Annexure - I: Design Basis For Each Boiler

ANNEXURE – I
DESIGN BASIS FOR EACH BOILER
01. Installation Semi outdoor
02. Fuel size (As received basis 100% less than -6 mm (minus 6
on site) mm) and free from foreign
material .The fines less than (-) 1 mm
shall be restricted to max. of 30% and
fines less than (-) 2mm shall be
restricted to max. of 50%). (As
received basis on site)
03 ULTIMATE ANALYSIS OF %
FUELS by weight
Fuel Design Coal Worst Coal
Carbon 37.50 33.90
Hydrogen 02.10 02.00
Nitrogen 00.90 00.84
Sulphur 00.40 00.60
Moisture 11.90 13.70
Ash 41.60 43.90
Oxygen 05.60 05.06
GCV of fuel Kcal/kg 3300 3000
PROXIMATE ANALYSIS %
by weight
Fixed carbon 24.50 23.50
Volatile matter 22.00 18.90
Moisture 11.90 13.70
Ash 41.60 43.90
Page 1 of 52
04. Boiler thermal efficiency on
GCV basis
- 100 % Design Coal % 84 ± 1

(GCV:3300Kcal/kg)
05. Fuel quantity
- 100 % Design Coal Kg/hr 31100

(GCV:3300Kcal/kg) (fuel
calculation by indirect efficiency
determination ASME PTC 4.1
method)
06. Boiler parameters
Steam flow Kg/hr
- 100% MCR 125000
07. Steam pressure Bar ( g) 65

at main steam stop valve outlet
08. Steam Temperature °C 465±5
09. Boiler outlet gas temperature °C 140
10 Water temp at inlet of °C 105

economizer
11. Ambient Temperature for °C
Efficiency Calculation 40
Insulation 40
Electrical 50
12 Relative humidity % 60
13 Electrical Data
LT volt V 415 ± 10%
HT volt V 6.6 ± 10%
Page 2 of 52
Control volt V 110 V ± 10%(AC)
Frequency Hz 50 ± 5%
14. Compressed air pressure Kg/ 7 ( Dry , oil & Moisture free)
cm^2(g)
15. Applicable code IBR 1950 with its latest amendments
ASME PTC 4.1 for efficiency calculation

by indirect method.
Start-up fuel LDO

16.
Page 3 of 52
ANNEXURE – II
TECHNICAL DATA SHEET
A). BOILER
1.0 GENERAL
1.1 Type of system : Atmospheric Bubbling

type Fluidised Bed
Combustion boiler.
1.2 Type of Boiler : Single drum Water

tube boiler
1.3 Type of feeding system : Pneumatic underbed
1.4 Type of Water Circulation : Natural Circulation
1.5 Type of Support : Top supported
1.6 Design Code : IBR 1950 with its latest

amendments
1.7 Design Pressure Kg/Cm^2 ( g) : 77
1.8 No. of Boilers Nos : Four
1.9 Bunker arrangement : Side bunker
2.0 PARAMETERS OF BOILER AT MCR FOR EACH BOILER

(Measured at Main steam stop valve)
2.1 Steam Flow Kg/hr : 1,25,000
2.2 Steam Pressure at superheater Bar(g) : 65

outlet
2.3 Steam temperature at superheater °C : 465+/-5

outlet
2.4 Feed Water Temperature at inlet of °C : 105

economiser
2.5 Airheater outlet gas temperature °C : 140
Page 4 of 52
3.0 DRUM (FOR EACH BOILER) Steam drum
3.1 Internal diameter mm : 1371
3.2 Matl. of Construction : SA516 Gr.70
3.3 Type of drum internal : Cyclone separator with

screen driers
4.0 BED TUBES (FOR EACH BOILER)
4.1 Type of tube arrangement : Inline, `U' Bend, studded
4.2 Tube size (ODxT) mm x mm: 51 x 6.35
4.3 Tube material : SA 210 Gr.A1
4.4 Header dia (OD) mm : 273.1
4.5 Header material : SA 106 Gr.B.
5.0 WATER WALL(FOR EACH BOILER)
5.1 Type of construction : Fin welded membrane

wall construction
5.2 Tube Size (ODxT) mm x mm : 51 x 4.50
5.3 Tube Material : SA 210 Gr.A1.
5.5 Header material : SA 106 Gr.B.
5.6 Fin material : Mild steel
6.0 SUPERHEATER (FOR EACH BOILER) Convection Radiant
6.1 Type of Flow : Counter Counter
6.2 Arrangement : Inline Inline
6.3 Tube size (ODxT) mmxmm: 44.5x4.5 44.5x4.5/5.0
6.4 Tube material : SA 210 Gr.A1 SA 213 T11/

SA 213 T22
Page 5 of 52
6.6 Header Material
- Inlet : SA 106 Gr.B SA 106 Gr.B
- Outlet : SA 106 Gr.B SA 335 P11
7.0 DE SUPERHEATER (FOR EACH BOILER)
7.1 Type : Interstage, Spray type,

fixed nozzle
7.2 Location : In between convection and

radiant superheater stages
7.3 Number off Nos : One
7.4 Material of pipe : SA 106 Gr.B
8.0 ECONOMISER(FOR EACH BOILER)
8.1 Arrangement : Inline, Plain tube
8.2 Type of flow : Counter Flow
8.3 Tube size (ODxT) mmxmm: 38.1 x 4.5
8.4 Tube material : SA 210 Gr.A1.
8.6 Header Material : SA 106 Gr.B.
9.0 SAMPLE COOLERS (FOR EACH BOILER)
9.1 Type : Shell and coil type
9.2 No. of coolers Nos : Four
9.3 Sampling Points : Feed water, Drum water,

saturated steam &
superheated steam
9.4 Material
- Coil : Stainless Steel
- Shell : Carbon Steel
Page 6 of 52
10.0 BLOWDOWN TANK (FOR EACH BOILER)
10.1 No. of unit : Two nos. (One no. for

continuous & another one no.
for intermittent blowdown)
10.2 Type : Steel plate, cylindrical
10.3 Material : SA 516 Gr.70
11.0 DRAFT EQUIPMENTS (FOR EACH BOILER)

FD ID PA
FAN FAN FAN
11.1 Type of the fan : <-------- Centrifugal ---------->
11.2 Flow m^3/s : 35.40 50.25 13.30
11.3 Total Pressure mmwc : 900 250 800
11.4 Medium : Ambient Flue Hot

air gas Air
11.5 Temperature °C : 40 140 150
11.6 Speed rpm : 1440 980 1440
11.7 Motor Rating KW : 430 180 160
11.8 Motor voltage V : 6600 6600 415
11.9 Motor Type : Squirrel induction Squirrel

type HT motor cage
induction
LT motor
11.10 Type of Coupling : <--------- Direct coupled ---------->
11.11 Bearing Lubrication : <------------- Grease --------------->
11.12 Type of Control : Pneumatic operated cylinder

actuated regulating damper
control
11.13 Qty x % MCR load : 2x60 2x 60 2x100
Page 7 of 52
12.0 BOILER FEED PUMPS (FOR EACH BOILER)
12.1 Capacity m^3/hr: 163.97
12.2 Pressure head mWc : 946
12.3 Feed water temperature Deg.C : 105
12.4 Motor rating KW : 615
12.5 Speed rpm : 2900
12.6 Motor voltage KV : 6.6
12.7 Quantity Nos : 2 (1 W + 1 S)
12.8 Type : Centrifugal
13.0 AIRHEATER (FOR EACH BOILER)
13.1 Arrangement and Type : Multitubular Recuperative

type arranged in staggered
fashion
13.2 Tube size (ODxT) mmxmm: 60.3 x 2.34
13.3 Tube Material : IS 1239
13.4 Flow medium
- Inside tubes : Fluegas
- Outside tubes : Air
14.0 FUEL FEEDING SYSTEM (FOR EACH BOILER)
14.1 Type of Feeders : Pocket Drag

feeder chain
14.2 Location : Below Below pocket

bunker feeder
14.3 No.of feeders Nos : 8 8
14.4 Feeder Rating KW : 1.5 2.2
14.5 Type of feed control system : VFD Constant

speed geared
motor.
Page 8 of 52
15.0 FLUIDISED BED FURNACE (FOR EACH BOILER)
15.1 Total No.of Compartments : 8
15.2 Material of Air nozzles : S.S Tip / MS Base
15.3 Method of nozzle attachment : Threaded on to DB plate
15.4 No.of Fuel Feed Points provided : 32
15.5 No.of Ash drain points per compartment : Two
16.0 DUCTING SPECIFICATION(FOR EACH BOILER) AIR FLUEGAS
16.1 Material of construction : IS2062 IS2062
16.2 Thickness mm : 5 6
17.0 INSULATION (FOR EACH BOILER)
17.1 Insulation Material : Lightly resin bonded

mineral wool
17.2 Cladding finish : Plain aluminium cladding

of 22 SWG thk
18.0 PAINTING SPECIFICATION (FOR EACH BOILER)
18.1 Two Coats of epoxy zinc rich primer : Applicable for structural
each of 30 µ DFT and one coat of components including
epoxy MIO of 110 µ DFT with blast cleaning platforms,walkways,
ladders
18.2 Two Coats of zinc phosphate primer : Applicable for insulated

each of 30 µ DFT and one coat of surfaces
epoxy MIO of 110 µ DFT with power tool
cleaning
19.0 REFRACTORY (FOR EACH BOILER)
19.1 Type of material used : Castable refractory
19.2 Construction : As per CVL std.

Engineering Practice
19.3 Casing Plate Thickness mm : 4
19.4 Casing plate material : IS 2062 Gr.A
Page 9 of 52
B). DEAERATOR cum STORAGE TANK (FOR EACH BOILER)
1.0 Deaerator
Type : Spray cum tray type.
Design standard : CVL
1.1 Design Conditions
Deaeration capacity kg/hr : 125,000
Design temperature Deg.C : 200
LP Steam at control Kg/cm^2(g) : 4

valve inlet
Deaerated Water temp. Deg.C : 105
1.2 Deaerated Water Storage Tank
Storage m^3 : 42
Support type : Saddle
Location : Will be placed over

the control room top.(
control room by Essar)
.
1.3 Material of construction
Plate material for shell, : SA 516 Gr.70

Dished end & storage tank
Pipe nozzles : SA 106 Gr.B
Spray nozzles/Trays : SS-304
Internals : IS-2062
Piping between Deaerator and : SA 106 Gr.B

Boiler feed pumps
C). CHEMICAL DOSING SYSTEM (FOR EACH BOILER)
1.0 High Pressure Dosing System
Type of system : Single tank (Mixing cum

metering Tank)
Tank capacity litres : 400
Page 10 of 52
Tank material : S.S.
Type of stirrer : Motorised
Type of pump : Positive displacement

piston pump.
No. of pumps Nos : 2 (1 W + 1 S)
Capacity of the pump lit/hr : 18
Head developed by the Ksc(g) : 95

pump
Motor rating KW : 0.37
Chemical to be dosed : Tri Sodium Phosphate
Piping material from HP to

steam drum : S.S
2.0 Low Pressure Dosing System
Type of system : Single Tank (Mixing cum

metering Tank)
Tank Capacity Litres : 400
Tank Material : S.S.
Type of stirrer : Motorised
Type of pump : Positive displacement

piston pump.
No. of pumps Nos. : 2 (1 W + 1 S)
Capacity of the pump lit/hr : 21 (Flow can be adjusted

by varying the stroke of
pump)
Head developed by pump Ksc(g) : 10
Motor rating KW : 0.37
Chemical to be dosed : Hydrazine/Sodium

Sulphite.
Piping material from LP to

Deaerator outlet : S.S.
D). DUST COLLECTION SYSTEM (FOR EACH BOILER)
1.0 Electrostatic Precipitator
Page 11 of 52
1.1 Design Data
Fuel : 100% Indian coal ( GCV:

3000 Kcal/kg)
Gas flow rate to ESP m^3/sec : 66.20
Gas temperature at inlet of ESP °C : 140
ESP inlet dust concentration gm/Nm^3 : 64.00 (with lime stone

addition)
59.00 (without lime
stone addition)
ESP outlet dust concentration mg/Nm^3 : 50 (with all fields in

service)
100 (with one field out of
service)
1.2 General Data Of ESP
Type of ESP : Horizontal flow, dry

type, single pass.
Number of precipitators for boiler : 1
Number of gas paths per precipitator : 1
Number of gas fields in series in direction of

gas flow : 5
Number of electrical fields per boiler : 5
Total no. of high voltage rectifier

units installed nos. : 5
Ash hopper outlet flange elevation mts. : 2.5 (2 Hopper/field)
Pressure drop across ESP

(flange to flange) mmwc : 30
Note
The technical/equipments informations indicated are predictions only and it is

liable for change during detail engineering stage without major change in Boiler
specified parameters.
ANNEXURE - III
Page 12 of 52
SCOPE CHART
LEGENDS
CVL : CETHAR VESSELS LTD

EPIL: ESSAR PROJECTS (INDIA) LTD.
NA : NOT APPLICABLE
SL. DESCRIPTION ENGINE SUPP FABRI- SUPER- E&C REMARKS

NO ERING LY CATIO VISION
N OF
ERECTIO
N
1.0 STEAM DRUM
Fully welded steam CVL CVL CVL CVL EPIL

drum with
internals, man
holes and
necessary nozzle
connections for
mounting valves &
fittings
2.0 WATER WALL
2.1 Water cooled CVL CVL CVL CVL EPIL

membrane
enclosure with
headers and
necessary
connections like
drains
2.2 Studded bed tubes CVL CVL CVL CVL EPIL MS studs
and headers
3.0 SUPERHEATER
3.1 CONVECTION
SUPERHEATER
3.1.1 Superheater tube CVL CVL CVL CVL EPIL

assemblies with
inlet and outlet
header
3.1.2 Superheater coil CVL CVL CVL CVL EPIL

supports
3.2 RADIANT
Page 13 of 52
N OF
ERECTIO
N
SUPERHEATER
3.2.1 CVL CVL CVL CVL EPIL
Superheater tube
assemblies with
inlet and outlet
headers
3.2.2 Superheater coil CVL CVL CVL CVL EPIL

supports
3.3 SUPERHEATER
LINKS
3.3.1 Drum to convection CVL CVL CVL CVL EPIL

SH inlet header
3.3.2 Convection SH CVL CVL CVL CVL EPIL

outlet header to
desuperheater
3.3.3 De-superheater to CVL CVL CVL CVL EPIL

radiant SH outlet
header
3.4 Desuperheater with CVL CVL CVL CVL EPIL

spray nozzles and
internals
3.5 Final SH outlet CVL CVL CVL CVL EPIL Piping length
header to main shall be as per
steam stop actual layout
valve/NRV
4.0 ECONOMISER
4.1 Economiser tube CVL CVL CVL CVL EPIL

assemblies with
inlet & outlet
headers
4.2 Economiser coils CVL CVL CVL CVL EPIL

supports
4.3 Access door CVL CVL CVL CVL EPIL
Page 14 of 52
N OF
ERECTIO
N
4.4 Economiser casing CVL CVL CVL CVL EPIL

with stiffner
4.5 Economiser Ash CVL CVL CVL CVL EPIL

hopper with
isolation gate
5.0 SOOT BLOWERS
5.1 Retractable soot N.R N.R N.R N.R N.R

blower at Rad SH
zone
6.0 DRUM COIL N.A N.A N.A N.A N.A

HEATER WITH
ITS PIPINGS
7.0 AIR PREHEATER
7.1 Air preheater tubes CVL CVL CVL CVL EPIL

and tube sheets
7.2 Access door CVL CVL CVL CVL EPIL
7.3 Airheater casing CVL CVL CVL CVL EPIL

with stiffner
7.4 Airheater ash CVL CVL CVL CVL EPIL

hoppers
8.0 DOWNCOMERS CVL CVL CVL CVL EPIL
9.0 RISERS CVL CVL CVL CVL EPIL
10.0 INTEGRAL
PIPING
10.1
WATER PIPING
From BFW pump
outlet to BFW
delivery header
including delivery
header
Page 15 of 52
N OF
ERECTIO
N
10.1.2 From feed pump CVL CVL CVL CVL EPIL

discharge to feed
control station
10.1.3 Feed water control CVL CVL CVL CVL EPIL

station outlet to
economiser inlet
10.1.4 From economiser CVL CVL CVL CVL EPIL

outlet to steam
drum inlet
10.1.5 From upstream CVL CVL CVL CVL EPIL

of feed control
station to DeSH
spray water control
10.1.6 From CVL CVL CVL CVL EPIL

desuperheater
spray water control
station to spray
water nozzle on
desuperheater
10.1.7 Boiler initial filling EPIL EPIL EPIL EPIL EPIL

line
10.1.8 Minimum CVL CVL CVL CVL EPIL

recirculation piping
from BFWP station
to deaerator
10.1.9 Balance leak off CVL CVL CVL CVL EPIL

lines from BFWP
station to deaerator
10.1.10 Pipe supports CVL CVL CVL CVL EPIL For pipings
supplied by CVL
10.2 STEAM PIPING
10.2.1 Steam piping EPIL EPIL EPIL EPIL EPIL

beyond main steam
stop valve
Page 16 of 52
N OF
ERECTIO
N
Piping length
10.2.2 Steam piping from CVL CVL CVL CVL EPIL shall be as per
main steam line to actual layout
PRDS-I (meant for
Deaerator initial
heating)
Piping length
10.2.3 Steam piping from CVL CVL CVL CVL EPIL shall be as per
PRDS-I to actual layout
deaerator
Piping length
10.2.4 Spray water piping CVL CVL CVL CVL EPIL shall be as per
from feed line to actual layout
PRDS
10.2.5 Pipe supports CVL CVL CVL CVL EPIL For pipings
supplied by CVL
10.3 COOLING WATER

PIPING
10.3.1 Piping between EPIL EPIL EPIL EPIL EPIL

cooling water pump
outlet and one
point near boiler
island (both supply
and return lines)
10.3.2 Piping between one CVL CVL CVL CVL EPIL

point near boiler
island and
individual
equipments
10.4 BLOWDOWN /
DRAIN
Blowdown piping
from steam drum
upto blow down
valve
10.4.2 Blow down valve CVL CVL CVL CVL EPIL

outlet upto
blowdown tank
Page 17 of 52
N OF
ERECTIO
N
10.4.3 Drain piping from CVL CVL CVL CVL EPIL

individual drain
points to common
header
10.4.4 Common drain CVL CVL CVL CVL EPIL

header
10.4.5 Common drain CVL CVL CVL CVL EPIL

header to
blowdown tank
10.4.6 Piping from CVL CVL CVL CVL EPIL Piping length
blowdown tank shall be as per
outlet to nearest actual layout
trench
10.4.7 Flash steam CVL CVL CVL CVL EPIL

recovery piping
from continuous
blowdown tank to
deaerator &
exhaust
10.4.8 Supports for CVL CVL CVL CVL EPIL

Blowdown, drain &
vent piping
10.4.9 Blowdown tank CVL CVL CVL CVL EPIL Each one no. for
continuous and
Intermittent
blowdown per
boiler
10.5 VENT
10.5.1 From individual CVL CVL CVL CVL EPIL

vent connections
on steam drum,
main steam line
upto safe elevation
10.5.2 Safety valve CVL CVL CVL CVL EPIL

exhaust piping upto
safe elevation
Page 18 of 52
N OF
ERECTIO
N
11.0 AIR BOX
11.1 Air box with air CVL CVL CVL CVL EPIL SS cap / SS body
nozzle & fuel nozzle fuel nozzle & SS
and ash drain Tip / MS Base air
pipe with gate nozzle
12.0 AIR DUCTING
12.1 Air flow measuring CVL CVL CVL CVL EPIL Aerofoil meter
device
12.2 From FD fan CVL CVL CVL CVL EPIL

discharge to
airheater inlet
12.3 From airheater CVL CVL CVL CVL EPIL

outlet to FD header
12.4 FD header CVL CVL CVL CVL EPIL
12.5 FD header to airbox CVL CVL CVL CVL EPIL
12.6 From FD header to CVL CVL CVL CVL EPIL

PA fan suction
12.7 From PA fan CVL CVL CVL CVL EPIL

delivery to PA
header
12.8 PA header CVL CVL CVL CVL EPIL
12.9 Fuel transport lines CVL CVL CVL CVL EPIL

from PA Header to
airbox
12.10 Dampers & metallic CVL CVL CVL CVL EPIL

expansion joints in
air ductings
13.0 GAS DUCTING
13.1 From water wall CVL CVL CVL CVL EPIL SS duct and non
outlet to metallic bellows
economiser will be provided.
Page 19 of 52
N OF
ERECTIO
N
13.2 From economiser CVL CVL CVL CVL EPIL

outlet to airheater
13.3 From airheater CVL CVL CVL CVL EPIL

outlet to ESP
13.4 From ESP outlet to CVL CVL CVL CVL EPIL

ID fan suction
damper
13.5 From ID fan outlet CVL CVL CVL CVL EPIL Ducting length
to chimney flange shall be as per
actual layout
13.6 Damper & CVL CVL CVL CVL EPIL

expansion joints in
fluegas ducting
13.7 Inlet & outlet CVL CVL CVL CVL EPIL

expansion joints of
ESP
14.0 FUEL FEEDING

SYSTEM
14.1 CVL EPIL EPIL EPIL EPIL
Bunker with
supporting
structure from
ground level
14.2 Supporting steel CVL EPIL EPIL EPIL EPIL

structures for
bunker roof & side
cladding
14.3 GI sheets for roof & CVL EPIL EPIL EPIL EPIL
side cladding for
bunker (upto top
level of bunker)
14.4 Fuel surge hopper CVL EPIL EPIL EPIL EPIL
14.5 Limestone bunker CVL EPIL EPIL EPIL EPIL
Page 20 of 52
N OF
ERECTIO
N
with supporting
structure from
ground level
14.7 Bed material CVL EPIL EPIL EPIL EPIL If required

bunker with
supporting
structure
14.8 FUEL FEEDERS
14.8.1 Pocket feeder with CVL CVL CVL CVL EPIL 8 nos.
VFD
14.8.2 Drag chain feeder

with constant CVL CVL CVL CVL EPIL 8 nos.
speed drive.
14.8.3 Fuel feeder CVL CVL CVL CVL EPIL

discharge chutes
upto mixing nozzle
14.8.4 Pocket feeder with CVL CVL CVL CVL EPIL 4 nos.
VFD for lime stone
feeding.
14.8.5 Couplings / CVL CVL CVL CVL EPIL

hardware
15.0 SUPPORTING
STRUCTURE
15.1 Supporting CVL CVL CVL CVL EPIL

structure from
ground level for
boiler
15.2 Operating platform CVL CVL CVL CVL EPIL

(steel)
15.3 Staircases, ladders CVL CVL CVL CVL EPIL

upto operating
floor
15.4 Handrails for CVL CVL CVL CVL EPIL
Page 21 of 52
N OF
ERECTIO
N
operating floor
15.5 Platform above CVL CVL CVL CVL EPIL

operating floor
15.6 Staircases, ladders CVL CVL CVL CVL EPIL

above operating
floor
15.7 Foundation bolts CVL CVL CVL CVL EPIL

for CVL supplied
equipments
15.8 Complete steel CVL CVL CVL CVL EPIL For ductings
supports for supplied by CVL
ducting
15.9 Refractory supports CVL CVL CVL CVL EPIL

& casing
15.10 Hanger rod CVL CVL CVL CVL EPIL
15.11 Supporting steel CVL CVL CVL CVL EPIL

structures for
boiler roof & side
cladding
15.12 Approach platform EPIL EPIL EPIL EPIL EPIL

from boiler to
turbine hall
15.13 GI sheets for roof CVL CVL CVL CVL EPIL

and side cladding
for boiler (upto
drum operating
floor)
15.14 Buckstay CVL CVL CVL CVL EPIL

assemblies for
furnace
16.0 DRAUGHT
EQUIPMENT
16.1
Page 22 of 52
N OF
ERECTIO
N
F.D FAN
16.1.1 CVL CVL CVL CVL EPIL 2 x 60 % with
FD Fan with base 30 % margin on
frame & coupling head and 20 %
hardware margin on
capacity
16.1.2 Damper at inlet & CVL CVL CVL CVL EPIL

outlet
16.1.3 Silencer for FD fan CVL CVL CVL CVL EPIL

suction
16.2 I.D FAN
16.2.1 ID Fan with base CVL CVL CVL CVL EPIL 2 x 60 % with
frame & coupling 30 % margin on
hardware head and 20 %
margin on
capacity.
16.2.2 Damper at inlet & CVL CVL CVL CVL EPIL

outlet
16.3 P.A FAN
16.3.1 PA Fan with base CVL CVL CVL CVL EPIL 2x100% with 30
frame and coupling % margin on
hardware head and 30 %
margin on
capacity.
16.3.2 Damper at inlet and CVL CVL CVL CVL EPIL

outlet
17.0 VALVES &

MOUNTINGS
17.1 MOTORISED
VALVES
Page 23 of 52
N OF
ERECTIO
N
Motorised Main
steam stop valve
with integral
motorised bypass
valve
17.1.2 Start-up vent valve CVL CVL CVL CVL EPIL
17.1.3 Contnious CVL CVL CVL CVL EPIL

blowdown valve
17.1.4 Isolation valves at CVL CVL CVL CVL EPIL

upstream of
1x100% FCV
17.1.5 Bypass valve for CVL CVL CVL CVL EPIL

1x100% FCV
17.2 BOILER FEED

WATER
CONTROL
STATION
1 x 100% feed
water control valve
17.2.2 1 x 30% Feed CVL CVL CVL CVL EPIL

water control valve
17.2.3 Manual iso. valve at CVL CVL CVL CVL EPIL

downstream side of
1x100% FCV &
upstream &
downstream of
1x30% FCV
17.2.4 Manual isolation CVL CVL CVL CVL EPIL

valve at upstream
& downstream side
of motorized
bypass valve
Page 24 of 52
N OF
ERECTIO
N
17.2.5 All isolation, drain CVL CVL CVL CVL EPIL
& root valves
17.2.5 Orifice plate CVL CVL CVL CVL EPIL

assembly for feed
flow measurement
17.3 DESUPER-
HEATER SPRAY
WATER
CONTROL
17.3.1 STATION CVL CVL CVL CVL EPIL
Spray nozzles,
internals and
headers
17.3.2 1x100% spray CVL CVL CVL CVL EPIL

control valve
17.3.3 Manual iso. Valve CVL CVL CVL CVL EPIL

at upstream &
down stream of
spray control valve
17.3.4 Manual bypass CVL CVL CVL CVL EPIL

valve for 1x100%
SCV
17.3.5 Associated pipings / CVL CVL CVL CVL EPIL

fittings
17.4 STEAM DRUM
17.4.1 Water level gauges CVL CVL CVL CVL EPIL 2 nos Bi-colour
multi port WLG
17.4.2 Spring loaded CVL CVL CVL CVL EPIL 2 nos.

mechanical
safety valve

& root valves
17.5 MAIN STEAM
Page 25 of 52
N OF
ERECTIO
N
LINE
Isolation & root
valves for drain
17.5.2 Spring loaded CVL CVL CVL CVL EPIL

mechanical safety
valve
17.5.3 Non return valve CVL CVL CVL CVL EPIL Loose item
17.5.4 Silencer for SH CVL CVL CVL CVL EPIL

safety valve &
start-up vent
17.5.5 Flow nozzle in CVL CVL CVL CVL EPIL Loose item
steam line

& root valves
17.6 OTHER
SECTIONS
All IBR valves in
steam line, feed
line and spray line

& root valves
17.6.3 Air box drain valve CVL CVL CVL CVL EPIL
17.6.4 Air box bleed off CVL CVL CVL CVL EPIL
valve
17.6.5 Air & gas line non CVL CVL CVL CVL EPIL
IBR valves
Page 26 of 52
N OF
ERECTIO
N
18.0 INSTRUMENTATI
ON & CONTROL
18.1 INSTRUMENTATI
ON
18.1.1
LOCAL FIELD
INSTRUMENTS
(All the transmitters
shall be smart type
HART compatible
with HART
protocol)
Thermocouple with
temperature 4 nos /
transmitter to CVL CVL CVL CVL EPIL compartment
measure
Bed temperature
Free board CVL CVL CVL CVL EPIL
Fluegas CVL CVL CVL CVL EPIL

temperature before
economizer

temperature before
multi tubular air
preheater

temperature after
multitubular air
pre heater

temperature after
ESP
Air temperature at CVL CVL CVL CVL EPIL

FD header
Feed water CVL CVL CVL CVL EPIL

temperature before
economiser
Page 27 of 52
N OF
ERECTIO
N
Feed water CVL CVL CVL CVL EPIL

temperature after
economiser
Steam temp. before CVL CVL CVL CVL EPIL

and after
desuperheater
18.1.2 Pressure gauges to

measure
Steam pressure at CVL CVL CVL CVL EPIL

steam drum
Steam pressure at CVL CVL CVL CVL EPIL

main steam line
Feed line pressure CVL CVL CVL CVL EPIL

before and after
feed control valve
18.1.3 Draft transmitter to

measure
CVL CVL CVL CVL EPIL One no. per
Air box pressure compartment
Furnace pressure CVL CVL CVL CVL EPIL
Flue gas pressure CVL CVL CVL CVL EPIL

before economiser

after economizer

after airheater

after ESP
Air pressure at FD CVL CVL CVL CVL EPIL

header
Air pressure at CVL CVL CVL CVL EPIL

primary air header
Page 28 of 52
N OF
ERECTIO
N
Air pressure before CVL CVL CVL CVL EPIL

airheater
18.1.4 Pressure
transmitter at
CVL CVL CVL CVL EPIL
Feed line
18.1.5 Flow transmitter at CVL CVL CVL CVL EPIL

spray water line
18.1.6 Pneumatically
operated power
cylinder actuated
regulating type
damper at
- ID fan inlet CVL CVL CVL CVL EPIL 2 nos.
- FD fan inlet CVL CVL CVL CVL EPIL 2 nos.
- PA fan inlet CVL CVL CVL CVL EPIL 2 nos.
18.1.7 Solenoid operated

power cylinder
actuated open &
close type damper
at
FD header CVL CVL CVL CVL EPIL 8 nos.
PA header CVL CVL CVL CVL EPIL 8 nos.
FD fan outlet CVL CVL CVL CVL EPIL 2 nos.
ID fan outlet CVL CVL CVL CVL EPIL 2 nos.
PA fan outlet CVL CVL CVL CVL EPIL 2 nos.
Page 29 of 52
N OF
ERECTIO
N
18.2 FIELD
INSTRUMENTS
REQUIRED FOR
CONTROL
18.2.1 SYSTEM
Three element
drum level control
consists of
Three nos. drum CVL CVL CVL CVL EPIL

level transmitter
One no. steam flow CVL CVL CVL CVL EPIL

transmitter
One no. feed flow CVL CVL CVL CVL EPIL

transmitter
One no. drum CVL CVL CVL CVL EPIL

pressure
transmitter
One no. I/P CVL CVL CVL CVL EPIL

convertor
18.2.2 Furnace draught

control consists of
Three nos. furnace CVL CVL CVL CVL EPIL

pressure
transmitter
Two nos. I/P CVL CVL CVL CVL EPIL

convertor
18.2.3 Auto combustion

control consists of
Three nos. steam CVL CVL CVL CVL EPIL

pressure
transmitter
Page 30 of 52
N OF
ERECTIO
N
Three no. air flow CVL CVL CVL CVL EPIL

transmitter
Two nos. I/P CVL CVL CVL CVL EPIL

convertor
18.2.4 Superheater steam

temperature control
consists of
Three nos. CVL CVL CVL CVL EPIL

thermocouple
Three nos. temp. CVL CVL CVL CVL EPIL

transmitter

convertor
18.2.5 Deaerator level

control
Three nos. level CVL CVL CVL CVL EPIL

transmitter
One no. I/P
convertor
18.2.6 Deaerator pressure

control
One no. pressure CVL CVL CVL CVL EPIL

transmitter

convertor
18.2.7 Blowdown tank

level control
One no. level CVL CVL CVL CVL EPIL

transmitters
Page 31 of 52
N OF
ERECTIO
N
convertor
18.3 Instrument air EPIL EPIL EPIL EPIL EPIL

piping from source
to battery limit
18.4 Instrument air CVL CVL CVL CVL EPIL

piping from boiler
battery limit to
individual
consuming point
18.5 Compensating CVL CVL CVL CVL EPIL

cables, impulse
piping, instrument
cables and signal
cables from field
instruments to
junction boxes
18.6 Cables beyond EPIL EPIL EPIL EPIL EPIL

junction boxes
18.7 Junction boxes for CVL CVL CVL CVL EPIL

the instruments
supplied by CVL
18.8 Marshalling cabinet EPIL EPIL EPIL EPIL EPIL
18.9 DCS/SCADA EPIL EPIL EPIL EPIL EPIL
18.10 Variable frequency N.E N.E N.E N.E N.E Not envisaged
drive for ID fan since HT motor
is considered
18.11 Variable frequency N.E N.E N.E N.E N.E Not envisaged
drive for FD fan & since HT motor
feed pump is considered
18.13 Vibration EPIL EPIL EPIL EPIL EPIL
Page 32 of 52
N OF
ERECTIO
N
monitoring system
18.14 Steam & water EPIL EPIL EPIL EPIL EPIL

analyzing system
(SWAS)
18.13 O2 analyser on CVL CVL CVL CVL EPIL

fluegas line
18.14 Other Fluegas EPIL EPIL EPIL EPIL EPIL

analysers other
than O2 analyser
18.15 Compressor & EPIL EPIL EPIL EPIL EPIL

driers for
instrument air
supply
18.16 Uninterrupted EPIL EPIL EPIL EPIL EPIL

power supply
system (UPS)
19.0 SAMPLE
COOLERS
19.1 CVL CVL CVL CVL EPIL
Feed water
19.2 Blowdown water CVL CVL CVL CVL EPIL
19.3 Saturated steam CVL CVL CVL CVL EPIL
19.4 SH steam CVL CVL CVL CVL EPIL
20.0 ELECTRICALS
20.1 Motor for FD fan CVL CVL CVL CVL EPIL HT motor
20.2 Motor for ID fan CVL CVL CVL CVL EPIL HT motor
20.3 Motor for PA fan CVL CVL CVL CVL EPIL LT motor
20.4 Motor for feed CVL CVL CVL CVL EPIL HT motor
Page 33 of 52
N OF
ERECTIO
N
pumps
20.5 Incoming cables to EPIL EPIL EPIL EPIL EPIL

LT MCC
20.6 415 V LT MCC for EPIL EPIL EPIL EPIL EPIL

boiler & its
auxiliaries
20.7 Local push button EPIL EPIL EPIL EPIL EPIL

stations for the
motors supplied by
CVL
20.8 Interconnecting LT EPIL EPIL EPIL EPIL EPIL

power &
control cables
including cable
trays from LT MCC
to drives supplied
by CVL
20.9 Complete Earthing EPIL EPIL EPIL EPIL EPIL

of electrical
equipments
20.10 Earthing pit EPIL EPIL EPIL EPIL EPIL
20.11 Subearth mat & EPIL EPIL EPIL EPIL EPIL

main earth mat
20.12 Lightning EPIL EPIL EPIL EPIL EPIL

protection system
& installation
20.13 All lightings for EPIL EPIL EPIL EPIL EPIL

boiler accessories
20.14 Power control EPIL EPIL EPIL EPIL EPIL

center,
transformer, switch
gear, starters
required for HT
motors
Page 34 of 52
N OF
ERECTIO
N
20.15 Air conditioning EPIL EPIL EPIL EPIL EPIL

system
21.0 REFRACTORY
21.1 Refractory and CVL CVL CVL CVL EPIL

refractory holding
materials
21.2 Casing for CVL CVL CVL CVL EPIL

refractory
21.3 Insulation with CVL CVL CVL CVL EPIL Only for items
plain aluminium supplied by CVL
cladding of 22 SWG
thk
22.0 BOILER FEED

WATER
PUMPING
22.1 STATION CVL CVL CVL CVL EPIL 2 nos. (1 W + 1
S)
Feed pumps
22.2 Auto recirculation CVL CVL CVL CVL EPIL

valves
22.3 Valves and CVL CVL CVL CVL EPIL

mounting at feed
pump outlet
23.0 SPARES
23.1 Commissioning CVL CVL CVL CVL EPIL

spares
23.2 Two years O&M EPIL EPIL EPIL EPIL EPIL

spares
23.3 Tools & tackles N.R N.R N.R N.R N.R Not required for
single drum
boiler
Page 35 of 52
N OF
ERECTIO
N
24.0 DUST
COLLECTION
SYSTEM
24.1
ELECTROSTATIC
PRECIPITATOR
Electrostatic
Precipitator
24.1.2 Transformers set CVL CVL CVL CVL EPIL

(TR set), Electrical
control panel ,
Rapper control
Panel etc.
24.1.3 Insulation CVL CVL CVL CVL EPIL
24.1.4 Supporting CVL CVL CVL CVL EPIL

structures from
ground level
including platform
& handrails
24.1.5 Motor control EPIL EPIL EPIL EPIL EPIL

center for ESP
24.1.6 Incoming cables EPIL EPIL EPIL EPIL EPIL

upto ESP MCC
24.1.7 Interconnecting LT EPIL EPIL EPIL EPIL EPIL

power & control
cables from ESP
MCC to LT drives
within ESP
24.1.8 Earthing of ESP EPIL EPIL EPIL EPIL EPIL

upto ground level
24.1.9 Earth pit & main EPIL EPIL EPIL EPIL EPIL
earth grid
Page 36 of 52
N OF
ERECTIO
N
25.0 DEAERATOR CUM Deaerator tank

STORAGE TANK shall be placed
above control
25.1.0 DEAERATOR room top and
control room of
25.1.1 Shell CVL CVL CVL CVL EPIL civil construction
by Essar.
25.1.2 Dished end CVL CVL CVL CVL EPIL
25.1.3 Internals CVL CVL CVL CVL EPIL
25.2 STORAGE TANK
25.2.1 Shell CVL CVL CVL CVL EPIL
25.2.2 Dished end CVL CVL CVL CVL EPIL
25.2.3 Internals CVL CVL CVL CVL EPIL
25.3 PIPING
25.3.1 DM water piping EPIL EPIL EPIL EPIL EPIL

upto inlet of
deaerator level
control valve
25.3.2 From deaerator CVL CVL CVL CVL EPIL Piping length
level control valve shall be as per
to deaerator actual layout
25.3.3 Steam piping upto EPIL EPIL EPIL EPIL EPIL

deaerator pressure
control valve
Piping length
25.3.4 From deaerator CVL CVL CVL CVL EPIL shall be as per
pressure control actual layout
valve to deaerator
storage tank
Piping length
25.3.5 Feed line from CVL CVL CVL CVL EPIL shall be as per
deaerator storage actual layout
tank to feed pump
Page 37 of 52
N OF
ERECTIO
N
25.3.6 Process condensate EPIL EPIL EPIL EPIL EPIL

return piping upto
deaerator
25.3.7 Vent piping from CVL CVL CVL CVL EPIL

deaerator vent
connection to safe
elevation
25.3.8 Overflow from CVL CVL CVL CVL EPIL Piping length
deaerator to DM shall be as per
water storage tank actual layout
25.3.9 Pipe supports CVL CVL CVL CVL EPIL For piping
supplied by CVL
25.4 SUPPORTING
STRUCTURE
Deaerator tank
25.4.1 Steel support for EPIL EPIL EPIL EPIL EPIL shall be placed
deaerator storage above control
tank from ground room top and
level control room of
civil construction
by Essar
25.4.2 Platforms and CVL CVL CVL CVL EPIL

ladders from RCC
control room top
floor
25.5 VALVES &

MOUNTINGS
Pressure control
valve with inlet /
outlet manual
isolation valves and
manual bypass
valve
25.5.2 Level control valve CVL CVL CVL CVL EPIL

with inlet / outlet
Page 38 of 52
N OF
ERECTIO
N
manual isolation
valve and manual
bypass valve
25.5.3 Safety valve for CVL CVL CVL CVL EPIL

deaerator
25.5.4 Two nos. water CVL CVL CVL CVL EPIL

level gauge
25.5.5 One no. pressure CVL CVL CVL CVL EPIL

gauge
25.5.6 Isolation & root CVL CVL CVL CVL EPIL

valves for drain
25.6 INSTRUMENTATI
ON & CONTROL
25.6.1 One no. temp. CVL CVL CVL CVL EPIL

gauge
25.6.2 One no. CVL CVL CVL CVL EPIL

Thermocouple
25.6.3 One no. level CVL CVL CVL CVL EPIL

switch
26.0 CHEMICAL
DOSING SYSTEM
26.1 Low pressure

dosing system
(Chemical : sodium
sulphite /
26.1.1 hydrazine) EPIL EPIL EPIL EPIL EPIL
DM piping upto the

inlet of preparation
tank
26.1.2 LP dosing tank CVL CVL CVL CVL EPIL

with agitator
26.1.3 Dosing pumps CVL CVL CVL CVL EPIL
Page 39 of 52
N OF
ERECTIO
N
26.1.4 Dosing pump motor CVL CVL CVL CVL EPIL
26.1.5 Associated piping, CVL CVL CVL CVL EPIL

valves, mountings,
fittings within
system
26.1.6 Base frame CVL CVL CVL CVL EPIL
26.1.7 Level gauge CVL CVL CVL CVL EPIL
26.1.8 Pressure gauge CVL CVL CVL CVL EPIL
26.1.9 Foundation bolts CVL CVL CVL CVL EPIL
26.1.10 Supports CVL CVL CVL CVL EPIL
26.1.11 LP dosing pumping CVL CVL CVL CVL EPIL

unit outlet to
inlet of LP
dosing connection
on feed line
26.2 High pressure

dosing system
(Chemical :
Trisodium
26.2.1 phospate) EPIL EPIL EPIL EPIL EPIL
DM Piping upto
the inlet of
preparation tank
26.2.2 HP dosing tank CVL CVL CVL CVL EPIL

with agitator
26.2.3 Dosing pumps CVL CVL CVL CVL EPIL
26.2.4 Dosing pump motor CVL CVL CVL CVL EPIL
26.2.5 Valves, mountings, CVL CVL CVL CVL EPIL

fittings within
system
26.2.6 Base frame CVL CVL CVL CVL EPIL
Page 40 of 52
N OF
ERECTIO
N
26.2.7 Level gauge CVL CVL CVL CVL EPIL
26.2.8 Pressure gauge CVL CVL CVL CVL EPIL
26.2.9 Foundation bolts CVL CVL CVL CVL EPIL
26.2.10 Supports CVL CVL CVL CVL EPIL
27.0 START-UP OIL

FIRING SYSTEM
27.1 One no. service oil CVL CVL CVL CVL EPIL
tank
27.2 Main oil storage EPIL EPIL EPIL EPIL EPIL

tank
27.3 Oil piping up to EPIL EPIL EPIL EPIL EPIL

service oil tank
27.4 One no. duplex CVL CVL CVL CVL EPIL

type pumping and
straining system
27.5 LDO fired burner CVL CVL CVL CVL EPIL
27.6 Oil distribution CVL CVL CVL CVL EPIL

header with flexible
hoses and
isolation valve for
the burner
27.7 Necessary CVL CVL CVL CVL EPIL

interconnecting
piping.
27.8 Minimum and CVL CVL CVL CVL EPIL

essential
instruments.
Page 41 of 52
N OF
ERECTIO
N
27.9 Atomising air CVL CVL CVL CVL EPIL

ducting from PA
header to air
distribution header.
27.10 Air distribution CVL CVL CVL CVL EPIL

header with
isolation valves.
27.11 Air hose piping CVL CVL CVL CVL EPIL

from header to
burners.
27.12 Refractory burner CVL CVL CVL CVL EPIL

block required to
mount the burner.
27.13 Non Redundant CVL CVL CVL CVL EPIL
Burner
Management
System (PLC)
28.0 FUEL HANDLING

SYSTEM
EPIL EPIL EPIL EPIL EPIL
Fuel preparation
and handling
system upto bunker
29.0 ASH DISCHARGE

SYSTEM
29.1 BED ASH
29.1.1 Bed ash drain pipe CVL CVL CVL CVL EPIL
29.1.2 Slide gate CVL CVL CVL CVL EPIL
29.1.3 Bed ash cooler
Air cooled bed ash CVL CVL CVL CVL EPIL

coolers
Inlet ducting from CVL CVL CVL CVL EPIL

FD fan outlet
Page 42 of 52
N OF
ERECTIO
N
Discharge ducting CVL CVL CVL CVL EPIL

to furnace
Automatic bed
ash drain control
* Solenoid CVL CVL CVL CVL EPIL

energized
power cylinder
actuated
open/close
damper CVL CVL CVL CVL EPIL
* Pressure switch
29.2 Rotary ash EPIL EPIL EPIL EPIL EPIL

discharge feeder
and constant speed
geared motor
below
economiser, air
preheater
29.3 Rotary ash EPIL EPIL EPIL EPIL EPIL

discharge feeder
with constant
speed geared
motor below dust
collecting
equipment
30.0 BED ASH EPIL EPIL EPIL EPIL EPIL

HANDLING
SYSTEM
31.0 FLY ASH EPIL EPIL EPIL EPIL EPIL

HANDLING
SYSTEM
32.0 CHIMNEY EPIL EPIL EPIL EPIL EPIL
33.0 PAINTING
33.1 Primer painting for CVL CVL CVL CVL EPIL

CVL components
Page 43 of 52
N OF
ERECTIO
N
33.2 FINAL PAINTING - EPIL - - EPIL
34.0 CIVIL WORKS
34.1 Loading data for CVL - - - -

equipment under
CVL scope
34.2 Grouting material EPIL EPIL EPIL EPIL EPIL

(Packing plate &
shims)
34.3 Grouting for EPIL EPIL EPIL EPIL EPIL

equipments and
boiler structural
steel column
34.4 Rain gutters and EPIL EPIL EPIL EPIL EPIL

drain piping for
boiler hopper, roof
and side cladding
35.0 UTILITIES
35.1 Initial fill of EPIL EPIL EPIL EPIL EPIL

lubricants & grease
35.2 Bed material EPIL EPIL EPIL EPIL EPIL
35.3 Charcoal & EPIL EPIL EPIL EPIL EPIL

kerosene for
startup
35.4 Chemicals and CVL EPIL EPIL EPIL EPIL

temporary piping
for alkali boilout
35.5 Target plate and CVL EPIL EPIL EPIL EPIL

temporary piping
for hydrotest
Page 44 of 52
N OF
ERECTIO
N
36.0 GENERAL
36.1 Fire fighting system EPIL EPIL EPIL EPIL EPIL
36.2 Packing & CVL CVL -- -- --

forwarding
36.3 Steam blowing EPIL EPIL EPIL EPIL EPIL
36.4 Pump required for CVL EPIL -- -- EPIL

Hydrotest
36.5 Boiler initial fillup EPIL EPIL -- -- EPIL

pump
FACILITIES
SL.NO DESCRIPTION RESPONSIBILITIES REMARKS
37.0 FACILITIES
37.1 Providing Erection EPIL

tools, tackles, hoists,
derricks, slings,
scaffolding, rigging
tools, welding sets,
instruments,
appliances,
consumables required
for unloading,
transporting, storing,
erection, inspection,
testing and
commissioning to
accomplish the work.
37.2 IBR approval at site EPIL
37.3 Stress relieving of EPIL

welded joints
37.4 Unloading at site EPIL
Page 45 of 52
37.5 Pre-commissioning EPIL

check, mass flushing
alkali boilout, steam
blowing, trial run of all
equipment calibration
of instrument &
control etc.
37.6 Providing instrument EPIL

for above testing
37.7 Performance test CVL
37.8 Construction of site EPIL

office and store room
37.9 Storage space and EPIL

access road
37.10 Local conveyance, EPIL

Boarding & Lodging
for CVL personnels
37.11 O&M staff for boiler EPIL

startup,
commissioning &
operation
37.12 Supply of construction EPIL

power and water
at free of cost
37.13 Telephone facilities EPIL
37.14 Emergency / first aid EPIL

medical facilities to
CVL staff and erection
crew
37.15 Security for CVL EPIL

supplied items
37.16 Lighting facilities at EPIL

erection site
37.17 Boiler Registration EPIL

formalities
Page 46 of 52
37.18 Transportation CVL
37.19 Transit insurance EPIL
37.20 Site storage insurance EPIL
37.21 Applicable taxes and EPIL

duties
37.22 Chemicals for Alkali EPIL

boilout
37.23 Acid cleaning Not required
37.24 Training for persons CVL

upto PG test
37.25 Drainage and sanitary EPIL

works
37.26 CEIG, Pollution & EPIL

factory approval
37.27 Explosive board EPIL

approval for main oil
storage tank
Page 47 of 52
ANNEXURE – IV
TERMINAL POINTS
01. Steam
- Main steam : Outlet of MSSV & NRV
- Deaerator steam during startup : Inlet of PRDS
02. Feed water
- DM water : Inlet of deaerator level control valve

@ 5 ksc(g) pressure
- Condensate from condenser : Inlet of deaerator
03. Exhaust Steam/air vent : Upto safe elevation (1m above

boiler house)
04. Blowdown/drain : Upto nearest drain trench
05. Cooling water/service water : At one point nearer to the boiler

house.
06. Fuel : Inlet of fuel surge hopper
07. Bed ash : Outlet of bed ash cooler
08. Fly ash : Outlet of ash hoppers below

economiser/airheater/ESP
09. Combustion air : Inlet of FD Fan
10. Instrument air/ : At one point nearer to the boiler

service air house
11. Sampling : At the outlet of sample coolers
12. Flue gas : Inlet of chimney
13. Instrument signals : Upto junction boxes
14. HP / LP dosing chemicals : At the inlet of chemical dosing

tanks
15. Electricals
LT / HT : Input & output terminals of individual

drives supplied by CVL
Page 48 of 52
ANNEXURE – V
MAKE OF BOUGHTOUT ITEMS
NOTE:
THE BELOW SAID LIST IS APPLICABLE FOR THE EQUIPMENTS

WHICH WILL BE UNDER CVL SCOPE AND DOES NOT IMPLY THAT
THE EQUIPMENTS /AND ITS SUBVENDORS SO LISTED ARE IN CVL SCOPE
OF SUPPLY.
SNO. DESCRIPTION MAKE
A MECHANICAL
1 FEED PUMPS
KSB / SULZER
2 GEAR BOX SHANTHI GEARS / ELECON / GREAVES
3 GEARED MOTORS IC BAUER / PBL / GREAVES/ BONFIGLIOLI/ REMI
4 FABRIC EXPANSION JOINT KELD ELLENTOFT / KELD BURGMANN
5 METALLIC EXPANSION JOINT FLEXICON BELLOWS / METALLIC BELLOWS /

LONESTAR INDUSTRIES / GBM / FLEXO-THERM /
FLUIDYNE ENGINEERS
6 COUPLINGS
TYRE/LOVEJOY COUPLINGS FENNER / JOHN
7 BEARINGS SKF / FAG
8 PLUMMER BLOCK MS ASSOCIATES (ARUN)/ SIBCO/ TRUFIT / ANTIMU
/ SKF
9 DIRECT WATER LEVEL
GAUGE
- TUBULAR CHEMTROL / MAGNETROL / DRESSER
- TRANSPARENT CHEMTROL / MAGNETROL / DRESSER
- MULTIPORT KEYSTONE YARWAY / HITECH
BICOLOUR WLG
10 START-UP BURNER CONTINENTAL / WESMAN
11 PHS UNIT VACUNAIR / WESMAN / THERMAL ENGINEERS
12 DOSING PUMP
- METERING SWELLORE / XL PUMP / MILTON ROY
- Y TYPE STRAINER ASIAN INDUSTRIAL SYSTEMS / UNIKLINGER /
SUNGOV / FORBES MARSHALL
Page 49 of 52
13 REFRACTORY & INSULATING
BRICKS
- CASTABLE & BRICKS R.V.REFRACTORY / ACE / TATA REFRACTORIES /
PADMAJA INC / DALMIA
14 INSULATION
- CERAMIC BLANKETS LLOYDS INSULATION/ ORIENT CERWOOL/
MURUGAPPA
- LRB ROCK WOOL INDUSTRIES / ROCK WOOL INDIA
LTD / LLOYD INSULATION (I) LTD / MINWOOL
- ALUMINIUM CLADDING BALCO / INDALCO / HINDALCO
15 STEAM TRAPS J.N.MARSHALL / FORBES MARSHALL
16 SPRING HANGERS SARATHI ENGG / PIPE SUPPORTS / SPRING
SUPPORTS
17 FLOW NOZZLES INSTRUMENTATION LTD, PALAKKAD / GENERAL
INSTRUMENTS / ENGINEERING SPECIALITIES
18 PAINTS
- RED OXIDE PRIMER PASUMEENA / BERGER / SHALIMAR / ASIAN
PAINTS
19 VIBRATORY MONITORING FORBES MARSHALL (SHINKAWA)/ SHENCK AVERY
SYSTEM / BENTLY NAVEDA
B VALVES
1 IBR VALVES (MANUAL)
> 21 KG/CM^2 PRESSURE KSB / BHEL / AUDCO
SS VALVES BDK/ INTERVALVE
2 MOTORISED VALVES ROTORK / AUMA / KSB PUMPS
EXCEPT STARTUP VENT &
BLOWDOWN VALVES (IBR)
3 MOTORISED STARTUP VENT ROTORK / AUMA / BHEL
VALVE (IBR)
4 MOTORISED BLOWDOWN ROTORK / AUMA / BHEL
VALVES (IBR)
5 MANUAL BLOWDOWN VALVE
> 21 KG/CM^2 PRESSURE BHEL
6 3 WAY VALVE BHEL / BDK
7 CONTROL VALVES FISHER XOMOX / DRESSER / CCI / IL
8 SAFETY VALVE FOR BOILER TYCO SANMAR / BHEL

FOR DEAERATOR & FAINGER LESSER / DARLING MUESCO
BLOWDOWN TANK
APPLICATIONS
9 SOLENOID VALVES ASCO
Page 50 of 52
10 SOLENOID OPERATED BALL EL-O-MATIC / INTERVALVE/ASCO
VALVE
11 BUTTERFLY VALVE EL-O-MATIC / INTERVALVE / BDK / TOMOE
12 NON-IBR VALVES VALVES INDIA / STEEL STRONG / KSB / BDK /
LEADER
13 BALL VALVES BDK / MICROFINISH / ROTEX / INTERVALVE
14 SOLENOID GANG ROTEX / AVCON / NUCON / FESTO CONTROLS /
SMC
15 VACUUM RELIEF VALVE NIRMAL INDUSTRIES / FISHER / FAINGER ENGG.
16 PRDS FISHER XOMOX / DRESSER / CCI
C ELECTRICAL
1 LT MOTOR ABB / SIEMENS/ CROMPTON GREAVES /
KIRLOSKAR / BBL
2 HT MOTOR
- UPTO 6.6 KV ALSTOM/ ABB/ BHEL/ CROMPTON GREAVES /
KIRLOSKAR
3 ACTUATORS ROTORK CONTROLS / AUMA
4 JUNCTION BOX BALIGA / GOVAN
D INSTRUMENTS
1 TEMPERATURE GAUGE FORBES MARSHALL / WIKA / WAAREE
INSTRUMENTS / GENERAL INSTRUMENTS
2 PRESSURE GAUGE / FORBES MARSHALL / WIKA / WAAREE
3 AIR PRESSURE GAUGE FORBES MARSHALL / WIKA / WAAREE
4 THERMOCOUPLES GENERAL INSTRUMENTS / PYRO ELECTRIC

5 PRESSURE SWITCH/ SWITZER / INDFOS
TEMPERATURE SWITCH
6 LEVEL SWITCH CHEMTROL / MAGNETROL
7 LIMIT SWITCH SIEMENS / JAI BALAJI/ HONEYWELL
8 DRAUGHT GAUGE SWITZER
9 TRANSMITTERS ROSEMOUNT / YBL / ABB
10 I/P CONVERTORS ABB / ROSEMOUNT / YOKOGAWA
11 AIRFILTER CUM REGULATOR PLACKA (JRU) / SHAVO
12 POWER CYLINDER (ON/OFF) ROTEX / VELJAN / NUCON
13 REGULATING POWER IL / KELTRON / RK CONTROLS
CYLINDER
14 COMPENSATING CABLES ASSOCIATED CABLES / TCL / CABLE
Page 51 of 52
CORPORATION LTD / TC COMMUNICATION
15 INSTRUMENTATION CABLES ASSOCIATED CABLES / TCL / CABLE
CORPORATION LTD / TC COMMUNICATION
16 O2 ANALYSER ABB / YBL / EMERSON
E OTHERS
01. FANS CVL
02. CHEMICAL DOSING TANK CVL
03. ORIFICE PLATES CVL
04. JUNCTION BOXES CVL
05. DESUPERHEATER CVL
06. SILENCERS CVL
07. METALLIC BELLOWS CVL
08. ESP CVL
09. DEAERATOR CUM STORAGE CVL
TANK
Page 52 of 52

Annexure - I: Design Basis For Each Boiler

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Annexure - I: Design Basis For Each Boiler

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ANNEXURE – I

DESIGN BASIS FOR EACH BOILER

01. Installation Semi outdoor

Fuel Design Coal Worst Coal

Carbon 37.50 33.90

Hydrogen 02.10 02.00

Nitrogen 00.90 00.84

Sulphur 00.40 00.60

Moisture 11.90 13.70

Ash 41.60 43.90

Oxygen 05.60 05.06

GCV of fuel Kcal/kg 3300 3000

Fixed carbon 24.50 23.50

Volatile matter 22.00 18.90

Moisture 11.90 13.70

Ash 41.60 43.90

- 100 % Design Coal % 84 ± 1

05. Fuel quantity

- 100 % Design Coal Kg/hr 31100

06. Boiler parameters

Steam flow Kg/hr

- 100% MCR 125000

07. Steam pressure Bar ( g) 65

08. Steam Temperature °C 465±5

09. Boiler outlet gas temperature °C 140

10 Water temp at inlet of °C 105

11. Ambient Temperature for °C

LT volt V 415 ± 10%

HT volt V 6.6 ± 10%

15. Applicable code IBR 1950 with its latest amendments

ASME PTC 4.1 for efficiency calculation

Start-up fuel LDO

TECHNICAL DATA SHEET

1.1 Type of system : Atmospheric Bubbling

1.2 Type of Boiler : Single drum Water

1.3 Type of feeding system : Pneumatic underbed

1.4 Type of Water Circulation : Natural Circulation

1.5 Type of Support : Top supported

1.6 Design Code : IBR 1950 with its latest

1.7 Design Pressure Kg/Cm^2 ( g) : 77

1.8 No. of Boilers Nos : Four

1.9 Bunker arrangement : Side bunker

2.0 PARAMETERS OF BOILER AT MCR FOR EACH BOILER

2.1 Steam Flow Kg/hr : 1,25,000

2.2 Steam Pressure at superheater Bar(g) : 65

2.3 Steam temperature at superheater °C : 465+/-5

2.4 Feed Water Temperature at inlet of °C : 105

2.5 Airheater outlet gas temperature °C : 140

3.1 Internal diameter mm : 1371

3.2 Matl. of Construction : SA516 Gr.70

3.3 Type of drum internal : Cyclone separator with

4.0 BED TUBES (FOR EACH BOILER)

4.1 Type of tube arrangement : Inline, `U' Bend, studded

4.2 Tube size (ODxT) mm x mm: 51 x 6.35

4.3 Tube material : SA 210 Gr.A1

4.4 Header dia (OD) mm : 273.1

4.5 Header material : SA 106 Gr.B.