PTSDCM0001 40000

<Please preserve this manual carefully.
For trouble free performance of your Thermax equipment, read and follow the instructions contained.>
THERMOSYPHON
Installation, Operation
And Maintenance Manual
DOCUMENT NUMBER -- PTSDCM0002
Improving your
business is our
business
Company Profile
THERMAX
Thermax Group
Thermax Ltd has a vision of becoming a globally respected high performance company offering
sustainable solutions in energy and environment.
The Thermax Group provides business to business solutions in the areas of heating, cooling,
captive power, water treatment, air pollution control, waste management & resource recovery
and chemicals to a wide range of industry in Indian and international markets.
In the energy business, Thermax executes projects in the areas of process heat, captive power
and waste heat recovery. It also offers a range of heating equipment, energy efficient chillers
and customized products such as waste heat and exhaust gas units. Thermax’s integrated
expertise in energy has made GE to choose it as the ‘vendor on first call’ for its global Combined
Heating Power and Cooling (CHPC) projects…
Thermax provides energy solutions to utilize waste heat to burn waste gases and biomass. These
include a variety of custmised turnkey solutions to generate heat, steam and power. It
undertakes the entire range of activities from concept of commissioning.
Clientele includes Refineries, Petrochemicals, Fertilisers, Paper & Pulp, Distilleries, Independent
Power Plants, Chemicals and a wide range of other industries.
Thermax offers industry its expertise over a hundred fuels including oil, gas and a wide variety of
solid fuels including biomass. The Group’s Joint Venture, Thermax Babcock & Wilcox (TBW) has
emerged as a leading and reliable project management company with installations the world
over; in the US, Saudi Arabia, Thailand, Egypt, Philippines and several other countries.
Leveraging its leadership position in electricity saving vapor absorption technology, it offers
process industries and commercial establishments like hotels, shopping malls and offices vapor
absorption chillers a boon in power-starved areas. These Eco-friendly, energy efficient
equipment have found prestigious customers such as BBC, Mercedes Benz, Audi, Bosch,
Panasonic, Henry Ford Museum.
I
Company Profile
In the environment area Thermax offers waste management expertise for solid, liquid and air
pollution. Thermax provides solutions from pre-treatment to waste water treatment and
chemical conditioning of water for unit and cooling water systems. Water recycling is a thrust
area for Thermax. Hi-grade resins from Thermax have found niche customers in US and Japanese
markets.
Thermax is a key player in the field of gaseous and particulate emission control, with special
focus on the emerging gaseous scrubbing business in India. Our state-of-the-art technology
enables us to offer turnkey projects well as air pollution control products.
And, the greatest utility of these solutions stems from the fact that they allow resource recovery
in process industries.
Thermax has an extensive international marketing network. Headquartered in Pune (Western

India), Thermax’s eleven international offices are located in South East Asia, Middle East, Africa,
Russia, UK and the US. Thermax’s 4 oversea subsidiaries play a significant role in generating
business in the International market. Thermax (Russia) Ltd., Thermax (Europe) Ltd., Thermax Inc.,
USA and ME Engineering, UK. Around 20 percent of the group’s turnover comes from exports to
the US and European markets, Japan, East Africa, the Middle East, South East Asian and CIS
countries.
The Thermax group’s manufacturing facilities. Spread over 14 plants, measuring a covered area
of over 65,000Sq.Mts. are ISO-9000 and ISO-14001 accredited. Thermax manufactures to
international standards like ASME, BS, DIN and GOST. The facilities have been inspected by
Lloyds, Bureau Veritas, SGS and TUV.
Thermax’s business is inspired by the conviction that ‘Improving your business is our business’.
II
Division Profile
C & H - HEATING
C & H - Heating
C & H - Heating is the flagship Product Business Division of Thermax Ltd, which has its core
business in the area of providing cost effective process heating solutions for both energy
generation and energy conservation. Thermax has began its business way back in 1966 by
manufacturing baby boiler. C & H - Heating is the seed for business growth for the company.
Today its high quality products are demand in India and in international markets. Its products
and expertise find applications in every conceivable heating application in the world.
History
C & H - Heating, made a modest beginning to manufacture by collaborating with Wanson of
Belgium. The collaboration introduced baby boilers in India. The baby boilers which we out side
the purview of the Indian Boiler Regulation Act was the most demanded product. The successful
acceptance of the product lead to pioneering of Thermic oil heating in India.
Thermal oil heating took the Indian industry by storm and today in India its brand Thermopac has
become to generic name. Thermal oil heating replaced several other heating methods such
Electrical, steam, steam-cum-electrical. The main reason is its highest energy saving capability
due to high system efficiency. To name a few industry which initially benefited the most are:
Textile, Footwear, Flatten Press, Rubber etc. Today every industry looks to thermal oil heating as a
most potential energy saving solution.
The division then made a modest beginning with a turnover of USD 0.05 million in 1968, and now
has grown to a USD 140 million group which offers a wide range of solutions to its customers in
the areas of energy generation & conservation and environment protection, all under one roof
with a singular mission.
To pursue this mission C & H - Heating has been continuously designing and upgrading its
products and services that results in energy efficient heating solutions to the customer making
optimum use available energy resources - conventional, non conventional and the renewable
energy sources.
C & H - Heating over the last 30 years has evolved into an Engineering major well known for its
core competencies in the field of Process Heating, Energy & Environment.
III
Division Profile
Products and Services

Our product portfolio encompasses providing process heating through different mediums such
as
Steam
Hot Oil
Hot Water
Hot Air
The product technology facilitates use of wide range of fuels viz.,
Light & Heavy Oil
Natural Gas
LPG
Bio-Gas
Cool Low and high Calorific values,
Lignite
Non conventional / agro based fuels

Rice Husk
Baggase
Groundnut Shell
Mustard stalk
De-oiled bran
De-oiled cake etc.
IV
Division Profile
With the strengths C & H - Heating caters to the need of variety of application in process
industries like
Agro products Packaging
Bottling & beverages Drugs & pharmaceuticals
Breweries & distilleries Plywood
Chemical & petrochemicals Rubber
Engineering Edible oil / solvent extraction
Food & dairy Textile / Synthetic fibers
Hotels Hospitals
..And more
All these innovations of providing energy efficient solutions have been evolved through a close
interaction with the market to understand the changing needs of he customers across the world.
Thermax has an extensive national and international marketing network. Headquartered in Pune
(Western India), Thermax’s eleven international offices are located in South East Asia, Middle
East, Africa, Russia, UK and the US. ME Engineering (ME) a well-established UK boiler company is
a subsidiary of Thermax in UK offering quality solution to the energy markets in UK and Europe.
Thermax has also established a subsidiary in the United States that is catering to the markets in
North and South America. Around 20 percent of the group’s turnover comes from exports. We
have around 20,000 installations spanning 45 countries.
‘If you need the heat, we have the source’.
V
Thermosyphon
Contents
Sr. No. Chapter Page No.
Chapter 1 : Installation
1.1 Introduction – Thermosyphon Series 1
1.2 Transportation & Unloading Instructions 8
1.3 Drawings 11
1.4 Installation Guidelines 12
1.5 Installation Guidelines for Thermosyphon System 17
1.6 Accessories and Other Assembly Guidelines 22
1.7 Thermosyphon Heater Instrumentation 28
Chapter 2 : Input Requirement

2.1 Thermosyphon Circuit Water Specifications 33
2.2 Electrical Input 33
2.3 Thermosyphon Plant Component Selection 34
2.4 Fuel Supply 35
Chapter 3 : Commissioning Process

3.1 Pre-Commissioning 46
3.2 Commissioning 53
3.3 Controls & Safeties 55
Chapter 4 : Operation
4.1 Heater Startup Process 58
4.2 Heater Running Attention 60
4.3 Heater Stopping Procedure 61
Chapter 5 : Maintenance
5.1 Maintenance Schedule 64
5.2 Log Book 65
5.3 Spare Parts 65
Chapter 6 : Troubleshooting 67,68
Chapter 7 : Care of Idle Units

7.1 Wet Preservation 69
7.2 Dry Preservation 70
7.3 Liquid Fuels and Combustion 71
Chapter 8 : Manuals 75
VI
Installation Thermosyphon
IMPORTANT INSTRUCTIONS
Important Instructions
TO: Owners and persons responsible for installation, operation and maintenance.
The performance of a Thermosyphon depends very greatly on its proper installation, which
includes among other things, such external accessories as chimney, tanks, pipes, etc.
This manual presents information that will help to install, operate and maintain the
equipment properly. It is expected that the contents be carefully read before handling
the unit. In case of any doubt for specific clarifications please consult nearest Thermax
office.
Thermosyphon is a product of many years of design & engineering effort, to provide long
life & excellent service on the job. This unit will provide continued trouble free service, if
instructions on installation, operation and maintenance are properly followed.
A good installation is a permanent asset while a bad one can be a constant source of
trouble. It can cost much more to correct a bad installation than to put a new one.
It is expected that the personal involved in Installation, Operation & Maintenance
possess necessary qualification competence and license (if applicable). It is solely the
responsibility of the owner & user to ensure that all applicable statutory norms are
adhered to during Installation, Operation & Maintenance of the equipment.
The electrical and mechanical devices supplied as a part of the unit were chosen
because of their known ability to perform, with proper operating techniques and
maintenance procedures. Tempering with the safeties & controls or bypassing any of
these is not permissible at any time.
Any “Automatic” features included in the design do not relieve the attendant of any
responsibility. Such features may free him of certain repetitive chores and give him more
time to devote to the proper upkeep of equipment.
No amount of written communication can replace intelligent thinking & reasoning.
This operating specification applies to our scope of supply only.
Note: Since the product improvement is continuing process, the information given in this manual
on specific features is subject to change without notice.
1
Thermosyphon Installation
01 THERMOSYPHON SERIES
THERMOSYPHON SERIES:
Figure F-1.1 : Thermosyphon Unit
2
1.1 Thermosyphon In General
Thermosyphon Principle
A fluid is lighter at a higher temperature than it is at a lower temperature. Thus if two columns of
a liquid are connected at the bottom and at the top and are at two different temperatures, a
circulating current of the liquid would be set up. The rate of circulation will depend upon the
difference in the densities of the lighter and heavier columns, their heights and the system
resistance (entire liquid loop) to flow. If the hotter liquid starts boiling then the Density difference
is substantial and this is the principle on which all the Thermosyphon systems work.
1.1.1 Introduction
Thermosyphon is a vertical, three pass, Natural circulation high pressure unit. The Thermosyphon
unit is a closed loop, high-pressure natural circulation unit using water as the heating media. It
has distinct advantage over traditional industrial heating systems like steam or Thermic-fluid.
Thermosyphon is out of preview of Indian Boiler Regulation Act 1957 latest revisions as it satisfies
the condition ‘it is not used for export of steam since it is a close loop system with process.”
Salient Features Of Thermosyphon

Thermosyphon is a high pressure, closed circuit, natural circulation water unit. It also uses natural
circulation of steam for the process.
• It is designed to heat with steam and water mixture in processes requiring temperatures
between 200°C (15bar) to300°C (85 bar).
• The use of water as a heating media eliminates all risks of contamination of the product.
• A static head provided by elevation difference between Thermosyphon steam header and
process is utilized for steam side/ heating media circulation.
• No water treatment required as the system is closed loop and no water losses
• Since it works on natural circulation so no circulation pump is required in the system, there by
reducing power cost and related maintenance cost.
• Overall thermal efficiency is improved since condensate losses are absent, unlike in high-
pressure steam units.
• There is no degradation of heating media as in the case of Thermic-fluid units.
• Heating media being water it is non toxic and is edible.
3
Construction And Operation Of Thermosyphon

Thermosyphon unit is made of two vertical concentric multi-start helical coils forming the basic
pressure part. The inner coil forms the combustion chamber. All the individual starts of both the
coils are connected to a steam header at the top and to a water header at the bottom. This
coil assembly is placed inside a jacket which is concentric with the coil.
The steam and the water headers are connected by down comers, thus forming the primary
circulation circuit. The supply line to the utility is taken from the steam header and is connected
to the utility. The return line from the utility is taken back to the steam header through a Hartford
loop thus forming secondary circuit.
Fuel is burnt in the combustion chamber formed by the inside surface of inner coil. Gases
thereafter pass through annular space between the two concentric coils (Pass II) and then
between outer coil & jacket (Pass III). The flue gases are finally vented to atmosphere via
chimney.
As water in the coil gets heated it sets in natural circulation from bottom header to the top
header and back from top header to the bottom header through the down comers which are
placed outside the heating zone.
Steam and water mixture circulates from unit top header to process & returns after
condensation to at the condensate inlet connection of the unit due to difference in density and
elevation differences as well as the process heat load. It is very important that a certain
minimum flow is maintained through the unit (which is achieved by properly designing the unit).
The major components of Thermosyphon product can be broadly categorised into
a) Burner – Oil/Gas/Dual fuel fired
b) Jacket coil assly
c) Control Panel / Instruments
d) Charging/Make up water pump
4
Major Components of the Unit:
a) Burner
Burner is the heart of the unit, which provides the fuel or heat input to the unit. The high thermal
efficiency & the trouble free operation of the unit will mainly depend on its design, its
compatibility with Thermosyphon unit, ability to burn the desired fuels with high efficiency &
reliability of the components.
All these desired features are incorporated in the design of the burners supplied by Thermax. The
unit is fitted with combustion equipment suitable to burn the fuels specified. Typically, there are
four combustion schemes, which can be broadly classified as
1. System suitable for Heavy oil combustion
2. System suitable for Light oil combustion
3. System suitable for Gaseous fuel combustion
4. System suitable for Dual block.
The unit is fitted with a monobloc burner. The burner is a

complete unit, inclusive of burner housing, fuel atomiser,
ignition equipment, diffuser plate and wegman cone.
Figure F-1.2 : Burner

b) Jacket & Coil Assembly
Coil assembly consists of two concentric coils fitted

into one another and connected to each other by
top and bottom header making a parallel flow
circuit. The heads are connected by down comer
from top to bottom outside jacket. The coil
provided is with multi start to have smooth start-up
and avoid any vapor lock. The top header is fitted
with a hart fort loop which connects external utility
circuit with the coil assembly.
The coil and jacket assembly forms a main unit

which is three-pass heat exchanger with first pass
from top to bottom in the inner coil. Second pass
between annular space of inner and outer coil from
bottom to top. Third pass between annular space
of jacket and outer coil from top to bottom.
The jacket is insulated from outside for human

Figure F-1.3 : Jacket & Coil Assly safety.
5
c) Electrical Control Panel
The electrical control panel supplied along with the

Thermosyphon unit, is designed to suit the unit
operating logic and provides the electrical supply
to the unit & its other electrical equipment like
motors of feed water pumps, Burners, controls etc.
It also interlocks low water safety to ensure safe
operation of the unit. The control panel consists of
the main on–off switch, switch gear for the
operation of the motors of feed water pump,
burner logic and hooter, indicating lamps, power &
control circuit wiring. The control panel is to be
connected to the various motors, safeties &controls
of the unit by proper cables & wires.
Figure F-1.4 : Electrical Control Panel TS
d) Charging/Make Up Water Pump
This pump is used for initially feeling of water into

the unit, as well as filling of water if there is any
water loss from the system.
These pumps are horizontal, single acting,

reciprocating type piston pumps.
This pump is not selected to charge water when

Thermosyphon unit is under pressure.
Electric motor is used to drive the pump and the

same is connected to the pump through belt.
Alignment of the pump and motor pulleys should
Figure: F-1.5 : Make up water be ensured before starting the pump as well as
lubricating oil level in the gearbox.
6
1.1.2 Technical Specifications:

Parameter Unit TS-02 TS-04 TS-06 TS-10 TS-15 TS-20 TS-25
Heat load KCal/hr 200,000 400,000 600,000 1,000,000 1,500,000 2,000,000 2,500,000
Heat load Kw 232 465 698 1,163 1,744 2,326 2,907
Design
Pressure Bar 90
Operating
Pressure Bar 85 ( Maximum )
Operating
temperature Deg C 300 ( Maximum )
Design
Temperature Deg C 353
Stack
temperature Deg C 360 ( for operating pressure of 85 Bar )
Light Oil ( HSD / LDO ) , Natural Gas , Heavy Oil ( FO )
Fuels
Efficiency on
FO % 84% 84% 84% 84% 84% 84% 84%
Efficiency on
LDO/HSD % 85% 85% 85% 85% 85% 85% 85%
Efficiency on
N.Gas % 83% 83% 83% 83% 83% 83% 83%
Fuel
consumption
on FO kg/hr 25 49 74 123 185 247 308
Fuel
consumption
on LDO kg/hr 28 45 67 112 168 224 280
Fuel
consumption
on N.Gas Nm3/hr 27 54 82 136 204 272 340
Firing
Control Two stage Modulation
7
1.2 Transportation & Unloading Instructions
1.2.1 Transportation
THERMOSYPHON and its accessories dispatched from our factory are normally packed in
wooden cases. During transportation, extreme care is taken to ensure safe and intact delivery of
the Unit. The unit and other wooden cases are loaded on the trucks as per upright markings.
Packing Slip/Dispatch particulars are sent to the customer immediately after loading the trucks.
Figure F-1.6 : Packing Cases should not be tilted while unloading or shifting.
1.2.2 Unloading Guidelines

Unload unit as close as possible to the unit house, the soil at the place of unloading should be
hard enough to bear the weight of the unit to prevent it from shrinking.
Instructions:
• The unit should be lifted for loading, unloading or shifting from one position to another,
only by means of lifting hooks provided on top of the unit. Refer Table T-1.1 indicating the
Dry weight of unit and its accessories.
• All parts should be unloaded in marked upright position only i.e. these should not be tilted
while unloading or shifting.
• The packing slip supplied with the material should be referred and the number of cases
supplied should be verified with the numbers received at site.
• The wooden / packed cases should be opened only in the presence of Thermax
Engineer or Thermax authorized person / dealer, for checking the inside material as per
the packing slips.
8
• If the cases are opened in the absence of Thermax Engineer / authorized person /
dealer, and if the material is found missing, the responsibility of Thermax shall cease.
• For any breakage / damages, insurance claim should be made.
• For any missing items, Thermax Engineer / authorized person / dealer shall report to
Thermax Limited for replenishment, provided the cases are opened in their presence.
• For any incorrect supply of material Thermax Engineer / authorized person / dealer shall
report to Thermax Limited for replacement, provided the cases are opened in their
presence.
Table T- 1.1 : Shipping weight & dimensions of major parts.
Parameter TS-02 TS-04 TS-06 TS-10 TS-15 TS-20 TS-25

Dimensions LxWxH LxWxH LxWxH LxWxH LxWxH LxWxH LxWxH
Main unit 2.8x1.35x1.95 4.0x1.8x2.1 4.2x1.9x2.2 4.8x2.1x2.3 5.2x2.5x2.3 6.2x2.5x2.3 6.5x3.2x3.0
Weight Kg Kg Kg Kg Kg Kg Kg
Main unit 2050 3350 3800 5500 8150 10250 19000
Note:
• The above parts are the major parts of the unit. There are many more smaller and light
wooden cases / loose parts supplied with the unit.
• The dimensions given in above table are the outermost dimensions, to facilitate the
unloading & shifting.
• Cranes and other unloading equipments should be suitable and exceed the
requirements of weights as mentioned in the above table.
9
1.2.3 Storage
• All the material should be stored under roof and should be protected from rain, water or
direct sunlight. (Refer Figure F-1.7).
Figure F-1.7 : Unit should be stored under roof.
• Unit & parts should not be stored under corrosive atmosphere
• Do not Pile up cases
• Do not store heavy material on soft soil
• Electrical components, motors and bearings should be tightly covered to prevent ingress
of water/moisture.
• Equipment can be rotated manually to prevent jamming.
• Whenever assembled, rotating equipments such as pumps, gearboxes etc is to remain

idle for extended number of days, extra precaution has to be taken care to avoid rusting
and jamming of bearings.
10
1.3 Drawings
A set of the following drawings is given by Thermax Ltd to guide the site persons. These drawings
should be carefully preserved for the reference.
The drawing numbers with Alteration numbers to be recorded in the box below for future records
by the customer before installation:
• P& I Diagram Drawing No. ALT NO.
• GATP & foundation Drawing No. ALT NO.
• Electrical Diagram Drawing No.

ALT NO.
(Supplied with Elect control Panel)
Nozzle displacements and loads on steam outlet and condensate return nozzle.
DISPLACEMENTS NOZZLE LOADS
STEAM CONDENSATE
STEAM OUTLET CONDENSATE RETURN OUTLET RETURN
X Y Z X Y Z
Direction Direction Direction Direction Direction Direction Fx,y Fz Fx,y Fz
UNIT mm mm mm mm mm mm N N N N
TS 02 2 3 10 5 3 9.2 9000 15000 6500 12000
TS 04 2 4 13.6 5 4 12.6 9000 15000 6500 12000
TS 06 2 4 14.5 5 4 13.5 9000 15000 6500 12000
TS 10 2 4.5 17 5 4.5 16 11000 21000 6500 12000
TS 15 2.7 5.8 18.25 5.5 5.8 17.25 11000 21000 6500 12000
TS 20 2.7 5.6 21.5 5.5 5.6 20.5 11000 21000 6500 12000
TS 25 3.3 7.5 24 6.3 7.5 23 11000 21000 6500 12000
STEAM O/L
CONDENSATE Z
RETURN
THERMOSYPHON Y
X
DIRECTION
11
1.4 Installation Guidelines

Thermax provides the post sales services to the customers through to guide from the services of
the Qualified & trained Engineers of Thermax or Authorized Representatives are made available
to the customers /users of the heater from the very next day of the receipt of the order.
Customer is provided with all the information & guidance on the complete Installation and
commissioning of the heater through our qualified & trained Engineers /authorized dealers or
associates.
1.4.1 Unit House Location:

The first step of the installation is deciding the location & size of the heater house. A good heater
house layout will provide adequate space for operation and maintenance. The heater house
layout should be finalized only in consultation with Thermax engineers or Thermax authorized
persons /dealers, well in advance before the delivery of the heater.
Guidelines for location and layout:

The following major factors decide the location and layout of the heater house is:
• The heater house should be located nearest to the utilities to reduce the losses in
transportation
• Safety of the plant & machinery.
• To avoid corrosive atmosphere or gases affecting heater and to its accessories.
• Adequate area near heater and other components for ease of operation & maintenance.
• Typical “Heater House Layout” given in the layout drawing shall provide for the reference in
deciding the unit house plan.
• Refer to GATP and foundation drawings of heater and its accessories.
• Locations of control panel, feed water pump. The same can be suitably located depending
upon the space available.
• The heater house floor loading for all models is approximately 25 MT/M². The floor in front of
the door of the heater house is also to be prepared to withstand this load, since the unit
would be unloaded on this floor and would, thereafter, be pushed inside the unit house.
• Provide adequate ventilation and lighting.
12
Caution : Dimensions of openings of doors of your heater house should be adequate enough to
push the heater and accessories inside the heater house.
Warning:
• Consider the mandatory Rules and regulations for machinery i.e. Factory Act, Fire
Insurance Association, etc. for deciding the location of the heater house.
• Do not finalize the heater house layout without consulting the Thermax Engineers or
authorized dealers/representatives.
• Don't reduce the size of the heater house unless confirmed by Thermax
13
1.4.2 Foundation Preparation and Details
A rigid, flat, leveled foundation is vitally essential for smooth, quiet operation, and lower
maintenance cost of the heater and other equipment. An improperly constructed or
inadequate foundation may cause vibration and possible misalignment of the equipment,
which may lead to metal failure, breakage and Cracks.
Guidelines:
• All foundations must be flat, leveled and rigid.
• The floor loadings, for designing foundations of the heater and accessories, are given in
‘General Arrangement and foundation detail’ drawing of the heater.
• The height of any foundation should be minimum 100 mm above the finish floor level unless
otherwise specified. This is to prevent the structure of equipment from water etc. that may
corrode and reduce the life of equipment and foundation bolts.
• Cast the foundation as per the dimensions given in the drawing.
• Consider the soil conditions while designing the foundations.
• An allowance must be made for a minimum of 25 mm of shimming and grouting when

determining the top surface of the foundation.
Caution : Proper and Sufficient Curing is to be done for all civil foundations.
Warning : Consult Civil engineering structural expert for designing the foundations based on soil
condition of your plant and live weight on the foundation. The qualified & experienced civil
engineer should supervise the foundation work.
14
1.4.3 Shifting On Foundation

Guidelines
• It is advisable to use a spreader type sling when handling/shifting the heater & other
equipment.
• Heater should be moved to its foundation as a unit, with care being taken to prevent
distortion or damage.
• After the foundation holes in the heater are lined up with anchor bolts in the
foundation, the equipment should be lowered over the anchor bolts.
1.4.4 Grouting and Leveling Guidelines

• All the accessories of the heater i.e. feed water Pump, Electrical Control panel etc. can
be placed on respective foundations and can be grouted & leveled.
• Prior to placing the heater and pump on the foundations, the location of anchor bolts
should be checked against the drawing to ensure that these bolts are placed correctly.
• Anchor bolts in concrete should be L or

T-shaped, and should be placed in pipe
or sheet metal sleeves approximately 50
mm larger in diameter then the anchor
bolts to allow for adjusting the bolts in
case they move slightly when concrete
is poured.
Figure F-1.10 : Types of Anchor Bolts
• Where some adjustment is required to level the heater, leveling should be done taking
top plate and unit as reference
• Before final grouting of heater, level the unit properly. For leveling large area shims
should be placed under the pedestal before tightening the anchor bolts. Distortion of
the equipment may occur when the bolts are not tightened equally or if short thick
shims providing only limited surface contact are used.
15
1.5 Installation Guidelines for Thermosyphon Systems
In Thermosyphon systems, generally, the interconnected piping (supply and return lines)
between the Thermosyphon Heater and the user equipment is generally in either OEM / client
scope.
Installation
Supply & Return Lines
Design & construction:
Recognized code of construction is to be adopted for the design and construction of the high-
pressure supply and return lines. Such code could be; ASME /ANSI B3.1 / IBR.
Supply and return lines must be installed with a constant slope of at minimum 5% from the
Thermosyphon heater to user point and return to the Thermosyphon heater. (Refer to Figure F-
1.11). An Air vent valve with plug arrangement, should be provided at the top most point on the
supply line near the user point (refer to Figure F-1.11).
Supply and return lines are to be designed such that the thermal expansion do not create any
undue stresses on the lines and on the Thermosyphon heater and enough flexibility is provided
for the considering thermal expansion of the pipelines. Piping Stress analysis is recommended for
the design and construction of the supply and return lines. This is mandatory for all installations.
Thermosyphon & heat exchanger nozzle displacements during operation and allowable loads
on them are also to be considered for stress analysis.
Table T-1.2 : The recommended line sizes based on the acceptable velocities are
Model Tube NB mm Tube OD x thickness. mm Tube content litres/m ‘V’

TS-02 80 88.9 x 5.5 4.77
TS-04 80 88.9 x 5.5 4.77
TS-06 80 88.9 x 5.5 4.77
TS-10 80 88.9 x 5.5 4.77
TS-15 100 114.3 x 8.6 7.41
TS-20 100 114.3 x 8.6 7.41
TS-25 100 114.3 x 8.6 7.41
* Design-pressure up-to 90 Barg
The total line length (supply and return inclusive) that needs to be provided must accommodate the
expanded water volume at operating conditions, so that the process heat exchanger is not fouled with
water.
16
The total length of required pipeline is calculated as given below. (Please refer to Figure F-1.11)
• TS water hold-up :Q (level 1) : _______________ liters.

(Basic coil + down comer and bottom header volume)
• Safe Filling quantity : Q1 = 1.2 x Q (level 2) : _______________ liters
• Expansion factor : E from Table T-1.3 : _______________ %
• Operating Volume : Qop = (1+E/100) x Q1 :_______________liters
(level 3)
• Piping volume to be
Provided : Pv = Qop – Q : _______________ liters
• Liter content of pipe : V from Table T-1.2 : _______________ liters/m
• Total pipe length : L = Pv / V : _______________ meters
To avoid likelihood of water entering the user point, an additional pipe length must be installed,
such that there is at-least 0.5 meters of vertical pipe distance between the operational water
level (level 3) and the bottom most point of any user point or bottom most unit tray. (level 4).
The bottom most point of any unit tray or user point should be at least 2 meters above the
header of Thermosyphon heater (refer to Figure F-1.11).
Total system volume including the user point volume should be > 1.50 times q as a general
guideline.
Sample calculation of length for Thermosyphon
• Thermosyphon water hold-up : Q : 1040___________ liters.

• Safe Filling quantity : Q1 = 1.2 x Q : 1248___ _______ liters
• Expansion factor : E from Table T-1.3 : 37_____________ %
For 75 kg/cm²g operating pressure
• Operating Volume : Qop = (1+E/100) x Q1 : 1710__________ liters

• Piping volume to be
Provided : Pv = Qop – Q : 670____________ liters
• Liter content of pipe : V from Table T-1.2 : 4.77 __________ liters/m
• Total pipe length : L = Pv / V : 141____________ meters
Hence the supply line length should be 70.5 m and return line length should be 70.5 m (50%
each)
Note: In case, if it is not possible, in practice to install the calculated length of supply and
return line, one can chose a one size larger tube diameter. Even in spite of doing so, if it is not
possible to install the required length of lines then the OEM / customer needs to contact
THERMAX LIMITED.
17
Table T-1.3: Expansion volume at different operating pressures

Filling in temperature Deg C 20
Pr. Temp saturation Vf Exp. Based on Water
kg/cm²g °C m3/kg %
-1 25.47013 0.00100172 0
5 158.291 0.0011001 9.8
10 183.3365 0.00113194 13.0
15 200.5336 0.00115717 15.5
20 213.9391 0.00117911 17.7
25 225.0604 0.00119907 19.7
30 234.6369 0.00121774 21.6
35 243.0906 0.00123551 23.3
40 250.6869 0.00125264 25.0
45 257.6043 0.00126932 26.7
50 263.9691 0.00128569 28.3
55 269.874 0.00130184 30.0
60 275.3896 0.00131787 31.6
65 280.5705 0.00133385 33.2
70 285.4603 0.00134984 34.8
75 290.0941 0.00136589 36.4
80 294.5007 0.00138205 38.0
85 298.7041 0.00139837 39.6
90 302.7243 0.0014149 41.2
95 306.5785 0.00143168 42.9
100 310.2813 0.00144876 44.6
105 313.8453 0.00146617 46.4
Inspection & Testing:
The inspection and testing has to done in conformance with the relevant/adopted code of
design and construction. This should include at-least the following
• 100% visual examination of all weld joints

• 10% radiography examination on randomly selected butt weld joints.
Upon completion the hydraulic test have to be done.
18
Figure F-1.11 : Installation Guidelines for TSA Units.
19
Caution :
• All fuel, steam & condensate piping should be thoroughly flushed or blown out (cleaned),
before connecting to the system. This will prevent foreign matter from blocking or
damaging the piping system.
• Avoid using elbows and short bends in the fuel, steam & condensate lines as far as possible
to reduce frictional losses.
• Do not use smaller diameter pipes than those specified for the Thermosyphon system, as
system pressure drop will go higher than available head & the Thermosyphon system may
not work.
• Do not use screwed connections anywhere in the Thermosyphon piping. Use welded
construction.
• Provide a rise of about 10 mm/meter in the steam supply piping from the unit towards the
user equipment and a similar slope from the user equipment to the unit in the condensate
return line.
• Do use expansion bends after every 30-meter’s of straight run or piping.
• Do use vents to let out air and gases at all high points. Presence of air will enhance
corrosion.
• Use drain valves at one or more low points in the installation.
20
1.6 Assembly Guidelines:

Accessories and Other Assemblies
The Unit installation consists of the following basic circuits:
• Flue Gas Ducting Layout

• Electrical System
To complete the installation work of the heater, these circuits should be completed as per the
following guidelines & instructions:
GUIDELINES
General:
• Place other accessories i.e. Feed water pump, electrical control panel etc. on their
respective foundations. These accessories should be carefully leveled and physically
aligned in their final position before grouting them.
• Complete the flue gas ducting work from Thermosyphon heater to chimney. Ensure that
all the joints in flue gas path are airtight and the size of ducting and connecting angle to
chimney is correct.
1.6.1 Flue gas system -Chimney

In view of pollution hazards a chimney to discharge the products of combustion is
recommended. The minimum height of the chimney should be about 3 meters (10feet) above
the highest point of the tallest building in a radius about 300 meters. The height of the chimney
shall be about 15 to 20 meters, unless taller ones are specified by statute.
Chimney can be either of the following designs:

a) Self supported
b) Guy rope Supported
c) Structural supported
d) Wall Mounted
However, Chimney for the unit should be of the adequate top diameter as per the
recommendations given in the table T-1.4 below.
Guidelines:
• Chimney design Reference can be taken from the IS 6533 specifications and considering
the Local geological conditions
• Provide all the Accessories of the chimney i.e. Aviation Lamp, Lightening Arrestor etc as
per the recommendations of the local statutory norms.
21
Chimney
Unit
Figure F-1.12 : Self Supported Chimney.
Warning :
• Follow rules and regulations of Smoke Nuisance Act and consult their local Pollution
Control Board’s office for further information & guidance on chimney design & height.
• Never reduce the Top Diameter of chimney than the recommended size.
• For units installed in countries other than India, follow the local regulations for stack
installation.
1.6.2 Flue Gas Ducts:

• The area or the size of the flue gas ducts needs to be the same as recommended in the
table T-1.4 below to ensure that the flues gas leave the heater & system easily without
any excessive pressure drop.
• The ducts can be of circular rectangular or square cross section.
Table T-1.4 :
MODEL TS-02 TS-04 TS-06 TS-10 TS-15 TS-20 TS-25
Minimum chimney top diameter

200 250 250 450 500 600 650
(mm)
22
Caution:
• Keep the cross sectional areas of the flue gas and air duct same as recommended. Do not
reduce the cross sectional areas.
• All The Ducts should be, preferably of fully welded construction. Any leakage means
reduction in the output of the unit.
• External columns, from ground, should support long ducts.
• Provide sockets with plugs at the distance of 1 meter from heater on flue gas ducts for
testing purpose.
• Provide long radius bends & avoid sharp bends in the ducts.
• Insulation of the ducts should be done after through check for the leakages, after the
commissioning of the flue gas system.
• Provide Insulation of proper density & the thickness as indicated in the table T-1.5 below.
The table below gives recommended insulation thickness in mm required for different pipe sizes
and different operating / fluid temperatures.
Table T-1.5 :
a) Mineral Wool –
Pipe dia Operating / fluid temperature oC

(NB) mm 90 150 200 260 315 375
25 25 40 65 65 75 90
40 25 40 65 65 75 90
50 25 40 65 65 75 90
80 25 40 65 65 75 90
100 25 50 75 75 100 100
150 40 50 75 75 100 115
200 40 50 75 75 100 115
250 40 65 90 90 100 125
300 40 65 90 90 100 125
Flat 40 65 90 90 100 125
Note : Insulation material assumed is Mineral wool having thermal conductivity 0.036 kcal/m
hroC and average density about 100-200 kg/m3.
Caution :
1) The surface temperature after insulation is 55 – 60oC.
2) Insulation upto 65mm should be in single layer and above 65 mm, multiplayer, e.g.
80mm two layers of 40mm each for 90mm inner layer of 40 mm and outer of 50mm.
23
b) Glass Wool –
Pipe dia Operating / Fluid temperature

(NB) mm 90 150 200 260 315 3756
25 25 25 25 25 40 40
40 25 25 25 25 50 50
50 25 25 25 25 50 50
80 25 25 40 40 50 65
100 25 25 40 40 50 65
150 25 25 40 40 65 75
200 25 40 40 40 65 75
250 40 40 40 40 65 75
300 40 40 40 40 65 75
Flat 40 40 50 50 65 75
Note : Insulation material assumed is Glass wool having thermal conductivity 0.045 kcal/hr oC @
100oC and average density about 80 – 100 kg/m3.
24
1.6.3 Electrical System
Figure F-1.13 : Electrical Control Panel

Guidelines:
Electrical Control Panel Box And External Electrical Switch
The Electrical Control Panel Box is supplied by Thermax, with the Unit, pre-wired with switches for
all motors for Thermosyphon heater system.
• Three phases, 415 V, 50 cycles A.C. electric supply with neutral and earth is required for
operating the unit.
• The supply to the heater should be given through a main switch fuse having adequate
capacity as mentioned in the following table. The back-up fuse capacity to suit the total
electric loading should also be maintained.
Earthing Of The Equipment

• Earthing wires of adequate cross-sections should be provided to link the heater, the
electrical control panel box, various motors, etc. to a suitable earth plate, as per Indian
Electricity Act.
Following size of earth conductors can be used:

Up to 3.75 kW 8 SWG GI wire
5.5 kW to 30 kW 3/8" GI fine wire rope
37 kW to 55 kW 5/8" GI fine wire rope
25
Warning: While installing the electrical cables keep in mind the rules and regulations
involved. Electrical components such as motors, drives, contactors etc, rubber components
and instruments are not covered in the warranty
Caution:
• Provide proper lugs to terminate the cables. Also provide ferrule numbers on cable for
identification.
• Provide adequate size switch fuse unit and cables.
• If the voltage fluctuation is going to be more than ± 6% of the specified voltage, we would
strongly recommend installing a voltage stabilizer of 1 KVA for the control circuit.
• Provide proper sized glands for the cable at the entry to control panel and at motor terminal
box.
• Earthing pit should be as per the norms.
• Use cable trays or trenches for laying the cables.
• Never increase or decrease the back up fuse MCCB capacity.
• Never combine neutral & Earth connection.
• Laminate the electrical diagram, with plastic sheet and paste inside the control panel or
near to it.
• Take enough photocopies of the electrical diagram for records.
26
1.7 Thermosyphon Unit Instrumentation

Controls & Safeties
The Thermosyphon heater has several safety features, which protect the system against the
effects of excessively high pressures and temperatures and low water level conditions. These
provided controls ensure trouble free & safe operation of the heater.
Controls :
a) Thermosyphon pressure High cut Off Pressure Switch

( For Two Stage Modulation Units)
This pressure switch senses the Thermosyphon pressure with the help of the connected
piping/tubing, If Thermosyphon pressure increases above the set pressure of the pressure switch,
the unit is stopped by automatically switching off the Burner. The Burner restarts automatically
when Thermosyphon pressure reduces below the differential Pressure setting of the pressure
switch. This pressure switch provided safeguards the unit against excessive pressure.
All pressure switches use a sensing element, bellows being the most common. The bellows type
performs well in applications where even shock and vibrations are present. The sensing element
can be used for a variety of process fluids. All Thermosyphon models supplied by Thermax is with
Pressure Transmitter and Pressure Indicating Controllers (PIC). For the burner which are two stage
type are operated through the pressure high set point given in PIC. There is no field mounted
pressure switch.
b) Pressure Transmitter – Thermosyphon pressure modulation.

Pressure transmitter is used to control the Thermosyphon heater pressure which is hooked up by
piping/tubing. The pressure transmitter is connected with the modulation controller. The pressure
transmitter senses the pressure and gives signal to the controller. This Thermosyphon pressure
controller regulates the heater pressure in the Thermosyphon heater by modulating the fuel-firing
rate & corresponding air of the burner. This is supplied with the heater.
This controller with other controls reduces the fuel & air, which is fed by the burner in the furnace,
when the Thermosyphon pressure increases. In addition, it increases the firing rate & air when the
pressure in the Thermosyphon pressure reduces. The increase or reduction in the firing rate is in
proportion to the increase or decrease of the Thermosyphon pressure in the heater.
This controller avoids the burner on-off operation of the heater, which is undesirable to the unit &
to the process. In short, it tries to maintain the steady pressure in the Thermosyphon, when the
process load/pressure fluctuations are within the reasonable limits. This pressure controller control
the firing between lowest & highest firing range of the burner.
27
Safeties :
a) Outlet Steam Pressure High Switch

When the Thermosyphon pressure increases higher then the set point given in PIC , pessure
switch provided senses the increased pressure and the heater is tripped by automatically
switching off the Burner. This ensures that the heater is not operated beyond this set point.
b) Pressure Switch – Rupture dick failure

When the Thermosyphon pressure increases higher then the normal operating pressure, the
rupture disk provided on the heater bursts, the heater pressure is released by lifting of safety
valve. This Pressure switch provided senses the rupture disc failure and the heater is tripped by
automatically switching off the Burner. This ensures that the heater is not operated when the
rupture disc bursts.
c) Digital Temperature Indicator & controller;
The system is provided with digital temperature indicator controllers, the same controls and
indicates,
• Thermosyphon heater outlet temperature
The Thermosyphon heater outlet TIS is used for indication of Thermosyphon outlet
temperature, if during operation the Thermosyphon temperature increases higher then
the set value, it will cut off the burner.
• Flue gas temperature
The fuel gas TIC is used for indication of flue gas temperature & as a safety, which cuts of
the burner incase of flue gas temperature rises above the set point. The TIS set point is +30
deg “C” above the normal flue gas temperature, The safety temperature setting is done
at the time of commissioning.
Resistance Temperature Detectors (RTD) are used with each TIC to sense the temperature.
d) Rupture Disk
Rupture disks are intended to provide a pressure relief opening. This rupture disk is designed to
burst at a specified temperature and pressure, thereby relieving excess pressure or preventing
excessive vacuum in a system. This rupture disc is installed before the safety valve, which bursts
when the unit pressure goes higher than the normal operating pressure.
Warning: It is imperative that this rupture disk be properly installed and safely vented in order to
avoid bodily injury, damage to property, pollution and loss of product.
28
Figure F-1.16 : Rupture Disk
Installation of Rupture Disk
• Place inlet of Safety Head on a flat work surface in position as shown with flow arrows
and locating pins up.
• Place NEW, UNDAMAGED, rupture disk on inlet so locating pins mate with the
corresponding holes in the rupture disk flange.
• Carefully align and place Safety Head outlet flange in position as shown. Ensure flow
arrows on the disk tag and on the Safety Head point in the same direction.
• Assemble unit with twelve point cap screws. Tighten the twelve point high strength cap
screws with socket finger tight before torquing. DO NOT SUBSTITUTE for cap screws
supplied. Do not lubricate blue fluoropolymer coated cap screws.
• Evenly torque the cap screws.
• The twelve point cap screw heads should be recessed into the Safety Head outlet after
installation.
29
Figure F-1.17 : Installation of Rupture Disk
Note: Uneven or under torquing can cause disk rupture below its marked burst pressure.
Excessive torquing can cause damage to the disk and Safety Head. Use the correct socket and
torque wrench with appropriate torque value range. The torque wrench must be calibrated.
e) Level Probe
Self monitoring low-water level limiter with periodic self checking level switch. The combination is
used to detect water falling to the lowest permissible level in system. A typical view of Level
probe mounting arrangement is shown in the figure. For more details on installation and
operational refer manual enclosed in the annexure chapter.
Figure F-1.18 : Level Probe
30
f) Unit Safety valve

Mechanical safety against Thermosyphon pressure high is provided by Safety valves fitted on the
top of the unit shell.
The Safety Valve of the heater is the ultimate safety to the unit. These safety valves are set at the
maximum working pressure of the unit.
When the pressure controller fails or the setting is more than the maximum working pressure of
the heater then the safety valves lift & vent out the pressure thus reducing the excessive pressure
of the heater and safe guard the heater against high pressure.
The safety valve is to be set after carrying out hydro testing of the heater, after setting the safety
valve to the maximum working pressure, ensure the safety valve lifts up at the set pressure by
taking trials.
Photograph and cross section of a safety valve are enclosed in Figure below F-1.19 and F-1.20
respectively.
VALVE SETTING
GUIDE ROD NUT
SPRING
VALVE
SEAT
STEAM
OUTLET
Figure F-1.19 : Safety Valve

BLOWDOWN
RING
STEAM INLET
Figure F-1.20 : Cross Section of Safety Valve
Note: In addition to the above said ontrols, there are additional monitors provided on the
burners, please refer the burner manuals for more details.
31
Input Requirements Thermosyphon
02 INPUT REQUIREMENTS
2.1 Thermosyphon Circuit Water Specifications

Thermosyphon heater water means the water, which is inside the unit. The water quality to
dosed as per the specifications given below.
Table T-2.1 :
Total hardness mg/kg < 0.01
Conductivity @ 25 °C Mew sec/cm 50 < k Water < 300
PH Value @ 25 °C 9~10.5
Silica acid (SiO2) Mg/kg< 4
Oxygen Mg/kg< 0.02
Iron (Fe) mg/kg< 0.02
Total CO2 mg/kg Trace
Hydrocarbon Trace
Phosphates (PO4) mg/kg2~6
2.2 Electrical Input

The electrical input to the electrical control Panel of the unit should be:
Three Phase, 415 +/- 6% Volts, 50+/- 3% Hz, A.C. Supply with Neutral & Earth connections.
33
Thermosyphon Input Requirements
2.3 Thermosyphon Plant Component Selection

All components in Thermosyphon System including Utility must be suitable to withstand the
system’s maximum temperature and pressure
i. System design temperature : 353°C
ii. System design pressure : 90bar
Note : Refer chapter installation guidelines for Thermosyphon system for more details on system
and utility pipe lines.
Thermosyphon Heater
Tube material must be of steam boiler quality carbon steel suitable for more than 300°C and 70
bar.
Piping:
Carbon steel material suitable for high temperature (300°C minimum) should be used.
eg. SA 106 Gr. B or equivalent, Schedule to be decided based on pressure rating
preferred.
2.4 Fuel Supply (Liquid Fuels)
2.4.1 Liquid Fuels

A typical arrangement for fuel oil storage and flow to the heater is shown in P&I Drawing. The
fuel firing system is designed to operate on FO (Furnace Oil) / LDO (Light Diesel Oil) / HSD (High
Speed Diesel). Since FO is viscous and requires pre-heating to make it flow, the fuel system is
provided accordingly.
In order to have flooded suction, these tanks are to be installed at a height not less then 3
meters from fuel pump. A typical P&I is enclosed.
a) Storage, Handling And Preparation Of Oil
34
In many industries, little attention is often paid to oil storage, handling and preparation facilities.
The Puddles of oil near the pump house and storage tanks – is an indication of leaky joints,
flanges and pipelines. Clogged filters, which impose an additional duty on the pumps. And poor
combustion, manifested by smoky or spluttering flames leading to high fuel consumption.
Spilt oil is an easily avoidable waste, and renders the ground slippery and dangerous. For
efficient burning, foreign matter such as dust, water, coke and sludge particles in fuel oil should -
be removed by adequate filtration. It is also necessary to examine several aspects, such as
pumpability of oil during winter months, type and capacity of the pump, the length of the -
pipelines, and the sizing of pipes. Correct pre-heating of fuel oil prior to combustion is very
important for fuel efficiency. We have covered some of these aspects, which have a significant -
effect on the fuel consumption in your boiler plant.
b) How To Store Fuel Oil

Large quantities of fuel oil are best stored in cylindrical tanks either above or below the ground.
Generally, the main storage tank is erected above ground when the capacity exceeds 70,000 -
liters. For lower capacities, underground storage may be more economical. When erecting a
storage tank above ground, remember to maintain safe distances from the surrounding
structures, as prescribed by the Explosive Department.
Storage tanks are generally made from welded mild steel plates. The overhead tank should be
mounted on concrete blocks, which provide a slight gradient of 1:50 towards the drain valve.
Each of the following fittings on storage tank has a definite role to play.
The outlet or draw-off pipe should be located at the raised tank end, no less than 15 cms. from
the bottom. It should be at least 15 cms. in diameter with outflow unit and provided with a -
outlet pipe line of 6 cms with a strainer at the outlet.
The vent pipe, of goose-necked type, should be located at the highest point of the tank to
facilitate filling by venting air and oil vapour during the filling operation.
The fill-pipe could be located either at the top or at the bottom of the tank. If located at the
top, it must be ensured that the pipe descends almost to the bottom of the tank. When located
near the bottom, it is important to position a non-return valve on the line to avoid fuel oil re-entry
into the oil tanker on account of back pressure. To avoid leakage of oil during decanting, it is
advisable to have a cam lock coupling at the filling end so that it fits easily on the delivery hose.
The drain pipe, which is fitted at the lower tank end bottom, is used to periodically remove the
accumulated water. It is a difficult task to drain the water and sludge from underground storage
tanks. The water and sludge which settle down at the bottom should, however, be removed by
a hand pump. It would be advantageous to have two suction pipes - one at a lower level and
the other at a higher level - so that in case the sludge accumulation is up to the lower point and
the suction line chokes up, the alternative line could be put into operation and adequate time
would be available to decide upon a time schedule for cleaning the tank.
Fuel oil as delivered may contain dust, dirt, gummy matter and water. During storage for
prolonged periods, these tend to form sludge, which accumulates in the various `dead spaces'
of the tank, where the oil is not agitated during normal operation of the tank. This results in
35
unsteady flames and clogging of filters. To avoid this, some means of agitation of oil in the tank
may be necessary.
Cleaning of storage tanks, about once a year, will remove the accumulated sludge. Besides
cleaning, periodic inspection and maintenance of the storage tank, out flow unit and auxiliaries
is important.
Table T-2.2 : Recommended fuel oil storage & service tank capacities in liters.
Unit Model Storage Tank For
8 HRS 16 HRS 24 HRS
TS02 3000 5000 8000
TS04 5000 10000 15000
TS06 6000 12000 18000
TS10 10000 20000 30000
TS15 15000 30000 45000
TS20 20000 40000 60000
TS25 25000 50000 75000
Please follow the rules and regulations involved in your state for storage of heavy oil.
c) Removal Of Contaminants
Fuel oil should be freed from possible contaminants such as dirt, sludge and water before it is
finally fed to the boiler.
Fuel oil arrives at the factory site either in tank lorries by road or by rail. Oil is then decanted into
the main storage tank. To prevent the possibility of contaminants such as rags, cotton waste,
loose nuts or bolts or screws from entering the system and damaging the pump, position a
coarse strainer of 40 mesh size (not more than 6 holes per linear inch) on the entry pipe to the
storage tanks. Progressively finer strainers should be provided at various points in the oil supply
system to filter away finer contaminants such as external dust and dirt, sludge or free carbon.
It is advisable to provide these filters in duplicate to enable one filter to be cleaned while oil
supply is maintained through the other.
TABLE T-2.3 :
Sizing Of Strainers
Location Strainer sizes Mesh Holes/Linear inch
Between rail/tank lorry decanting

point and main storage tank 40 6
Between storage tank and service tank 80 9
Between service tank and Oil pre-heating

& pumping station of Unit 80 11
36
d) Pump Capacity-from Storage tank to Day or Service tank

It is advisable to use a positive displacement pump such as a screw/internal gear pump, for
pumping oil.
It is also necessary to size the pipelines properly so that there is no excessive pressure drop and
the required oil flow rates are obtained. On expansion of facilities, the adequacy of pipe sizes -
for transporting larger quantities of oil should be reviewed. It is preferable to lay the oil pipelines
over ground as any oil leaks would then be visible and could be quickly attended to.
Fuel oil has to be pumped from the main storage tank to the day service tank. Depending upon
the desired quantity of oil to be pumped, and the distance between the storage tank and the
service tanks, adequate pumping capacity will have to be provided. A gear pump of 2000
Ltrs/hr. at a pressure of 3 to 4 bar (50 PSI) is sufficient for these boilers.
e) Fuel Oil Pre-Heating- For Storage Tanks/Service Tank

Fuel oil increases in viscosity as temperature drops, which makes handling a little difficult,
particularly in winter. At low ambient temperatures, heavy oil is not easily pumpable.
Recommended pre-heat temperature for pumping is 40øC for heavy oil in case of light oil when
the ambient temp. drops below 20 deg C Preheating temp for pumping is 30 deg C.The pre-
heating of oil in the storage tank to render it pumpable can be accomplished in two ways either
by steam heating or electrical heating.
The outflow unit is essentially a heat exchanger, with steam or electricity as the heating medium.
The unit protrudes from the suction connection into the oil space. The arrangement of outflow
units are as under.
i) Electrical Outflow Heater-
A pipe of about 150 mm NB is welded to the tank and the oil supply pipe is taken at the
bottom of this pipe. An electric immersion type single phase or three-phase unit with a
temperature sensor is inserted in the pipe. Capacity of this unit is 3 kW. An electric heating
tape or steam tracing should be used to heat the oil in the pipe line from the tank to the
boiler. For pipe lengths less than 20 feet, heating tape of 220 V AC, 2 KW capacity should
be wound. For longer pipes the heating tapes should be of 3 KW capacity.
Whenever electrical unit is used for outflow heating, it is essential that a minimum oil level
switch and a Digital temperature indicator cum controller, is installed and preferably with
additional dial type indicator installed very close to it.
The TIC should be set at 45øC.This TIC is to be interconnected with unit contactor to switch
off the unit in case of the pre heat temperature is increased above the set point.
37
Also if level of oil in service tank drops to about 150 mm above the unit level then also the
unit should be switched off this will prevent the unit element getting overheated/burst.
ii) Steam Heating :
An alternative arrangement, in case steam is available, is to tap out a small amount of

steam from the steam main pipeline by a 12.7 mm (1/2") NB pipe and to connect the pipe
to the units steam inlet through a 1/2" solenoid valve. Supply for the solenoid valve should
be given through a thermostat fitted on the unit. The valve will remain open as long as the
temperature of outgoing oil is less than the present temperature, i.e. 45°C. The outlet of the
steam heating coil may be connected to a tracer pipe of 12.7 mm (1/2") NB running all
along the pipe touching the oil pipelines from the service tank to the fuel filter on the unit.
This will heat the oil in the pipe to the required temperature. A steam trap should be fitted at
the end of tracer pipe. The tracer pipe and the oil pipe then may be legged together for
better heat transfer to the oil. For details of this type of heating arrangement, please refer
drawing in this manual.
As the steam consumption may not be very high, a steam outflow unit is preferable. It is
suggested that heating cords may be used in the bypass line to prevent the fuel oil from
cooling down.
It is recommended to install a bucket type filter of about 30 litre capacity with large filter
area before oil service tank. This shall reduce the maintenance time and frequency of
cleaning the filter due to its large capacity.
All the pipe lines and circulation header are to be insulated if fuel is heavy oil to minimise
the heat loss.
If the ambient temperature, during any part of the year, is going to fall below the pour point
of the oil used, then all the pipe lines, fuel oil circulation header and pump should be
provided with suitable steam/electrical heat tracing arrangement.
f) The Fuel Oil Service /Day Tank To Heater House

The service tank should be located in proximity to the heater.
The principles enumerated earlier for the maintenance of main storage tanks apply here too.
The service tank may be sized for a shift's consumption or daily consumption - the choice
depends on capacity required, ease of location of tank near the heater house, pumping
capacity, horse power, etc. Certain additional precautions may, however, be taken with
respect to service tanks. Capacity of service tank should be 4.5 kL maximum when placed
outside the boiler house or less than 1KL if placed inside the boiler house (as per the
recommendations of explosives dept. in India).
i) Service tanks should not be located above furnaces, hot air or flue gas ducts, etc.
ii) They should be provided with overflow pipes which lead directly below to a sump. As a
further refinement, limit switches could be provided to avoid the possibility of oil overflow.
38
iii) In gravity feed systems, the difference in height between the service tank and the fuel
pump should be at least 3 meters.
iv) The tank should have hinged manhole, level indicator, drain, overflow, out flow unit, air
vent etc.
v) The level indicator should be positioned such that it can be seen from boiler control
panel for ease of operation.
Figure no F-2.1 Drawing of the outflow unit arrangement & service tank
39
g) Preparation Of Fuel Oil For Combustion

The pre-heating of heavy oil in the storage tanks renders it pump-able. However, heavy oil
generally has to be heated further so that its viscosity is appreciably lowered to about 10-12 CST
to suit the burner. This operation is extremely vital if we are to ensure that fuel oil is properly
atomized by the burner - an essential condition for efficient combustion.
The oil is pre-heated by electricity .The capacity of the pre-unit depends on the oil flow rate and
the required rise in temperature. A suitable capacity oil pre-heating and pumping station is
provided with the unit for this purpose.
h) Ring Main System (Applicable For Heavy Liquid Fuels)

Medium & heavy fuel oils require pre-heating in the Oil Pre heating Stations, to lower their
viscosity up to 10 -12 CST so that satisfactory atomization & combustion takes place. In most of
the fuel oil systems, to save heat, a part of the heated oil is returned to the fuel oil header, at the
fuel pump suction.
This therefore raises the fuel oil temperature in the pump suction header beyond 100 degrees
“C”, especially when the burner operates continuously in low load. Since the fuel oil has some
amount of water & low boiling oil fractions, present, this could evaporate at temperatures
beyond 100°C causing cavitations problems in the main pressurizing pump. The rise of
temperature up to 120 degrees ”C” & variation in fuel oil temperature tends to cause cavitations
& variation in burner fuel pump pressure. Many a times this causes premature failure of fuel
pumps.
In addition, the key parameter to be maintained in the pressure jet burner system is the oil
pressure at the burner inlet. Any variation in this could adversely affect the combustion
parameters.
An effective method of avoiding such failures & performance problems is to adopt fuel oil ring
main systems.
Operating principle of a ring main is that the fuel pressure in burner pump suction line should be
maintained higher than the vapor pressure corresponding to oil preheat temperature.
Table No T-2.4 Ring Main Circuit Pressures
Fuel pre-heat
Temperature in deg C 100 105 110 115 120 125 130 135 140 145
Ring main pressure
kg/cm2 1.5 1.7 1.9 2.1 2.3 2.5 2.9 3.3 3.9 4.5
The ring main pump capacity should be at least equal to 1.5 times the sum of maximum firing
rates of all burners connected to the ring main, or 1.25 times the capacity of burner fuel pump.
40
Figure F-2.2 : Light Oil Line
Figure F-2.3 : Heavy Oil Line
41
Caution:
• Use only M.S. pipes with welded or flanged joints.

• Avoid using elbows and short bends as far as possible.
• Fuel piping should be thoroughly flushed before being connected to the unit.
• Never reduce the diameter of the pipelines than mentioned in the drawing.
• Use only gate valves. Globe valves offer more resistance and hence pressure drop is more
than gate valves,
• Select fuel storage tank of adequate capacity. Keep in mind the rules and regulations
involved in your state.
• Use outflow Unit For heavy oil and insulate the pipelines to reduce heat loss.
• Provide the digital temperature indicator cum controller with the out flow unit to cut off the
heating at preset temperature. Also, provide dial type fuel temperature indicator near to
the digital TIC.
• Avoid over heating of the fuel oil at the out flow unit.
• Use flame proof enclosure for the out flow unit switch gear, if installed near the fuel tank
• Air vent of the fuel day/service tanks should be taken out side of the heater house to
prevent vapors of the low boiling fractions of the fuel oil to get accumulated in side the
boiler house.
• Use recommended (size and mesh) strainers to clean the fuel at every stage.
2.4.2 Gas Fuels

The heater user should ensure that the gas supply pressure is in the range of 1-2 kg/cm2 at the
isolating valve of the heater gas train. The heater gas train components are selected & sized for
this pressure range only.
If the gas supply pressure is higher than above, the user should reduce it to 1-2 kg /cm2 before
connecting it to the heater gas train.
Installation of the Gas Pipe line & burner Gas train
• Note that gas train components are designed for low pressure and hence testing with
high pressure compressed air/nitrogen can damage the gas train.
• The gas train should be installed at about 500 mm above the floor level to ensure easy
maintenance of its components, particularly the regulator, strainer and solenoid valves.
• The part of the Gas-train comprising main gas solenoid valves should be as near as
possible to the burner, so that gas flame is established quickly and residual gas burning is
minimum after burner shut down.
• The gas supply pressure at the inlet of the gas train should be checked to be in
conformity with specified pressure range. (Refer P&I Drg. for gas fired units)
• The manual quick shut-off valve should be opened very slowly so that the diaphragm of
the regulator is not subjected to sudden pressure surge.
• The pressure setting of the pilot and main gas regulator should be kept at near minimum
during initial start up of the burner, and the final setting should be done during burner
firing to achieve the required firing rate.
42
• The supply gas pipe is to be connected to gas train inlet ball valve with the help of a
union or a flanged joint. The supply gas pipe should be thoroughly cleaned and flushed
out with air, to ensure that all dirt particles are removed before connection to gas train.
• Gas filter, pressure regulator and gas solenoid valves should be accessible for routine
maintenance and adjustments and suitable platform may be provided.
• Unauthorized tampering of gas pressure adjustment and other settings should be

prevented. Adjustments, if at all required, should be done by trained and authorized
personnel only.
• Brackets and supports for gas piping should not be welded to the gas pipe. Suitable
screwed clamps only should be used.
• After installing gas line with fittings, it is necessary to carry out leakage test using
compressed air/ nitrogen gas at a pressure of 7 kg/cm2 by isolating the gas train
components. All the lines with flanges should be tested for leakage with the help of soap
solution.
• Gas train and its components should be tested for leakage using air at pressure not more
than 2000 mm WC.
• If the gas is saturated with water vapor, drain point should be provided at lowest point in/
near the gas train for drawing the condensed water vapor.
• Vent Piping:
i. Vent shall terminate in a safe place, preferably in the open air above roof level.
ii. If it is not feasible or practical to terminate above roof level vent, line exit must be
at least 5 meters from potential ignition source.
iii. Vent line should not pass through electrical intake chambers, transformer rooms
and lift shafts.
iv. Care should be taken such that there will not be any ingress of foreign material
and water into vent line.
• It is advisable to install the gas train closer to the unit in unit house. Adequate space shall
be provided for gas train installation, maintenance and operation/access.
• The unit house should be properly ventilated, preferably by large windows on all sides.
Note : Please make sure that while installing the gas train, regulations of Fire Insurance
Association, Explosives Act, factory inspectorate etc. are strictly adhered to.
43
Figure F-2.4 : P&I of Gas Train ( Typical ) For details refer respective unit P& I D.
44
Thermosyphon Commissioning Process
62
03 COMMISSIONING PROCESS
3.1 Pre-Commissioning
The pre-commissioning is the part of the commissioning activity of the unit.
Pre Commissioning is commenced on completion of all the connections as per the preceding
chapters; P & I diagram electrical diagram and the assembly work.
The persons entrusted with operation, servicing and observation must be present during pre-
commissioning. It would be better, during commissioning operation; direct superiors of heater
operators should be present. Also please refer the Instruction manual prior to commissioning.
Thermax representative shall provide the guidance & supervision of the critical activities during
Pre-commissioning & commissioning. Thermax representative shall ensure that all the settings &
actions are completed as per the detailed checklists. However the users/customers should
ensure that the following and all other jobs, as suggested by Thermax representative are
completed before inviting them for commissioning.
3.1.1 Pre – Commissioning Checks -

A. General :
) Check and level all the equipment and tight their foundation bolts.
) Check all the motor windings for damage and moisture with megger.
) The process lines and the unit is to be hydro tested.
) Check and ensure that all the pipelines and ducting are supported properly.
) Check all the filter/strainer and valves for its operation.
) Arrange unit operators and other manpower required to operate the unit.
) Arrange boiling out and feed water treatment chemicals.
) Insulate all the lines and equipment after they have been hydro tested completely.
) Clean and flush instrument line by compressed air or liquid medium.
46
Commissioning Process Thermosyphon
) Fill the recommended lubricants/grease into the moving items. (Refer manufacturers
manual for details)
) After unit erection, check the complete system with respect to given layout.
B. Unit :
• Check alignment of the unit and tighten its foundation bolts.
• Replace all the factory fitted gaskets.
• Check all the mountings and fittings whether they are fitted with proper gaskets at their
respective locations.
C. Feed Water System :
) Get the water treatment plant commissioned and ensure the quality of Feed Water is
within the specified acceptable limits.
) Flush the feed water storage tank and pipelines.
) Flush the make up water pump completely before commissioning as this is filled with anti
corrosive compound before dispatch, to prevent rusting in storage. This compound should
be drained and the pump flushed completely.
) The water level low safety is working.
) The pressure gauge is fitted at pump outlet
) The strainer at pump suction strainer is cleaned.
Caution : Feed water parameters are to be maintained as per the specifications given.
D. Flue Gas Circuit :
) Check the chimney and duct connections and make sure that they are airtight.
) All necessary bolts provided on ducting should be checked for mechanical fitness.
) Check and provide supports to ducting.
) Check the functioning of various dampers provided in the ducting.
) Insulate the part of ducting inside the heater house.
47
E. Electrical System:
) Tighten all the terminals in control panel, as they might get loose during transportation.
) Check the functioning of main switch and provide correct fuse.
) Check whether proper earth wires have been connected to all the motors and panels.
) Check if all the settings of overload relays of motors, pressure switches, etc. are all right.
) Do the loop checking of all the wires connected from control panel to instruments, drives
and burner.
) Check for the earthing connection to electrical panel, to all motors & instruments.
) Check for the correct electrical supply.
) Start the drives and check for its correct rotation, if needed correct it.
) Do Electrical testing of the burner and check for its sequence operation
) Check for the Trouble free operation of level controller.
) Check functioning of all interlocks and safety circuit.
F. Fuel Systems:
i) Liquid fuels :
) Ensure that the Fuel system is complete in all respect.

) Line sizes are correct & are supported & clamped properly.
) No Objection Certificate is obtained from the explosives dept. or the concerned
government agency for the storage of the fuel & that the fuel storage formalities are
completed before filling the fuel oil in the tanks.
) Fuel storage tank & day tank are tested leakages & all leakages are rectified.
) Manhole, Vents, drains, fuel level indicating arrangement, over flow, out flow unit
arrangement, is properly made as per the instructions in the Assembly guidelines
) Ensure Use of oil quality gaskets in the fuel lines and at the tanks
) Fuel storage tank & day tank are cleaned dry & then flushed thoroughly before filling
the fuel oil.
) Ensure that Ring main system is constructed as per the P&I diagram in case of heating
oil.
) The pipelines are flushed thoroughly by air & fuel oil before connecting them to the
basket filter of Ring main system & of OPH station.
48
) Start the outflow unit of tank, after ensuring the proper electrical connections to the TIC
& to the unit in case of heating oil.
) Check that the Outflow unit is cutting off the electrical supply at the temperature set
point of the TIC.
) Ensure that dial type temperature indicator is also fitted very close to the out flow unit.
) Set the outflow unit at 40 DegoC maximum for FO.
) For LDO the Out flow unit can be set at 50-55 DegoC if so needed.
) Electrical tracing is a must for the FO pipelines from Main Storage tank to day tank &
from day tank (after outflow unit) and if the ambient temperatures are below the pour
points of the fuels.
) The air is removed from the basket filter, through air vent plug.
) Check the direction of rotation of fuel pumps by Kick Start only. Do not run the fuel
pumps for more than 3-4 seconds to check the direction of rotation.
) Correct the direction of rotation if found incorrect by changing the phase.
) Remove the air from the air plug of the fuel pump to ensure that the air is removed
completely. Ensure that the plug is re-fixed tightly.
) Ensure that the pressure gauges are fitted at the ring main system, Burner fuel pump
(OPH) out let, burner inlet & By pass lines
) Circulate the Fuel oil in the system by staring the Ring main & Main Fuel pumps, after
starting the units (Service /day tank out flow unit, heat tracing and burner preunit).
) Set the fuel pump pressures (Ring main & main Fuel Pump)
) Clean the fuel strainers in line, as & when the fluctuations in the fuel pressures are
observed.
) The circulation should continue until the fuel pre-heat temperature is achieved & the
fuel system is clean from dirt or burrs.
) Maintain the ring main pressure up to 3-4 kg/cm2
ii) Gas fuels:
) No Objection Certificate is obtained from the explosives dept. or the concerned

government agency for the storage of the fuel & that the fuel storage formalities are
completed before storing the fuel.
) Before supply is given to the burner, ensure that the user commissions the gas supply
system & the compliance to all the recommendations are made.
) The unit user has to hand over a copy of the gas system commissioning & handing over
report to Thermax engineer/representative, before commencement for the boiler
/burner commissioning.
) The user has to ensure the consistent supply of adequate quantity of the gas at desired
pressure is made available to the boiler burner.
) Check that the burner & components supplied along with the heater are suitable for
the particular gas supply & its incoming pressure.
49
) Ensure that the gas supply pipeline sizes are correct, are supported & clamped
properly.
) When the gas is stored in the gas storage tanks ensure that the gas pressures is reduced
to the desired pressure with the help of proper gas trains & then supplied to the burner
(Ref P & I diagram).
) Wherever the piped gas supply is given ensure that the gas pressure given to the
burner is as desired (Ref P & I diagram).
) Ensure that the pipelines are tested to the desired pressure as recommended by the
gas supplier.
) Ensure that the safety & firefighting equipment are in place & are operative.
) Dos & don’ts of the gas supply system are to be displayed in the heater house near the
burner.
3.1.2 Hydro Test & Boiling Out
a) System Hydro Test

Before filling the system with water ensure that the following components are removed and
blanked off.
• Safety Valve
• Rupture disc
• Pressure switch / Transmitter
• Level Probe
i) First fill the system with DM water with the top most vent valve open and until water
overflows.
ii) Start pressurising the system by filling the water into system by hand pump.
iii) Pressure should be applied in stages (in steps of 10 to 20 bars.) up-to the recommended
hydro test pressure for the unit.
iv) At each stage examine the system for any water leakages from all weld joints and all
isolation valves.
v) The test should be conducted for at least 24 hours.
vi) If there is no sign of any leakage and if there is no drop in the pressure the test should be
considered satisfactory.
50
Safety Valve setting:
The safety valve is set at the maximum working pressure of the unit. After completion of
hydro test, safety valve is to be installed on the unit and system pressure is to be raised slowly
in stages by filling DM water. Raise the unit pressure upto the maximum working pressure,
once the required pressure is achieved carry out the setting of safety valve. The exact lift
pressures of the Safety valves and the safety valve sit backpressure are observed and set.
This is one of the major and critical settings to be done on the unit.
This safe guards the unit against excessive pressure.
b) System Chemical Boil out
Chemical to be used Commercial grade Tri sodium Phosphate
Dosage 50 g/m3
Reason for Boiling out: The boiling, removes residues, oxides and scale etc. that are on the
internal surfaces of the system. In addition it forms a protective Iron Phosphate film, which will
help to protect the system against oxidation and corrosion.
Boiling Out Procedure
• Fill the system upto the required level; the feed water must be treated with the above said
chemicals.
• Ensure all drain and air vents are tightly closed and blind the safety valve nozzle.
• After filling the water to the heater up to the required level, the heater is then to be heated
(under low firing) to a pressure of between 10-15 kg/cm²g.
• Fire the unit and keep it at low flame. This will help to raise the pressure slowly.
• When the Thermosyphon heater pressure reaches about 2-kg/cm², continue to raise the
pressure at slow rate. This will avoid thermal stresses.
• When the Thermosyphon heater pressure reaches to 10 – 15 kg/cm2, stop the burner firing.
• Maintain the unit at the said pressure for between 1 and 2 hours.
• Close watch for the system pressure and corresponding saturation temperature to be kept
and it should closely follow the required values.
• The pressure should then be allowed to drop to between 3 and 5 kg/cm²g and then drain
valve opened, with care, to allow the dirty boiling water to be drained off.
• Repeat the cleaning process at least three times. The rinse water should be visually free of
suspended solids.
Warning:
• Only water of specified quality (Refer Appendix A for water specification) should be used
throughout. Condensate not permitted.
• Care should be taken when draining the boiling water under pressure – Danger of scalding.
The dirty water has to be transferred into a vessel of cold water.
• The drainage pipe work should be fixed system capable of handling the discharge of the
system blow-down and cleaning medium temperature at between 10 and 15 kg/cm²g.
51
3.1.3 Hold-On Test

This test is required to check the instrument impulse lines and Safety valve-Rupture disc flanges.
Upon completion of the hydro test and chemical boil-out the unit should be restored to the
normal operating status i.e. all the instruments (Pressure switches / Safety valves-Rupture discs/
level switches / transmitter etc.) are to be connected.
Ensure that all the instruments are connected to the heater. Fill the unit with DM water and
pressurized as in hydro test but only upto the normal working pressure. Hold at the operating
pressure for 1 hour. Look for any water leakage/dripping at the instrument connectors. If there is
no leakage and if there is no drop in pressure the system can be cleared for commissioning.
Level switch setting:

After completion of Hold on test, level switch setting of Thermosyphon unit is to be set and
checked.
Since the unit is full of water at this point the panel should indicate healthy water level
condition. (Low level lamp should be OFF) Lower the water level by draining the water from
unit through drain valve. When the level drops below the level switch, the unit should go to
the trip mode (with alarm and red lamp indication)
Now increase the water level using the water pump. The system should come to the healthy
condition when the required level reaches. Check the repeatability of the level switch
operation by increasing and Decreasing water level for at least 5 to 10 times.
3.1.4 Filling and refilling procedure

After ensuring the proper functioning of level switch, final filling of water into the unit is to be done
and maintain the required water level. Only dematerialized or distilled water should be used.
Condensate is not permitted. For initial filling of the system and for normal operation 30g/m3 of tri-
sodium phosphate concentration should be used. This will provide a minimum conductivity
required for the operation the level detection electrodes. An additional benefit of the presence
of the tri-sodium phosphate is the elevation of the pH level. This promotes the formation of a
phosphate film on the pipe surface, which inhibits general corrosion as well as oxygen pitting.
Ensure that the drain valve is not blocked with weld slag beads or other foreign debris.
Only feed water according to specification may be used. (Refer chapter input requirement for
water specification) On final completion of filling operations, the filling pump must be
disconnected and the drain valve sealed.
After filling with the required quantity (as per the safe filling quantity calculated (QOP) and
checking for the level indication lamp status) the water has to be degassed. This can be done
by heating up to 3 bar and venting the air via valve.
52
Note: care must be taken during degassing procedures to ensure that the steam jet can be
released without endangering life or machinery components.
During operation of the unit if water low level indication comes, firing of the heaters is to be
stopped and start filling the water till the low-level indication alarm goes off. The desired water
level should be always maintained in the system.
Note: Care must be exercised during the depressurizing procedures to avoid creating
hazardous situations.
3.2 Commissioning
The commissioning activity starts after all the pre commissioning activities are completed
satisfactorily and all the controls and safeties are working normally.
For commissioning and trial operation, heat utility must be provided. This is required to set the
firing system as well as all controls and safety facilities can be adjusted.
Warning: The commissioning of the unit is to be done by the Thermax Engineer / authorized
representatives only to avail Thermax warrantee benefits.
The burner must be checked before commissioning. Special attention should be given to the
operating instructions given in the supplier’s manual.
For all fuel supply systems, the design and installation must satisfy the local authority regulations,
but particular attention should be given to the design and installation of oil fuel systems.
Initial Firing And Venting Procedures
1. The burner must be set up in accordance with the manufacturer’s recommendations.

The fuel must be of the appropriate quality for which the burner was designed. This fuel
must be of consistent quality.
2. All ancillary equipment required for operational or safety purposes must be functioning in
a satisfactory manner.
3. With the vent valve closed, the first firing is carried out on low fire.
4. Before starting the burner ensure that modulation switch is in OFF position.
5. Take the burner in low fire mode by manual low fire selection.
53
6. Put ON the burner selector switch

7. The burner programmer cycle starts as per the sequence controller and establishes flame
8. The burner operates at low flame there by slowly raising the Thermosyphon pressure.
9. Gradually raise the Thermosyphon pressure to 3 – 5 bar, When the pressure within the
system has reached 3 – 5 bar, Stop the firing by switching of the burner.
10. After a period of about 5 minutes any air present in the system should have separated
out. The vent valve should then be opened carefully and the air vented off. Venting
should not be more then 30-45 seconds at a time.
Note : Venting of the unit is required to remove non-condensable gases.
11. The vent valve should be closed and the heating and venting process repeated several
times each occasion.
12. The operational pressure should be increased until a pressure in the region of 30 bar has
been reached.
13. Watch for the system pressure and corresponding saturation temperature.
14. Repeat the venting procedure at the regular intervals until the actual temperature
reaches the saturation temperature (i.e. within –2 to –5°c).
15. If during this process low level indication comes, stop the unit , start filling the water till the
low-level indication alarm goes off.
16. Before taking the unit to full firing rate, vent of the unit to be done once.
The system is now ready for full load firing.
After the venting process has been completed at this pressure, the valve should be closed and
made airtight with a plug and copper gasket.
The firing process can be started. The control parameters for the pressure controller and burner
system must be set in accordance to the manufacturer’s instructions.
This first operation of the Thermosyphon unit is done in presence and under the guidance of
Thermax Engineer /authorized representative of the Thermax. The fine setting of burner is to be
set for the optimum combustion parameters of smoke Index & O2/Co2 percentage.
The water level controller needs to be checked for its normal functioning and the operation of
the low level safety.
Note:
• If the low level indication comes during operation, stop the unit and fill the water till the low
level indication goes. This tends to happen when the load on unit increases.
• If the water level is high in the circuit the saturation temperature will not correspond to steam
pressure and steam temperature will shoot up. So the required level of water is to be
maintained in the system.
54
Pressure Switch Setting (High Pressure cut off):

After the raising the Thermosyphon pressure to its maximum working pressure, the Thermosyphon
pressure high cut of pressure switch is set.
The pressure switch controls the unit pressure by cutting off or cutting in the burner. This stops the
firing of the burner, there by reducing the heat input. Hence this is the device, which controls the
steam pressure in the boiler. After setting the pressure switch, the pressure switch operation
should be checked thoroughly.
Table T-3.1 : Important Readings/Settings For Commissioning
SR. ACTIVITY DESIGN DATA/ SET POINT

NO.
a. FUEL CIRCUIT
1. Fuel consumption of boiler burner in high flame Refer technical Specifications
2. Fuel consumption of boiler burner in low flame Refer technical Specifications
3. Fuel pump pressure 25 kg/cm2(g) (Approx.)
Note : The above are only reference setting; however, the actual settings may vary from site
to site.
3.3 Controls & Safeties

The Thermosyphon heater has several safety features, which protect the system against the
effects of excessively high pressures and temperatures and low water level conditions. The
number and type of these devices are dependent upon the requirements of the local licensing
authority. Additional monitors supplied at the request of the customer can supplement them.
In the event of any of the safety devices described below under being activated, the unit is shut
down automatically. The unit may only be restarted when the fault has been rectified and the
control, panel reset manually.
The function, testing and operation details of all the safety devices are mentioned in the
following appendix.
55
The following contribute for the safe operation of the unit.
Sr. Conditions Controls Remarks

No
1. Thermosyphon Pressure Rupture disc ruptures. Tripping of Burner
very High
2. Thermosyphon Pressure Safety Valve Release the pressure
very High
3. Thermosyphon level low Level Probe and controller Tripping of Burner
4. Thermosyphon pressure Pressure switch Tripping of Burner

high
5. Thermosyphon supply Temperature indicating Tripping of burner
temperature high controller
6. Rupture disk failure Pressure switch Tripping of burner
7. Stack temperature high Temperature indicating Tripping of burner
controller
8. Thermosyphon pressure Pressure transmitter Modulates the burner as
controls per the process load
demand
9. Burner flame failure Flame sensor Tripping of burner.
If any of the safety devices described is activated. The burner will be shut down and locked out.
The fault must then be identified and rectified. Faults will activate an audible alarm. Upon
rectification of the problem, the unit may then be brought back into operation.
In addition to above safeties the burner is also supplied additional monitors and safety devices
for safe operation of burner.
Warning
• Restarting without sufficient water can cause overheating of the riser tubes and may lead to
pipe rupture after a relatively short period of time.
• In the case of a burner fault especially on ignition fault, do not repeat the boiler ignition
sequence more than three times.
• In case of running unit if low water level faults comes frequently, stop the unit and check for
other possibilities.
In the case of low water level alarm, the following checks must be made to ascertain whether
sufficient water remains within the system to ensure continued safe operation of the boiler.
The checks should include (as a minimum):
- That the low water level alarm do function properly and that they indicate the
presence of water.
- For visual water leakage’s (piping, rupture disc, all valves and connections).
- In any case of slight doubt, let the system cool down, drain and check the water
volume.
56
The temperature of the heating surfaces must be lower than 140°C before further attempts are
made to restart the boiler (this corresponds to a system pressure of 5 bar). This is necessary due
to the risk of explosion.
If frequent topping up of water in the system is necessary, it is likely that the system network has
developed a leak. The source of the leak must be located and rectified otherwise the oxygen,
that could be introduced, as a result of refilling, will cause pitting and general corrosion.
Training:
During the unit Installation, pre-commissioning, commissioning and efficiency & output Trials,
Thermax engineers /authorized representatives ensure that the Unit operators and other
technical personnel responsible for the operation and maintenance are geared up & trained to
operate & maintain the unit as per the norms laid down by Thermax Ltd.
These norms and the good operation & maintenance practices of unit are also explained in the
next Chapter of operation & maintenance. These should be read & practices for the trouble free
operation and long life of the unit & its accessories.
Unit handing over for commercial Use:

After the successful commissioning and output trials the unit is to be handed over to the
user/owner for the commercial use.
The unit handing over procedure includes the signing and stamping of the Erection &
commissioning checklists and certificates of Thermax Ltd by the owner/user’s responsible person
and the commissioning engineer of Thermax / authorized Dealer.
These signed/stamped commissioning and handing over reports/certificates are forwarded to

the Customer Care /technical service department of Thermax ltd, for the scrutiny of the site
reports. If any discrepancies are observed in Installation, performance or settings, Thermax ltd
takes immediate corrective action by informing the concerned Thermax engineer/authorized
representative/dealer and also to the owner/user of the unit.
Warning:
• In no case the owner /user should use the unit for the commercial use /production, without
completing the Handing over formality from Thermax, to avail the committed warrantees of
the Unit & its supplied parts/equipment.
• In case of failure on the part of the owner/user to comply with the above handing over
procedure, all the warrantees of Thermax Ltd, as per the order terms, will cease to exist and
in such case Thermax shall not be responsible for any failure of the supplied equipment or
components.
57
Thermosyphon Operating Instructions
04 OPERATING INSTRUCTIONS
Operating Instructions
Operation of the unit needs to be properly understood by the operational staff /operators. The
training has been imparted by Thermax /dealers during commissioning of the unit.
Hence, the operation & maintenance of the unit has to be as per the guidelines given in the
following chapters for the Starting, running & maintenance of the unit.
Before Starting
1. Ensure that instructions given in the manuals has been followed
2. Ensure that Thermosyphon Pressure switch setting is not altered and set as per the
requirement.
3. Ensure all drain valves and vent valves of unit are tightly closed.
4. Also ensure that all electrical connections are in proper condition and no safeties
are short circuited.
5. Prior to the operation, inspect the heater for obstacles and debris that may be
hazardous and unsafe.
58
Operating Instructions Thermosyphon
4.1 Start Up Process

START
Fill up fuel in the fuel service tank & open the valves in the fuel line, charge the fuel into oil line
For gas fired units : Ensure that gas filters are clean.
Put ON main switch individual isolator switches for all equipments & control supplies to Unit
Control Panel.
For heavy oil ringmain system is used. Select & put ON the fuel pump, fill up fuel lines by
circulating fuel.
For Oil fired Units: Put ON the Oil pre-heating tank electrical unit. For gas fired units : Check the
inlet gas pressure to gas train. If it is within acceptable limit, open the inlet valve of gas train.
For Gas fired units: Check the main and pilot gas pressure and set it if required.
Before starting the burner ensure that modulation switch is in OFF position.
After ensuring required water level in the unit & optimum fuel temperature, the burner can be
started.
Put ON the burner selector switch in auto position.
The burner programmer cycle starts. After pre-purging time, supply is fed to ignition
transformer, commencing electrical sparking in the burner. At the same time burner/Gas
solenoid valve is energised, commencing fuel spray or gas supply inside the combustion
chamber & flame is established. Flame is detected by flame sensor. Thus burner starts in low
flame. The low flame firing is to be continued so that heating is gradual.
Put ON the modulation switch, the burner would go in high flame position. The burner
modulation would depend on unit pressure, which in turn will vary depending on the load.
End
59
Thermosyphon Operating Instructions
4.2 Unit Running Attention
It is advisable on part of the operator and the other operational staffs, to make it a practice
check the following points periodically during the running of the unit.
• That no excessive sound is heard from the motors, pumps and process line.
• That all valves and joints are leak proof.
• No part of the unit is getting over heated
• No undue vibrations are observed from any part of the unit.
• Flame in the combustion chamber is steady and non flickering.
• Exhaust from the chimney is normal and almost color less
• That no sparking or loose contact is there in the electric circuit of the control panel of the
unit.
• Drives current are within limit.
• All safety, control and indicating instrument working correctly.
• That the logbook is filled hourly and correctly for all the parameter of unit. For Reference
format see below chapter “LOG BOOK”.
• All maintenance instructions followed religiously.
60
Operating Instructions Thermosyphon
4.3 Unit Stopping Procedure
START
Put OFF the burner modulation switch, the burner comes to low fire position
Put OFF the burner switch
Put OFF switches for all other equipments & close all relevant valves. .For gas fired unit ensure
that all gas isolating valves are closed.
Isolate unit control panel by putting OFF all electrical supply.
END
Caution : Shutdown Precautions
1. The damage that dissolved oxygen can cause within the system cannot be under
estimated. For this reason, all connections in the pipe work system must be pressure and
vacuum tight i.e. welded.
2. The use of valves with stuffing box seals and flanged connections can be avoided.
3. During heater shutdowns, the system pressure falls below atmospheric pressure
producing a vacuum. Under these circumstances, air can leak into the system and
oxygen can dissolve into the water. This can lead to oxygen pitting of the inner surfaces
of the pipe work.
4. For shutdowns greater than one month, the water and steam system should be
blanketed with nitrogen.
5. The nitrogen supply used for blanketing the system should be manually or automatically
activated when the pressure in the pipe work falls below 0.5 bar.
6. An adequate supply of nitrogen should be maintained in the system during all lengthy
shutdown periods (more than one month).
7. Upon re-commissioning, the venting procedure outlined should be adopted.
61
Thermosyphon Maintenance
05 MAINTENANCE
The performance of a unit depends greatly on the maintenance carried out. The heater, its
surroundings, water pipelines, filters, strainers, etc. should be kept clean to maintain proper fluid
flow to the unit so that it works efficiently.
For easy detection of faults and to know deviation from standard/normal setting/readings
obtained at the time of commissioning should be recorded and should be referred to after
every major servicing/repairs and replacement of parts, is carried out.
The maintenance checks be carried out and preferably should be recorded on a logbook daily
by the unit operator.
Following care to be taken during for annual/periodic maintenance:
All electricity supply should be switched off and maintenance staff should ensure that no
electric supply is available at the equipment by :
1. Switch of mains supply.
2. Removing the fuses/ Switching off all the MCBS.
3. Removing the cables from technical strips.
4. Put “shutdown” board on equipment control, introduce work permit systems and record
on log book.
5. Ensure proper earthing of all the electrical equipments.
6. Maintenance staff should carry required personnel protections and use proper tools –
tackles.
7. Use leather hand gloves while working on hot surface, do not use nylon, polyster clothing
during maintenance of the unit.
8. Before opening the pressure part ensure that the pressure is released and air vent valve
of the unit is open. Also ensure the heating media has been cooled down.
9. None of the safeties and controls should be by passed during operation of the unit.
10. The fuel storage formalities and safety precaution given in instruction manual should be
followed.
62
Maintenance Thermosyphon
11. Pressure part or the furnace should not be taken for maintenance before 24 hours
(minimum) from the time of shut down. The faster cooling is harmful to the pressure part
and furnace.
12. The heater house should be kept free from spillage of water / oil.
13. Hot surface should be insulated properly.
14. Use only Thermax make / supplied genuine spare parts for the safety of units.
15. All the users, operational and maintenance personnel should make sure that during
installation, operation and maintenance of the unit, regulations under Unit Act, Factories
Act, Fire Insurance and Explosives Act, Pollution Control Act are strictly adhered to.
Warning:
• All the safety precaution mentioned above and also in the product instructions manual
are to be strictly followed by the user.
• Do not tamper with the settings of controls and safeties unnecessarily. It is to be noted
that it is totally unsafe to short circuit safeties and operate the burner.
• Burner settings are very critical and any tempering without knowledge may lead to
disturbed firing conditions & can lead to sever back fire /accidents.
63
5.1 Maintenance Schedule

Table T-5.1 :
Half
Maintenance Activity Daily Weekly Monthly Quarterly Yearly
yearly
Checking Water level in unit *
Check Pressure switches -
*
operation
Check all instruments -
*
operation
Overload relays – operation *
Clean filters & basket filters in
*
water, oil and gas line
Calibration of all instruments *
Wires tightening on relays,
*
terminal strips and instruments
Check make up water quality *

Check Safety Valves operation *
Motor Current check
*
fan & Ringmain pumps
Cleaning of furnace *
Grease all motors’ Bearings *
Dust removal from control panel *
Clean the burner gas spuds.
For gas fired units
*
Cleaning of burner nozzle. *

Checking & setting burner
*
consumption
Tighten all foundation bolts *

Check operation of level probe
*
and controller.
Note: Increase routine maintenance on pro-rata basis if the number if the number of working
hour increases. For maintenance details on burners, please refer the manufacturers manual
for more details.
64
Maintenance Thermosyphon
5.2 Log Book
Record of daily checks and servicing operation as well as other checks and servicing operation
must be kept in an operating log book and signed daily by the responsible operating personal.
This is to ensure that the deviations, if any, from standard/normal readings, may be noted and
attended to immediately, this can avoid major breakdowns and unwanted stoppage of the
plant.
Note: It is suggested that these Logbooks are maintained by the users. An hourly record of the
observations of the operational parameters and maintenance instructions are filled in without
fail by the operating personnel of the unit.
5.3 Spare Parts

It is suggested that certain essential spares may be kept in stock to avoid idle time due to
unpredictable breakdowns. If there is any breakdown due to component failure, it is better to
replace the defective component and if possible repair the defective component if repairable,
at leisure, as replacement is faster and easier.
The list of essential parts for Thermosyphon unit is given below and can be used for guidance.
Part List, specific to the Model & serial no with part no of each component can be taken up
from nearest office.
65
Table T-5.2 :
Sr. Component Description Quantity to be

Part Nos.
No stocked at by user
Gasket Spiral wound Mettalic ANSI Class
1 73P0005160 2
1500 Rating - 50NB
Gasket Spiral wound Mettalic ANSI Class
2 73P0005159 2
1500 Rating - 50NB
Refer OILON Manual for
3 Burner Nozzle 1
model number
4 Rupture disc ( Bursting Pr.90 bar ) P36RD1014M 1
5 Gland Seal for Make up pump 73P0005777 1
6 Washer (sp)cu-OD28xID22 PXX0190009 4
7 Washer (sp)cu-OD20.5Xid12 PXX0190006 4
8 LEVEL SWI, ELECTODE-500 LG, GESTRA P43S020130 1
9 TEMP.GAU.H GURU 0-400 1/2"BSPT 73P0005328 1

PR,GAUGE,BRDN-GP-0-160 KG, D150-
10 P41PG1104G 1
1/2" BSPT,BT
TEMP. EMNT (RTD)- PT100- 1/2"BSP- D6x
11 P44TE10050 1
L425A
TEMP. EMNT (RTD)- PT100- 1/2" BSP, D-
12 P44TE10420 1
6X L-130
13 PRESSURE SWITCH 73P0005954 1
14 PR.SWITCH : GM-201-02-B3K-2 73P0005956 1

VALVE, NEEDLE- SS-1/2"NPT X OD 1/2",
15 P33NP1008S 1
SUPERFREEZE
66
Thermosyphon Trouble Shooting
06 TROUBLE SHOOTING
Trouble Shooting
Some of the common problems and remedial action is as given below:
Observation Cause Remedy
Check the overload relay of

Overload Protection
the motor
Check the contactor coil and

proper neutral connection.
Motor Contactor
Make up Water Pump does Check the contacts of the
not start contactor
Check the motor windings.

Water pump motor
Rewind/Replace as required
Check & Correct mains and

Control Phase not available
fuses
Soot deposition inside the unit Inspect and clean the unit.
Check for proper opening

Higher flue gas air bypass and closing of diverter
damper.
High flue gas temperature
Genset operating on very high
Overloading of the unit
load then designed.
Excessive scale formation
Inspect and do de-scaling of
inside the unit, due to which
the unit.
low heat transfer.
Pump inlet strainer choked Check & clean the strainer

Water pump not developing
pressure Throttle the glove valve on
Very low circuit pressure
Pump outlet line.
67
Trouble Shooting Thermosyphon
Thermosyphon Circuit
Observation Cause Remedy
Air is trapped and not
Remove all air through vent.
removed completely
Observe the leakage prone

Leakages through valve
point and make all joints for
glands or seat
Pressure not developing in zero leakage.
circuit
Improper circulation in TS Maintain the level of water as
Circuit per commissioning procedure.
Leakages through threaded

Tighten the joints properly.
joints
Make up more water and see
in transparent tube eternally
Level is not sufficient
for choking.
Level Switch not indicating
level
Level probe is not cut as per Please follow the instruction of
recommendation level probe mounting.
NRV connected in reverse Please check and correct if

Make up water not entering direction necessary.
into TS circuit even though
valve Seat of globe valve is not Check the operation of globe
opening valve for opening.
Over firing of the heater, set

Circuit pressure higher than
fuel consumption as per the
normal operating pressure
heater capacity.
Rupture disk failure
Re-commission the heater and
Water level high due to which
maintain the required water
pressure shooting high
level.
68
Thermosyphon Care of Idle Units
07 CARE OF IDLE UNITS
Units used seasonally and idle for long period should be laid up "Dry" or "Wet" during the period
of idling.
7.1 Wet Preservation

If the unit is to be kept idle for a short period, it should be laid up "Wet" as follows:
i. Fill the unit completely with water, up to overflow level. By admixing an alkalizing agent,
(Use MAXTREAT 3100/3200) bring the pH value of the unit water to 9.5 and add a
corresponding quantity of oxygen binding agent. Sodium hydroxide or a corresponding
phosphate, for instance, can be used as the alkalization agent.
Oxygen binding agents are, for instance: Hydrazine, Sodium Sulphite and sodium
bisulphate. Depending on the standstill period, the hydrazine content in the unit water
should be for instance :
Standstill duration Hydrazine surplus g/m3 N2H4

Up to 1 week 20 to 30
Up to 1 month 50 to 100
Longer 100 to 300
For better mixing, the unit should be heated briefly after admixing hydrazine, up to about
85 °C, to drive out the oxygen in it. Take care that no pressure builds up in the process.
Before renewed commissioning of unit, the unit water must be drained off until the
operational water level has been reached, provided the steam is allowed to contain
hydrazine (the steam must not contain hydrazine if it comes into contact, for instance,
with foodstuffs, clothing or dressings). Otherwise, the unit must be drained and refilled.
Close all valves. In all cases the exhaust gas flaps or gate valves must be kept closed.
ii. Check for any leakage and take samples of water at regular intervals to ensure alkalinity
and Sulphite are maintained.
73
Care of Idle Units Thermosyphon
7.2 Dry Preservation
If the unit is to be kept idle for long period it should be laid up "Dry" as follows: -
i. Drain the unit thoroughly, clean it internally and externally both fire and water side and
dry it out.
ii. Place trays of lime inside the unit shell to absorb any moisture. Then close the door,
manholes, dampers, etc., properly so that no ingress of moisture or air can take place.
iii. Water service tank, pumps, and all piping should also be dried out.
It is essential that the unit is thoroughly clean while using the wet or dry laying up method. To
prevent corrosion on the gas side of the heating surface, it is recommended that all heating
surfaces are dusted with hydrated magnesia to neutralise any acid remaining on the unit
heating surfaces.
NOTE : When working with caustic liquids or chemicals, it is imperative that the relevant
accident prevention regulations are observed and made accessible to the persons carrying
out the work.
74
7.3 Liquid Fuels And Combustion

7.3.1 Fuel For Heater
Thermosyphon unit is designed to operate on liquid as well as gaseous fuel. Fuels with a very
wide range of heating value can be used for heating in these units. Like water it is extremely
important that the quality of fuel going into the unit is carefully controlled in order to obtain
good performance out of the unit. While water quality affects the Unit performance due to its
effects inside the heating surfaces the fuel quality affects the outside of the heating surfaces. To
ensure the optimum performance we need to know the properties of the fuel and make
necessary adjustments. We shall discuss below some of the important properties of fuels.
7.3.2 Composition Of Fuels

Most of the fuels comprise of compounds formed out of carbon and hydrogen and in some
cases other elements like sulphur etc. Very often fuels also contain oxygen in the molecules.
Most of the fuels used in Units are derived from petroleum. These fuels are very rich in carbon
and hydrogen. The liquid fuels generally have more carbon and less hydrogen when compare -
to gaseous fuels. The carbon content for petroleum based liquid fuels would be generally 82 -
88% and hydrogen content 10 to 14%. Petroleum based gaseous fuels generally have a carbon
content from 78 - 82% and hydrogen content from 13 - 18%. Natural gas has a much higher
hydrogen content and a much lower carbon content. Depending on the carbon hydrogen
ratio the burning characteristics change. Burners for burning these fuels need to be specially
designed for the purpose. It is also possible to design burners to burn a range of liquid fuels and
also liquid fuels as well as gaseous fuels usually one at a time, depending upon the specific fuel
composition in use it is necessary to adjust the burner. If fuel composition changes after initial -
adjustment it is necessary to readjust the burner to suit the new composition.
There are two popular ways of analyzing fuel composition. One method is to have a complete
chemical analysis of the quantities of various elements present called ultimate analysis. The
other method is to analyse quantities of behavioral groups of components present in the fuel,
called as proximate analysis of fuel.
As the ultimate analysis of the fuel gives the quantities of elements present this information can
be used for theoretical calculations of the air required to burn and the heat out put on burning.
It should be mentioned here that theoretical calculation of heating values may not be exact
due to the difficulties in judging exactly whether some of the combustible atoms are already
linked to oxygen or not.
The component wise analysis is used to judge how the fuel would behave during the burning
process. Typically, the quantity of wax content will indicate probable problems one may
encounter due to wax solidification. Generally, a higher viscosity of petroleum oils at room
temperature would indicate a higher carbon hydrogen ratio giving a higher flame luminosity
giving a higher radiant heat transfer in the flame, at the same time indicating a possibility of
sluggish combustion.
73
There is a very important value to understand the burning behaviour of the fuel called carbon
residue, also sometimes referred to as Conradson carbon. The carbon residue is not normally
reported either in the ultimate analysis or in the component wise analysis unless specifically
asked for. The carbon residue is very difficult to burn and a portion of this residue can be
expected to precipitate as soot unless very special care is taken in the geometry of the
combustion chamber, the temperature of the combustion chamber and the residence time of
burning and such other parameters.
7.3.3 Calorific Value Of Fuel

The calorific value is the quantity of heat the fuel gives out due to combustion. Carbon burns
forming carbon dioxide. Hydrogen burns to form the oxide of hydrogen, which is water. Sulphur,
if present, forms sulphur dioxide and some sulphur trioxide
There are two different ways of evaluating the calorific value of fuel. One value is known as the
gross calorific value (GCV) The GCV is the heat given out due to the combustion of the fuel with
all the water which has been formed having already condensed. In other words, the GCV is the
heat which has been released by the combustion and includes the latent heat given off by the
steam which had formed during the combustion condensing to water later on. It can be clearly
seen that GCV is not available for use while using the fuel in actual practice because the steam
formed does not in practice condense but goes off to the atmosphere through the chimney.
Therefore, GCV is not a useful figure to evaluate the heat obtainable by using the fuel.
However, as GCV is the easier quantity to measure generally after the fuel is tested the calorific
value is reported in terms of GCV.
The useful heat available from the combustion of a fuel is known as the lower calorific value
(LCV). The LCV is the heat given out by the fuel during combustion in actual practice. The
value of LCV is arrived at during testing of the fuel by first obtaining the value of GCV using say a
bomb calorimeter and then deducting 539.6 kcal/kg of steam formed during combustion of a -
dry sample of fuel. Sometimes, calorific value is denoted by NCV (Nominal calorific value).
NCV is the same as LCV. Unit of calorific value is kcal/kg or kcal/Nm3.
7.3.4 Physical Condition Of Fuel

Combustion systems are designed taking into accounts not only the chemical composition or
calorific value but also physical parameters like viscosity, Lubricity etc. For proper atomisation in
a burner, it is necessary to maintain liquid fuels at a viscosity of 10 to 15 centistokes at the burner
tip.
74
7.3.5 Cleanliness
The most important consideration in the physical condition of the fuel is the cleanliness of the
fuel. Unfortunately, this aspect is very often the most ignored resulting in a very sad state of
affairs with respect to the operational efficiency of the unit, wear out of critical parts and
unreliable operation. In spite of actual experience of repeated tripping and unreliable
operation of Units resulting in production losses there have been many cases where instead of
ensuring cleanliness of fuel, energy has been wasted attempting retuning of burners changing of
electrical circuitry. The foremost priority in unit operation after ensuring properly treated feed
water supply should be assuring a clean fuel. Cleanliness of the fuel can be assured only if great
care is taken right from the moment the fuel arrives in the plant by filtering at the time of taking
the oil into the storage tank, further filtering between the storage tank and the day tank, further
filtering between the day tank and the fuel pump, and keeping these filters always clean.
Combustion is generally the oxidation of carbon, hydrogen and sulphur in the fuel. For all
practical purposes oxygen is supplied by providing sufficient atmospheric air. The air delivery is
so adjusted geometrically with respect to fuel delivery to ensure proper mixing. In spite of the
best possible mixing it is necessary to provide more than just sufficient air for the chemical
reaction to ensure complete combustion. This excess air necessarily needs to be kept a
minimum by as efficient a mixing as possible so that the flue gas quantities are kept a minimum
achieving minimum loss of heat through the chimney. The entire expertise of a burner design
revolves around this important concept.
7.3.6 Chemistry of combustion :-

Typical chemical reactions involved are-
C + O2 = CO2 (+ 8050 kcal/kg of carbon)
C + 0.5 O2 = CO (+ 2410 kcal/kg of carbon)
CO + 0.5 O2 = CO2 (+ 2410 kcal/kg of carbon)
H2 + 0.5 O2 = H2O (+ 33865 kcal/kg of H2)
S + O2 = SO2 (+ 2210 kcal/kg of S)
These calculation help estimating stoichiometric air required. Calorific values are estimated in
laboratory. (Some imperial formulae may be used for approximate estimates of cal-values for
different fuels).
Amount of stoichiometric air required is proportional to gross calorific value (GCV).

Approximately 1 kg air is required per 745 kcal of GCV.
In practice, certain amount of excess air has to be supplied in order to compensate for the lack
of contact between fuel and oxygen. This amount will vary from 30 to 80% depending upon fuel
and furnace design. In some cases (e.g. external refractory lined furnaces) further excess air
73
needs to be supplied to limit furnace temperature below caking/ash softening temperature.

The total amount of air should be judiciously distributed as primary and secondary air. It shall be
noted that secondary air is very effective for combustion of gaseous products (including the CO
generated in the reducing zone of thick bed of low volatile matter fuels like coke). Pressure
required for primary air needs to be just sufficient to push it up to the top of fuel bed, without
pressurising the furnace. Secondary air should be supplied at high pressure through jets, which
will penetrate through the cross section of gas across it.
On complete combustion of solid fuels, amount of CO2 gas generated, on stoichiometric basis
by volume is between 18 to 20% for most of the fuels. However, with practical amount of excess
air, best CO2 could be between 13 to 14%. More than 14% CO2 may be associated with
incomplete combustion and presence of CO in flue gas. If furnaces need extra air for cooling,
the CO2 may reduce to 7 to 10%.
74
Thermosyphon Annexures
08
104
MANUALS
Manuals :
Sr. No. Item Model

1 OILON Monoblock Burner OILON- LO- KP 50 H
2 Level Probe – Gestra Make GESTRA NRG19-11
3 Rupture Disc – BS & B FMC SANMAR OS-E-55-C
4 Make Up Pump - Damp Kolben Damp Kolben –DK/BF/IBF-1330-25
5 Pressure Transmitter - Rosemount Rosemount - 115GP9S12B1M4
1) PR.SWITCH : GM-201-02-B3K-2
6 Pressure Switch - Switzer 2) PR.SWITCH : GM-S24-0G-U7-3
74
Thermosyphon
In case of any doubt or clarification, please contact

THERMAX LIMITED
ADDRESS TEL NO. FAX NO.

DHANRAJ MAHAL,2ND FLOOR 022-22045391 / 2 022-22040859
CSM MARG, GATEWAY OF INDIA 022-22952058 / 9
NEAR REGAL CINEMA
COLABA,
MUMBAI 400 039 – INDIA
AZIMGANJ HOUSE 033-22826711 033-22826796
5TH FLOOR, 7 CAMAC STREET 033-22826712
KOLKATA 700 016 – INDIA 033-22826713
email : thermcal@giascl01.vsnl.net.in
9 COMMUNITY CENTRE, 011-26145319/26145014 011-26145311
BASANT LOK 011-26145326/26145098 011-26148679
NEAR PRIYA CINEMA 011-26145701 011-26148662
NEW DELHI 110 057 – INDIA 011-26145147
FATHIMA AKHTAR COURT 044-24353831-4 044-24353841
III FLOOR, 312 ANNA SALAI
TEYNAMPET,
CHENNAI 600 018 – INDIA
PUNE AREA OFFICE 020-2775941 020-27472049
D-13, MIDC AREA, (10 LINES) 020-27475679
CHINCHWAD, 020-27477066
PUNE 411 019 – INDIA
409-411 MAHAKANT 079-6575806 079-6577270
OPP. VS HOSPITAL 079-6575408
ASHRAM ROAD
AHMEDABAD 380 006 – INDIA
54/1 CENTRAL STREET, 080-3467761/ 080-3467760
8TH CROSS, 080-3467762
KUMARAPARK WEST,
BANGALORE 560 052 – INDIA
6-3-649 NALANDA COMPLEX, 040-23312013 040-23312335
2ND FLOOR, BEHIND MEDINOVA 040-23310254
SOMAJIGUDA 040-23396820
HYDERABAD 500 482 – INDIA 040-23390915
85 / B AMIN CHAMBERS, 0265-22332636 0265-22310051
SAMPATRAO COLONY, 0265-22345442
PRODUCTIVITY ROAD,
BARODA – 390 005 – INDIA
COMPLAINT INFORMATION FORM
In case of any complaints please furnish following information for arranging

prompt After-Sales-Service.
Name of Company __________________________________________________
Address ___________________________________________________________
Phone No. Telex No. Fax No.
Unit Model ________________________________Sr.No.___________________
Design pressure/Temperature _________________Year of make______________
Defective equipment _________________________ Make __________________
Model No._______________________Sr. No.____________________________
Date of Installation _________________________________________________
Date of Commissioning ______________________________________________
Contact Person Mr.__________________________________________________
Plant/Department ___________________________________________________
Weekly Off ________________________________________________________
Nature of Complaint _________________________________________________
__________________________________________________________________
__________________________________________________________________
Name of person :-
Designation :-
Date :-
THERMAX LIMITED
COOLING & HEATING - HEATING
D – 13, M.I.D.C. CHINCHWAD, PUNE – 411 019.
Tel : 020 – 27475941. Fax : 020-27472049 / 27475679.

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<Please preserve this manual carefully.

Thermax has an extensive international marketing network. Headquartered in Pune (Western

Products and Services

The product technology facilitates use of wide range of fuels viz.,

 Light & Heavy Oil

 Cool Low and high Calorific values,

Non conventional / agro based fuels

 De-oiled cake etc.

Agro products Packaging

Bottling & beverages Drugs & pharmaceuticals

Breweries & distilleries Plywood

Chemical & petrochemicals Rubber

Engineering Edible oil / solvent extraction

Food & dairy Textile / Synthetic fibers

‘If you need the heat, we have the source’.

Chapter 2 : Input Requirement

Chapter 3 : Commissioning Process

Chapter 6 : Troubleshooting 67,68

Chapter 7 : Care of Idle Units

Figure F-1.1 : Thermosyphon Unit

1.1 Thermosyphon In General

Salient Features Of Thermosyphon

• There is no degradation of heating media as in the case of Thermic-fluid units.

• Heating media being water it is non toxic and is edible.

Construction And Operation Of Thermosyphon

The major components of Thermosyphon product can be broadly categorised into

a) Burner – Oil/Gas/Dual fuel fired

b) Jacket coil assly

c) Control Panel / Instruments

d) Charging/Make up water pump

Major Components of the Unit:

The unit is fitted with a monobloc burner. The burner is a

Figure F-1.2 : Burner

Coil assembly consists of two concentric coils fitted

The coil and jacket assembly forms a main unit

The jacket is insulated from outside for human

c) Electrical Control Panel

The electrical control panel supplied along with the

Figure F-1.4 : Electrical Control Panel TS

d) Charging/Make Up Water Pump

This pump is used for initially feeling of water into

These pumps are horizontal, single acting,

This pump is not selected to charge water when

Electric motor is used to drive the pump and the

1.1.2 Technical Specifications:

1.2 Transportation & Unloading Instructions

1.2.2 Unloading Guidelines

Table T- 1.1 : Shipping weight & dimensions of major parts.

Parameter TS-02 TS-04 TS-06 TS-10 TS-15 TS-20 TS-25

Figure F-1.7 : Unit should be stored under roof.

• Unit & parts should not be stored under corrosive atmosphere

• Do not Pile up cases

• Do not store heavy material on soft soil

• Equipment can be rotated manually to prevent jamming.

• Whenever assembled, rotating equipments such as pumps, gearboxes etc is to remain

• P& I Diagram Drawing No. ALT NO.

• GATP & foundation Drawing No. ALT NO.

Light & Heavy Oil

Cool Low and high Calorific values,

De-oiled cake etc.