CORPORATE TECHNICAL - PUNE 21-04-2008 Boiler specification.

xls

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28 TPH BI-DRUM TYPE AFBC BOILER

BOILER SPECIFICATION Sr. No. Description A GENERAL DATA 1 Type of System 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Type of Boiler Type of Water Circulation Site Location Type of Support Type of feeding System Application Code - Pressure Parts -Design Application Code - Non Pressure Parts -Design Site Elevation above mean sea level Design Wind velocity Seismic Coefficient Area Classification Environment Boiler Location Boiler performance testing m km/hr Unit DNL Specification Atm. Fluidized Bed Combustion (AFBC) system Bi-Drum Water Tube Boiler Natural Circulation DNL, Nandesari, Baroda Bottom supported Pneumatic under bed feeding system IBR 1950 with latest amendments Standard Engineering Practices. Approx. 400 As per IS 875 As per IS 1893 Safe & Non Hazardous Non Corrosive Semi Outdoor BS 845 Part I Indirect Method / Equivalent CVL Specification Atm. Fluidized Bed Combustion (AFBC) system Bi-Drum Water Tube Boiler Natural Circulation DNL, Nandesari, Baroda Bottom supported Pneumatic under bed feeding system IBR 1950 with latest amendments # # # # Safe & Non Hazardous # Semi Outdoor BS 2885 / IS-8753/ASME PTC 4.1 Indirect method 31 24

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

Design Pressure kg/cm2(g) 31 Steam flow at Maximum Continuous Rating TPH 24 (MCR) - Excluding of dearerator steam-F&A 30c Minimum operating Capacity - F&A 30c TPH 10 Steam Pressure at main steam stop valve outlet kg/cm2(g) 28 / Boiler operating Pressure Steam Temperature at main steam stop valve C Saturated steam corresponding to operating outlet pressure Steam dryness fraction @ MSSV outlet % 99 Make up water temperature at deareator inlet C Room Temperature ( 30C) Feed water Temperature at inlet of Economizer C 105 Boiler Outlet Gas Temperature C 170 Continuous Blow down % 1.0-3.0 % Intermittent Blow down % Approx. 6% Ambient Temperature (for performance) C 40 Ambient Temperature (for Electrical ) C 50 Ambient Temperature (for Insulation ) C 40 Relative Humidity (for performance) % 60 LT Power 415 V +/- 10% , 50 +/- 5%HZ Main Fuel for MCR generation Indian Coal / Imported Coal Fuel Size 100% less than 6 mm & Free from foreign material Secondary fuel with Main fuel Pet Coke maximum 20 % of the total heat value basis. Consumption & GCV For Indian Coal Kg/hr # kg/hr / GCV 3800 kcal / kg Kcal/kg Consumption & GCV For Imported Coal Kg/hr # kg / hr / GCV 5800 kcal / kg Kcal/kg Six Point Gas/Air Temperature measurement To be provided Provision for Gas/FO burner To be provided

# 28 Saturated steam corresponding to operating pressure # Room Temperature ( 30C) 105 170 # # 40 50 40 60 415 V +/- 10% , 50 +/- 5%HZ Indian Coal / Imported Coal 100% less than 6 mm & Free from foreign material # 4996 kg / hr @ GCV 3800 kcal / kg 3164 kg / hr @ GCV 6000 kcal / kg Included. Included.

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28 TPH BI-DRUM TYPE AFBC BOILER

BOILER SPECIFICATION Sr. No. 39 40 41 42 Description Boiler Thermal Efficiency on GCV Basis Start up fuel Comp. Air Pressure Boiler Accessibility Unit % ata DNL Specification 83 +/- 1 Charcoal mixed with diesel 5.0 (Free from Oil & Moisture) Sufficient no. of doors are to be provided at boiler plenum Air Distribution Plate (ADP) and In bed coils and also above the in bed coils. CVL Specification 83 +/- 1 # 7.0 (Free from Oil & Moisture) #

B 1 2 3 4 5 6 7 C 1 2 3 4 5 6 D 1 2 3 4 5 6 E 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 F

FURNACE Type No. of compartments Materials of nozzles Pressure drop in fluid bed nozzles No. of fuel feed point No. of ash drain points Access door, Peepholes BED COIL Arrangement Tube size (OD X T) Tube Pitch Tube material of construction Header size (OD) Header material of construction WATER WALL Type of construction Tube size (OD*T) Tube material of construction Header size (OD) Header material of construction Design Pressure DRUM STEAM DRUM Materials of construction Internal diameter / Thickness Type of dished end Type of tube end connections Type of steam separators Local drum Level Gauges No of Safety Valves MUD DRUM Materials of construction Internal diameter Type of dished end Type of tube end connections Type of steam separators Local drum Level Gauges Remarks BANK TUBES

Water cooled membrane wall with refractory Water cooled membrane wall with lined furnace refractory lined furnace Nos THREE THREE Air nozzle: MS Tip/MS base, Fuel nozzle: MS Air nozzle: MS Tip/MS base, Fuel cap/MS body nozzle: MS cap/MS body mm WC # # Nos 6 Nos 3 Yes # In-line mm x mm 51.0 x 6.3 mm # SA 210 Gr.A1 (Seamless) / Equivalent mm SA 106 Gr.B (Seamless) / Equivalent Fin welded membrane wall construction mm x mm 50.8 x 3.25 BS 3059 Part 1 Gr.320 ERW # SA 106 Gr.B (Seamless) / Equivalent kg/cm2(g) In-line 51.0 x 6.3 # SA 210 Gr.A1# 219.1 SA 106 Gr.B# Fin welded membrane wall construction 50.8 x 3.25 BS 3059 Part # Gr. # ERW 168.3 / 219.1 SA 106 Gr.B # 31

6 3

219.1

31

mm

Nos Nos

SA 516 Gr.70/ Eqvt. # Semi ellipsoidal Expanded # # 2 SA 516 Gr.70/ Eqvt. # Semi ellipsoidal Expanded # # Fully welded Mud drum with man holes and nozzle connections

SA 516 Gr.70/eqvt. 1220 Semi ellipsoidal Expanded Screen driers # 2 SA 516 Gr.70/ Eqvt. 760 Semi ellipsoidal Expanded Screen driers # Fully welded Mud drum with man holes and nozzle connections

mm

Nos

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28 TPH BI-DRUM TYPE AFBC BOILER

BOILER SPECIFICATION Sr. No. 1 2 3 G 1 2 3 4 5 6 7 8 9 10 H 1 2 3 4 5 6 7 8 10 I J K L 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2 2.1 2.2 2 2.1 2.2 2.3 2.4 2.5 2.6 Description Arrangement Tube size (OD X T) Tube material of construction ECONOMIZER Arrangement Type of flow Tube size (OD*T) Tube material Header size (OD) Header material Economizer design Pressure Ash Hopper with isolation gate Shield Plates at the inlet of economiser Access door, AIRHEATER No. of air preheater Arrangement & Type Tube size (OD X T) Tube material No. of gas pass No. of air pass Tube side Fluid Ash Hopper with isolation gate Access door, DOWN COMER RISER AIR BOX FANS FD FAN Make of Fans Nos. of fans per boiler MCR Capacity of fan Static head before fan inlet Medium Temperature Fan speed Recommended drive motor, EFF-II Type, IP-55 FD fan Base frame & coupling hardware Pneumatically operated damper VFD for Motor Canvas duct at discharge, Silencer at suction ID FAN Make of Fans Nos. of fans per boiler MCR capacity of fan Static head before fan inlet Medium Temperature DNL Specification In-line mm x mm 50.8 x 3.25 BS 3059 Part 1 Gr.320 ERW Staggered, plain tube Counter mm x mm 50.8 x 4.06 BS 3059 Part 1 Gr. 320 ERW # SA 106 Gr.B kg/cm2(g) Yes Yes Yes One Multitubular recuperative type arranged in staggered fashion mm x mm 60.3 x 2.34 IS 1239 Unit CVL Specification In-line 50.8 x 3.25 BS 3059 Part # Gr. # ERW Staggered, plain tube Counter 50.8 x 4.06 BS 3059 Part # Gr. # ERW 168.3 SA 106 Gr.B 31 Yes # Yes One Multitubular recuperative type arranged in staggered fashion 60.3 x 2.34 IS 1239 1 1 2 2 # Yes Yes # # # # CVL 1 x 100% 9.69 700 Cold Air 40 1440 40 1440 110 Yes # Yes # CVL 1 x 100% 15.06 400 Flue gas 170 170 31

# Yes Yes # # # # # 1 x 100% m3/sec # mmWc # Cold Air C RPM Kw # Yes Yes Yes Yes # 1 x 100% m3/sec # mmWc # Flue gas C

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28 TPH BI-DRUM TYPE AFBC BOILER

BOILER SPECIFICATION Sr. No. Description 2.7 Fan speed 2.8 Recommended drive motor, EFF-II Type, IP-55 2.9 2.1 2.11 2.12 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 2.9 2.1 2.11 M 1 2 3 4 5 6 7 8 9 N 1 1.1 1.2 1.3 ID fan Base frame & coupling hardware Pneumatically operated damper VFD for Motor Canvas duct at discharge, Silencer at suction PA FAN Make of Fans Nos. of fans per boiler MCR capacity of fan Static head before fan inlet Medium Temperature Fan speed Recommended drive motor, EFF-II Type, IP-55 Unit RPM Kw DNL Specification 1440 # Yes Yes Yes Yes # 2 x 100% m3/sec # mmWc # Hot air C 150 - 160 RPM Kw # Yes Yes No m3/hr mwc C Kw RPM nos # # 105 # 2900 2 (1W+1S) Centrifugal Yes KSB 2 (1W+1S) Centrifugal Yes KSB 75.00 (415 V) 2900 Yes # Yes # CVL 2 x 100% 1.53 700 Hot air 150 - 160 2900 2900 30 Yes # No 33.84 401.5 105 CVL Specification 1440 110

PA fan Base frame & coupling hardware Manually operated damper VFD for Motor FEED PUMPS Capacity Pressure Head Feed water Temperature Motor rating, EFF-II Type, IP-55 Speed Quantity Type Minimum recirculation system with DP switch Make of feed pumps DUCTING SPECIFICATION AIR DUCTING Material of construction Thickness Air flow measuring device, Dampers & metallic expansion joints in air ductings FLUE GAS DUCTING 2 2.1 Material of construction 2.2 Thickness 2.3 Damper & expansion joints in flue gas ducting O REFRACTORY 1 Type of material used 2 Construction P INSULATION 1 Insulation material 2 Cladding finish 3 4 Q Density of Insulation Material Outside surface temperature PAINTING SPECIFICATION

IS 2062 Gr.A / IS 1079 mm Yes 4

IS 2062 Gr.# 4 Yes

IS 2062 Gr.# mm Yes # Standard Engineering Practice Lightly resin bonded mineral wool Plain aluminum cladding of 22 SWG thk. kg/m3 C 5

IS 2062 Gr.# 5 Yes Castable refractory CVL standard engineering practice # Plain aluminum cladding of 22 SWG thk. 100 # 60 60

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28 TPH BI-DRUM TYPE AFBC BOILER

BOILER SPECIFICATION Sr. No. 1 2 R 1 1.1 1.2 1.3 1.3.1 1.3.2 1.3.3 1.3.4 2 2.1 2.2 2.3 Description Sand Blasting Two coat of red oxide DEAERATOR CUM STORAGE TANK Deaerator Type Design standard Design conditions Deaeration capacity Design temperature LP steam at deaerator inlet Deaerator water temperature Deaerated water storage tank Storage capacity Support type Location Unit Sand blasting Yes DNL Specification # Yes CVL Specification

Spray cum tray type ASME kg/hr C Ksc(g) C m3 28000 220 4 105

Spray cum tray type ASME 28000 220 4 105

15 15 Saddle Saddle Will be placed above concrete ceiling of control Will be placed above concrete ceiling room which will be provided by the customer of control room which will be provided by the customer SA 516 Gr.70/eqvt. SA 106 Gr.B/eqvt. SS-304 IS-2062 IS-1239 Feed water, Drum water, Saturated steam Carbon steel Stainless steel SA 516 Gr.70/eqvt. SA 106 Gr.B/eqvt. SS-304 IS-2062 IS-1239 Feed water, Drum water, Saturated steam Carbon steel Stainless steel

Material of construction 3.1 Plate material for shell, dished end & storage tank 3.2 Pipe nozzles 3.3 Spray nozzles/Trays 3.4 Internals 3.5 Piping between Deaerator & Boiler feed pumps S SAMPLE COOLERS 1 Sampling points 2 3 T 1 2 3 4 5 6 7 8 9 10 U 1 2 3 4 5 6 7 Casing material Coil material MOTOR CONTROL CENTRE Make IS standard Type Location Mounting Protection Power supply Frequency Control voltage Cable entry FUEL STORAGE BUNKER No. of Bunker Type Material to be stored Bulk density of fuel Material of construction Storage volume of Bunker (water volume) Storage hours

# CVL IS 8623 IS 8623 Single front, free standing & non drawout type Single front, free standing & non drawout type Indoor Indoor Floor mounting Floor mounting IP-55 IP-55 415V+/-10%.3 phase, 4 wire, earthed neutral 415V+/-10%.3 phase, 4 wire, earthed neutral 50 hz. +/-5% 50 hz. +/-5% 230V, A.C, 50 hz, 2 wire 230V, A.C, 50 hz, 2 wire bottom bottom One Vertical Crushed Ind. Coal / Imported Coal kg/m3 IS-2062 m3 Hours 118 16 Hr. for Ind. Coal 16 Hr. for Ind. Coal 800 IS-2062 118 One Vertical Crushed Ind. Coal 800

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28 TPH BI-DRUM TYPE AFBC BOILER

BOILER SPECIFICATION Sr. No. 8 9 10 11 12 13 14 15 V 1 2 3 W 1 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 4 5 6 7 8 T 1 1.1 1.2 1.3 1.4 2 2.1 2.2 3 4 5 6 7 8 9 10 10.1 10.2 Description Discharge gate type Stiffeners Top cover (chequered plate) Supports Valley angle 2 mm of SS lining upto 2 mtr. Height from the bottom conical portion pf bunker Supporting structure from operating floor Fuel surge hopper FUEL FEEDERS Type of feeders No. of Feeders Drive arrangement CHIMNEY Capacity Design basis Fuel GCV Sulphur content Corrosion Allowance (internal) Size Height Top Diameter (OD) Bottom Diameter (OD) Supporting arrangement Material of construction Lightning Arrestor Aviation lamps Platforms at top & intermediate level BAG FILTER Specification Application Fuel Medium Type Gas Temperature Normal Maximum Inlet dust concentration Outlet dust concentration Max. press. drop across the bag Design pressure Filter Media Bag Thickness (approx.) Type of cleaning Compressed Air requirements Quantity Moisture content DNL Specification Manually operated sliding gate To be Provided To be Provided To be Provided Degree Not exceeding 65 Yes Yes Yes Unit CVL Specification Manually operated sliding gate # # # Not exceeding 65 Yes Yes Yes

Pocket feeder Nos VFD Dedicated to 28 TPH, 28 kg/cm2 press., Sat. steam temp. Coal along with Max. 20 % Pet Coke 6

Pocket feeder 6 VFD Dedicated to 28 TPH, 28 kg/cm2 press., Sat. steam temp. #

Mm M Mm Mm # # # Self supported IS 2062/eqvt. Yes Yes Yes Bag Filter with internals To collect the fly ash from boiler gases Coal Flue gas Reverse pulse jet # C C gm/Nm3 # mg/Nm3 mm WG # mmWC (-) 500 Ryton mm On-line, pulse jet Nm3/hr # gm/m3 #

3 42 1370 2190 Self supported IS 2062/eqvt. Provided Provided Provided Bag Filter with internals To collect the fly ash from boiler gases Coal Flue gas Reverse pulse jet # 170 180 56.5 100 150 (-) 500 Ryton 1.8 On-line, pulse jet 60 (approx.) below 10

170 180 50

1.8

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28 TPH BI-DRUM TYPE AFBC BOILER

BOILER SPECIFICATION Sr. No. 10.3 10.4 11 11.1 11.1.1 11.1.2 11.2 11.2.1 11.2.2 11.3 11.3.1 11.3.2 11.4 11.4.1 11.4.2 12 12.1 12.2 12.3 12.4 12.5 13 13.1 13.2 13.3 13.4 14 15 16 17 18 19 20 X Description Unit DNL Specification Oil content gm/m3 # Pressure kg/cm2(g) Construction details Top plenum Material Mild steel Thickness mm Casing Material Mild steel Thickness mm Hopper Material Mild steel Thickness mm Tube sheet Material Mild steel Thickness mm Timer Quantity 1 No. Type Solid state sequential Pulse duration MS 20 to 200 (adjustable) Interval Sec. 1.5 to 60 (adjustable) Power supply 230 VAC Differential pressure switch Make Switzer Type Diaphragm Pressure range mmWC 25 to 250 Power supply 230 V, 50 hz, single phase Inlet & Outlet dampers, Exhaust connections to To be provided. ID Fan. Temperature Sensor and alarms To be provided. RAL with Motor To be provided. Access Platform and Doors To be provided. By pass arrangement in case of hot gases To be provided. Pressure Switch for Air To be provided. Hopper Heaters with Thermostat. To be provided. DUST COLLECTION SYSTEM MDC will all internals and end connections Yes ASH HANDLING SYSTEM FUEL HANDLING SYSTEM LP DOSING SYSTEM LP dosing tank with agitator Dosing pumps Dosing pump motor HP DOSING SYSTEM HP dosing tank with agitator Dosing pumps Dosing pump motor ASH DISCHARGE SYSTEM Slide gate NO No Yes Yes Yes Yes Yes Yes CVL Specification below 0.2 5 6

Mild steel 3 Mild steel 3 Mild steel 5 Mild steel 3 1 No. Solid state sequential 20 to 200 (adjustable) 1.5 to 60 (adjustable) 230 VAC Switzer Diaphragm 25 to 250 230 V, 50 hz, single phase # # # # Yes Yes Yes Yes No No Yes Yes Yes Yes Yes Yes 3 5 3 3

Y Z AA 1 2 3 AB 1 2 3 AC 1

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28 TPH BI-DRUM TYPE AFBC BOILER

BOILER SPECIFICATION Sr. No. Description 2 Rotary ash discharge feeder & constant speed geared motor below bank, Economizer, air preheater, MDC Unit Yes DNL Specification CVL Specification

CORPORATE TECHNICAL - PUNE 21-04-2008 Boilerspecification.xls

28 TPH BI-DRUM TYPE AFBC BOILER

SCOPE MATRIX Sr. No. Description STEAM DRUM 1 1.1 Fully welded steam drum with internals, man holes & necessary nozzle connections for mounting valves & fittings MUD DRUM 2 2.1 Fully welded Mud drum with man holes and nozzle connections BANK TUBES 3 3.1 Bank tubes 3.2 Bank tubes casing with ash hopper & chutes WATER WALL 4 4.1 Water cooled membrane enclosure with headers & necessary connections like drains 4.2 Bed Tubes and Header ECONOMIZER 5 5.1 Economizer tube assemblies with inlet & outlet headers 5.2 Economizer coils support 5.3 Access door 5.4 Economizer casing with stiffener 5.5 Economizer Ash hopper with isolation gate AIRHEATER 6 6.1 Air preheater tubes and tube sheets 6.2 Access door 6.3 Airheater casing with stiffener 6.4 Airheater ash hoppers DOWN COMER 7 RISER 8 INTEGRAL PIPING 9 9.1 Water piping 9.1.1 From feed pump discharge to feed control station 9.1.2 Feed water control station outlet to Economizer inlet 9.1.3 From Economizer outlet to steam drum inlet 9.1.4 Boiler initial filling line 9.1.5 Minimum recirculation piping from BFWP station to deaerator 9.1.6 Pipe supports (9.1.1 to 9.1.3 and 9.1.5) 9.1.7 Pipe supports (9.1.4 ) 9.1.8 NRVs and stop valves in water feed line. 9.2 Steam piping 9.2.1 Steam piping beyond MSSV 9.2.2 Pipe support beyond MSSV 9.3 Cooling water piping 9.3.1 Piping between cooling water pump outlet & one point near boiler island (both supply & return lines) 9.3.2 Piping between one point near boiler island & individual equipment Engg. V V V V V V V V V V V V V V V V V Supply V V V V V V V V V V V V V V V V V Fabrication V V V V V V V V V V V V V V V V V E&C V V V V V V V V V V V V V V V V V

V V V DNL V V DNL V DNL DNL DNL V

V V V DNL V V DNL V DNL DNL DNL V

V V V DNL V V DNL V DNL DNL DNL V

V V V DNL V V DNL V DNL DNL DNL V

CORPORATE TECHNICAL - PUNE 21-04-2008 Boilerspecification.xls

28 TPH BI-DRUM TYPE AFBC BOILER

SCOPE MATRIX Sr. No. 9.4 9.4.1 9.4.2 9.4.3 9.4.4 9.4.5 9.5 9.5.1 9.5.2 10 10.1 11 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.10 12 12.1 12.2 12.3 12.4 12.5 12.6 13 13.1 13.2 13.3 13.4 13.5 13.6 13.7 13.7.1 13.7.2 13.7.3 Description Blowdown/Drain Blowdown piping from steam drum upto blow down valve Blowdown valve outlet upto blowdown tank Drain piping from individual drain points to common header Support for blowdown,drain & vent piping One no. blowdown tank (common for continuous & intermittent blowdown) Vent From individual vent connections on steam drum Safety valve exhaust piping upto safe elevation AIR BOX Air box with air nozzle & fuel nozzle & ash drain pipe with gate AIR DUCTING Air flow measuring device From FD fan discharge to airheater inlet From airheater outlet to FD header FD header FD header to air box From FD header to PA fan suction From PA fan delivery to PA header PA header Fuel transport lines from PA header to airbox Dampers & metallic expansion joints in air ductings GAS DUCTING From bank outlet to Economizer From Economizer outlet to airheater From airheater outlet to MDC From MDC outlet to ID fan suction damper From ID fan outlet to chimney flange Damper & expansion joints in flue gas ducting FUEL FEEDING SYSTEM 2 mm of SS lining upto 2 mtr. Height from the bottom conical portion pf bunker Bunker with supporting structure from operating floor Supporting structure upto operating floor for bunker- RCC Supporting steel structures for bunker roof & slide cladding GI sheets for roof & side cladding for bunker (upto top level of bunker) Fuel surge hopper FUEL FEEDERS Pocket feeder with variable frequency drive control (6 Nos.) Fuel feeder discharge chutes upto mixing nozzle Couplings/hardware Engg. V DNL DNL DNL DNL V V V V V V V V V V V V V V V V V V V V V DNL V V V V V V Supply V DNL DNL DNL DNL V V V V V V V V V V V V V V V V V V V V V DNL V V V V V V Fabrication V DNL DNL DNL DNL V V V V V V V V V V V V V V V V V V V V V DNL V V V V V V E&C V DNL DNL DNL DNL V V V V V V V V V V V V V V V V V V V V V DNL V V V V V V

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28 TPH BI-DRUM TYPE AFBC BOILER

SCOPE MATRIX Sr. No. 14 14.1 14.2 14.3 14.4 14.5 14.6 14.7 14.8 14.9 14.10 14.11 14.12 14.13 15 15.1 15.1.1 15.2.2 15.2 15.2.1 15.2.2 15.3 15.3.1 15.3.2 16 16.1 16.2 16.2.1 16.2.2 16.2.3 16.2.4 16.3 16.3.1 16.3.2 16.3.3 16.4 16.4.1 16.4.2 16.4.3 16.4.4 Description SUPPORTING STRUCTURES Supporting structure from operating platform Operating platform - RCC Ladders upto operating floor Handrails for operating floor Platform above operating floor Ladders above operating floor Foundation bolts for V supplied equipments Insert plate for boiler supports Complete steel supports for ducting Refractory supports & casing Hanger rod Supporting steel structures for boiler roof & slide cladding GI sheets for roof and slide cladding DRAUGHT EQUIPMENT FD FAN FD fan with base frame & coupling hardware Damper at inlet ID FAN ID fan with base frame & coupling hardware Damper at inlet PA FAN PA fan with base frame & coupling hardware Damper at inlet MOTORISED VALVE Main steam stop valve BOILER FEED WATER CONTROL STATION 1 x 100% feed water control valve Manual Iso. Valve at downstream & upstream side of FCV Manual bypass valve for feed control valve All isolation & drain valves STEAM DRUM Water level gauges Spring loaded mechanical safety valves All isolation & drain valve OTHER SECTIONS All IBR valves in feed line All isolation, drain valves Air box drain valve Air & gas line non IBR valves Engg. V DNL DNL DNL V V V DNL V V NA DNL DNL Supply V DNL DNL DNL V V V DNL V V NA DNL DNL Fabrication V DNL DNL DNL V V V DNL V V NA DNL DNL E&C V DNL DNL DNL V V V DNL V V NA DNL DNL

V V V V V V V V V V V V V V V V V V

V V V V V V V V V V V V V V V V V V

V V V V V V V V V V V V V V V V V V

V V V V V V V V V V V V V V V V V V

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28 TPH BI-DRUM TYPE AFBC BOILER

SCOPE MATRIX Sr. No. Description 17 INSTRUMENTATION & CONTROL 17.1 LOCAL FIELD INSTRUMENT 17.1.1 Thermocouple to measure bed temperature (2 Nos. per compt.) 17.1.2 17.1.3 17.2 17.2.1 17.2.2 17.2.3 17.2.4 17.3 17.3.1 17.3.2 17.3.3 17.4 17.4.1 17.4.2 17.4.3 17.5 17.5.1 17.5.1.1 17.5.1.2 17.5.1.3 17.5.1.4 17.5.2 17.5.2.1 17.5.2.2 17.5.3 17.5.3.1 17.5.3.2 17.5.3.3 17.5.4 17.5.4.1 17.5.4.2 17.5.5 17.5.5.1 17.5.5.2 17.6 Thermocouple to measure free board Thermocouple to measure feed water temp. before Economizer TEMPERATURE GAUGE Temperature gauge to measure fluegas temp. after bank Temperature gauge to measure fluegas temp. after Economizer Temperature gauge to measure Fluegas temp. after multitubular air preheater Temperature gauge to measure Air temperature after multitubular air preheater PRESSURE GAUGE Pressure gauge to measure steam pressure at steam drum Pressure gauge to measure bed pressure Pressure gauge to measure feed line pressure before feed control valve AIR PRESSURE GAUGE Air pressure gauge to measure FD header pressure Air pressure gauge to measure PA header pressure Air pressure gauge to measure air box pressure FIELD INSTRUMENTS REQUIRED FOR CONTROL SYSTEM Three element drum level control consists of One no. drum level transmitter One no. steam flow transmitter One no. feed flow transmitter One no. I/P converter Furnace draught control consists of One no. furnace pressure transmitter One no. I/P converter Auto combustion control consists of One no. steam pressure transmitter One no. air flow transmitter One no. I/P converter Deaerator level control One no. level transmitter One no. I/P converter Deaerator pressure control One no. pressure transmitter One no. I/P converter Instrument air piping from source to battery limit Engg. Supply Fabrication E&C

V V V V V V V V V V V V V

V V V V V V V V V V V V V

V V V V V V V V V V V V V

V V V V V V V V V V V V V

V V V V V V V V V V V V V DNL

V V V V V V V V V V V V V DNL

V V V V V V V V V V V V V DNL

V V V V V V V V V V V V V DNL

CORPORATE TECHNICAL - PUNE 21-04-2008 Boilerspecification.xls

28 TPH BI-DRUM TYPE AFBC BOILER

SCOPE MATRIX Sr. No. Description 17.7 Instrument air piping from boiler battery limit to individual consuming point 17.8 Compensating cables, impulse piping, instrument cables & signal cables from field instrument to junction boxes 17.9 Junction boxes for the instruments supplied by V 17.10 Compressor & driers for instrument air supply 18 SAMPLE COOLERS 17.1 Feed water 18.2 Boiler water 18.3 saturated steam 19 ELECTRICALS 19.1 Motor for FD fan 19.2 Motor for ID fan 19.3 Motor for PA fan 19.4 Motor for Feed pumps 19.5 Incoming cables to LT MCC + CONTROL PANEL 19.6 415V LT MCC+CONTROL PANEL for boiler & its auxiliaries 19.7 Local push button stations for the motors supplied by V 19.8 Interconnecting LT power & control cables including cable trays from LT MCC to drives supplied by V 19.9 Earthing of electrical equipments supplied by V above ground level 19.10 Earthing pit 19.11 Subearth mat & main earth mat 19.12 Lightning protection system & installation 19.13 All lightings for boiler accessories 19.14 Air conditioning system 20 REFRACTORY 20.1 Refractory & refractory holding materials 20.2 Casing for refractory 20.3 Insulation & cladding 21 BOILER FEED WATER PUMPING STATION 21.1 Feed pumps (2 x 100% (1W + 1S)) 21.2 Minimum recirculation system with DP switch 21.3 Valves & mounting at feed pump outlet 22 SPARES 22.1 Commissioning spares 22.2 Tools & tackles 23 DEAERATOR CUM STORAGE TANK 23.1 DEAERATOR 23.1.1 Shell 23.1.2 Dished end 23.1.3 Internals Engg. V V V DNL V V V V V V V DNL V V V V DNL DNL DNL DNL DNL V V V V V V V DNL Supply V V V DNL V V V V V V V DNL V V V V DNL DNL DNL DNL DNL V V V V V V V DNL Fabrication V V V DNL V V V V V V V DNL V V V V DNL DNL DNL DNL DNL V V V V V V V DNL E&C V V V DNL V V V V V V V DNL V V V V DNL DNL DNL DNL DNL V V V V V V V DNL

V V V

V V V

V V V

V V V

CORPORATE TECHNICAL - PUNE 21-04-2008 Boilerspecification.xls

28 TPH BI-DRUM TYPE AFBC BOILER

SCOPE MATRIX Sr. No. 23.2 23.2.1 23.2.2 23.2.3 23.3 23.3.1 23.3.2 23.3.3 23.3.4 23.3.5 23.3.6 23.3.7 23.3.8 23.3.9 23.3.10 23.4 23.4.1 23.4.2 23.4.2 Description DEAERATOR WATER STORAGE TANK Shell Dished end Internals PIPING DM water piping upto inlet of deaerator level control valve From deaerator level control valve to deaerator Steam piping upto deaerator pressure control valve From deaerator pressure control valve to deaerator storage tank Feed line from deaerator storage tank to feed pump Process condensate return piping upto deaerator Vent piping from deaerator vent connection to safe elevation Overflow from deaerator to DM water storage tank Pipe supports (23.3.2 to 23.3.7) Pipe supports (23.3.1 & 23.3.8) SUPPORTING STRUCTURE Saddle support for deaerator storage tank Platform & ladders Any other supporting structure to place the deaerator at elevated Engg. V V V DNL V V V V NA V DNL V DNL V V DNL Supply V V V DNL V V V V NA V DNL V DNL V V DNL Fabrication V V V DNL V V V V NA V DNL V DNL V V DNL E&C V V V DNL V V V V NA V DNL V DNL V V DNL

23.5 VALVES & MOUNTINGS 23.5.1 Pressure control valve with inlet/outlet manual isolation valves & manual bypass valve 23.5.2 Pressure relief valve 23.5.3 Level control valve with inlet/outlet manual isolation valve & manual bypass valve 23.5.4 Safety valve for deaerator 23.5.5 Two no. water level gauge 23.5.6 One no. pressure gauge 23.5.7 Isolation valve for drain 23.6 INSTRUMENTATION 23.6.1 One no. temp. gauge 23.6.2 One no. Thermocouple 23.6.3 One no. level switch 24 INSULATION 24.1 Supply & application of insulation for steam drum, water drum, membrane water wall panel, boiler bank panel, economizer, air preheater, headers, riser & down comer 24.2 Insulation for Air & gas ducting supplied by V 24.3 Insulation for hot water & steam piping supplied by V 25 CHEMICAL DOSING SYSTEM 25.1 LP DOSING SYSTEM

V V V V V V V V V V

V V V V V V V V V V

V V V V V V V V V V

V V V V V V V V V V

V V V

V V V

V V V

V V V

CORPORATE TECHNICAL - PUNE 21-04-2008 Boilerspecification.xls

28 TPH BI-DRUM TYPE AFBC BOILER

SCOPE MATRIX Sr. No. 25.1.1 25.1.2 25.1.3 25.1.4 25.1.5 25.1.6 25.1.7 25.1.8 25.1.9 25.1.10 25.1.11 25.2 25.2.1 25.2.2 25.2.3 25.2.4 25.2.5 25.2.6 25.2.7 25.2.8 25.2.9 25.2.10 26 26.1 26.2 26.3 26.4 27 28 29 29.1 29.2 29.3 29.4 29.5 29.6 Description LP dosing tank with agitator Dosing pumps Dosing pump motor DM piping upto the inlet of preparation tank Associated piping, valves, mountings, fittings within system Base frame Level gauge Pressure gauge Foundation bolts Supports LP dosing pumping unit outlet to inlet of LP dosing connection on feed line HP DOSING SYSTEM HP dosing tank with agitator Dosing pumps Dosing pump motor Piping upto the inlet of preparation tank Valves, mountings, fitting within system Base frame Level gauge Pressure gauge Foundation bolts Supports ASH DISCHARGE SYSTEM Bed ash drain pipe Slide gate Rotary ash discharge feeder & constant speed geared motor below bank, Economizer, air preheater Rotary ash discharge feeder & constant speed geared motor below dust collecting equipment ASH HANDLING SYSTEM FUEL HANDLING SYSTEM CHIMNEY Self Supported Chimney Chimney foundation Lightning Arrestor Aviation lamps Platforms at top & intermediate level Connection between Chimney & ID fan Engg. V V V DNL V V V V V V V V V V DNL V V V V V V V V V V DNL DNL V V DNL V V V V Supply V V V DNL V V V V V V V V V V DNL V V V V V V V V V V DNL DNL V V DNL V V V V Fabrication V V V DNL V V V V V V V V V V DNL V V V V V V V V V V DNL DNL V V DNL V V V V E&C V V V DNL V V V V V V V V V V DNL V V V V V V V V V V DNL DNL V V DNL V V V V

30 CIVIL WORKS 30.1 Loading data for equipment under V scope 30.2 Grouting material (Packing plate & shims)

V DNL

__ DNL

__ DNL

__ DNL

CORPORATE TECHNICAL - PUNE 21-04-2008 Boilerspecification.xls

28 TPH BI-DRUM TYPE AFBC BOILER

SCOPE MATRIX Sr. No. Description 30.3 Grouting for equipments & boiler structure steel column 30.4 Rain gutters & drain piping for boiler hopper, roof & side cladding 31 31.1 31.2 31.3 31.4 31.5 32 32.1 32.2 32.3 32.4 32.5 33 33.1 UTILITIES Initial fill of lubricants & grease Bed material (Sieved natural sand, size - 0.7 to 2.0 mm) Charcoal & kerosene for startup Chemicals & temporary piping for alkali boilout Target plate & temporary piping for hydrotest GENERAL Fire fighting system Packing & forwarding Steam blowing Pump required for hydrotest Boiler initial fill up pump FACILITIES DESCRIPTION Providing erection tools, tackles, hoists, derricks, slings, scaffolding, rigging tools, welding sets, instruments, appliances, consumables required for unloading, transporting, storing, erection, inspection, testing & commissioning to accomplish the work IBR approval at site Stress relieving of welded joints Unloading at site Pre-commissioning check, mass flushing alkali boilout, steam blowing, trial run of all equipment calibration of instrument & control etc. Providing instrument for above testing Performance test Construction of site office & store room & dismantled after actual completion of jobs & successful commissioning of boiler Lockage & covered storage for tools & tackels of V Storage space & access road Local conveyance, boarding & lodging for V personals Canteen charges for staff & worker of V O & M staff for boiler startup, commissioning & operation Supply of construction power & water at free of cost Telephone facilities Emergency/ first aid medical facilities to V staff & erection crew Safety & security for V personal working at site Lighting facilities at erection site Boiler registration formalities Engg. DNL DNL DNL V DNL DNL NA DNL V DNL V DNL Supply DNL DNL DNL V DNL DNL NA DNL V DNL V DNL Fabrication DNL DNL DNL V DNL DNL NA DNL __ DNL V DNL E&C DNL DNL DNL V DNL DNL NA DNL __ DNL V DNL

RESPONSIBILITY

33.2 33.3 33.4 33.5

V V DNL V V V V V DNL V V DNL DNL DNL DNL V DNL V

33.6 33.7 33.8 33.9 33.10 33.11 33.12 33.13 33.14 33.15 33.16 33.17 33.18 33.19

CORPORATE TECHNICAL - PUNE 21-04-2008 Boilerspecification.xls

28 TPH BI-DRUM TYPE AFBC BOILER

SCOPE MATRIX Sr. No. 33.20 33.21 33.22 33.23 33.24 33.25 33.26 33.27 33.28 Description Transportation Transit insurance Site storage insurance Applicable taxes & duties First fill lubricants & Chemicals for alkali boilout Acid cleaning Training for persons upto PG test at site Drainage & sanitary works CEIG, pollution & factory approval Engg. Supply Fabrication DNL DNL DNL DNL V NA V DNL DNL E&C

CORPORATE TECHNICAL - PUNE 21-04-2008 Boilerspecification.xls

28 TPH BI-DRUM TYPE AFBC BOILER

TERMINAL POINTS Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Air Main steam Deaerator steam Fuel Flue gas Ash Ash Instrument air / service air Cooling water Condensate return Make up water LP dosing - DM water Control cabling Blow down Drains & Vents Electricals Earthing - over ground earthing Exhaust / Vent Description Feed water Terminal Points Inlet of deaerator level control valve Suction flange of FD fan damper Outlet of MSSV Inlet of deaerator pressure control station at 5 kg/cm2(g) Inlet of fuel storage bunker Outlet of chimney Outlet of bed ash drain gate Outlet of ash feeder at the bottom of bank, economizer, airheater, MDC & bag filter At 1 m distance from boiler first column At 1 m distance from boiler first column At inlet of condensate return flange on deaerator Inlet of deaerator level control station Inlet of LP dosing skid At the inlet of power cum control panel for boiler Terminated at the inlet of drain header, at the outlet of blow down tank Outlet of respective valves & flanges Input terminals of LT MCC for boiler Terminated at the earthing node next to equipment Terminated 1m above the boiler house roof.