Annexure I

SCOPE OF EQUIPMENT SUPPLY AND SERVICES

ONE NUMBER, BIDRUM, NATURAL CIRCULATION, BALANCED DRAFT, TOP
SUPPORTED, OUTDOOR, WATER TUBE TYPE, CONTINUOUS ASH DISCHARGE
TRAVELLING GRATE SPREADER STOKER BOILER SUITABLE FOR 100% BAGASSE
AND COMPRISING OF THE FOLLOWING:
Mechanical
1.

Pressure parts

Steam drum of fusion welded construction provided with necessary nozzle and
with dished ends on both side with man ways.

Steam drum internals comprising cyclones, scrubbers & demisters. (Drum internals
are of carbon steel construction except demister, which is of SS construction).

Steam drum suspension / Support rod.

Mud drum of fusion welded construction with dished ends on both side with man
ways.

Furnace water wall tubes of fin welded water-cooled membrane wall construction
together with inlet and outlet manifolds provided with necessary stubs. Necessary
openings in the furnace for access doors, peep holes and fuel distributor.

Convective & non drainable type primary superheater and secondary superheater
with all inter connecting piping and headers. Suitable spacers are provided for
primary and secondary superheater.

One no. fixed orifice attemperator of spray type located in between primary super
heater and secondary superheater to control the superheater temperature within +
5 deg.C in the control range of 50-100% BMCR for bagasse firing. Stainless Steel
liner is provided for the desuperheater header / pipe at spray point to withstand
erosion and thermal shock.

Boiler bank tubes of single pass design. Boiler bank tubes are expanded into the
steam and water drum.

Economiser of plain tube construction complete with inlet and outlet manifolds and
coil support.

Economiser assembly is arranged in banks and provided with

adequate inter bank gap.

2.

All pressure parts tube material will be of hot finished seamless tube.

Feed Water system

Feed water piping from deaerator storage tank outlet to boiler feed pump suction
including suction header and from boiler feed pump discharge including discharge
header.

Feed water piping from boiler feed pump discharge header to feed control station
inlet and from feed control station outlet to Economiser inlet header.

Feed water piping from Economiser outlet header to steam drum.

Spray water piping from boiler feed pump discharge to boiler de-superheater.

Spray water piping from boiler feed pump discharge to pressure reducing &
desuperheater stations (PRDS).

3.

Hangers and supports for piping, as required.

Valves and fittings as per P & IDs enclosed.

Steam system

Circulating system including all down comers and risers.

Saturated steam piping from steam drum to primary super heater inlet header.

Steam piping from primary superheater outlet header to secondary super heater
inlet header through spray type attemperator.

Main steam piping from secondary super heater outlet header to main steam stop
valve along with integral bypass valve. (Max. pipe length of 15 m considered).

Soot blower steam piping from primary super heater header outlet to respective
soot blowers in superheater, boiler bank and economiser.

Upstream piping for pressure reducing and de-superheater station (PRDS) for
Deaerator from main steam piping and down stream piping to deaerator.

One no. steam pressure reducing and de-superheating station (fixed orifice type)
for supplying steam to deaerator during start up including pressure control valve
and temperature control valve (1 x 100% pneumatic pressure control valve and 1 x
100% pneumatic temperature control valve with manual isolation valve at inlet &
outlet and manual by pass valves). PRDS capacity of 15 TPH is considered.

Target plate and temporary piping required for steam blowing including motorised
isolation valve.

4.

Hangers and supports for piping, as required.

Drain and Vent piping

Safety valve exhaust & Start up vent piping up to a safe elevation.

High pressure boiler blow down piping up to continuous blow down tank.

Drain piping from individual drains to drain header and from drain header to
intermittent blow down tank.

Drain piping from continuous blow down tank to intermittent blow down tank with
level control valve.

Blow down piping from outlet of intermittent blow down tank & terminated at
discharge flange of intermittent blow down tank.

Each One no. blow down tank for continuous & intermittent blow down and Flash
steam recovery piping from continuous blow down tank to deaerator.

Cooling water supply / return piping from terminal point near boiler front row
column to all equipment within the boiler island requiring cooling water.

Service water supply / return piping from terminal point near boiler front row
column to all equipment within the boiler island requiring service water.

Boiler initial filling line from terminal point near boiler front row column to the water
wall drain header.

Raw water quenching line for Intermittent Blow Down tank from terminal point.

5.

Non Pressure parts

Tubular Carbon Steel Air Heater (with ERW tubes and gas flow through tubes) to
preheat the combustion air and comprising of tube sheet, casing and associated
supports and structures.
Corten steel tubes will be provided for first six rows (from air side) to avoid cold end
corrosion during boiler startup and part load operation.
Airheater provided with air side by pass for FD / SA with motor operated damper.
Refractory layer provided on top of tube sheets to prevent erosion and corrosion of
airheater tubes at the gas entry side.

Over Fire Air nozzle at required elevation in furnace wall along with necessary
ducting.

Pre dust collector in the flue gas path to collect the larger un-burnt / ash particle
from the gas stream and prevent fire hazardous in ESP.

Casing & Hoppers:

Carbon steel casing with stiffeners and supports for Economiser. Double casing
arrangement is provided to prevent Economiser tube bends from erosion.

Furnace front ash discharge chute (Carbon steel construction) submerged into
submerged ash conveyor along with manually operated plate gates. By pass chute
with gate to discharge the ash on the ground for front ash discharge chute.

Bottom ash riddling hoppers (Carbon steel construction) with manually operated
plate gates.

Fly ash hoppers (Carbon steel construction) below economiser, air preheater and
electro static precipitator with manually operated isolation plate gate at the outlet of
respective fly ash hoppers.
Boiler Supporting Structures, Plat forms, Stair case & operating floor:

Buck stays, tie bars as required.

Boiler supporting steel work of bolted and welded construction from rolled steel
section starting from purchasers RCC finished floor level (+ 300 mm elevation).
Structural section will be as per Indian standards.

Galleries, ladders and stairways with hand rails providing access to the essential
levels of the boiler and auxiliaries. Gratings are of open bar type. (Gratings,

platforms, handrails, stair treads are of Galvanized Iron construction and structural
steel like column, beams and bracings will be provided with corrosion resistant
painting).

Two nos. staircases from finished floor level to steam drum operating floor level
(Refer General Arrangement drawing Elevation enclosed)

Canopy (Color coated metapoly sheet of 0.6 mm thick) over boiler furnace and
side cladding (Color coated metapoly sheet of 0.6 mm thick) for boiler up to steam
drum operating floor level from top for weather protection. Roof structure and
structure for side cladding sheets.

Weather protection hoods for outdoor motors.

Support and suspension steel, access platform for all equipments, piping and
ducting.
Air and Flue gas ducting:

Air ducting (5mm thickness) with required stiffeners, expansion joints, resin bonded
mineral wool insulation, cladding (plain Aluminium cladding for hot air ducting) and
necessary fixing components for the following.
o

Forced draft air fan cold air suction ducting.

Cold air ducting from forced draft air fan to air heater.

Hot air ducting from air heater to furnace bottom.

Secondary air fan cold air suction ducting.

Cold air ducting from secondary air fan to air heater.

Hot air ducting from secondary air fan outlet to over fire air nozzle / fuel
pneumatic spreader.

Flue gas ducting (6 mm thickness) with required stiffeners, expansion joints,

resin bonded mineral wool insulation, cladding (plain Aluminium cladding) &
necessary fixing components for the following:
o

Flue gas ducting from boiler to Economiser.

Flue gas ducting from Economiser to air heater.

Flue gas ducting from air heater to electro static precipitator.

Flue gas ducting from electro static precipitator to Induced draft fan inlet.

Flue gas ducting from Induced draft fan outlet to inlet of chimney.

(All the above duct plate material will confirm to Carbon Steel (IS 2062))
Travelling grate:

Continuous ash discharge travelling grate complete with variable frequency
electric drive.
Self lubricated bearing (graphite bearings) are provided for the travelling grate
stoker shaft. The grate bars are made of Spheroidal Graphite Iron.
Thermocouples are provided on the skid bar, cross beam and riddling hoppers
for measuring grate bar temperature.
Refractory & Insulation:

Lightly resin bonded mineral wool insulation (Designed for 20 Deg. C differential
temperature between ambient and outside surface temperature with an air
velocity of 1.0 m/sec over the surface) and plain aluminum cladding for boiler
furnace, boiler bank, economiser, air heater, electro static precipitator, ducting,
piping and other auxiliaries as required along with fixing material.

Casting for access doors and peep holes.
6. Auxiliaries

Two nos. (2 x 50% MCR capacity) radial, single suction, simply supported and
backward curved blade, cold Secondary Air (SA) fan with variable frequency
drive (480 V drive motor) and including base frame, coupling, coupling guard,
suction silencer and suction hood.

Fan will be provided with pneumatically

operated Inlet Guide Vanes (IGV). Grease lubrication is provided for the fan
bearings.

Two nos. (2 x 50% MCR capacity) radial, single suction, simply supported and
backward curved blade, Forced draught (FD) fan with variable frequency drive
(480 V drive motor) and including base frame, coupling, coupling guard and
suction hood. Fan will be provided with pneumatically operated Inlet Guide
Vanes (IGV) / Damper. Grease lubrication is provided for the fan bearings.

Two nos. (2 x 50% MCR capacity) radial, single suction, simply supported, and
backward curved Induced Draught (ID) fan with variable frequency drive
(480 V drive motor) and including base frame, coupling, coupling guard. Fan will
be provided with pneumatically operated inlet Damper Control (IDC). Impeller

will be provided with hard facing / replaceable liner to minimize erosion. Grease
lubrication is provided for the fan bearings.

Motorised isolation dampers at SA/ FD/ ID fan outlet.

RTD for measuring the bearing temperature of fans.

Individual base frame for fans & motors.

Valves, mountings and fittings including the following:

o

Two nos. Spring loaded safety valves on steam drum and one no safety valve
on super heated main steam line.

Silencers for startup vent valve and superheater safety valve to limit the noise
level to 110 dBA at 3 m distance.

One x 100% pneumatically operated feed control valves with motorised

isolation valves at upstream and manually operated downstream isolation
valve.

One x 30% pneumatically operated feed control valve with motorised isolation
valve at upstream and manually operated downstream isolation valve.

One x 100% motorised by pass valve for feed control valves.

Manual drain valves for above feed control station.

One x 100 % pneumatically operated superheater spray control valve with

motorised isolation valve at upstream and manually operated downstream
isolation valve and one no.100% motorised bypass valve for desuperheater.

One no. non return valve in the main steam line.

One no. non return valve & one no. motorised isolation valve in feed water
line before Economiser.

Required nos. manual isolation for drain and vent.

One no motorised main steam stop valve with motorised integral bypass at
superheater outlet.

One no pneumatic startup vent valve (with inching facility) with motorised
isolation valve.

Each one no. motorised continuous blow down & intermittent blow down
valve.

Two nos. motorised isolation valve at feed pump discharge.

7. Soot Blowers

Electrically operated long retractable soot blowers for superheater zone and
rotary soot blowers for boiler bank and economiser zone complete with pressure
reducing station and other accessories, valves/fittings. Sequential operation of
soot blowers will be realized in Distributed control system.

One x 100 % pneumatically operated soot blower pressure control valve with
manual isolation valve at upstream and downstream and one no. 100% manual
bypass valve.
Steam for the soot blowers is taken from the outlet of the primary superheater
and the pressure is reduced to the level required for soot blowing. The degree of
superheat of the steam to soot blowers will be more than 20 0C.

8. Deaerator cum storage tank, Boiler Feed water pumps & Chemical dosing
system:
Deaerator cum storage tank:

o

One no. Spray cum tray type deaerator of 215 TPH capacity and De-aerated
water tank of 15 minutes storage of boiler MCR generation capacity between
NWL to trip level.

Deaerator is located on separate structure. (Refer enclosed General

Arrangement drawing for the location of deaerator)

One x 100% pneumatically operated deaerator pressure control valve with

manual operated isolation valve at up stream and downstream and one no.
manual by pass valve.

One x 100% pneumatically operated deaerator level control valve with

manual operated isolation valve at up stream and downstream and one no.
manual by pass valve.

Steam piping from pressure control valves to deaerator.

Feed water piping from level control valve to deaerator.

Over flow piping from deaerator terminated near deaerator with solenoid
operated control valve.

Ladders or staircases, as required.

Lightly resin bonded mineral wool insulation with plain aluminium cladding of
0.70 mm thick.

Valves and fittings, as required (Refer P & ID).

Boiler Feed Pumps:

o

Three x 50 % MCR (Two working + One stand by) capacity centrifugal,

multistage, ring section type boiler feed pump (Non-API design) complete
with base frame, coupling, mechanical seals, connection flange, Automatic
Recirculation Valve, suction strainer and ring oil lubrication for pump
bearings.

Minimum re-circulation piping and balance leak-off piping from boiler feed
water pumps to inlet of deaerator tank.

RTD for measuring the bearing temperature of pumps.

Individual base frame for pump & motor.

Vibration monitoring system for boiler feed water pumps bearings.


Chemical Dosing System:

o

One no. Skid mounted Low Pressure dosing (NALCO 4221 / Erythorbate)
system comprising of one no. mixing cum storage tank (stainless steel) with
motorised agitator and 2 nos. positive displacement pumps(1W+1S).

One no. Skid mounted High Pressure dosing (Tri-sodium phosphate) system
comprising of one no. mixing cum storage tank (stainless steel) with
motorised agitator and 2 nos. positive displacement pumps(1W+1S).

Low Pressure Dosing piping (stainless steel) from Low Pressure dosing tank
to Boiler feed pump suction.

High Pressure Dosing piping (stainless steel) from High Pressure dosing tank
to Steam drum.

Valve and fittings as required.

High Pressure / Low Pressure dosing system dilution water line from one
point near boiler front row column to respective dosing tanks.

9. Fuel Storage & feeding system:

Bagasse Storage & feeding system:

o

Si x nos. of bagasse chute at feeder inlet. Manual ly operated isolation gates

at inlet of bagasse chute. Bagasse chute with supporting structures.

Six nos. of three drum feeders with variable freq uency drive (VFD) for
bagasse fuel feeding.

Six nos. of pneumatic fuel spreaders along with c onnecting chutes from
feeder discharge.

Rotary dampers connected by shaft with drive motors and adjustable

deflector plate in each fuel chute.

10. Pollution control equipment

Electrostatic precipitator:

o

One no. Electrostatic precipitator of single stream type to limit the outlet dust
concentration to 50 mg/Nm3 at the outlet of ESP with all fields working.

Complete accessories including emitting & collecting electrodes, casing,

hoppers, hopper level indicators, hopper heater, rapping mechanism, T/R
sets, supporting structures, stairways, walkways, handrails, housing, carbon

steel expansion joints, Lightly resin bonded mineral wool insulation with plain
aluminium cladding of 0.70 mm thick, inlet and outlet funnels, gas distribution
screens, electrical and mechanical interlock system, manually operated
isolation gates at hopper discharge. Hopper heaters are thermostatically
controlled.

(Stairways,

walkway,

handrails

are

of

Galvanized

Iron

construction).
o

T/R set panel and rapper controller panel.

Electric lifting / handling arrangement for T-R sets.

11. Chimney:
One no. carbon steel self supported chimney of 40 m height with necessary

platforms, ladders, aviation lights, lightning protection, lightly resin bonded

mineral wool insulation with 0.70 mm thick plain aluminium cladding for 2m
height from bottom for personnel protection.
Chimney counter flanges, expansion joint near the chimney and fasteners for

connection.
12. Front & Ridding Ash Handling System
Submerged belt conveyor (SBC) system for discharging Coarse ash from the

1.

front of the boiler up to a

distance of approximately 10 m from one side of the furnace. (Further
disposal of ash by client Common Belt Conveyor
2 nos. screw conveyors for conveying riddling hopper ash (ash under the

2.

grate) to the submerged belt conveyor (SBC)

13.

Controls and Instrumentation:

Local field instruments
o

As per enclosed P & I Diagram.

Field instruments required for the following control loops:

o

Three Element drum level control

Auto combustion control

Furnace draft control

Superheated steam temperature control

Soot blower pressure control

Continuous Blow down control

Deaerator level & pressure control.

PRDS Control.

One no. remote water level indicator for steam drum.

One O2 analyzer in flue gas path.

Vibration monitoring system for ID fans bearings & BFP Bearings

Control and instrument cables from field instrument to Distributed Control System
including junction boxes.

Impulse piping wherever necessary for the items which are under our scope of
supply.

Instrument air piping from one point near the terminal point to individual boiler
equipment, as required.

Service air piping from one point near the terminal point to individual boiler
equipment, as required.

Each one no. SOx, NOx & SPM and CO analyser for flue gas.

Distributed control system for boiler. Redundancy is considered in processor,

power supply and communication module. One no. PC for engineering station
and two nos. PC for operator station (Both engineering station & operator station
are located in control room at a distance of Approx. 50 mtrs from the first row of
boiler column).

14. Electrical

Drive motors of all auxiliaries covered under the scope.

480 V Variable frequency drive for fuel feeders, stoker drives, FD fan (6 pulse
VFD) SA fan (6 pulse VFD), ID fan (6 pulse VFD).

4160 V Variable Frequency Drive for Boiler Feed Pump (12 pulse VFD) & ID Fans (6 pulse VFD).

Electric actuators for valves / dampers as required.

Local push button stations for 480 V drives and 4160 V drives.

15. General

Foundation and anchor bolts, lugs and fins, as required for boiler, fans, chimney,
pumps and boiler accessories in our scope.

Initial fill of lubricants and grease.

Commissioning spares as required.

Special tools and tackles, as per enclosed list (Refer Section 6).

Suitable operating mechanism complete in all respect with access for operation
of all manual and power cylinder operated dampers.

Two coats of Epoxy primer painting at shop prior to dispatch & one coat of touchup primer painting (only supply of touch-up primer paints).

16. Scope of services

Supervision of erection & commissioning of mechanical, electrical, C&I

equipment as included in our scope of supply.

Performance test of boiler.

Training of purchasers operating personnel at site (Schedule to be mutually

discussed).

ASME S stamping for pressure parts manufactured in our shop.

Annexure II(A)

Indicative Man Power Deployment Plan For Erection & Commissioning of 180 TPH TG Boiler
at M/s Isolux Columbia
S.No.
Category of Person
Plase -I
Plase -II
Plase -III
(Structure
erection )
4

(Pressure
Parts)
-

(Auxillaries & Ducting )

Structural Welders

Fitter

Gas cutter

Grinder Man

Riggers

20

17

Khalasi

14

13

Helpers

10

14

16

Pressure parts fitter

HP Welders

10

Attachment welders

11

Mill right fitter

32

72

63

Total

Prepared By

Note :
1

The above is a tentative requirement, which may have to be increased as per the site
requirement.

Annexure II (b)
INDICATIVE LIST OF MINIMUM TOOLS & TACKLES REQUIRED For Erection & Commissioning of

180 TPH TG Boiler at M/s

S.No.
1

Items
Welding Transformer

Welding Rectifier/Generator

Hand cutting sets

4
5

Motorized Winch with rope, D- shackle, Pulley, Wire

rope with suitable multi sheeves pullys
Motorised winch with rope

Isolux Columbia
Capacity
400 A

Qty.
15Nos.

450 A

20 Nos.

Remarks

15 sets
10MT

4Nos.

3 T- 5 T

5 No.

Grinding Machine

AG 7

8 Nos.

Grinding machine

AG 4/5

12 Nos.

Grinding machine

FF2

4 No.

Pensil Grinder

For drum lifting

2 No.

Chain Pulley Block

5 MT

12 No.

With 10 Mtrs chain

10

Chain Pulley Block

3 MT

18 Nos.

With 10 Mtrs chain

11

Chain Pulley Block

2 MT

15 Nos.

12

Chain Pulley Block

1 MT

10 Nos.

13

Mother Oven

2 Nos.

14

Portable Oven

15 Nos.

15

Drill m/c with magnetic stand

2 No.

16

Master level

2 No.

17

Dial gauge with magnetic stand

6 Nos.

18

Vernier Calipers

2 Nos.

19

Hydra crane

20

Hydraulic tube expander

21

Hydraulic test pump (Motorized)

22

Crane of required capacity

2No.

23

Theodolite

01No.

24

Tube Cutting Machine

02No.

25

Tube chamfering Machine

01 No

12MT14MT

3 No.
2 M/c

350
Kg/cm2

1 No.

Note : You will also arrange the following:

1)
Spare rollers & mandrel etc. in adequate quantities for the expending machines.
2)
All other tools viz. spanners, tapes, right angles, hammers, D-shackles, wire ropes, Nylon ropes, coir ropes, pulleys
etc. will be arranged as per Requirement.
3)

The above is a minimum requirement, which may be augmented as per the site requirement to speed up the job.

4)

You will submit the test certificate & calibration certificate of all the tools.
for ISGEC HEAVY ENGINEERING LIMITED