APPROACH NOTE
NAME OF THE PROPOSAL : Installation of 4th (fourth) Boiler
Feed Pump in CDCP Boilers of COB-11
BACKGROUND:
Existing Facility :
In coke dry cooling plant(CDCP) of coke oven battery-11
there are 4 (four) numbers of waste heat recovery boilers
operates in series with four coke dry cooling chambers.
Three numbers of boiler feed pumps are installed to supply
feed water to boilers. These feed pumps are of type HDA
80/12 and of M/S. KSB make. The discharge capacity of each
pump is 66 m3/Hr. The rated power of motor is 260KW and RMP
is 2970.
Limitations Experienced :
In the original design and operation philosophy of coke dry
cooling plant (CDCP) of COB-11, it was envisaged to run two
coke dry cooling Boiler-Chambers modules. The third Chamber-
boiler module was to remain as a standby. The fourth module
was to be under maintenance.
There are three numbers of installed feed pumps for CDCP
Boilers . Out of these three feed pumps , one was envisaged
to remain in operation, second was envisaged to remain as
stand by & third one was to be under maintenance.
But, due to plant operational requirement, now 3 boiler-
chambers are in continuous operation. To cater feed water
demand for these three boilers, two boiler feed pumps are in
continuous operation. The third feed pump remains as stand
by. If, any pump goes for maintenance, there is no standby
feed pump to meet water demand of boilers.
The discharge capacity of each installed pump is 66m3/hr
with specific gravity of fluid equal to 0.93. This amount to
optimum flow capacity of 61.38 Ton/Hr for each pump.
When three boilers remain in operation, the average water
requirement is around 70 Ton/Hr and the maximum
instantaneous water requirement comes to around 80Ton/Hr. As
two number of feed pumps run continuously the combined
discharge capacity goes beyond 120 T/Hr against a
requirement of 70Ton/Hr. This causes pumps to run around
shut off head. Due to this high pressure pumps internal get
damaged frequently. The average life of any feed pump in
CDCP is around one year. Single pump running is not
successful as the pump get over loaded and trips frequently.
As two feed pumps run continuously, if third one goes for
maintenance, there is no standby pump to meet any
eventuality.
NEED :
Coke production from CDCP of Coke oven Battery#11 is
directly related to hot metal production in Blast Furnace-8.
Any break down in feed pumps in CDCP compels COB#11 to go
for less coke pushing. This adversely affect the hot metal
production from BF-8.
OBJECTIVE :
(1) To make the uninterrupted Coke production from
COB#11 reliable and effective, installation of
fourth feed pump is essential in CDCP Boilers.
(2) The proposed higher capacity feed pump shall ensure
running of single pump instead of two . It will save
substantial amount of electrical power. When the
existing two pumps run, it consume 464 KW of
electrical power . The proposed single pump shall
consume 333KW of electrical power. This shall enable
a saving of 3144KW/day of power. Thus a tangible
benefit or Rs.4716000/- per year( considering power
cost of Rs.5.00/KW).
PROPOSAL :
Project Description : Installation of 4th (fourth) Boiler
Feed Pump in CDCP Boilers of COB-11
Capacities of Major Production Units : Coke Oven Battery#11,
CDCP unit having average coke production capacity of
2250Ton/day.
Main Raw Materials & their Availability : Not relevant
Market Demand : Not relevant
Alternatives Considered : Nil
Selection of Alternative : NA.
Link Project & Their Status : Nil
SCOPE OF WORK :
(A) Procurement of (1) a new feed pump Model No-HDA
100/9, Make KSB, with its electrical &
instrumentation accessories (2) electric motor
suitable for HDA 100/9 Feed pump (3)Pump foundation
(4) Valves & pipe arrangements.
(B) Erection, commissioning & stabilization of operation
of Feed Water system of CDCP Boilers of COB#11.
BROAD IMPLEMENTATION STRATEGY :
Number & Description of Packages : One purchase package.
Mode of implementation : Procurement from M/s KSB, erection
& commissioning by M/s KSB including civil foundation, pump
input & output connection with suitable valve & pipe
arrangements, electrical & instrumentation system
installation.
Integration of cabling, start –stop switch, instrumentation,
DCS shall be done by CO&CCD (Electrical)
Implementation schedule : Shutdown is required for
connection of inlet & outlet pipes and integration of
electrical systems.
PROJECT OWNER/ CO-ORDINATOR :
OWNER : RAJIV PANDEY ,CGM (POWER FACILITIES)
CO-ORDINATOR : SHIEKH ZAKIR,GM (PBS)
BENEFITS ENVISAGED :
(1) Reliable working of Coke Dry cooling Plant of COB#11
(2) Cost saving of Rs.47,16,000/- per year by reducing
electrical power consumption.
CAPITAL COST :
Rs 12202000/-
EXPECTED SERVICE LIFE OF EQPT :
20 years.
JUSTIFICATION OF URGENCY :
(1) Frequent breakdown of existing feed pumps and its
adverse effect on coke production in COB#11.
(2) Non availability of standby pump during maintenance
