Waste Heat Recovery Power Plant 2mw 100tpd Orissa

WASTE HEAT RECOVERY POWER PLANT(2MW)– 100TPD
ORISSA SPONGE IRON CLUSTER

BEE, 2011
Detailed Project Report on Waste Heat Recovery
Power Plant (2MW)- 100 TPD
Sponge Iron SME Cluster, Orissa (India)
New Delhi: Bureau of Energy Efficiency;
Detail Project Report No.: ORSA/SPONGE/WHP/10
For more information Telephone +91-11-26179699

Bureau of Energy Efficiency (BEE)
Fax+91-11-26178352
(Ministry of Power, Government of India)
Websites: www.bee-india.nic.in
4th Floor, Sewa Bhawan
Email: jsood@beenet.in/ pktiwari@beenet.in
R. K. Puram, New Delhi – 110066
Acknowledgement
We sincerely appreciate the efforts of industry, energy auditors, equipment manufacturers,

technology providers, consultants and other experts in the area of energy conservation for
joining hands with Bureau of Energy Efficiency (BEE), Ministry of Power, and Government
of India for preparing the Detailed Project Report (DPR) under BEE SME Program in
SMEs clusters. We appreciate the support of suppliers/vendors for providing the adoptable
energy efficient equipments/technical details to the SMEs.
We have received very encouraging feedback for the BEE SME Program in various SME
Clusters. Therefore, it was decided to bring out the DPR for the benefits of SMEs. We
sincerely thank the officials of BEE, Executing Agencies and ISTSL for all the support and
cooperation extended for preparation of the DPR. We gracefully acknowledge the diligent
efforts and commitments of all those who have contributed in preparation of the DPR.
vii
CONTENT
List of Annexure vii
List of Tables vii
List of Figures viii
List of Abbreviation viii
Executive summary ix
About BEE’S SME program xi
1 INTRODUCTION ........................................................................................................1
1.1 Brief Introduction about cluster ...................................................................................1
1.2 Energy performance in existing situation ....................................................................4
1.3 Existing technology/equipment ...................................................................................5
1.4 Establishing the baseline for the equipment ................................................................5
1.5 Barriers for adoption of new and energy efficient technology / equipment ...................6
2. TECHNOLOGY/EQUIPMENT FOR ENERGY EFFICIENCY IMPROVEMENTS .........8
2.1 Detailed description of technology/equipment selected ...............................................8
2.2 Life cycle assessment and risks analysis ..................................................................10
2.3 Suitable unit/plant size in terms of capacity/production .............................................10
3. ECONOMIC BENEFITS FOR THE INSTALLATION OF FUEL ECONOMIZER ........11
3.1 Technical benefits .....................................................................................................11
3.2 Monetary benefits .....................................................................................................11
3.3 Social benefits ..........................................................................................................12
3.4 Environmental benefits .............................................................................................12
4. INSTALLATION OF FUEL ECONOMIZER ...............................................................13
4.1 Cost of technology/equipment implementation ..........................................................13
4.2 Arrangement of funds ...............................................................................................13
4.3 Financial indicators ...................................................................................................14
4.4 Sensitivity analysis in realistic, pessimistic and optimistic scenarios .........................14
4.5 Procurement and implementation schedule ..............................................................15
ANNEXURE ...........................................................................................................................16
viii
Annexure 1: Process Flow Diagram .......................................................................................16
Annexure 2: Detailed technology assessment report – Fuel Economizer for 100 TPD ...........17
Annexure 3: Detailed drawing for civil work required for Fuel EconomizerError! Bookmark not defined.
Annexure 3: Detailed drawing for civil work required for Fuel EconomizerError! Bookmark not defined.
Annexure 4: Detailed financial calculations & analysis ...........................................................19
Annexure 5: Details of procurement and implementation plan ................................................24
Annexure 6: Details of technology/equipment and service providers ......................................25
Annexure 7: Quotation or techno-commercial bid ...................................................................27
List of Table
Table 1.1: Energy consumption of typical units have 50 TPD kilnError! Bookmark not defined.
Table 1.2: Specific energy consumption for typical units with 50 TPD kilnsError! Bookmark not defined.
Table 1.4 Coal consumption of Sponge iron Cluster ...................Error! Bookmark not defined.
Table 2.1: Fuel Economizer Specifications .................................Error! Bookmark not defined.
Table 3.1: Energy and monetary benefits ...................................Error! Bookmark not defined.
Table 4.1: Project detail cost ......................................................Error! Bookmark not defined.
Table 4.2: Sensitivity analysis ....................................................Error! Bookmark not defined.
Lists of Abbreviations
BEE - Bureau of Energy Efficiency

DPR - Detailed Project Report
DSCR - Debt Service Coverage Ratio
GHG - Green House Gases
HP - Horse Power
IRR - Internal Rate of Return
MoP - Ministry of Power
MoSME - Micro Small and Medium Enterprises
NPV - Net Present Value
ROI - Return On Investment
SIDBI - Small Industrial Development Bank of India
SME - Small and Medium Enterprises
ix
EXECUTIVE SUMMARY
APITCO Ltd. is executing BEE-SME program in Orissa Sponge Iron Cluster, supported by
Bureau of Energy Efficiency (BEE) with an overall objective of improving the energy
efficiency in cluster units.
Rourkela and Sundargarh area is renowned for Sponge iron manufacturing business and
is a big hub for sponge iron supply. There are about 107 sponge iron units in the cluster
and majority of industries located in Sundargarh area engaged in production of sponge
irons which further converted into billets through induction furnace for further use.
The major Energy consumption in sponge Iron cluster is of thermal energy derived from
coal and electrical energy from grid electricity. Electricity is used for supplying energy for
motor driven drives like kiln min drive, cooler main drive, crushers, bag filters, pumps,
ESPs etc. and also for lighting purpose. If the percentage share of the total energy
consumption is considered then the electrical is not more than 2% where as the remaining
98% is the thermal energy requirement. HSD is used as fuel in DG sets for generation of
electricity during the power failure from Electricity board.
In the plant it is observed that a good amount of heat energy is expelled out of the kiln in
the form of waste gases, more over an extra amount of electrical energy is given via
forced draft fan to reduce the heat content of the flue gases for the environmental concern.
The flue gases from the kiln’s ore feeding end contains a good percentage of carbon
monoxide which is further burnt in the ABC i.e. the After Burning Chamber which causes
rise in the outlet flue gases temperature. The waste heat of the flue gases can be used for
generating power which results in the power consumption.
The DPR highlights the details of study conducted for assessing the potential for reducing
thermal energy consumption during operation by installing fuel economizer at the various
units in the cluster, possible energy savings and its monetary benefit, availability of the
technologies/design, local service providers, technical features and proposed equipment
specifications, various barriers in implementation, environmental aspects, estimated GHG
reductions, capital cost, financial analysis, and schedule of project Implementation.
Total investment required and financial indicators calculated such as debt equity ratio,
monetary saving, IRR, NPV, DSCR and ROI etc for proposed technology is furnished in
Table below:
x
S. No. Particular Unit Value
1 Project cost (in Lakh) 725
2 Power Savings KW/annum 14256000
3 Monetary benefit (in Lakh) 499

4 Simple payback period Months 18
5 NPV (in Lakh) 660.29
6 IRR percentage 37.01
7 ROI percentage 34.78
8 Average DSCR Ratio 2.24
The projected profitability and cash flow statements indicate that the project
implementation i.e. installation of waste heat power plant will be financially viable and
technically feasible solution for the cluster.
xi
ABOUT BEE’S SME PROGRAM
Bureau of Energy Efficiency (BEE) is implementing a BEE-SME Programme to improve

the energy performance in 29 selected SMEs clusters. Orissa Sponge Iron Cluster is one
of them. The BEE’s SME Programme intends to enhance the energy efficiency awareness
by funding/subsidizing need based studies in SME clusters and giving energy
conservation recommendations. For addressing the specific problems of these SMEs and
enhancing energy efficiency in the clusters, BEE will be focusing on energy efficiency,
energy conservation and technology up-gradation through studies and pilot projects in
these SMEs clusters.
Major activities in the BEE -SME program are furnished below:
Activity 1: Energy use and technology audit
The energy use technology studies would provide information on technology status, best
operating practices, gaps in skills and knowledge on energy conservation opportunities,
energy saving potential and new energy efficient technologies, etc for each of the sub
sector in SMEs.
Activity 2: Capacity building of stake holders in cluster on energy efficiency
In most of the cases SME entrepreneurs are dependent on the locally available
technologies, service providers for various reasons. To address this issue BEE has also
undertaken capacity building of local service providers and entrepreneurs/ Managers of
SMEs on energy efficiency improvement in their units as well as clusters. The local service
providers will be trained in order to be able to provide the local services in setting up of
energy efficiency projects in the clusters
Activity 3: Implementation of energy efficiency measures
To implement the technology up-gradation project in the clusters, BEE has proposed to
prepare the technology based detailed project reports (DPRs) for a minimum of five
technologies in three capacities for each technology.
Activity 4: Facilitation of innovative financing mechanisms for implementation of

energy efficiency projects
The objective of this activity is to facilitate the uptake of energy efficiency measures
through innovative financing mechanisms without creating market distortion
xii
Waste Heat Recovery Power Plant 2 MW-100 TPD
1 INTRODUCTION
1.1 Brief Introduction about cluster
The state of Orissa is located in the South –East coast of India in the banks of Bay of
Bengal. The state capital is Bhubaneswar. It is renowned for the Sponge Iron business.
They even export to various countries throughout the world.
There are about 107 sponge iron industries in the cluster and majority of industries are
located in Orissa.
The major Energy consumption in Ice making cluster are thermal energy from coal and
grid electricity. Electricity is used for driving the prime movers of installed in the plants i.e.
Reduction Kiln main drive, Cooler Kiln main, air compressors, pumps, and other drives
and even for lighting purpose. The majority of the energy share is by the thermal energy
drawn by burning coal which comes out to be around 98% of the total energy consumption
the remaining is by the electrical energy.
1.1.1 Production process

Non-coking coal and iron ore along with limestone in the required size range and quantity
are continuously fed into the feed – end of the inclined rotary kiln through a feed pipe. The
materials move along the length of the kiln due to its inclination and rotation. Air is blown
in through required number of air tubes suitably located along the length of the kiln. At the
feed-end of the kiln air is blown in through nozzles for drying and pre heating of the
charge. Initial heating of the kiln is carried through a central oil burner located at the
discharge feed end. As the charge moves through the kiln, it is heated by the hot gases,
which flow in the opposite direction to the charge (i.e. counter current flow). The initial part
of the kiln (about 30%) is called the pre heating zone, where moisture in the charge and
volatiles in the coal are removed / burnt off as waste gases. The required heat in this
zone is provided by the combustion of the feed coal. The remaining portion of the kiln is
called as the reduction zone. In this zone, oxygen in the iron ore is removed leaving
metallic iron as per the following chemical reaction.
3FeO3 + CO -------------------- 2 Fe2O4 + CO2
Fe2O4 + CO -------------------- 3FeO + CO2
FeO + CO -------------------- Fe + CO2
The CO is generated for the above reaction according to CO2 + C  2CO, at temperature
above 900 deg. C, carbon monoxide will combine with the oxygen in the iron ore forming
carbon dioxide and thus reduce the ore to metallic state.
1
Higher the temperature, the faster would be the oxygen removal. After the removal of
oxygen and grater is the metallization of sponge iron. Metallization levels can roughly be
checked by density of the sponge iron. It can also be judged by the metallic luster if a
sample is rubbed against a rough surface.
After the iron ore has been metallic to the desired level, sponge iron and residual char are
discharged from the kiln into a rotary drum type cooler. In the cooler sponge iron is cooled
to below 60 deg. C before the material is discharged on to a belt conveyor. If the sponge
iron were exposed to air at high temperatures (about 150 deg. C) it would tend to re
oxidize. It is therefore, necessary that the temperature of the product at the point of
discharge from the cooler is as close as possible to the ambient temperature. The
reduction process occurs in solid state. The crucial factor in this reduction process is the
controlled combustion of coal and its conversion to carbon monoxide to remove oxygen
from the iron ore.
The overall process extends to a period of 10 to 12 hours inside the kiln. During this time,
iron ore is optimally reduced and the hot reduced sponge iron along with semi-burnt coal
is discharged to a rotary cooler for indirect cooling to a temperature of around 120°C.
Sponge iron being magnetic in nature, the discharge from cooler main drive consisting of
sponge iron, chars & other contaminations are routed through electromagnetic separators,
to separate other impurities from sponge iron. The product is then screened in size
fractions of lump (+3mm) and fines (0-3 mm). Separate bins are installed to preserve its
quality, reduce re oxidation and facilitate faster loading on to the trucks.
Detailed of process flow chart are finished in Figure 1.1 below:
2
Figure 1.1: General process flowchart of a typical Sponge Iron unit
Raw material feeding at

ground hopper (Coal Ore)
Coal Sized Iron Over size

ore
Crushing Crushing
Screening
Screening
Coal bin Iron ore

bin Dolomite
Over Setting up of
sized Production of mixed
raw materials for kiln
feed
Processed in rotary kiln at

1000 c
Indirect cooling in rotary cooler

with water spray
Screening of mixed end product

(sponge iron and un-burnt coal)
S.I. Lumps - S. I. Fines -

Char Dolochar
Drum type
Drum type magnetic
magnetic
separator
separator
S. I. Lump Char bin
bin S. I. Fines bin Dolochar
3
1.2 Energy performance in existing situation

1.2.1 Fuel and electricity consumption of a typical unit in the cluster
The main energy used in a typical sponge iron industry is the thermal energy derived from
coal and electrical energy from grid supply. Electricity is used for driving the prime movers
like kiln drives, compressors, pumps, Bag filters, crushers, FD and ID fans etc. and even
for lighting power consumption. The energy consumption details are given below in the
Table 1.1 below:
Table 1.1: Energy consumption of typical units have 100 TPD kiln
Annual
No.
Electricity
of Annual Annual Coal
consumpti
S. No Name of Industries TPD 100 Produc Consumption
on
TPD tion (Tons/annum)
(millions of
Kiln
kWh)
1 Govindam Projects P Ltd. 200 2 62415 4.99 108186
2 Jay Iron & Steel Pvt. Ltd. 200 2 59862 4.75 93119
3 Kalinga Sponge Iron Limited 200 2 58800 6.17 91467
4 Maa Shakamburi Sponge ltd. 100 1 29651 2.9 46124
5 Pooja Sponge Private Limited. 200 2 60000 4.7 93333
6 Shree Ganesh Metallics Ltd. 400 4 122000 9.8 199562
7 Singhal Enterprises Pvt. Limited 200 2 60500 6 95270
8 Sponge Udyog private limited 200 2 59700 4.8 92866
9 Sri Mahaveer Ferro Alloys Pvt. 200 2 60366 5.99 93887
Limited
10 Sri Mangalam Ispat Limited 200 2 61000 5.2 94888
11 Surendra Mining (IND) P. Ltd 200 2 59000 4.11 92714
12 Vishal Metallic Limited 100 1 28000 4.1 44091
1.2.2 Average production by a typical unit in the cluster

The average productions in a sponge iron unit depend on the installed TPD for a single
100 TPD kilns it varies in between 28000 to 30000 tons per annum.
1.2.3 Specific Energy Consumption
For production of sponge iron both thermal and electrical energy are required. The major
share of the energy is for the thermal energy which is around 98 % and the remaining is of
the electrical energy. The over all specific energy consumption of the units is given below:
4
Table 1.2: Specific energy consumption for typical units with 100 TPD kilns
Over all Specific
No. of
S. Annual energy
Name of Industries TPD 100 TPD
No. Production consumption
Kiln
(TOE/ Tons)
1 Govindam Projects P Ltd. 200 2 62415 0.53
2 Jay Iron & Steel Pvt. Ltd. 200 2 59862 0.47
3 Kalinga Sponge Iron Limited 200 2 58800 0.48
4 Maa Shakamburi Sponge ltd. 100 1 29651 0.48
5 Pooja Sponge Private Limited. 200 2 60000 0.47
6 Shree Ganesh Metallics Ltd. 400 4 122000 0.50
7 Singhal Enterprises Pvt. Limited 200 2 60500 0.48
8 Sponge Udyog private limited 200 2 59700 0.47
9 Sri Mahaveer Ferro Alloys Pvt. Limited 200 2 60366 0.48
10 Sri Mangalam Ispat Limited 200 2 61000 0.47
11 Surendra Mining (IND) P. Ltd 200 2 59000 0.48
12 Vishal Metallic Limited 100 1 28000 0.48
1.3 Existing technology/equipment

1.3.1 Description of existing technology
In the present condition there is no arrangement for the recovery of the waste heat which
is expelling out of the kiln. The pre heating is of the ore is done in the 1st zone of the kiln
where the temperature reaches to 7000C, just before the reduction zone. And the heat
contained in the flue gas is force fully reduced by the help of the FD fans or GCT
arrangements just after the ABC chamber. The heat contained in the flue gas coming out
of the kiln is made to increase more in ABC as because the unburned carbon monoxide is
made to burn in the ABC for converting it completely to cordon dioxide. This hot expelled
out gas is conditioned in the ESP and FD or GCT arrangements and then is released in
the atmosphere.
1.3.2 Its role in the whole process

As the system proposed is not replacing any of the existing technology thus to describe
the role in the whole process is not applicable.
1.4 Establishing the baseline for the equipment

1.4.1 Design and operating parameters
The present energy consumption for the production of sponge iron is given in the Table
1.4. The coal consumption depends on the production per batch which can be considered
to be 24 hours per day.
5
1.4.2 Coal consumption in existing system

The coal consumption in the process of sponge iron manufacturing the units having at
least one 100 TPD kiln is given below with the specific coal consumption of the unit.
Table 1.4 Coal consumption of Sponge iron Cluster

Specific
Annual
Coal
Electrical Annual Coal
No. of Consumpti
S. Annual energy consumption
100 on
No Name of Industries TPD Product consumpti (from coal of
TPD (tons of
. ion on CV 3000
Kiln coal/ tons
(millions kcal/kg)
of Sponge
of kWh)
iron)
1 Govindam Projects P Ltd. 200 2 62415 4.99 108186 1.73
2 Jay Iron & Steel Pvt. Ltd. 200 2 59862 4.75 93119 1.56
3 Kalinga Sponge Iron Limited 200 2 58800 6.17 91467 1.56
4 Maa Shakamburi Sponge ltd. 100 1 29651 2.9 46124 1.56
5 Pooja Sponge Private Limited. 200 2 60000 4.7 93333 1.56
6 Shree Ganesh Metallics Ltd. 400 4 122000 9.8 199562 1.64
7 Singhal Enterprises Pvt. Limited 200 2 60500 6 95270 1.57
8 Sponge Udyog private limited 200 2 59700 4.8 92866 1.56
9 Sri Mahaveer Ferro Alloys Pvt. 200 2 60366 5.99 93887 1.56
Limited
10 Sri Mangalam Ispat Limited 200 2 61000 5.2 94888 1.56
11 Surendra Mining (IND) P. Ltd 200 2 59000 4.11 92714 1.57
12 Vishal Metallic Limited 100 1 28000 4.1 44091 1.57
1.4.3 Operating specific coal consumption of existing system.

The detailed energy audit studies had been undertaken in various units of the cluster to
evaluate the specific coal consumption in the cluster. Based on the installed TPD the
specific energy consumption varies from 1.56 to 1.73 tons of coal to tons of production. On
installing the fuel economizer there is a reduction of coal consumption by 5% of that of the
present coal consumption.
1.5 Barriers for adoption of new and energy efficient technology / equipment
1.5.1 Technological Barriers
The major technical barriers that prevented the implementation of the waste heat boiler in
the cluster are:
Lack of water availability.

1.5.2 Financial Barrier
Implementation of waste heat power plant requires high investment compare. Hence,
many of the owners don’t show interest due to high initial investment.
6
Energy Efficiency Financing Schemes such as SIDBI’s, if focused on the cluster, will play
a catalytic role in implementation of identified energy conservation projects &
technologies. The cluster has significant potential for implementing the fuel economizer.
1.5.3 Skilled manpower
Not applicable
1.5.4 Other barrier(s)
Information on energy efficient technologies is not available among cluster unit owners,
though the suppliers are available in near by states to the sponge iron cluster. Such
technology has a substantial potential to save power consumption in the cluster.
7
2. TECHNOLOGY/EQUIPMENT FOR ENERGY EFFICIENCY IMPROVEMENTS
2.1 Detailed description of technology/equipment selected

2.1.1 Description of equipment
The project activity is installing the waste heat power in the existing operation. This
arrangement uses to recover the waste heat of the exhaust flue gas coming out from the
ABC outlet is feed in the waste heat boiler for generating power. The flue gas contains the
heat content which is considerable to recover by adopting the proper heat recovery
system. The sensible heat of the flue gases can be recovered to an extent. Complete
recovery of waste heat is neither theoretically possible nor economically viable and hence
only optimum quantity of the heat is recovered during this process. The waste heat
recovery power plant has following special features:
The most effective feature implementation point of view is that it does not require
any additional space for installation.
It significantly reduces the effect the temperature of the flue gases expelling out in
the atmosphere.
2.1.2 Technology /Equipment specifications

The detailed specification of the Waste Heat Recovery power plant suggested is furnished
in table 2.1 below:
Table 2.1: Waste heat recovery power plant Specifications

Boiler: IBR 1950 with its latest amendments
S. No. Specifications UNIT Data

1 Design Pressure Kg/cm2 75
2 Design Temperature oC 317
3 Hydro test Pressure Kg/cm2 112.5
4 Type Vertical
5 Type of tubes Bare
6 Tube outer diameter mm 50.8
7 Tube thickness mm 4.47
8 Fin thickness mm 5
9 MOC of tubes BS 3059 Seamless
10 MOC of fins IS 2002
11 MOC of headers SA 106 Gr.B
8
Turbine: Multi stage, Horizontal Spindle, Bladed Design, Axial Flow, Impulse, Bleed
cum Condensing Steam Turbine.
S. No. Specifications UNIT Data

1 Make KESSELS
2 Turbine Rating MW 2
3 Inlet steam pressure Kg/cm2 64
4 Inlet steam Temperature oC 485
5 Inlet steam flow TPH 18
6 Bleed Steam TPH 1.75
7 Exhaust steam pressure Bar 0.18
8 Steam flow to condenser TPH 9.125
9 Power Generated (MAX) MW 2
2.1.3 Justification of the technology selected & Suitability
The flue gas coming out of the reduction kiln is having a very high thermal energy which
not been used for any of the process activity. Further the high temperature content of the
gas is made to cool down by the force draft fan in waste gas treatment zone which is then
fed to the ESP for the waste gas cleaning due to the environment concern. This
technology is very useful for exchanging the heat of the waste flue gases for generating
power.
2.1.4 Superiority over existing technology/equipment

In the present process condition extra amount of energy is required to reduce the waste
heat of the exhaust flue gas. This is the energy required to run the FD fans for cooling the
flue gas for the safety of the environment. With the installation of the waste heat recovery
boiler good amount of heat is absorbed for per heating water and producing steam.
Utilizes the waste energy of the flue gas which unused in the previous system.
Reduces the environmental effect.

2.1.5 Availability of proposed technology/equipment
Such equipment suppliers are available and are already been installed in some of the
sponge iron plants in Raipur. The detail of the supplier is provided in Annexure-6.
2.1.6 Source of technology/equipment for the project
The source of the technology is indigenous and is available.
2.1.7 Service/technology providers
A detail of supplier has been furnished in Annexure 6.
2.1.8 Terms of sales
9
No any specific terms and conditions
2.1.9 Process down time during implementation

The process down time for installation of waste heat recovery boiler is Zero due to no
major changes required for installing this technology.
2.2 Life cycle assessment and risks analysis
The life of the waste heat recovery boiler system is considered for 15 years. There is no
risk involved as the technology is installed in few plants and running successfully.
2.3 Suitable unit/plant size in terms of capacity/production
The Waste heat recovery power plants are categorized by the following plant sizes they
are 100 TPD, 200 TPD & 300 TPD if they are installed side by side and the flue gas output
can be merged together from the out let of ABC.
10
3. ECONOMIC BENEFITS FOR THE INSTALLATION OF WASTE HEAT

RECOVERY BOILER
3.1 Technical benefits

3.1.1 Fuel savings per year
Waste Heat carried away by the flue gases is being recovered by the Waste Heat
recovery Boilers and gainfully used for Steam and hence power generation.
Fuel: The fuels available for power generation are:
Off Gases from DR kiln after “After Burning Chamber (ABC)The waste Heat Boiler will be
installed behind the ABC of DR kiln in bypass configuration. The flue gases after ABC will
be taken to unfired furnace chamber and them flow over banks of super heater, convective
evaporator and economizer before being discharged to atmosphere through ESP, ID Fan
and chimney of DR Kiln. In case of outage of Waste Heat Boiler, Flue gases will pass
through GCT- ESP ID Fan and Chimney. The flue gases will pass over various heat
transfer surfaces to ESP and then finally discharges in to chimney by ID Fans. The boiler
will have its own ESP, ID fans and Chimney.
3.1.2 Electricity savings per year
The power savings due to installation of WHR boiler and turbine is 14256000 kWh per
annum.
3.1.3 Improvement in product quality
There is no significant impact on the product quality.
3.1.4 Increase in production
There is no increase of production capacity.
3.1.5 Reduction in raw material consumption
Not Applicable
3.1.6 Reduction in other losses
Not Applicable
3.2 Monetary benefits
The monetary benefit due to installation of waste recovery power plant for 100 TPD kiln is
Rs. 499 lakhs per annum due to the generation of power. A detail of the saving is given in
Table 3.1 below:
11
Table 3.1: Energy and monetary benefits
S. No. Parameter Unit Value
1 Power generation kwh/day 48000
2 Auxilary power consumption kwh/day 4800
3 Power available for grid kwh/day 43200
4 Power available for grid kwh/year 14256000
5 Power Cost Rs./kWh 3.3
06 Energy cost due to power generation using flue Rs.lakhs/year 499

gases
3.3 Social benefits

3.3.1 Improvement in working environment in the plant
There is no such benefit achieved by waste heat recovery boiler..
3.3.2 Improvement in skill set of workers

The technology selected for implementation is waste heat recovery power plant will create
the awareness among the workforce on advancement of the waste heat recovery system
and how it will reduce the total energy consumption by existing process.
3.4 Environmental benefits

3.4.1 Reduction in effluent generation
None
3.4.2 Reduction in GHG emission such as CO2, NOX, etc
The major GHG emission reduction source is CO2. The technology will reduce coal
consumption and emission.
3.4.3 Reduction in other emissions like SOx
No significant impact on SOx emissions.
12
4. INSTALLATION OF WASTE HEAT RECOVERY POWER PLANT
4.1 Cost of technology/equipment implementation

4.1.1 Cost of technology/equipments
The total cost of waste heat recovery power plant is estimated to be Rs. 746 lakhs, which
includes all the required equipment and man power for the installation of the waste heat
recovery power plant. Other details are mentioned in the quotation attached in Annexure
7.
4.1.2 Other costs
Other charges include cabling and panel modification. Project cost details are furnished in
Table 4.1 below:
Table 4.1: Project detail cost
S. No. Particular Unit Value

1 Cost of Boiler Rs. in lakhs 373.50
2 Cost of System Rs. in lakhs 210.00
3 Erection & Commissioning Lump sum 25.00
4 Civil work Lump sum 50.00
5 Taxes Rs. in lakhs 42.00
6 Other Misc. cost(supervision, other cost) Rs. in lakhs 10.00
7 Total cost excluding EPC Rs. in lakhs 710.50
8 EPC cost Rs. in lakhs 35.53
9 Total Investment Rs. in lakhs 746.03
4.2 Arrangement of funds

4.2.1 Entrepreneur’s contribution
The entrepreneur’s contribution is 25% of total project cost, which works out at Rs. 186
lakhs.
4.2.2 Loan amount
The term loan is 75% of the total project, which is Rs. 560 lakhs.
4.2.3 Terms & conditions of loan
The interest rate is considered at 10% which is prevailing interest rate of SIDBI for energy
efficiency related projects. The loan tenure is 5 years and the moratorium period is 6
months.
13
4.3 Financial indicators

4.3.1 Cash flow analysis
Considering the above discussed assumptions, the net cash accruals starting with 255.68
lakh in the first year operation and increases to 12225 at the end of fifth year.
4.3.2 Simple payback period
The total project cost of the proposed technology is Rs. 746 lakh and monetary savings
due to generation of power is Rs.499 lakh and the simple payback period works out to be
18 months.
4.3.3 Net Present Value (NPV)
The Net present value of the investment at 10% interest rate works out to be Rs.1194.06
lakh.
4.3.4 Internal rate of return (IRR)
The after tax Internal Rate of Return of the project works out to be 42.03 %. Thus the
project is financially viable.
4.3.5 Return on investment (ROI)
The average return on investment of the project activity works out at 24.33%. The average
DSCR is 2.09.
4.4 Sensitivity analysis in realistic, pessimistic and optimistic scenarios
A sensitivity analysis has been worked out to ascertain how the project financials would
behave in different situations like there is an increase in power savings or decrease. For
the purpose of sensitive analysis, two scenarios are considered are.
Increase in power savings by 5%
Decrease in power savings by 5%
In each scenario, other inputs are assumed as constant. The financial indicators in each of
the above situation are indicated along with standard indicators.
Table 4.2: Sensitivity analysis

Particulars IRR NPV ROI DSCR
Normal 37.01 660.29 34.78 2.24
5% increase in power savings 41.97 795.54 35.61 2.45
5% decrease in power savings 31.91 525.04 33.74 2.02
14
4.5 Procurement and implementation schedule
The project is expected to be completed in 10 Months from the date of release of

purchase order. The detailed schedule of project implementation is furnished in Annexure
5.
15
ANNEXURE
Annexure 1: Process Flow Diagram
Process flow diagram will remain the same after implementation of proposed waste heat
recovery power plant.
16
Annexure 2: Detailed technology assessment report –Waste heat recovery boiler for
100 TPD
S.No Parameter Unit Existing Proposed
System WHR Power
Generation
1 Rotary kiln Capacity TPD 100 100
2 No of kilns in the plant No 2 2
3 Total Installed Capacity TPD 200 200
4 Iron ore Consumption Tons/hr 10.89 10.89
5 Iron ore Consumption TPD 2178 2178
6 Coal Calarific Value kcal/kg 3000 3000
7 Lump coal consumption Tons/hr 6.75 6.75
8 fine coal consumption Tons/hr 4.14 4.14
9 Total Coal Consumption Tons/hr 10.89 10.89
10 Total Coal Consumption TPD 2177.78 2177.78
11 Dolamite Consumption Tons/hr 0.28 0.28
12 Flue gas generated by kiln nm3/hr 24000 24000
13 Total flue gas generated at installed capacity nm3/hr 48000 48000
14 Density of flue gas kg/m3 1.3 1.3
15 Actual gas flow kg/hr 62400 62400
16 Flue Gas Temperature at out let of kiln C 1005 1005
17 Enthalphy of flue gas at kiln out let @ 950C kcal/kg 290 290
18 Enthalphy of gas at Boiler out let @ 170 C kcal/kg 39.15
19 Flue gas temperature at inlet of ESP C 170
20 Heat value available in flue gas kcal/hr 15653040
21 Radiation heat loss(1%) kcal/hr 156530
22 Blow down loss(2%) kcal/hr 313061
23 Actual heat available after loss kcal/hr 15183449
24 Steam enthalphy or total heat at 66kg/cm2, 800
490C kcal/kg
25 Feed water temperature oC 126
26 Enthaly of feed water kcal/kg 127
27 Generated steam @66 kg/cm2, 485 C kg/hr 22561
28 Power generation by generated steam MW 2
29 Power generation kwh/day 48000
30 Auxilary power consumption kwh/day 4800
31 Power availale for grid kwh/day 43200
32 Power availale for grid kwh/year 14256000
33 Power Cost Rs./kWh 3.3
34 Energy cost due to power generation using Rs.lakhs/year 499
flue gases
35 Investment cost of power plant Rs. Lakhs 625
36 O& M cost Rs. Lakhs 12.5
37 Manpower Cost Rs. Lakhs 43.2
38 Total investment Cost including O&M, Rs. Lakhs 681
Manpower
39 Payback period years 1.36
17
18
Annexure 4: Detailed financial calculations & analysis

Assumptions
Name of the Technology WASTE HEAT RECOVERY BOILER
Rated Capacity 2 MW
Details Unit Values Basis
No of working days Days 330
No of Shifts per day Shifts 3
Capacity Utilization Factor %
Proposed Investment
Proposed Investment
Cost of Boiler Rs. in lakhs 373.50
Cost of System Rs. in lakhs 210.00
Erection & Comissioning Lumpsum 25.00
Civil work Lumpsum 50.00
Taxes Rs. in lakhs 42.00
Other Misc. cost(supervision, other
cost) Rs. in lakhs 10.00
Total cost excluding EPC Rs. in lakhs 710.50
EPC cost Rs. in lakhs 35.53
Total Investment Rs. in lakhs 746.03
Financing pattern
Own Funds (Internal Accruals) Rs. in lakhs 186.51 Feasibility Study
Loan Funds (Term Loan) Rs. in lakhs 559.52 Feasibility Study
Loan Tenure Years 5 Assumed
Moratorium Period Months 6 Assumed
Repayment Period Months 66 Assumed
Interest Rate % 10 SIDBI Lending Rate
Estimation of Costs
O & M Costs % on Plant &
4 Feasibility Study
Equip
Annual Escalation % 5 Feasibility Study
Estimation of Revenue
Power generation kW/Annum 14256000
Detailed calculations
Savings per unit Rs./kWh 3.30 enclosed in DPR
St. line Depn. % 5.28 Indian Companies Act
IT Depreciation % 7.84 Income Tax Rules
Income Tax % 33.99 Income Tax
19
Estimation of Interest on Term Loan Rs. (in lakh)

Years Opening Balance Repayment Closing Balance Interest
1 559.52 83.93 475.59 65.21
2 475.59 111.90 363.69 53.66
3 363.69 111.90 251.78 51.12
4 251.78 111.90 139.88 48.23
5 139.88 111.90 27.98 45.04
6 27.98 27.98 0.00 41.16
Total 559.52
WDV Depreciation Rs. (in lakh)

Particulars / years 1 2 3 4 5 6
Plant and Machinery
- Cost 746.03 687.54 633.63 583.96 538.17 495.98
- Depreciation 58.49 53.90 49.68 45.78 42.19 38.88
- WDV 687.54 633.63 583.96 538.17 495.98 457.10
Projected Profitability Rs. (in lakh)

Particulars / Years 1 2 3 4 5 6 Total
Revenue through Savings
savings in Coal 470.45 470.45 470.45 470.45 470.45 470.45 2822.69
Total Revenue(A) 470.45 470.45 470.45 470.45 470.45 470.45 2822.69
EXPENSES
O & M Expenses 29.84 31.33 32.90 34.54 36.27 38.09 202.98
Total Expenses(B) 29.84 31.33 32.90 34.54 36.27 38.09 202.98
PBDIT(A)-(B) 440.61 439.11 437.55 435.90 434.18 432.36 2619.71
Interest 65.21 53.66 51.12 48.23 45.04 41.16 304.42
PBDT 375.40 385.46 386.43 387.68 389.13 391.20 2315.29
Depreciation 39.39 39.39 39.39 39.39 39.39 39.39 236.34
PBT 336.01 346.07 347.04 348.29 349.74 351.81 2078.95
Income tax 107.72 112.69 114.46 116.21 117.92 119.75 688.76
Profit after tax (PAT) 228.29 233.37 232.57 232.08 231.82 232.06 1390.19
Computation of Tax Rs. (in lakh)

Particulars / Years 1 2 3 4 5 6
Profit before tax 336.01 346.07 347.04 348.29 349.74 351.81
Add: Book depreciation 39.39 39.39 39.39 39.39 39.39 39.39
Less: WDV depreciation 58.49 53.90 49.68 45.78 42.19 38.88
Taxable profit 316.91 331.55 336.75 341.89 346.94 352.31
Income Tax 107.72 112.69 114.46 116.21 117.92 119.75
20
Projected Balance Sheet Rs. (in lakh)

LIABILITIES
Share Capital 186.51 186.51 186.51 186.51 186.51 186.51
Reserves & Surplus 228.29 461.66 694.24 926.31 1158.13 1390.19
Term Loans 475.59 363.69 251.78 139.88 27.98 0.00
TOTAL LIABILITIES 890.39 1011.86 1132.53 1252.70 1372.61 1576.69
ASSETS
Gross Fixed Assets 746.03 746.03 746.03 746.03 746.03 746.03
Less: Accm. depreciation 39.39 78.78 118.17 157.56 196.95 236.34
Net Fixed Assets 706.63 667.24 627.85 588.46 549.07 509.68
Cash & Bank Balance 183.75 344.61 504.67 664.23 823.54 1067.01
TOTAL ASSETS 890.39 1011.86 1132.53 1252.70 1372.61 1576.69
Net Worth 414.80 648.17 880.74 1112.82 1344.64 1576.69
Debt Equity Ratio 2.55 1.95 1.35 0.75 0.15 0.00
21
Projected Cash Flow Rs. (in lakh)

Particulars / Years 0 1 2 3 4 5 6
Sources
Share Capital 186.51 - - - - - -
Term Loan 559.52
Profit After tax 228.29 233.37 232.57 232.08 231.82 232.06
Depreciation 39.39 39.39 39.39 39.39 39.39 39.39
Total Sources 746.03 267.68 272.76 271.97 271.47 271.21 271.45
Application
Capital Expenditure 746.03
Repayment Of Loan - 83.93 111.90 111.90 111.90 111.90 27.98
Total Application 746.03 83.93 111.90 111.90 111.90 111.90 27.98
Net Surplus - 183.75 160.86 160.06 159.56 159.30 243.47
Add: Opening Balance - - 183.75 344.61 504.67 664.23 823.54
Closing Balance - 183.75 344.61 504.67 664.23 823.54 1067.01
IRR Rs. (in lakh)

Particulars / months 0 1 2 3 4 5 6
Profit after Tax 228.29 233.37 232.57 232.08 231.82 232.06
Depreciation 39.39 39.39 39.39 39.39 39.39 39.39
Interest on Term Loan 65.21 53.66 51.12 48.23 45.04 41.16
Cash outflow (746.03) - - - - - -
Net Cash flow (746.03) 332.89 326.42 323.09 319.69 316.25 312.61
IRR 37.01%
NPV 660.29
Break Even Point Rs. (in lakh)

A. Variable Expenses
Operation & Maintenance Exp (75%) 22.38 23.50 24.67 25.91 27.20 28.56
Sub Total 22.38 23.50 24.67 25.91 27.20 28.56
B. Fixed Expenses
Operation & Maintenance Exp (25%) 7.46 7.83 8.22 8.64 9.07 9.52
Interest on Term Loan 65.21 53.66 51.12 48.23 45.04 41.16
Depreciation 39.39 39.39 39.39 39.39 39.39 39.39
Sub Total 112.06 100.88 98.74 96.25 93.50 90.07
C. Sales 470.45 470.45 470.45 470.45 470.45 470.45
D. Contribution 448.07 446.95 445.77 444.54 443.24 441.88
E. Break Even Point (B/D) 25.01% 22.57% 22.15% 21.65% 21.09% 20.38%
F. Cash Break Even 16.22% 13.76% 13.31% 12.79% 12.21% 11.47%
G.BREAK EVEN SALES 117.66 106.19 104.20 101.86 99.24 95.90
22
Return on Investment Rs. (in lakh)

A.Net Profit Before Taxes 336.01 346.07 347.04 348.29 349.74 351.81 2078.95
B.Net Worth 414.80 648.17 880.74 1112.82 1344.64 1576.69 5977.86
34.78%
Debt Service Coverage Ratio Rs. (in lakh)
CASH INFLOW
Profit after Tax 228.29 233.37 232.57 232.08 231.82 232.06 1390.19
Depreciation 39.39 39.39 39.39 39.39 39.39 39.39 236.34
Interest on Term Loan 65.21 53.66 51.12 48.23 45.04 41.16 304.42
TOTAL 332.89 326.42 323.09 319.69 316.25 312.61 1930.95
DEBT
Interest on Term Loan 65.21 53.66 51.12 48.23 45.04 41.16 65.21
Repayment of Term Loan 83.93 111.90 111.90 111.90 111.90 27.98 83.93
TOTAL 149.14 165.56 163.03 160.13 156.95 69.14 149.14
Average DSCR 2.24
23
Annexure 5: Details of procurement and implementation plan

Project Implementation schedule
S. Month Month Month Month Month Month Month Month Month Month
No Activity
1 2 3 4 5 6 7 8 9 10
1 Placement of
Orders for
Equipment
2 Manufacturing
3 Erection and
commissioning
4 Trial runs
24
Annexure 6: Details of technology/equipment and service providers
Equipment details Source of technology Service/technology providers
Waste heat recovery Indian A.V.U. ENGINEERS PVT . Ltd.

Power plant AN ISO - 9001-2008 CERTIFIED
COMPANY)
Survey No . 53 , Bahadurpally ,
Quthbullpur Mandal ,
R R Dist, Hyderabad 500043 .
Andhra Pradesh, INDIA.
Phone : +91-40-23090968 ,
23092343, 9493547191
E-mail : office@avuengineers.com
avupurchase@yahoo.com
25
26
Annexure 7: Quotation or techno-commercial bid
TECHNICAL PROPOSAL
FOR
1 x 10 TPH WHR BOILERS
IN SPONGE IRON PLANT
SUBMITTED TO
M/s. APTICO.
SUBMITTED BY
27
ARTICULATED VESSELS & UTILITY

ENGINEERS PVT LTD.
SECUNDERABAD- 500 009
AV-UE/WHRS-APTICO/Q/11-12:110 Date: 03-

11-2011
M/s. APTICO
Kind Attn: Mr. GOPALA RAO
Dear Sir,
Ref:: With reference to the telephonic discussion had with our MD. Mr. PARAMVIR SINGH
We thank you very much for showing interest in AV-UE for your boilers. As required by you, we
are pleased to submit herewith our Commercial Proposal for Supply, Erection & Commissioning of
2 x 10 TPH WHR Boilers at 66 Kg/cm2 (g) Pressure and 485±5 ºC Superheated Steam and
Common Deaerator System for your Power Plant.
AV&UE supplies boilers designed and manufactured to several national & international
standards like IBR, ASME Sec VIII Div 1 & BS 113.
28
We trust the above is in line with your requirement & in the meantime, if you need any
further clarifications to evaluate our proposal please feel free to contact us.
Assuring you of our best attention, always.
Thanking you,
Yours faithfully,
for ARTICULATED VESSELS & UTILITY ENGINEERS PVT. LTD.
PARAMVIR SINGH
MANAGING DIRECTOR
INDEX
S.No. DESCRIPTION PAGE No.

1. BRIEF DESCRIPTION OF THE SYSTEM 4-5
2. EQUIPMENT DESCRIPTION 6-8
3. TECHNICAL PROPOSAL 9
4. THERMAL DESIGN DATA 10
29
5. GUARANTEED PARAMETERS 11 - 14
6. EQUIPMENT TECHNICAL DATA 15
7. INSTRUMENTS & SPECIAL VALVES 16 - 18
8. SCOPE OF SUPPLY AND EXCLUSIONS 19 - 24
9. TERMINAL POINTS 25
10. WATER QUALITY REQUIREMENT 26 - 28
MATERIAL OF CONSTRUCTION OF MAJOR
11. 29
QUIPMENTS
12. CODES & STANDARDS APPLICATION 30
13. INSPECTION & DOCUMENTATION 31
LIST OF PRINCIPAL VENDORS FOR BOUGHT
14. 31 - 35
OUT COMPONENTS
15. GENERAL SPECIFICATIONS 36 - 37
1.0 BRIEF DESCRIPTION OF THE SYSTEM:
i) THREE PASS THERMAL TECHNOLOGY FOR OPTIMUM HEAT RECOVERY
a) FIRST PASS CONSISTS OF:
FIRST ZONE OF WATER COOLED MEMBRANE WALLS

30
Provides Maximum Recovery of Heat through Radiation. Fin welded

membrane wall construction provides Gas tight furnace and structural
rigidity.
b) SECOND PASS CONSISTS OF:
SCREEN TUBES:
The Screen section consists of bare tubes arranged to form a tube bundle.
The tubes are arranged in such a manner that they face the gas flow
directly. The top and bottom ends of the tubes are duly welded to headers,
which in turn are connected to the water wall / water circuits respectively.
SUPER HEATER WITH MEMBRANE WALLS
Two stage Super heater with interstage spray type Attemperator enclosed
by fin welded extended water walls. In this zone the waste heat is utilized to
superheat the steam by convection and also additional recovery of heat by
water walls by radiation.
EVAPORATOR WITH MEMBRANE WALLS
Efficient utilization of waste heat to generate saturated steam by both

convection and radiation. Flag type evaporators which are arranged in a
manner to ensure natural circulation with ease.
c) THIRD PASS CONSISTS OF:
ECONOMISER
This zone consists of economizer, the heat is recovered to preheat the

Boiler Feed Water.
ii). Downward and upward flow through multipass arrangement of heat transfer
surfaces to enable positive dust settlement through hoppers.
iii). Inter-Bank Soot Blowers for Superheater, Evaporator, Economiser sections

for online cleaning.
iv). the equipments will be constructed in modules; this modular construction

ensures easy transportation and easy maintenance.
v) Upper and Lower Headers of the Membrane Wall and the Evaporator are
connected to the Steam Drum by Risers & Down Comers.
vi) Thermal Expansion joints are provided to absorb Thermal Expansion

impact of the Boiler.
31
vii). Feed Water Control Valve is located down Stream of the Economizer to
avoid steaming in the Economizer.
viii). Superheated Steam Temperature is controlled through Intermittent Spray

Type Desuperheater located between primary & secondary super heater
banks.
ix). Equipped with High Quality Standard Valves, Mountings & Instruments.
x). The Internal Trays and the Column Shell of the Deaerator shall be made of
SS-304 material to eliminate rust formation due to Oxidation.
xi). The system ensures arresting of total dust through 3-Stage trapping
system.
At the Furnace Entry, the primary heavy dust is collected/ removed

through Dust Hopper, provided at the bottom of the Furnace, by
rotating valve.
The Carry-Over dust particles from the Furnace chamber are

removed in the Super heater and collected at Dust Hopper at the
bottom of the Super heater Chamber.
Finally the dust particles will be removed in the dust collectors

provided at the bottom of the economizer hopper.
xii). Please appreciate that the Dust particles carried by the flue gases from the
Sponge Iron plant are just not Dust particles, but also has appreciable heat
content in it. So removal of the dust from the Kiln exhaust flue gases,
before entering Boiler chamber would result in loss of heat content, which
ultimately hampers the over-all Thermal efficiency of W.H.R. System.
Therefore, the 3-stage dust removal system suggested and incorporated in
design (as above in Sl.No.11) is the most efficient and appropriate solution
to maintain high Thermal Efficiency of the system and render the overall
system dust free.
xiii). Most efficient, reliable, dependable and performance based system.
xiv). Since we have already supplied, Erected and Commissioned a number of

WHR Systems, we assure you that the Erection & Commissioning of the
WHRS, at your site, shall be within the stipulated schedules exhibiting a
superior quality of workmanship.
32
2.0 EQUIPMENT DESCRIPTION:
2.1 RADIATION SECTION:
The objective of this section is to absorb the radiation heat & cool the gases well below
the ash melting point temperature. The radiation chamber is a hollow passage for flue
gas flow made of water cooled walls. The water-cooled walls consist of bare seamless
tubes welded to each other by means of plain strips. These bare tubes are then
welded to top and bottom headers, which in turn are connected to the steam drum
respectively. The entire chamber is fully fusion welded to provide gas-tight chamber.
Since heat transfer occurs in this section, predominantly by radiation mode, this
chamber is called radiation chamber. The entire first pass is of this construction only.
Heavy carry-overs from the Sponge Iron Kiln freely fall in to the hopper, without any
hindrance. The hopper portion is lined by Castable refractory. Since there is no other
heat transfer surfaces along this path, the choking problem is completely eliminated.
2.2 SCREEN TUBES:
The Screen section consists of bare tubes arranged to form a tube bundle. The tubes
are arranged in such a manner that they face the gas flow directly. The top and bottom
ends of the tubes are duly welded to headers, which in turn are connected to the
steam drum / water circuits respectively. The Screen section is of sloping tubes,
connected to the steam drum by means of the front wall tubes of the second pass
water wall casing. The bottom header is connected bottom headers of rear water wall
casing. Thus individual risers & down comers are eliminated. This reduces site
erection activities to a considerable extent.
2.3 SUPERHEATER SECTION:
The super heater section heats the saturated steam at corresponding saturation
temperature to required final temperature. The super heater section is divided in to two
parts. The first part which heats saturated steam called Primary Super heater. The
second part, which further heats superheated steam to the final required temperature,
is called the Secondary Super heater. The Super heaters are of bare tube
construction, tube material being SA 213 T11.
2.4 DE- SUPERHEATER SECTION:
33
Between the both the super heaters, an de-super heater is provided. The sole purpose
of the de-super heater is to control final temperature of the super heater temperature.
The De-Super heater is Spray Water Type, Which sprays relatively cold Boiler Feed
Water in to the steam leaving the Primary Super heater. This causes the temperature
of steam at outlet of primary Super heater to reduce. By varying the quantity of
desuperheater spray water, the temperature of steam entering the secondary super
heater can be controlled. Since the final temperature of steam leaving Secondary
Super heater depends on the inlet temperature of steam, an attemperation at
intermediate level is an efficient method of Final Superheat Temperature Control.
2.5 EVAPORATOR SECTION:
This section is formed by flag tube type evaporators, arranged in bundles, to ensure
natural circulation of the steam and water. The bundles are constructed in Modules
fashion, which will helpful to transportations as well as easy maintenance of the Boiler.
The Heat Transfer takes mainly due to convection. The Tubes are welded to headers
which in turn connected to risers and down comers.
2.6 ECONOMISER SECTION:

The Economizer section is provided to cool down flue gases to the required outlet
temperature and use this heat to increase the temperature of Boiler Feed Water
entering the Steam Drum. The economizer is of bare tube construction. The
economizer is also constructed in modules. The feed water valve is located at the
downstream of the economizer section to stop the steaming in the economizer.
2.7 GAS CIRCUIT
Exhaust gas from 1 x 100 TPD Plant ABC (After Burning Chamber) of kiln enters the
radiant chamber where it gets cooled sufficiently before entering into second and third
chamber. The gas then passes through the two stage superheater section, evaporator
section and Economiser section and let into the ESP. ID Fan draws the cooled exhaust
gas and lets into atmosphere through the chimney.
2.8 BLOW DOWN TANK
We have considered one no. common blowdown tank (Common for CBD & IBD for
each boiler) to which the boiler blowdown, boiler drain lines from various systems will
be connected.
2.9 WATER AND STEAM CIRCUIT
Deaerated water enters Economiser and gets heated. The heated water then enters
the steam drum and then circulated (Natural Circulation) in evaporator sections and
water wall. Saturated steam is collected in the steam drum. Saturated steam is
then superheated in convection super heaters and taken out to turbine. Inter stage
desuperheater is provided to control the steam temperature.
2.10 SOOT BLOWING SYSTEM

34
Soot blowing system consists of retractable and rotary soot blowers which use steam
as blowing media. Retractable soot blowers are provided in the superheater zone.
Rotary type soot blowers are provided in the evaporator and Economiser zones. Piping
to individual soot blowers are adequately sized and properly routed to prevent the
entry of water droplets into the soot blowers. Steam traps are provided in the pipeline
to remove the condensate from the system.
2.11 DEAERATOR CUM STORAGE TANK:
This system consists of Deaerator in which the oxygen content in the feed water
is reduced to the required level by spraying water as droplets in the presence of
steam. There will be a storage tank below the Deaerator to store deaerated water.
2.12 CHEMICAL DOSING SYSTEM:
2.12.1 LP CHEMICAL DOSING SYSTEM

The feed water contains traces of oxygen due to the incomplete mechanical /
Thermal deaeration. These traces of Oxygen are scavenged by chemical deaeration.
Chemicals like sodium sulphite or hydrazine is dosed to the suction pipe of feed
pump by LP dosing. In LP dosing sodium sulphite react with oxygen and forms
sodium sulphate or Hydrazine React with O2 and forms water & nitrogen.
2.12.2 HP CHEMICAL DOSING SYSTEM

Scale formation is limited by converting hardness salts to a free flowing sludge. HP
dosing is done by carbonate control and phosphate control by addition of
sodium carbonate / or Trisodium phosphate respectively. Other chemicals such
as sodium hydroxide carbonate or calcium oxyphosphate can also be added. Best
result of calcium carbonate or magnesium hydroxide or calcium silicate,
magnesium silicate will be available as free flowing sludges where caustic
35
alkalinity is 10 to 15% of the dis-solved solids. OH alkalinity leads to prevention of

magnesium phosphate as bad scale by converting magnesium to magnesium
hydroxide. Sludge conditioner can also be used, if there is no effective means of
blowdown is available it is better not to concentrate on internal treatment.
3.0 TECHNICAL PROPOSAL:
S.NO. DESCRIPTION VALUE

3.1 BASIC DATA
Latest Version of IBR 1950. Where code is not
Construction Code applicable good engineering practice will be
applicable.
Three pass Vertical, Water tube, Natural
circulation single drum Boiler with membrane
Type of Boiler water walls furnace, Primary & Secondary
Super heaters, Bare tube Evaporator Bundle
and Economiser.
3.2 STEAM
36
CHARACTERISTICS
Pressure at SHO 66 ± 0.5 Kg/cm²(g)
Temp. at SHO
485 ± 5 °C
Flow at SHO 10000 Kg/hr

Design Pressure 75 Kg/cm²(g)
Hydro Test Pressure 112.5 Kg/cm²(g)
3.3 FLUE GAS PROPERTIES
Type of Flue gas Sponge Iron Kiln Exhaust Flue gas
Kiln Gas Flow 25000 Nm3/hr
Gas Inlet Temperature 950 °C
Gas Outlet Temperature at
160 ± 10 °C
exit of Economiser
FLUE GAS ANALYSIS
3.4
(V/V)
CO2 17.0 %
H2O 15.0 %
O2 02.4 %
N2 65.6 %
Gas density 1.303 Kg/Nm3
Dust Loading 40 gm/Nm3
Water temperature inlet to
126 °C
Economiser
Blow down losses
2%
(considered)
Radiation losses
2%
(considered)
Cooling water temperature 35 °C
Temperature for Guarantee 45 °C
Temperature for electrical
50 °C
design
Relative humidity 84%
Still air velocity 1m/s
3.5 ELECTRICAL DATA
Supply AC Three Phase
Voltage 415 + 10 V
Frequency 50 CPS
37
4.0 THERMAL DESIGN DATA:
S.No. Description Unit Value

4.1 Heating Surface Areas
a. Water walls m2 415
b. Screens m2 21
c. Evaporator -I m2 173
d. Evaporator -II m2 186
e. Primary Super heater (SH-I) m2 74
f. Secondary Super heater (SH-II) m2 69
g. Economiser 1 & 2 m2 508
Total m2 1446
4.2 Flue Gas Pressure Profile
a. Radiation chamber mmWC 10
b. Superheater I & II mmWC 10
c. Evaporator I & II mmWC 20
d. Economiser I & II mmWC 65
e. Ducting mmWC 20
f. ESP (Not in AVUE Scope) mmWC 35
Total mmWC 160
4.3 Flue Gas velocity Profile
a. Radiation chamber m/s 7-5
b. Superheater -II m/s 7-6
c. Superheater -I m/s 7-6
d. Evaporator I & II m/s 7-6
e. Economiser I & II m/s 7-5
4.4 Steam & Water Pressure Profile
a. At the outlet of MSSV Kg/cm2 (g) 66
b. Drum working Pressure Kg/cm2 (g) 68
c. Economiser inlet pressure Kg/cm2 (g) 70
d. Super heater S.V. Set Pressure Kg/cm2 (g) 70
e. Drum S.V.1 Set Pressure Kg/cm2 (g) 72.5
f. Drum S.V.2 Set Pressure Kg/cm2 (g) 73.5
4.5 Flue Gas Temperature Profile
a. Radiation chamber inlet Deg C 950
b. Inlet to Superheater -II Deg C 740 -730
38
c. Inlet to Superheater -I Deg C 660-650

d. Inlet to Evaporator I & II Deg C 560-550
e. Inlet to Economiser I & II Deg C 365-355
f. Inlet of ESP Deg C 160 ± 10
4.6 Water/ Steam Temperature
a. Inlet to Economiser Deg C 126
b. Economiser Outlet Deg C 267
c. Inlet of Super heater -I Deg C 281
d. Outlet of Super heater-I Deg C 405
e. Inlet of Super heater -II Deg C 385
f. Outlet of Super heater-II Deg C 485± 5
5.0 EQUIPMENT TECHNICAL DATA:
S.No Description Value

5.1 Specification of Radiation chamber (membrane water walls)
a. Design code IBR 1950 with its latest amendments
b. Design pressure 75 kg/cm² g
c. Design temperature 317 °C
d. Hydro test pressure 112.5 kg/cm² g
e. Type Vertical
f. Type of tubes Bare
g. Tube outer diameter 50.8 mm
h. Tube thickness 4.47 mm
i. Fin thickness 5 mm
j. MOC of tubes BS 3059 Seamless
k. MOC of fins IS 2062
l. MOC of headers SA 106 Gr B
5.2 Specification of Secondary Superheater
d. Working temperature 490± 5 °C
e. Hydrotest pressure 112.5 kg/cm² g
f. Type Horizontal
g. Type of tubes Bare
h. Tube outer diameter 38.1 mm
i. Tube thickness 4.06 mm
j. MOC of tubes SA 213 T11
k. MOC of headers SA 106 Gr B / SA 335 P11
39

5.3 Specification of Primary Superheater
d. Working temperature 405 °C
e. Hydrotest pressure 112.5 kg/cm² g
f. Type Horizontal
j. MOC of tubes SA 210 Gr A1
k. MOC of headers SA 106 Gr B
5.4 Specification of Evaporator 1 &2
e. Hydro test pressure 112.5 kg/cm² g
f. Type Flag
5.5 Specification of Economiser 1 &2
e. Hydrotest pressure 117 kg/cm² g
f. Type Horizontal
5.6 Steam Drum specification
40

d. Hydrotest pressure 112.5 kg/cm² g
e. Length 3750 mm
f. Inner diameter 1220 mm
g. Thickness 56 mm
h. Material of construction SA 516 Gr 70
i. Quantity per boiler 1 no.
j. Corrosion allowance 1.5 mm
k. Internals Demister pad
l. Quantity of safety valves 2 nos.
m. Drum S.V.1 Set Pressure 73.5 kg/cm² g
n. Drum S.V.2 Set Pressure 74.5 kg/cm² g
5.7 Specification of Attemperator
a. Type Fixed Nozzle spray type Attemperator
b. Nos One
c. Location Between primary & secondary SH
d. MOC of headers SA 335 P11
e. Header outer diameter & 219.1 mm, Thickness as per IBR
Thickness
5.8 Specification of Soot Blowers
Long Retractable Rotary soot blower
a. Location Super heater Evaporator &
Economiser zones
b. Qty 2 4
c. Steam temperature Super-heated steam
d. Steam pressure 20-30 kg/cm2(g)
e. Source of Steam SH steam form primary SH Outlet header
f. Drive Motorized
5.9 Specification of HP Dosing System
a. Major Parts Storage Tank – 1 No., Stirrer – 1 No.,
Dosing Pumps – 2 Nos.
b. Size of Storage Tank 600 mm x 500 mm
c. Tank Capacity 150 liters
d. MOC of Tank SS
e. MOC of Chemical Basket SS 304
f. Pump Capacity 6 LPH
41

g. Pump Type Reciprocating Plunger Type
h. Type of Operation Motorised
5.10 Specification of LP Dosing System
a. Major Parts Storage Tank – 1 No., Stirrer – 1 No.,
Dosing Pumps – 2 Nos.
b. Size of Storage Tank 800 mm x 650 mm
c. Tank Capacity 200 liters
d. MOC of Tank SS
e. MOC of Chemical Basket SS 304
f. Pump Capacity 6 LPH
g. Pump Type Reciprocating Plunger Type
h. Type of Operation Motorized
3.12 Deaerator cum Storage Tank
a. Design Code As per IBR 1950 with Latest Amendments
& Good Engineering Practice
b. Outside Diameter 1200mm
c. Length of shell (tan to tan) 4500 mm
d. Thickness of shell 12 mm
e. Type of dish end 2: 1 Ellipsoidal with straight face
f. Thickness of dished end 12 mm
g. Operating pressure 2.45 kg/cm² a
h. Design Pressure Full Vacuum/ 3.5 kg/cm² g
i. Hydro Test Pressure 5.25 kg/cm² g
j. Operating temperature 126 °C
k. Design Temperature 180 °C
l. Design Outlet feed water 10.6 m3/hr
capacity
m. Corrosion allowance 3.2 mm over & above design code
requirement
Condensate Oxygen content Design = 300 ppb / Normal = 42 ppb
(at DA inlet)
n. Condensate Oxygen content 0.005 ml/Ltr (7 PPB)
(at DA outlet)
o. Storage capacity Normal Level 30 m3
to Low-Low water level)
5.11 Specifications of Blow down tank
a. Design code IBR
b. Tank height 1000 mm
c. Tank OD 960 mm
d. Shell thickness 10 mm
42

e. Type of ends Dished
f. Material of construction SA 516 Gr 70
5.12 Boiler feed water pumps
a. Qty 2 Nos (1 W +1S, Common for Two WHR
Boilers)
b. Design water flow 20 m3 /hr
c. Pressure head 865 mmWC
d. Temperature 126 ºC
e. Speed 2900 RPM
f. Type Centrifugal
5.13 Specifications of Sample Coolers
a. Type Shell & Coil type
b. Sampling Points Feed water line (Common for two boilers), Blow
down line, Saturated steam line & Superheated
Steam line
c. Shell Material Carbon Steel
d. Coils Material Stainless Steel
5.14 Ducting
a. Material of Construction MS
b. Thickness 5 mm
5.15 ID Fan
Flow 12.3 m3/sec
Developed head (Design) 180 mmWC
Temperature (Design) 180 ± 10 °C
Motor rating Later, KW
Speed Later, RPM
Quantity 1 no
Type of Fan Centrifugal
Medium Ambient
Motor Voltage, V 415
Type of control Pneumatically generated power cylinder actuated
regulating damper control with VFD
5.16 Painting
a. Two Coats of Red Oxide in shop All the equipments supplied by AV-UE
b. Final painting All the equipments supplied by AV-UE
43
6.0 GUARANTEED PARAMETERS:
Following are the guaranteed parameters for WHRSG:
Steam output at SH outlet Kg/h 10000
Steam pressure at SH outlet Kg/cm2 (g) 66 ± 0.5
Steam temperature at SHO °C 485 ± 5
Design pressure Kg/cm2 (g) 75
Hydro test pressure Kg/cm2 (g) 112.5
Gas Flow Kiln Nm3/hr 25000
Gas side pressure Drop mm WC 160
Gas Inlet Temperature (Considered Normal Condition) °C 950

Gas outlet Temperature (It may vary based on 160 ± 10
°C
Temperature and Gas flow)
Blow down losses (considered) % 2
Radiation losses (considered) % 2
44
7.0 INSTRUMENTS AND SPECIAL VALVES:
7.1 Field Mounted Instruments:
a. Feed Water Circuit:
S.No Location of inst. Measured Qty Instrument provided

variable Nos
1 Eco inlet header Pressure 1 Field mounted Local Pressure gauge
2 -do- Temperature 1 Field mounted RTD
3 Eco outlet header Temperature 1 Field mounted RTD
4 -do- Pressure 1 Field mounted Local Pressure gauge
5 Feed line Flow 1 Field mounted local orifice plate
6 -do- Flow 1 Field mounted local DP transmitter
7 Feed pump outlet Pressure 2 Field mounted Local Pressure gauge
8 Feed pump inlet Pressure 2 Field mounted Local Pressure gauge
b. Attemperator Spray water line:
S.No Location of Measured Qty Instrument provided

inst. variable Nos
1 Attemperator Pressure 1 Field mounted local pressure gauge
line
c. Steam Drum:
S.No Location of Measured Qty Instrument provided

inst. variable Nos.
1 Steam drum Level 2 Field mounted local level gauge of
Transparent type with illumination
2 -do- Level 2 Field mounted Diff. Pressure transmitter
3 -do- Pressure 1 Field mounted Local Pressure gauge
d. Steam Drum to Soot Blower Steam line:

variable Nos
1 After PCV in SB line Temperature 1 Field mounted local temperature gauge
2 After PCV in SB line Pressure 1 Field mounted Local Pressure gauge
3 After PCV in SB line Pressure 1 Field mounted local Pressure
transmitter
45
e. Steam line from Steam Drum to Main Steam Stop valve:

variable Nos
1 Steam line after SH-2 Temperature 1 Field mounted local Thermocouple
2 Main steam line Pressure 1 Field mounted local Pressure gauge
3 -do- Pressure 1 Field mounted local Pressure
transmitter
4 -do- Temperature 1 Field mounted local Thermocouple
5 -do- Flow 1 Field mounted local orifice plate
6 -do- Flow 1 Field mounted local DP transmitter
f. Flue gas path:
S.N Location of inst. Measured Qty Instrument provided

o variable Nos
1 Flue gas flow path Temperature 1 Field mounted local thermocouple
(at boiler inlet)
2 Flue gas flow path Pressure 1 Field mounted manometer
(at boiler inlet)
3 Flue gas flow path Pressure 1 Field mounted Local Pressure transmitter
(at boiler inlet)
4 Flue gas flow path Temperature 1 Field mounted Local thermocouple
(between SH-1 and
SH-2)
5 Flue gas flow path Temperature 1 Field mounted Local thermocouple
(between SH-1 and
Evaporator -1)
6 Flue gas flow path Pressure 1 Field mounted local manometer
between
Evaporator - II and
Economiser
between
Evaporator - II and
Economiser
after Economiser
after Economiser
10 Flue gas flow path Temperature 1 Field mounted local Temperature gauge
before ID fan
before ID fan
after ID fan
46
g. Blow down tank:
S.No Location of inst.Measured Qty Instrument provided

variable Nos
1 Blow down tank's Temperature 1 Field mounted local Temperature gauge
drain line
2 Blow down tank’s Level 1 Field mounted local level gauge of
level gauge tubular type
h. Deaerator cum storage tank:

variable Nos
1 Deaerator cum Level 1 Field mounted Local Level gauge of
storage tank Transparent type with illumination
2 Deaerator cum Level 1 Field mounted Level switch
storage tank
3 Deaerator cum Level 1 Field mounted Diff. Pressure transmitter
storage tank
2 Deaerator cum Pressure 1 Field mounted Diff. Pressure transmitter
storage tank
5 Deaerator cum Pressure 1 Field mounted local pressure gauges
storage tank
i. Low Pressure Dosing system:

variable Nos
1 LP Dosing system Level 1 Field mounted Local Level gauge
2 LP Dosing system – Pressure 1 Field mounted local pressure gauges
Discharge line of
Dosing pumps
j. High Pressure Dosing system:

variable Nos
1 HP Dosing system Level 1 Field mounted Local Level gauge
2 HP Dosing system Pressure 1 Field mounted local pressure gauges.
– Discharge line of
Dosing pumps
7.2. LIST OF CONTROL VALVES:
47
S.No Description of equipment / Controlled Qty Details of control valve

pipeline on which the variable Nos
instrument is mounted
1 Attemperator line Flow 1 Pneumatic actuated
2 Soot blower line Flow 1 Pneumatic actuated
3 Start-up vent line Flow 1 Pneumatic actuated
4 Feed line Flow 1 Pneumatic actuated
5 DM Water line (to Deaerator) Flow 1 Pneumatic actuated
7.3. LIST OF MOTORISED VALVES:
S.No Description of equipment Qt Details of control valve

/ pipeline on which the y
instrument is mounted No
s
1 Main steam line 1 Electric motor actuated with Limit switches for Open
/ Close indication. - Gate valve (along with manual
bypass valve)
8.0 SCOPE OF SUPPLY & EXCLUSIONS:
AV-UE : ARTICULATED VESSELS & UTILITY ENGINEERS

SCOPE
CL : CLIENT SCOPE
ENGG : DETAILED ENGINEERING SUP : SUPPLY

FAB : FABRICATION E&C : ERECTION & COMMISSIONING
S. REMARK
DESCRIPTION ENGG SUP FAB E&C
No. QTY S
8.1 WATER WALLS
a. Membrane Water Walls 1Set AV-UE AV-UE AV-UE AV-UE
b. Hoppers 1Set AV-UE AV-UE AV-UE AV-UE
c. Screen section 1Set AV-UE AV-UE AV-UE AV-UE
d. Support tubes with cleats 1Set AV-UE AV-UE AV-UE AV-UE
e. Headers for Support tubes 1Set AV-UE AV-UE AV-UE AV-UE
f. Buckstays 1Set AV-UE AV-UE AV-UE AV-UE
8.2 SUPER HEATER –II
a. Headers with coil bundle 1Set AV-UE AV-UE AV-UE AV-UE
b. Bends 1Set AV-UE AV-UE AV-UE AV-UE
c. Supports 1Set AV-UE AV-UE AV-UE AV-UE
48
S. REMARK
No. QTY S
8.3 SUPER HEATER –I
8.4 DESUPERHEATER
a. De-Superheater assembly 1Set AV-UE AV-UE AV-UE AV-UE
4.5 EVAPORATOR BANK-I
8.6 EVAPORATOR BANK-II WITH CASING
As
c. Supports casing AV-UE AV-UE AV-UE AV-UE
Req.
8.7 STEAM DRUM
a. Shell 1 No AV-UE AV-UE AV-UE AV-UE
b. Dished ends 2 Nos AV-UE AV-UE AV-UE AV-UE
As
c. Demister pads AV-UE AV-UE AV-UE AV-UE
Req.
As
d. Cyclone separators AV-UE AV-UE AV-UE AV-UE
Req.
e. Saddles 2 Nos AV-UE AV-UE AV-UE AV-UE
As
f. Internal piping AV-UE AV-UE AV-UE AV-UE
Req.
g. Manholes 2 Nos AV-UE AV-UE AV-UE AV-UE
As
h. Nozzles AV-UE AV-UE AV-UE AV-UE
Req.
As
i. Canopy on steam drum AV-UE AV-UE AV-UE AV-UE
Req.
8.8 ECONOMISER I & II
c. Supports casing 1Set AV-UE AV-UE AV-UE AV-UE
8.9 RISERS & DOWNCOMERS
a. Pipes 1Set AV-UE AV-UE AV-UE AV-UE
b. Bends & fittings 1Set AV-UE AV-UE AV-UE AV-UE
8.10 SOOT BLOWERS
a. Retractable blowers 1Set AV-UE AV-UE AV-UE AV-UE
49
S. REMARK
No. QTY S
b. Rotary blowers 1Set AV-UE AV-UE AV-UE AV-UE
c. Drive motors 1Set AV-UE AV-UE AV-UE AV-UE
d. Limit switches 1Set AV-UE AV-UE AV-UE AV-UE
Power cabling from Control
e. Panel to Soot blowers 1Set AV-UE AV-UE AV-UE AV-UE
motors
Signal Cabling from Soot
f. blower limit switches to 1Set AV-UE AV-UE AV-UE AV-UE
Control Panel
g. Soot blower Supports 1Set AV-UE AV-UE AV-UE AV-UE
h. Soot blower drain valve 1Set AV-UE AV-UE AV-UE AV-UE
i. Pressure Reducing Station 1Set AV-UE AV-UE AV-UE AV-UE
8.11 FEED WATER PIPING
Water treatment plant to
a. Make up water control 1Set CL CL CL CL
station
Make up water control
b. 1Set AV-UE AV-UE AV-UE AV-UE
station to Deaerator
Deaerator to BFWP
c. 1Set AV-UE AV-UE AV-UE AV-UE
suction
BFWP Discharge to FW
d. 1Set AV-UE AV-UE AV-UE AV-UE
Flow control station
FW flow control station to
e. 1Set AV-UE AV-UE AV-UE AV-UE
Economiser
Economiser to Steam
Drum
FW Piping to
f. 1Set AV-UE AV-UE AV-UE AV-UE
Desuperheater FCV
Desuperheater FCV to
g. 1Set AV-UE AV-UE AV-UE AV-UE
Desuperheater
8.12 STEAM PIPING
As
a. Steam drum to PSH AV-UE AV-UE AV-UE AV-UE
Req.
As
b. PSH to Desuperheater AV-UE AV-UE AV-UE AV-UE
Req.
As
c. Desuperheater to SSH AV-UE AV-UE AV-UE AV-UE
Req.
As
d. SSH to MSSV AV-UE AV-UE AV-UE AV-UE
Req.
Main steam stop valve to
Common header 15 Mtrs
50
S. REMARK
No. QTY S
Common header to
f. 1Set AV-UE AV-UE AV-UE AV-UE
Turbine ESV 30 Mtrs
Super heater PRV to Soot
g. 1Set AV-UE AV-UE AV-UE AV-UE
blowers
Venting points to Safe As
h. AV-UE AV-UE AV-UE AV-UE
height Req.
SH line to Startup vent As
i. AV-UE AV-UE AV-UE AV-UE
valve Req.
Startup vent valve to As
j. AV-UE AV-UE AV-UE AV-UE
Silencer Req.
Superheater safety valve As
k. AV-UE AV-UE AV-UE AV-UE
to Silencer Req.
Turbine extraction to As
m. CL CL CL CL
Deaerator PCV Req.
Steam piping from
common steam header to As
n. CL CL CL CL
turbine emergency stop Req.
valve
Steam piping from
o. CL CL CL CL
PRDS-1 for deaerator Req.
initial heating
Steam piping from PRDS-1 As
p. CL CL CL CL
to deaerator Req.
Steam piping from
o. CL CL CL CL
PRDS-2 for ACC ejector Req.
and GCV
Steam piping from PRDS- As
o. CL CL CL CL
2 to ACC ejector and GCV Req.
Deaerator PCV to As
p. CL CL CL CL
Deaerator Req.
8.13 COOLING WATER PIPING
As
a. Source to Battery limit CL CL CL CL
Req.
Battery limit to Individual As
b. CL CL CL CL
eqpts. Req.
8.14 DRAIN PIPING
As
a. Steam Drum to BD Tank AV-UE AV-UE AV-UE AV-UE
Req.
Individual drain points to As
b. AV-UE AV-UE AV-UE AV-UE
BD Tank Req.
51
S. REMARK
No. QTY S
BD Tank to Nearest As
c. CL CL CL CL
surtrench Req.
8.15 BLOW DOWN TANK
a. Shell & dished ends 1 No AV-UE AV-UE AV-UE AV-UE
b. Valves & Mountings 1Set AV-UE AV-UE AV-UE AV-UE
c. Foundation bolts 1Set AV-UE AV-UE AV-UE AV-UE
d. Instruments as per list 1Set AV-UE AV-UE AV-UE AV-UE
e. Nozzles 1Set AV-UE AV-UE AV-UE AV-UE
8.16 DUCTING
As
a. ABC outlet to Boiler inlet AV-UE AV-UE AV-UE AV-UE
Req.
As
b. Boiler outlet to ESP inlet AV-UE AV-UE AV-UE AV-UE
Req.
As
c. ESP outlet to ID fan inlet AV-UE AV-UE AV-UE AV-UE
Req.
As
d. ID fan outlet to Stack inlet AV-UE AV-UE AV-UE AV-UE
Req.
8.17 HOPPERS
a. For first Pass 1 No AV-UE AV-UE AV-UE AV-UE
b. For Second Pass 1 No AV-UE AV-UE AV-UE AV-UE
c. For Third Pass 1 No AV-UE AV-UE AV-UE AV-UE
8.18 EXPANSION JOINTS
a. At inlet of boiler 1 No AV-UE AV-UE AV-UE AV-UE
At other ducting supplied
b. 1 No AV-UE AV-UE AV-UE AV-UE
by AV-UE.
ESP inlet and outlet
c. 2 Nos CL CL CL CL
expansion joints
8.19 STRUCTURE
Boiler Supporting Structure
As
a. up to operating Floor CL CL CL CL
Req.
(RCC)
Boiler supporting structure As
b. AV-UE AV-UE AV-UE AV-UE
from Operating Floor Req.
Platform & handrails above As AV-UE
c. AV-UE AV-UE AV-UE
Operating floor, Req.
As AV-UE
d. Ladders staircases AV-UE AV-UE AV-UE
Req.
Foundation bolts for As AV-UE
e. AV-UE AV-UE AV-UE
structures Req.
Supports for AV-UE As AV-UE
f. AV-UE AV-UE AV-UE
supplied ducting Req.
52
S. REMARK
No. QTY S
Supporting steel structures AV-UE
As
g. for boiler roof & side AV-UE AV-UE AV-UE
Req.
cladding
8.20 FIELD INSRUMENTS
a. As per standards practice 1Set AV-UE AV-UE AV-UE AV-UE
b. Remote Level Gauge 1Set AV-UE AV-UE AV-UE AV-UE
c. Instrument hardware 1Set AV-UE AV-UE AV-UE AV-UE
Instrument (Signal &
As
d. control) cabling from field AV-UE AV-UE AV-UE AV-UE
Req.
instruments to local JB’s
Instrument cabling from
As
e. local JB s to DCS and vice CL CL CL CL
Req.
versa
Instrument air piping from As
f. CL CL CL CL
source to battery limits Req.
Instrument air piping from As
g. AV-UE AV-UE AV-UE AV-UE
battery limit to instruments Req.
8.21 CONTROL PANEL
Control panel with its
a. 1Set CL CL CL CL
accessories
b. DCS 1Set CL CL CL CL
c. UPS 1Set CL CL CL CL
8.22 SILENCER
silencer for Steam drum
a. 2 Nos AV-UE AV-UE AV-UE AV-UE
safety valves
Silencer for Superheater
b. safety valve and start-up 2 Nos AV-UE AV-UE AV-UE AV-UE
vent valve
8.23 VALVES & MOUNTINGS
a. As per IBR requirement 1Set AV-UE AV-UE AV-UE AV-UE
8.24 SAMPLE COOLERS
a. On FW line 1 No AV-UE AV-UE AV-UE AV-UE
b. On saturated steam line 1 No AV-UE AV-UE AV-UE AV-UE
c. On superheated steam line 1 No AV-UE AV-UE AV-UE AV-UE
d. On Blow down line 1 No AV-UE AV-UE AV-UE AV-UE
8.25 ELECTRICALS
a. MCC Panel 1 No CL CL CL CL
Compensating cables,
Impulse piping & As
b. CL CL CL CL
instrument cable, signal Req.
cables, control cables from
53
S. REMARK
No. QTY S
field instruments to JB’s
Incoming cables to LT As
c. CL CL CL CL
MCC Req.
As
d. Local push button station CL CL CL CL
Req.
As
e. Lighting for plant CL CL CL CL
Req.
As
g. Earthing materials CL CL CL CL
Req.
8.26 REFRACTORY
As
a. On gas Inlet duct CL CL CL CL
Req.
As
b. On hoppers CL CL CL CL
Req.
As
c. Refractory anchors CL CL CL CL
Req.
As
d. Application curing CL CL CL CL
Req.
INSULATION WITH As
8.27 CL CL CL CL
ALLUMINIUM CLADING Req.
8.28 DEAERATOR
a. Deaerator 1 No AV-UE AV-UE AV-UE AV-UE
d. Storage tank 1 No AV-UE AV-UE AV-UE AV-UE
e. Valves & Mountings 1Set AV-UE AV-UE AV-UE AV-UE
f. Instruments 1Set AV-UE AV-UE AV-UE AV-UE
g. PRV station 1Set CL CL CL CL
8.29 HP DOSING SYSTEM
a. Motorized stirrer 1 No AV-UE AV-UE AV-UE AV-UE
d. Dosing pumps 2 Nos AV-UE AV-UE AV-UE AV-UE
e. Storage Tank 1 No AV-UE AV-UE AV-UE AV-UE
As
f. Interconnecting piping AV-UE AV-UE AV-UE AV-UE
Req.
g. Instruments 1Set AV-UE AV-UE AV-UE AV-UE
8.30 FEED WATER PUMPS
a. Centrifugal pumps 2 Nos AV-UE AV-UE AV-UE AV-UE
b. Electric motors 2 Nos AV-UE AV-UE AV-UE AV-UE
Flexible spacer type with
c. 2 Nos AV-UE AV-UE AV-UE AV-UE
MS guards
Cabling from MCC to As
d. CL CL CL CL
LPBS Req.
e. LPBS As CL CL CL CL
54
S. REMARK
No. QTY S
Req.
As
f. Conical strainers AV-UE AV-UE AV-UE AV-UE
Req.
As
g. Auto Recirculation valves AV-UE AV-UE AV-UE AV-UE
Req.
Cooling water supply
As
h. piping from Battery limit to CL CL CL CL
Req.
Feed water pump skid
Cooling water return piping
As
i. from Feed water pump CL CL CL CL
Req.
skid to Battery limit
Blow-off piping from Feed As
j. CL CL CL CL
Water pumps to Deaerator Req.
Leak-off piping from Feed
As
k. water pumps to near-by CL CL CL CL
Req.
surface trench
Spill-back piping from Auto
As
l. Recirculation valves to CL CL CL CL
Req.
Deaerator
8.31 LP DOSING SYSTEM
a. Motorized stirrer 1 No AV-UE AV-UE AV-UE AV-UE
d. Dosing pumps 2 Nos AV-UE AV-UE AV-UE AV-UE
e. Storage Tank 1 No AV-UE AV-UE AV-UE AV-UE
As
f. Interconnecting piping AV-UE AV-UE AV-UE AV-UE
Req.
g. Instruments 1Set AV-UE AV-UE AV-UE AV-UE
8.32 ELECTRO STATIC PRECIPITATOR
a. ESP & its components 1Set CL CL CL CL
8.33 INDUCED DRAFT FAN
a. ID FAN 1 No CL CL CL CL
b. Motor 1 No CL CL CL CL
c. Coupling 1 No CL CL CL CL
Pneumatic operated
d. 1 No CL CL CL CL
Control damper
8.34 RCC STACK 1 No CL CL CL CL
ASH HANDLING SYSTEM
8.35 (After RAV’s on boiler 1Set CL CL CL CL
and ESP)
8.36 PAINTING
As
a. Shop primer AV-UE AV-UE AV-UE AV-UE
Req.
55
S. REMARK
No. QTY S
As
b. Site final painting CL CL CL CL
Req.
8.37 CIVIL
As
a. Civil load data AV-UE AV-UE AV-UE AV-UE
Req.
As
b. All civil design & civil works CL CL CL CL
Req.
Control room for control As
c. CL CL CL CL
panel /MCC etc. Req.
8.38 OTHER ITEMS
As
a. First fill of lubricants AV-UE AV-UE AV-UE AV-UE
Req.
As
b. Alkali bailouts AV-UE AV-UE AV-UE AV-UE
Req.
Complete water treatment
c. 1 No CL CL CL CL
plant
d. DM water storage tank 1 No CL CL CL CL
Air Compressor with
f. 1Set CL CL CL CL
accessories
8.39 Erection & Commissioning
For
Erection & supplied
a. AV-UE AV-UE AV-UE AV-UE
commissioning equipmen
ts
8.40 IBR Formalities
Issue of certificate of
a. AV-UE AV-UE AV-UE AV-UE
materials supplied
b. Site IBR activities AV-UE AV-UE AV-UE AV-UE
c. Statutory IBR Fees CL CL CL CL
9.0 TERMINAL POINTS:
S. No. Description Terminal
56
S. No. Description Terminal

9.1 DM water At the inlet of Deaerator LCV.
9.2 Condensate Return At the inlet Nozzle of Deaerator.
9.3 Startup Vent Steam At the outlet of silencers to 1 m safe elevation
9.4 Relief Steam from SH At the outlet of silencers to 1 m safe elevation
Safety valve
9.5 Main steam At inlet of Turbine ESV (30 Mtrs)
9.6 LP steam for From the outlet of Deaerator PRV station.
Deaeration
9.7 Drain At Blow down tank / nearest floor trench (within 10
meters from Boiler)
9.8 Electrical Power At individual equipment / drives
Inlet/outlet of MCC
9.9 Instrument signal At the outlet of local JB boxes. Local junction
boxes will be mounted on the WHRB Main Support
Columns.
9.10 Instrument air From one point near the boiler. (Within 5 meters
from the WHRB) to individual Instruments
57
10.0 WATER QUALITY REQUIREMENT:
FEED WATER SPECIFICATION:
Drum Operating pressure bar (g) 61-100 Remarks

Hardness, max ppm Nil Note 4
pH at 25 deg C 8.8 to 9.2 Note 1
Oxygen, max ppm 0.007
Total Iron, max ppm 0.01
Total Copper, max ppm 0.01
SiO2, max ppm 0.02 Note 4
Conductivity at 25 deg C after cation 0.5 Note 4

exchanger in H+ form and after CO2 removal
max s / cm
Hydrazine residual ppm 0.01 to 0.02
BOILER WATER SPECIFICATION:
Drum operating pressure bar (g) 61 to 100 Remarks
PH at 25 deg C 9.8 to 10.2

Phosphate residual, ppm 15-25 Note 7
TDS, max ppm Not more than 100 Note 5

Specific electrical conductivity at 25 deg C, max Not more than 200
s / cm
Silica, max ppm To be controlled on the basis
of silica in boiler water and
drum Pr. And boiler water pH
relationship to maintain less
than 0.02 ppm in steam
leaving the drum
Sodium sulphite as Na2SO3, ppm Note 2
58
Notes:
All the measurements of feed water shall be made at high-pressure heater outlet or economiser
inlet.
1 Morpholine or any other volatile amine may be used to elevate the pH. The concentration
of volatile chemical in feed water shall not exceed 1 ppm. (Expressed as ammonia)
2 Sodium sulphite shall be dosed in the feed water, after the tapping point for desuperheater
spray so that it does not get contaminated.
3 The phosphate and pH shall be maintained in accordance with coordinated phosphate pH curve, to
prevent the presence of free hydroxide in boiler water.
4 If the feed water is used for desuperheating spray, for all pressures
4.1 Hardness shall be nil.
4.2 SiO2 shall not exceed 0.02 ppm.
4.3 Conductivity at 25 deg C measured after cation exchanger in H+ form after CO2
removal not to exceed 2 micromho / cm.
5 Total alkalinity in boiler water shall not exceed 20% TDS.
6 Presence of oil or organic matter is not allowed in feed water which will induce foaminess
and cause carryover of impurities in to steam.
7 The phosphate and pH are recommended in accordance with coordinated phosphate curve
to prevent presence of free hydroxide in boiler water. If the recommended pH is
consistently obtained phosphate residual can be maintained near lower limits.
59
The above curve is for Boiler water pH = 10, for drum pressures of 60 to 98 bar(g)
Phosphate Curve
10.8
10.4
10
PH value at 25 C
9.6
Series1
9.2
8.8
8.4
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

PPM PO4
60
11.0 MATERIAL OF CONSTRUCTION OF MAJOR EQUIPMENTS:
Description MOC Remarks
Steam Drum Shell 516 Gr 70/ Equiv.
Drums Dished Ends 516 Gr 70/ Equiv.
Internal Piping in Steam Drum SA 106 Gr B
Steam Purifier in Steam Drum SS 304 Non-IBR
Superheater 1 Tubes SA 210 Gr. A1
Superheater 2 Tubes SA 213 T11
Inbed Coils SA 210 Gr. A1
Economiser Tubes BS 3059 Smls
Water walls/ Evaporator BS 3059 Smls
Air Preheater IS 1239 Non-IBR
Bed Coils SA 210 Gr A1
Blow Down Tank IS 2062
Superheater 1
SA 106 Gr. B HFS
Outlet Header
SA 106 Gr. B HFS
Inlet Header
Superheater 2
SA 335 P11 HFS
Outlet Header
SA 106 Gr. B HFS
Inlet Header
61
Inbed Headers & Water Wall Headers SA 106 Gr. B HFS
Economiser Headers SA 106 Gr. B HFS
Deaerator IS 2062
OTHER ITEMS:
Flanges for Pressure Parts : SA 105 / Equiv.

Inlet Duct : IS 2062 Gr. B / Equiv.
Outlet Box : IS 2062 Gr. B / Equiv.
Saddle Support : IS 2062 / Equiv.
Stud/ Bolt/ Nuts for Press. Part : SA 193 Gr.B7/SA 194 Gr. 2 H/ Equiv.
Ducting : IS 2062 Gr. B
Structurals : IS 2062 Gr. B
Hoppers : IS 2062 Gr. B
12.0 CODES AND STANDARDS APPLICATION:
The Design, Manufacture, inspected and testing of Waste Heat Recovery Steam
Generating System (WHRSG) and accessories will comply with latest editions of
the codes and standards indicated below or equivalent international standards and
will meet statutory regulations and safety codes:
- Design code (Press. Parts) : IBR 1950

- Materials : ASME/ASTM/I.S
- Design code (Piping) : ANSI B 31.1
- Design code (Non-Press. Parts) : GEP
- Pipe fittings & flanges : ASME-B16.5,B16.11,B 16.9
- Welding & Welder test : ASME Sec.IX & ANSI B 31.3
- N.D.E : ASME Sec. V
- Safety valves : IBR
- Testing of valves : ASME-B31 & B.S.6755,
- Steel valves –flgd & BW : ANSI-B16.3,B16.10& 16.25
- Centrifugal pumps : API 610 / DIN 1944
- Code of practice for general
construction in steel : I.S. 800
- Criteria of Earth quake resistant
design of structures : I.S. 1893
- Stairs, Ladders and Walkways : BS 5395
62
- Code of Practice for design loads for

Building & Structures Wind load
- Heat Exchangers : ASMESec.VIIIDiv.1& TEMA
- Storage Tanks : API 650
- Fasteners (Bolts & Nuts) : EJMA
- Surface preparation : Acc. To AV-UE
- Painting : Acc. To AV-UE
- Sound pressure measurement :ISO 6190 & ISO 1680
13.0 INSPECTION & DOCUMENTATION:
WHRSG will be fabricated and tested under stage wise and final inspection of Chief Inspector
of Boilers, AP and following approvals shall be obtained.
- General Arrangement drawing with Fabrication part drawings.

- Materials Test Certificates for compliance with specification.
- Stage wise inspection during fabrication by QC of AV-UE & CIB
- Relevant Weld procedures and qualification tests.
- Final equipment dimensions verifications.
- Hydro Test and any other tests as required by the code/CIB/Client
We will furnish the following documentation after dispatch of the equipment:
63
Material Test Certificates, Check Test Reports, Stage Inspection Reports, Radiographic
Test Results, Charts for Stress Relieving, Thinning and Ovality Reports, Works Test
Certificate, Works Guarantee Certificate etc., along with following documents:
As Built Drawings (in ammonia print) : 2 Sets

As Built Drawings (in soft copy) : 1 Set
I.B.R. Documentation Folder (original) : 1 Set
I.B.R. Documentation Folder (photocopy) : 2 Sets
Installation Instruction Manual : 2 Sets
Operation and Maintenance Manuals : 2 Sets
14.0 LIST OF PRINCIPAL VENDORS FOR BOUGHT OUT COMPONENTS:
PRESSURE PARTS ENDOR LIST:
Plates (Boiler quality) : SAIL / Imported

Tubes & Pipes (Boiler quality) : MSL / JINDAL / Imported
INSTRUMENT VENDOR LIST:

64
A. Air Filter Regulator:

Shavo Norgen (India) Pvt Ltd, Placka, Veljan, SMC Pnematic
B. Flow Nozzle / Orifice:
AV&UE(Orifice), Star Mech, JN Marshall, Hydro Pneumatics, GIC, Eureka
Industrial Equipment ltd
C. Instrumentation & Ext. Cables:
Finolex, Finecab
D. I/P Converters:
Watson Smith (Mtl), H&B / Rosemount, Moore, Anirudh Engineers, Forbes
Marshall, Fischer, ABB, MIL, Imported
E. Level Gauges & Level Switches:
Levcon instruments Pvt Ltd, Protolona Instruments, Yarway, Hitech, Becon pvt. Ltd
(Solatron Make), Chemtrol (level switch), Pune Techtrol, Imported
F. Pressure, DP, Flow & Level Transmitter:
ABB, Emerson, Yokogawa, Fuji, Rosemount, Siemens, H&B, Imported
G. Pressure & Temperature Gauges:
General Instruments Co., Radix Electro Systems, H.Guru, Pyro electric, Wika,
Waaree instruments, Forbes Marshall, Radix Micro Systems
H. Pressure Switch & Temperature Switches:
Indfoss, Switzer, AN Instruments
I. RTD and Thermocouples:
Tempsen, Radix Electro Systems, Pyroelectric, GIC, Nutech Engineers, Detriv,
Thermal instruments, Waree
J. PLC:
Allen Bradely, LSS, Schneider Electric, Siemens, Tata Honeywell, ABB, GE
Fanuc, Rockwell automation
K. EWLI:
Level State, Radix Electro Systems, Yarway, Solatron
L. O2 Flue Gas Analyser (In Situ Tpe):
65
Ametek, Chemtrol, Enotech, ABB Kent, Land Combustion, Emerson, Forbes

marshall, YBL
M. Flue Gas Analyser
Codel, Chemtrol, Ametek, ABB Kent, Land CCombustion, Emerson, Forbes
marshall, YBL
N. VFD:
ABB, Siemens, GE, Allan Bradley, L&T, Dan Foss, Schneider, Eurotham
Automation, Vacon, Fuji Electric-VFD
O. Desuperheater / PRDS:
Forbes marshall, Yarway, Fisher Sanmar, AV&UE (De-Super heater), Mazda, JN
Marshall, Dewrence, Chemtrols
P. Single Loop Controller:
Bells Controls, Siemens ltd, Tat Honeywell Ltd, Yokogawa Blue Star ltd
Q. SWAS:
AV&UE, Forbes Marshal, Swan, Rosemount, Chemtrol, Yokogawa, VJ
Engineering, ABB
ELECTRICAL VENDOR LIST:
A. Motor Control Centers:

AV&UE, Seimens, L& T
B. Motors –LT
Kirloskar, BHEL, Siemens, BNGEF, Bharat Bijlee, ABB, Rotomotive, Alstom
C. Power Control Cables:
Cable Corporation of India, Polycab, UCl, NICCO, Fort Closter, TCL
D. Transducers:
BABB, Siemens, AE, Alstom, Minilee
E. LT Switch Gear Components:
Siemens, L&T, ABB, Alstom , LG -LS
F. CTs & PTs:
Precise, Kappa, Indcoil, Alstom, Areva
G. Push Button Station:
66
GEPC, Standard Gold, Technic, Vaishnov

H. Selector Switches:
Kavcee, SCI, GEPC
I. Digital Meters:
Enercon, Neptune, HPL, IMP
J. Protection Relays:
Alstom, LG - LS
K. Auxiliary Relays:
Alstom, LG – LS, Siemens
L. Cable Trays & Accessories:
APT Engineering, Premier, Jamuna metals, Globe
M. Air Circuit Breaker / MCCB:
Seimens, L&T, GE power, Schneider Electric
N. Analog Meters:
AE, Rishabh
O. Motor Protection Relays:
Alstom, LG -LS
P. Contractor:
Siemen, L&T, GE power, Schneider Electric, BCH, Telmechanique, LG -LS
Q. Ac Switches:
Seimens, L&T, GE power, Schneider Electric, LG -LS
R. DC Switches:
Kaycee
S. VFD panels:
ASEA Brown Boveri Limited, Danfoss industries Private Limited, Eurotherm Del
India Limited, L&T, Siemens L:imited, TB Wood,s India PCT Limited, Amtech, HI
Rel, AV&UE
T. Junction boxes:
AV&UE, SAI-BEE , Mithsagar, Baliga
MECHANICAL VENDOR LIST:
A. Feed Water Pumps:

KSB, Sulzer, Kirlosker
67
B. Insulation:
i. Mineral Wool insulation:
Llyod Rock Fibres, Rock Wool Industries, Orient, Mine wool , Thermo wool
ii. Aluminium Caldding:
Balco, Indal, Hindlaco, Anish Metals, Alluminium India
iii. Refractory & insulation Bricks:
ACC, Dalmia Refractory, Tata Refractories, Pacific Refractories, Castwell
C. Fans & Accessiroes:

Air Flow, Ritz, CB Doctor, imported
D. Chemical Dosing System:
AV&UE, Metapow, Positive Metering Systems
E. Pipe work, Valves & Fittings:
i. Safety valves:
TYCO Sanmar, MH Valves, Fainger & Lesser, Diaton China, BHEL, Mazda
ii. Blow down valves:
Levcon, BHEL, Fluid Line, Diaton China, MH Valves
iii. Control Valves:
MIL, Fisher Xomox, Imported, Mascot Valves, Samson Controls
iv. Solenoid Valves:
Rotex, ASCO
v. Manual Valves
BHEL, KSB, Alsa, Prime, Fluidline, Daiton
F. Paints:
Asian paints , Berger paints India Limited
68
15.0 GENERAL SPECIFICATIONS:

15.1 QA AND WELD PLAN:
Appropriate Q.A. Plan covering WPS, PQR, thinning and Ovality, mock up test,
radiography, D.P. Test, other NDEs, stress relieving, surface preparation,
activities/inspection, acceptance criteria, verifying documents, etc.., taking into
consideration technical requirements of the code/specifications of the client and his
consultant will be submitted on receipt of the order for comments/approvals and
finalization of the hold points.
15.2 INSPECTION AND ACCEPTANCE BY BUYER/OWNER:

You will have complete access to undertake inspection of the equipment as per the
hold points or at any other stage including final testing. All facilities available with
us will be extended free of cost to carry out the inspection. However, inspection
and acceptance by you does not absolve our contractual/guarantee obligations.
15.3 PROGRESS REPORTING:

We will furnish progress report on a fortnightly basis covering the following:
a) Basic Engineering
b) Detailed engineering specifications and drawings
c) Q.A Plan and W.P.S.
d) Procurement
69
e) Fabrication & Testing
15.4 CONCESSION REQUEST:

Any deviations arising during execution of the contact will be submitted to you with
corrective action for approval. No rectification will be carried out without your
written approval.
15.5 WELDING:
We will clearly indicate details of the welding in the fabrication drawings. Only
qualified welders as per IBR will be employed. The welding will be carried out as
per established WPS and PQR with approved electrodes and Filler Rods.
15.6 SHOP TESTING:

On successful completion of fabrication, all the Pressure parts will be subjected to
hydrostatic test in the presence of IBR/Third party Inspection authority/OWNER.
15.7 STATUS AND SUB-CONTRACTING:

The equipments offered vide this proposal will be manufactured and tested at our
works, located at Hyderabad. Any sub-contracting will be informed to you in
advance.
15.8 WARRANTEES:
We warrantee the equipment to be free from defective raw materials and faulty
workmanship for a period of 18 months from the date of dispatch or 12 months
from the date of commissioning, whichever is earlier. Any parts found defective
under normal working conditions will be supplied free of cost. However this
warrantee does not cover normal wear and tear in operation and damages during
transit and erection.
Bought out components are guaranteed by us only to the extent of guarantees

given to us by our suppliers. Electrical components such as heaters, motors,
contractors etc., rubber components and instruments such as pressure gauges,
thermometers, comb stats, etc.. are, however, not covered under this warranty.
70
The warranty is subject to :
a) Installation having been completed within three months of dispatch of the

equipment and as per our installation instructions.
b) The supply/installation having been formally accepted as per the handing over
clause.
c) Supply of right gases as per relevant specification.
d) The equipment or part thereof not being subject to accident, alternation, abuse
or misuse.
e) The equipment being operated and maintenance as per our operation and
maintenance manual.
71
COMMERCIAL PROPOSAL
FOR
1 x 10 TPH WHR BOILERS
IN SPONGE IRON PLANT
SUBMITTED TO
M/s. APTICO.
SUBMITTED BY
ARTICULATED VESSELS & UTILITY

ENGINEERS PVT LTD.
SECUNDERABAD- 500 009
72
M/s. AV-UE/WHRS-APTICO/Q/11-12:110 Date: 03-11-2011
M/s. APTICO .
Kind Attn: Mr. GOPALA RAO
Dear Sir,
Sub: Commercial Proposal for Supply, Erection & Commissioning of 1 x 10 TPH Waste
heat recovery Systems.
Ref: With reference to the telephonic discussion had with our MD. Mr. PARAMVIR
SINGH
We thank you very much for showing interest in AV-UE for your boilers. As required by you, we
are pleased to submit herewith our Commercial Proposal for Supply, Erection & Commissioning of
1 x 10 TPH WHR Boilers at 66 Kg/cm2 (g) Pressure and 485±5 ºC Superheated Steam and
Common Deaerator System for your Power Plant.
AV&UE supplies boilers designed and manufactured to several national & international
standards like IBR, ASME Sec VIII Div 1 & BS 113.
We trust the above is in line with your requirement & in the meantime, if you need any
further clarifications to evaluate our proposal please feel free to contact us.
Assuring you of our best attention, always.
Thanking you,
Yours faithfully,
PARAMVIR SINGH
MANAGING DIRECTOR
73
1.0 PRICE SCHEDULE:

The Prices are quoted as per scope of supply given in our Technical offer.
Total Cost
SNO. DESCRIPTION Qty (Nos)
In Laks
1 x 10 TPH WASTE HEAT RECOVERY BOILERS:
Supply of 1 x 10 TPH WHR Boilers includes Water

1. wall furnace, Two stages Superheater,
Desuperheater, Evaporators, Economiser as per 1 set
our scope of supply.
Complete Boiler structural & Non pressure part
includes main columns, bracings, tie beams,
2. 1 set
foundation bolts, walkways, handrails, staircases,
2,82,10,900
flue gas ducting etc., as per scope of supply
3. Boiler integral feed water & Steam pipelines 1set
Blow down tank, HP Dosing system, Sample
4. coolers & Soot Blowers with Controls as per our 1set
scope of supply
Valves, Mountings & Instruments as per our scope
5. 1 set
of supply
FEED WATER SYSTEM:
10.6 M3 Deaeration capacity Deaerator cum 5 M3

1. Storage Tank with Valves Mountings and 15,68,700
1 set
Instruments
2. Feed Water Pumps with Motors (each 10.6 M3 26,45,000
2 sets
Capacity)
i. Feed water piping from to Deaerator to
Economiser Inlet
3. ii. Common Steam pipeline from MSSV to 1 set 16,57,000
Common Header
iii. Common header to Turbine ESV
4. LP Dosing System 1 set 3,60,000
ERECTION & COMMISSIONING:
1. Erection & Commissioning

For Each 21,50,000
2. Boiler
Site IBR Activities & Approvals
TOTAL 3,73,41,260
74
2.0 COMMERCIAL TERMS AND CONDITIONS:
PRICES - Prices quoted are Ex-works, Hyderabad basis.

Packing & Forwarding charges are included in our
quoted price.
Transit Insurance has to be Bourne by Client
FREIGHT - Extra on to-pay basis.
TAXES & DUTIES - Extra at actual.
DELIVERY - The Equipment will be delivered on Ex-works,

Hyderabad basis within Ten (10) Months from the
date of receipt of your technically and commercially
clear order along with advance.
VALIDITY - Our offer is valid for a period of 30 days from the date
of this quotation.
PAYMENT TERMS - FOR SUPPLIES
20 % advance along with Order.
20 % against drawings approval.

Balance 60% against Proforma Invoice prior to
dispatch of each equipment on prorate basis.
GUARANTEE - The above system will be guaranteed against

defective raw materials and bad workmanship for a
period of 18 months from the date of supply or 12
months from the date of commissioning, whichever is
earlier.
FORCE MAJEURE: - We shall not be liable for any penalties/liquidated

damage charges for delayed deliveries due to
reasons beyond our control such as War, Riots,
Inclement weather, Floods, Act of God etc.
PARAMVIR SINGH
MANAGING DIRECTOR
75
76

Waste Heat Recovery Power Plant 2mw 100tpd Orissa

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WASTE HEAT RECOVERY POWER PLANT(2MW)– 100TPD

ORISSA SPONGE IRON CLUSTER

For more information Telephone +91-11-26179699

We sincerely appreciate the efforts of industry, energy auditors, equipment manufacturers,

1.1 Brief Introduction about cluster ...................................................................................1

1.2 Energy performance in existing situation ....................................................................4

1.3 Existing technology/equipment ...................................................................................5

1.4 Establishing the baseline for the equipment ................................................................5

2. TECHNOLOGY/EQUIPMENT FOR ENERGY EFFICIENCY IMPROVEMENTS .........8

2.1 Detailed description of technology/equipment selected ...............................................8

2.2 Life cycle assessment and risks analysis ..................................................................10

2.3 Suitable unit/plant size in terms of capacity/production .............................................10

3. ECONOMIC BENEFITS FOR THE INSTALLATION OF FUEL ECONOMIZER ........11

3.1 Technical benefits .....................................................................................................11

3.2 Monetary benefits .....................................................................................................11

3.3 Social benefits ..........................................................................................................12

3.4 Environmental benefits .............................................................................................12

4. INSTALLATION OF FUEL ECONOMIZER ...............................................................13

4.1 Cost of technology/equipment implementation ..........................................................13

4.2 Arrangement of funds ...............................................................................................13

4.3 Financial indicators ...................................................................................................14

4.4 Sensitivity analysis in realistic, pessimistic and optimistic scenarios .........................14

4.5 Procurement and implementation schedule ..............................................................15

Annexure 4: Detailed financial calculations & analysis ...........................................................19

Annexure 5: Details of procurement and implementation plan ................................................24

Annexure 6: Details of technology/equipment and service providers ......................................25

Annexure 7: Quotation or techno-commercial bid ...................................................................27

BEE - Bureau of Energy Efficiency

3 Monetary benefit (in Lakh) 499

Bureau of Energy Efficiency (BEE) is implementing a BEE-SME Programme to improve

Major activities in the BEE -SME program are furnished below:

Activity 1: Energy use and technology audit

Activity 2: Capacity building of stake holders in cluster on energy efficiency

Activity 3: Implementation of energy efficiency measures

Activity 4: Facilitation of innovative financing mechanisms for implementation of

1.1 Brief Introduction about cluster

1.1.1 Production process

Detailed of process flow chart are finished in Figure 1.1 below:

Figure 1.1: General process flowchart of a typical Sponge Iron unit

Raw material feeding at

Coal Sized Iron Over size

Coal bin Iron ore

Processed in rotary kiln at

Indirect cooling in rotary cooler

Screening of mixed end product

S.I. Lumps - S. I. Fines -

1.2 Energy performance in existing situation

1.2.2 Average production by a typical unit in the cluster

1.3 Existing technology/equipment

1.3.2 Its role in the whole process

1.4 Establishing the baseline for the equipment

1.4.2 Coal consumption in existing system

Table 1.4 Coal consumption of Sponge iron Cluster

1.4.3 Operating specific coal consumption of existing system.

Lack of water availability.

2. TECHNOLOGY/EQUIPMENT FOR ENERGY EFFICIENCY IMPROVEMENTS

2.1 Detailed description of technology/equipment selected

2.1.2 Technology /Equipment specifications

Table 2.1: Waste heat recovery power plant Specifications