Boiler Mechanical

VOLUME – 2, SECTION – B
TECHNICAL SPECIFICATION
STEAM GENERATOR AND AUXILIARIES
MECHANICAL SYSTEM
For
Renovation & Modernization

of
BPSCL Unit # 1 to 5 (5 × 220 TPH)
Prepared and submitted by:
STEAG Energy Services India Pvt. Ltd.
(An ISO 9001:2008 certified Company)

(A wholly owned subsidiary of STEAG Energy Services GmbH, Germany)
A-29, SECTOR-16, NOIDA, UP- 201 301, India
JULY 2016
PROJECT NO.: PROJECT NAME: BPSCL UNIT 1 TO 5 PACKAGE / SYSTEM: STEAM GENERATOR &
ETRM012 BOILER (220 TPH) AUXILIARIES (MECHANICAL)
BOKARO POWER SUPPLY CO. (P) LIMITED,

UNIT # 1 TO 5 BOILERS (5 × 220 TPH)
Subject Technical Specification for Steam Generator and

Auxiliaries
Client Bokaro Power Supply Co. (P) Ltd.
Old ADM Building
Ispat Bhawan
Bokaro Steel City -827 001
Consultant STEAG Energy Services (India) Pvt. Ltd.
A-29, Sector-16 NOIDA
Uttar Pradesh 201301, INDIA
Contract Title Consultancy Services for R&M of Boiler # 1 to 5
Revision No. 03
Contract Agreement No. BPSCL/CEO/P&C/09-10/C-261/84 dated 19.01.2012
Work Order No. BPSCL/CEO/P&C/09-10/C-261/8449
Project Team
STEAG BPSCL
Mr. Hemant Gajjar (ED, ET) Mr. S K Mitra (GM)
Mr. R. Paul (PM - Mechanical) Mr. P K Sinha DGM (Boiler)
Mr. Mrinal Mohan (Mechanical) Mr. T. K. Banerjee DGM (Turbine)
Mr. Manish Agarwal (I&C) Mr. Y. K. Mishra DGM (Operation)
Mr. Vikas Khare (I&C) Mr. A. K Das DGM (C&I)
Mr. A. K Nayak DGM (Electrical Operation & Testing)
Mr. A. Nayak Manager (Boiler Maintenance)
Mr. Gautam Mandal Manager (C&I) and
Other Site Officials
REVISIONS
03 05.06.2014 MM RP RP
02 26.11.2013 MM RP RP
01 12.08.2013 MM RP RP
00 31.08.2012 RP KBP KBP
Revision Date Prepared by Checked by Approved by
R&M/SPECIFICATION BID DOC. No. VOLUME-2 REV. NO.: R03 PAGE 2 OF 116
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TABLE OF CONTENTS
SECTIONS PAGE
1.0 INTRODUCTION .......................................................................................................................................... 5
1.1 SALIENT FEATURES OF BOILER 1 TO 5 ....................................................................................................... 7
1.2 FACTORS GOVERNING SCOPE ..................................................................................................................... 8
1.3 ABBREVIATIONS............................................................................................................................................ 10
2.0 INTENT OF SPECIFICATION.................................................................................................................... 12
2.1 INTENT OF SPECIFICATION FOR BOILER .................................................................................................. 13
2.2 GENERAL DESCRIPTION OF EXISTING STEAM GENERATOR ................................................................. 13
2.3 ECONOMISER ................................................................................................................................................ 14
2.4 AIR HEATER ................................................................................................................................................... 15
2.5 FUEL BURNING EQUIPMENTS ..................................................................................................................... 15
2.6 MILLS AND FIRING SYSTEM ......................................................................................................................... 15
2.7 FANS ............................................................................................................................................................... 18
2.8 INSULATION & REFRACTORY ...................................................................................................................... 19
2.9 ESP ................................................................................................................................................................. 19
2.10 CODES & REGULATION ................................................................................................................................ 19
2.11 DESIGN PARAMETERS ................................................................................................................................. 20
2.12 PAST HISTORY .............................................................................................................................................. 20
3.0 STEAM GENERATOR AND AUXILIARIES SPECIFICATIONS ............................................................... 24
3.1 GENERAL ....................................................................................................................................................... 25
3.2 PRESSURE PARTS ........................................................................................................................................ 28
3.2.1 Design of Pressure Parts ................................................................................................................. 28
3.2.2 Material of Pressure Parts ............................................................................................................... 29
3.2.3 Scope of Work (General) ................................................................................................................. 29
3.2.4 Economizer ...................................................................................................................................... 29
3.2.5 Water wall & Roof tubes .................................................................................................................. 29
3.2.6 Superheaters ................................................................................................................................... 31
3.2.7 Headers ........................................................................................................................................... 32
3.2.8 Buckstays......................................................................................................................................... 33
3.2.9 Valves .............................................................................................................................................. 33
3.2.10 Hangers & Supports ......................................................................................................................... 33
3.2.11 Penthouse ........................................................................................................................................ 34
3.2.12 Piping ............................................................................................................................................... 35
3.2.13 Coal, Oil and Gas Burners ............................................................................................................... 35
3.2.14 Ducts, Dampers & Actuators ............................................................................................................ 38
3.2.15 Boiler Structural Columns, Floor grills, platforms, railings etc. ......................................................... 40
3.2.16 Fans ................................................................................................................................................. 43
3.2.17 Fuel Oil System ................................................................................................................................ 43
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3.2.18 Boiler Blowdown system .................................................................................................................. 43

3.2.19 Insulation & Refractory ..................................................................................................................... 44
4.0 TERMINAL POINTS & EXCLUSIONS ...................................................................................................... 52
5.0 PERFORMANCE ASPECTS ..................................................................................................................... 55
5.1 GENERAL ....................................................................................................................................................... 56
5.2 PERFORMANCE GUARANTEES ................................................................................................................... 56
5.3 GENERAL REQUIREMENTS ......................................................................................................................... 56
5.4 PERFORMANCE REQUIREMENTS ............................................................................................................... 56
5.4.1 Steam generator Output .................................................................................................................. 56
5.4.2 Furnace Draft: .................................................................................................................................. 57
5.4.3 Flue Gas Temperature at APH inlet ................................................................................................. 57
5.5 PERFORMANCE GUARANTEE TEST ........................................................................................................... 57
6.0 PRE COMMISSIONING & COMMISSIONING ACTIVITIES ...................................................................... 60
6.1 PRE COMMISSIONING ACTIVITIES .............................................................................................................. 61
6.2 COMMISSIONING AND INITIAL OPERATION OF THE FACILITIES ............................................................ 64
7.0 SPARES .................................................................................................................................................... 65
7.1 MANDATORY SPARES .................................................................................... Error! Bookmark not defined.
7.2 RECOMMENDED SPARES ............................................................................................................................ 66
7.3 START-UP & COMMISSIONING SPARES ..................................................................................................... 66
8.0 BILL OF QUANTITIES............................................................................................................................... 68
9.0 DATA SHEETS .......................................................................................................................................... 74
10.0 DRAWINGS AND DOCUMENTS .............................................................................................................. 95
11.0 ANNEXURES ........................................................................................................................................... 100
ANNEXURE-I: SCHEMATIC FOR STEAM GENERATOR ........................................................................................ 101
ANNEXURE-II: SCHEMATIC FOR THE MILLING SYSTEM ..................................................................................... 102
ANNEXURE-III: OVERHAULING SCOPE ................................................................................................................. 103
ANNEXURE-IV: RECOMMENDED SPARES ............................................................................................................ 113
ANNEXURE-V: PRELIMINARY SCHEDULE FOR ONE BOILER ............................................................................. 114
ANNEXURE-VI: SUB VENDORS’ LIST OF THE CONTRACTOR FOR MECHANICAL EQUIPMENTS .................. 115
ETRM012-1-M-TS-001
1.0 INTRODUCTION
ETRM012-1-M-TS-001
INTRODUCTION
Bokaro Power Supply Company Pvt. Ltd. (BPSCL) established in 2001 a Joint Venture Company
of Steel Authority of India Ltd.(SAIL) and Damodar Valley Corporation (DVC) and is engaged in
power and steam generation and supplies power and steam (at various pressures) to SAIL’s
Bokaro Steel Plant (BSL) located at Bokaro for meeting the process requirement of BSL.
The Plant has 8 boilers (5 boilers each of 220 TPH and 3 boilers each of 260 TPH capacity) and
6 turbine generators (one 12 MW back Pressure Turbine Generator (TG), 2 TGs each of 55MW
capacity and 3 TGs each of 60 MW capacity).
Existing Capacity
Equipment Quantity Specification Capacity

BOILERS
BOILERS (no. 1 to 5) 5 Multi-fuel Boiler 220 t/h each
BOILERS (no. 6 to 8) 3 Multi-fuel Boiler 260 t/h each
TURBINE-GENERATOR
TURBINE-GENERATOR 1 Back Pressure Steam 12 MW
TURBINE-GENERATOR 2 Condensing Steam 55 MW each
TURBINE-GENERATOR 3 Condensing Steam 60 MW each
Date of commissioning of Boiler 1 to 5 and TG 1 to 3 are as follows:
Equipment No. 1 No. 2 No. 3 No. 4 No. 5

Boiler 17.04.1972 14.07.1972 06.06.1974 15.07.1978 26.07.1980
TG 13.12.1974 13.07.1972 13.10.1973 - -
The Plant is located on an area of 97 acres (approx) adjacent to BSL and has the following
facilities for generation of power and steam.
BPSCL Power Plant is located in the premises of Bokaro Steel Plant (BSL) and has an
aggregate installed capacity to generate 302MW of power besides 660 Tonne per Hour (TPH) of
steam.
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1.1 SALIENT FEATURES OF BOILER 1 TO 5

Type T -156
Original manufacture / Commissioned by Krasny Kotelshik (Russia)
Rated steaming capacity t/hr 220
Working Pressure: Boiler drum, ata(g) 115
Superheater outlet ata(g) 100
Superheated steam temperature °C 540
Feed water temperature °C 215
No. of safety valves 2
Blowing capacity of each safety valve t/h 115 T/hr
Setting of drum Safety valve, ata. 124 Kg/cm2
Setting of Super-heater safety valve, ata 105 Kg/cm2
Drum: Internal dia x thickness, mm 1600x100
Length, mm 13940
Material, steel 22 K
Furnace size, mm 7160x9912
3
Furnace chamber volume, m 1222
Type of Air pre-heater (Total Qty - 24 Nos. each Tubular
Boiler)
Type of coal Mill Horizontal rotating drum type
No. of Burner (Opposed firing type) 06 Nos.
WATER AND STEAM PARAMETER
TYPE Properties UNIT QUANTITY

Demineralised water
Alkalinity Mg/Kg 0.02
Hardness - 0.00
Silica Mg/Kg 0.03
PH - 6.5 - 7.2
Ammonia Mg/Kg 0.2
Oxygen (O2) Mg/Kg 0.02
Iron (Fe) Mg/Kg 0.03
Conductivity M Mho 4.00
Boiler Feed Water
Oxygen (O2) Mg/Kg 0.007
PH - 8 – 8.5
Hydrazine Mg/Kg 0.08
Ammonia Mg/Kg 0.3 (Max)
Iron (Fe) Mg/Kg < 0.01
Silica
Steam
PH - 8.5
Silica Mg/Kg 0.02
ETRM012-1-M-TS-001
Conductivity  Mho 5.00

Boiler Drum Water Clean Compartment Salt Compartment
PH 8–9 10 – 11
Phosphate (Mg/Kg) 10 40
Silica (Mg/Kg) 0.01 0.04
Conductivity ( Mho) 100 400
The Boiler was originally designed for firing multi fuel like coal with Gross Calorific Value (GCV) in
range of 4500 - 5000 kcal/kg , Blast furnace (BF) and Coke Oven (CO) gas. At present the unit
operates on coal with GCV in the range of 3800 kcal/kg to 4300 kcal/kg. Due to aging problem
and uncertainty in the continuous supply of BF and CO gas the generation has reduced
drastically. The performance data indicates that the output from these Units has been declining
and it is now operating well below its original designed performance rating. In view of the above
condition there is a steady decline in the boiler efficiency.
The fact that the unit was commissioned well over 30 years ago made it necessary to evaluate
the condition of the different sub-systems. This permitted a realistic assessment on whether there
is need to replace or repair/modify in order to achieve higher efficiency output and reliability
sustainable over the next 20 years at least. The assessment also provides the basis for a realistic
estimation of costs and benefits in order to present a proposal for the renovation and
modernization of the unit.
Bidder should access the condition of the boiler by site visit and do necessary testing and
inspection for the retainable portion of the boiler. The bidder is allowed to check the available
assessment report, Energy Audit Report, etc for his satisfaction prior to submission of his offer.
As a part of R & M activity, Steam Generator technical specifications are prepared for retrofitting,
keeping in view changes in existing equipment and civil foundations. The objectives of R&M work
of Steam Generator & Auxiliaries are as below:
a) Retaining steam generation capacity to minimum 185 TPH with worst coal only (CV
3800KCAL/KG) and minimum 210 TPH with coal + gas (BF+CO) of 50000 NM3 /Hr. &
10000 NM3/Hr respectively.
b) Extending unit life by 20 years of reliable operation.
c) In this regard technical specification of steam generator is arrived in detail in the following
sections.
1.2 FACTORS GOVERNING SCOPE

In the present condition, it is not possible to operate these units to its original design parameters
at rated capacity without major renovation.
Only proven options for retrofit, which are site-specific to, the requirements of BPSCL, are
considered.
In general, the goal is aimed at retaining the unit generation to minimum 185 TPH with coal firing
and to extend its life by 20 years of reliable operation.
The optimized scope is governed by the following:
1. Replacement of components, which have exhausted their life.

2. Replacement of components for which spare parts will not be available in future.
3. Repair of parts, which could be retained service without compromising reliability and safety.
ETRM012-1-M-TS-001
4. Change of components that are needed to adhere to prescribed environmental standards.

5. Necessary modifications in the system to run the unit at rated capacity with the available low
calorific coals.
6. Obsolete technology.
The specification has compiled measures specific to units 1 to 5 of BPSCL that are considered as
the Essential Scope.
ETRM012-1-M-TS-001
1.3 ABBREVIATIONS
• ABT - Availability Based Tariff
• APH - Air Pre heater
• ASME - American Society of Mechanical Engineers
• ASTM - American Society For Testing & Material
• BFP - Boiler Feed Pump
• BFG - Blast Furnace Gas
• BMCR - Boiler Maximum Continuous Rating
• BTG - Boiler-Turbine Generator
• C&I - Control & Instrumentation
• CFD - Computerized Fluid Dynamics
• COG - Coke Oven Gas
• DC - Direct Current
• EJMA - Expansion Joint Manufacturers Association
• EMCR - Economic Maximum Continuous Rating (with 3% make up)
• EPRS - Effective Projected Radiant Surface
• ERW - Electric Resistance Welded
• FCNRV - Feed Control Non Return Valve
• FD - Forced Draught
• FRLS - Fire Retardant Low Smoke
• GCV - Gross Calorific Value
• HFO - Heavy Fuel Oil
• HGI - Hard Groove Index
• HP - High Pressure
• HT - High Tension
• IBR - Indian Boiler Regulations
• ID - Induced Draught
• LDO - Light Diesel Oil
• LP - Low Pressure
• LRSB - Long Retractable Soot blower
• MCC - Motor Control Centre
• NB - Nominal Bore
• NWL - Normal Water Level
• NDT - Non-Destructive Testing
• PC - Pulverized Coal
• PCF - Pulverized Coal Feeder
• PF - Pulverized Fuel
• PTFE - Poly-Tetra-Fluro-Ethylene
• RC - Raw Coal
• RCF - Raw Coal Feeder
• RTD - Resistance Temperature Detector
• RLA - Residual Life Assessment
• RMT - Running Meters
• SH - Super heater
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• SPM - Suspended Particulate Matter

• SS - Stainless Steel
• SWG - Standard Wire Gauge
• TDS - Total Dissolved Solid
• TEFC - Totally Enclosed Fan Cooled
• TMCR - Turbine Maximum Continuous Rating
• VVD - Variable Voltage Drive
• VWO - Valve Wide Open
• WB - Wall Blowers
• XLPE - Cross Linked Poly Ethylene
ETRM012-1-M-TS-001
2.0 INTENT OF SPECIFICATION
ETRM012-1-M-TS-001
2.1 INTENT OF SPECIFICATION FOR BOILER

This specification pertaining to the R&M of BPSCL boiler 1 to 5 (220 TPH) Steam Generator and
Auxiliaries is intended to cover the scope of work for rehabilitation of the Steam Generator so as
to make it capable of producing the steam at desired parameters. The existing steam generator
design is based on the use of coal with high calorific value as well as BF and CO gas. At present
the available coal is of lower calorific value and there is uncertainty in continuous availability of
BF and CO gas from steel plant. The bidder is expected to re-engineer the steam generator to
give the guaranteed output and performance with the use of coal as primary fuel and BF and CO
gas as secondary fuel, which is specified in clause no..3.1.4. The existing steam generator has
operated for over 30 years and its performance has degraded on all fronts especially on account
of inadequate supply of coal of designed GCV , BF and CO gas from steel plant and general
deterioration in water-wall, super-heaters, economizer, air pre-heaters, oil & coal burners, valves
& ducts etc. of boiler. The bidder is expected to renovate the boiler by adopting latest
development and improved metallurgy options for boiler components so that it is able to operate
and give satisfactory and reliable performance for further period of 20 years with high availability
and improved efficiency.
2.1.1 The boiler design is to be upgraded by replacing existing burners with separate /
coaxial burners for coal and gas, to give flue gas temperature of 384 ± 5 C inlet to
Air-preheater top block. The renovated boiler shall be capable of feeding steam not
less than 185 TPH (firing coal of GCV 3800 kCal/kg) & minimum 210 TPH at rated
parameter when firing both coal and gas.
2.1.2 The specification has described the scope of work and endeavored to cover all the
major equipment and related activities and work necessary for repair/ replacement/
retrofit. However any other minor item/service which has not been specifically
mentioned but is required for the completeness of the work shall also be supplied by
the contractor. The bidder is therefore advised to visit the site and acquaint himself
with the condition of the plant and equipment to enable him to make assessment of
the complete job.
2.1.3 The objective of specified R&M work of Steam Generator and Auxiliaries is as below:
a) Enhance the operating life of the steam generator by 20 years.
b) Modernize Steam generator control system on PLC platform.
2.2 GENERAL DESCRIPTION OF EXISTING STEAM GENERATOR

The Boiler supplied by M/S Krasny Kotelshik (Russia) for BPSCL Boiler 1 to 5 is of Conventional,
Single Drum, Natural Circulation, Balanced Draft, Opposed Fired, Dry Bottom Type. The furnace
walls, super heaters and the economizers are self-contained assemblies and are suspended from
a supporting structure. Furnace oil as well as gas can be used as fuel for preheating during start
up and to provide combustion stability at low loads.
The steam generator has two enclosures:
a) The furnace or Radiant Zone.

b) The rear pass or Convection Zone.
The schematic for the steam generator is shown in Annexure I.
2.2.1 The boiler furnace is opposite fired at 1 elevation with 6 nos. coaxial burners firing coal
supported by gas and oil burners.. The design specifications of boiler furnace are indicated
below.
ETRM012-1-M-TS-001
Width : 9912 mm
Depth : 7160 mm
Volume : 1222 cubic meters
Type : Bare Tube Construction
2.2.2 The Super heater system consists of First pass Ceiling Superheater, Screen Superheater,
Second pass Ceiling Superheater, Convective I Superheater and Convective II
Superheater mentioned in the order of steam flow. The location of these Super heaters with
reference to the gas flow direction will be in the order of Screen Super heater, Convective I
Super heater and then Convective Super heater. The SH spray has been provided between
Convective II and Convective I in steam flow direction. The heating surface areas of super
heaters are indicated below. Their sizes are given below:
Ceiling Super Heater : 220 square meters

Screen Super Heater : 705 square meters
Convective Super Heater : 1870 square meters
2.2.3 The Superheater Steam Temperature Control under part load condition is ensured by
Desuperheaters or Spray Control System. There is only one stage of Desuperheating
located in between the Convective I Superheater and Convective II Superheater.
2.2.4 The steam Temperature Control for Superheater system thus ensures the rated
temperature of 540°C at Convective II Superheater outlet
2.3 ECONOMISER
The economizer is of continuous loop, drainable horizontal, alternate straight and staggered coil
arrangement, arranged in two banks as upper and central block over APH II and lower block is
located between APH I and APH II with water flow upwards and gas flow downwards. The design
specification of the Economizer include-
Type : Continuous Seamless

Heating Area : 2195 square meters
Number of banks : 2 (Two) Arrangement: Alternate
Inline and Staggered
arrangement
Nos. of coils in upper & central : 29 coils @ 132 pitch (11 bends
block per coil)
Dimension : 32 mm x 3.5 mm thick
Nos. of coils in lower block : 26 coils @ 110 pitch (6 bends
per coil)
Dimension : 32 mm x 3.5 mm thick
Sr. No. Location Material of Construction (Russian Type)

1 Economizer SA 209T1,T11
2 Waterwalls SA 210GrC
3 Downcommers and steam outlet tubes CT20
4 Ceiling Superheaters SA 209T1
5 Screen Superheaters 12XIMP Φ, SS347H
6 Convective I Superheater 12XIMP Φ
ETRM012-1-M-TS-001
7 Convective II Superheater 12XIMP Φ

8 Steam bypass tubes 12XIMP Φ
9 Superheater blowdown tubes 12XIMP Φ
10 Outlet tubes from economizer to drums CT20
11 Feed pipes CT20
Note:
i. Material composition of 12XIMPΦ are 0.12% C, 1% Cr, 0.3% Mo, 0.20% V (Temperature
limit up to 595C)
ii. Material composition of CT 20 are 0.20% C, 0.17 – 0.37% Si, 0.35 – 0.65% Mn, 0.25% Cr
(Temperature limit up to 450C)
2.4 AIR HEATER

Air Heater is tubular type and there are one APH with flue gas through tubes and air outside. The
design specification of the Air Heater include-
Type : Tubular type

Heating area : 16260 square meters
Numbers : 1
2.5 FUEL BURNING EQUIPMENTS

The primary fuel for the plant is BF, CO gas and coal with furnace oil for startup. The burner is of
co axial type capable to fire all fuels. The design specification of Fuel Burning Equipments
include-
Burner
Type : Wall fired Burners
Number of Main Burners : 6
Number of Oil Burners : 6
Capacity – main burners : Pulverized Coal 8 TPH

BF Gas 16000 m3/hr
CO Gas 3000 m3/hr
Furnace Oil 500 Kg/hr
2.6 MILLS AND FIRING SYSTEM

The pulverized fuel system adopted for BPSCL boilers 1 to 5 employs a drum type ball mill with
the indirect firing utilizing hot air as a drying-cum-transporting medium. The ball and tube mill is of
suction type with coal input from RC feeder and hot air from one side dry and lifts the pulverized
coal to the separator from where oversized particle are sent back to pulverizer. The coal dust
collected in the cyclone is transported to the coal dust bunker by screw conveyor. The mill fan
takes the suction air from the cyclone and pressurizes the coal dust collected in the coal dust
bunker through blade type dust feeder to the furnace. The schematic for the milling system is
attached in Annexure II.
The Existing Milling plant details are as below:
Raw Coal Bunker
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Number of bunker per boiler 2

Bunker volume (m2) 270
Raw Coal Feeders
Number of feeder per boiler 2
Type CY 700/5040T
Rates output (t/h) 30/32.6
Speed of feeder (m/sec) -
Motor rating (KW) 14
Motor speed (rpm) 500/1500
Motor rated voltage (V) 415
Drum type Ball Mills
Number of mills per boiler 2
Type W5M 287X470
Rated output (tph) 16
Drum rotation speed (rpm) 18.7
Drum dia. X length (mm) 2870 x 4700
Weight of balls (tons) 35
Diameter of balls (mm) 40
Hardness of balls (BHN) 300
Motor speed (rpm) 745
Dust Separator
Number of units per boiler 2
Diameter (mm) 3300
Collecting Cyclone
Number of units per boiler 2
Diameter (mm) 2350
Screw Conveyor
Diameter (mm) 500
Length (m) 96
Capacity (TPH) 45
Blade Type Dust Feeders
Number of feeders per boiler 6
Maximum capacity of coal (TPH) 8
Maximum capacity of pulverized fuel coal (TPH) 2.66
Number of outlet branches 2
Dimensions of inlet port (mm) 800 x 800
Diameter of outlet port (mm) 115
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Reducing gear ratio 49

Blade height (mm) 38
Weight of one feeder with motor (kg) 1475
Motor rating (KW) 3.4
Motor speed (rpm) 500 – 1500
Motor rated voltage (V) 220 DC
Coal Dust Bunkers
Number of bunkers per boiler 2
Capacity of each bunker (T) 90 – 100
Volume of each bunker (m3) 125
Ball Mill Lubrication Pumps
Number of systems 2
No. of rotary gear pumps per system 2
Capacity (l/min) 50
Pressure (kg/cm2) 10 – 13
Motor rating (KW) 3
Discharge oil filter capacity (micron) 25
Flow rate (l/min) 100
Two nos. oil tank capacity (m3) 1.2 / 2.0
The existing design fuel characteristics are as below:
Middling Coal Properties

Fixed carbon 27 – 30 %
Volatile matter 22 – 25 %
Moisture 1–3%
Ash 35 – 40 %
Ash fusion temperature 1350 – 1400 C
CV 4500 - 5000 Kcal/kg
BF Gas Characteristics
CO 23 %
CO2 17 %
CH4 0.75 %
H2 3.5 %
N2 56 %
CV 850 Kcal/m3
Specific Gravity 1.3 Kg/m3
Self Ignition Temperature 680 C
Explosiveness with air -
Lower Limit 37 %
ETRM012-1-M-TS-001
Upper Limit 71 %
CO Gas Characteristics
H2 60 %
CO 8%
CO2 2%
O2 0.5 %
CH4 24 %
N2 60 %
Heavy Hydrocarbon 2%
CV 4200 Kcal/m3
Specific Gravity 0.45 Kg/m3
Self Ignition Temperature 560 C
Explosiveness with air -
Lower Limit 5.6 %
Upper Limit 34.7 %
Fuel Oil Analysis
Grade LV and HV oil
Specification IS-1593-1960
Kinematic viscosity at 50C 80 (LV) 370 / 1500 max (HV)
(Centistokes/Redwood seconds)
Flash point PM C (Pensky-Martens Closed Cup 66
method)
Water content ( % vol) 1.0 max
Sediments (% wt) 0.25 max
Ash (%wt) 0.10 max
Sulphur total (%wt) 3.5 max
GCV (kcal/kg) 10000±1.2 %
Acidity inorganic NIL
Specific gravity at 15C 0.90
2.7 FANS
Two numbers of Forced Draft and Induced Draft fans per boiler are used for maintaining draft in
the furnace. The Mill Fan is used in indirect firing for sending the coal into the furnace. The design
specifications of fans include-
2.7.1 Forced Draft

Type : BDH/18-11
Make : Russian
Number per Boiler : 2
Capacity at 30C : 112300 cubic meters / hr.
Pressure : 440 mm water column
Rating : 220 KW
Speed : 980 rpm
Induced Draft
ETRM012-1-M-TS-001
Type : Double Suction, D-21.5X2

Make : Russian
Capacity : 199000 cubic meters / hr.
Temperature For flue gas : 200C
Rating : 400 KW
Speed : 580 rpm
2.7.2 Mill Fan

Type : Bm 50/1000-16
Make : Russian
Capacity : 53500 cubic meters / hr.
Temperature : 300 C max.
Rating : 300 KW
Speed : 1450 rpm
2.7.3 Soot Blowers

The design specifications of Soot Blowers include-
Located at Water Walls

Type : Wall Blowers
2.8 INSULATION & REFRACTORY

The boiler has necessary lining and insulation along with fixing material to limit the outside
surface temperature to the required level.
The complete integral piping, valves and fittings, all air and gas ducting with dampers/ gates and
necessary refractory materials are also provided.
2.9 ESP
ESP Type : FAA – 4 x 52.5H – 69 – 135 – A2
Gas flow, m3/sec : 155.5
Gas temperature, deg C : 170
Maximum temperature, deg C : 220
Pressure drop across ESP, mm.Wg. : 22
Inlet dust concentration, gm/Nm3 : 50 - for coal only
35 - for mixed fuel
Outlet dust concentration, mg/Nm3 : 150 - for coal & mixed fuel
ESP collection efficiency, % : 99.7 - for coal only
99.572 - for mixed fuel
Effective migration velocity, m/sec : 6.548 - For coal only
7.683 - for mixed fuel
No. of ESPs per boiler : 2
No. of fields per ESP : 4
T / R Panel rating : 70 KV / 1000 mA
2.10 CODES & REGULATION

2.10.1 Pressure Parts
ETRM012-1-M-TS-001
The pressure parts of the main Boiler sections identified for up-rating in this Proposal will be
modified / designed in accordance with the latest applicable Indian Boiler Regulation or other
acceptable international codes whichever is superior. The materials used will be in accordance
with ASTM Standards.
The manufacture of the equipment and the erection at the Site will be done as per Indian Boiler
Regulation Codes.
The shop and erection inspection will be carried out as per Indian Boiler Regulations.
2.10.2 Non-Pressure Parts

For the non-pressure parts identified for modification, it is proposed to adopt Codes and
Standards in accordance with standard practice of customer. All materials used for non-pressure
parts will conform to various Indian Standards or equivalent International Standards.
2.11 DESIGN PARAMETERS

The design parameters of the boiler are as below:
Main steam Flow at Convective II SH outlet 220t/hr

Main steam Temperature at Convective II SH outlet 540ºC
Main steam Pressure at Convective II SH outlet 100 atag
Feed water Temperature at Eco Inlet 215ºC
Number of safety valves 2
Blowing capacity of each safety valves 115 tph
Set pressure for drum safety valve 124 ata
Set pressure for superheater safety valve 105 ata
2.12 PAST HISTORY

Boiler Tube Leakages (Area wise)
a) Incidences of tube failures

Unit 1 to 5 from August 2010 – 2011
Year WATER ECONOMISER Super Ceiling Screen Feed line PBD Sub-
WALL Heater Super Super Bend Total
Heater Heater
Unit I 1 1 2 - - - 1 5
Unit II - 2 1 - - - - 3
Unit III 1 1 1 - 1 1 - 5
Unit IV - 2 1 1 - - - 4
Unit V 1 6 1 - - - - 8
Total 3 12 6 1 1 1 1 25
b) Number of Forced outages month wise from August 2010 – 2011
Unit U-1 U-2 U-3 U-4 U-5

AUG - - 2 1 2
SEP - 1 - - -
ETRM012-1-M-TS-001
Unit U-1 U-2 U-3 U-4 U-5

OCT - - - - 1
NOV - - - - 1
DEC 1 1 - 1 -
JAN - 1 1 1 1
FEB 2 - - 1 -
MAR 2 1 1 1 -
APR - 1 1 - 1
MAY - 1 2 1 -
JUNE 2 2 1 - 2
JULY 1 - 2 - 2
AUG - - - - 1
Total 8 8 10 6 11
Total Outage 408 1141 562 613 713
Hours
c) Historical catalogue of major works carried out for different Unit
i. RLA study has been done for Unit No # 4 by M/S ALSTOM on 2008
ii. Roof structures partially changed.
iii. Central column of boiler 2 changed
iv. APH blocks of Boiler 2, 3 ,4 changed.
v. Ceiling SH of Boiler 2 changed.
Note: In addition to that following modifications were carried out by M/S BHEL for all the 5 units in
90’s:
i. The panels for Convective I and II superheaters were changed with different material.
ii. Eight (8) numbers of Screen superheater panels and ceiling SH were changed.
iii. All Economizer panels were changed.
iv. Water walls and header changed partially.
ETRM012-1-M-TS-001
PROJECT NO.: PROJECT NAME: BPSCL UNIT 1 TO 5 BOILER (220 TPH) PACKAGE / SYSTEM: STEAM GENERATOR & AUXILIARIES (MECHANICAL)
ETRM012
d) Deviations in operating parameters of BOILER Unit#1 to 5
Description Unit Design/Max. U#1 U#2 U#3 U#4 U#5

Steam Generation TPH 220 125 135 125 145 200
GCV kcal/kg 4500-5000 3947 3947 3947 3947 3947
Condensate Injection (L/R) TPH - - - - -
Drum Pressure ksc 110 86 87 89 88 88
Water & Steam Parameters
Main steam flow t/h 125 135 125 145 200
Main steam temperature °C 540 527 510 525 520 527
Main steam pressure atag 100 85 84 84 83 84
Feed water flow TPH 125 135 125 150 200
Feed Water inlet temp to ECO °C 215
Feed Water Pressure kg/cm2 150 136 140 140 139 136
Air and Flue Gas Parameters
No. of mills in service 1 2 1 1 1
Coal flow TPH - - - - -
Total Air flow TPH - - - - -
BF gas flow (x 103) M3/hr 96 38 74 70 60 80
BF gas pressure mmwc
CO gas flow (x 103) M3/hr 18 Passing passing passing passing passing
CO gas pressure mmwc
Hot air temperature at mill inlet °C 350 262 210 270 238 290
Air dust temperature after mill °C 85 85 80 80 75 80
Mill fan suction vacuum mmwc 480 495 367 300 621
ETRM012-1-M-TS-001
ETRM012
Description Unit Design/Max. U#1 U#2 U#3 U#4 U#5

Mill fan discharge pressure mmwc 750
Flue gas temp. after Convective I S/H (L&R) °C 600
Flue gas temp. at top economizer inlet (L/R) °C 590 / 599 560 / 552 565 / 575 593 / 580 580 / 578
Furnace Pressure (Left / Right) mmwc -4 +6 / +6 0/0 +1 / +1 -1 / -1 -2 / -2
O2 % % 2-4 4.2 5.5 5.4 2.3 3.8
Motor Current
ID Fan A/B Amp 75 66 / 68 75 / 75 70 / 70 70 / 70 68 / 66
FD Fan A/B Amp 22 08 / 18 12 / 10 14 / 12 15 / 16 17 / 18
Ball Mill A/B Amp 64 44 40 / 44 40 42 42
Mill Fan A/B Amp 34 32 20 / 25 42 20 / 18 22
ETRM012-1-M-TS-001
3.0 STEAM GENERATOR AND AUXILIARIES

SPECIFICATIONS
ETRM012-1-M-TS-001
STEAM GENERATOR AND AUXILIARIES SPECIFICATIONS

3.1 GENERAL
3.1.1 Scope of Work
The scope of work envisaged for the proposed R&M work is categorized into following broad
categories:
a) Pre bid site visit by prospective bidders to analyze the site condition and finalize work
quantum required for testing / inspection of the equipments.
b) Bidders are required to collect all the necessary information during pre bid site visit.
c) Bidders are required to finalize any necessary scope based on inspection of the unit and
discussions for boiler and auxiliaries and boiler main structure during pre bid visit.
d) Engineering / Re-engineering / Re design work of the furnace as specified in the
specification.
e) Supply of equipments / Items would be as specifically required by the Owner mentioned in
this specification.
f) Services, like dismantling and removal of scrap to specified location should be planned to
fit the schedule of the shutdown period. No, extra time would be given for carrying out the
same. Erection, commissioning, trial operation, and testing including Performance
Guarantee Testing should be planned to fit the schedule of the shutdown period. No, extra
time would be given for carrying out the same
g) Associated civil and structural works essential for completion of scope.
h) Repair / overhauling of all components / systems / subsystems necessary to ensure
sustained commercial, safe operation at rated output.
i) Along with the replacement/ retrofitting activity to be done under the scope of R&M, bidder
has to undertake a complete overhaul of the boiler plant and finally carry out the outer
painting with appropriate industrial paints with owner’s approval.
j) Provide all the necessary calculations, drawings & other related O&M documents for the
equipment supplied.
k) Any other work which is not covered in the above, but in the spirit of essentiality for
successful completion of the R&M scheme to achieve targeted output and performance will
be in scope of the bidder.
3.1.2 Scope of Engineering/ Re-Engineering / Re-Design work

Major scope involves Re-engineering / re-designs of:
a) Gas tight furnace with furnace vacuum -4 mmwc (at reference level of 21 m) on all
operating conditions for rated steam parameter of minimum 185 TPH (firing coal of GCV
3800 kCal/kg) & minimum 210 TPH (firing both coal and gas) at 100 ata and 540C at
superheater outlet.
b) The furnace roof to be made leak proof with membrane type arrangement to ensure gas
tight sealing.
c) Pressure parts with membrane type water walls, with necessary modifications in headers
and pipings.
d) Integral piping with necessary modifications to suit to the new furnace design.
e) Structural steel work up to 200 MT including beams, ladders, platforms, support and
foundation bolts, insert plates etc. Any extra work done would be on unit rate basis.
f) Furnace to be designed for burning coal of GCV 3800 Kcal/kg as primary fuel with BF and
CO gas as secondary fuel. Separate/co-axial burners are proposed for meeting the above
requirements.
g) All internal piping for steam, service & instrument air, etc.
h) Burner system by supplying new burners along with their firing control system based on
PLC including associated valves (pneumatic / electromagnetic valves) and instrumentation.
Associated panel, cables and local instrumentation is in the scope of the bidder. The
supplied PLC shall have provision for including all the existing controls as per details given
ETRM012-1-M-TS-001
in Annexure – 2of Technical Specification (C&I Section). Any additional required tapping
points along with root valves, as required, is in the scope of bidder.
i) Dampers, expansion bellows and associated controls / piping based on conditional
assessment of the same.
j) Attemperator system comprising of direct spray type (single or double stage as per the
technology used, conforming the provenness of the system). The above condition should
conform to meeting the design super heater inlet and outlet temperatures and pressure
parameters at different loading conditions.
k) Flue gas temperature at air-preheater top block inlet to be restricted to 384C (design).
l) Valves and fittings
m) Vents up to safe elevation
n) External canopy for the boiler at steam drum operating floor.
o) Instrumentation control panels
p) Insulation and refractory
q) Bidders to provide the CFD model of the boiler for dynamic operating conditions.
r) Bidders to carry out overhauling and repair work in the areas of boiler & auxiliaries that is
not covered in the R&M scope mentioned above. Bidder to quote the price for the
overhauling job along with the R&M job. The detail scope of overhauling is attached in
Annexure - III
s) All other auxiliaries and steam generator components required for safe, reliable and
continuous year round steam generation.
Owner intends to retain unit out put on sustainable basis. Contractor shall include in his scope of
work any minor modification (if required) in the boiler pressure parts, to meet the proposed unit
output considering the use of coal quality specified (design CV 3800 Kcal/kg) to achieve balance
of flue gas and steam temperatures.
The bidder is required to retain the existing second pass of the boiler and to match the first pass
of the boiler with the second pass with the available technology ensuring gas tightness and
thermal expansion at dynamic load condition.
Engineering / design of all other system including civil system / equipment as required / specified
to fulfill the intent of this specification and meet the overall objectives.
3.1.3 General requirement
Specified hereafter in this section are the Owner’s minimum requirements which are to be
complied with / satisfied for various Equipments / Systems which are to be supplied new /
replaced by the Contractor in course of renovation work as per the scope of works detailed in this
specification for Steam Generator and auxiliaries.
Without FGMO
Boiler Output
Steam Flow Minimum 185 TPH (firing coal of GCV 3800 kCal/kg) &
minimum 210 TPH (firing both coal and gas)
Main steam Condition 100 ata and 540C
Makeup water 3% + Make-up required for (BMCR steam flow – VWO
steam flow)
CW inlet Temperature 33°C
Ambient Air Temperature & Humidity 35°C & 60% RH
ETRM012-1-M-TS-001
Furnace exit plane is defined as the plane, vertical plane above furnace nose tip for two pass
steam generator. For maintaining Furnace exit gas temperature (at furnace exit plane) less than
Initial ash deformation temperature (IDT) minus 60°C mentioned in table titled “Ash fusion Range”
under clause no…3.1.4 and to balance the temperatures of flue gas and steam, minimum
retrofitting/re-designing of superheater panels are required. The Bidder shall have to carry out the
detailed analysis of the existing design of the steam generator for assessment of the requirement
specified elaborately in this specification with the range of coals and other inputs made by the
owner. If, needed, bidder shall also work out the complete thermal redesign of the steam
generator for making suitable adjustments in the heat transfer surfaces as mentioned above to
satisfy all requirements with the specified design criteria. Bidder has to furnish the design
parameters in the data sheet.
However, the bidder utilization of various specified requirements indicated by the Owner shall in
no way relieve the bidder of his responsibilities to meet the targeted objective of renovation, or of
providing sustained, safe, commercial operation of the plant.
The Owner's specified requirements as indicated below (in Table-3.1) shall be complied for the
most stringent conditions resulting from range of coals specified or from range of operating
condition specified.
Table-3.1: Specified requirements

i. Types of coal used for firing. Coals from the range of design /worst now
specified by the owner for future operation.
ii. Steam generator operating condition: a) With design / worst coal at BMCR conditions
(i) Capacity: Minimum 185 t/h b) With HP Heaters in service
(ii) Furnace Draft: -4 mmwc c) Without HP Heaters in service.
(iii) Flue gas temperature at inlet to
APH top block to be 384 C.
3.1.4 Design Coal

Gross Calorific Value of 3800 Kcal/Kg.
Proximate Analysis
Test Type Moisture Ash Volatile Matter Fixed Carbon
% % % %
As fired basis 10.00 45.00 10 – 25 30 - 45
Ultimate Analysis
Test type Moisture Ash C% H% N% S% O%
% %
Air dry 10 36.05 45.98 2.81 0.91 0.44 3.81
basis
Coal Hard Groove Index – 55
Ash Initial Deformation Temperature – 1100°C
Ash Fusion Temperature – 1300°C
3.1.5 Worst Coal

The worst coal predicted is same as that of designed coal of GCV 3800 Kcal/Kg.
ETRM012-1-M-TS-001
Note:
Design Coal: The Steam generator shall be capable of delivering the steam at MCR output
conditions and guaranteed performance using the design coal.
Performance ash / furnace oil analysis as available from site.
Ash Analysis:
SiO2 59.29%
Al2O3 27.28%
Fe2O3 6.59%
TiO2 1.52%
P2O5 0.55%
SO3 0.43%
CaO 1.05%
MgO 0.38%
Na2O 0.41%
K2O 2.49%
Furnace Oil Analysis:

Grade 1500 secs conforming to IS: 1593.
Flash Point 65 minimum (Degree C).
Viscosity (RWI) 80 – 90
Water Content (Max.) 1 % by volume
Sediments (Max.) 0.25 % by weight
Ash (Max.) 0.1 % by weight
Sulphur (Max.) 4.5 % by weight
Acidity Nil
Specific Gravity at 15 degree C 0.95
Gross CV 10000 Kcal/Kg
BF Gas Characteristics:
CO 23%
CO2 17%
CH4 0.75%
H2 3.5%
N2 56%
3.2 PRESSURE PARTS

3.2.1 Design of Pressure Parts
The design of pressure parts which are to be replaced (tubes, headers, etc.) shall be supplied by
the Contractor as per Indian Boiler Regulations (IBR) or other acceptable international codes
whichever is superior. It is however, the responsibility of the contractor to get on behalf of the
Owner various calculations and other technical documentations approved by the statutory
authorities in the country.
ETRM012-1-M-TS-001
The thickness of the pressure parts (steam and water tubes/headers, etc.) shall be calculated
using IBR formulae / factor of safety etc. (and not as per codes / formulae not acceptable to IBR).
Such thickness as per IBR formulae shall be arrived at after allowing for tube bend thinning
allowance, where applicable as per IBR / accepted International codes conforming to the IBR.
Additional erosion allowance on the calculated tube thickness shall be provided at the specified
locations as per IBR. The supplied pressure parts shall conform to the IBR in respect of
tolerances, freedom from defects and mechanical tests. The pressure parts shall accompany with
the IBR III-B certificate and approved drawings along with dispatch.
3.2.2 Material of Pressure Parts

The material used for Boiler pressure parts including boiler tubing, headers, piping, vessels,
valves & fittings etc. and other components shall be equal to or better than the following unless
specified otherwise:
Design Metal Temperature Material

Up to & including 400C Carbon steel to ASTM A-106 Gr. B/C or SA
210C or approved equivalent.
Above 400C but below 550C Alloy steel to ASME SA-335: P-11/P-12/P-22 / -
23; ASME SA213:T-11/T-22/T-23 or approved
equivalent
Up to & including 605C Alloy steel ASME SA- 335 / 213 P-91 / T-91, T-
92 or approved equivalent
Above 605C Austenitic Stainless steel, 304 H, TP 347 H or
approved equivalent
3.2.3 Scope of Work (General)

a) Replacement of the water wall tubes from bare wall tube design to membrane wall is to be
done.
b) Water wall headers have to be re designed to accommodate the membrane type design.
c) Replacement of roof SH with membrane tubes covering 1st & 2nd pass roof.
d) The joint preparation and repairing Weld Preparation System (WPS) shall be checked and
approved by inspecting authority before start of erection work.
e) Minor modifications of the pressure parts to be done in the available space to ensure gas
and steam parameters are within the design margin and that the flue gas temperature at air
pre-heater top block inlet is restricted to 384C (design).
f) Stress relieving of welded joints where ever requires shall be carried out.
3.2.4 Economizer
The scope of work has been covered in Annexure – III: Overhauling Scope of the Technical
Specification (Item no. 17 & 18). Overhauling scope of work and material for execution shall be
provided by the owner. However, if any minor modification is envisaged by the bidder to
accommodate their proposed design, the same shall be in bidder’s scope.
3.2.5 Water wall & Roof tubes

3.2.5.1 Existing Water Wall & Header details
S. No. Particular Unit Values/range

A) Front Water wall tubes
Material -- SA210GrC
Number -- 152
ETRM012-1-M-TS-001
S. No. Particular Unit Values/range

Size (OD x thickness) mm 60.3 x 5
Front Water wall headers
Size (OD x thickness) mm 273 x 26
Length of lower left & lower right header mm 2432
Length of lower inter left & lower inter right header mm 2656
B) Rear Water wall tubes
Number -- 152
Rear Water wall headers
Length of lower inter left & lower inter right header mm 2656
C) Left Water wall tubes
Number -- 105
Left Water wall headers
Length of left middle header mm 2304
D) Right Water wall tubes
Number -- 105
Right Water wall headers
Length of middle right header mm 2304
E) Total water wall heating surface m2 3829
For all A,B,C & D above
1. Intended Working pressure at header (design) Kg/cm2 115
2. Intended working header metal temperature (design) C 320/330
3.2.5.2 Scope of Work & Supply

a) Water wall tubes are to be replaced from the existing bare tube staggered arrangement to
membrane type with new separate burner panel to accommodate both coal and gas
ETRM012-1-M-TS-001
burners. The design shall be such as to prevent distortion of steel work due to thermal
expansion.
b) Necessary provisions shall be made in the furnace for admitting the required quantity of
over fire air at various levels, considering the various fuel mixes.
c) The furnace EPRS should be so selected to give acceptable furnace outlet temperatures
while firing coal or gas or the combination of both the fuels. The furnace design shall
incorporate necessary manholes, peep holes, openings for the fuel distributors, ignition /
reflection arch and refractory covering in the lower furnace area if required.
d) The burner panel tube material & size shall be same as that of modified water wall tubes in
furnace zone to accommodate the new bigger size burners. The height of the firing zone
should be sufficient to completely burn out the coal particles thus restricting the unburnt in
bottom and fly ash within design limit. All gooseneck bend tubes of water wall to be
replaced.
e) All Bottoms “S” panel including cathouse tubes to be replaced.
f) Provision has to be made to accommodate existing wall and retractable soot blowers.
g) Provision for manhole / peepholes to be made at suitable accessible areas.
h) Proper clamping should be there with provision of required expansion of water wall and roof
tubes.
i) Complete assemblies of Water Wall Panels including Headers to be replaced with new
assemblies as per new furnace design. Each of the headers shall have at least two
numbers of stubs for inspection and cleaning.
j) Complete Replacement of roof tubes with membrane tube along with header.
3.2.5.3 Technical Requirement

a) An additional tube thickness of with suitable tolerance as per IBR norms for water wall
tubes shall be provided on all water wall tubes coming within a radius of half a meter of
each wall blower to guard against premature tube failure due to soot blowing. Alternatively,
fabricated tubes may be provided in the soot blowing radius to guard against impact of soot
blowing.
b) There shall not be any flame impingement on water walls.
c) Minimum 10% thinning allowance shall be provided wherever there is a bend in the tubes
of furnace and water walls.
d) Bidder to check the feasibility of welding minimum 10 mm diameter carbon steel wear bar
on all the corners of the furnace bottom hopper (S shaped panel) up to three meters from
the side and additional 0.5m vertical height for prevention of tube damage due to falling
slag/ ash erosion. Better solution in respect of the same from the bidder would be
acceptable.
e) Adequate numbers of furnace observation and tapping points shall be provided for local
instruments, gauges, switches, test pockets etc.
f) The bottom ‘S’ panel tube & Goose neck bends shall be of same material as that of
modified tubes with erosion allowance of 0.6 mm over and above calculated thickness as
per IBR and other specification requirements.
g) Provide minimum +10% thinning allowance over and above the calculated thickness
wherever there is bend in the tubes of ‘S’ panel.
h) As per NFPA 85 furnace shall be designed so that the maximum head capability of induced
draft fan system with ambient air does not exceed the design pressure of furnace ducts and
associated equipments. The furnace enclosure shall have sufficient strength to sustain any
inadvertent pressure extremity inside it.
3.2.6 Superheaters
3.2.6.1 Details of existing superheater tubes & piping
ETRM012-1-M-TS-001
3.2.6.1.1 Scope of Work & Supply

3.2.6.2 Convection Super Heater I

3.2.6.3 Details of existing Convective Superheater loop I packet

3.2.6.4 Convection Super Heater II

3.2.6.5 Attemperators and Spray system

3.2.6.5.1 Scope of Work & Supply
a) The de-superheating system shall be complete with all required, control valves & bypass
regulating valves with suitable valve mounted electrical actuator,piping and supports etc.
b) Superheater attemperation spray system (spray nozzles, liners & assemblies with higher
capacity units) with capacities of each Super heater attemperator spray water systems to
be re-designed for 15 % of the rated main steam flow.
c) Single/Two stage attemperation system may be considered for better temperature control.
d) Replace existing valves for Super Heater spray system with modified special purpose (multi
stage, multi path valve with class V leakage) valves/or zero leak metal contact sealing
valves and auto spray controls and measurements to be provided. Necessary isolation
valves also to be replaced and included in the scope of work.
3.2.7 Headers
Scope of Work & Supply
The bidder is required to supply new bottom and top header for membrane water wall. Necessary
retrofit of the existing superheater and economizer headers to be done to meet the scope
requirements.
Technical Requirement
a) All headers shall be located outside the gas path. In case headers are located in the gas
path, the same shall be protected by insulation to avoid direct exposure to gas.
Downcomers shall be in the totally unheated portions of the steam generator.
b) All headers should be properly supported and provision of expansion should be there.
c) Inspection stubs of length 600mm and 88mm dia size shall be provided in all the headers
for suitable access for maintenance and inspection. No hand hole plate assembly design
shall be used.
ETRM012-1-M-TS-001
d) The header vents, drains, pressure gauges, steam and safety valve connections shall be of
weld-end type. Instrument tapings as required including test connections shall be provided.
e) The superheater outlet headers shall be of the extended type to accommodate the safety
valves.
f) All tubes or attachments to headers shall be full strength welded. No seal welded joints
shall be used.
g) All headers shall be thoroughly cleaned and be free of scale by shot blasting on the inside.
h) Drains from steam drum, headers, gauge glasses and integral piping of steam generator
shall be terminated into one or more drain collection headers which will be connected to
blowdown tank.
i) For Nitrogen (N2) blanket and N2 preservation in case of header replacement, suitable
connections for N2 supply shall be provided as per manufacturer’s recommended
procedures. Nitrogen will be provided at one point at 16 kg/cm2 (g) approximately. Further
piping up to equipment for the preservation of the boiler, draining of the boiler and purging
of the gas line including pressure control station if required any and required instruments
shall be in bidders’ scope. The purging for the burner gas lines up to the
nozzle/spud/burner inlet shall be automatic.
3.2.8 Buckstays
a) Replacement of buck stay and railings floor grills etc as per new furnace design.
b) All buck stay including the corner fixing arrangement, sealing of gaps and refractory work is
proposed to eliminate air ingress in this area.
3.2.9 Valves
Bidder to retrofit / replace the existing impulse type drum safety valves within the existing
arrangement.
Bidder to replace the existing superheater impulse type safety valves with new spring loaded
safety valves. Bidder to also provide silencers for the existing start-up vent valves.
3.2.9.2 Technical requirement
a) Specific requirement of valves:

i. For valves, the direction of flow shall be clearly stamped on the body of the valve.
ii.Hand wheels for all the valves shall close the valve in clockwise direction when viewing
from the top. All hand wheels shall be clearly marked indicating the direction of
opening/closing.
iii. For safety relief valves and start-up vents the allowable noise level shall not exceed 115
dBA for one quarter hour or less per day.
iv. All valves shall be provided with proper name plates indicating complete information
about the valves.
3.2.10 Hangers & Supports

All the boiler hangars and supports shall be replaced with new ones within the scope boundary
based on the existing stress and new values in case an additional load change in considered in
the design.
3.2.10.2 Technical Requirements

a) Design & manufacturing of piping hangers and supports should conform to ANSI/ASME
code for pressure piping, B31.1.
ETRM012-1-M-TS-001
b) Each threaded connection and adjustable rod shall be with lock nuts.
c) Hanger support rods of less than 10 mm diameter for supporting pipes of 50 Nb and
smaller and less than 13 mm diameter for supporting pipes of 65 mm Nb and larger, shall
not be used.
d) Attachments to piping shall be by clamps/lugs. Bolted pipe clamps shall have a minimum
thickness of 5 mm for weather protected locations and 6 mm for locations exposed to
weather. Beam clamps shall be forged steel equipped with a rod to fix a nut.
e) All sliding surfaces of supports and restraints shall have Teflon lining on one surface
coming in contact with stainless steel lining on the other surface.
f) All pipes hangers and supports shall be designed to withstand all static and dynamic
loading conditions which act upon the system and associated equipments. Piping supports
and equipment loading condition to be considered may include but are not limited to:
i. The total load of pipe, fittings, valves, insulation and medium transported or test medium
whichever is heavier. The total calculated load should minimize the effect of piping
system loading on the structure.
ii.Thermal expansion and contraction.
iii. Stress from cyclic loading of equipments.
iv. Vibration transmitted to or from equipment or terminal connection.
v. Wind loading on outdoor piping.
vi. Loading due to seismic forces if required by code or specification.
g) All rigid rod hangers and variable spring shall be designed to carry the operation load in hot
condition. Where hangers’ rod angularity exceeds 4 degrees from cold to hot position, the
hanger and structural attachments shall be offset in the cold position in such a manner that
the hanger rod is vertical in hot position unless otherwise specified.
h) The values of cold and hot settings of the hangers along with end moments and forces
shall be supplied.
i) Bidders need to submit the detail stress analysis report based on above load calculation.
3.2.11 Penthouse
a) Ceiling tubes hanger’s replacement. Modified spring type sealing arrangement with better
refractory system having plastic refractory material to avoid ash ingress in to the pent
house.
b) Replace pent house casing with new insulation
c) Repair of Boiler roof with new powder coated sheets.

a) Restoration of Hangers inside pent house.
The hangers inside the penthouse are to be repaired / replaced and restored as per
requirement of the new furnace design.
b) Modified spring type sealing arrangement with better refractory system having
plastic refractory material:-
The gaps between vertical coils entering pent house & horizontal ceiling tubes are required
to be repaired/ sealed with castable refractory and asbestos roof.
c) Replacement of penthouse refractory and casing:-
Castable refractory is required to be laid over the tubes & then a 3 mm casing of boiler
steel is to be provided over it to avoid flue gas /ash leakage.
d) Repair of Boiler roof with new powder coated sheets.-
The boiler roof is also to be repaired with new powder coated sheets. The most common
polymers used are polyester, polyester-epoxy (known as hybrid), straight epoxy (Fusion
bonded epoxy) and acrylics.
ETRM012-1-M-TS-001
3.2.12 Piping
3.2.12.1 Steam generator Integral Piping
The bidder should estimate the quantum of work that has to be done on the integral piping during
the pre bid site visit except upriser pipes which have to be replaced completely. Based on the
above estimation Bidder to finalize the actual scope of work.

a) The integral pipe work shall consist of blow off bends, high and low pressure drains, water
gauge piping, water and steam connections to feed water regulator, feed pipe work from
economizer outlet manifold to the steam generator steam pipe works, safety valve escape
pipe works, upriser ,downcomer etc.
b) The steam generator integral piping consists of all the interconnecting piping between one
meter away from the economizer inlet header and the superheater outlet header up to
MSSV.
c) The number of size and the arrangement of these integral piping shall be based on the
permissible pressure drops in these pipes and the distribution required in the respective
headers of the various sections of the steam generator.
d) These piping shall be properly supported and provided with the required tapping, stubs and
thermo wells for measurements.
e) The calculation of wall thickness required for pipelines subject to internal and/or external
pressure shall be based on the formulae and recommendations as given in the applicable
codes. Adequate allowances shall be made towards thinning due to bending, weakening at
branch connections, threading, commercial tolerances on pipe wall thickness, corrosion
and erosion, etc. and the same shall be subject to approval by Owner/Consultant. In any
case a minimum corrosion allowance of 1.0 mm shall be considered while selecting the
thickness.
f) Formal flexibility analysis calculations shall be carried out in case of pipelines subjected to
restrained thermal expansions or contractions and the report to be submitted to the owner /
consultant for approval.
g) All pipelines with size greater than NB 50 mm are considered as shop fabricated piping and
detailed piping layout drawings shall be prepared for all such pipelines.
h) Detailed bills of material shall be prepared for all piping systems. In case of shop fabricated
piping, the bill of material shall correspond to the layout drawing prepared.
i) All piping shall be routed so as to avoid interference with other pipes and their hangers and
supports, electrical cable trays, ventilation ducting, structural members, equipment, etc.
Adequate clearances shall be ensured with respect to the above to accommodate
insulation and pipe movements.
j) The piping shall be arranged to provide clearance for the removal of equipment requiring
maintenance and for easy access to valves and other piping accessories required for
operation and maintenance.
k) Overhead piping shall have a minimum vertical clearance of 2.3 meters above walkways
and working areas and 8.0 meters above roadways.
l) Drains shall be provided, at all low points and vents at all high points as per actual layout.
Pipelines shall be sloped towards the drain points.
m) All pipe racks shall be provided with walkways of 750 mm wide.
n) All pipe bends shall have a radius of five nominal pipe diameter unless otherwise specified
by the Owner / Engineer.
3.2.13 Coal, Oil and Gas Burners

ETRM012-1-M-TS-001
a) Replacement of existing multi fuel (Coal, oil & gas) separate /coaxial burners with modified
wall mounted low NOX coaxial/separate coal and gas (BF & CO) swirl burners with special
long lasting burner tips
b) Provision for new multi fuel scanner and igniters (High Energy Arc Igniter). Direct firing is
possible with furnace oil. (Complete replacement of burner panel for accommodating the
new burner, new igniters, new scanners) .
c) Replacement of oil gun as per O&M and the requirement of new modified ignition systems
d) Provision for new secondary and fuel dampers with separate operational system to have
flame optimization and combustion control to meet the variation in coal quality
e) Provision for nitrogen purging at suitable location is to be considered.

A. Coal Burners
a) Existing coal burners shall be replaced with new coal burners suiting the coal demand of
the modified furnace design. The new coal burner shall be designed to take care of
following requirements:
i. The minimum turndown ratio of coal firing system shall be 2:1.
ii.The coal burner design shall ensure a steady log mean density of coal air mixture
distribution as it enters the combustion zone, without allowing the coal dust to settle
down.
iii. The burner design shall minimize erosion and the flame should not touch the water
walls.
iv. The burners shall be designed to ensure smooth variation in the fuel flow without
affecting the air fuel ratio.
v. The air fuel ratio around the burner shall be optimized to ensure low emission of NOx.
vi. The NOx emission under various conditions & regime of operation shall at no time
exceeds the permissible.
b) Each coal burner shall be served by individual separate coal pipe. The material and
construction of burner including burner tips should withstand radiation from the furnace
when not in use, and shall not be damaged. Parts subjected to high temperature which
cannot be protected by other means shall be made of alloy steel. The burner design shall
be such as to be free from distortion & deposits under all operating condition in the furnace.
The angle of confluence between the coal burner primary air and secondary air shall be
such that the inherent carbon monoxide produced is removed by scrubbing action without
any significant reduction in velocities of the air stream.
c) Burners parts subject to abrasion shall be coated with suitable coating / lining for erosion
resistant (preferably ceramic). The minimum operating life of burner parts without any major
maintenance and replacement shall be 16000 hrs.
d) Burner shall be removable or replaceable from outside the steam generator without entry to
the furnace.
B. Gas Burners
The bidder is required to supply gas burners capable to fire both BF and CO gas. The new gas
burner shall be designed to take care of following requirements:
a) The burner shall be designed to cater to 50% BMCR condition and shall also be capable
for being fired along with coal burners. Each BF and CO gas burner shall be capable for
burning minimum quantity of each gas as per existing capacity (Clause 2.5, Page no. 15
of 120).
b) The burner should be designed for handling large gas volume and create adequate
turbulence for effective air/fuel mixing.
c) Suitability of all burner components for above-mentioned area and ambient conditions.
d) Availability of Burner shall be min. 98 %
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e) The firing scheme shall incorporate automatic purge interlock to facilitate restarting after
such conditions. Automatic ignition system to initiate the flame in the furnace shall be
included. However facility for the manual operations shall also be provided. Ignition
system shall be complete with igniters suitable for ignition of fuel directly. Necessary
piping, valves, control and instrumentation and all other equipment necessary for the
completeness of this system shall be provided.
f) The system shall be designed for burning gas even when the furnace is under cold
condition (i.e., capable of cold start up with gas).
g) Gas and air piping should be located reasonably close to the burner and sized for the
pressure and volume requirements of the burner, with supply pressures high enough to
permit subsequent regulation at each burner. Gas piping drops should not exceed 10% of
initial supply pressure.
h) Each branch of gas burners shall have one isolating valve as per NFPA requirement for
the isolation of a branch from rest of the branches. One manual isolation valve shall be
provided on both CO and BF Gas lines to isolate all burners. Bidder to confirm boiler can
be operated with one branch isolation. These Valves shall be arranged based on the
feasibility in the layout.
i) Minimum velocity of gas should be 12 m/s for BFG/CO gas shall be maintained to avoid
settling of tar and dust at lower velocity which can create problems of chocking in nozzles.
j) The turndown ratio should be about 6:1
k) The air fuel ratios around burners shall ensure low NOx emission at all load condition.
l) The burner design should be such that the excess air requirement should be within the
range of 7% to 10% depending upon the furnace configuration, combustion air
temperature and operating load.
m) The safety shutoff valve ahead of the flow control station and individual
burner/Nozzle/Spud shutoff and vent valves shall be furnished with motorized drives.
Block and Bleed valves shall be provided on BFG & CO Gas as per the NFPA
requirements.
n) All flanges shall be in accordance to ASME B16.5.
o) Block & bleed valves, purge valves shall be mounted in series and installed near each
burner/ nozzle/spuds.
p) The burner should have Fixed/ Adjustable Gas spuds with stabilizers, connected to a
common ring header
q) A vent valve shall be connected to the intermediate pipe piece between two block valves.
The discharge pipe from the vent valve shall be led to a safe location above steam
generator roof. The vent valve shall open to atmosphere simultaneously with the tripping
of the burner shutoff valves and vent valves shall be supervised by the BMS logic.
r) The burners should have in built observation ports to provide visual access to the flame.
The observation ports should be protected by temperature resistance glass.
s) The burners shall be provided with their separate flame sensing devices so that the
admission of fuel may be automatically shut off and gun withdrawn in case of flame
failure. The flame sensing devices shall be self-contained and shall be unaffected by dirt,
oil film and ambient conditions.
t) The burners should have in built igniters. The electrode material should be of non
consumable type and capable to withstand radiation from the flame without retraction
while the burner is firing.
u) Automatic and manual Shut off valves for gas atomizing and clearing media
v) The burner should have fuel flow control valves and flow meters.
w) The burner should have flexible hose piping for easy connectivity.
x) The burner should have proven combustion control system with control of fuel air and
secondary air control to maintain proper fuel ratio in combustion zone.
y) All valves, joints in the pipelines etc. shall be completely 100% leak proof.
z) Nitrogen purging system shall be provided for the burners to clean and purge the burners.
The Nitrogen purging shall be after the block and bleed valve of individual
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burner/nozzle/spud as per the manufacturers practice. Hard deposits of tar shall be

removed during the annual / regular maintenance of the boiler. However provision shall
be made in burner for easy removal of spuds during maintenance.
aa) The design criteria for the equipments in and around the BFG, Coke oven Gas shall follow
the Hazardous area classification as mentioned below.
i. For BFG area Class – I, Zone – II, Group – II A, T2 to the extent of IS – 5572.
ii. For Coke Oven Gas it is Class – I (Group C), Division 2, Zone – II, Group – II B T2 to
the extent of IS – 5572.
bb) The burners shall be remotely operated and the entire operation of initial purging and fuel
gas/fuel oil firing shall be automatic after the initial command. Adequate number of
position indicating contacts for integration into BMS logic shall be provided.
3.2.14 Ducts, Dampers & Actuators

Secondary air ducting including dampers and expansion joints within the specified terminal points
is within the bidder’s scope of work. The list of actuators required for the duct outside the
specified terminal points along with the type is furnished in the amended Annexure – II of C&I
which has to be procured by the bidder and installed in the ducts outside the specified terminal
point.
Except to the extent specified above, all other air and flue gas ducting and expansion bellows
scope of work has been covered in Annexure – III: Overhauling scope of the technical
specification (item no. 4 & 8)

Replacement of Dampers & Actuators
Need based repair/ replacement of the existing Dampers & Actuators to be carried out as per the
technical requirements stipulated in the following clauses:
a) Bidder shall furnish a list of all dampers, their purpose and torque rating etc. together with
the details of actuators and accessories for control from PLC system. Powered dampers
shall also have provisions for manual operation during emergency/ maintenance along with
graduated local position indicator.
b) The dampers shall be of heavy-duty construction. All dampers/louvers shafts shall be rigidly
constructed to prevent bending, vibrations and distortion. They shall be balanced about the
bearing shaft axis.
c) The frames of the dampers shall be rigid and self supported. The control dampers and
isolation dampers shall be electrically operated.
d) All dampers shall be designed to withstand the operating air and flue gas temperature
without distortion. The spindles shall be adequately sized and bearings suitably insulated to
protect over-heating. The construction shall be such that the shaft bearings are mounted
outside the damper box channel and arranged for convenient inspection.
e) Stuffing boxes shall be provided on all damper blade shafts.
f) The isolating damper design shall provide positive shutoff when closed.
g) All regulating dampers controls coming under auto regulation shall be able to provide the
desired relationship between percentage opening and the flow.
h) The auto regulating dampers shall be capable of being operated between 20% to 80%
opening as per the optimal requirements of control systems to achieve stable, steady and
smooth automatic control of the plant and processes under all operating conditions.
i) All dampers shall be arranged to facilitate local manual operation from a gallery or floor level.
The operating gear shall be fitted with a graduated indicator and shall be designed such that
the damper may be retained in any position. The isolating dampers shall, in addition be fitted
with locking devices to permit locking in the fully open and shut positions.
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j) Backlash, play, etc. with linkage mechanism, actuator and final control element shall not
affect the proper function of all shut off &regulating dampers.
k) Thermal expansion of ducting shall not produce stress in louvers, linkage arrangement etc.
l) Outlet dampers of scanner air fans and emergency dampers of scanner air shall be dead
weight gravity type.
m) All the inlet dampers shall be located in horizontal duct.
3.2.14.3 Replacement of Metallic (SS) Expansion Joints

Replacement of metallic expansion joints with new metallic expansion joints within the new
terminal points of R&M. Out of this scope, compensator will be provided by the owner.
Need based repair/ replacement of the existing expansions joint shall be carried out conforming
to the following stipulations:
a) The expansion joints shall be of metallic multi-bellows construction and shall be used to
reduce the reactions (forces and moments) at the connected equipment terminals due to
thermal expansion/connection and/or vibration of connected equipment and piping.
b) The design, material, construction, manufacture, inspection, testing and performance of the
expansion joints shall comply with the currently applicable requirement of EJMA, Boiler and
Pressure Vessel Code Section III, ANSI B-31.1 and all statutes, regulations and safety
codes.
c) Expansion joints suitable for the service conditions and most adverse operating conditions of
the ductwork shall be provided.
d) Expansion joints shall not support the ductwork.
e) For the flue gas ducts or for air ducts where ingress of ash / dust particles from atmosphere
or air preheaters etc. is expected, the expansion joints shall be designed with suitable
insulation pillow / bolsters to take care and avoid dust accumulation.
f) The minimum trouble free operational life of expansion joint shall not be less than 20000 hrs
of operation from the date of commissioning.
3.2.14.4 Technical requirement for Ducts

a) The ducting system shall be complete with all required expansion joints, mating flanges,
dampers (interconnecting, isolating and control dampers), supports, access doors, platforms
insulation’s etc. The top of the ducts and /or the outer cladding shall be cambered to facilitate
drainage of water.
b) The duct work shall be free to expand, but it shall be rigid against wind and seismic
disturbances. Adequate provision shall be made for all expected expansion or contraction.
c) All ducts shall be rectangular in cross section and will be of welded construction, properly
stiffened and reinforced.
d) Access and inspection doors shall be provided at suitable locations. The access doors shall
be of a minimum size of 450 mm x 450 mm.
e) Necessary regulating and isolating dampers at suitable points are to be provided for the
efficient operation and maintenance of the steam generator. All the dampers shall have an
effective area not less than that specified for the ducts they control.
f) Isolation dampers should be of guillotine type flow control damper shall be of ‘louver’ or
butterfly type with the necessary frames, shafts, blades, bearings, linkages, seals, etc.
g) All air and flue gas ducting shall be leak proof to avoid pressure losses and atmospheric air
entry etc.
h) All supporting steel work hangers, thrust brackets and castings for the ducts shall be
provided.
i) Performance guarantee (PG) test points at APH inlet and outlet and FD fan outlet duct to be
provided at suitable location.
j) Acoustic insulation if required shall be used on air and gas ducts to restrict the noise level to
less than 85 dBA at 1.0 m from duct outline.
ETRM012-1-M-TS-001
Type of duct construction:

The ducts shall be of rectangular cross-section and shall be of all welded construction. Circular
ducts are not acceptable. Following requirements shall be complied with:
a) 6 mm thick steel plates for gas ducts.

b) 5 mm thick steel plates for air ducts.
c) A corrosion allowance of 1.5 mm shall be considered for stress calculation for the flue gas
ducting.
d) Duct stiffening shall be by means of rolled sections.
e) The thickness of the duct plate shall be suitably increased, if required, in the transition zone
at Steam Generator outlet where the flue gases change direction, to increase the wear life of
the duct plates.
Material of Construction:
a) Duct plates, turning vanes : ASTM A 36 or equivalent (For ducts operating above
perforated plates. 400°C gas temperature, suitable Alloy steel material
shall be provided to Purchaser's approval).
b) Structural shapes : ASTM A 36 or equivalent
c) Pipe struts, trusses, bracing : ASTM A 53 or equivalent seamless steel pipe.
d) Erection bolts for ducts : ASTM A 307 or equivalent
e) Bolts for connection to structural : ASTM A 325, AISIA 325 (friction type) or equivalent
steel
f) Stainless Steel : ASTM A 316 L
g) Gaskets : "Relrosil" by Hitco or equivalent
h) Access & Inspection doors : Reinforced Steel Plates.
3.2.15 Boiler Structural Columns, Floor grills, platforms, railings etc.

Bidder to quote for only 200MT of structural steel as the same is only available for the repair/
replacement of boiler structural columns, floor grills, steps & hand rails, and other exposed
metallic parts vulnerable to corrosion in the scope of this specification. However, unit rate shall be
given for requirement of the additional quantity.
3.2.15.2 Technical requirements for boiler structural columns

a) Columns shall be designed to support the load combination, which produces the maximum
interaction ratio. Exterior columns shall be designed to resist wind moments between braced
elevation as appropriate. Columns shall also be designed to resist moments caused by
discontinuous vertical bracing or non-concentric bracing work points.
b) Main structural elements will be welded continuously. Intermittent welds will be used only on
secondary members, which are not exposed to weather or other corrosive influence. The
size of fillet welds will not be less than 6mm.
c) Connection and splices will be made by welding or bolting with high tensile turned and fitted
bolts. For bolted joints, min. two bolts will be used.
d) Fabrication of all structural steel work shall be done in accordance with IS: 800 "Code of
practice for use of Structural Steel in General Building Construction". Workmanship shall
match to the best practice in modern structural shops.
e) All steel and other materials used for steelwork and in association with steelwork will conform
to appropriate Indian standards.
f) The Bidder will be responsible for the design and the detailing of all connections. The design
of connections will provide for adequate strength for the transfer of force in the structural
elements indicated on the design drawings. For purposes of detailing of connections, the
ETRM012-1-M-TS-001
allowable stresses in material, bolts and welds will be as per IS: 800 and IS: 816 or as
specified in the design drawings.
g) For all full strength butt welding of plates and sections thicker than or equal to 10mm, edge
preparation will be done and got approved by the Owner / Consultant.
h) Two numbers of washers will be used for all bolted connections, one washer bearing against
the head and other bearing against the nut.
i) The welding and welded work will conform to IS: 816 and other relevant codes unless
otherwise specified. Electrodes will conform to IS: 814 and will be approved by the Owner /
consultant.
j) Welding will be done by Electrical Arc Process. Automatic welding will be employed for
important structures as specified in the drawings. Generally, submerged arc, Automatic &
Semi-automatic welding will be employed. Only where it is not practicable, Manual Arc
welding may be resorted to. In case of Manual Arc Welding, recommendations of electrode
manufacturer are to be strictly followed.
k) Only qualified welders suitable for the job will be employed. The Owner/ consultant at his
discretion can order periodic tests in accordance with IS:817 of the welders and/ or of the
welds produced by them at no extra cost. Welds will be made using requisite jigs and fixtures
to avoid distortions or damage to members during/ after welding. Welds on exposed work will
be finished uniformly smooth to present a neat appearance.
l) All electrodes for use in the work to which the specification relates will be kept under dry
conditions. Electrodes which are damaged by moisture will not be used unless it is certified
by the manufacturer that when it is properly dried there will be no detrimental effect. Any
electrode which has part of its flux coating broken away or is otherwise damaged will be
discarded.
m) The Bidder will prepare the edges with an automatically controlled flame cutting torch
followed by grinding correctly to the shape, size and dimensions of the groove, prescribed in
the design and shop drawings in case of U-groove joint, the edges will be prepared with an
automatic flame cutting torch in two passes following a bevel cut with a gouging pass, or by
machining.
n) The welding surfaces will be smooth, uniform and free from fins, tears, notches or any other
defect, which may adversely affect welding. Welding surfaces or the surrounding surfaces
within 50mm of weld will be free from loose scale, slag, rust, grease, paint, moisture or any
other foreign material. Pre-bending of plates for three plate welded sections will be done
where found necessary.
o) After completing each run of weld, all slag will be thoroughly removed, and the surface
cleaned before starting the next run of weld. The weld metal, as deposited (including tack
welds if to be incorporated) will be free from cracks, slag, inclusions, gross porosity, cavities
and other deposition faults. The weld metal will be properly fused with the parent metal
without serious undercutting or overlapping at the toes of the weld. The surfaces of the weld
will have a uniform and consistence contour and uniform appearance.
p) All weld runs found defective will be cut by using chipping hammer, gouging torch, or suitable
grinding wheel in such a manner that adjacent material is not injured in any way. Peeling of
the welds involving deformation of the weld surface either during de slagging or thereafter
will not be allowed.
q) All welds will be 100% visually inspected to check the following:
i. Presence of undercuts
ii. Visually identifiable surface cracks in both welds and base metals.
iii. Unfilled craters
iv. Improper weld profile and size
v. Excessive reinforcement in weld
vi. Surface porosity
r) Before inspection, the surface of weld metal will be cleaned of all slag, spatter matter; scales
etc. by using wire brush or chisel.
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s) All the required NDT tests (like Dye Penetrant test, Ultrasonic test, Radiography test, etc…)
shall be performed on all the weld joints as per relevant codes and standards after the
completion of visual inspection of the weld joints.
3.2.15.3 Technical requirement for Staging, Galleries and Ladders

a) The civil works including preparation of finished floor, foundations and all required structures,
supports, ladders, etc. are in Bidder’s scope.
b) The required structural columns, frame for the economizer, air pre-heater ducting and piping
equipment, stair cases to steam generator drum level, soot blower locations, access
openings shall be provided with liberally sized stairs, handrails and walkways.
c) The steam generator and its accessories will be provided with steel supporting structure
made from rolled steel sections, having adequate strength for the loads imposed by the
steam generator and associated equipment.
d) All gangways, passages, stair cases / ladders, working platforms and railing shall be
provided. A clear working platform of minimum 2000 mm to be provided for the steam
generator at all levels. All statutory requirements regarding staging, platform/stair cases etc.
should be observed.
e) Two staircases on either side of the steam drum to be provided with suitable platform on the
drum.
3.2.15.4 Technical requirement for Platforms and Walkways

a) Arrangement of platforms, walkways and landings shall provide safe access to all openings
for inspection and cleaning purposes, permanent and test measuring points, control devices,
local instruments, vents and drain valves, soot blowers, safety valves etc.
b) Platforms, walkways and stair cases shall be supported from unheated structures of steam
generator or building and shall never be supported from pressure parts or other moving parts
of the steam generator.
c) Platforms & walkway panels and stair treads shall be made of structural steel open bar
gratings.
d) Minimum width of platforms and walkways shall be 1000 mm.
e) Minimum headroom above the top of platform or walkways should be 2200 mm.
f) Members supporting floor panel shall not deflect by more than 1/325 of the span.
3.2.15.5 Technical requirement for Stairs and Ladders

Scope of work related to existing staircase, ladders and handrails is not included in R&M scope.
However, bidder needs to ensure any additional approach point and platforms necessary in line
to the proposal is under the scope of the bidder.
3.2.15.6 Technical requirement for Grating For Platforms, Walkways And Stair Treads
a) Gratings shall be of structural steel with a minimum depth of 25mm and a minimum width of
750mm and shall conform to BS4952 Part I.
b) Minimum thickness of load bearing and spare bars shall be 3mm. Thickness of other binding
bars shall be minimum 6mm.
c) Clear distance between the load bearing bars shall not exceed 40 mm. for diamond pattern
and 30mm for rectangular pattern.
d) The deflection of grating panel shall not exceed span/200 or 10mm whichever is smaller.
3.2.15.7 Technical requirement for Handrails

a) Top rail, knee rail and vertical post shall be 32mm NB (medium) tube conforming to IS: 1239.
b) The spacing of vertical post shall not exceed 2.5 meters.
c) The height of handrail shall be 2.5 meter with rail at mid height.
d) At platform and landings toe guard of 100 x 5mm shall be provided.
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3.2.16 Fans
3.2.16.1 Scanner Fans (2nos each / unit)
Two numbers each of scanner air fans of suitable capacity for each unit is to be supplied along
with ducting and civil foundation (if any) is in the scope of the bidder.
a) Two (2) 100%, one AC motor driven and the other DC motor driven scanner air fans shall
also be provided for the flame scanner cooling. Power source shall be provided by owner,
however DC Starter panel shall be provided by contractor.
b) The fan shall be horizontal, radial and with backward curved blades.
c) The fan shaft shall be of simply supported directly driven design
d) Isolation dampers to be provided at fan discharge.
e) The direction of rotation of all the similar fans shall be same.
f) The rotor of the fans shall be dynamically balanced and tested for its parameters at the
works and test certificate and inspection certificate to be provided by the contractor. The
rotor shall be dynamically re-balanced at site if the vibration levels, are found unacceptable.
3.2.16.2 Performance Requirements for Fans

a) All equipment and their accessories shall perform continuously with the levels of noise and
vibration as specified below:
b) All equipment shall provide acceptable and not excessive back ground acoustical level.
Measured noise level produced by any rotating equipment or a group of equipment closely
located shall not exceed 85 db (A) at a distance of 1 m from it in any direction.
c) Vibration isolation of proven design shall be supplied by the contractor for preventing
transmission of vibration from the equipment to other neighboring equipment and structures
for all fans.
3.2.17 Fuel Oil System

Fuel oil system should be compatible with the new PLC based system and new burner system.
Repair / Replacement of oil gun during R & M and the requirement of new modified ignition
systems for both coal and gas burners.
In case of replacement, the new oil burners shall be wide range air/ steam atomized type (as per
site conditions) having turn down ratio 4:1 for each. This condition is stipulated to achieve
minimum oil consumption for flame stabilization. The oil burners shall be complete with tips,
extension pipes, burner shut-off valve, flexible hoses and accessories.
3.2.18 Boiler Blowdown system

Two (2) blow down tanks (i.e. One (1) continuous blowdown tank (CBD) and one (1) intermittent
blowdown tank (IBD)) for each boiler with all necessary drains, spray lines, overflow lines and
vent pipes along with drip tray, pipes, valves & fittings as required shall be provided. The vent
pipes of the blow down tank shall be extended up to the roof of the Power House building & led
up to such locations (terminated 3 meters (Min.) above the SG roof) where the vented out steam
cannot interfere with the operation of any other equipment or movement of personnel. All drains
to be terminated at one single point near boiler. Necessary civil foundation for erection of the
tanks shall be in the scope of the bidder.
ETRM012-1-M-TS-001
There shall be two blow down tanks for each steam generator, one intermittent Blow Down (IBD)
tank and other Continuous Blow Down (CBD) Tank. The Intermittent Blow down tank shall be
sized to receive following:
i) All blow down and drains from Steam Generator.
ii) Drains from water wall headers, attemperators headers, CBD tank.
iii) Alternate drains from main steam lines
iv) Any other drains from High Pressure piping.
The Continuous Blow Down (CBD) tank shall receive the continuous blow down from the steam
generator drum. CBD system shall be designed for a blow down capacity of 10m3.
Maximum blow down is expected to be 5% of BMCR. Facility for complete bypass of CBD tank
shall also be provided.
IBD & CBD tanks shall be located at ground level near Steam Generator.
Tank design shall not allow discharge of any free water from vent.
The size of vent pipe shall ensure no pressurization of Blow down Tank.
The steam from the intermittent and the continuous blow down tank shall be vented out to the
atmosphere and the drain shall be connected to the sewage after the same has been cooled by
the cooling water. Necessary cooling system for this shall also be furnished. Suitable
arrangements to prevent overflow in this tank shall be furnished. The valve in the blow down line
shall be power operated and regulating type, having an isolating valve on either side of which
upstream side valve shall be motorized. The water level control station shall be complete with the
control valves, isolating valves, bypass valves.
Tank shall be designed and fabricated as per requirements of IS: 2825/BS: 806.
Provide wear plates in the tank to prevent erosion due to high pressure/velocity drains. All drain
connection to the Tank to be tangential.
Provide mating flanges for level switches and other instruments.
Provide drain valves and drain piping at the bottom of the tank. All drain from tank shall be cooled
to ambient temperature.
Provide manholes with bolted doors on tank.
3.2.19 Insulation & Refractory

The existing insulation, cladding and refractories of all the equipments in the Boiler scope shall be
completely replaced with new material. The new insulation cladding and refractory shall be
supplied and installed such that the skin casing temperature of any surface within the terminal
points is not more than 60°C with ambient temperature of 50°C, surface air velocity of 0.25
meter/second, emissivity of aluminium cladding as 0.2 and the boiler operating at 100% BMCR.
Refractory provided in the burner opening, peephole, manhole, wall blowers openings, furnace
bottom ash hopper also need replacement. The refractory in furnace second pass needs to be
replaced.
Modified spring type sealing arrangement with better refractory system having plastic refractory
material to avoid ash ingress is to be provided in to the pent house.
ETRM012-1-M-TS-001
Thermal Insulation, Cladding and Refractory
General
The complete existing insulation, cladding and refractory on the boiler, ducting, critical piping,
regenerative vessels and any other surfaces within this specification scope shall be totally
replaced by the new refractory, insulation and aluminium cladding. The material for refractory and
thermal insulation of the equipments, covered in this specification shall confirm to relevant Indian
Standards unless otherwise specified. It shall also comply with all currently applicable statutes,
regulations, and safety codes of the locality in which it is to be applied.
All the insulation material permanent or removable shall be designed for useful life of fifteen (15)
years.
Mechanical integrity shall not be affected by vibrations of the equipment on which it is applied.
Design Criteria
The insulation thickness furnished shall be based on the following design condition (in Table-
3.5).
Table-3.5: Design Criteria for Insulation

S.N. Criteria Design Condition
1 Ambient Temperature 50°C
2 Surface velocity 0.25 m/sec
3 Emissivity of Aluminium 0.2
4 Insulation surface temperature ambient +10 (max)
5 Thermal conductivity Not less than maximum values as per IS :
8183
6 Pipe/Equipment / boiler wall temperature Max. fluid design Temp
7 Overall heat transfer coefficient & insulation To be calculated as per relevant codes and
thickness standards ASTM-C-680-89
The minimum insulation thickness, however, shall not be less than 75 mm for steam generator
surfaces and 25 mm for other surfaces.
Codes & Standards

Material and application of insulation material, protective cladding, wire mesh etc. shall be
confirming to latest edition of following Codes:
a) IS: 8183
b) IS: 3677
c) IS: 3144
d) IS: 14164
e) IS: 280
f) ASTM-B 209
Insulation Material
Material
Insulation material for all equipment, ducting etc. shall conform to following requirements
Parameters Requirement
i. Material a) Lightly resin bonded mineral wool with low halogen
ETRM012-1-M-TS-001
Parameters Requirement
content of Best grade conforming to IS: 8183 (Handmade
mattresses are not acceptable)
b) Material shall be rock wool only. Slag wool shall not be
accepted.
ii. Bulk density of lightly resin a) For use up to 400°C - 100 kg/m3
bonded mineral wool b) For use above 400°C - 150 kg/m3
mattresses
Physical Requirements
Following criteria shall be met by testing as per relevant clauses of IS: 3144.
a) Shot content: 5% by weight (max.) size of any shot not to exceed 5 mm.
b) Bulk Density: To comply with (i) & (ii) of Codes & Standards given above.
c) Weight gain by moisture absorption: 2% (max.)
d) Sulphur Content: Not exceeding 0.6%
e) Alkalinity as percentage of Na2O: Not exceeding 0.6%
f) Maximum oil content: Not exceeding 0.3% by weight.
g) Total Carbon content: Not exceeding 0.3% by weight
h) Settlement: Nil (when tested as per Cl. 22.0 of IS 3144)
i) Hand ability: Full hand able without any lump formation and disintegration of material
j) Loss by weight after combustibility test: Not exceeding 5% by weight.
The insulation mattress shall be incombustible when tested by the method prescribed in clause
15 of IS: 3144 and shall meet the requirement of the mercantile marine department, Lloyd’s
register of Shipping, underwriter, fire hazard codes and other international standards.
In addition to above requirements, insulation material (and protective covering) shall:
Be fresh incombustible, rust proof, non hygroscopic,

a) Be capable of withstanding continuously and without deterioration the maximum temperature
to which they will be subjected.
b) Not to react chemically, either to itself or with other components.
c) Not sustain any fungi or vermin and must not pose health hazards.
The mineral wool shall

a) Pass, standard combustibility test both immediately after application and after subjected to
maximum operating temperature for not less than 100 hrs.
b) Not to suffer permanent deterioration as a result of contact with moisture due to
condensation and shall be free from objectionable odour.
c) Not to cause corrosion of the surface being insulated or of cladding on it under normal site
conditions.
d) Not to suffer any quality deterioration under specified service conditions (both cold/hot face
temp.) of use.
e) The use of finishing materials containing asbestos in any form for insulation is not permitted.
f) Insulation mattress/section shall be supplied in thickness of 25, 40, 50 and 75 mm. Insulation
of higher thickness shall be made up in multiple layers using mattress/slabs of thickness
specified above. However, if the required thickness is such that by using above
mattress/slabs the calculated thickness is not achieved, the mattress/slabs in increment of
25 mm shall be acceptable for outer layers. The min. thickness however, shall not be less
than 25 mm and number of layers shall be minimum and innermost layer shall be thickest.
Sheeting Material
ETRM012-1-M-TS-001
The Sheeting material for all insulated surfaces, equipment and piping as defined shall be
aluminium, conforming to ASTM A-209-1060 temper H-14. or IS: 737. The thickness of aluminium
sheeting to be used shall be as follows
Table-3.6: Sheeting Material thinness

S.No Particulars With Lightly bonded With pre formed pipe
mattress
a For dia of insulated surface of 450 mm & 16 SWG —
above and for flat surfaces
b For dia of insulated surfaces less than 0.941 mm (20 SWG) 0.941 mm (20 SWG)
450 mm
c For Steam Generator outer casing 16 SWG - Ribbed
aluminium
Binding and lacing Wires

Binding and lacing wires shall be provided in line with following Table-3.7.
Table-3.7: Binding and Lacing Wires

S No Temperature range °C Material Thickness of wire
A Up to 400 Galvanized Steel 20 SWG
B Above 400 Stainless steel 20 SWG
Straps
Straps shall confirm to material given in the following Table-3.8.
Table-3.8: Straps
S No Temperature range °C Material
a Up to 400 Galvanized Steel
b Above 400 Stainless Steel
1. Straps shall be 20 mm wide and 0.6 mm thick

2. For securing Aluminium sheeting material, stainless steel or anodized aluminium bends shall
be used.
3. Screws shall be Galvanized steel, check headed, self tapping type.
Hexagonal wire Mesh

Hexagonal wire mesh shall be conforming to following details given below:
Table-3.9: Hexagonal Mesh

S No Temperature range °C Material Size
a Up to 400 Galvanized Steel 10-13mm aperture and wire size
min. 0.71 mm
b Above 400 Stainless steel 20 SWG
Non-metallic components like 3 mm thick millboard, aluminium pigment sealant, white glass cloth,
insulating cement, neoprene washer shall be provided.
Application of Insulation
General
ETRM012-1-M-TS-001
a) All surfaces to be insulated shall be cleaned of all foreign materials such as dirt, grease, rust
etc. and shall be dry before the application of insulation.
b) Before applying the insulation the contractor shall check that all instrument tapping, clamps,
lugs and other connections on the surface to be insulated have been properly installed as
per the relevant erection drawing.
c) All flanged joints shall be insulated only after the final tightening and testing.
d) The insulation shall be applied to all surfaces when they are at ambient temp. Ample
provision shall be made for the maximum possible thermal expansion and the insulation shall
be applied to avoid breaking/telescoping due to alternate periods of expansion and
contraction.
e) All cracks voids and depressions shall be filled with finishing cement, suitable for the
equipment-operating temperature so as to form a smooth base for the application of
cladding.
Application of Insulation on Piping

a) All vertical pipes shall be provided with the suitable insulation supports to prevent
collapsing/crushing of insulation due to its self-weight. Support rings shall be provided on all
vertical piping with a difference in elevation of 4 meter or above, and there shall not be more
than 3 m straight length between support rings.
b) Longitudinal joints of insulation mattress sections of horizontal piping shall be on the bottom
or at the sides of the pipe.
c) When more than one layer of insulation mattress/section is required on piping the
circumferential joints on adjacent layers shall be staggered by at least 150 mm and
longitudinal joints shall be staggered by at least 50 mm.
d) The mattress type insulation shall be formed to fit the pipe and applied with the mattress
edges drawn together at the longitudinal joints and secured by lacing wire. Pipe section
insulation shall be fitted on pipe using binding wires.
e) Where insulation is applied in two or more layers each layer of mattress shall be backed with
hexagonal wire mesh. For the first layer of insulation and in case of single layer insulation,
hexagonal wire mesh shall be provided on both the surface of the mattress.
f) The ends of all wire loops shall be firmly twisted together with pliers, bent over and carefully
pressed into the surface of the insulation. Any gap in the insulation shall be filled with loose
mineral wool or finishing cement.
g) Insulation mattress/section ends shall be terminated at a sufficient distance from the flanges
to facilitate removal of bolts.
h) The insulation shall be held in place by fastening over with binding wire for insulation surface
with diameter up to and including 550 mm and with metal bends for insulation surfaces with
diameter over 550 mm. The fastening shall be done at intervals of not more than 250 mm
except where specified otherwise. The ends of the binding wires shall be hooked and
embedded in the insulation. The straps shall be mechanically stretched and fastened with
metallic clamping seals of the same materials as the strap.
i) Insulation for application on bends and elbows shall be cut into mitred segments, sufficiently
short to form a reasonably smooth internal surface. After the application of insulation material
place, insulating cement shall be applied as required to obtain a smooth surface.
j) Weather hoods shall be provided for insulated piping passing through floors/walls.
k) All pipe attachments coming on horizontal pipes, inclined pipes and bends shall be insulated
along with pipe such that there will be no insulation applied to hanger rod and the component
connecting hanger rod to pipe attachment. All pipe attachments exposed to weather shall be
provided with weatherproof covering.
l) Upstream of all drain lines and the lines connected to steam traps, shall be insulated up to
and including first isolating valve for heat conservation. Rest of such lines such as
downstream of the drain valves, traps etc. and other lines such as safety valve discharges,
vents, etc. shall be insulated for personnel protection.
ETRM012-1-M-TS-001
Application of Insulation on Valves & Fittings

a) All valves fittings and specialties shall be insulated with the same type and thickness of
insulation as specified for the connected piping with the special provisions or exceptions as
given below.
b) All valves and flanges shall be provided with removable box type of insulation covered with
box fabricated from aluminium sheets of thickness same as the connected pipe cladding.
Adjoining pipe insulation shall be bevelled back to permit removal bolts and nuts. The portion
of the valve which cannot be covered by box type insulation shall be filled by loose insulating
material of packing density at least equal to that of the insulating material of adjoining pipe.
The insulation for valves/flanges shall be applied after the finishing has been applied over
the connected piping. The cladding shall be applied in such a manner that the bonnet flange
can be exposed easily without disturbing the complete insulation and cladding.
c) Flanges on lines having temperature up to and including 150 deg.C shall not be insulated.
d) Union shall not be insulated.
e) Expansion joints, metallic or rubber, shall not be insulated unless otherwise specifically
indicated.
f) Safety valves shall be insulated.
Application of Insulation on Steam Generator and other flat surfaces and equipments
Insulation to various areas shall be applied as under.
S.N. Insulation Area Form of Insulation

(a) SG surfaces, hot air and flue gas ducts Mineral wool block or Mineral wool
blankets
(b) All other surfaces (not enclosed by boiler casing Calcium silicate block or as per (a)
above
Application of Insulation on Furnace

For the steam generator furnace, if provided with skin casing and the super heater, and
economizer casings where cold-water wall are involved, a first covering of refractory material
shall be applied to the external tube surface before the application of any further heat resistant
insulating material.
Application of Insulation on Doors

The access doors and inspection doors in the boiler shall be lined with refractory material. The
access doors in other portions of the steam generator e.g. pent house shall be insulated in a
similar manner corresponding to any casing, flue-ducts or air ducts where such openings and
access doors occur.
Mineral wool Blanket Insulation

a) Provide expanded metal or hexagonal wire mesh on both sides for single layer mattress and
on first layer in case of multi-layer insulation, Subsequent layers of multi-layer insulation to
have only one side wire netting.
b) The edges of adjacent blanket to be laced together, by appropriate lacing wire.
c) Any gap between joints between insulation layers shall be filled by loose mineral wool
confirming to IS: 3677.
d) All insulation to be secured by 1.63 mm dia wire netting over blankets with ends of wire
tightly twisted, and pressed in to insulation surface.
e) Impelling pins shall be placed on centers not exceeding 300 mm.
Air & Flue Gas Ducts
ETRM012-1-M-TS-001
Air & Flue Gas ducts with external stiffeners shall have first layer of insulation between the
stiffeners and a second layer of insulation over stiffeners so that stiffeners are also insulated and
a level surface is achieved
Application of Metal Cladding

a) All insulated surface of steam generator, air heater, air & flue gas ducts, critical pipeline etc.
shall be covered with aluminium cladding of 20 SWG.
b) Weatherproof flushing shall be installed where the panels intersect with columns and at other
similar joints.
c) Removable insulated covers shall be provided over the manholes.
d) Asphalt and craft paper moisture barrier shall be provided to the aluminium cladding for
outdoor application. Such moisture barriers shall be fixed to the inner surface of cladding or
shall be connected to the outside surface of insulation before application of cladding.
e) Cladding on top surface of steam generator and ductwork and equipments shall be suitably
reinforced to prevent damage by personnel walking thereon.
f) All cladding for outdoor application shall be with neoprene washers.
g) All openings and joints in outdoor cladding for piping connections, supports of access shall
be suitably flushed and weather-proofed where such flashings or weather-proofing cannot
effectively control the entry of moisture, then such openings and joints shall be weather-
proofed by application of aluminium pigment sealer.
h) All insulation shall be protected by means of an outer covering of aluminium sheathing. All
insulation/cladding joints shall be sealed and made effectively weather and waterproof. All
flat surfaces shall be given suitable slope to prevent collection of pools of water on the
cladding surface. All sheathing shall be protected internally by the application of two coats of
bitumastic paint.
i) All longitudinal joints shall have a minimum overlap of 50 mm and shall be located at 45
degree or more below the horizontal for horizontal equipment. Joints shall be made with
cheese headed self-tapping galvanized steel screws at 150 mm centers.
j) All circumferential joints shall have a minimum overlap of 100 mm and shall be held in
position by stainless steel or anodized aluminium bands, stretched and clamped.
k) Removable box type cladding for valves and flanges shall be fitted on the connected pipe
cladding, with bands.
l) Aluminium cladding shall not come directly into contact with either the equipment surface or
with the supporting arrangement on the equipment surface. To this end, adequate layers of 3
mm thick ceramic board shall be provided between the cladding and any supporting
arrangement equipment surface, and fitted with self tapping screws/metal bands, as
applicable.
m) For bends, fittings etc. the cladding shall be provided in segments as to ensure a smooth
finish of the cladding.
n) For cladding on vertical pipes/equipment, provision for load take up shall be made at every 2
to 4 meters along pipe/equipment axis.
o) All joints shall be sealed with acrylic emulsion weather barrier.
p) Galvanic corrosion shall be prevented by carefully avoiding permanent contact of aluminium
cladding with copper, copper alloys, tin, lead, nickel or nickel alloys including Monel metal.
Refractory
Material
The refractory material shall comply with relevant Indian Standards. The refractory selected shall
ensure perfect sealing and shall have good thermal cycling properties allowing quick shut/shut
down of steam generators.
The refractors material shall

a) Have high bulk density and minimum moisture content.
b) Be capable of withstanding service temperature of 1700 deg. C
ETRM012-1-M-TS-001
c) Be resistant to slagging products due to coal, and to impurities of oil like V2O5, Fe2O3, K2O2,
Na2O etc. and to erosion due to fly ash.
d) Be chemically inactive towards alkalis, iron, or silica, shall pose no health hazard to working
personnel, and shall not have any explosive properties.
e) Have sufficient strength to withstand forces generated in boiler, without any rupture or
damage.
Application of Refractory
Application of refractory shall be such that:
a) To ensure perfect sealing, easy maintenance, minimum time for application.

b) To ensure minimum number of joints, all the joints to be filled and tightly packed with loose
powder or same material.
ETRM012-1-M-TS-001
4.0 TERMINAL POINTS & EXCLUSIONS
ETRM012-1-M-TS-001
TERMINAL POINTS:
S. No System Description
Steam Generating Units
1. Service Water 1 m away from individual equipment in steam
generator area.
2. Instrument Air and Service Air 1 m away from boiler of Unit – 1 at 8 m level. Bidder
shall provide quantity and quality of the compressed
air to the owner.
3. Cooling Water (CCW) 1 m away from individual equipments in steam
generator area.
4. HP Steam Inlet of MSSV
5. Water Spray Line for Superheater 1 m tapping from feed water line. All valves in the
scope of Steam Generator package.
6. Drains Stub joints from header to blowdown tank.
7. Boiler Blowdown Connection of blowdown pipe on the drum
8. Feed water About 1 m away from the bottom economizer inlet
header at left and right side.
9. Vents At safe elevation (1 m above roof)
10. Coal 10 m from burner inlet.
11. Fuel Oil Outlet flange of the first isolating valve from common
header for main line & first valve from recirculation
header for recirculation line.
12. BF Gas Pipe Outlet flange of the BF Gas line isolating valve of each
burner. Any new gas pipe, valves and dampers
associated with implementation of Gas Firing Controls
and its integration with PLC system is under the scope
of bidder.
13. CO Gas Pipe Tapping point from the common gas header in left and
right side of Furnace first pass. Any new gas pipe,
valves and dampers associated with implementation
of Gas Firing Controls and its integration with PLC
system is under the scope of bidder.
14. Secondary Air Duct Tapping point from the common secondary air header
in left and right side of the furnace first pass. Any new
ducting, dampers, expansion bellows and actuators
and its interfacing with PLC system is under the scope
of bidder.
15. Flue gas ducting Outlet of the first compensator of furnace exit.
16. Atomizing Steam line Outlet flange of the first isolating valve from common
header & first valve from boiler drum for individual line.
17. Gas purging steam line Outlet flange of the first valve from the gas purging
header in both side at burner floor.
EXCLUSIONS:-
Following are excluded from the scope of supply and services.

1. Steam Turbine
ETRM012-1-M-TS-001
2. Generator
3. STG Building
4. Air Pre Heater
5. HP Dosing System
6. Electrostatic Precipitator
7. Coal and Ash Handling Plant
8. Bottom ash handling system
9. Entire Milling system including feeders, cyclone separator, PC bunker, Raw coal Bunkers,
screw feeders, mill fan, etc...
10. FD Fan and ID Fan
11. Boiler Drum and internals
12. All electrical systems other than Scanner Fans (02 nos.) as per Clause no. 3.2.16.1, Page
no. 43 of 116 of Volume – 2, Section – B of Technical Specification and actuators as per list
provided by the owner which will be supplied by the bidder.
13. DCS
14. Water Treatment System
15. Air-conditioning and Ventilation System
16. Ambient Air Quality Monitoring
17. Illumination
18. Above ground and below ground earthing
19. Boiler Elevator
20. Fire fighting system, unless otherwise specifically indicated.
21. Administrative Building
22. Communication system
23. Hydrogen Generation plant
24. Fuel oil Unloading & Forwarding Pumps and Tanks with piping.
25. Auxiliary steam piping
26. Civil works other than Scanner Fans (02 nos.) foundations as per Clause no. 3.2.16.1, Page
43 of 116), Volume – 2, Section – B of Technical Specification and any civil works related to
installation and cabling for new panels in the control room which will be in scope of the
bidder.
ETRM012-1-M-TS-001
5.0 PERFORMANCE ASPECTS
ETRM012-1-M-TS-001
PERFORMANCE ASPECTS
5.1 GENERAL
The term Performance Guarantee wherever appears in the technical specifications shall have the
same meaning and shall be synonymous to “Functional Guarantees”
Volume 2, Sec-A, clause no. 9 “Tests” describes conditions in details for all the tests to be carried
out.
The contractor after completion of the R&M work shall carry out the Trial operation /reliability run
of the unit and after which Performance Guarantee test shall be carried out as per stipulated
conditions herein and Volume 1 clause 9 and 10.
5.2 PERFORMANCE GUARANTEES

In the performance Guarantee test, Contractor has to prove the performance guarantee
parameters within the shortfall limits as specified in the Commercial document.
Liquidated damages to be specified in the Commercial Document.
5.3 GENERAL REQUIREMENTS

The steam generator unit and auxiliaries shall be designed for maximum reliability and
availability, operability and maintainability particularly in respect of the following:
All equipment and systems shall be of proven design, using proven materials with well-
established physical and chemical properties and as appropriate to the service as intended.
The retrofitted steam generator unit and its auxiliaries shall be suitably designed and provided
with required instrumentation for rapid starting, loading and unloading without causing undue
vibration, distortion, differential expansion or producing excessive thermal stresses.
Start up curves for the re-engineered boiler is to be provided.
5.4 PERFORMANCE REQUIREMENTS

5.4.1 Steam generator Output
Following parameters are to be ensured and the same is to be declared in the Bid / data sheets.
1. Minimum 210TPH with firing design coal & gas (With minimum 50000 NM3/Hr. BFG &
3000 NM3/Hr. COG ) and 185TPH steaming capacity by firing only design coal subject to
the condition that
(i) Main Steam pressure of 100 + 1 ata after approx. two meter from the stop valve at the
existing tapping point at 100% BMCR when firing coal and combination of coal and gas
(BFG/CO) and
(ii) Main Steam temperature of 540 + 5°C after approx. two meter from the stop valve at the
existing tapping point at 100%BMCR when firing coal and combination of coal and gas
(BFG/CO).
The parameters specified are subject to further condition that in case of change in input
parameters, suitable correction curves shall be applicable. The correction curves shall be
applicable for the following parameters:
i) Steam generation: Collector pressure (80-90 at) and temperature corrected.
ii) Pressure: Main steam pressure shall be ensured by isolating the unit from the collector.
ETRM012-1-M-TS-001
The tolerance / shortfall limit shall not be more than 5 TPH steam capacity decrease in either
case.
2. Minimum Stable load without oil firing in terms of percentage of design capacity (in TPH)
shall be 40% of design steaming capacity or guaranteed figure given by the bidder,
whichever is better.
5.4.2 Furnace Draft:

Following parameters are to be ensured and the same is to be declared in the Bid / data sheets.
Gas tight furnace with furnace vacuum of -4 mmwc (at reference level of 21 m) on all operating
conditions for rated steam parameter of minimum 185 TPH with worst coal only (CV 3800
kCal/kg) and minimum 210 TPH with coal + gas (BF+CO) of 50000 NM 3/hr & 3000 NM3/hr at 100
ata and 540 C at superheater outlet.
5.4.3 Flue Gas Temperature at APH inlet

Maximum flue gas temperature at APH top block inlet shall be 384°C & as per Table 3.1 and
same shall be guaranteed for all loading conditions at design coal. If, the contractor is not able to
achieve the flue gas temperature at APH top block inlet to the specified limit within 90 days after
conducting PG test, the same will be accepted with liquidated damages as mentioned in the
commercial document.
5.5 PERFORMANCE GUARANTEE TEST

General Requirements
The Contractor shall guarantee that the equipment offered (supplied new as per this specification)
for the Steam Generator after renovation shall meet the ratings and performance requirements.
The Steam Generator shall be able to operate continuously and generate their full output after
R&M and there shall be no restrictions in operations of these units, including base load, peak load
and cyclic load operation. The design capabilities of the plant operations including cold / warm /
hot start-ups after R&M shall in no way inferior to original design.
The guaranteed performance parameters furnished by the Bidder in his offer, shall be without any
tolerance values and all margins required for instrument inaccuracies and other uncertainties
shall be deemed to have been included in the guaranteed figures. After R&M the contractor shall
conduct performance test and demonstrate all the guarantees covered under performance
guarantees and performance requirements, as per the test procedures specified in the Vol-II at
relevant clauses, and provisions mentioned in commercial documents.
REJECTION CLAUSE
Boiler steaming capacity:
In case the boiler steaming capacity falls below the required design figure as stated in the
specification with design coal, and the contractor is not able to bring the boiler steaming capacity
to the specified limit within 90 days after conducting PG test, the boiler will be rejected and boiler
shall be taken back by the contractor and in such case, owner will recover all the payments
(including taxes & duties) made by them to Contractor on account of the rejected boiler.
PERFORMANCE TESTS
 All performance guarantee tests shall be performed in accordance to the latest ASME-PTC.
 The final performance tests at site shall be conducted by the Bidder, in the presence of
Owner, to demonstrate the guarantees as well as proper functioning of various equipments
and the availability of margins as designed in various equipments, and shall be binding on
both the parties after successful demonstration of trial run.
ETRM012-1-M-TS-001
 The Bidder's commissioning engineer shall make the plant ready for each such tests which
shall commence within three (3) months after the plant and equipment have attained stable
operation, at the end of trial operations or such extended periods, as may be mutually
agreed upon.
 All the test instrumentation required for the performance and efficiency tests shall be
supplied by the Bidder and shall be taken back by him upon satisfactory completion of all
such tests at site. All the test instrumentation shall be calibrated by the Bidder from a
recognized test institute, as approved by the Owner.
 All calibration standards and procedures shall be subject to Owner's approval. All costs
associated with supply, calibration, installation, conductance of tests and return of test
instrumentation shall be included. All the temperature test wells, pressure test connections
and all other test connections and/or sampling methods shall conform to relevant ASME
performance test codes and the Bidder shall fully elaborate the provisions made.
 Ambient conditions: - 35°C temperature (Dry bulb) and 60% relative humidity. The reference
air temperature for the efficiency guarantee/ testing shall be taken as the temperature of air
(i.e. 35°C) entering FD fans.
Notes:
 Performance tests shall be run at a time mutually agreeable to Owner and the Bidder as
soon as tests can be practically scheduled, following written notice from the Bidder that the
equipment furnished is ready for testing.
 Initial testing and any retesting required due to errors or omissions of the Bidder shall be at
the Bidder's expense. Owner shall have access to test records during and after the test. A
preliminary copy of all test data and report shall be promptly furnished to Owner within 18
working days after the test; and the final report shall be furnished to Owner within 20
calendar days after receipt of third party laboratory test results. Bidder shall expedite third
party laboratory test results to the earliest delivery possible. The Bidder shall give written
notice to Owner at least 30 days prior to the dates on which tests can be made.
 Acceptance of the equipment by Owner does not relieve the Bidder from any obligation or
responsibilities arising under the guarantee and warranty provisions of this contract.
 Immediately prior to testing, the equipment shall be operated at a constant load within the
control range long enough to minimize fluctuations in operating characteristics, such as
pressure and temperatures. The rating shall be held constant during the test period. The
duration of the test period shall be the minimum required for obtaining representative data.
 During the above, boiler testing program, the bidder along with the owner should ensure that
boiler is able to generate 100% of the guaranteed steaming capacity.
 Procedures and techniques for the Bidder's tests shall be submitted to Owner including
name of the item to be tested, location of measurement points, manufacturer and model
number of major instruments to be used, any applicable correction curve(s) for off-design
conditions, and a verifiable method of calculation of the test results. All the test procedures
shall be approved from Owner’s end prior to actual tests.
ETRM012-1-M-TS-001
 All temporary instrumentation for the tests shall be furnished by the Bidder including its
installation and removal after satisfactory completion of the tests. Bidder shall list all
temporary instrumentation in his test procedure.
 If the average steam temperature during the test period is lower than 538°C due to improper
setting of the spray water controls, corrections shall be made to the steam temperature to
account for spray water use. The Bidder and Owner shall coordinate efforts to ensure that
controls are properly set. If the steam temperature level is not achieved during the test
period; and the attemperator spray control valve is closed, the test shall be treated as a
failure.
 The Bidder shall furnish correction curves, for Owner's approval, covering the expected
ranges of variations for all the parameters.
 In all other aspects, not spelt out above, or in specifications, where ASME code stipulates
agreement between the parties concerned before the test, the Bidder shall get these
approved by the Owner.
 No negative tolerance on account of instrument inaccuracy or otherwise shall be allowed on

the guaranteed values.
 Necessary performance test procedure, write-up, schemes, instruments schedules, detailed

procedures clearly indicating periods of tests, frequency of observations, etc., shall be
prepared and submitted for all the tests for Owner's review/approval.
ETRM012-1-M-TS-001
6.0 PRE COMMISSIONING & COMMISSIONING ACTIVITIES
ETRM012-1-M-TS-001
6.1 PRE COMMISSIONING ACTIVITIES

Contractor’s Scope shall include all pre-commissioning and commissioning activities, required for
successful performance of all equipments and systems under this package and shall include, but
will not be limited to, activities detailed in Technical Specification. Contractor scope shall also
include supply of all materials and services including the following for successful conductance of
pre-commissioning and commissioning activities.
Complete pre-commissioning work including tests of facilities such as hydraulic testing of

pressure parts, air and gas tightness tests of steam generator enclosure, chemical cleaning of
pressure parts , Boiler flushing , etc. and all other tests as mutually agreed in the Contractor’s
quality assurance program as well as those identified in the specification.
The contractor shall submit all the commissioning procedures to the owner for approval before
the commissioning of the unit.
Technical Requirements
Upon completion of erection / retrofitting of the equipments and systems contractor shall perform
pre commissioning activities on the steam generator to make steam generators ready for safe,
reliable, efficient and sustained operation. Pre commissioning activities of each steam generator
shall generally include but shall not be limited to the following:
Hydraulic Testing of Pressure Parts

a) Hydraulic test to assess pressure withstanding capability of the pressure parts with all fittings
and mountings in position shall be performed by the Contractor to satisfy the requirements of
the Indian Boiler Regulations.
b) For conducting hydraulic test, the water shall be made alkaline by addition of suitable
chemicals and after the test, water shall be suitably drained and the steam generator
preserved.
c) All valves, high pressure piping along with interconnected pipes connecting the pressure
parts as replaced, shall be subjected to hydraulic test along with the pressure parts within the
scope of specification. All blank flanges or any removable plugs required for blocking the
openings not closed by the valves and piping shall be furnished by the Contractor. Any
defect/leakage noticed during the testing shall be rectified and the unit shall be retested by
the Contractor.
d) The hydraulic test shall be considered successful only on certification to that effect by the
concerned inspecting authority as per the provision of the IBR and the engineer.
Air & Gas Tightness Test

After completion of all work on pressure parts and before application of any insulation, an air and
gas tightness test shall be performed by the contractor to check and establish the gas tightness of
the complete Steam Generator system from the outlet of FD fan through the steam generator to
the air heater. The test shall be conducted for physical detection of leakage using fog generated
by fogging machine. For this purpose complete system under testing shall be filled with fog and
pressurized to a positive pressure of at least 100 mm WC. The fogging shall be continued during
such pressurization. The leakage, if any, shall be detected visually. Any defect, noticed during
such gas tightness tests shall be corrected and the unit retested. Chemicals used for fog
generation shall be such that these do not have any adverse effect on the boiler parts exposed to
it.
Chemical Cleaning of Pressure Parts

The Contractor shall perform thorough and efficient cleaning operations of all the internals of the
boiler parts like economizer, water wall, feed water line, piping, start-up recirculation lines and
ETRM012-1-M-TS-001
associated piping and all other pressure parts and associated high pressure piping covered under
these specifications (except those portions which are to be steam blown).
The cleaning operation shall consist De-mineralized (DM) water flushing, the chemical cleaning
using acids like hydrofluoric acid or as recommended by the manufacturer, DM water rinsing, DM
water flushing, passivation, nitrogen capping etc. Complete chemical cleaning procedure, the
scheme and layout including parameters of the pumps, size of tanks, materials of construction,
the rate of consumption and total requirements of steam and water for such cleaning process
need to be submitted prior to cleaning operation and shall be approved by the Owner.
The Contractor shall furnish all labour, materials such as the required chemicals and other
consumables, all equipment such as acid transfer and acid circulating pumps complete with drive
motors, acid storage and acid mixing tanks, all temporary piping, valves and specialties and local
instruments for pressure, temperature and flow measurements and any other items needed to
carry out the process. All equipment required for chemical cleaning of Steam Generator shall be
supplied by the contractor.
The Owner will arrange to supply raw water and De-mineralized water required for the cleaning
operations at the Terminal Points.
The procedure for hydraulic test, air and gas tightness test and cleaning and preservation of the
boiler shall be submitted by the contractor for approval by the purchaser before conducting the
pre commissioning test as per the specification.
The Contractor shall take care to dispose off used chemicals and the effluents from the cleaning
operations, after neutralization, meeting all the statutory regulations and in a manner acceptable
to the Owner. This includes construction of suitable neutralization pit, channels, disposal
equipments etc.
The Contractor shall specifically make all necessary arrangements for prevention of any fire
accidents, explosions etc. during the performance of the chemical cleaning operations.
The Contractor shall ensure that during the cleaning process the procedure adopted shall be
such as to consume minimum de-mineralized water.
The cleaning procedure shall include final flushing and draining of the boiler under a nitrogen gas
cap and / or filling the boiler with inhibited water or any other proven procedure recommended by
the manufacturer for the preservation of the boiler, which is acceptable to the owner. The
Contractor shall furnish a detailed procedure for boiler preservation during detailed engineering
for Owner's approval.
All equipment needed for such preservation including the nitrogen cylinders, interconnecting
piping and any regulating equipment for N2 cap and other preservatives shall be provided by the
Contractor for the Steam Generator and the same shall also become the property of the Owner
after completion of the chemical cleaning.
All the temporary equipments like pumps, tanks, piping etc. as mentioned above, brought on to
Site by the Contractor for performing the chemical cleaning operation, on the completion of the
cleaning operation of the unit and when no longer required shall be dismantled by the Contractor
and shall remain the property of the Contractor.
The Contractor shall provide adequate safety and protective equipment for all his employees and
ensure that they are worn at all times during working. Specialized treatment equipment (such as
required for first aid when using hydrofluoric acid) for steam generators must be provided at the
ETRM012-1-M-TS-001
place of handling acid. An acid cleaning report and log of each cleaning must be provided by the
Contractor to the owner, immediately after the cleaning operation.
After completion of chemical cleaning, the bidder will inspect all the headers with boroscope for
any foreign material and also check the internal condition for that the bidder will cut the hand-hole
plates on the headers and the same will be repositioned by welding after inspection is over.
The bidder is supposed to provide the detail report for hydro test and chemical cleaning of the
boiler to the customer.
Steam Blowing
The Contractor shall carryout the steam blowing for superheater tubes, superheater headers and
superheater desuperheating spray water lines to clear any blockage, contamination etc. The fuel /
DM water requirement for the steam blowing to be specified in the data sheet.
The Contractor will give recommended procedures, method of blowing, and scheme for steam
blowing indicating clearly any additional system to be cleaned by steam blowing, other than the
systems stated above.
The Contractor shall furnish his recommendations regarding termination/acceptance criteria for
steam blowing, which, in any case, shall be approved by the Owner, based on acceptability of
such criteria for 'Steam Turbine'.
The systems, which should be ready and operational before steam blowing and which are in the
scope of the Contractor shall be made ready / operational by the Contractor by the scheduled
date for starting of steam blowing.
Supply of spool pieces and / or blanks, as required, cutting / welding / edge preparation and re-
welding required for blanking and replacing any instrument fitting valve etc. by spool pieces, will
be the responsibility of the Contractor. In addition to this the supply and erection of all materials
like temporary piping, its supports etc. required for complete steam blowing shall also be in the
scope of the Contractor.
The steam generator and its accessories equipment shall be operated by the Owner under
supervision of the Contractor to generate steam at the parameter and quality in line with the
approved steam blowing procedure.
The 'Contractor' shall ensure successful and timely completion of steam blowing of all systems.
The 'Contractor' will render all help / services as required during steam blowing, including series
of test/operating personnel/supervision.
After successful completion of the steam blowing, all temporary piping/blanks/spool pieces etc.
shall be removed and the system shall be restored back to normal, ready for further
commissioning/operation.
Reliability Run
Once the initial operations are over, the Contractor shall notify that the unit is ready for Reliability
Run. The plant will be put on Reliability Run when the Owner is fully satisfied that the offered
Plant has been proven with regard to its safety. A 7 days’ notice will be issued by the Contractor
to the Owner about the completion of the Plant /Unit being ready for the Reliability Run. The
duration of Reliability Run of the complete Unit in the automatic position of control system under
varying load shall be fourteen (14) days, out of which at least seventy two (72) hours shall be in
continuous operation on Full load at design parameters and design input as per Clause 3.1.4 &
ETRM012-1-M-TS-001
3.1.5 of Technical Specification. This protocol will confirm the acceptance of the participating
parties that all the Plant/ unit systems have been completed and are put in auto operation with all
necessary adjustments and final testing of all controls and protections are made for operating
over the full load range and the Plant/ Unit is ready for the Reliability run.
Other conditions for the reliability run shall be discussed and finalized between the owner, the
contractor and any appointed /authorized agency of the Owner after completion of the initial
operations.
6.2 COMMISSIONING AND INITIAL OPERATION OF THE FACILITIES

Supply of all consumables (except coal and fuel oil for firing) like chemicals, nitrogen for
blanketing, consumables for air / gas tightness tests and any other consumable as may be
required for above pre-commissioning/ commissioning activities.
Supply of all temporary equipments such as tanks, piping, including supports, valves, nitrogen
blanketing equipments including nitrogen cylinders, pumps and all necessary instrumentation for
successful conductance of pre-commissioning and commissioning activities.
The temporary equipments specifically brought by the Contractor solely for the pre-
commissioning and commissioning work shall on completion of these activities, remain the
property of the Contractor. However, the nitrogen blanketing equipment including nitrogen
cylinders shall get included in the Contractor’s permanent scope of supply and become property
of the owner.
The selection of material of all the temporary equipments/ instruments shall be compatible with
the service conditions expected during pre-commissioning/ commissioning activities.
All temporary equipments and instruments shall be clearly listed out in the bid.
Supply of all labour, skilled / semi skilled technicians, supervisors, engineers and any other
manpower required shall be under the scope of the bidder.
Technical Requirements
Commissioning Test / Checks
After completion of renovation work, the Contractor shall carryout commissioning checks at site
on all the equipments and the systems that are supplied new or which were modified to ensure
satisfactory performance of the equipment / system as whole and to check its integration with
steam generator before commencement of trial run. The Contractor should prove the temperature
difference between the Boiler outlet Main Steam Left and Right temperature within ±5ºC at rated
load condition. The total Attemperator spray to control the boiler outlet temperature within limits
shall also be specified in the data sheet and verified during the commissioning test.
ETRM012-1-M-TS-001
7.0 SPARES
ETRM012-1-M-TS-001
SPARES
General
The Contractor's scope shall include in his scope of supply all the necessary Start-up and
commissioning spares and Recommended spares and indicate these in the relevant schedules of
the Bid Forms & Price Schedules separately. The general requirements pertaining to the supply
of these spares is given below:
7.1 RECOMMENDED SPARES

In addition to the spare parts mentioned above, the Contractor shall also provide a list of
recommended spares for 3 years of normal operation of the plant and indicate the list and total
prices in relevant schedule of the Bid Forms & Price Schedules. The owner reserves the right to
buy any or all of the recommended spares. The recommended spares shall be delivered at
project site at least two months before the scheduled date of initial operation of first unit.
However, the spares shall not be dispatched before the dispatch of the main equipment.
Prices of recommended spares will not be used for evaluation of the bids. The price of these
spares will remain valid up to 6 months after placement of Notification of Award for the main
equipment. However, the Contractor shall be liable to provide necessary justification for the
quoted prices for these spares as desired by the owner.
The Bidder to provide the list of recommended spares including price considered essential in the
format provided in Annexure-IV.
7.2 START-UP & COMMISSIONING SPARES

Start-up & commissioning spares are those spares which may be required during the start-up and
commissioning of the equipment/system. All spares used till the Plant is handed over to the
owner shall come under this category. The Contractor shall provide for an adequate stock of such
start up and commissioning spares to be brought by him to the site for the plant erection and
commissioning. They must be available at site before the equipments are energized. The unused
spares, if any, should be removed from there only after the issue of Taking Over certificate. All
start up spares which remain unused at the time shall remain the property of the Contractor.
The Bidder shall include in his scope of supply, all the necessary Start-up and commissioning
spares and indicate these in the relevant schedules of the Bid Forms & Price Schedules. The
general requirements pertaining to the supply of these spares is given below:
The Contractor shall indicate the service expectancy period for the recommended spare parts
under normal operating conditions before replacement is necessary.
All spares supplied under this contract shall be strictly inter-changeable with the parts for which
they are intended for replacements. The spares shall be treated and packed for long storage
under the climatic conditions prevailing at the site e.g. small items shall be packed in sealed
transparent plastic with desiccators packs as necessary.
The Contractor will provide owner with cross-sectional drawings, catalogues, assembly drawings
and other relevant documents so as to enable the owner to identify and finalize order for
recommended spares.
Each spare part shall be clearly marked or labeled on the outside of the packing with its
description. When more than one spare part is packed in a single case, a general description of
the content shall be shown on the outside of such case and a detailed list enclosed. All cases,
containers and other packages must be suitably marked and numbered for the purposes of
identification.
ETRM012-1-M-TS-001
All cases, containers or other packages are to be opened for such examination as may be
considered necessary by the owner.
The Contractor will provide the owner with all the addresses and particulars of his sub-suppliers
while placing the order on vendors for items/components/equipments covered under the Contract
and will further ensure with his vendors that the owner, if so desires, will have the right to place
order for spares directly on them on mutually agreed terms based on offers of such vendors.
The Contractor shall warrant that all spares supplied will be new and in accordance with the
Contract Documents and will be free from defects in design, material and workmanship.
In addition to the recommended spares listed by the Contractor, if the owner further identifies
certain particular items of spares, the Contractor shall submit the prices and delivery quotation for
such spares within 30 days of receipt of such request with a validity period of 6 months for
consideration by the owner and placement of order for additional spares if the owner so desires.
The Contractor shall guarantee the long term availability of spares to the owner for the full life of
the equipment covered under the Contract. The Contractor shall guarantee that before going out
of production of spare parts of the equipment covered under the Contract, he shall give the owner
at least 2 years advance notice so that the latter may order his bulk requirement of spares, if he
so desires. The same provision will also be applicable to Sub-contractors. Further, in case of
discontinuance of manufacture of any spares by the Contractor and/or his Sub-Contractors,
Contractor will provide the owner, two years in advance, with full manufacturing drawings,
material specifications and technical information including information on alternative equivalent
makes required by the owner for the purpose of manufacture/procurement of such items.
ETRM012-1-M-TS-001
8.0 BILL OF QUANTITIES
ETRM012-1-M-TS-001
BILL OF QUANTITIES
The summarized List of Items to be supplied and quantities under the contract for Boiler (One
unit) scope is as follows.
Sr. Total
Item Description of R&M job Code quantity Unit price CIP
No price
BOILER & ITS AUXILIARIES 1 2 3 =1x3
1. Pressure Parts
2. Economizer Minor need based LOT
modification of
Economizer coil along
with headers based on
agreed scope of work
3. Water wall i)Replacement of 100%
gooseneck bend tubes
(complete)
ii)Replacement of Burner 100%
panel tubes and top/
bottom bends
iii)Replacement of 100%
Bottom “S” panel and
cathouse tubes
iv)Replacement of water 100%
wall tubes with
membrane design with
openings for soot
blowers
4. Ceiling Super i) Complete replacement 100%
heater of roof tubes of fin design
along with headers.
5. Attemperator i)Replacement of SH 100%
attemperator with higher
capacity units
ii) Capacities of super
heater attemperator
spray water systems to
be designed for 15% of
the rated main steam
flow.
6. Convective I & Minor need based LOT
II Superheater modification of
superheater coil along
with headers based on
agreed scope of work
7. Valves i) Retrofitting / 100%
replacement of the
existing impulse type
drum-safety valves
in the existing
arrangement and
ETRM012-1-M-TS-001
Sr. Total
No price
replacement of the
existing superheater
impulse type safety
valves with new
spring loaded safety
valves.
ii) Installation of 100%
silencers on the
existing start-up vent
valves
8. Scanner air fan The Scanner air fan with 100%
Motor, ducting, PLC 2 sets
connectivity and other
auxiliaries.
9. Pent house i) Modified spring type 100%
sealing sealing arrangement
with better refractory
system having
plastic refractory
material to avoid ash
ingress in to the pent
house.
ii) Replacement of pent 100%
house casing along
with new insulation.
10. Boiler Roof Repair the boiler roof to 100%
new powder coated
sheets
11. Buck Stay i) Replacement of 100%
buck stay and
damaged railings
floor grills etc as per
modified furnace
design
ii) Buck stay including
the corner fixing
arrangement,
sealing of gaps and
refractory work is
proposed to
eliminate air ingress
in this area.
12. Hangers & 100% replacement of 100%
Supports hangers and supports of
the critical piping &
furnace (Feed water &
MS piping)
13. Insulation i) Replacement of all 100%
&Refractory insulation and cladding
ETRM012-1-M-TS-001
Sr. Total
No price
of boiler, ducts,
condensate and steam
pipes. Replacement of all
cladding sheets with
aluminum sheets.
ii)Replacement of
Refractory for manholes,
peep holes, burner
opening & wall blower
opening etc
14. Ducts Scope of repair / LOT
replacement of flue gas
ducting and air ducting
are covered in Annexure
III: Overhauling scope of
the technical
specification and
consequently shall not
be in the scope of work
of the Bidder. Material
required to execute the
overhauling job shall be
provided by the owner.
However, Secondary air
ducting and dampers in
the secondary air duct
within the specified
terminal points shall be
in the scope of the
bidder.
15. Dampers Scope of repair / LOT
replacement of dampers
are covered in Annexure
– III: Overhauling scope
of the technical
specification and
consequently shall not
be in the scope of work
of the Bidder. Material
required to execute the
overhauling job shall be
However, dampers in the
secondary air duct within
the specified terminal
points shall be in the
scope of the bidder.
16. Impulse lines All impulse piping and 100%
root valves covered
under the scope of new
ETRM012-1-M-TS-001
Sr. Total
No price
BMS supply shall be in
the scope of the bidder.
However, for the
existing system, length
of the impulse piping for
the purpose of
quotation shall be
Over and above the
specified value shall be
on unit rate basis.
17. Burners and i) Replacement of 6 nos.
Ignition System existing multi fuel
(Coal, oil & gas)
coaxial burners with
modified wall
mounted low NOX
separate / coaxial
coal and gas (BF &
CO) swirl burners
with special long
lasting burner tips
ii) Repair / replacement
of oil gun as per
O&M and the
requirement of new
modified ignition
systems
iii) New secondary and 100%
fuel dampers with
separate operational
system to have
flame optimization
and combustion
control to meet the
variation in coal
quality
iv) Replacement of 100%
scanner ignitors
(High Energy Arc
Ignitor). Complete
replacement for
accommodating the
new burner, new
ignitors, new
scanners and flame
sensing camera.
Civil
18. Boiler Civil works for Scanner L.S.
ETRM012-1-M-TS-001
Sr. Total
No price
Foundation Fan (2 nos.) foundations
as per Clause no.
3.2.16.1, Page no. 43 of
116, Volume – 2, Section
– B of Technical
Specification and any
civil works related to
installation and cabling
for new panels in the
control room, which will
be in the scope of the
bidder.
19. Boiler Structure Need based repair/ Up to 200
replacement of structural MT and
steel rest on
unit rate
basis
20. All other Civil works for Scanner
Foundation Fan (2 nos.) foundations
as per Clause no.
3.2.16.1, Page no. 43 of
116, Volume – 2, Section
– B of Technical
Specification and any
civil works related to
installation and cabling
for new panels in the
control room, which will
be in the scope of the
bidder.
ETRM012-1-M-TS-001
9.0 DATA SHEETS
ETRM012-1-M-TS-001
DATA SHEET-: DATA TO BE FILLED BY BIDDER
STEAM GENERATOR AND AUXILIARIES
SL. NO. Description Unit Bidder’s Note

1.1 Type of Steam generator / Furnace
1.2 Fuel required for :
 Startup / Warm-up
 Flame stabilization
 Load carrying
1.3 Furnace Size (Width x Depth) mm
1.4 Furnace Chamber Volume m3
1.5 Capacity at SG (BMCR)
1.6 Drum (In case of replacement)
Drum: Internal dia x thickness, mm
Length, mm
Material, steel
Drum pressure (Ref. Note-1) Ata (g) 115
1.7 Main steam pressure at Super heater outlet Ata (g) 100
(Ref. Note-1)
1.8 Main steam temperature Super heater outlet °C 540
(Ref. Note-1)
1.9 Flue gas temperature at air preheater top °C
block inlet
1.10 Explosion force / Implosion
1.11 Operation (Base load / constant. Pressure /
sliding pressure)
1.12 Code (IBR / ASME or any other equivalent
international standard)
1.13 Heat Release Rates (Ref. Note-2)
1.13.1 Volumetric basis kcal/m3/hr
1.13.2 Net heat Input to plan area (NHI / PA) kcal/m2/hr
1.13.3 Burner Zone kcal/m2/ hr
1.14 Gas Temp. at Furnace outlet at SGMCR °C
(Ref. Note - 3)
1.15 NOx Emission limits (for coal firing)
1.16 Unburnt combustibles in Bottom ash %
1.17 Unburnt combustibles in Fly ash %
1.18 Excess Air at APH inlet (20% maximum) %
1.19 Ambient temp. for performance test °C
1.20 Furnace tube arrangement (Membrane type)
1.21 Type of tubes and header for pressure parts
(Seamless)
1.22 Flue gas velocity in SG second pass (≤ 10 m/s
m/s)
ETRM012-1-M-TS-001
NOTES:-
1.0 The value indicated is as required.

2.0 For calculating heat release rates:
2.1The net heat is the effective heat in the furnace. This shall be calculated on the basis of
the gross heating value (GHV) of the fuel corrected by subtracting radiation loss,
unburnt combustible loss, latent heat of water in the fuel and adding the sensible heat in
both the fuel and the combustion air above specified ambient temperature.
2.2The volumetric heat release shall be calculated by dividing the NH by the net furnace
volume (The net furnace volume shall be reckoned up to furnace outlet plane). Bidder
shall furnish the method that bidder uses to calculate the net furnace volume, in his bid.
2.3Plan area shall be obtained by multiplying the width with the depth of the furnace.
2.4Burner zone heat release rate shall be obtained by dividing net heat by 2 x (furnace width
+ furnace depth) x burner zone height, where burner zone height is equal to (vertical
distance between top and bottom row burners + 3 meters).
3.0 Furnace exit gas temperature is the temperature of flue gas at furnace outlet plane. Bidder
shall furnish a sketch of the furnace indicating the furnace outlet plane with relevant
dimensions of the furnace.
Unit 100%BMCR 60% BMCR

1.0 PERFORMANCE DATA
1.1 Load Data MW
1.1.1 Steam flow from Superheater T/hr
1.1.2 Superheater Desuperheating spray water Kg/hr
flow
1.1.3 Steam flow for soot blowing, oil burner T/hr
atomization etc.,
1.2 Calculated Flow Quantities Kg/hr.

1.2.1 Total air to Air Preheater (APH) inlet
1.2.2 Air leakage thru APH
1.2.3 Air at APH outlet
1.2.4 Total secondary air
1.2.5 Flue gas at APH inlet
1.2.6 Flue gas at APH outlet
1.2.7 Coal firing:
a) With Design Coal
b) With Worst Coal
1.2.8 FD fan outlet air
1.2.9 Hot air at mill inlet
1.2.10 ID fan inlet flue gas
1.2.11 Tempering air for each pulverizer
1.2.12 Total air to each pulverizer
1.3 Steam/Water Pressure& Pressure

Drops, Kg/cm2g
ETRM012-1-M-TS-001

1.3.1 Steam at Superheater outlet
1.3.2 Pressure drop in Superheater(s)
1.3.3 Steam in Boiler Drum
1.3.4 Pressure drop in Economizer*.
1.3.5 Water at Economizer inlet **
1.4 Steam/Water Temperature deg.C

1.4.1 Steam at Superheater outlet
1.4.2 Water at Economizer inlet
1.4.3 Water at Economizer outlet
1.5 Flue Gas Temperature deg.C

1.5.1 Theoretical Combustion Zone
1.5.2 Furnace Exit
1.5.3 Low temperature Superheater Inlet
1.5.4 Low temperature Superheater Outlet
1.5.5 Platen Superheater Inlet
1.5.6 Platen Superheater Outlet
1.5.7 Secondary Superheater (Convective II)
Inlet
1.5.8 Secondary Superheater (Convective II)
Outlet
1.5.9 Primary Superheater (Convective I) Inlet
1.5.10 Primary Superheater (Convective II) Outlet
1.5.11 Economizer Inlet
1.5.12 Economizer Outlet
1.5.13 APH Inlet
1.5.14 APH Outlet (uncorrected)
1.5.15 APH Outlet (corrected)
1.5.16 Electrostatic Precipitator Inlet
1.5.17 Electrostatic Precipitator Outlet
1.5.18 I.D. Fan Inlet
1.5.19 I.D. Fan Outlet
1.6 Air Temperature deg.C

1.6.1 FD fan inlet
1.6.2 Air at APH Inlet
1.6.3 Air at APH Outlet
1.6.4 Secondary air at burner inlet
1.6.5 Coal air mixture at Pulverizer outlet
1.6.6 Coal air mixture at burner inlet
ETRM012-1-M-TS-001

1.7 Air Pressure Drops Secondary air mm WG
1.7.1 FD fan inlet duct
1.7.2 FD fan outlet
1.7.3 Air heater inlet
1.7.4 Air heater outlet
1.7.5 Mill inlet
1.7.6 Mill outlet
1.7.7 PF Pipe from Mill Fan discharge to Furnace
1.8 Flue Gas Pressure & Pressure Drops mm WG

1.8.1 Furnace pressure
1.8.2 Drop Across Superheater
1.8.3 Drop Across Economizer
1.8.4 Drop Across APH (gas side)
1.8.5 Drop Across Electrostatic Precipitator
(ESP)
1.8.6 Drop thru' Ducts & Dampers from-
a) APH outlet to ESP Inlet
b) ESP outlet to ID fan Inlet
c) ID fan outlet to Stack Inlet
1.8.7 Total drop through the system
1.9 Excess Air (%)

1.9.1 At Burners
1.9.2 At Furnace Exit
1.9.3 At Economizer Outlet
1.9.4 At APH Outlet
1.9.5 At ID fan Inlet
1.10 Percentage load change per minute

without exceeding the limits on unburnt
combustibles or NOX while maintaining
safe flame conditions
1.11 Time required for draining the complete

steam generator
1.12 Acid dew point temp. adopted deg. C

1.12.1 For Design Coal Firing
1.12.2 Worst Coal Firing
1.13 Flue gas velocities m/Sec.
ETRM012-1-M-TS-001

1.13.1 In Superheater Section
1.13.2 In Economizer Section
1.13.3 In APH inlet
1.13.4 In Ducts
1.13.5 ESP inlet
1.14 Percentage of Oxygen in Flue Gas

1.14.1 At Furnace exit
1.14.2 At Economizer outlet
1.14.3 At APH inlet
1.15 Heat Absorbed per Unit Weight of Coal Kcal/ Kg.

Fired
1.15.1 In Economizer with-
a) Design Coal
b) Worst Coal
1.15.2 In Superheater with -
a) Design Coal
b) Worst Coal
1.15.3 In Water Walls with -
a) Design Coal
b) Worst Coal
1.15.4 Total heat absorbed
a) Design Coal
b) Worst Coal
1.16 Losses and Efficiency %

1.16.1 Standard/Code as per which the losses &
efficiency will be measured
1.16.2 Moisture in fuel loss for :
a) Design Coal firing
b) Worst Coal firing
1.16.3 Hydrogen in fuel loss for
1.16.4 Moisture in Air loss for
1.16.5 Unburnt Combustible Loss for
1.16.6 Radiation loss for
ETRM012-1-M-TS-001

1.16.7 Dry gas loss for
1.16.8 Unaccounted loss for
1.16.9 Other losses (if any) for
1.16.10 Total losses for
1.16.11 Heat Credits considered for the following
items (to be filled in by Bidder)
a) ………….
b) ………….
c) ………….
1.16.12 Total Heat Credit for
1.16.13 Efficiency for
1.16.14 Calculations for losses, heat credit and
efficiency (to be furnished by Bidder)
1.17 Energy Quantities Kcal / hr.

1.17.1 Energy to Steam & Water
1.17.2 Heat output of unit
1.17.3 Heat input from fuel
1.17.4 Furnace dimension (L × B × H) mm
1.17.5 Net heat input per m3 of Furnace volume Kcal/ hr/m3
1.17.6 Maximum net heat input per m2 of furnace Kcal/hr/m2
plan area
1.17.7 Maximum Burner Zone heat release rate Kcal/hr/m2
1.17.8 Maximum heat liberation rate Kcal/hr/m2
1.17.9 Maximum heat input/ burner Kcal/hr
1.17.10 Maximum furnace Cooling factor Kcal/hr/m2
ETRM012-1-M-TS-001

1.17.11 Minimum furnace residence time Sec
1.18 Particulate matter concentration

1.18.1 Particulate concentration at ESP inlet for
a) Design Coal firing g / Nm3
b) Worst Coal firing g / Nm3
c) Chemical Quantity for dosing Kg/hr
1.19 Distribution of Ash (Kg/hr.)

1.19.1 Furnace bottom hoppers with
a) Design Coal
b) Worst Coal
1.19.2 Economizer hoppers with
a) Design Coal
b) Worst Coal
1.19.3 APH hoppers with
a) Design Coal
b) Worst Coal
1.19.4 Any other hoppers with
a) Design Coal
b) Worst Coal
1.20 Instrument and Service Air Requirement

for the Boiler & auxiliaries
1.20.1 Quantity m3/min.
1.20.2 Pressure Kg/cm2 (g)
1.21 Purity of saturated steam leaving the ppm

drum
1.21.1 Total dissolved solids
1.21.2 Silica content
1.21.3 Sodium
1.21.4 Chlorides
1.21.5 Copper
1.21.6 Iron
1.21.7 Moisture
1.22 Waterwall
1.22.1 Type
1.22.2 Number of tubes
1.22.3 Design tube thickness, mm mm
1.22.4 Outside diameter, mm
1.22.5 Actual thickness used, mm
ETRM012-1-M-TS-001

1.22.6 Margin on tube thickness over and above
pressure requirement, mm
1.22.7 Tube Pitch, mm
1.22.8 Material specification and composition
1.22.9 Effective heating surface area M2
1.22.10 Maximum steam side metal temperature,
deg.C
1.22.11 Maximum gas side metal temperature,
deg.C
1.22.12 Number and type of thermocouple fittings
1.22.13 Material of water wall support (composition)
1.22.14 Number of headers
1.22.15 Header dimension (Dia. x thickness) mm
1.22.16 Number of buckstay (Specific for each
elevation)
1.22.17 Dimension for the buckstay
1.22.18 Type of support for water wall
1.23 Superheater
1.23.1 Type (Radiant / convection)
1.23.2 Platen (drainable / non-drainable)
1.23.3 Horizontal headers (drainable / non-
drainable)
1.23.5 Effective heating surface area M2
1.23.6 Total circumferential heating surface area,
M2
1.23.7 Gas flow path area, M2
1.23.8 Heat Absorption, (×106 kcal/h)
1.23.9 Depth of each bank in the direction of the
gas flow, mm
1.23.10 Maximum average gas velocity (m/sec)
1.23.11 Tube Pitch(Across/Parallel) to gas flow,
mm
1.23.12 Clear space between the two banks in the
direction of gas flow, mm
1.23.13 Maximum steam side metal temperature,
deg.C
1.23.14 Maximum gas side metal temperature,
deg.C
1.23.15 Number and type of thermocouple fittings
1.23.16 Type of flow (counter or parallel)
1.23.17 Material of tube support (composition)
1.23.18 Design standard
ETRM012-1-M-TS-001

1.23.19 Design tube thickness, mm
1.23.20 Outside diameter, mm
1.23.21 Actual thickness used, mm
1.23.22 Margin on tube thickness over and above
pressure requirement, mm
1.23.23 Number of elements/section
1.23.24 Total number of tubes replaced
1.24 Headers: Superheater

1.24.1 Material specification
1.24.2 Location (outside/inside gas path)
1.24.4 Maximum operating pressure Kg/cm2 (g)
1.24.5 Design pressure Kg/cm2 (g)
1.24.6 Design temperature °C
1.24.7 Design standard
1.24.8 Outside diameter mm
1.24.9 Thickness mm
1.24.10 Whether any diaphragm is used in any
header and if so give details
1.24.11 Details of final outlet header connection
1.24.12 Method of internal inspection
1.24.13 Total volume M3
1.24.14 Maximum header unbalance
1.25 Superheater Temperature Control

1.25.1 Attemperator Superheater
a. Type
b. Number of stages of Attemperation
c. Position in steam circuit
d. Size of desuperheater header mm
e. Specification of material
f. Superheater steam temperature range deg. C
that can be maintained between 60% to
100% of Boiler MCR,
g. Spray nozzle material
h. Maximum spray water flow rate and T/hr
corresponding steam output,
i. Minimum spray water rate and T/hr
corresponding steam output
1.26 Safety Valves

1.26.1 Drum
ETRM012-1-M-TS-001

Type
Number
Set Pressure (Open) kg/cm2(g)
Set Pressure (Close) kg/cm2(g)
Blowdown ratio %
Relieving Capacity Kg/hr
Total Relieving Capacity Kg/hr
Percentage of BMCR flow %
1.26.2 Super heater
Type
Number
Set Pressure (Open) kg/cm2(g)
Set Pressure (Close) kg/cm2(g)
Blowdown ratio %
Relieving Capacity Kg/hr
Total Relieving Capacity Kg/hr
Percentage of BMCR flow %
1.27 Piping, Valves and Specialities for

Critical (external) Piping
1.27.1 Pipes & Fittings
1.27.2 Basic codes and standards for design
fabrication and erection testing and
inspection
1.27.3 Welding of piping
Type of weld
Special electrode details (type, quantity)
Number of welds envisaged for each piping
covered in this specification
1.28 Economizer
1.28.1 Type (Plain, drainable, non-steaming)
1.28.3 Manufacturer
1.28.4 Water side effective heating surface area M2
1.28.5 Gas side effective heating surface area M2
1.28.6 Gas flow path area M2
1.28.7 Heat transfer co-efficient (gas to water) at Kcal/M2/ hr
100% BMCR
1.28.8 Provisions made for economizer on load
cleaning
1.28.9 Details of recirculating system
1.28.10 Design pressure of tubes kg/cm² (g)
ETRM012-1-M-TS-001

1.28.11 Design temperature of tubes °C
1.28.12 Minimum allowable feed water temperature °C
1.28.13 Outside diameter of tubes mm
1.28.15 Header dimension (Dia. x thickness) mm
2.0 FLUE GAS TEMPERATURE AT AIR deg.C

HEATER TOP BLOCK INLET
Unit Forced Draft Induced Draft

Fans Fans
3.0 DRAFT FANS considered in calculations
3.1 Capacity (flow rate for each fan) NM3/hr
a. At 100% Boiler BMCR
b. Max flow rate the fan can handle
c. Min flow rate the fan can handle
d. Fan critical speed rpm
e. Coupling type between fan and motor
3.2 Static Pressure mmWC
a. At 100% Boiler BMCR
i) For fan inlet
ii) For fan outlet
b. Min safe pressure
3.3 Design margin provided
a. Flow rate %
b. Static pressure %
3.4 Density of air/gas at working temperature Kg/Cm3
3.5 Fan efficiency at
a. Design (Test block) condition
b. 100% BMCR
c. 60% Boiler MCR
3.6 Power Consumption KW
a. At 100% Boiler MCR
b. At 60% Boiler MCR
c. Shaft HP at 100% Boiler MCR
3.7 Features of Construction
a. Blades provided with renewable wearing Yes/No
noses?
b. Mode of adjustment of gas/air flow
control
3.8 Lube Oil System
a. Number of pumps per fan
ETRM012-1-M-TS-001

Fans Fans
b. Number of pumps in standby / service
c. Type of pump
d. Number of oil cooler per fan
e. Number of oil coolers in standby /service
f. Relief valves provided? Yes/No
g. Pressure switches provided? Yes/No
h. Thermometers provided? Yes/No
i. Electric heaters with oil tanks provided? Yes/No
j. Quantity of Cooling water required (T/hr)
3.9 Accessories
a. Type of coupling provided
b. Coupling guards provided? Yes/No
c. Base plate and foundation bolts Yes/No
provided?
d. Forced lubrication unit with pumps, Yes/No
filters, coolers, connected piping etc.
provided?
e. Local instruments provided? Yes/No
f. Provision for vibration sensors made? Yes/No
g. RTDs for fan and motor bearings Yes/No
provided?
3.10 Minimum load of fan at which it can operate
in parallel without any knocking and
bumping
4.0 PULVERIZED COAL BURNERS

4.1 Type
4.2 Make
4.3 Number of coal burners fed by each pulverizer
4.4 Number of elevations of burners
4.5 Number of burners per elevation
4.6 Total number of coal burners
4.7 Number of coal burners in operation from 20% to 100%
Boiler MCR, their locations and tilt (if applicable)
4.8 Design data
a. Temperature of coal air mixture deg.C
b. Maximum allowable temperature of burners deg.C
c. Turn down ratio
d. Temperature of hot secondary combustion air deg.C
e. Capacity of each burner at
i) 100% Boiler MCR
ii) 92.2% Boiler MCR
ETRM012-1-M-TS-001

Fans Fans
iii) Maximum
f. Type of combustion air entry
g. Pressure drop in the coal burner mmWC
h. Velocity of coal air mixture at entry to burner m/s
i. Log mean density of coal air mixture
j. Critical coal air fall out velocity and corresponding
load
k. Velocity of secondary air at entry to burner m/s
l. If burner tilt offered in degrees Yes/No
m. Number & type of burner tilt drives (if applicable)
n. Percentage of excess air at the burner
4.9 Construction features
a. Angle of fuel entry (fixed/ variable)
b. Cooling device (while in operation/idle)
c. Provision of measurement of burner metal tip
temperature
d. Mode of adjustment of combustion air
4.10 Materials of construction
a. Coal burner nozzle
b. Guide plates
c. Drive liner
d. Connecting liner
e. Air damper
f. Support bearing inside wind box
g. Connecting bar
h. Level
4.11 Whether the following accessories provided
a. Drive for tilting coal burners? Yes/No
b. Flexible connection between coal pipe and burner? Yes/No
c. Position indicator for all dampers? Yes/No
d. Limit switches? Yes/No
e. Drive for air damper? Yes/No
4.12 Codes and Standards applicable
Unit Gas Burners

5.0 GAS-BURNERS
5.1 Gas Burners
5.1.1 Manufacturer
5.1.2 Type
5.1.3 Design data
a. Number of gas burners
ETRM012-1-M-TS-001

Fans Fans
b. Elevation of boiler burners (if applicable)
c. Number of burners per elevation (if applicable)
d. Scavenging medium
e. Duration of scavenging
f. Parameters of scavenging medium
g. Temperature of gas at burner inlet deg.C
h. Maximum / minimum gas pressure range required at Kg/cm2g
burners
i. Turndown ratio
j. Capacity of each burner Kg/hr
k. Percent Boiler MCR capacity that can be carried by
i. All the burners
ii. One single burner
5.1.4 Construction features
a. Angle of fuel oil entry (fixed/variable)
b. Mode of adjustment of combustion air
c. Type of diffuser
d. Type of cooling/ sealing device
e. Type of drive for each oil burner for
insertion/retraction
5.1.5 Materials of construction
a. Gas burner mixing plate/ spray plate
b. Guard pipe
c. Diffuser
d. Concentric tubes
e. Clamp
f. Gaskets
g. Flexible tubing
h. Burner body
i. Burner tip
5.1.6 Whether the following accessories provided
a. Limit switches Yes/No
b. Clamps Yes/No
c. Gaskets Yes/No
d. Flexible hose Yes/No
e. Insertion, retract facility Yes/No
f. Position indicators Yes/No
g. Inbuilt flame scanner Yes/No
h. Separate inlet for different fuels Yes/No
i. Flow regulator Yes/No
j. Flow meter Yes/No
ETRM012-1-M-TS-001

Fans Fans
k. Safety valves Yes/No
5.1.7 Codes and Standards applicable
5.2 Gas Ignition System

5.2.2 Type
5.2.3 Number of ignitors
5.2.4 Number of spare ignitors
5.2.5 Heat input per ignitor Kcal/hr
5.2.6 Retractable or stationary?
5.2.7 If ignitors are offered then following data shall be
furnished
a. Whether suitable for firing both BF & CO gas / Yes/No
Furnace oil?
b. Electrode material
c. Expected life of electrodes
d. Experience list of bidder for similar igniters Yes/No
furnished?
Unit HFO / LSHS

Burners
6.0 OIL-BURNERS
6.1 Oil Burners
6.1.1 Manufacturer
6.1.2 Type
6.1.3 Design data
a. Number of oil burners
b. Elevation of boiler burners (if applicable)
c. Number of burners per elevation (if applicable)
d. Atomizing medium and its temperature
e. Scavenging medium
f. Duration of scavenging
g. Parameters of scavenging medium
h. Temperature of oil at burner inlet deg.C
i. Atomizing steam parameter
- Maximum flow rate Kg/hr
- Maximum / minimum steam pressure range required Kg/cm2g
for atomizing
j. Maximum / minimum oil pressure range required at Kg/cm2g
burners
k. Turndown ratio
l. Oil viscosity before the burners Centistokes
ETRM012-1-M-TS-001

Fans Fans
m. Combustion air temperature deg.C
n. Capacity of each burner Kg/hr
o. Percent Boiler MCR below which oil gun is required
for flame stabilization.
i. All the burners
ii. One single burner
6.1.4 Construction features
a. Angle of fuel oil entry (fixed/variable)
b. Mode of adjustment of combustion air
c. Type of diffuser
d. Type of cooling/ sealing device
e. Type of drive for each oil burner for
insertion/retraction
6.1.5 Materials of construction
a. Oil burner mixing plate/ spray plate
b. Guard pipe
c. Diffuser
d. Concentric tubes
e. Clamp
f. Gaskets
g. Flexible tubing
h. Burner body
i. Burner tip
6.1.6 Whether the following accessories provided
a. Limit switches Yes/No
b. Clamps Yes/No
c. Gaskets Yes/No
d. Flexible hose Yes/No
e. Insertion, retract facility Yes/No
f. Position indicators Yes/No
6.2 Oil Ignition System

6.2.2 Type ( high energy are ignitors)
6.2.3 Number of ignitors
6.2.4 Ignitor spark rate per minute
6.2.5 Number of spare ignitors
6.2.6 Heat input per ignitor Kcal/hr
6.2.7 Retractable or stationary?
6.2.8 If high energy arc ignitors are offered then following
ETRM012-1-M-TS-001

Fans Fans
data shall be furnished
a. Whether suitable for firing both HFO/LSHS? Yes/No
b. Electrode material
c. Expected life of electrodes
d. Experience list of bidder for similar igniters Yes/No
furnished?
Unit Parameter
7 THERMAL INSULATION (For the area mentioned in
the specification)
7.1 Insulating materials
7.1.1 Type of insulating material(s)
7.1.2 Manufacturer's name
7.1.3 Maximum temp(deg.C) the insulating materials can
withstand
7.1.4 Insulating materials standard
7.1.5 Density of insulating materials Kg/M3
7.1.6 Thermal conductivity (Kcal/M/hr deg.C) at mean
temperature of
a. 50 deg.C
b. 100 deg.C
c. 150 deg.C
d. 200 deg.C
e. 250 deg.C
f. 300 deg.C
g. 350 deg.C
7.1.7 Resistance to micro-organism Yes/No
7.1.8 Incombustibility Yes/No
Unit Mineral Pourable Segmented Al Other

fiber insulation Cement sheet (specify
mattress (mm/ Qty) blocked jacket details)
(mm/Qty) calcium (mm/ (mm/
silicate Qty) Qty)
(mm/ Qty)
7.2 Steam Generating Plant &
Auxiliaries, Insulation &
Casing details
7.2.1 Furnace extended side
backpass walls
7.2.2 Enclosure
a. Roof
ETRM012-1-M-TS-001
Unit Mineral Pourable Segmented Al Other

fiber insulation Cement sheet (specify
mattress (mm/ Qty) blocked jacket details)
(mm/Qty) calcium (mm/ (mm/
silicate Qty) Qty)
(mm/ Qty)
i) Horizontal
ii) Vertical
b. Extended side
i) Horizontal
ii) Vertical
c. Bottom
i) Horizontal
ii) Vertical
7.2.3 Any other (give details)
area including auxiliaries
and ducting etc.
7.3 ID fans with drives
7.4 Fan duct
7.5 Platforms and rails
7.6 Supporting structure for
fuel gas system
7.7 Dampers/vanes with
actuators
7.8 Fabricated components for
insulation of flue gas
system
7.9 Other (list down items)
7.10 Total weight of the
package
Unit
8 GENERAL TECHNICAL INFORMATION
DATA, DRAWINGS TO BE FURNISHED
ALONGWITH PROPOSAL
8.1 Performance Data No. of Reference
Drg./Leaflet/Write-up
8.1.1 Boiler efficiency Vs load
8.1.2 Characteristic curves showing the variation
of superheated with load clearly indicating
the regime of attemperation
8.1.3 Characteristic curves of Steam Generating
unit showing variations in efficiency, steam
temperature and pressure with loads, for
coal firing
8.1.4 Correction curves for Steam Generator
ETRM012-1-M-TS-001
Unit
efficiency for variation in parameters such
as
a. Load
b. Superheater outlet pressure
c. Superheater outlet temperature
d. Feed water inlet temperature
e. Excess air
f. Humidity
g. With variation in coal quality parameters
from those stated
h. Flue gas temperature at air heater outlet
i. Ambient air temperature
8.1.5 ID fan blade angle lines; stall lines equal
efficiency lines; and system resistance
lines for all ID fans and Electrostatic
Precipitator sections in service and also
with one ID fan and one Electrostatic
Precipitator section out of service both at
50 Hz and 47.5 respectively showing the
BMCR and test block points, for both one
fan and two fan operation.
8.1.6 Furnace oil & gas burners output
characteristics
8.1.7 Characteristic curves showing the acid &
dew point temperature Vs. sulphur content,
moisture content in the coal and
percentage of excess air
8.1.8 Characteristic curves of the SH Spray
attemperator
9 STEAM BLOWING REQUIREMENTS

 Coal in MT
 Furnace oil in kilo liters
 Raw Water in cum.
 Start up power in kWh and peak in kVA
10 COMMISSIONING REQUIREMENTS
 Coal in MT
 Furnace oil in kilo liters
 Raw Water in cum.
 Start up power in kWh and peak in kVA
ETRM012-1-M-TS-001
GUARANTEED PERFORMANCE PARTICULARS AND DATA
Unit
1. Guaranteed Capacity of Steam Generator
at rated pressure and temperature
2. Furnace draft at guaranteed operating
condition
3. Minimum boiler load for flame stability only
with coal firing (without oil support)
4. Furnace pressure with combined coal and
gas firing at 100 %BMCR
5. Boiler Superheater steam temperature from deg.C
60% to100% Boiler MCR
6. Steam purity and wetness
7. Flue gas temperature at APH top block
inlet
8. NOX emission should not exceed 260 gm of
NOX per gigajoules
ETRM012-1-M-TS-001
10.0 DRAWINGS AND DOCUMENTS
ETRM012-1-M-TS-001
GENERAL
All I.B.R. test certificates required to be submitted to the Boiler directorate/chief inspector of
Jharkhand and all approvals to be obtained by the Bidder. It shall be the responsibility of the
Bidder to provide all necessary information / documentation / follow up and arrange inspection of
the Boiler Inspector.
Single line drawing to be provided by Bidder will include: 3 element drum level control, furnace
draft control, steam temperature control etc. Bidder will provide P & I drawings, GA, plot plan, etc.
Detailed list of drawings for information / approval to be finalized, during kick-off meeting.
All the drawings shall be approved and vetted by the Owner /their Consultants.
All drawings which are to be approved and finally approved drawings, instruction and
maintenance manuals of all equipments and other details will be handed over as under before
commissioning.
6 sets for the Owner including soft copy on CD.

2 sets for the consultants to the Owner including soft copy on CD.
The Bidder shall submit all major drawings for approval, as well as a drawing list from which the
Owner/Consultant will select those drawings which they consider necessary for completion of
drawing approval. Before starting manufacturing of the equipment, the Bidder shall have to take
approval of the design drawings from the Owner/Consultant. Any manufacturing done prior to
approval of the drawings shall be rectified in accordance with approved drawings by the Bidder at
his own cost, if any discrepancy arises and the equipment shall be supplied within stipulated
period.
General Arrangement drawing shall be submitted for approval to the Owner/Consultant prior to
the commencement of detailed engineering by the Bidder. These drawings shall show to scale,
location and all major equipment including electrical. Equipment and overall dimensions as well
as tie-in dimensions and clearances shall be clearly indicated.
The Bidder will be required to furnish all the necessary drawings data, etc. of the plant/equipment
with appropriate ‘status” stamp in adequate number of copies as indicated below:
Sr. No Status of the drawing / document etc. No. of copies for No. of copies for
Owner Consultant
1. Reference/information 2 prints 2 prints
2. For approval 2 prints 3 prints
3. Final & certified duly signed 4 prints & 1 2 prints
reproducible soft copy
in CD
4. Operation maintenance manual 3 copies + CD 1 CD
5. Performance & acceptance test 2 copies 2 copies
procedure
6. All other documents 3 copies 2 copies
The Bidder shall submit copies of all drawings which are required to be approved by the
Owner/Consultant. The drawings which are approved by the Owner/Consultant shall not be
deviated from.
ETRM012-1-M-TS-001
The drawings submitted by the Bidder for approval shall contain all information regarding the
manner in which equipment is going to be located and all the loading data for the civil foundation.
The drawing should show details of piping and electrical connections to be made by the
Owner/Consultant for connecting the Bidder’s equipment in the system.
The operating & maintenance instruction and the erection procedures together with drawings of
the equipment as completed shall be in sufficient detail to enable to Owner to properly
erect/install the equipment, to maintain, dismantle, reassemble and adjust all parts of the
equipment.
The manuals shall give step-to-step procedures for all operations likely to be carried out during
the life of the plant/equipment including during erection, commissioning, testing, operation &
maintenance, dismantling and repair.
The manuals shall also contain copies of approved drawings as well as the performance/rating
curves and copies of test certificates, if applicable. The maintenance instructions shall include the
lubrication procedures, periodicity of lubrication as well as the brands of Indian lubricants to be
used to ensure trouble free operation.
Indicative list of drawings to be submitted are given below. The final list including classification for
information / approval will be finalized during the kick-off meeting.
The following data/documents, along with the bid except that the items marked * to be furnished
after the contract is awarded on the successful bidder.
Sl. Description Whether

no required
1. Documents in support of the successful performance record of plant & Yes
equipment, similar to those being proposed now, which have been supplied &
installed by the bidder in the past
2. Similar documents as above from the bidder's sub-vendors (for sub- vendors to *
be selected after the award of EPC contract)
3. Detail schedule for supply , erection & commissioning Yes
4. General arrangement drawing for steam generator up to stack indicating major Yes
dimensions and elevations
5. Tentative dimensional figure for the proposed furnace along with the EPRS and Yes
volumetric heat release rate at different zones.
6. The detail documents along with the calculation supporting description at Sl. No. *
4 of this table are to be supplied during contract stage.
7. General arrangement drawing for furnace elevation, side elevation, and cross- Yes
section of the steam generating unit showing location of headers and drums.
8. General arrangement for furnace fire and illumination system *
9. Piping and instrumentation diagram for Steam & water system Yes
10. Piping and instrumentation diagram for Air and flue gas system Yes
11. Boiler performance data sheet *
12. Main steam line pressure drop calculation *
13. Piping line list *
14. Thermal insulation schedule (for piping & boiler) *
15. Scheme of steam and water showing instrument tap-off points *
ETRM012-1-M-TS-001

no required
16. Scheme of air and gas path with instrument tap off points *
17. Scheme of fuel gas supply and burning system with instrumentation *
18. Cold start up, warm start up (Overnight shutdown) and hot start-up curves. *
19. Correction curves *
20. Description of supply and firing system including associated equipment and *
drawings
21. Details combustion calculations *
22. Equipment general arrangement drawing for : *
ID Fan
Air and flue gas duct drawing
Scanner air fan
Ignitor air fan
Coal & gas firing system
Boiler
Pressure parts
Boiler structure
Boiler Seal trough
Any other equipment modification
23. Technical specifications for ID Fan including fans blade angle lines, stall line, *
equal efficiency line, system resistance line with all fans in service from 47.5 Hz
to 52.5 Hz respectively showing SGMCR & test block points, for both one fan and
two fan operation as applicable.
24. Technical specifications for Scanner air and ignitor air fan *
25. Technical specifications for Boiler safety valve ( Drum & SH) & blow down valves *
26. Utility requirements *
27. Design basis for boiler structural *
28. Isometric drawings for critical piping *
29. Quality Assurance/Quality Control document as relevant to his proposal Yes
30. Manufacturing quality plan , Quality assurance plan & field quality plan for all *
bidder supplies
31. Bidder's total plan (schedule, duration & frequency) on the regular maintenance *
work of the proposed plant, also describing how the owner personnel will be
trained and utilized in the work
32. Bidder's complete list of all technical deviations
a) Commercial requirements of this bid Yes
b) Conditions of contract Yes
33. A Complete list of the Internationally accepted codes & standards which the Yes
bidder will follow in the design, material selection, manufacturing, erection, tests
at works and tests at site
34. B Bar-chart for the bidder's proposed design, manufacturing, procurement and Yes
delivery activities
35. Complete list of all tests to be carried out, with code/standard followed and brief ****
description of test procedure, for a) Tests at works b) Tests during erection &
commissioning. c) Operational & flexibility tests d) Reliability demonstration tests
36. Acceptance tests *
37. Extended performance tests *
ETRM012-1-M-TS-001

no required
38. List of spares Yes
39. Consumable spares (for day to day maintenance, inspection & overhaul of plant *
& equipment requiring regular attention)
40. Overhaul spares (for planned overhauls to ensure the required availability) *
41. Strategic spares (generally high cost and/or long lead-time spares required *
infrequently, may be once in the plant's life time)
42. Manufacturing drawings for those spare parts going out of production beyond *
three (3) years of plant operation
43. Engineering and master drawing schedule indicating when the drawings and data *
will be submitted for review within four (4) weeks from the date of issue of notice
of proceed
44. As build drawings of the equipments and system supplied *
Note:
a) The Bidder may note that the drawings, data and manuals listed are minimum
requirement only. The Bidder shall ensure that all other necessary write-ups, curves and
information required to fully describe the equipment offered are submitted with his bid.
b) All drawings shall be prepared by using AutoCAD and documents shall be generated
using Electronic version. The paper copy of the drawings & document shall be submitted
for approval & reference. All final drawings and documents shall be submitted in CD in
AutoCAD 2000 and MS office format as applicable for Owner’s future reference.
c) All drawings and documents along with QAP should be submitted for approval & consent.
d) Bidders must arrange all IBR drawings duly approved by boiler inspectorate.
ETRM012-1-M-TS-001
11.0 ANNEXURES
ETRM012-1-M-TS-001
ANNEXURE-I: SCHEMATIC FOR STEAM GENERATOR
ETRM012-1-M-TS-001
ANNEXURE-II: SCHEMATIC FOR THE MILLING SYSTEM
ETRM012-1-M-TS-001
ANNEXURE-III: OVERHAULING SCOPE

Overhauling / Revisioning /Repair of equipments and parts (HP, LP) other than those covered in
R & M part.
Scope of Work
Item no – 1
Ball mill
1. Opening of suction and discharge spout including air blaster if any then removing & shorting
of balls & shifting the old & worn-out balls to scrap yard.
2. Repair of suction & discharge spout body, repair includes changing of damaged liners, spout
rings & inspection doors.
3. Removal of old pinion assembly with its pedestal, clearing of pinion foundations frame,
positioning of pedestal with new pinion assembly & alignment with girth gear & gear box.
4. Repair / replacement of worn-out Trunion ring of suction & discharge side.
5. Inspections, removal & replacement of damaged radial and axial drum liners. Tightening of
all drums liners bolts after providing wedges and tack welds all bolts wherever necessary.
Liners are to be cut, grinded & matched. Shifting of old / damaged liners to scrap yard.
6. Repair of damaged shell plate of drum (16mm thick) with new plates. Repair includes gas
cutting and welding.
7. Inspection of gear box, cleaning and thorough inspection of cooling coils etc. replacement of
worn-out parts if any, assembly of gear box after tightness checking of bearings. Positioning
of gear box and alignment.
8. Repair / replacement of pinion foundation frame by removing old one & fixing new one.
9. Rectification of suction & discharge end cover flanges, rectification of flange gap by removing
foreign materials.
10. Removal & assembly of suction & delivery end covers if required for rectification, same is to
be done fixing each end covers.
11. Replacement / reversal of girth gear tightening of all segment bolts, parting plane bolts,
check run out of girth gear & fix control bolt after reaming and tack weld all bolts. Grinding of
teeth, if needed.
12. Repair / replacement of reducer foundation frame.
13. Inspection of suction & delivery bearings. Repair / replacement of damaged brigs. Matching
of bearings with drum journal, replacement of oil indicator & all cooling lines. Clean all oil
distributor headers.
14. Repair / changing of suction pipe (including compensator & explosion vent) from R. C. feeder
to Ball Mill up to spout-
i. dia 1020 x 6 mm
ii. dia 600 x 6 mm
15. Shifting of new balls to site & loading them into the mill.
16. Fixing of suction & discharge spout.
17. Replacement of discharge end pipe (up to 8’M floor) by changing of damaged pipe (dia 1100
x 6 mm) including compensators & explosion vents. Pipe piece changing as per requirement
up to separator. Concrete breaking & re-casting as per need.
18. Alignment of HT motor, reducer & pinion.
19. Coupling of pinion & reducer and reducer & motor.
20. Repair/replacement of all cooling water pipes and associated valves.
21. Trial run and liquidation of defects.
Item No – 2
Mill fan
ETRM012-1-M-TS-001
1. Dismantling & assembly of :-

a) Reducer of diameter 1100mm, L-1m
b) Impeller.
c) Casing with delivery pipe up to terminal point of R&M.
d) Shaft assembly with bearings, housing & gauge glass.
e) Foundation frame including its pedestal assembly / matching.
f) Cooling coils to be tested, if damaged to be changed / repaired.
2. Explosion vents inspection / repair.
3. Delivery/ Suction duct inspection and repair/replacement.
4. Alignment of HT motor.
5. Trial run balancing and liquidation of defects.
Item No – 3
Capital repair of F. D. Fans
1. Casings to be repaired with repair /replacement of discharge compensator.

2. Impeller to be inspected. Defects to be attended / replacement of impeller.
3. Shaft to be inspected, repaired / replaced.
4. Bearing housing to be inspected. Repaired / replacement as per the need.
5. All bearing end covers to be repaired / replaced.
6. Coupling to be replaced, if needed.
7. Cooling coil and cooling water pipe lines along with the valves to be repaired / replaced.
8. Both suction and discharge dampers to be repaired and made operative.
9. Oil topping in the bearing hauling if any leakage persists is to be attended.
10. Cleaning of the area and shifting of scraps to scrap yard.
11. Static balancing of Impeller.
Item No – 4
Secondary air dampers & ducts
1. Complete replacement of secondary air duct from FD Fan discharge via bottom and top APH
ring header and outlet duct up to the terminal point of R&M of air duct and BM inlet.
2. Replacement of all compensators in the above mentioned secondary air path.
Item No – 5
Slag conveyor, slag bath & slag crusher
1. Conveyor
a) Blanking of slag bath after removing distance piece and fixing blank plate. Repairing of
distance piece if needed. Removal of blank and fixing distance piece after repair is over.
b) Covering of slag bath channel.
2. Decoupling of screw conveyor & coupling after repair is over.
3. Dismantling & revisioning/replacement of gear box, assembly is position & alignment with
screw after repair/replacement.
4. Dismantling of dome of screw conveyor & fixing after repair is over.
5. Cleaning of slag bath.
6. Dismantling & removal of screw weighing 01 ton each.
7. Repair of slag bath body by cutting and welding.
8. Assembly of new screw conveyor in position.
9. Assembly of bearing on screw conveyor. Fixing side plate & coupling hub.
10. Assembly of plate bearing.
11. Repair / replacement of cooling water line of slag conveyor.
ETRM012-1-M-TS-001
12. Repairing of base frame of motor & gear box and supporting structure of screw conveyor.
13. Replacement of coupling & gear box, if needed.
14. Alignment and coupling of motor & gearbox.
Crusher
1. Dismantling of gear box of slag crusher & revisioning after decoupling with crusher drum.
2. Dismantling of crusher drum from position.
3. Assembly of crusher drum & its cover in position.
4. Assembly of plate bearing & coupling hub on crusher drum.
5. Positioning & alignment of gear box & crusher drum.
6. Coupling of crusher & gear box. Changing of coupling and gear box, if needed.
7. Repair & assembly of cooling water line of crusher.
8. Repairing of base frame of motor, gearbox & crusher.
9. Alignment and coupling of motor & gear box.
Item No – 6
Cyclone & Separator of Mill System
1. Complete replacement of 1100 mm dia Ball Mill Discharge pipes from BM discharge up to
separator and from cyclone up to Mill Fan suction. Replacement of all compensators in this
line.
2. Replacement of separator cone. Braking of concrete and re casting as per requirement.
3. Complete replacement of the plates of cyclone.
4. Replacement of connecting pipe of separator to cyclone along with replacement of
compensators.
5. Replacement of bottom pipes of separators cones dia 290 mm.
6. Replacement of mill fan suction dampers.
7. Replacement / Revisioning of atmospheric suction damper of mill system.
8. Revisioning of on-off valves including modification of inspection holes & repair of pipes.
9. Overhauling & making free of separators link, vanes & its sector assembly, broken links are
to be replaced.
10. Changing of damaged explosion vents of cyclones and separators.
11. Scaffolding making & removal as per need.
Item No – 7
Coal dust pipes of Mill System
1. Complete replacement of bends, straight pipes, dampers, compensators, etc., from Mill Fan
discharge up to the terminal point of R&M of coal pipes.
2. Scaffolding making & removal as per need.
Hot, warm & cold air dampers
Replacement/repair of all hot, warm and cold air dampers in the mill system.
Item No – 8
Ducts & Compensators of Flue gas path
1. Replacement of compensator and plates in the flue gas duct from shot hopper to ESP inlet.
2. Repair of compensator and replacement of plates in the duct from ESP outlet to ID fan inlet.
3. Repair of furnace explosion vent & its duct.
ETRM012-1-M-TS-001
4. Complete replacement of cover plates of 2nd pass bottom hoppers (04 Nos.)
Item No – 9
Seal Pot and platforms
Seal Pot
1. Revisioning of Seal pots (03 Nos.)

2. Changing of drain pipe of size 60 x 5 mm. and bends.
3. Replacement / revisioning of valves: (Φ 80 mm, 50 mm, 20 mm)
Platform
1. Repair/replacement of platform and stair case along with railing all around the Boiler from
0’M to 32’M.
2. Repair/replacement of platform of BF & CO gas line at 16’M, 21’M & 27’M along with their
railing.
3. Repairing / replacement of PBD platforms along with stair cases.
Item No – 10
Gas line valves
1. Dismantling of dia 600 mm. hermetically sealed dumpers & gear box from position of CO &
BF gas line at 16 M and 27 M level. The wt. of each damper is about 200 kg.
2. Revisioning/replacement of dampers (Dia 600 mm)
i) Revisioning of dampers involves making shaft free / changing replacing the rubber
flap/seal, changing of stopper bolts, brackets & spring.
ii) Replacement of damper involves shifting of new dampers from store to site and shifting of
old dampers to scrap yard as per direction of site In- charge.
3. Assembly of dampers and gear boxes after revisioning.
4. Revisioning of bleeder valves of size dia 80 mm.
5. Rev. / replacement of hermetically sealed dampers of BF gas line (size dia 1200mm).
flap/seal, changing of stopper bolts, brackets, spring & revisioning of its gear box.
old dampers to scrap yard as per direction of site In- charge.
6. Revisioning / replacement of regulating dampers size dia 1200 mm. the job involve making
dampers free.
flap/seal, changing of stopper bolts, brackets & spring.
old dampers to scrap yard as per direction of site In-charge.
7. Cleaning of duct pipe at 16 M level of B. F. gas line, pipe size dia 1200mm.
Item No – 11
Gas Line Job
1. Incorporation of modern technology hydraulic sealing system in place of existing sector gate
system for blanking and de-blanking purpose in BF and CO gas line. Modification of platform,
erection of new structure and supports for hydraulic sealing as per requirements.
2. Replacement of BF and CO gas line from T joints at 16 m up to terminal points of R&M of BF
Gas line.
3. Replacement of BF and CO gas line bends by fabrication of the same and straight pipe of
CO line at 16 m level up to terminal points of R&M.
ETRM012-1-M-TS-001
Item No – 12
Overhauling of drum
1. Opening of drum manholes. Cleaning & assembly after repair of drum. The manholes
holding should be leak proof in hyd. test.
2. Plugging of drum inside about 52 Nos. and removal after repair (plugs will be supplied by
BPSCL).
3. Changing of gasket of drum cyclone. gas cutting and removing the keys of flanges and again
fixing after gasket positioning and tack welding of key.
4. Repair / positioning of filter trays & filter plates by cutting & welding.
5. Inspection and choking removal of all sampling lines, CBD lines and phosphate dozing line.
Item No – 13
Overhauling of HP & LP Valves
A. H. P. Valve
1. Dismantling of Valves.
2. Repair / replacement of spindle, valve’s seat & discs, lapping of sheet as per
requirements.
3. Revisioning of stuffing boxes including new inner & outer gland packing.
4. Changing of bushes & bearings.
5. Revisioning of gear boxes including changing of internal & bearings as per requirement.
6. Final assembly & oil topping in gear boxes.
7. Checking of the operation of valves.
Lists of valves to be serviced
S.N Description of Valves Valve Size Valve No. Quantity

1. Main Steam Valve 273 x 18 252 01
2. Super Heater Blow Down Valve 100 x 12 255 / 256 02
3. Feed Line Valve 100 x 12 324 / 372 02
4. Feed Line Valve 175 x 16 323 / 371 02
5. Feed Line Valve 76 x 8 325 / 227 02
6. Feeds Check Valve 175 x 16 FC Valve 01
7. Feed Line NRV (Non Return Valve) 175 x 16 NRV 01
8. Armature Valve / Eco. Drain Valve / DM Line 76 x 8 -- 10
Valve
9. EBD Valve 65 x 8 257 / 258 02
10. Drum Mountings, Vents, Drain Valves, 25 x 4 / 10 x 2 -- 175
Sample Line Valves etc.
Note: Payment will be done on the basis of actual No.
Job involves:
1. Dismantling of valves.
2. Repair / replacement of spindle, valve’s seat & discs, lapping of sheet as per
requirements.
3. Revisioning of stuffing boxes including new inner & outer gland packing.
4. Changing of bushes & bearing.
ETRM012-1-M-TS-001
5. Revisioning of gear boxes including changing of internal & bearings as per requirement.
6. Final assembly & oil topping in gear boxes.
7. Checking of the operation of valves.
B. L. P. Valve
1. Changing of spiral gasket / seretted rings

2. Changing of all flange & gland bolts
3. Repair/replacement of spindles, bushes & new gland packing.
4. Repair /replacement of operating wheels
5. Final checking of the operation of valves.
Lists of valves to be serviced

S.N Description of Valves Valve Size Valve No. Quantity
1. purging and drains valves 25 x 4 / 40 x 6 -- 50
2. Cooling water Line Valves 25 x 4 / 40 x 6 -- 50
Note: Payment will be done on the basis of actual no.
Job involves:
1. Changing of spiral gasket / seretted rings.

2. Changing of all flange & gland bolts.
3. Repair / replacement of spindles, bushes & new gland packing.
4. Repair / replacement of operating wheels.
5. Final checking of the operation of valves.
Item No – 14
Changing of HP & LP Valves (As per need)
HP Valves LP Valves
Size Nos. Size Nos.

Ф 10 mm 15 Ф 10 mm 15
Ф 20 mm 20 Ф 20 mm 20
Ф 65 mm 05 Ф 40 mm 05
Ф 100 mm (class – 2500) 02
Ф 100 mm (class – 1500) 02
Ф 175 mm (class – 1500) 01
Ф 225 mm (class – 2500) 01
Note: Nos. of valves may increase or decrease as per need.
Job involves:
1. Cutting of valve and shifting it to boiler spare store.

2. Shifting of new valve from store to site.
3. Fitting of valve and joint welding.
4. Stress reliving is to be done for valve class – 2500.
5. Radiography of all valve joints.
ETRM012-1-M-TS-001
Note: Payment will be done on the basis of actual no.
Item No – 15
OVERHAULING OF (A) R. C. FEEDERS, (B) C. D. FEEDERS, (C) BUNKRES
(A) R. C. FEEDERS & (B) C. D. FEEDERS
1. Decoupling of motor, gearbox and motor removal.
2. Removal of front and rear cover.
3. Removal of scrapper chain.
4. Repair of feeder body, dismantling of front and rear sprocket assembly with guide
mechanism.
5. Replacement of guide plates of bottom and top.
6. Changing of old base plates and shifting to scrap yard.
7. Changing of old measuring plate and shifting to scrap yard.
8. Cutting of new base plate, edge preparation and shifting to site to 8M.
9. Cutting of new measuring plate edge preparation and shifting to site at 8M.
10. Installation of new base plate in position and welding.
11. Installation of new measuring plate in position and welding.
12. Replacement / patch welding of coal inlet chute of raw coal feeder above (10M).
13. Repair of manhole of feeder.
14. Rectification of feed control mechanism.
15. Revisioning of old sprocket mech. / changing of bearings.
16. Installation of front and rear sprocket assembly in position.
17. Fixing of big sprocket assembly with driving shaft.
18. Revisioning of gear box and changing of gearbox internals.
19. Revisioning of tension mechanism of driving sprocket.
20. Shifting of scrapper chain from TPP store to site.
21. Fixing of new scrapper chain in position.
22. Alignment of gearbox with driving sprocket and fixing of driving roller chain. Alignment of
motor with gearbox.
23. Painting of feeder body.
24. Trail run of feeder, adjustment of scrapper chain tension, fixing of chain guard and coupling
guard.
25. Revisioning / repair of raw coal bunker gate.
26. Decoupling and removal of c. d. feeder.
27. Dismantling of feeder, revisioning of feeder, charging of bush and bearing.
28. Revisioning of feeder gate / changing of gate bush if required.
29. Revisioning of gearbox, charging of worm wheel, worm shift along with bearing.
30. Fitting of gearbox in position with feeder and coupling of c. d. feeders.
31. Changing of dust pipe line, patching and attending leakage of dust pipe lines of the feeder.
(C) Bunkers
1. Preparation of scaffolding for raw coal bunkers, coal dust bunkers from 13M and above all
around the bunkers.
2. Cutting of 16mm thick MS plates of proper size and transporting them to raw coal bunkers
and coal dust bunkers area at 13 M level.
3. Lifting, fitting, and WELDING of MS plates of required size around the damaged portion of
raw coal bunker & coal dust bunkers.
4. Patch repair of damaged portion of top cover of raw coal bunker and coal dust bunker.
5. Changing of measuring rope, pulley counter weight for dust bunker. Repair of coal dust line
from dust screw conveyor to coal dust bunker.
Item No – 16
Thermal insulation and aluminium sheeting work of boiler during its Capital repair
ETRM012-1-M-TS-001
1. Shifting of bamboos for scaffolding at site

2. Transporting of insulation materials i, e slag wool, cement, asbestos powder etc. from store
to site.
3. Transporting of Al / GI sheets from store to site.
4. Breaking & removal of old insulation as per directive of site in-charge. as different position of
the boiler duct, h. p. pipe line & l. p pipe line etc.
5. Complete insulation of the portions where repair has been done as per the directive of the
site in-charge.
6. Complete insulation of the damaged portions of duct, pipelines, hoppers etc. as per the
directive of the site in-charge.
7. Removal of thermal insulation of all the headers at the drum floor.
8. Removal of thermal insulation of all the piping outside the boiler.
9. Fixing of thermal insulation of all the header at the drum floor.
10. Fixing of thermal insulation at all the piping outside the boiler.
Total area of the insulation per unit of boiler – 4000 M2 (Approx).
Item No – 17
Tig Welding Joints For Repairing/Replacement of Boiler Tubes & Super Heater Drain Lines
Sl. No Area No. of Joints Remarks

1. Economizer Ø32 x 4 250
2. Screen S. H. Tubes Ø32 x 4 200
3. Convective – I Ø38 x 4 100
4. Convective – II Ø42 x 4.5 100
5. SS Pipe – 16 mm & 10 mm 100
6. Feed Line (Steel-20) Ø133 x 10 50
7. Feed Line (Steel-20) Ø175 x 16 30
8. a) Feed Line Ø76 x 7.6 50
b) Economizer Drain
c) Soot Blower Line
d) D. M. Water Line
9. H. P. Drain Line Ø38 x 4 & Ø32 x 3.5 100
10. Stub Joints 200
Note:
1. Payment will be done on the basis of actual no. of joints.

2. Argon gas required for Tig welding is to be arranged by the party.
3. Job involves:
a) Cutting of clamps.
b) Cutting & removal of damaged tubes.
c) Shifting of new tubes at site.
d) Fitting & welding of joints.
e) Proper clamping of high pressure tubes (SH tubes, Economizer tubes and water wall
tubes).
Item No – 18
Radiography of Welding Joints
ETRM012-1-M-TS-001
Sl. No Area No. of Joints to be Radiographed

1. Economizer - Ø32 x 4 250
2. Screen S. H. Tubes - Ø32 x 4 200
3. Convective – I - Ø38 x 4 100
4. Convective – II - Ø42 x 4.5 100
5. SS Pipe – 16 mm & 10 mm 100
6. Feed Line (Steel-20) - Ø133 x 10 50
7. Feed Line (Steel-20) - Ø175 x 16 30
8. a) Feed Line - Ø76 x 7.6 50
9. Steam Line - Ø 225 x 18 02
Note: Payment will be done on the basis of actual No. of joints.
Item No. – 19
1. Rectification of all SH headers,panels,feed lines, steam lines, upriser, downcomer and feed
line hanger support outside the terminal points of R&M job as applicable..
Item No. – 20
ID Fan:
1. Blanking of outlet ducts.
2. Removal of all inspection doors.
3. Opening of dome and side plates and locking of impellers.
4. Dismantling and removal of bearings.
5. Lifting of impeller along with shaft and shifting it to repair bay.
6. Impeller to be repaired / replaced.
7. Inspection of shaft and air-seal. To be repaired / replaced.
8. Inspection of foundation & anchoring bolts. To be repaired / replaced as per the inspection
report.
9. Mounting of impeller (Old/New) on shaft.
10. Repairing of casing all around (from inside & outside).
11. Casings liners to be repaired / replaced.
12. Changing / repairing of cooling water coil and associated inlet & outlet lines along with the
valves.
13. The entire suction damper flaps to be repaired. Dampers to be made operative.
14. Both the bearing housings and mechanical coupling are to be inspected. Defect to be
rectified, if any. If needed, bearing housing to be replaced.
15. Positioning of impeller along with shaft in the hauling and locking of impeller.
16. Fitting of both side’s bearings and their assembly.
17. Removal of outlet blanking plates.
18. Oil topping in the bearing housings. If any leakage persists, is to be attended.
19. After inspection, unlocking the impeller and fixing of all the inspection doors in position.
20. Fixing of coupling on shaft.
21. Changing of explosion vents & repair of vent’s duct in flue gas line duct from ID Fan suction
side common duct to discharge side chimney duct.
22. Preparation of scaffolding around ID Fans (after blanking point and up to chimney duct).
23. Cutting of 3.5 mm thick M.S Plates as per required size and shifting them from store to ID
Fan area.
24. Fixing and welding of these M.S Plates around the damaged portion of the flue gas duct from
ID Fan suction side common duct to discharge side chimney duct.
25. Repair / replacement of compensator.
26. Removal of scaffolding and cleaning of work area.
ETRM012-1-M-TS-001
27. Shifting of all scraps to scrap yard.

28. Static / dynamic balancing of Impeller.
30. Coupling of ID Fan with HT motor.
Inputs to be given by the vendors
1. The vendor has to arrange sufficient no. of general tools / tackles, welding machines, cutting
sets, grinding machines, lighting arrangements with cable etc.
2. The vender has to arrange all sifting & lifting equipments like ,winch machine, Hydra, Crane
etc along with truck, trailer etc.
3. The vender has to arrange sufficient quantity of consumables like general & special type
welding electrodes, filler rods etc. approved by BPSCL, industrial gases, grinding wheels,
cotton waste, markin cloth, hose pipes, kerosene oil / diesel, grease etc.
4. Sufficient no. of measuring instruments like ultrasonic thickness measuring instrument
(minimum – 02 nos.), equipment & radio isotope for radiography testing, DPT kit & material
for DPT, S/R equipment, ultrasonography machine, Vibrometer, vernier, screw gauge etc.
required for pre and post-operating parameter study has to be arranged by the vendor.
5. The vendors has to provide all size of MS, HT and SS Nut and Bolts with washer as per
requirements.
6. The vendor has to provide all size of metallic, non metallic glands made by Champion,
gaskets and asbestos rope as per requirements.
7. The vendor has to provide all type of scaffolding materials as per requirements.
Inputs to be given by the BPSCL
1. All spares like valve, damper, pipe, tube, plate, refractory materials, slag wool with cement,
asbestos powder, mill system spares, etc., as per requirement.
2. Points of electrical supply at all required positions.
3. Water supply as per requirements.
ETRM012-1-M-TS-001
ANNEXURE-IV: RECOMMENDED SPARES

Bidders to provide list of recommended spares along with price in the following proforma.
S. Description Qty/Unit Unit Price Total Price (Rs) properly

No. packed for supply to
purchaser’s stores at site
ETRM012-1-M-TS-001
ETRM012
ANNEXURE-V: PRELIMINARY SCHEDULE FOR ONE BOILER
Preliminary Schedule for BPSCL R&M job (One boiler - 220 TPH)
Month
Job Description 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
Order placement and kick off meeting with successful bidder
Design & review engineering
Detail Engineering by package contractor / EPC contractor
Review engineering by Steag
Manufacturing & delivery at site
Site Mobilization, Dismantling, R&M Installation Works & Commissioning at Site for 1st
Boiler
ETRM012-1-M-TS-001
ANNEXURE-VI: SUB VENDORS’ LIST OF THE CONTRACTOR FOR MECHANICAL

EQUIPMENTS
SUB VENDOR LISTS OF THE CONTRACTOR FOR MECHANICAL EQUIPMENTS
Sr. No. Equipment / System Name of Vendors

1. LP VALVES & SPECIALITIES L&T AUDCO, Chennai
FOURESS ENGG LTD, Bangalore
BDK ENGG INDUSTRIES LTD, Hubli
KBL
PUNE CRESCENT VALVES LTD, Mumbai
LEADER VALVES LTD, Jalandhar
H.SARKAR & CO, Kolkata
INTERVALVE
2. CONTROL VALVES DRESSER, MASONAILAN , XOMOS,
FISHER,KSB-MIL, COSO, HORA, CCI
3. WATER STEAM CYCLE PIPES BOCCARD, TECHNIP, TECHTUBI, ESSENER,
HOCHDRUCK, NORDON, MAHASHTRA,
SEAMLESS, INDIAN SEAMLESS, TISCO,
JINDAL SAW PIPES, RATANAMANI METALS &
TUBES LTD., ALSTOM, BHEL, THERMAX,GB
ENMASH,BOSTIN
4. WATER STEAM CYCLE BEND JOINTS, RELIANCE, DEE
FITTINGS DEVELOPMENT, GMW,STEWARTS & LLOYADS
5. HANGERS & SUPPORTS LISEGA,PIPE SUPPORTS (FORMERLY
MYRICKS) / SPRING SUPPORT
6. WATER / WATER HEAT GEA-ECHOFLEX , ALFA LAVAL, IDMC,L&T
EXCHANGERS
7. REFRACTORY KFS/ PARSHURAM/ PACIFIC / ACC / SRU / TATA
REFRACTORY
8. HP & LP DOSING SKID PSI/ FLUID CONTROLS/ KISHOR/ ENPRO
9. INSULATION LLOYDS/ MURUGAPPA / ORIENT / ROCKWOOL
INDIA / PUNJ LLOYD
10. CLADDING BALCO / HINDALCO/ INDIAN ALUMINIUM /
LLOYAD
11. SAFETY VALVES L&T/ BHEL / JNM/ CHEMTROL / TYCO SANMAR
12. BLOWDOWN VALVE BHEL/ SEMPELL/ LEVCON / KSB / L & T
13. RELIEF VALVES BHEL/ L&T/ JNM
14. IBR VALVES AUDCO/ BHEL/ KSB/ ROCKWELL,
MIL,DRESSER , TYCO
15. NON-IBR VALVES L&T/ KSB/ FOURESS
16. BUTTERFLY VALVES SAUNDERS/ FOURESS/ BDK/ INTER VALVE
17. LARGE BUTTERFLY VALVE BDK , SUFA, AUDCO, FLOVEL, CRESCENT,
FOURESS
18. BALL VALVES KSB/ AUDCO/ FISHER-XOMOX/ FUIDLINE
19. CHEMICAL PUMPS KISHOR/ VK PUMPS/ AK HUBLI
ETRM012-1-M-TS-001
Sr. No. Equipment / System Name of Vendors

20. EXPANSION JOINTS CORI ENGINEERS/ TECHPRO/ TRF/ MACNELLY
BHARAT/ BEVCON
21. STRUCTURAL STEEL JINDAL STEEL, TATA STEEL, VIZAG STEEL,
SAIL
The above list indicates the suppliers generally considered for supply of the major equipment /
system identified. However, contractor can offer alternate makes, purchaser has the right to add /
delete name of any vendor from the list during kick off meeting.
ETRM012-1-M-TS-001

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VOLUME – 2, SECTION – B

Renovation & Modernization

BPSCL Unit # 1 to 5 (5 × 220 TPH)

Prepared and submitted by:

STEAG Energy Services India Pvt. Ltd.

(An ISO 9001:2008 certified Company)

BOKARO POWER SUPPLY CO. (P) LIMITED,

Subject Technical Specification for Steam Generator and

3.2.18 Boiler Blowdown system .................................................................................................................. 43

Equipment Quantity Specification Capacity

Date of commissioning of Boiler 1 to 5 and TG 1 to 3 are as follows:

Equipment No. 1 No. 2 No. 3 No. 4 No. 5

1.1 SALIENT FEATURES OF BOILER 1 TO 5

WATER AND STEAM PARAMETER

TYPE Properties UNIT QUANTITY

Conductivity  Mho 5.00

1.2 FACTORS GOVERNING SCOPE

The optimized scope is governed by the following:

1. Replacement of components, which have exhausted their life.

4. Change of components that are needed to adhere to prescribed environmental standards.

• SPM - Suspended Particulate Matter

2.0 INTENT OF SPECIFICATION

2.1 INTENT OF SPECIFICATION FOR BOILER

2.2 GENERAL DESCRIPTION OF EXISTING STEAM GENERATOR

The steam generator has two enclosures:

a) The furnace or Radiant Zone.

The schematic for the steam generator is shown in Annexure I.

Ceiling Super Heater : 220 square meters

Type : Continuous Seamless

Sr. No. Location Material of Construction (Russian Type)

7 Convective II Superheater 12XIMP Φ

2.4 AIR HEATER

Type : Tubular type

2.5 FUEL BURNING EQUIPMENTS

Number of Main Burners : 6

Number of Oil Burners : 6

Capacity – main burners : Pulverized Coal 8 TPH

2.6 MILLS AND FIRING SYSTEM

The Existing Milling plant details are as below:

Raw Coal Bunker

Number of bunker per boiler 2

Reducing gear ratio 49

The existing design fuel characteristics are as below:

Middling Coal Properties

2.7.1 Forced Draft

Type : Double Suction, D-21.5X2

2.7.2 Mill Fan

2.7.3 Soot Blowers

Located at Water Walls

2.8 INSULATION & REFRACTORY

2.10 CODES & REGULATION

2.10.2 Non-Pressure Parts

2.11 DESIGN PARAMETERS

Main steam Flow at Convective II SH outlet 220t/hr

2.12 PAST HISTORY

a) Incidences of tube failures

b) Number of Forced outages month wise from August 2010 – 2011

Unit U-1 U-2 U-3 U-4 U-5

Unit U-1 U-2 U-3 U-4 U-5