ASME Standard 3500 Kg/Hr and 2000 Kg/Hr Steam Boiler Systems

 1. PURPOSE

This Material Requisition is intended for the supply of two integral boiler systems comprising of the basic boiler equipment and associated boiler house components with a rating of 3500kg/hr and 2000 kg/hr dry saturated steam at 10.5 Bar. The work to be performed under the terms of this Specification includes supplying, Testing and commission of the boiler package.

2. BASIC EQUIPMENT:

2.1. Boiler System

Packaged boilers mounted on heavy steel base frame factory assembled and tested, designed to be transported and installed with a minimum possible assemblyat KPRL.

Item	Description
1	Continuous Rating (MCR) 3500 Kg/Hr, Steam at Terminal Pressure – 10.5 Bar. Constructed in accordance with requirement of the ASME Boiler and Pressure Vessel Code, Section IV and tested to ASME V OR as per European Pressure Equipment Directive (PED)”. Mounted on a heavy duty structural steel base with extended skid and burner platform
2	Continuous Rating (MCR) 2000 Kg/Hr, Steam at Terminal Pressure – 10.5 Bar. Constructed in accordance with requirement of the ASME Boiler and Pressure Vessel Code, Section IV and tested to ASME V OR as per European Pressure Equipment Directive (PED)”. Mounted on a heavy duty structural steel base with extended skid and burner platform.

2.1.1. General Performance and Design Requirements The Boiler should provide Saturated Steam at Terminal (Steam Manifold) meeting the following:

i. Pressure 10.5 Bar G

ii. Temperature: 185°C

iii. Tolerance: 10%

2.1.2. Utilities:

i. Fuel: with the following parameters for HFO

Test	Method	Specification
Density	ASTM D 1298	940	Max
Sulphur Content, %Wt	ASTM D 1552	2.3	Max
Net Calorific Value, KJ/Kg	ASTM D 4868	41,000	Min
Viscosity (Kinematic)@ 50°C, cSt	ASTM D 445	120-150
Ash Content, %Wt	ASTM D 482	0.02	Max

ii. Raw Municipal Water with the following parameters

Sr. No.	Parameters	Units	Fresh water
1.	pH	-	7.5-8.0
2.	Conductivity@250C	μS/cm	500
3.	Total Dissolved Solids(TDS)	mg/l	330
4.	Total Hardness as CaCO3	mg/l	110

2.1.3. Boiler pressure vessel: Design Requirements

i. The boiler will be designed and built to comply with the latest codes for American Boiler Manufacturers Association (ASME) or the European Pressure Equipment Directive (PED) and be inspected and stamped by an authorized boiler inspector.

ii. The boiler shall be factory insulated around its full circumference with at least 2" thick fibrous, NON-ASBESTOS INSULATION.

iii. The base and other components of the boiler shall be factory painted with hard-finish silicone enamel or equivalent. iv. Design: Three-pass single-flame tube/smoke tube technology v. Boiler equipment to have the following parts as a minimum:

a. Blow-off tap

b. Water level indicator

c. Pressure limiter

d. Pressure transducer (4-20 mA)

e. Low-level limiter electrode

f. Pressure gauge

g. Level transducer (4-20 mA)

h. Pressure gauge shut-off valve with testing function

i. Steam dryer

j. Steam removal valve

k. Full-lift safety valve

l. Feed water non-return valve

m. Feed water shut-off valve.

n. Drain shut-off valve

o. Quick shut-off blow-down valve

p. Inspection opening, steam side

q. Inspection opening, water side

r. Inspection opening, flue gas side

2.1.4. Control and safety technology

i. Provide water column with cocks, gauge-glass set, and blowdown valves for gauge glass and column.

ii. Feed water Pump Control will be an integral part of the water column. The control will be selected to automatically actuate a motor driven feed water pump to maintain boiler water level within normal limits.

iii. Low Water Cut-off (LWCO) shall be an integral part of the water column. The LWCO shall be factory installed and wired into burner control circuits Page 31 of 48 to prevent burner operation if water level falls below safe operating limits.

iv. Provide boiler feed water and condensate return pump control, integral with water column to maintain water level automatically by controlling pump operation. The feed water piping shall incorporate means for field connection of chemical feed line.

v. Steam Safety Valves shall be provided in types, sizes and quantities to comply with ASME Code requirements. vi. Provide operating-pressure controller for burner to maintain steam pressure setting. vii. Provide high-limit-pressure controller with manual reset for burner to prevent steam pressure from exceeding safe system pressure.