Project Nebula

BASIC ENGINEERING

CONCEPT NOTES FOR

Boiler

Document Number
P90-TG59-01-0013

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Introduction
• Boiler is a closed vessel in which water is heated, converted into steam and which is circulated
for further use
• Boiler is an equipment that has a huge impact on the running efficiency, operation cost, safety,
space and pollution of a plant.
• It provides steam to the plant that is used in plant operation for various purpose like heating,
cleaning of equipment, generation of vacuum and various other uses.
• It operates at high pressure so it is also critical from the safety point of view also.

Aim:
• To install a Smoke Tube IBR boiler with LDO cum natural gas as a fuel of 3 Ton/hr. (F&A
rating) to produce steam at 10 kg/cm2 for Project NEBULA.

Process:
• Soft water will be used to create steam that will be used in plant for various purpose.
• The water from WTP and Tertiary RO will be send to boiler feed water tank.
• High pressure feed water pump will be used to overcome high pressure inside boiler to pump
water.
• Fuel (LDO) will be burned to produce energy that is used to convert water into steam. Air will
be blown via blower.
• The steam will be used in plant and generate condensate.
• High temp reactors condensate will be sent to flash steam separator and recovered steam will
be send directly to feed water tank through sparger pipe and condensate sent to condensate
collection tank via PPPU pump.
• Pure condensate from dryer, flaker and other equipment will directly send to boiler feed water
tank and flash steam will recovered there also.
• Low temperature reactors condensate also sent to condensate collection tank via PPPU pump
and flash steam will be recovered from there.
• 1st PPPU pump will be installed at crossover pipe rack junction at plant, 2nd at plant ground
floor for pure condensate and 3rd at ETP area.
• Recovered condensate from plant will collected in condensate collection tank of SS304 at
utility area and further sent it to feed water tank through polishing softener bed.
• Condensate from MEE will sent directly to ETP

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• Plant network will be of HP and LP steam by installing PRS at plant entrance of 3.5 kg/cm 2g
for LP network.
• 2nd PRS installed near MEE to get required pressure (6.5 kg/cm2g) for MEE and 3rd PRS for
stripper section with 3.5 kg/cm2g outlet pressure.
• The chemicals will be dosed into the feed water via dosing pump.
• These chemicals will prepare in the chemical dosing tank via mixing of chemicals into the
water.
• The flue gases generated will be send to atmosphere via stack.
• Effimax will be there for performance monitoring of boiler

Block Diagram

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Q & S component
Q components
• The dryness of the steam is maintained at above 97%.
o It will increase the quality of the steam, reduce the time for heating, reduce problem of
water hammering and prevent the collies, jacks, piping and piping instruments from
erosion and corrosion.
o Mechanical separators at the places where there will be a chance that water get
carried with steam like expansion loops (because of turns).
• Pressure of the stream should be moderated by pressure reduction valve in
o High pressure steam (HP)
o Low pressure steam (LP)
As different reactors required different pressure.
• Feed water quality for the boiler.
o Hard water cause corrosion, scaling and slurry formation.
o If it is not taken care it will decrease the efficiency and will led to more fuel
consumption.
o It will decrease the dryness of the steam because of foaming and priming.
o Also the frequency of blow down will increase.
o Dissolves gases will cause corrosion and erosion because of electrochemical
reactions that occur at high temperature.
o Chemicals are dosed in the feed water to increase the PH (PH boosters) that will
decrease the solubility of salts, Corrosion inhibiters to prevent scaling and Oxygen
scavengers to remove oxygen.
o Y type Strainers will be placed that will prevent suspended to enter the boilers and
feed water pump.
o The inlet of the feed water will not be from the bottom but 100-150mm above the tank
bottom to prevent the suspended solids to enter the boiler pump to boiler.
o Additional polishing softener installed for polishing of condensate polishing from plant
to avoid any contaminated water entering into boiler
• LDO will be free from suspended solids and dirt
o It will lead to improper burning inside the burner and also create a coating on the
sparking rods.
o Bucket filters are placed at inlet of boiler.
• Filters are provided at the inlet of the blower to prevent dust particles to enter the boiler.

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o It will lead to improper burning inside the burner and also create a coating on the
sparking rods.
• To prevent condensate formation which will lead to decrease in dryness of the steam proper
insulation will be used along with steam traps.
o It will decrease the over efficiency of the steam network system and lead to
unnecessary losses.
o It will also lead to water hammering which can will erode the pipe line.
• Stack temperature must be in range from 180-270 ˚C.
o If the temperature increases the heat transfer taking place in the boiler is not proper
and it will be an indication of formation of scaling and soot on the heat transfer area
o Maintenance to the boiler should done with proper cleaning of heat transfer surface
on a regular interval.
o Increase in stack temperature can also be a case that fuel in not burning properly or
in improper durations.
o So at that time burner maintenance must be done.
o If the temperature is low, it will reach the dew point of moisture that quench SO2 with
it and will corrode the stack.
• Stack will be having a performance analysis meter for analysis the burning operation.
o It will monitor CO2, O2, CO and efficiency of the boiler.
o It will help us to keep a good track of boiler performance.
• Feed water temperature plays a key role in the for the quality of the steam
o The temperature of the feed water is low it will reduce the quality of the steam
produced as there are disturbance in the water pool temperature which can hinder the
steam generation process.
o The dissolved gases also need to be removed from the water that can be easily done
in the feed water.
o It will also help some time to remove the temporary hardness that might left after the
WTP plant.
• Water level inside boiler play a key role from for the quality of the steam generated
o The steam will have less dryness if the water level increases as the surface area for
the boiling decreases which will lead to problems of foaming.
o If the water level decreases, it will cause over heating of the tubes and will increase
the pressure of the steam.
• TDS inside the boiler feed water will cause the reduction in the boiler efficiency.

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o It will cause scaling inside the boiler and will reduce the efficiency of the boiler.
o It will also cause corrosion.
o It also causes priming and foaming that will reduce the dryness of the boiler.
o Provision of surface blowdown will be given.
• Removal of non-condensable and air from at the point of startup.
o It will cause the reduction of steam temperature even at same pressure.
o It will create a film on the heat transfer surface that will act as an insulation and will
unnecessarily increase the steam demand.
o By-pass will be provided for each steam trap to make the air vent from the system.
o Air vent valve is also provided in the boiler to vent the air.
S components
• The 2 safety valves are installed at the top of the boiler at 10.3 kg/cm2g and 10.5 kg/cm2g.
(Will set final at time of commissioning)
• Interlocks with alarm are provided at various places as mentioned

Place Interlock Cause Provided

Feed water tank Water Extra low It will damage the Team
level (10 %) boiler by
overheating.
Boiler water level • Water level It will damage the Vendor
switch (20%) boiler by
• Water level overheating.
switch (10%)
Pressure When the It will Cause the Vendor
pressure exceeds explosion of the
10 kg/cm2. boiler
Fuel pressure If the fuel pressure It will cause Vendor
is less than 14 improper burning
kg/cm2. and in some case
back firing too.
Burner (UV cell) If there is a flicking It will cause Vendor
flame improper burning
and in some case
back firing too.

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• Alarms where interlock action is not needed

Place Alarm Cause
LDO Tank Level LDO Extra low level (10 %) It will not cause any thing
from the safety point of
view.
Flue Gas temperature If the temperature exceed It is needed when there is a
280°C time for maintenance.
High TDS of boiler When the TDS of the feed The blowdown action will be
water exceed 3500 ppm. needed.
Blower Pressure Power pressure Low It will send the indication as
the boiler will
Flue gas Damper valve open It will not allow the gases to
flow outwards

• Flame arrestor is used at the top of LDO storage tank to prevent it from fire.
• NRV are used at the inlet and outlet of LDO line to the burner to protect line from back firing.
• IBR pipe line, valves, fittings and mountings to be taken in the boiler and steam lines (HP
steam).
• Rack and pinion valve is used to for the blowdown as it will give safety.
o It locks the handle when the valve is open and prevent it from coming out at the time
of blowdown.
o Because of gear system it opens gradually and this prevent water hammering.
• A rupture disk is mounted at the refractory of the boiler to protect the system from back fire
and open itself.
• Hand gloves and safety mask are to be used when the dosing chemicals are feed to dosing
tank.
• Expansion loop are provided the line from expansion (thermal stress) at elevated
temperatures.
• To prevent condensate formation which will lead to water hammering of the steam proper
insulation will be used along with steam traps.
• Blower will be provided with acoustic hood if the noise is greater the 70 dBs

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Raw Materials
• Soft water from WTP
• RO water
• LDO
• Chemicals for dosing
• Sulfamic acid (maintenance time only and is already being used in ETP)

Handling and Specification of Raw Material

• Soft water
o Softener plant is installed of 3 m3/hr. capacity for boiler to produce soft water
o The specification of the boiler feed water.
Hardness ~10 ppm
Dissolved O2 0.1 ppm max.
pH value 8.5 to 9.5
Free CO2 Nil
Bound CO2 ~5 ppm
TDS 400 ppm max
Temperature 90 °C max
• LDO
o The LDO will be used as fuel.
o A tanker of 10 kl of from Hindustan Petroleum Corporation limited.
o The burner will be taken accord to the LDO specification.
o Following things that need to be checked
DATA VALUE
Density 909.4 kg/m3
Kinematic Viscosity 3.67 cSt
Pour point 0 °C
Calorific value
Flash point 91°C
Water content 0.05%
Sulphur content 1.22%
Appearance Dark

o Spark arrestor will be needed for the tanker exhaust.

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• Chemicals for dosing
o Three grades of chemicals are used corrosion inhibitors, PH boosters and O2
scavenger.
o They come in packing of 25 L in HDPE drums. The amount used will be provided by
vendor.
o PPE’s needed are
▪ Hand gloves
▪ Breathing mask
▪ Safety shoes
▪ Protective eye goggles
PHILOSOPHY

Utility:
• Though boiler itself produces steam it need steam in feed water tank.
• WTP is needed in order to get soft water for boiler.
• RO plant for boiler feed water
• Compressed air for working of control system.

Mechanical:
Boiler
• It will have provision of both surface and bottom blowdown.
• A rupture disk is provided to at the refractory of the boiler when there is back firing.
• Proper stare cases will be provided so that maintenance and regular lookup at the top of the
boiler will not have problem.
• Air vent valve and steam outlet will be provided at the top of the boiler.
• The steam outlet has a separator that will prevent the inlet of water along with steam.
• Fusible Plugs are used to protect boilers from low levels.
• Nozzle for 2 level indicators, 2 level switches (mobery), pressure indicator, temperature
indicator, pressure switch, 2 safety valves, TDS meter and have a manhole at the top.

Feed Water Tank

• 2 kl closed tank for the storage tank of feed water
• Material of construction will be MS

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• List of nozzles is as follows: -
1. Steam inlet
2. Feed water outlet
3. Condensate inlet
4. Soft water inlet
5. Temperature indicator and transmitter
6. Level indicator and transmitter
7. Level indicator
8. Vent
9. Drain
10. Overflow
11. Spare
12. Service
13. Manhole with cover
• The feed water tank will be 3 m elevation to provide proper suction pressure for feed pump.
• Steam is used to heat feed water up to 90oC.
• LRB glass wool will be used for insulation with aluminum cladding.
• Proper support for the tank and thickness of wall will be taken care while designing.

Dosing Tank and Pump

• Dosing tank will be of 50L and material of construction is HDPE.
• Hose of ½” will needed to make dosing in the tank.
• A line of 1” will be provided from WTP of soft water to make chemicals.

Feed pump suction circuit

• The piping will be of MS and LRB glass wool will be used for insulation.
• Y type strainer will be used to separate suspended particles out of the feed water.
• The size of the suction line will be one size higher than the size of piping to reduce the pressure
drop.
• Gate valve will be outlet of the tank and the inlet of the feed water pumps.
• The feed water pump appropriate for the boiler will be taken on the recommendation of the
vendor.

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Day tank for LDO
• A tank of 990L of MS will be used for it.
• The LDO used by the boiler will be taken from this tank.
• A flame arrestor will be installed in line for overflow line up to drum.
• It will have level switch for high and low level also LT for backup with indication in DCS panel.
• A manhole at top and a drain line will be provided at the bottom for maintenance purpose.
• A return line at the top of the tank for the reuse of left LDO after usage in burner.
• List of nozzles

1. LOD Inlet (on top)

2. LDO outlet 1 (on shell at bottom)
3. LDO Outlet 2 (on shell at bottom)
4. Overflow (on shell at top)
5. Level indicator (on shell)
6. Service (on shell at bottom )
7. Temperature indicator and transmitter (on top)
8. Level transmitter/ Level switch (on top)
9. Drain (at bottom)
10. Vent (on top)
11. Spare (on top)
12. Manhole with cover (on top)

LDO Feed Line

• The lines will be of MS as GI will get corroded by the sulfur present in the fuel.
• Gear pump of appropriate head and flow rate (0.6 m3/hr., 25m) will be used for the firing of
LDO.
• 2 Basket Filters of 80 mesh and one “Y” type strainer is providing before the pump to make
feed free from dirt and slurry in the LDO.

Stack
• The self-supported Chimney of MS will be used for Material of Construction.
• The velocity of flue gases will be greater than 10 m/s.
• We will use lightening arrestor.

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Efficiency Monitoring System
• Boiler efficiency monitoring and automation system will be there for smooth operation of boiler
with high efficiency with help of SCADA system
• It includes flow meter for steam, LDO and gas. Also helps to measure flue gas concentration
• It has auto blowdown with measurement of TDS with help of TDS sensor

Flue Gas Duct

• The insulation of LRB glass wool will be provided on the line to keep the temperature.
• Expansion Joint will be provided in the duct to protect it from thermal stress.
• A damper valve will be provided at outlet of the boiler for maintenance of the stack.
• MS for Material of Construction
Air Preheater
• External parallel cum counter flow heat exchanger consisting of bank of carbon steel tubes
carrying air and enclosed with a shell having flue gases coming from boiler. Whole assembly
will be mounted on a structure with inlet, outlet combustion air & flue gas duct.
• One soot blower will be there in APH to remove the soot in working condition.
• A damper valve will be provided at inlet and outlet of the APH for maintenance work and
smooth operation.
• MS for Material of Construction

Blowdown Pit
• The blowdown pit will be of 2 KL.
• A vent will be provided at the top of tank.
• The inlet and outlet of the will be at ground level.
• A normal RCC tank will be used for it.
• Rack and Pinion valve will be used for the blow down valve.
• There will be a pump at the outlet that will send blowdown to ETP.

Steam traps
• There are various steam traps and all have different usage the table below will give us an idea
for usage under different condition.

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Inverted Bucket Float Type Thermodynamic Bellow

Live steam loss √ _ √ √

Very response
√ √ X _
to condensate
Response on
_ √ X √
start up

Back Pressure √ √ X √

Light load √ √ X √

Dirt √ X X √

Non
√ √ X X
Condensates
Water
√ X √ X
Hammering

Service Life √ _ X _

X Not Permissible
√ Permissible
_ Need special conditions

• The cost also plays a key role in the selection as the Thermodynamic (TD) traps are cheaper.
• So steam line we can use TD and use bypass in start and they will be installed after 10m.
• Compact module ball float type steam trap for the reactors.

Pressure Reducing station

• For low pressure steam we have installed pressure reducing station at plant, MEE and stripper
as per process pressure requirement.
• LP network for plant are with pressure reducing station set at 3.5 Kg/cm2
• Steam network for MEE are set with pressure reducing station outlet at 6.5 Kg/cm2
• Steam supply for stripper with set pressure at pressure reducing station outlet of 3 kg/cm2

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Piping
• Material of construction of pipes, pipe fittings and valves used for steam line will be MS,
seamless of IBR grade.
• Expansion loops will be provided in the steam line in every 30 m.
• Steam trap will be installed at interval of 30 mtr on pipe rack header for both low pressure and
high pressure steam lines.
• LRB glass wool will be used for insulation with aluminum cladding.
• Pipe line will have a slope of 100mm: 50m that will be taken care at the time of piping for
proper removal of condensate.
• A drain line will be given to the drainage of level indicators and level switch (mobery) of IBR
grade.
• Mechanical separators are placed at the after expansion loops and the inlet of the reactors.
• Air vent valves will be provided at the end top point of the coil or jacket that will lead to removal
of air from the line.

Header
• The separate outlet for all the lines in plant.
• It is insulated with LRB glass wool with aluminum cladding.
• It will have a condensate drain line with a TD type steam trap.
• Compact ball float type steam trap installed at plant area apart from header.

Condensate Recovery system

• Two separate header will be provided based on HP & LP outlet steam to the condensate line
of reactors up to PPPU pump then will have common header for condensate to condensate
collection tank. That will be done based on the plant layout.
• PPPU (Power Pressure Pumping Unit) will be provided to pump the condensate again in the
condensate collection tank.
• The steam line will be provided to of appropriate pressure as per requirement.
• Separate PPPU pump will be provided for ETP condensate
• Flash separator will be installed for steam recovery from high pressure and temperature
reactors

Civil:
• Details will be covered in concept notes of plant.

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Electrical:
• The system will be considered under flameproof area.
• Proper protection system will be installed i.e. time setting of relays.
• The motors used will be of IE3 class for all the running equipment.
• It will have proper lighting arrangement for proper illumination in night.
• All running equipment’s will have local emergency stop button with protection.
• All the equipment and structure will have double earthing.
• Further more details will be included in concept notes of electrical.

Instrumentation:
• RTD, level indicator, level switch (low and high) and temperature indicator for the feed water
storage tank.
• Level switch (low and high) for LDO storage tank.
• A conductivity meter to measure the TDS of blow down water (inside boiler) and feed water.
• 2 Level switch of (high 50%, low 35%, extra low 20% and dangerously extra low 10%), 2 level
indicators, pressure indicator, temperature indicator, pressure transmitter, TDS meter and two
safety valves will be provided on the boiler.
• LDO flowmeter will be placed in the line of the LDO line.
• Steam flowmeter will be placed in the line of steam.
• A modulation system will be provided so that controlling the flow of the LDO and air inlet in
high and low system by solenoid valve for LDO and dampening system for the air valve.
• UV cell with a photo resistor will be provided to keep a look on the firing inside the boiler.
• Flow control valve for the steam line will be provided in the feed water tank to maintain the
temperature.
• Pressure indicators for the LDO line that enter the burner and that return back to the LDO
tank. Pressure indicator for inlet LDO line.
• Pressure indicators for the feed water inlet line at the inlet of boiler.
• Pressure indicators, transmitter for the feed air inlet.
• Temperature indicator, transmitter and pressure indicator for the flue gas at the outlet of
boiler.
• NRV valve for feed water inlet line after feed water pump, fuel inlet and outlet line from the
burner

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• A control valve to maintain the temperature of the feed water to 90°C by changing the flow
rate of the steam.
• Flow measure and recording meters for feed water, LDO, Steam, Blowdown, Make Up water
and Condensate recovered.
• Stack analysis device will be provided at the top of the Stack. Following parameters are
needed
o Percentage O2
o Percentage CO
o Stack Temperature
o Stack Flowrate
• Following are the interlocks and locks will be provided.
Place Interlock Cause Provided
Feed water tank Water Extra low It will damage the Team
level (10 %) boiler by
overheating.
Boiler water level • Water level It will damage the Vendor
switch (20%) boiler by
• Water level overheating.
switch (10%)
Pressure When the It will Cause the Vendor
pressure exceeds explosion of the
10 kg/cm2. boiler
Fuel pressure If the fuel pressure It will cause Vendor
is less than 14 improper burning
kg/cm2. and in some case
back firing too.
Burner (UV cell) If there is a flicking It will cause Vendor
flame improper burning
and in some case
back firing too.

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• Alarms where interlock action is not needed
Place Alarm Cause
LDO Tank Level LDO Extra low level (10 %) It will not cause any thing from
the safety point of view.
Flue Gas If the temperature exceed It is needed when there is a
temperature 280°C time for maintenance.
High TDS of boiler When the TDS of the feed water The blowdown action will be
exceed 3500 ppm. needed.
Flue gas Damper valve open It will not allow the gases to
flow outwards

• PLC panel will indicate the following things

o Temperature of steam
o Steam Flowrate.
o Total steam used.
o Pressure of the boiler.
o Temperature of Flue gas.
o TDS of the boiler.
o Feed Water flowrate and total use.
o Flowrate of LDO and total use.
o Total Blowdown.

Parameters for test:

• Hardness test
o Titration with EDTA with an indicator as EBT.
o Sample Points
▪ Boiler feed water
▪ Return condensate
▪ Make up water
• TDS Meter
o Conductivity Meter celebrated to measure TDS
o Sample Points
▪ Boiler feed water
▪ Return condensate

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▪ Make up water
• pH Meter
o pH meter for calculation of pH.
o Sample Points
▪ Boiler feed water
▪ Return condensate
▪ Make up water
• Dissolved O2 test
o To calculate the dissolved O2 using titration or DO calculation meter.
o Sample Points
▪ Boiler feed water
▪ Return condensate
▪ Make up water
• Meters for measuring all these parameters will be provided in the boiler vicinity.

Effluent Generate
• Blowdown will generate an effluent of 1-1.5 kl of 3500-4000 ppm TDS that will go to ETP.
• Effluent will be generated of 12-13 kl on maintenance of the Boiler of high TDS.
• BOD and COD

Safety:
• The boiler will have two pressure safety valves at top.
• Safety posters and MSDS to be displayed in all working areas.
• Internal HAZOP study will be conducted for all process
• Walking and operational areas will be clearly marked with yellow strips.
• Earthing to individual equipment.
• Fire extinguisher and smoke detectors will be arranged properly.
• Proper insulation will be provided on all the drain lines.

Statutory Aspects:
• It will be covered in separate concept notes.

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PFD

3.0 SIZING
Sr. Component MOC Capacity
No
1. Feed Water Tank MS 2 KL
2. LDO Day Tank MS 990L
3. Dosing Tank HDPE
4. Boiler MS 3000 kg/hr.
5. Feed Water Pump SS304 5.4 m3/hr.
6. LDO Gear Pump MS 5.4 m3/hr.
7. Chemical Dosing
Pump
8. Blower MS 3200 m3/hr.
9 Stack MS
10. Blow Down Pit RCC 2 KL
11. Bucket Filter MS 80 mesh. no

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4.0 NEW CONCEPTS
• Steam Quality Analyzer
o Existing Procedure
▪ Nothing is done to calculate the Quality of Steam
o Through Points
▪ It will calculate the dryness fraction of the steam by passing it through
moisture separator.
▪ Dryness play a key role in wear and erosion of the coil and pipe line.
o Benefits
▪ It will give us an estimation of the quality steam.
▪ It will tell us about the proper working of the boiler.
o Discussion
▪ The locations at which the sensor will be used.
▪ Heat of feed water via submerged perforated tubes via steam
o Existing Procedure
▪ The steam will be directly inserted in the feed water tank at one point.
o Thought Process
▪ If the steam is spread in the tank vis small pores it will cause effective
heating
o Benefit
▪ It will increase the steam utilization efficiency.

Tank

Steam inlet

5.0 LAYOUT

6.0 ANNEXURE

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