DBR of Boiler for Ambuja Cement

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TECPRO SYSTEM LIMITED

AMBUJA CEMENT LTD

DESIGN BASIS REPORT FORBOILER

2

28.06.20

12

Revised as per HOLTEC

comments dated 26-6-2012 NK NK

A

!

122.06.20

12

Revised as per HOLTECcomments dated 1"-6-

2012NK NK

A!

00#.06.20

12$or Approva%

&!'(NTK

NK A!

INL SIGN INL SIGN INL SIGN

REVISION DATE DESCRIPTION OF REVISION PREPARED CHECKED APPROVED

PROJECTWASTE HEAT RECOVERY BASED POWER PLANT

AT RABRIYAWAS, RAS DISTRICT, RAJASTHAN.

OWNER AMBUJA CEMENT LTD.

OWNER’S CONSULTANT

HOLTEC CONSULTING PRIVATE LTD.,Holtec Cente, A!Bloc", S#$%&ntlo", G#'&on.

EPC CONTRACTOR

TECPRO SYSTEMS LIMITEDCHENNA).

SYSTEM DESIGNER &

SUPPLIER

NANJING TRIUMPH (AINENG ENVIRONMENT

) ENERGY Co., Lt*. NANGJING,CHINA

EPC CONTRACTOR

CONSULTANT

HI+ POWER ASSOCIATES PRIVATE LIMITEDCHENNA)

TECPRO DOC.NUMBER TSL!-/0-10A0D0--1 HIQ DOC.NUMBER

Tot&l No o2 P&'e$ 3 4 Re5.-4

TEC*RO !+!TE'! LT, CHENNA)*ae 1




AMBUJA CEMENT LTD

Po6ect No. 3 -/

Cl7ent N&8e 3 A89#6& Ce8ent Lt*,

R&97:&;&$.

Con$#lt&nt N&8e 3 Holtec Con$#lt7n' P5t.

Lt*.

!o/rce o Heat Cement Ki%n E3a/st ases

Bo7le C&<&c7t:

A4C 5oi%er H* !ection 1870 (3r 11.0

(cm2

9a:

A4C 5oi%er L* !ection "00 (3r 2.80

(cm2

9a:

*re3eater 1 5oi%er H* 10180 (3r 11.0

(cm2 9a:

*re3eater 1 5oi%er L* 170 (3r 2.80 (cm2

9a:

*re3eater 2 5oi%er H* 10180 (3r 11.0

(cm2

9a:

*re3eater 2 5oi%er L* 170 (3r 2.80 (cm

2

9a:

!/per3eated !team Temp. 9H*: ""oC 9or A4C 5oi%er:

"0oC 9or *H 5oi%ers:

!/per3eated !team Temp. 9L*: 180oC 9or *H 5oi%ers:


0

1




AMBUJA CEMENT LTD

No. o 5oi%ers " Nos

Reerence HEAT 'A!! 5ALANCE ,)ARA' 9$A007;1C-<010#-

01: RE& 01

. INTRODUCTION3

'(s Am=/>a Cement Ltd. is 3avin 1 no. o Ki%ns ?it3 C%iner prod/ction capacit@o 660 T*, ?it3 t?o strins o 06-stae pre3eater. Ki%n 3as one C%iner coo%er.E3a/st ases rom iven so/rces are present%@ re>ected to atmosp3ere.

O=>ective is to /ti%ie t3e ?aste 3eat o ases to enerate steam and enerate

po?er or captive /se =@ drivin steam enerator.

'(s Ho%tec Cons/%tin *rivate Limited 3as =een appointed as cons/%tant to

carr@o/t *'C !ervices or t3is pro>ect. T3e E3a/st as 3eat o Ki%n ?3ic3 is

present%@ =ein ?asted ?i%% =e /ti%ied to prod/ce steam. T3e e3a/st as

temperat/res at o/t%et o a%% pre3eater =oi%er to =e maintained so as to /%B%% t3e

process 3eatin re/irement.

AMBIENT CONDITIONS

Ambient temp

er atur

e°C Max. 45

Aver age.27

Min. 5

e!ative "umi#it$ %Min&Max& Aver age' ( )&**&+,

e!ative "umi#it$ -r per - r man/e ( +,

Ambient -r ACC #e0ign °C 42 #eg C

Ambient -r E!e/tri/a! #e0ign °C 5, #eg C

TEC*RO !+!TE'! LT, CHENNA)*ae "




AMBUJA CEMENT LTD

SITE CONDITIONS

Sei0mi/ 1ne II

Ba0i/ in# 0pee# m&0 5,m&0

Site E!evatin 3 Abve 0ea !eve! m )),

C#e0 an# Stan#ar#0

Sr. No.

DetailsReferred for

a IBR 1950 With Latest Amendments Pressure parts alulations

! AS"# Setion II Part A $ #dition %010 "aterial Speifiations

AS"# Setion II Part D $ #dition %010 "aterial Properties

dPressure &essel 'and!oo()

"ehanial *alulations

4. B&$7$ o2 De$7'n

T3is desin =asis is intended to cover re/irements or desin o Daste Heat

Recover@ 5ased *o?er p%ant at Ra=ri@a?as Ra>ast3an or '(s Am=/>a Cement Ltd.

t3ro/3 '(s Tecpro !@stems Ltd. C3ennai.

T3e e3a/st ases rom eac3 o Ki%n ?i%% enter t3e respective connected DHR5.

T3e 3eat rom 3i3 temperat/re e3a/st ases ?i%% =e recovered in DHR5 and

ater recover@ o 3eat ases at %o?er temperat/re ?i%% =e e3a/sted to t3e E!*.

T3e s@stem 3as o%%o?in ma>or sections

1. !/per 3eater

2. Evaporator

". Economier

#. Condensate *re-3eater

. !team ,r/m

6. ,amper

7. 5oi%er eed p/mp

8. ,e-aerator

TEC*RO !+!TE'! LT, CHENNA)*ae #




AMBUJA CEMENT LTD

;. 5%o? do?n Tan

10. C3emica% dosin s@stem

11. ,/st dis%odin s@stem

4.4. WASTE HEAT RECOVERY BOILERWASTE HEAT RECOVERY BOILER

T3e *H =oi%er s3a%% =e H*( L* dr/m =oi%er vertica% conB/ration ?it33orionta% t/=es. A4C =oi%er s3a%% =e H*( L* dr/m =oi%er vertica%conB/ration ?it3 3orionta% t/=es. T3e *H A4C =oi%ers are tops/pported o/tdoor Fnit s/ita=%e or t3e speciBed *re-3eater andC%iner Coo%er e3a/st o cement p%ant. T3e =oi%ers desined or /%%@a/tomated operation rom ,C!. T3e t/=e t3icness s3a%% =e ".2mm

2.2 Ste&8 D#8

T3e !team dr/m is o ?e%ded constr/ction and p%aced on str/ct/reover t3e evaporator sections. T3e materia% o constr/ction is made o !A 16 r.70. Necessar@ no%es and connections or pipin andBttins are provided ?it3 s/pports. Hined man3o%es are provided in=ot3 3eads o t3e dr/m. T3e dr/m is provided ?it3 s/ita=%e t?o staeinterna%s to eGective%@ separate sat/rated steam and to maintain t3ere/ired steam p/rit@. 'inim/m dia. O steam dr/m s3a%% =e 1"72mm. T@pe o steam separator is ,emister.

2." D#ct Enclo$#e

Necessar@ /e as d/ctin rom *H o/t%et to *H =oi%er and do?nstreamto an a%on ?it3 t3e dampers speciBed e%se?3ere in t3e contract. )n%etand o/t%et dampers o *H =oi%er s3a%% =e /i%%otine sea%ed motoriediso%ation dampers. ,amper provided in t3e =@pass d/ct 9*H do?ncomer: s3a%% =e motoried re/%atin 9'/%ti-Lo/ver: t@pe. *H =oi%ercasin and d/ctin t3icness or *H =oi%er s3a%% =e minim/m o 8 mm?it3 ade/ate stiGeners.

$or A4C /e as d/ct rom mid tap point to ,e-d/ster and /rt3er toA4C =oi%er to t3e eistin =a B%er a%on ?it3 dampers speciBede%se?3ere in t3e contract. )n%et and o/t%et dampers o A4C =oi%er s3a%%=e /i%%otine sea%ed motoried iso%ation dampers. ,amper provided int3e coo%er e3a/st s3a%% =e motoried re/%atin 9'/%ti-Lo/vrer: [email protected] No res3 air damper s3a%% =e provided in t3e air =%eed %ine tore/%ate t3e 3ot air temperat/re. ,/ctin t3icness or A4C =oi%er s3a%%=e minim/m 6 mm ?it3 ade/ate stiGeners.

TEC*RO !+!TE'! LT, CHENNA)*ae

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1

02




AMBUJA CEMENT LTD

'OC o *H A4C dampers

Considerin t3e temperat/re o /e as( air vent t3e A4C =oi%er and

*H =oi%er are enc%osed ?it3 car=on stee% casin 9o speciBed t3icness:?it3 o/tside ins/%ation. Necessar@ access doors or ease o operationand maintenance s3a%% =e considered.

4.=.E5&<o&to

*H =oi%er Evaporator section is o 3orionta% in%ine t/=es and cross-o?arranement ?it3 3eaders considerin 3i3 d/st content in t3e /eas. T3is desin eat/re to =e considered s3a%% tae into acco/ntminim/m acc/m/%ation o d/st on 3eatin s/race.

T3e A4C =oi%er evaporator section is 3orionta% in%ine t/=earranement ?it3 3eaders.

)t s3a%% =e connected to t3e steam dr/m t3ro/3 ade/ate%@ sieddo?n comers and risers to ens/re ade/ate circ/%ation /nder a%%operatin conditions.

2. S#<e%e&te

!/per 3eater s3a%% =e minim/m t?o stae desin ?it3 primar@ andsecondar@ sections. 9$or A4C 5oi%er On%@:An inter stae de-s/per

3eater o varia=%e m/%ti no%e oriBce ?it3 eterna% contro% va%ve t@peto =e provided in =et?een t3e s/per 3eaters to contro% t3e Bna% steamtemperat/re. T3e de-s/per3eatin s@stem s3a%% =e provided ?it3 a%%re/ired iso%atin va%ves pipin ins/%ation s/pports re/%atinva%ves etc. !/pp%ier s3a%% /rnis3 detai%ed *) diaram ?it3 %ine siesand instr/ments. T3e spra@ ?ater s3a%% =e tapped oG rom t3e eed %ineat a point /pstream o t3e eed contro% station. *H 5oi%er !/per3eateris o !in%e stae on%@.

2.6 Econo87$e

T3e economier is considered as t3e 3eat recover@ /nit or raisin t3eeed ?ater temperat/re =eore enterin t3e steam dr/m o respective=oi%ers. T3e economier s3a%% =e Horionta% or A4C =oi%er and *H=oi%er.

2.7 Con*en$&te Pe%e&te S:$te8 7n A+C 9o7le





AMBUJA CEMENT LTD

Condensate pre-3eater 9C*H: s3a%% =e considered as t3e additiona% 3eatrecover@ /nit to raise t3e condensate temperat/re =eore enterin intode-aerator to red/ce t3e steam cons/mption in de-aerator.

2.8 G&$ 0 A7 C7c#7t

E3a/st as rom *re-3eater =ein at 3i3er e%evation t3e as d/ctinto *H =oi%er ?i%% 3ave a top entr@. Hot air rom C%iner Coo%er =ein at%o?er e%evation t3e air d/ctin to A4C =oi%er ?i%% =e provided ?it3=ottom entr@ in pre d/st co%%ector. *rior to A4C =oi%er entr@ pre d/stco%%ector s3a%% =e provided to red/ce t3e d/st concentration =eoreenterin into t3e =oi%ers. T3e e3a/st rom respective so/rces s3a%%o?s t3ro/3 t3e vario/s 3eat transer sections o eac3 =oi%er. T3iss3a%% =e /rt3er connected to t3e eistin do?nstream e/ipments.,amper ?it3 epansion >oints as speciBed e%se?3ere in t3e contract

s3a%% =e provided or iso%atin t3e =oi%er d/rin emerenc@ conditions. T3e dampers to =e considered s3a%% =e ;;.;I sea%in dampers.

2.; D#$t D7$lo*'7n' S:$te8

T3e d/st acc/m/%ated on t3e 3eat transer s/race o *H =oi%er s3a%% =eremoved and dropped into t3e =ottom 3oppers =@ rappin mec3anism.Hammers mo/nted on a rotatin s3at drop 9=@ ravit@: and strie anvi%s9so%id s3at: t3at are attac3ed to t3e press/re part inside t3e =oi%ercasin. Rappin intensit@ s3a%% =e contro%%ed =@ t3e ?ei3t o 3ammersand t3e %ent3 o 3ammer mo/ntin arm. T3e re/enc@ is c3aned =@

ad>/stin t3e speed o t3e s3at. T3e desin o t3e d/st disposa% s@stems3a%% =e proven.

T3e co%%ected d/st in t3e 3oppers =e%o? t3e *H =oi%er and ot3er d/st

co%%ection points in t3e s@stem s3a%% =e transported t3ro/3 t3e mass

o? t@pe conve@or to t3e eistin d/st conve@in s@stem o t3e cement

p%ant. Eac3 d/st co%%ectin 3oppers s3a%% =e provided ?it3 p%ate ate

Rotar@ air %oc va%ve. T3ese rotar@ air %oc s3a%% disc3are t3e d/st to

t3e mass o? t@pe conve@or =e%o? t3e /%% %ent3 o t3e =oi%ers. T3e

disc3are o t3is mass o? t@pe conve@or s3a%% =e connected to t3e

Bna% mass o? t@pe conve@or to transport t3e d/st to t3e eistin

conve@in s@stem.

$or A4C 5oi%er

,/e to t3e a=rasive nat/re o t3e c%iner rains pre d/st co%%ector at t3e

in%et o A4C =oi%er to =e considered. T3is s3a%% ease t3e erosion and





AMBUJA CEMENT LTD

a=rasion tendenc@ o t3e 3eatin s/races and a%so to co%%ect d/st. )n

addition to t3e a=ove =ottom entr@( vertica% o? o Hot air in to t3e

=oi%er so t3at an@ partia% rains t3at ot carried a?a@ a%so sett%es at t3e

=ottom 3opper o t3e DHR5 d/e to ravit@. T3e co%%ected d/st in t3e

3oppers =e%o? t3e A4C =oi%ers and ot3er d/st co%%ection points in t3es@stem s3a%% =e transported t3ro/3 t3e mass o? t@pe conve@or to t3e

eistin d/st conve@in s@stem o t3e cement p%ant. Eac3 d/st

co%%ectin 3oppers s3a%% =e provided ?it3 p%ate ate Rotar@ air %oc

va%ve. T3ese rotar@ air %oc s3a%% disc3are t3e d/st to t3e mass o?

t@pe conve@or =e%o? t3e /%% %ent3 o t3e =oi%ers.

2.10 Met%o* o2 Fl#e G&$ 0 Hot A7 I$ol&t7on

*H 5oi%er

$%/e as tappin s3a%% =e taen at a 3i3er e%evation o t3e eistin *Heit /e as d/ct so as to matc3 ?it3 t3e as entr@ point o t3e DHR5. T3e eit o t3e DHR5 is aain to =e connected to t3e *H ans in%et d/ctat a %o?er e%evation.

T3e t@pe o dampers and t3eir positionin s3a%% =e c%ear%@ speciBedconsiderin no d/st acc/m/%ation on t3e dampers.

A4C 5oi%er

T3e air a=ove t3e in%et section o t3e C%iner coo%er ater miin ?it3t3e am=ient air rom t3e coo%er an ?i%% =e at a ver@ 3i3 temperat/re. T3e 3ot air mit/re tapped a=ove t3e coo%er rate in t3is section ?i%%t3en =e rec@c%ed as secondar@ and tertiar@ air to t3e i%n or c%inerprod/ction. T3e section ater t3e secondar@ and tertiar@ air tappin ist3e %ocation identiBed or tappin t3e 3ot air re/ired or 3eat recover@.

4. Co88on Blo; Do;n T&n"

One no. =%o? do?n tan to =e considered or eac3 to ?3ic3 t3e =oi%er5%o? do?n =oi%er drain %ines rom vario/s s@stem ?i%% =e connected.

2.12 W&te &n* Ste&8 C7c#7t





AMBUJA CEMENT LTD

$eed ?ater enters t3e common condensate pre-3eater de-aeratorrom de-aerator o/t%et to economier rom 5$*( eed contro% stationrom economier o/t%et it is ed to t3e !team dr/m. $rom t3e dr/m t3e?ater enters to t3e evaporator in%et 3eader. Ater a=sor=in 3eat romt3e 3eat so/rces steam-?ater mit/re ormed and moved to t3erespective steam dr/m t3ro/3 nat/ra% circ/%ation. !eparatedsat/rated steam rom steam dr/m s3a%% =e 3eated in respective s/per-3eater.

2.1" Co88on De!&e&to c#8 $to&'e t&n"

*ress/ried de-aerator s3a%% =e provided =@ t3e s/pp%ier a%on ?it3 L*dosin s@stem. T3e %ocation o de-aerator a%on ?it3 5$* s3a%% =eprovided in t3e T 3a%% .T3is s@stem s3a%% consists o ,e-aerator in?3ic3 t3e o@en content in t3e eed ?ater is red/ced to t3e re/ired

%eve% =@ spra@in ?ater as drop%ets in t3e presence o steam. !toraetan =e%o? t3e ,e-aerator to store de-aerated ?ater.

2.1# C%e87c&l Do$7n' S:$te8

LP Do$7n' S:$te8

!ince eed ?ater contains traces o o@en d/e to t3e incomp%etemec3anica% ( t3erma% deaeration. Traces o o@en s3a%% =e scavened=@ c3emica% deaeration. C3emica%s %ie sodi/m s/%p3ite or 3@draines3a%% =e dosed in t3e s/ction pipe o eed p/mp =@ L* dosin. L* dosin?it3 sodi/m s/%p3ite is to =e considered to reacts ?it3 o@en and toorm sodi/m s/%p3ate or in case o 3@draine it reacts ?it3 O2 andorms ?ater and nitroen.

HP *o$7n' $:$te8

!ca%e ormation is %imited =@ convertin 3ardness sa%ts to a ree o?ins%/de. H* dosin is done =@ car=onate contro% and p3osp3ate contro%=@ addition o sodi/m car=onate or trisodi/m p3osp3ate respective%@.Ot3er c3emica%s s/c3 as sodi/m 3@droide car=onate or ca%ci/m

o@p3osp3ate can a%so =e added. 5est res/%t o ca%ci/m car=onate ormanesi/m 3@droide or ca%ci/m si%icate manesi/m si%icate ?i%% =eavai%a=%e as ree o?in s%/de ?3ere ca/stic a%a%init@ is 10 to 1I o t3e disso%ved so%ids. OH a%a%init@ %eads to prevention o manesi/mp3osp3ate as =ad sca%e =@ convertin manesi/m to manesi/m3@droide. T3e H* dosin s@stem s3a%% add t3e c3emica% to t3e =oi%er?ater to tae care o t3e inress o t3e 3ardness sa%t and to increaset3e =oi%er ?ater pH.

TEC*RO !+!TE'! LT, CHENNA)*ae ;




AMBUJA CEMENT LTD

2.1 Dater /a%it@ inde o circ/%ation coo%in ?ater

N0. )tem 'ae-/p ?ater /a%it@ Remar

1 pH 7.0-;.2

2!/spended

so%id9!!: ＜10m(L

" Oi% rease ＜

# C% J"00 m(L

met3@% orane

a%a%init@J00 m(L

6 Ca2

"0-200 m(L

7 $e2 ＜0. m(L

8 !O#2- J100 m(L

; !iO2 J17 m(L

10 $ree c3%orine 0.-1.0 m(L

,eminera%iation ?ater /a%it@ re/irement

No. )tem 'ae-/p ?ater /a%it@ Remar

1 pH 8.0-;.

2 Hardness J0.0"mmo%(L

" T/r=idit@9$TF: J2

# oi% J2.0 m(L

Tota% err/m J0." m(L

6 Cond/ctivit@ J110 !(cm

4.> Bo7le $te&8 *#8 2ee* ;&te, 9o7le ;&te $t&n*&*$

T3e /a%it@ contro% standards o dr/m eed ?ater（5176-2008）

are aso%%o?s


0

2

0

2




AMBUJA CEMENT LTD

!(N )tem Fnit Contro% standards

1 !! m(L J

2

*Hva%/e（2,e

C）

nondimension M7

" Tota% 3ardness mmo%(L J0.0"

#disso%vedo@en m(L J0.0

Oi% content m(L J2

6 )ron content m(L J0."

T3e /a%it@ contro% standards o steam dr/m ?ater（5176-2008）are aso%%o?s

!(N )tem Fnit Contro% standards

1 Tota% a%a%init@ mmo%(L J1#

2 pH（2）non

dimension 10～12

"disso%ved

so%id m(L ＜100

# *O#"- m(L 10～"0

!O"2- m(L 10～"0

6Re%ativea%a%init@

nondimension ＜0.2

2.17 5oi%er $eed */mps

T?o 902: nos 901 ?orin01 stand=@:. eac3 capa=%e o meetin eed?ater re/irement at 110I 5'CR capacit@ o eac3 =oi%er 9ec%/dint3e p/mp marins: 3orionta% m/%tistae =arre% casin centri/a%t@pe =oi%er eed p/mps driven =@ e%ectric motor ?o/%d =e provided.Eac3 p/mp ?o/%d =e provided ?it3 orced %/=ricatin oi% s@stem or%/=rication o t3e =earins co/p%ins etc. A%% necessar@ protective ands/pervisor@ s@stem ?o/%d =e provided to ens/re sae and tro/=%e-reeoperation o t3e eed p/mps.

3.1 Design Data

! No ,escription


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AMBUJA CEMENT LTD

A C!iner pr#u/tin /apa/it$BD6 5, T6D

B Sur/e - ex"au0t C!iner C!er 6re "eater

%8I Stage'

C Nature - ex"au0t 9t Air :!ue ;a0

D 9E ATIN; SIDE <nit A=C b.i!er 69 b.i!er > ?

2. ea/"

Am!ient +emperature ,*

'a.#

Averae.27

'in.

'a.#

Averae.27

'in.

>Tta! Ex"au0t :! avai!ab!e - r

#e0ign)

Nm &"r >74@,,,

IC > B

>)2@,,,

IC 2 B

>)2@,,,

-lo rate (/hr %%%%0 12230

2 Ex"au0t tapping !/atin Mi# Tap O-- 6re "eater Exit

4 Den0it$ g&Nm)

>.2+ >.4)

5 Temper atur e °C

a At tapping pint°C

),IC> B)),

IC2 B)),

b In!et - 9°C

)55IC> B)25

IC2 B)25

7 Out!et - 9 °C >,, >7*

+ Cmp0itin( b$

v!ume

a CO2 Ni! 2.7&24.2

b CO

/ N2 7*.,, 35.%43

2.

# 92O ,.>, ) 3 ).5

e O2 2,.) 4 4.

*Du0t /n/entratin in ex"au0t

ga0)

gm0&Nm 5,IC>B >,+

IC2B >,+

10 :u!ing -a/tr ,.,,,>

,.,,,>

>> 6re00ure





AMBUJA CEMENT LTD

a At In!et - 9B mm/ 5,IC > 72,

IC 2 72,

bMax. pre00ure #rp a/r00 9B

bi!er

mm/E, E 7,

/

Max. pre00ure #rp a/r00 9B0$0tem%taping t taping'

in/!u#ing in!et #u/t@ ut!et

#u/t@pre#u0ter%in /a0e - A=C'

an# bi!er

mm/ E*, E>,,

>> N. - 9B Nos. > 2

>2 Cn#en0er t t$pe ACC

>)Cn#en0ing pr e00ur e g&/m2%a' ,.2 at 42 #eg C

>4ater Temper atur e °C )4 )4

>56er generatin v!tage 8 ,,F>,(

3.2. Output Specifications

a) Flue Gas Specifications

Sr. No. Details 6nit

*lin(er

*ooler

Pre 'eater 1

Boiler Pre 'eater %

Boiler

1 Am!ient +emperature ,*

55 5

% #7haust /as outlet

temperature,*

10

0

19 19

Pressure drop arossW'RS mmW*

3

0

0 0

b) Steam Specifications

Sr. No

Steam Data 6nit*lin(er *ooler

Pre 'eater 1

Boiler Pre 'eater %

Boiler

1

Steam 8eneration 'PLP

+P'15.2.5

10.121.5

10.121.5

TEC*RO !+!TE'! LT, CHENNA)*ae 1"




AMBUJA CEMENT LTD

%

Steam Pressure at 'PLP

Super heater main steam

stop ale outlet

%(/m:a;

11.5

%.2

11.5

%.2

11.5

%.2

Steam temperature at

'PLP Super heater mainsteam stop ale outlet

,

*

5120

05120

05120

4. Design Specifications

4.1 Super Heater

i. "aterial of *onstrution

a. +u!es < SA %10 8r. A1) Seamless

!. 'eaders < SA 103 8r. B

ii. Desi/n

'eader si=e< Durin/ detail en/ineerin/

a. 8as Side Speifiations

+>pe of flo< *ross flo

Arran/ement< Sta//ered

Sr.

No.Details 6nit

*lin(er

*ooler

Pre 'eater 1

Boiler Pre 'eater %

Boiler

A Inlet

1 #7haust /as flo rate Nmhr 1?000 1%000 1%000

% #7haust /as flo rate @/hr %%%55 12932 19232

#7haust /as inlet temperature

for 'P Super heater

,* 55 %5 %5

? #7haust /as inlet temperaturefor LP Super heater

,* 195 %1 %1

Outlet

1 #7haust /as flo rate (/hr %%%55 12932 12932

TEC*RO !+!TE'! LT, CHENNA)*ae 1#

0

1

0

2

0

2




AMBUJA CEMENT LTD

% #7haust /as outlet temperaturefor 'P Super heater

,*

1 11 11

#7haust /as outlet temperature

for LP Super heater

,* 19 %0 %0

? #7haust 8as &eloit> at 'P

super heater

ms ?.9 5.3 5.3

5 #7haust 8as &eloit> at 'P

super heater

ms ?.% 5.1 5.1

!. -luid Side Speifiations

Sr. No.

Details

6nit*lin(er *ooler

Pre 'eater 1Boiler

Pre 'eater %Boiler

A Inlet

1 -lo rate 'P LP (/hr 1520

00

10120

150

10120

150

%Steam inlet

+emperature 'PLP,*

1221%

1221%

1221%

Desi/n pressure

'PLP(/m

%:a; 1.5

.2

1.5

.2

1.5.2

? Wor(in/ pressure

'PLP(/m

%:a; 1%.5

.%1%.5.%

1%.5.%

5 Desi/n temperature

'PLP

,* ?%5

%50

50

%50

50

%50

3 Wor(in/ temperature

'PLP

,* 5

12005120

05120

+>pe of fin $ Bottom to

ros of !aretu!e t>pe)

Balane ros isfinned tu!e

t>pe

Bare t>pe Bare t>pe

2 -ins per Inh ? $ $

9 -in materials *S $ $





AMBUJA CEMENT LTD

10 +>pe of fin eldResistant

elded$ $

Outlet

1 -lo rate 'PLP (/hr 1520 500 10120150 10120150

%Superheatedsteam outlettem erature

,* 5

12005120

05120

'eatin/ surfae area

'PLPm

% 12%

5312

5312

? Safet> ale set pressure 'PLP

(/m%:/; 1%.5

%.21%.5%.2

1%.5%.2

4.2 H! "#aporator


a. +u!es < SA %10 8r. A1) Seamless


Inner *asin material < IS %03% 8B or e uialent ,uter *asin/ material< 8I*olour sheet 0.5mm thi(

ii. Desi/n Speifiations

a. 8as Side Speifiations

!. 'eader si=e < %19.1

Sr.

No.Details 6nit

*lin(er

*ooler

Pre 'eater 1

Boiler

Pre 'eater %

Boiler

A Inlet

1 #7haust /as flo rate @/hr %%%55 12932 12932


% #7haust /as inlet temperature

'PLP

,* 1

1

11

192

11

192


0

1

0

2

0

2




AMBUJA CEMENT LTD

Outlet

1 -lo rate (/hr %%%55 12932 12932

% #7haust /as outlet temperature

'PLP

,

* 1951?% %119 %119

#7haust 8as &eloit> 'PLP ms ?.??.%

5.??.9

5.??.9


Sr.

No.D 6nit

*lin(er

*ooler

Pre 'eater 1

Boiler

Pre 'eater %

Boiler

A Inlet

1 Water inlet

temperature 'PLP

,*

1221

1221

1221

% Desi/n pressure (/m%

:a;1?.5

?

15

?

15

?

Wor(in/ pressure (/m%

:a;1.5.5

1?.5

1?.5

? Desi/n temperature ,*

19

1??

199

1??

199

1??

5 Wor(in/ temperature'PLP

,

* 19?19 19?19 19?19

3 +>pe of fin $

-in t>pe Bare t>pe Bare t>pe

-ins per Inh $

? $ $

9 -in materials*S $ $

10 +>pe of fin eldResistant elded $ $

Outlet

1Water steam

mi7ture outlet

temperature

,* 129

15

129

12

129

12


0

1




AMBUJA CEMENT LTD

% 'eatin/ surfae area m%

9%0

5%59

%911

%2

%911

%2

4.3 H! "conomi$er


a. +u!es < SA %10 8r. A1



a. 8as Side Speifiations !. +>pe< Sta//ered. 'eader Si=e <%19.1

d. Inner *asin/ "aterial <IS %03% or euialente. ,uter asin/ < 8I*oloured sheet 0.5mm thi(

Sr.

No.Details 6nit

*lin(er

*ooler

Pre 'eater 1

Boiler

Pre 'eater %

Boiler

A Inlet

1 #7haust /as flo rate @/hr %%%55 12932 12932


% #7haust /as inlet temperature

'PLP

,* 191?%

%1$$ %1$$

Oulet

1 -lo rate(/hr

%%%55 12932 12932

% #7haust /as outlet temperature

'PLP

,* 11%? 193$$ 193$$

#7haust 8as &eloit> 'PLP ms ?.3 5 5


Sr. No.

Details 6nit*lin(er *ooler

Pre 'eater 1Boiler

Pre 'eater %Boiler


0

10

2




AMBUJA CEMENT LTD

A Inlet

1 -lo rate 'PLP (/hr 1520

?%010120$$ 10120$$

% Water inlet temperature 'PLP ,

*1%?

100 1%0 1%0

Desi/n pressure 'PLP (/m%

:a; 150

13$$ 13$$

? Wor(in/ pressure 'PLP (/m%

:a; 1.5

%01?$$ 1?$$

5 Desi/n temperature 'PLP ,* 19? 19? 19?

3 "a7 Wor(in/ temperature

'PLP

,* 19?

19? 19?

+>pe of fin $

-in t>pe Bare t>pe Bare t>pe

2 -ins per Inh $

? $ $


10 +>pe of fin eld Resistantelded

$ $

Outlet

1 -lo rate 'PLP (/hr 1520?%0

10120$$ 10120$$

% Water outlet temperature 'PLP ,*

13

1%?120 120

'eatin/ surfae area 'PLP m% 139

%?52?9 ?9

4.4 %on&ensate !re Heater '%!H ( on I*)


a. +u!es < SA %10 8r. A1

. 'eaders < SA 103 8r. B


a. -lue 8as Speifiations

TEC*RO !+!TE'! LT, CHENNA)*ae 1;




AMBUJA CEMENT LTD

Sr.

No.Details 6nit

*lin(er

*ooler

Pre 'eater 1

Boiler

Pre 'eater %

Boiler

A Inlet

1 #7haust /as flo rate (/hr %%%55 $$$ $$$

%#7haust /as inlet

temperature,* 1%3 $$$ $$$

Outlet

1 -lo rate (/hr %%%55 $$$ $$$

%#7haust /as outlet

temperature,* 100 $$$ $$$

#7haust 8as &eloit> ms .? $$$ $$$


Sr. No.

Detail 6nit*lin(er *ooler

Pre 'eater 1Boiler

Pre 'eater %Boiler

A Inlet

1 -lo rate (/hr

?%510 $$$ $$$

% Water inlet temperature ,* 3% $$$ $$$

Desi/n pressure%

(/m:a;

10 $$$ $$$

? "a7 Wor(in/ pressure%

(/m:a;

10 $$$ $$$

5 Desi/n temperature ,* 150 $$$ $$$

3 Wor(in/ temperature ,* 95 $$$ $$$

+>pe of fin $ -in t>pe Bare t>pe Bare t>pe

2 -ins per Inh $

? $ $


1 +>pe of fin eldResistantelded

$ $


01




AMBUJA CEMENT LTD

Outlet

1 -lo rate (/hr ?%510 $$$ $$$

% Water outlet,

* 95 $$$ $$$

'eatin/ surfae area m% %?52 $$$ $$$

4.+ Steam Drum

i. "aterial ,f *onstrution

a. Shell

< SA 513 8r 0

!. Dished 'ead

< SA 513 8r 0

. No==les

< SA 103 8r B

d. -lan/es

< SA 105


Sr.

No.Ite 6nit

*lin(er

*ooler

Pre 'eater 1

Boiler

Pre 'eater %

Boiler

1 Wor(in/ Pressure 'PLP (/m%:a; 1%.5

.%

1%.5

.%

1%.5

.%

% Desi/n Pressure 'PLP (/m%:a;

1.5.2

1.5.2

1.5.2

Wor(in/ +emperature 'PLP ,*

190

13

190

13

190

13

? Desi/n +emperature 'PLP ,* 19?

1?%19?1?%

19?1?%

5 Shell $$$$ $$$$ $$$$ $$$$

a Shell Internal Diameter 'PLP mm 12001500

15001500

15001500

! Shell +hi(ness 'PLP mm %313

1313

1313





AMBUJA CEMENT LTD

Steam drum shell len/th mm 45000 45000 45000

3 Normal ater leel 'PLP C 100 mm Beloenterline

50 mm Beloenterline

100 mm Beloenterline

50 mm Beloenterline

100 mm Beloenterline

50 mm Beloenterline

Dished 'ead 'PLP $$$$ $$$$ $$$$ $$$$

a +>pe of Dished 'ead 'PLP #llipsoidal head#llipsoidal

head

#llipsoidal

head

! Dished 'ead Internal diameter

'PLP

mm 1200

1500

1500

1500

1500

1500

Dished end thi(ness 'PLP mm %3

13

13

13

13

13

2 Num!er of "anholes 'PLP Nos %% % %

9 Loation of "anhole 'PLP $$$$

,n dished end ,n dished end ,n dished end

Documents

DBR of Boiler for Ambuja Cement