 4 ! 0
 4
   4 !
4 
 




6(4
   
7 
  
!

! 4

 

44


.
# 


#2 1  

#22 1 )6  11 58


 ' 
 4/ 9$# :
 >/  !&
  
 4/!
 9"
  /4 0 !!7  !&
   47

  !&
   0:
 
 4/ 
 9$#:  (
 
 9*#:

=
.  .
$ @( !
 9# $1N1 :!    9 1:
'4 
)  ) ( !
 0

=
#  
# '

!!  !
 9# $1N1 :  
*  ! 9# #1: 



#22         


9 %
 (
 + 
  !!!
!4:

 "
  !
!
  9$:!      !
!
  4 9 :  

 ( 9:
   
  )
 4 
  (9.: !
(91:
$ @(
/
 ( 
# ;
    !8&
 4 !
 
   

 ( !!   


  
  
  




 1  963

!
:
 '4 9 :

 ( 9:
 

 ( 
 0
! !
 9: 
  
 '(9.: !
(91: 
 9-:
 '
 9-:  9:
$ '  
  0 4 0 !

 7477
777 

"  9:7 


 94:7
 
 9 :  
  
!  4! 40(

6
& 44
  
 94:
 
 9 :7 0
044&  !!
 


1
# 


 ((
 
 0

<>A
=5= =6=

B"5"



>5"

>>C>
>>C>

 $ * ,  #  $ - . 1

>8>

5 >'A

"
$
%5BB>%A65B=6=N J 5'@6B6B>A
%5BB>%A65B=5=N J 5'@6B5@A>A

=5= $#R
=5=
=6=
=6=      4
$#R 

$#R

 
 1$

 !

D%<6B
5A 56A65B '?
C6>;'5+)SK=

$ =5=
 
   
 /4 
  ( 
1  ! 
.  *
- "
  
,  
* !
 
 
# & 
$   
 =5=
 
+
 
 
%

! 
  
 !
 *
 A(  
 =5=
 
4  
 
 %! 
%

 '0 

" $ %
(
 + 
  !!!
!
4



# 


#2 5  3


=
.  .
 4 
 
9*1:  (
  
/

=
# 7 
  

 9#1#1:!

 9#1:
  !
 9#1$1:
  4 
 
9*1:(
  
/
$ 60( 
/
 (4 
 
9*1 :! 

 
  
 91,:7(
  
/

=
.  
#  ! 9# # :
  
  

BG
60

  40 !!7 !!/
 

 ! 0
!!7 
 


/!!9   

  EE :! 

! 
  4 
 
9
:
% 0
  
!!7
   


 

  7
 

A  
/1-L

7 !!4
   A 

!
4  0
 !!

 

"

   



# 


5  3

% & 4 


9*1:7 4 
9*1 : ! 
9# #1 : 

6 4 


9*1:   4 
9*1 :)
 
   (
  7
  

 0

 
 49+/)

   M 7
:6

  4
 (


#2 - 7  &  3


6)

   4/0
(4 
9*17*1 :
A  
&  4 
 
9*1: 
4 
 
9*1 : 4
 ! 9# #1 :



 !
!


 
 !!
 ; 
 &
4  0  ! ! 
 (! 9# #1 :


!
A 4 )
4 
9*1:  ! 

 &0

; 


 
 
 
  !4( 4 
9*1 :
4 
 
9*1:40

 7!! 0  !


 A 
 
!!
/

*1 # #1

*1

')

  4 




# 


#2# ) 5'


  9. 11: 
  )

)9.1#1:)(

 0
 0
 0!)

   
 (4 !!
 !! 4! 

 
 BG"
 ! !! "  
 
 EE 
 @(9. 11: 
   !!(
 ( 

9.1#1:
$ @!
  
 91-:(
 4 &(  /
!
4 
# 
  
 91,:  (
 
9,:  
 91-:
"  
 
*    
! 9 1:  
 BG

 7 )&  
 91-: 04
4 
 !

9
:4 (
, '  
 91-:  (
  
9,:7  9# :

! 9 1:  (
  A 
! 9 1:  
 
(

 40&0  9 1:!(
 

 4
-  
9

: 
 91-: 4
 7(  
9 1:(
 
 
! 9 1: 

 91*:A !  

! 9 1:  9 1:
. &  
 91-: 0  
 4 
9
:





$
$
#

&
   
 


$
# 


#2% 1 ? .@
% &
 4(  +/!

4  (
!G11
A    4

 ( 6 /
!

4 
 (
!
/7
( 



+&  


 0    (
 
 (
4




91*:7"
  91,: %
 91-:76! 9 1:7! 
9# #1N1 :7%
 ;'
 9#1 :

% & 
 
!

% & ! ! 
 
 
!
(
 
A 

  /11 A 
!0 7!4 0  A    
/1-T9!

 
 :6 4 !  
 004 

A !!
  4!     A 
 
 
(8

  
 

 (0   !4(
 
  !
(40
   ! 4
A  
 &(
  (JA5 J ! !
! 07
(
  



4  
 ; 
 ! 

   
 7




4(!
44

 

A  

 3
!
 

 

   (0
0
 

 !



 
 %
 
! 



 


%
 

 




  
 

B 

 40
 

  / 
 


 4 &7
( ! 
 !



#
# 


A  
 91-:3
!!(
 (4 
 (
 9#1 1 :
>/
 (
 !
( &  !
A 
 !!
/

A (
 ! 04)


(

 /!

4  


A 

 40

  48  
(!

 !!

6  / / 



 A 
 !!
/((
!4
)4
 J)(J 

A8 $'(
  
 (
 9#1 :

   
 (
  
&
   9

:
  (
E(
 
 49
  
 &


:
  ( 
! 9 1:
 
 
  


74
 
  
0
6

 !
4  
$ %     
  (
! (
 9

!!
4 :
 
 J(J !A 
 !!
/

4
 
 (
 7 U11$
# 
  
 91-:

 91*:(
 

 (
 
 

 (
 

 
 

%
 (
  






  
 (
 

-  


   
82 ) 

&  

 
 ! 
  
 ! 
 
   
%
 ;
 N6! & 1 1# 1 1# #
%
 ;
 N6! 
 9
!!
4 : )) 1$ )) 1*
"
N   1# 1$ 1# # 1*
 4 9
!!
4 :N   )) 1$# )) 1*,#
%4 
 
N!  1 1 1$# 1$#


 N!    - -


*
# 


#2( 5  -




 (!)

 /

 7 4
0
 04 

+/
!

4 
 4 
#


&' 1  1 ' &2

&' 1 

 1 
12

=
.  .
 6&0
 7! 9# #1:  
( !
 9# $1:  (
 5
 

=
#  ..
 
!! 9# #1:  7
&07
! !
 
9# $1:  
/
40

!9. 1:

= 
 6&07  9# $1:  7
(
  

!9. :

=
.  
 6&0!
  4
 9 1:!
  4  (

 ! 


+  

&' 1 

 1 
12

=
#  
 6&0
 
! 9 1N :
 9 1:

=
.  
$ 
! 
!     (
    
 

3A 
!! 9# #1 :4 
 
9*1:
(
 5)
 


,
# 


=
.  .
# (   9# $1 :  

% &  /
 
  

V4(
 
! 9 1:! 
9# #1:L  04(! 9# #1: !
 
9# $1:W
16074

 40
 !! 
9# #1:

=
#  
* 
!!
 9#1$1:  7
!

 9#1:
   

 

 40

 9#1#1:% &  
/
  4(
! 9 1:! 
1
E*#
111
E #
* 6&0
 9 1:7 !
 9# $1 :(
 5
 
/

40

!9. 1:
BG
6 !!(
   !

7
!! 9# #1:
  A 
&07
! 4
 ! 9-$:! 9# #1$:
  7
 (
  4
 9. 11-:

=
.  
, 0
4 
    4 & 
! 7
  74 
 
4
 A /
!

4 
11
- A !4
 
 7!
 4 0
 !!


-
% 

&'

% 

&'
%2 

&  )
4  !!
(
 

 !
% 
 



 !(
  !


44 07 !!

  (
% & 1)
 
  (

0

BG
 (0
5)
 4
 4 0(
 

 
7

4 (
 
!0(B
05)
 

%2 ) 


4 07 /
    J>J  
 91-: 


! 9 1:  9# :0

   4
!  040

    9# : >M> 9
:

6)

 
07       4 


 
 
 A !

4 

4 ! ! 


11#
1-
>

>
#  1
+
   

% & /
   !9/:4
  9
:
/M1"$1)111#" #
C =/=4440

 9
3
: ! 9# #1:7


E$1#17 ! 9# #1 :

E*# #
1

"   #  #


.
% 

&'

&  )
 % 9 1:(
  04
 !


!!
3


=
.  .
 6&0
 6! 7
!! 9# #1:  7

   9# $1:  (
 1
 9$ 1#: 
  
'4
 N  ( 

=
#  ..
 
!! 9# #1: 

  7
&07
! 
!
 9# $1:
(
  


!9. 1:% & /
 
 4(    ! 9# #1:7(
   4
1
07
  44
 40

  ! 

= 
 &0 

  7
!  !
 9# $1:

40

!9. 1:% &  /
  4(
 !
 9# $1:    7(
   411

=
.  .
 
! 
 
!   9# :   
  

7
  


 91*:

=
#  
 6&0
 
! 7
!
! 9 1N :  9# :
  
  
7
  


 91*:


1
% 

&'

=
.  
 6
9,1:
 
 91-:7
5
 9$ 1:X" #(

4(
 5
 Y
 4  !)4  
 

 91*:
$ 4  43 7
 
37
 /! 

4>  
 
! 7   
 7  
(
 1
 
 @!
  
 

4 0
# 4 0  7 &  /
 ! 07U 7 7(
 
  4
#

 

A /
 ! 0

* 6
  
9,1 :

  
 91,:
, 4 
  
 V(
 
9,1 :(
 9# :W  

   X" #
(
 (
 Y
- 
! ( 9##11: 

9.1#1:7(  /
9. 11:! 
!



 
 
7
 


 
 


. 5 
  
7  ( (
  04
 !


 9. 11:40 
  !)!
 ))   
 91-:
1  !!
4! 7
  !!   4! 
 A
 9. 11: 
  
 
9.1#1:404



! ! 4
  
 
J<AJ@(
  

 43 0
 40 
  
!+& 
 !
 

 0
 
40 

 !4
  
 



% 

&'

%2   5  3


=
.  
 6&9$111:75
 9$ 1-:
   4 
 
7

4 
 
9*1 :

  
 91,:
 0


(9.$1:

=
.  .

 
!! 9# #1 :  

4
 6&0! 4 
 
9*1:  

4 
!
 9# #1 :
$ (  9# $1 :  (
 1
 9$ 1#:  9 1:


'4 
)  ) ( !
 0

=
#  
 65
 9$ 1:7
!! 9# #1 :  

4 

 
! A &0 
    
 &0(0! 
9# #1 :
 65
 9$ 1:
  4 
 
9*1:6 &0
  
&0(0
!4 
 
  

4 
! 
9# #1 :
 + !
 9#1$1:
(
 
J8
'!

J
$ 
!!
 9#1$1:  7
!

 9#1:
   7

!

 9#1#1:



 ( 


J% &
  4 
 
(
 4 
 
&J

# $111

*1 *1 # #1

#1#1 #1$1 $ 1- #1# #1$1 $ 1 $ 1, #$1

*1 # *1 $111 # #1 #1 $ 1 #1 *1 # # #1 *1

!
E$1#1
E !
E*#11
E !
E ##1



% 

&'

%2  6  5  3  5 !6


)

  4 


 (!9*17*1 :0
 &(
 4 
 
&

% /
  4 
9*1:
 0(
 4 
 
&A  0
  /
  4 
 
9*1 :

4  4 


7 !
  7 
 4
 

4

" B

"
 5)
 

 ( 0 !
 
( 



A !  4&( 


   !!
  
!! 4 
9*1 :

A  4 


 
  4
!
 
4 
 
&

  N$


67 4 


 
9*1 :4)
 
&  4
!



% 

&'

%2 C
  -
A 
7
   
  !  40A
7
4 
 
9*1 :7  (
 5)
 9$ 1-:


  
 
91,:(
  &9$111:



 (
   !!7

4 
 
 7
 

4&( 
9
:

 A
!

4 
  (   
(
  (G

;
 ;
 
!
E 


 
 8  2
$111 1 #
 # 1 #

'!



- C
 
+
JJ(4 
 
9*1 : 4
 6! 9
:
A  
J4J (4 
 
9*1:X

 


Y ! 9# #1 :
+
! 9# #1 : 
M4

=
.  .
 ( 




,

=
#  
+
!
 9#1$:7&
 
!
 ! 
! 

7
40(
 (
!
/
  17!!
E*#)11
1
E #74(!

 9#1:!
 9#1$:
A 

4 ! ! 
 /11 
'J+
   
 "
J
*1 *1


*1 # #1
'87
JJ '87
J4J


$
% 

&'

%2# +  1   9  &


 :

%2#2  )6


=
.  .
 +
 4/ 
 9$#:
 
   &9$111:

=
#  
 6&0
! !
 9# $1:  (
 5)
 9$ 1#:
  A  
 4/ 
 9$#:
 
   &9$111:

=
.  
 65)
 9$ 1$:+
 9*#:
 
   &9$111 :

 4/ 
 
!
 4/ 9$# :  !
 74



 
 4/!
$ 
!!  
 9#1,:  

A 
 4/  4!&84 


 7 
 


%2#2         


9 %
 (
 + 
  !!!
!4:

 

 /
 9$#: 
N"
  
 
 
%
 %9*#: 
 /
 
  &9#: 
 /
 
$ 
 
  
   
    

/
 
# A
 (
/  
 /
 
* A
(9.:
 9-:  
,  /4 9 :
 

 ( 9:(  
  9:7 
(

(
  
 !
A
 /4 9 : & 

 ( 
 !


- 
!!  
   

" $(
 7! 
*


#
% 

&'

%2%   5 

V !(
 ! 
4
 7

(
 


4
 W
 + 4  4
  
 9#11:
 A(

 4
   9,1:4( 9 1:4
  
 + 
!
  4(
  
 ! 

 '
 9
J'

  'J:
$ +!4
   9,1:7 40
 
 9$ :74
 9*:
!  4
  
 
# 5
  
!9$#:  &9$111,: 4
 

 9#11 :
* + 4
  
 9#$:  (
  &9$111*:!A 
!
 4
 0 ! 0


 
, 
!! 9# #1:  9 1:

4
- 64
 9 1:
 

 9#1#1 :(
  

  
7
4  !

4 !!!/-1R%
!4 
 
  9# *:
. %0  !
 

   )3
1Z)
(
  4 
 N4 
 


. +

JJ7 !  4
  
 9#$: 
!
 
.  +

J4J7     

 
. A(
 44 0
  (
 4
 

 7  
(
 &09.$1:  7

4 
 ! 9# #1:
 A 

 44 0 47(

  
4
  
 
.$ +

J%J  4
  
 

 
.#   !
    (
4M)94U:L(
   43 
1Z16



  4&9JJ: 

 
 9==J: !   4

1


JKJ

A
  41Z1
4
"

JJ 4
 9*:! 


%  A  
& &43 JJ)91Z1



 :6


7 4
 

 4

 0
%
  !

'
 "
 
  7  (
 4
 
 44 06!
 9.#1:
 
44 04
  (
 4
 7 
    7

4 
! 6&0
! 9.$1:
 +!



7

 


  
% 9* :

4 9* $:L 4
 
 


% & &
  

9* :(
  
4 
 
9*1:4
  
 
4 
 
9*1 :L
07
4(&
 
  

9J' 

6
J:


*
% 

&'

%2( 
 !
 (
 ! 
 !!
9
:

; !
4 7!
 

!  !
 9
:

A !
  4( (7  

4  
 ! 
4(-1R%11R%

!
 (
 ! 


  !
  4 +
  !
  4



64!
4  0
 !
  4/
 0(
 7(  
!!
!!6!
 (
 

 7 /
 
4
 &(
  

 


 4! 
7 3
07 4

   
   


,
% 

&'

%2*   1  <3 


! 
  
 
(&7
 !!
 
!
 (
 
 

!
=

   !"
=%0


  40

 
4( !!4! 


/
; 
!



! 


4 &

 8!!9/! :   





   !
!(& &
  
=


9(
 
 !!
:) &
> 
 
 

 
! ! 

0    1  1


  &


 
A
! 
  
 0440!!
 

 0(
 
A
! !  09 &:7
   

 

 
A
! 
 
 
 
  &A 


 ( 
E 0 4! 400

 !


! 
 
7
 !
 !'
J"(
   !J


/
; 
!
%0

 !




! 

"(
  !!9
:


-
% 

&'

%2 . -
  -9 !(
 ! 
4
 :
A
 & 04
 !!
  ((
  
!
  4  A ! !!EE   
/#1R%

" $
'

  ! !  4
  
 

40 (=
)@!=60

 4(!!
!!
 7(

 !

4 

7 4

   &
 
!7   

 ! !   4
  
 
4
40    


  

"
 


 4&

"
 


"
   



  


  


 
 9 1: 

  (
  

=E=!

9 =E=!

 
!

( 4 
 4
 
 40
 
  4A 

  
 
=E=
!

:A 
 44
   9,1: 

  
 !!7 
  

 !

 
 

!(
   

 ! 4
  
 %
0

408
  4
  
 A
 4 4
 

 0 !

8
  
8
 (

A    4 &


40( 
(

 44
   9,1:A 


 
 
 
44

 
( &A 4
   4


0
  

(
  
( (
  4
 

  
(0
 4
 

 
4
40 8( 4
  
 
  
  
E ! 
(0
4
 
4
( 

!
4 (
 44
   
 (
 


4( 9 1:4  4
  
 

')
8(

 ! 4


') & 



  


.
(  )

(  )

; 
 !!7 (03 !4(&
 4A 

 4
 ( ! 
  !!! 
; 
 !!4!!
7! C"+
$ .*

 (
 4 
! 
!!!
4

0 7
! %
 "(
 
%! !
 

MB 

) "2 ) 


 9' - 6

1  (
 <0 
1 6!  
 1   % 
 
 %0 '  (
 !  !(
 
 
,1 
   !(
  
 
$11 & 
$ 5)'
 
$ + 
  !  !(
 + 
$*   &
  !(
  !&
#1 !
'
  
E*#) #
#1 ;
 '
 
#1 6! '
  6!!
4 
#1$ !'
  
E*#) #
#1# '
'
  
E*#) #
#1# '
'
 
# 1    
E*#) #
#     )
# N    !(
 + 
# $N   
  !(
   &
# # !   
E$1)11
# # !  
# # !  
#$   ) 6!!
4 
*1  
 "
 
*1 % 
 "
 
.  %

! 
E*#)11
.#1 !
 


$1
* +
, 

, -  '

* +

+ - 1   &  


7 -  '
!




3
 7 77$7#7*7,7-7.7177 -
"
  7 77$7#7 7 ,7 -
>/
 0
!!
  ! #

  
 7 7 $7 #7 *
! & *7 .
>/
   &  ,7-7.7 17 7 7 
' !!
 7*77 7 7 7 #7177
>/
!


 !! 7*7
3
04 
3

 7*77 $7


$
* +
, 

, -  '


7 -  ' @
 A !! /
 0


 !
 ) 5!
    
 0!


 4

 >/
 0
4&!
 ) 
  
! 9: :
 ) % &
 



 A !!N!
!
 
!  0!

 ) C!
 !!!
!
 !  0
$ 


! 9:  
 ) '!

 !!N!
!

# 

!&
 !
!

 )  !
!
  0
 ) 607
 
* B 
4 
 (9!


 
 
:% &
3
  



 5!
 
  


 0
  


07
 

 
 

/

% &



 +&  !

4 !
/
, >/
 0



 % 

4&
!
!

 ) % &
3
  
 !
7
0
 )   


- 6 
   
 4/
 ) 
( 
. '

 ) %  (!  !(!! 04 
1 '
 !
 ( ::
 ) 6!
 ) 6  
 >/
( !!
 
 ) '! (!40(
  !4&!
 ( !


 ! 
 ) 80!
 040 
 
  
 
  

 ) 6!
 
 7
 
! 9:
0 :
 !

 
0

0  
!!

  !


 
! 
 ) :
$  

&(
 ) %

# >/

 !
 ) ::
* "

 ) '(
, ; 
 ) % &

  (

0
- 
 7&   
 ) 
( !
  
. &
 
3
   
 
3
!
 6  (
 
3

 %  
 
3

 
 %  
 !


$
* +
, 

, -  '

1  7 ! 


 0
7( !&
 


 ) '0  
 A !!

0
 % 



 % &
!!

0
 ')4  !!
 6 
!!!
EE 
 !


 ) % &
!
 
 
0
 A !!
(!
 ) % &!
!
 
!!
/
 4 
$ >/
/
   :
 ) 
(
 (
 
# A 7
 7
4  4

 ) '3
0!! 4
7  (
 
4  4

* A !

!
  ! 4


 ) !
  !
(
   
 
! 
, 5!
   
 (
- A 

 (!  0
 ) '!  

 ) % & 
 

. A 
 4  &
 ) A
 4 
 ) 
( &7
3

1 A 
4 
 ) %  
 ) ')4  0
 0
 "
4
 
 ) 
(4
 
  6

 (
 ) 6 

 (
 % &4 
3

  
)
7/
!!7
4

 
  !!7 
 4 

74
(4 

 ) % &
  !!
 ) % &

 ) % &!!!
 ) % & 4 
 


: A !!  4!) 4!


 0 
!
!
: <
: A
  440
0
  
! 



$
. / 0 

. / 0 


2. 0<- A
 3&<(&  !! 
 4()$ (7 (
 !
4&(


  !!

 A !!  4
 7(
 
73
!!(
 

!
7 & 7(!  !   A 
!!  4!
7 7



0 4

  6
 !!

 !&
 4/7!&!!
7
(&7 4/  
)
(4


!!
  *J4  
 6
 !!

!&

7
  4(
 
*
91#:
& ! 0 0  (
   4
/

(
L  4(
 



 
$ A 
7
   
4 &(

!
  
!!(&" 4 &% !
7
0740

4 &
   40)$ 7

 

7 (
 



43
4&
  A !&
 4/4!7
!
7
4
  
 
 !!(
 !! 

4

 
!   4
 
07


 4
  !
   4
7 
   !
!
 7
!
74 &
 7
 
3
7
(
 !


  A !!EE (
 4 &(
 !  
4
4!
!!/N J& !! 

4

 0 9 

 :7!&

  4 4!
 !!EE 
4
4
! 4&9;
4
74    :
 $  (
 !

 &3
4!

!  ) '  6

C!!  >0  % &


 4 
EE 


4

 0   ! 
 
  >0  '
  -1 

  
   

/ "

 
 
  
      (
 !! 

4


  !

6   
  4 &
6   

/ % &
    EE !
 
 !!   
  
4 7/!
  
  
%!
   

/ % &
 

  
>/    
/ % &
  !
7
 !!   
  
+ 
   >0*  A !
 
  4
8
 ! 

0
      

  !
!
 
!& >0*  % 
0
4 

 4/ ! 

0  !  4 &


$$
. / 0 

2. ) 
& 1 !
  


 ' !!

 
!
  !!(&
 
 
% & !!  06
0
7! 
%
"!<
 ;
&
 ! ! 
 7 N!&N 7
  4

  
   4(  / 7
 
! !9<N"
 NA
:
   /

0!
!
 7( 
 
 7  4
 
!


$ /

0!
!
 
 
   4  (
 ! !7
 
 
   4 

#   4
   44  
 4
  
 
*   4
   4 7 &! 7 
 0  4

 4
  
 

2.  1 



 

 8
7
&
N!
 N 4/N! N
 7
4
 0=
4 (
 A  

 !
!
 N

N 

!
!
 N
 7  0 !!
 
7
 

!
!

7 (
4&  (
  !

 !!
 (7
 !!
 7   4
!
  !
 ;

!
  !(  !843 !! 0
!&74!&
 A !&
    0
!4
 0
!!&7
  
 7
( &4 
 !

  0 
 



! !!>/!

4 
(
  
 
(  
 44!7 &
 !%
 
 0!!!0
!!
(
 !!
 9(
 
!
! !!/! 4 :7(
 
!!

 4 


7 !  (
   !
 

A  
!!
  
  


!  
!!
$ A 
   !!!!
(
 0A A& "

 N
4 0!!!A   0!


3
  
 7   4
  
 
0
0
4 
 



$#
. / 0 

/  
)D) 0E)A A-!/ "<2
D0<A- !0A "<2

"2 A-!)0!<" D"!0 -A!"


)-AD-A 0
) 
EE  & N

 ) "

 

 & N

 ) 
  EE  & N
 )  
 
 & N
) 5

 4
 9
 4

:
# 

4
 & N

# "
  
4
 & N
# 
NA 4
 & N

0A)A-0D-A 0
# ) 
EE  " %
% ) "
  EE  " %
( )  
 
 " %
* ) 5 

. 

 " %
. "
  
 " %
. 
NA  " %
. < ! 4
 9
 4

:
1 

 " %
1 "
  
 " %
1 
NA  " %
+
 :
   )
 " %
   )"
   " %
 ;  !   < 
 
 " %
$ "
   " %
# 
NA  " %

 -<0<- )<!0!<"

 !
 '+C 
0
F!5-0!<" 0 
!&!&: N
 C   C 
 

4
  

 "
  
4
  

 
NA 4
  

$ 
  
# "
    
* 

!!
, "
  
!!
- 
M
E L CMC
 L M/
 

"A>NA6+> 6BA@'>55 >'A5'


$*
. / 0 

)   )


  <  5   /&  6
3'

   


9;
 !!
4 : 
 B/
! 11 -111

 
 ( 

0
! [
  &

! [
+ 
 
%!
 \ 

[]
[M5 0
 
M6/
 &   
\M'+=+
]M69
:

4
L9

:'
   
 L9

:'
 ! 4
 L
9
: 
M69
:

4
L9

:
4
 !L9

:






)  3


 )

  &
 & \
0' 1 

"

  
!%



 '


5
N; (
' 


A!

C
4

A



5

& 
" 

B


  

! ; ; [ [   ;



BEE   
"
  BEE   


 
+
 (0! 
 
 &  
  ' ' 

 
 ' '     ;
 
 6    
4
6    
%
 6    
%!
 ' '

[  8
 M5

\!!
4  0
 !&!! ;M5;&
+M5+
'M6!



$,
. 11$ $1$ $1
* $ $111- #1#1 .111 .1 1$ .11$ 1* 1 .11 $ 
,1 ##11
. 11. .$1 ,1 $1 . 11 . 11
*  *  1 # #1 $111* $# #*1 .1 1. , .11 .1#1 # $1 .1 1 #*1 .11.
.$11* $ 1- .$11$ $1.


$111, $ 1 $1 *-
*- .11 .$11 #$ .#1 .$1 *$$ #1, $ 1$ 1, $ $ 1 .$11# ,1 #  1- .11 $111 .11# . .$11

1

A


% %

(5 (5
2    1
=
.  .

#5 %A
    /
 1  

.1
$

,1 $ $111$ .11- $# $* $# *1 $111 .$11 .11
    /
 1  

.1 $1- $1


*- # * .11 #11 $ 1# #*11 *# # $1 # # #1 #1 # #1 #11
. 11
*$ 1 *1 ##11 $111 *1
$*
.1$ *$ 1-1 1-1 1-1 %5BB>%A65BG
$$ .1 +
'>@'>@>)N J @>"
$ .1 1,
. 11, $
B%6B625@A>A)N-J
##11, $>
N J @>"
$    1 . - , * # $   *
%6B"'6B )N-J @>"
-
><>"'6B )N J
#* 1 ,>N, %556B;A>'6BN5@A)N J @>"
.11
-.*

$-
    /
 1  

/
 1  

) "2 ) " ) "2 ) " ) "2 ) "
1* 

 # #1 !  .$11# <0
1, "
  
 # #1 !  .$11* <0
1-  
 G'

 # * %
   .#1 !

1-1  
   ##11 ; 
1-1 A! 
 ##11, ; 
1-1 A! 
 ##11 ; 
$# ! #*11 A!!

*1 % #*1   !

*# %
  #*1   !

,1 "
 #*1   !

,1 "
   *1  
 

1   *1 %4 
 

1 6!  *   


 1   4 4
 * $ 6

#11 
  
 *- %  

#11 
  
 *$ 5
  
 
#$ A 4
  
 *$ 1 5
  
 
* 
  *$$ 4

 

,1 
   *- 
$111 & , 3 ! 
$111 & ,1 >/
!

$111 & -.* 
!

$111$ & .111 (
$111* & .11 /4 9  :
$111, & .11 /4 9  :
$111- & .11# /4 9  :
$1 
 
 .1 1 
$1 
 
 .1 1$ 
$1 
 
 .1 1, 
$1$ 
 
 .1 1. 
$1- 
 
 .11 / ! 
$1. 
 
 .11 / ! 
$1 
 
 .11 / ! 
$ 
 
 .11$ / ! 
$ 
 
 .11- / ! 
$ 
 
 .11. / ! 
$$ 
 
 .11 / ! 
$* 
 
 .1 / ! 
$ 1 5)
 .1 / ! 
$ 1 5)
 .1 / ! 
$ 1$ 5)
 .1$ / ! 
$ 1# 5)
 .1#1 A

$ 1- 5)
 . C! 
$  40
 
 .$1 /
!(
$# 
 4/ 
 .$1 / !(
$# 
 4/  . 11 /
$*  !&
 . 11 /
#1 ;
 
 . 11$ /
#1#1 '

 
 . 11, /
#1, !  
 . 11. /
# ;
 . 11 /
#     .$11 <0
# $1N1  !
  .$11 <0
# #1 !  .$11$ <0


$.
.1 ,1 ,
$ #11 #*1 , $#
.$1 .1#
*1 $> . 11.
$# .1 1$ $ 1* .11 .1 1.
* $ .  1 $111, . 11$ $ 1 1- $1 1* $* $#
$
$* + *# "
$$ .111 .1 .11 .$1
*- .$11 $ .1* *1 ,1 ,1 #1 # #1 $111 .
.1$ .#1 $1
+
" #*1 .11$ , .1 1 ,1
*- *  .11 #$ . $  $1$ 1, $ 1 $111 , . 11 #*1

$ 1


$ 1-

.11
$1
*-

(5 (5

#5 #5

$111- $111* *1 .11 #1, ,> .$11- # .$11* #  1 .11 ,> $# . .11$ .$11
$111$ $1 , $1 ,
    /
 1  

*- $ 1$
# $1
2    1
=
# , (.  ..

# * # #1 *$ .11. $ 1# .11# #1 $111 .$11# ##11 # $1  *$$ 1
.11- $1. $1# . 11 $ 1#
$1-
* #1#1 .$1$ .11, .11- $ 1$ #1#1 #1$1 # #1 .1#1 .$11, #*11 #1, #11
$1, $1- $ 1, . 11
$,  ##11
$ 1- .$11$
.1,
1-1
1-1

.1 1, @%5BB>%A65BG
. 11, + '>@'>@> )N J @>"
##11, $ B%>6B62@6"6B> )N J
. - , * # $   $> B%>6B62@6"6B> )N J
#*1 * %6B"'6B )N-J @>"
- ><>"'6B )N J
.11 ,>N, %556B62@6"N5@A>A)N J
56"'6B )N$J @>"
1-1
" C>BA )N J @>"

#1
-.*
    /
 1  

/
 1  

) "2 ) " ) "2 ) " ) "2 ) "
1* 

 #1 !

 . C! 
1, "
  
 #1 ;
 
 .$1 /A
!(
1-  
 G'

 #1$1 !
 .$1 / !(
1-1  
   #1#1 '

 
 .$1$ / !(
1-1 A! 
 #1#1 '

 
 . 11 /
1-1 A! 
 #1, !  
 . 11 /
$# ! # ;
 . 11$ /
*1 % #     . 11, /
*# %
  # $1N1  !
  . 11. /
,1 "
 # #1 !  . 11 /
,1 "
   # #1 !  . %

!9 :
1   # #1 !  .$11 <0
1 6!  # * %
   .$11 <0
 1   4 4
 ##11 ;  .$11$ <0
#11 
  
 ##11, ;  .$11# <0
#11 
  
 ##11 ;  .$11* <0
#$ A 4
  
 #*11 A!!
 .$11, <0
* 
  #*1   !
 .$11- <0
,1 
   #*1   !
 .#1 !

$111 & #*1  !

$111 & *1  
 

$111 & *1 %4 
 

$111$ & *   


$111* & * $ 6

$111, & *- %  

$111- & *$ 5
  
 
$1 
 
 *$$ 4

 

$1 
 
 *- 
$1 
 
 , 3 ! 
$1$ 
 
 -.* 
!

$1# 
 
 .111 (
$1, 
 
 .11 /4 9  :
$1- 
 
 .11 /4 9  :
$1. 
 
 .11$ /4 9  :
$1 
 
 .1 1 
$ 
 
 .1 1$ 
$ 
 
 .1 1, 
$ 
 
 .1 1. 
$$ 
 
 .11 / ! 
$# 
 
 .11 / ! 
$* 
 
 .11 / ! 
$, 
 
 .11$ / ! 
$ 1 5)
 .11# / ! 
$ 1 5)
 .11, / ! 
$ 1 5)
 .11- / ! 
$ 1$ 5)
 .11. / ! 
$ 1# 5)
 .11 / ! 
$ 1* 5)
 .1 / ! 
$ 1, 5)
 .1 / ! 
$ 1- 5)
 .1$ / ! 
$  40
 
 .1# / ! 
$# 
 4/ 
 .1* / ! 
$# 
 4/  .1, / ! 
$*  !&
 .1#1 A



#
.1#
$#
,-1 #*1 $1$ $1 .1 1.
* $ .$11 $* *$$ $  $# $ 1$ .11$ $ 1 ,1 ,1 .11 # #1 . 11. . #*1 1
.11#
*- .1, $111, . 11$ $1 .11. #*1
-* $,  1 $# . #1, .$11, .1 1$ #1 1, .$11# $ 1 #  .11 $111 .$1 $ 1# $1. $  .$11
##$1
. .111 $1* .111 . 11 . 11
*  ,-1 #$ .#1 ,1 #*1 .$1$ #1$1 .11* .$1 #$1 $ 1- .$11 1* .1#1 .$1$ .1 1 #1, ,1

A






*-
% %

(5 (5
2    1
= 

5 5

%A %A
#5 #5
    /
 1  

# * # #1 .$1 .1 # $1 $* #1#1 # *1 # #1 $ 1 .11


$ . 1 $1 .1 .1
$ $
* #1#1 $111* .11 .11- .1$ #*1 $111 $# *1 $ 1, 1- #$ #1  *$
$1- $$ . 1 , # $1 #11
##1
*- $111- $111$ *1 #11 *# .11# $111 .$11$ 1 .$11* $ 1$ .1
$1# $
1-1 1-1 1-1

.1 1, %5BB>%A65BG
. 11, + '>@'>@> )N J @>"
##11, $ B%6B62@6"6B> )J
, * # $   $> B%6B62@6"6B> )J
#*1 * %6B"'6B )N-J @>"
- ><>"'6B )N J
#*11- ,>N, %556B62@6"6BN5@A )N J
##11-  56"'6B )J @>"
. 11- .11

#
-.*
    /
 1  

/
 1  

) "2 ) " ) "2 ) " ) "2 ) "
1* 

 #1$1 !
 .1 / ! 
1, "
  
 #1#1 '

 
 .1$ / ! 
1-  
 G'

 #1#1 '

 
 .1# / ! 
1-1  
   #1, !  
 .1, / ! 
1-1 A! 
 # ;
 .1#1 A

1-1 A! 
 #     . C! 
$# ! # $1N1  !
  .$1 /A
!(
*1 % # #1 !  .$1 / !(
*# %
  # #1 !  .$1 / !(
,1 "
 # #1 !  .$1$ / !(
,1 "
   # * %
   . 11 /
1   #$1  . 11 /
1 6!  #$  4 . 11$ /
 1   4 4
 ##11, ;  . 11, /
#11 
  
 ##11- ;  . 11- /
#11 
  
 ##1 ;  . 11. /
#$ A 4
  
 ##$1 (  . 1 /
* 
  #*11- A!!
 . 1 %

!9 :
,1 
   #*1 A!!
 .$11 <0
$111 & #*1   !
 .$11 <0
$111 & #*1   !
 .$11 <0
$111 & #*1   !
 .$11$ <0
$111$ & *1  
 
 .$11# <0
$111* & *1 %4 
 
 .$11* <0
$111, & *   

 .$11, <0
$111- & * $ 6
 .#1 !

$1 
 
 *- %  

$1 
 
 *$ 5
  
 
$1 
 
 *$$ 4

 

$1$ 
 
 *- 
$1# 
 
 ,-1 &+ ) 
$1* 
 
 ,-1 &+ ) 
$1- 
 
 , 3 ! 
$1. 
 
 -* >/
!

$ 
 
 -.* 


$ 
 
 .111 /&(
$ 
 
 .111 /&(
$$ 
 
 .11 /4 9  :
$# 
 
 .11 /4 9  :
$* 
 
 .11# /4 9  :
$, 
 
 .1 1 
$ 1 5)
 .1 1$ 
$ 1 5)
 .1 1, 
$ 1 5)
 .1 1. 
$ 1$ 5)
 .11 / ! 
$ 1# 5)
 .11 / ! 
$ 1, 5)
 .11 / ! 
$ 1- 5)
 .11$ / ! 
$  40
 
 .11# / ! 
$# 
 4/ 
 .11* / ! 
$# 
 4/  .11- / ! 
$*  !&
 .11. / ! 
#1 !

 .1 / ! 
#1 ;
 
 .1 / ! 


#
DEAERATOR
ARC VALVE
Series TDM
Installation- and
maintenance instructions
Content

1. Dangers and safety precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3


1.1 Danger to persons and materials . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Avoid dangers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3. Packing and marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4. Assembly and disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6


4.1 Installation at the jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2. Disassembly of the TDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Assembly of the TDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Disassembly of the bypass section . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.5 Assembly of the bypass sections. . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5. Commissioning of the TDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6. Maintenance instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7. Warranty conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

8. Instructions in case of damages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

9. Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

10. Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10.1 Sectional drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10.2 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
10.3 Datasheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2
1. Dangers and safety precautions
Minimum flow valves have the same potential danger as pressure vessels. Therefore
planning, installation, operation and maintenace shall be done according the necessary
safety precautions.

1.1 Danger to persons and materials


ƒ The minimum flow valves should only be operated within their limits of design and
layout

ƒ No changes are to be made without our approval. Only use original spare parts

ƒ Safety regulations, site regulations and installation safety precautions are to be


followed

ƒ Please follow the instructions as given in this installation-, maintenance and assembly
instructions

1.2 Avoid dangers


ƒ Maintenance of the Automatic Recirculation Valve shall only be done by trained
personnel

ƒ Before disassembly, the installation has to be shut off and the valve pressureless and
cooled down

ƒ Please make sure that these safety precautions can only be cancelled after ending the
assembly of the valve

ƒ Please be aware that also in a pressureless valve there might still be medium

ƒ Wear protective clothing

3
2. Description
The SCHROEDAHL Automatic Recirculation Valve model TDM is applied in centrifugal
pump systems in order to provide an automatic leak-off flow in case of low load condi-
tions.
The application range of the series TDM with a multistage pressure let-down section is,
independent of the temperature, for the operating pressures from 64 bar (a) to 250 bar
(a) (900 psig to 3600 psig). The valve consists of an upper and a lower housing, each
provided with a flange. The bypass housing, and as an option also the start-up housing,
are located horizontally at the side of the valve. The valve trim comprises a check valve
as also a control- and throttle section.

The valve protects centrifugal pumps, especially boiler feed pumps, against overheating,
by maintaining, automatically, a minimum flow. At flows, lower than the required mini-
mum flow the check valve activates, by means of a lever, a vortex plug. When lifted of its
seat, the vortex plug allows a flow throuh the pressure reduction section to the suction
tank (or condensate tank). The opening characteristic is linear; the bypass flow increases
when the check valve moves from its switch point further into its closing position. Becau-
se of the modulation bypass control, the total of process flow and minimum flow remains
approximately constant.
The check valve, shaped like a differential control piston and spring loaded, has such
a high own frequency, that waterhammering is avoided. The check valve dampens
pulsations because of its throttling effecton the mainflow and stabilises unstable pump
characteristics in the partial load range.
The housing is made from forged steel and is provided with a chromium steel liner in the
check valve area. All moving parts and guides consist of alloy steel which are compatible.
Alternative materials are available as options (see drawing and parts lists).

4
3. Packing and marking
The Automatic Recirculation Valve is shipped, depending on size, in an aluminium box
(reusable), skid-carton or in a wooden crate.
The standard factory conservation is sufficient to protect the valve for a period of approx.
6 month (the stocking area should be dry and ventilated).
If special packing or conservation is required, this should be stated with the order. The
valve nameplate is attached to every valve housing. Specific valve data are indicated on
the valve nameplate as per sample below.

Fax:02265/9927927

If spare parts are required, the following valve data should be provided with the inquiry
(order):
production number K ........ (stamped in valve body), valve model number and part
number (check parts list).

5
4. Assembly and disassembly
The Automatic Recirculation Valve type TDM is usually installed vertically, with the
mainflow upward, and directly on the pump discharge flange. The bypass housing is
connected to the bypass piping (and the piping consequently to the feedwater tank or
other tank), so that a recirculation flow will be possible. Other installation positions of
the valve (horizontal, upside-down) are possible, if so ordered only! No special tools are
required for the installation, assembly or disassembly of the valve.

4.1 Installation at the jobsite


In order to prevent damage to the flange finish and / or the bolts the complete valve
should be installed in the piping free of tension / stress. Before tightening the bolts
with a torque wrench (torques as recommended by the factory!), please ensure that the
machined flange surfaces and packing rings are clean.

4.2. Disassembly of the TDM


ƒ Remove the TDM from the piping system

ƒ Disassemble the bypass housing (pos. 09). Pull the bypass trim „M“ out of the
assembly (careful!)

ƒ Apply a screwdriver between the collar of the control head (pos. 11) and the valve
body (pos.01)

ƒ Remove the upper body (pos.02) from the lower body (pos.01) by loosening the
hexagon nuts (pos. 28)

ƒ The check valve (pos.07) and spring (pos.06) can now be removedfrom the lower
body (pos.01)

ƒ Clean all parts and check for any damages

ƒ In case of damaged seats (check valve seat or bypass seat), this should be repaired
by lapping the respective parts on the seats. Replace ring (pos.30) if required

6
4.3 Assembly of the TDM
ƒ Replace the check valve (pos.07) with the spring (pos.06) in the lower body (pos.01)

ƒ Now the upper body (pos.02) is placed on the lower body (pos.01) and the hexagon nuts
(pos. 28) are tightened (check cross sectional drawing!)

ƒ Carefully insert the bypass section „M“ in the valve body and ensure that the lever (pos. 13)
fits (slides) in the slot in the check valve (pos.07)

ƒ The bypass housing (pos.09) with the bypass orifice (pos. 23, 31, 36-38) is now carefully
replaced and tightened to the housing (pos.01) with the hexagon nuts (pos. 29)

4.4 Disassembly of the bypass section


Occasionally, and because of contamination of the fluid, a complete disassembly of the bypass
trim may be required. At each inspection the bypass should be checked for proper operation.
In case of damages, the bypass section should be removed, disassembled and the damaged
parts replaced.
Inspection:
ƒ Check the seating of the vortex plug (pos. 12) and the vortex bushing (pos.10) for any
damages

ƒ When damaged the vortex plug and vortex bushing should be replaced as an unit

ƒ Check glyd-rings pos. 33.1, 34.1 and 35.1 for any damages

Note:
ƒ In case of doubt the complete bypass assembly (pos. 10-16, 21, 23, 31-36) may be
replaced and the disassembled bypass may be send to the factory for repair

ƒ Replace the complete seal set

7
4.5 Assembly of the bypass sections
Proceed in the reverse order as per disassembly instruction above.

5. Commissioning of the TDM


The valve is commissioned together with the pump. When the mainshut-off valve in the
pump discharge piping (to the boiler or process) the specified bypass flow is maintained
through the bypass section (and to the piping of the bypass system). By closing or ope-
ning the main shut-off valve, the opening and closing of the bypass can be checked.
The switch point of the valve can be established acoustically (use a technical stetho-
scope or even a screwdriver to the ear will do). In case a manual start-up connection is
provided on the valve, the minimum flow is achieved through this section.The automatic
bypass is closed during commissioning and the manualstart-up is opened. The automatic
bypass section is spared (protected) during commissioning in this way, as the fluid might
still be contaminated and/ or carry solids!

6. Maintenance instructions
The TDM has been designed in a special way so that no special maintenance is required.
Maintenance is restricted to cleaning the trim together with the pumpat regular intervals.
After disassembly of the valve, all seals should be replaced(by new seals) before re-
assembly of the valve.

7. Warranty conditions
If no special conditions have been agreed upon the order, the warranty is limited to 24
months after shipment or 8000 hours of operation. The warranty does not include dama-
ges caused by improper handling,dirt in the system or normal wear.

8
8. Instructions in case of damages
In order to judge the damages (and the cause), the following information is required:

1) The production number of the valve


i.e. K..-.... (Year of manufacturing / production no.)
2) Valve model type and size e.g. TDM DN..., PN...
3) A description of the system in which the valve is installed
4) Please use the datasheet, page 14, for communication of loaddata information

9. Customer service
In case information is required, or in case of breakdown, the following organisation
can be addressed:
SCHROEDAHL-Arapp SCHROEDAHL International Corp.
Spezialarmaturen GmbH & Co. KG 2400 Augusta Dr., Suite 285
Sales international dept. Houston, Texas 77057
Schoenenbacher Str. 4 USA
51580 Reichshof-Mittelagger
Germany Phone: 001-713-975-8351
Fax: 001-713-780-0421
Phone: +49 2265 9927-0
Fax: +49 2265 9927-927

9
SCHROEDAHL offers advise, delivery, installation, commissioning, maintenance, repair
and modification. Our customers are offered an extensive customer service, which is
worldwide available, 24 hours a day.
Quality assurance of SCHROEDAHL valves is made according to the high quality require-
ments of German and international quality authorities.
We fulfill all requirements acc. DIN, UVV, VdTÜV, ADStandards, TRD and all international
standards as ASME as well as DIN ISO 9001/EN29001.

Besides the Automatic Recirculation Valves we also have the following products
in our programme:
ƒ Control valves for powerplants and industrial applications

ƒ Desuperheaters

ƒ Strainers

ƒ Adjustable pressure regulating valves for pressure reduction

ƒ Flow actuated control valves for various applications

10
10. Attachments

10.1 Sectional drawing


P = pump end
R = pipeline end
B = by-pass end
Installation P- R vertical

R 02
03 40
26 04
28 41
06 08
30
34 33 35
07.1 34.1 25 33.1 35.1 12 10 36 23 09
07
07.2

01
42
B
03.1
13 14 11 16 15 21 31 32 29 27

11
10.2 Parts list
Housing
Material Recommended
Pos. Description Spare parts
CS SS
01 Lower body 1.0460 1.4404
02 Upper body 1.0460 1.4404
03 Valve stemguide 1.4552 1.4552
03.1 Valve stemguide 1.4552 4) 1.4552 4)
04 Guide bolt 1.4021 1.4021
06 Spring 1.4310 1.4310 X
07 Check valve (assy.) 1.4404 1.4404 X
07.1 Check valve 1.4404 1.4404
07.2 Stem 1.4404 1.4404
08 Liner 1.4301 1.4301
09 Bypass branch 1.0460 1.4404
25 Guide pin 1.4305 1.4305
26 Bolt 1) 1)
27 Bolt 1) 1)
28 Hexagon nut 2) 2)
29 Hexagon nut 2) 2)
30 O-Ring