Boiler Work Scope :-

Job: Improvement of 1 no. boiler at site.

Detailed Scope:
1)Monobloc Gas Fired Burner system 01 Nos.
Make: Oilon, Finland, Model: GP-600 M or equivalent
Suitable for Natural gas
Regulation Fully modulating (Stepless modulation)
Capacity range (Gas): 1400 - 6750 kW
Turn down ratio (Gas): 1 : 4.1
Ignition method: Ignition gas solenoid valve
Length of combustion head: 310 mm
Noise level: 88 dBA at 1 m distance
In accordance to European regulation EN676 & CE certified
Consisting of:
- Inbuilt combustion fan with direct driven electric motor
- Combustion fan-motor: 11.0 kW (mounted on the burner)
- Duplex shut off valve for NG, Size DN65, I/L gas pressure110 mbar
min. & 360 mbar max.
- 90 Elbow for duplex shut off valve
- Ignition gas solenoid valve for NG
- Ignition transformer, electrode with cable
- Combustion head extension
- Flame sensor:UV
- Butterfly valve for gas flow control
- Air regulating mechanism for air flow control
- Combustion Head (mm): 310L x 395D
- High gas pressure switch
- Low gas pressure switch
- Air pressure switch
- Leakage detection unit.
- Pressure Transmitter on steam drum.
2) Complete power cum control panel PLC Based 01set
Standard PLC (Siemens) panel for existing SM60 Or Equivalent
Supply voltage: 415V + 5%, 3 Ph, 4 wire & 50 Hz + 5 % 3 /4
wire
Control voltage: 240V, A.C., 1 Ph
Input/ Outputs as mentioned below: DI: 20 DO: 12 AI: 5 AO: 1
20% extra on these with Ethernet communication port
Consisting of:
- Panel box with power & control sections partition plate
- Floor mounted, Double door, bottom cable entry
- Burner management system (PLC based), (Replacing
Existing Panel) Burner
Flame relay,
- Switch gear for combustion air fan-motor
- Switch gear for fuel pump-motor
- Switch gear for existing TF Circulation & Transfer pump
- Interlocking arrangement between offered panel & Field
Instrumentation
- MCB / MCCB (Fuse less panel)
- Hooter
- Necessary contactors, switch, indicating lamps etc.
Free standing type confirming to IP 42 with MCB/MCCB. The panel
box is made out of 14/16 SWG CRCA sheets and painted with
polyurethane paints / synthetic enamel.
The power & control section are physically isolated with partition
plate. The power section is provided with a main incomer isolating
switch with MCCB. The required switch gears for all the feeders are
housed in the power section.

 Burner management system along with necessary start stop button,

auxiliary contactor, and control circuit of all motors, indication
lamps & hooter for the alarm are housed in the control section.
Temperature indicator & switch is provided in the control panel to
indicate the heater stack temperature. This switch gives high stack
temp alarm, lamp indication & burner trip interlock.
This PLC based complete power cum control panel will have color
5.7 HMI.
Data logging capacity 1 month
3) LMV 52, VFD & Oxygen monitoring System. 01 set
As per below scope
Scope and specifications for Oxygen Monitoring are as below;
a) Separate Type Zirconia Oxygen Converter
Model: ZR402G-T-E-E-A Make Yokogawa or Equivalent
Features:
* LCD Touch panel for ease of operation
* Sensor diagnostics with production of cell life
* Converter displays the cell temperature and cell emf in
addition to Oxygen concentration
* Interactive Graphical Display besides concentration display
* Maximum distance between probe & Converter can be 500 Mtr.
Specifications:
* Measurement Range: 0.01 to 100% Vol% O2
* Output Signal: Two 4 to 20 mA DC
* Digital Communication: HART
* Repeatability: +/- 0.5%
* Linearity: +/- 1 %
* Response: T90 is less than 5 sec.
* Construction: NEMA 4X/IP66
* Contacts outputs: 4 points
* Self Diagnostics
* Ambient temp.: -20 to + 55 deg. C
* Power Supply: 100 to 250 V AC, 50/60 Hz
b) Zirconia Oxygen Detector (Probe) with Dust Filter
Model: ZR22G-040-S-A-E-T-T-E-A/CV/F1 Make Yokogawa or Equivalent
Features:
* Built-in Heater assembly of the probe can be replaced on site,
reducing maintenance cost
* Probe uses a long life, high reliability Zirconia sensor.
* Special coating protects the platinum and prevents the sensor
from deteriorating or becoming damaged.
* No special tool is required for cell replacement. Cell can be
easily removed by removing four screws from the top of the
probe.
* Platinum is molecularly bonded to the Zirconia element leaving
no possibility of separation.
Specifications:
* Sample Gas Temperature: 0 to 700 deg. C
* Insertion length: 400 mm
* Sample Gas Pressure: -5 to + 250 kPa
* Probe Material: SUS 316
* Installation: Flange mounting
* Flange: ANSI CLASS 150-2-RF(Equivalent)
* Construction: Heater and thermocouple replaceable.
* Construction: NEMA 4X/IP66
2 Probe Protector (Abrasive Shield) 450 mm
It is used when sample gas flow velocity is 10 m/Sec. Or more
and dust particles wears out the detector.
3 Cables (10 Mtr)
a) 2-Core Power Cable, 1.5 mm2 between Probe & Converter
b) 6-Core Signal Cable, 1.5 mm2 between Probe & Converter

4 SS Tube between Probe & Manual Calibration unit

4) GWF Turbine type gas flow meter. EQZ Model 01 set Or Equivalent
With Local Mechanical Display with over run brake mechanism , Provide reading in SMC.
5) Single Element 01 set
On feed water line after feed water pump:
One: Main feed control valve with accessories
One: Bypass valve for level control valve
Two: Isolation valves for level control valve
On Boiler Drum:
One: Boiler level transmitter
One: Set of items for transmitter hook up
One: Level indicating PID controller (panel mounted)
On bypass line to Feed water tank:
One: Bypass line control valve
One: Bypass valve for above control valve
Two: Isolation valves for above control valve
One: Non return valve
6) Auto Blow-Down System
As per listed item
1 Special IBR approved sensing chamber Thermax- 1 No. Or Equivalent
2 Isolation Valve, Expert - 1 No. Or Equivalent
3 DCV, Thermax -1 No. Or Equivalent
4 Conductivity Sensor, Awvaz- 1 No. Or Equivalent
5 Conductivity Controller with wall mounted panel,Fuji - 1 No. Or Equivalent
6 Electrically actuated Surface Blow down valve,Inditech -1 No. Or Equivalent
7) Vertex Type Flow meter
Following listed meters is required :Sr.No

Location /Area

Pipe line Size

End Connection

Qty required

UOM

Boiler No-01 (Safe area)

4"

F/E ASA #300

Nos

8"

F/E ASA #150

Nos

4"

F/E ASA #300

Nos

3"

F/E ASA #300

Nos

Amine plant for LPS (Ex proof area)

Amine Plant for HPS (Ex proof
area)
GE- 2 Plant for HPS(Ex proof area)
Ethoxylation plant for- LPS-(Ex proof
area)

3"

F/E ASA #150

Nos

MEE plant for LPS-(Ex proof area)

1.5"

F/E ASA #150

Nos

3
4

Technical specifications:Type of flow meter: Vertex Flowmeter

Flanges: WNRFASA (Saturated steam) as per process connection mention in above table
MOC: SS316L
Flanges: ASTM A106 or as per manufacturer standard
Accuracy: 2 % of Actual reading at FSD/ 1 of Actual reading at FSD. With temperature
Compensation
Output: 4 20 mA, HART (Smart)
Inbuilt Density compensation present
Inbuilt Temperature Compensation
IP IP 67
Enclosure Ex proof (Ex proof area)
Display & transmitter: ATEX & Intrinsically safe sensor & transmitter for Ex proof area.(Ex Poof Area)

Calibration: 7 point flow calibration

Multivariable Mass flow

Local Display
IBR approved
Add on panel in safe area for Remote Display of totalizer value(FIT) for Each 5 nos steam meter & will be having
space for 2 more (FIT) in panel
Communication: Each meter or FITs panel to have communication port for PLC OR DCS
8) Gas Safety Shutoff Valve , model 80F40 , Qty- 01 Nos. Or Equivalent
9) ERECTION, INSTALLATION AND COMMISSIONING JOBS FOR BOILER(RBF-60), (All cables, tubes, piping,
fittings, electrical/instrument fittings, cable trays, Nut-bolt, gaskets to be supplied by vendor on unit cost
basis)
1) Flow Meter (01 Qty.for Boiler + 05 Qty.for process) installation , pipe modification at site, cabling and related cable
tray with all material.
2) Single element Fitting at Boiler (RFB 60)with all related Materials , pipe and fittings.
3) Auto blow down Fitting at Boiler (RFB 60) with all related Materials , pipe and fittings.
4) Tube replacement in Boiler (RFB 60) with all related Materials and pipe.
5) Old panel dismantling and new PLC panel installation for RFB 60 work
6) Control and power cabling .
7) IBR design, activities & documentation.
Technical Specification & Scope of Supply
1) Flow meter:
Vertex type flow meter installation with bend, flange, reducer in old plant, Qty: 5 No
Vertex type flow meter installation with bend, flange, reducer in boilers, Qty: 1 No
Fixing of 05 Nos Flow Indicator totalizer (FIT) with add on panel (non flame proof enclosure) at boiler house.
Cabling & hardware for same flow meter fitting
2) Single element:
Single element control system installation in RFB 60 boiler.
Feed water piping from feed pump to boiler and return line to feed water tank
IBR piping with bend, flange, and reducer etc.
3) Auto blow-down:
Auto blow down system installation.
VLI header installation with valves for PT and LT
4) Boiler Tube changing:
Boiler tube dismantling and installation with pipe material- Size: 50.8, Qty: 5 Nos
5) MCC/ PLC panel:
Old panels dismantling and new MCC/PLC panel installation.
6) Cabling and Instrumentation:
Power cabling for RFB 60 boiler.
Control and Instrument cabling for boiler and all supplied flow meter.
Cable tray installation for each boiler and all supplied flow meter.
SS tubing work for flow meters and pressure transmeter.
All cables shall be FRLS.
(Note : All cables to be considered as per company
specification)
7) IBR activities for all work covered in this project:
Preparation of all drawings, reports, applications for necessary submissions & revisions till approval from IBR.
Documentation of all material certificates, inspection reports as per IBR procedures.
Site activities in accordance with IBR rules & regulations with all necessary in-process inspections & reports.
Successful final testing to start up the modified system as per IBR rules.
As built drawings & document set in line with IBR rules for our record.
BATTERY LIMIT

ELECTRICALS
-- Incomer of control panel and incoming termination.
Exclusions from vendors scope
Insulation and cladding
Scaffolding
Painting
Civil and foundations
Cabin for PLC panel