Solid Fuel Fired Vertical Thermal Oil Heater with Bubbling Bed

THERMOPAC
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INSTRUCTION MANUAL
FOR

THERMOPAC – VTB SERIES

FUEL – PETCOKE/ IMPORTED COAL (BUBBLING BED)

(Model - VTB 04, 06, 10, 15, 20, 25 & 30)

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COOLING & HEATING DIVISION 2 VTBB STD-T
THERMOPAC
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INSTRUCTION MANUAL
FOR

THERMOPAC - VTB SERIES

(Model - VTB 04, 06, 10, 15, 20, 25 & 30)

PUBLICATION NO. : **********

JUNE 2016
IN CASE OF ANY DOUBT OR CLARIFICATION, PLEASE CONTACT OUR NEAREST OFFICE

ADDRESS TEL NO. FAX NO.

THERMAX LIMITED, 020-27475941
TECHNICAL SERVICES, (5 LINES)/
(COOLING & HEATING DIVISION) 020-27470346
D-13, MIDC INDUSTRIAL AREA,
R.D. AGA ROAD,
CHINCHWAD,
PUNE 411 019 (INDIA)

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THERMAX LIMITED
INDIA

DHANRAJ MAHAL,2ND FLOOR 022-22045391 / 2 022-22040859

CSM MARG, GATEWAY OF INDIA 022-22952058 / 9
NEAR REGAL CINEMA
COLABA,
MUMBAI 400 039 – INDIA
AZIMGANJ HOUSE 033-22826711 033-22826796
TH
5 FLOOR, 7 CAMAC STREET 033-22826712
KOLKATA 700 016 – INDIA 033-22826713
Email : thermcal@[Link]
9 COMMUNITY CENTRE, 011-46087200 011-26145311
BASANT LOK 011-26148679
NEAR PRIYA CINEMA 011-26148662
NEW DELHI 110 057 – INDIA
FATHIMA AKHTAR COURT 044-24353831-4 044-24353841
III FLOOR, 312 ANNA SALAI 044-24303400
TEYNAMPET,
CHENNAI 600 018 – INDIA
PUNE AREA OFFICE 020-2775941 020-27472049
D-13, MIDC AREA, (10 LINES) 020-27475679
CHINCHWAD, 020-27477066
PUNE 411 019 – INDIA
409-411 MAHAKANT 079-6575806 079-6577270
OPP. VS HOSPITAL 079-6575408
ASHRAM ROAD
AHMEDABAD 380 006 – INDIA
RNG PALLAZZO, 080-2237121-26 080-3467760
NO.1 (FIRST FLOOR),
SOUTH END STREET,
KUMARAPARK EAST,
(BEHIND SHIVANANDA STORES),
BANGALORE 560 001 – INDIA
6-3-649 NALANDA COMPLEX, 040-23312013 040-23312335
ND
2 FLOOR, BEHIND MEDINOVA 040-23310254
SOMAJIGUDA 040-23396820
HYDERABAD 500 482 – INDIA 040-23390915
A / 144 SHAHEED NAGAR, 0674-3096360. 0674-2541647
1ST FLOOR
BHUBANESHWAR - 751 007, ORISSA

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THERMAX LIMITED
(OVERSEAS OFFICES)
ADDRESS TEL NO. FAX NO.
THERMAX LIMITED., + 32 2 2736 92 44 + 3 22 2 736 92
REPRESENTIVE OFFICE - Mobile No. : +32 473 450 56
BENELEX, FRANCE AND SPAIN 186
AVENUE DU PRINCE HERITIER, 192
BE – 1200 BRUSSELS,
BELGIUM
E-mail :
[Link]@[Link]
C/o. PT Multi Usaha Mandiri 00-62-21-83793255 00-62-21-
TH
BIDAKARA BLDG. 6 FLR, 00-62-21-83793259 83793258
[Link] GATOT SUBROTO KAV 71-73, Mobile : 00-62-81-6810272 Mobile – 0062-
PANCORAN, JAKARTA 12870 (Mr. Mahesh Kulkarni) 81-
INDONESIA 6810272
E-mail : mahesh@[Link]
C/O SPENOMATIC (K) LTD, 00-254-20-4440233/ 00-254-20-
[Link] NO. 39935 00-254-20-4440206/ 4451919
WAIYAKIWAY, CLOSE TO ABC PLACE, 00-254-20-4440207
NEXT TO HOPE HOUSE (BABY HOME)
WESTLANDS, NAIROBI, K E N Y A
E-mail : info@[Link]
THERMAX (RUS) LTD., 00+7 4997832461 00-7495-
ULITSA VAVILOVA,OFFICE 915,HOUSE 69, 00+7 4997832462 1347410
VAVILOVA STREET, MOSCOW 117846, Mobile:00-7-9166739904
RUSSIA (Mr. Shankar Mukherjee)
E-mail : thermax-moscow@[Link]
(REPRESENTATIVE OFFICE), 00-66-2-655790 00-66-2-
TH
4 FLOOR NAI LERT TOWER, Mobile : +66-813720099 6555791
2/4 WITHAYU ROAD, LUMPHINI, (Mr. Nitin Gupta)
PATHUMWAN, BANGKOK 10330,
THAILAND
E-mail : “Nitin”<ngupta@[Link]>
P O BOX 17156 JEBEL ALI 00-971-4-8861424 00-971-4-
DUBAI, U.A.E. Mobile: 00-971-506445102 8861309
E-mail : rautvm@[Link] (Mr. V.M. Raut)
THERMAX EUROPE LTD 00-44- 1908 378914 00-44-1908
2, STUDIO COURT, QUEENS WAY Mobile:00-447977464192 379487
BLETCHLEY, MILTON KEYNES (Mr. Dinesh Kamat)
MK2 2DG, UNITED KINGDOM
E-mail : kamatdinesh@[Link]
E-mail : bharatkapoor@[Link]
BLDG. NO. 114, FLAT NO. 68 00-73-272-543582 00-73-272-
PROSPECT LENIN, ALMATY 480100 543582
KAZAKSTAN
E-mail : thermax@[Link]

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ADDRESS TEL NO. FAX NO.

C/o PRO-ACTIVE MH RESOURCES 00-60-3-21669801 / 00-60-3-21669802
RD
[Link], 3 FLOOR (SOUTH WING) 21612677
BANGUNAN GETAH ASLI Mobile: 00-60-19-
P.O. BOX 18, 148, JALAN AMPANG 3179779
50450, KUALA LUMPUR, MALAYSIA (Mr. D. Unnikrishnan)
E-mail : thermax@[Link]
MIZAMI NIGERIA LIMITED., 00-234-802-2908770 /
SUITE 21 B, WEST PAVILION, 00-234-1-7763709
ST
ENTRANCE 1, 1 FLOOR, TAFAWA,
BALEWA SQUARE COMPLEX,
PO BOX 12539, IKEJA, LAGOS,
NIGERIA,
E-mail : [Link]@[Link]
THERMAX LIAISON OFFICE 00880-2-407161/ 00880- 00880-2-8312963
C/o. TRADE LINKERS LTD., 2-411806 / 00880-2-
35, NEW ESKATON ROAD 9347754 / 00880-2-
SUFIA HOUSE, DHAKA, 8311511
BANGLADESH Mobile : +880-
E-mail: debasish@[Link] 173017929
C/O. DAR-AL-RIYADH HOLDINGS 00-(966 3) 8919897 / 00-(966-3) 891 4388/
PO BOX 20753 Ext. 203 00-(966-3) 891 1656
AL KHOBAR 31952 00-(966 3) 891 9594
SAUDI ARABIA
E-mail : thermax@[Link]
C/O LALAN ENGINEERING PVT. LTD +94 11 4614208 / +94 11 4614209
344 GRANDPASS RAOD, 4614210
COLOMBO - 14, Mobile : +94777769126
SRI LANKA
E-mail:[Link]@
[Link]
C/o. Unimex Intertrade Inc. 0063 24537851, 0063 9296982
113, Mindanao Avenue 0063 29296964
Quezon City Mobile : 0063
Manila 9285073339
PHILLIPPINES
E-mail : dasharun@[Link]
THERMAX HONGKONG LIMITED 00-852 2961 4041 00-852 2961 4042
907, SILVERCORD TOWER 2, Mobile : 00-852-
30, CANTON ROAD, 97581624
TSIM SHA TSUI, KOWLOON, (Mr. Rajoo Jagtap)
HONG KONG

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CONTENTS

INSTALLATION 1
TECHNICAL SPECIFICATIONS 2
OPERATIONS 3
MAINTENANCE 4
ANNEXTURE 5
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SECTION 1

INSTALLATION

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SECTION 2

TECHNICAL
SPECIFICATIONS

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SECTION 3

OPERATION

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SECTION 4

MAITENANCE

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SECTION 5

ANNEXTURE

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INDEX

CHAPTER 1: INTRODUCTION ......................................................................................... 2

CHAPTER 2: SAFETY....................................................................................................... 3
SAFETY INSTRUCTIONS............................................................................................... 3
CHAPTER 3: VERTICAL THERMOPAC (VTB) IN GENERAL ......................................... 5
1. THERMIC FLUID PUMP ......................................................................................... 7
2. COMBINED DEAERATOR CUM EXPANSION TANK ............................................. 9
3. DRAIN / OVERFLOW / MAKE-UP TANK .............................................................. 10
4. DIESEL ENGINE DRIVE IN CASE OF POWER FAILURE .................................... 10
5. COMBUSTION AIR SYSTEM ............................................................................... 12
6. FLUE GAS SYSTEM ............................................................................................. 12
7. ASH HANDLING SYSTEM .................................................................................... 12
8. ELECTRICAL CONTROL PANEL ......................................................................... 13
CHAPTER 4: TRANSPORTATION, UNLOADING & STORAGE.................................... 14
1. TRANSPORTATION AND UNLOADING .............................................................. 14
2. RECEIVING AND INSPECTION ........................................................................... 14
3. STORAGE ............................................................................................................ 14
4. FOUNDATION ...................................................................................................... 15
5. HANDLING ........................................................................................................... 16
6. GROUNTING AND LEVELING ............................................................................. 16
CHAPTER 5: GUIDELINES FOR INSTALLATION OF THERMOPAC ........................... 17
1. ERRECTION SEQUENCE OF THERMAL OIL HEATER....................................... 17
2. DO’S AND DON’TS FOR THERMOPAC INSTALLATION ................................................... 20
4. CHIMNEY ............................................................................................................. 24
5. INDUCED DRAFT FAN ......................................................................................... 26
6. FORCED DRAFT FAN .......................................................................................... 26
7. UTILISATION CIRCUIT ............................................................................................... 26
8. REFRACTORY AND INSULATION ........................................................................... 27
8.1 METHOD OF CERTIFYING A GOOD REFRACTORY JOB ..................................................... 28
8.2 HEATING UP SCHEDULE .............................................................................................. 29
CHAPTER 6: FUEL SUPPLY ........................................................................................... 30
1. IMPORTED COAL/PETOCKE HANDLING ........................................................... 30
2. ASH HANDLING/ CLEANING METHODS: ....................................................................... 31
CHAPTER 7 : LIST OF DRAWINGS ............................................................................. 32

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CHAPTER 1: INTRODUCTION
We take pleasure in greeting you as a proud owner of THERMOPAC. Our best
compliments to you for this selection.

Heater with its high performance and automatic modern styling confirms to the most
exacting standards of safety, performance and efficiency. You are assured of satisfactory
performance from the heater, which is manufactured with the latest engineering
techniques, modern production equipment and highly skilled engineers and workers. The
most critical parts used in heaters are the best in world by any standard.

The performance of a THERMOPAC depends very greatly on its proper installation, which
includes among other things, such external accessories as chimney, tanks, pipes, etc. A
good installation is a permanent asset, while a bad one can be a source of constant
troubles. It costs as much to put up a bad installation as it would to put up a good one.
Therefore, the importance of a good installation need not be over emphasized. Guidance
is offered in this manual on the installation of the THERMOPAC and its accessories. The
instructions given must be followed. If changes become necessary, they should have our
prior approval. This would save unnecessary expenditure in making alterations after the
installation has been completed.

Please note that this manual is designed to cover a wide range of products of various
sizes and capacities in this series. There may be slight variances in configuration and/or
specifications of components in your unit with respect to some previous standards. In
case of doubt and/or for more specific clarification, kindly consult our nearest office /
engineer. The operation and maintenance guidance is also included in this manual to
assist the user in starting, stopping and routine maintenance.

IMPORTANT NOTE

This operating specification applies to our scope of supply. In respect of equipment

components of the THERMOPAC or of the system which are not included in our scope of
delivery, technically competent persons employed by the respective supplier or installer
must provide the operator with operating specifications and must give corresponding
instructions during the course of commissioning and trial operation.

It is presumed that the THERMOPAC operator avails of the necessary technical

knowledge and skills to be able to independently conduct general servicing operations on
valves, pumps, firing systems and other equipment components. Regardless of this,
instruction by a technically competent person is necessary. If the THERMOPAC operating
personnel should change, it may be necessary to again have these persons instructed by
technically competent persons, for example by our customer service/customer training for
our part of the delivery. Interventions, which detrimentally affect safety of the installation,
e.g. in the area of electrical controls, on safety valves, level limiters and temperature
limiters etc., are not permissible.

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Wishing you many years of trouble free performance from this HEATER and
thanking you for choosing THERMOPAC.

CHAPTER 2: SAFETY
Thermax Limited has incorporated all the possible safeties in the Boiler / Heaters;
however, the user is advised to follow the safety precautions during installation, operation
and maintenance. Thermax also helps training all personnel involved on operation and
maintenance.

WARNING: The equipment must be operated and maintained by authorised and trained
operators only. It is mandatory to strictly follow all the instructions given for safe
installation, operation and maintenance of the equipment. The user will not hold Thermax
Limited responsible for the mishaps or the accident occurring due to negligence or by not
following the instructions.

SAFETY INSTRUCTIONS

General:

1. The installation and commissioning of the equipments must be performed by

trained / licensed operators under supervision of Authorized Thermax staff /
Franchise.

2. Heater house should have proper ventilation and lighting arrangement.

3. The installation of units should be done as per the instruction manual and
drawings supplied along with the unit.

Care to be taken during for annual/periodic maintenance:

1. Before entering into the furnace for maintenance, care should be taken to vent out
all the flue gases by running the blowers. Before entering the furnace ensure that
the oil and electrical supply to the instruments is disconnected and the furnace is
cooled to ambient temperature.

2. All electricity supply should be switched off and maintenance staff should ensure
that no electric supply is available at the equipment by :

(a) Switching of mains supply

(b) Removing the fuses / Switching off the MCBS
(c) Removing the cables from terminal strips
(d) Put “shutdown” board on equipment control
(e) Introduce work permit system and record on logbook.

3. Ensure proper earthing of all the electrical equipment.

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4. Maintenance staff should use proper tools and tackles Safety Shoes, Helmets,
Safety Belts, etc. wherever applicable.

5. Do not use nylon / polyester clothing, during the operation and maintenance of the
boilers/ heaters.

6. Use leather hand gloves while working on hot surface.

7. If more than one unit is connected to one common duct / chimney, ensure that the
flue gas duct of the unit under maintenance is removed / disconnected from the
main flue gas duct or chimney.

8. If more than one unit is connected to common steam / hot / Thermic fluid header,
disconnect the steam line / hot water / hot Thermic fluid line from the common
header to take care of any reverse flow of steam / gases / hot water / Thermic fluid.

9. Before opening the pressure part of the boiler / heater ensure that the pressure is
released completely and the air vent valve is full open and ensure that there is no
discharge of vapour from the air vent line. Also ensure that the water / heating
medium have cooled down to ambient temperature.

10. None of the safeties and controls should be bypassed during the operation of the
unit.

11. The fuel storage formalities and safety precaution given in instruction manual
should be followed.

12. Pressure part or the furnace should not be taken for maintenance before 24 hours
(minimum) from the time of shut down. The faster cooling is harmful to the pressure
part and furnace.

13. The boiler/ heater house should be kept free from spillage of water / oil.

14. Hot surface should be insulated properly.

15. Use only Thermax make / supplied genuine spare parts for the safety of units.

16. All the users, operational and maintenance personnel should make sure that
during installation, operation and maintenance of the boiler and heater, regulations
under Boiler Act, Factories Act, Fire Insurance and Explosives Act, Pollution
Control Act are strictly adhered to.

17. All the safety precaution mentioned above and also in the product instruction
manuals are to be strictly followed by the user as well as Thermax authorized
personal.

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CHAPTER 3: VERTICAL THERMOPAC (VTB) IN GENERAL

Vertical THERMOPAC (VTB) is a solid fuel fired Thermic fluid heater. The heat (KCal /
Hr) is delivered in the form of Thermic fluid at 280°C max (Standard scope) & it’s
circulated in the process from the heater. The vertical THERMOPAC system consists of
following sub systems:

The Thermic fluid of VTB system includes following:

a. Furnace for combustion (Bubbling bed) of solid fuels to liberate heat,

c. Heater for picking up this heat in the heat carrier fluid.

d. Circulation of heated fluid to user system and back to heater.

e. Dissipation of heat to user's process.

The combustion system for solid fuels consists of fuel handling refractory lined chamber,
air and flue gas handling system (induced draught) with blowers and pollution control
equipment. The furnace construction is done at site. It includes foundation, erection of
supporting structure, building up refractory chambers, fixing up top structures, fuel
feeders,

The heaters are assembled in Thermax factory in one or more models. They are to be
erected in position and assembled with other related parts and ducts at site. The heaters
should always be handled with the help of main lifting lugs provided, without tilting them.
They should not be subjected to any impact or damage.

The fluid circulation system consists of a main pump coupled to electric motor, emergency
diesel engine drive with clutch and V belts, De-aerator and expansion vessels, safety
valve of Thermic fluid and an orifice plate. It also includes a set of instruments to ensure
safe operation of system and indicate temperatures, pressures and flows at various
locations.

The users systems for flow distribution and temperature controls across various
equipments are usually to be provided by client in consultation with our service
engineers.

The Thermopac unit and the pump set are to be mounted on separate slabs. These slabs
must be cast out of non- combustible material like concrete and should be properly
leveled. These slabs prevent any oil or water driftage going underneath the units and
help in keeping the units, as well as the surroundings clean. Layout Drawing indicates

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the various clearances around the Thermopac and pump set. The front clearance is to
allow adequate room for removal of coil, operation and maintenance.

The Heater Room should be properly ventilated, preferably by large windows on all sides,
in order that the surrounding room temperature is max. 45°C. It is to be noted that in
case of the artificial ventilation, extraction of air is not recommended as this may create
negative pressure in the Thermopac room, which can be detrimental to the proper
operation of the unit. Make sure that while installing the Thermopac, regulations of Fire
Insurance Assn., etc. are strictly adhered to.

Thermopac is a solid fuel fired heater. Fuel is burnt on the stationary grate or bubbling
bed in a refractory lined combustor. This unit is available with only Petcoke, imported coal
combination with Coal, wood, briquettes, lignite and husk as fuels. It has conventional
rectangular furnaces. The secondary air enters the furnace in tangential direction,
thereby cyclonic motion is given to the flue gases, which improves the combustion of
volatiles & residence time of flue gases inside furnace is increased causing better heat
transfers.
The fuel (Imported Coal / Petcoke) is burnt on the bubbling bed in a refractory lined
combustor. Also screw feeder is provided for the feeding of imported coal/ Petcoke.
Screw feeder speed can be modulated, which is governed by the Thermic fluid outlet
temperature of the heater. Varying the speed of the screw feeder regulates the fuel feed
to the combustor. This reduces the ON/OFF working of the heater due to load
fluctuations & fuel feeding at uniform rate can be achieved.
The Petcoke & importedhigh chromium air nozzle is provided on bed to bubbling of fuel.

4
9

6 5 2
3

8 1 10

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1. Furnace, 2. Radiant Coil, 3. Convective coil, 4. Flue gas connecting duct. 5. Air
pre-heater (APH), 6. Pollution control equipment (PCE), 7. Force draft fan,
[Link] draft fan, 9. Chimney, 10. Screw feeder

1. THERMIC FLUID PUMP

This is a centrifugal pump which can be operated at a very high temperature i.e. 280°C.
The basic function of pump is to ensure sufficient flow of Thermic fluid through the heater.
Installing the pump in accordance with the manufacturer’s specifications and these
instructions will prolong the life of the pump and contribute significantly to the successful
operation of your heater system. The pump manufacturer’s installation and operation
instructions can be obtained from the manufacturer.

Note following for pump installation:

1. Locate pump adjacent to the heater. Its base must be firm, level (preferably
concrete), and free from vibration.

2. Route pump per the manufacturer’s requirements. It should be equipped with

flexible connections at the suction and discharge sides. The primary function of
these connections are to prevent stresses due to pipe expansion from being
placed on the pump and to isolate pump vibrations from the pipe work and the
heater. They also allow for expansion and deflection of the pipe work. These
connections should be rated for high temperature since they are considered part of
the piping system.

3. Connect suction pipe work directly to the deaerator section via a vertical run with
as few elbows as possible. It should contain the strainer and an isolating valve.
The discharge pipe work must be connected directly to the heater inlet, and should
contain an isolating valve. See that pipe work connections match up accurately
with pump flanges. Refer to the pump manufacturer’s recommendations for the
specific pump inlet piping requirements.

4. The piping in the immediate vicinity of the pump must not be supported by the
pump. The pump is not designed to bear the weight of the piping, and weight on
any part of the pump will throw it out of alignment.

5. Proper alignment directly affects bearing, coupling, and seal life expectancy. The
pump is properly aligned before it leaves the factory. Because the system expands
in operation, pump must be realigned when the system is at operating temperature.

6. The coupling alignment of the pump and driver must be carefully checked for
angular and axial alignment. Check pump manufacturer’s instructions for these
specifications. The use of a dial indicator to check the axial and angular alignment
is recommended.

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COOLING ARRANGEMENT FOR CIRCULATING PUMP (IF applicable)

The pedestal and Stuffing Box (gland) of the Thermic fluid circulating pump should be
cooled by allowing water to pass through the chamber provided, while the pump is in
operation. The cooling water inlet pipe line should be connected to a threaded port
provided on the Pedestal and Stuffing Box of the circulating pump, with a valve prior to
the water entry.

The outlet of the water from the other port should be connected to drain or a cooling
system. There should not be any valve in the cooling water outlet pipe. A flow switch can
be installed in the water inlet pipe which will actuate alarm when cooling water supply
ceases for some reason. The quantity of cooling water, passing through, should be so
adjusted that the rise in temperature of cooling water will not be more than 30°C. Cooling
water supply should be more than 7 liters/min. at approx. 1 kg/cm2g.

MECHANICAL SEAL PUMP:

If the pump is fitted with Mechanical Seal (optional supply) follow the guide lines given by
seal supplier or pump supplier for cooling arrangement.

AIR COOLED PUMP:

An air cooled pump does not have an oiler. This type of pump has a sleeve bearing which
is, like the seals, lubricated by thermal fluid. An air cooled pump has a grease nipple
located at the drive end of the pump near the coupling connection. This comes pre-
greased, and should be greased at intervals as recommended by the manufacturer

Thermal fluid is not sufficient lubrication for bearings. All seals on air cooled pumps are
lubricated by thermal fluid, therefore the pump must never be run dry, i.e., without thermal
fluid in it.

CAUTION:

Do not start the pump, unless cooling lines for mechanical seal is checked and
approved by our visiting site engineer.

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2. COMBINED DEAERATOR CUM EXPANSION TANK

Deaerator cum Expansion tank is provided in the return line.

The Thermic fluid in the complete circuit expands in volume, when it is heated. The rate
of expansion in volume is 7% per 100°C rise in temperature of Thermic fluid. Hence the
selection of size of expansion tank depends upon fluid content of the total system. As a
guide-line the expansion tank capacity should be minimum 20% of the total volume of oil
to be filled up in the system. The Deaeration vessel capacity depends upon the flow rate.
Its size can be roughly decided considering 2.5 to 3 m/s fluid velocity at its inlet nozzle.

The standard de-aerator cum expansion tanks supplied is suitable for most of the
standard processes. In case the volumetric expansion of Thermic fluid of the system is
more then the capacity of expansion tank provided, a separate extra expansion tank
needs to be incorporated.

The Thermic fluid also contains some higher fractions which flash off at elevated
temperature while commissioning. These are to be driven out of the system to have
proper functioning of the equipment. The combined expansion and deaerator tank is so
designed as to take care of the expansion of Thermic fluid and also to drive away the
gases or entrapped air.

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This tank should be installed at least 1 meter (3 feet) above the highest point in the
Thermic fluid pipeline. It is also necessary to confirm that the NPSH available at pump
suction is more, by at least 0.5 m, than the

NPSH required for your pump. Supports are welded to the tank, with the help of which
the tank can be fixed and bolted to the structure.

For details of connections from and to the tank, refer P & I diagram.

3. DRAIN / OVERFLOW / MAKE-UP TANK

The tank kept on the ground as shown in P & I diagram to which drain and overflow from
the combined expansion and deaerator tank are connected, has to be of a capacity at
least equal to the capacity of the combined expansion and deaerator tank. The over flow
pipe should be taken till the bottom of this tank and should be provided with sparger
arrangement to avoid hot oil coming in contact with air to prevent it from degradation.
While installing the Thermic fluid circulating pump, arrangement should be made to install
a small pump of 1000 liters/hr. at about 30-40 MLC of pumping head. Make up pump is
connected to the suction side of the TF circulating pump, for charging the system with
Thermic fluid when required. It is necessary to have such an arrangement, because it is
not advisable to use the Thermic fluid circulating pump for charging Thermic fluid in the
system. This will also help in filling the system from bottom driving out all the entrapped
air.

4. DIESEL ENGINE DRIVE IN CASE OF POWER FAILURE

A Diesel engine is provided as emergency drive, parallel to motor to keep the Thermic
fluid in circulation when electric power fails.
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COOLING & HEATING DIVISION 10 VTBB STD-I
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When the power fails, circulation in the Thermic fluid circuit will stop. However there is
always some amount of the fuel in the furnace, which keeps burning. Also there are hot
flue gases present in the heat exchangers. The fluid in the heat exchanger is at stand
still and starts picking up heat from the flue gases. This increase the oil temperature in
the coils. Each thermic fluid have safe operating limit called as film temperature which
should not be crossed, else thermic fluid will degrade.

To avoid this, a separate diesel engine driven pump is provided in parallel to the
electrically driven pump.

The engine is to be started manually immediately on failure of TF circulating pump. First

before starting the engine pulleys need to be engaged by belt provided. Power is
transmitted through V belts to main pump. The pump runs at lower speed (1000 to 1100
rpm) and delivers approximately 1/3rd of the rated flow through the heater. Thus the fluid
flows at 1/3rd of the rated velocity, which is sufficient to take away the radiant heat
liberated by hot bed and refractory and to avoid rise in film temp thereby avoiding
degradation of thermic fluid.

CAUTION: As this is a critical safety to take care of power failure condition its
healthiness is always to be ensured by starting the diesel engine daily and adhering
the maintenance schedule of diesel engine as recommended by supplier.

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COOLING & HEATING DIVISION 11 VTBB STD-I
THERMOPAC SECTION 1
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5. COMBUSTION AIR SYSTEM

One forced draft fans supply the air required for the combustion of the fuel. Air required
for the combustion can be divided as primary and secondary. Primary air contributes to
the combustion of the fixed carbon in the fuel. Secondary air contributes in the
combustion of the volatile matter of the fuel.

Primary & secondary air from FD fan gets heated in APH.

The primary air duct from APH connected to the furnace below bed. This air supplies the
oxygen required for the combustion. Suction damper is provided at FD fan to regulate the
air quantity as required.

Secondary air duct is further connected to nozzles of furnace structure above the bed.
There is control damper provided in the primary as well as secondary ducting which
controls air pressure head. Depending upon volatile matters in fuel we have to control
secondary air quantity.

6. FLUE GAS SYSTEM

Flue gas is a product of the combustion of the fuel. The flue gas typically consists of the
CO2, N2, and O2 as a major constituent with the temperatures of the order of the 850 ~
950°C. The flue gases give their heat to the thermic fluid circuit, which is utilized in the
process. Flue gases generated in the combustion chamber first transfer their heat to the
radiant coil. Then the gases are passed through the three pass heat exchanger. The flue
gases further pass on to second stage heat recovery in APH and gases are cooled down
to around 220 - 230°C. The gases then pass through the pollution control equipment (
TMC / TREMA ). The solid particles in the flue gases are separated in it and clean gases
goes to the Chimney through ID fan. Gases get exhausted in the atmosphere through the
chimney.

7. ASH HANDLING SYSTEM

The ash is another product of combustion and consists mainly of the non-combustible
residue and mineral matters. The ash is collected at various points along flue gas path.
Majority of the ash is collected at the control equipment ( TMC / TREMA ), then APH and
below ash selling chamber. This ash at APH and ash settling chamber is at a high
temperature at around 500 – 600 °C. So hoppers / chambers at these points should have
refractor lining. (ie. Insulate and firecrete layers).

The ash at TMC & APH is discharged through sliding gate arrangement in a closed
chamber constructed below it. To remove the ash 1) close the sliding gate 2) Open the
ash door provided to the closed chamber 3) Remove the ash 4) close the door 5)
Reopen the sliding gate.

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COOLING & HEATING DIVISION 12 VTBB STD-I
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The ash at TREMA is discharged through Rotary Airlock Valves ( RAV ) and collected in
the barrels or gunny bags suitably and dumped from time to time.

8. ELECTRICAL CONTROL PANEL

The Electrical Control Panel Box is supplied with the Thermopac separately and has to be
erected close to the Thermopac. The location and foundation details of the panel box are
given in the "General Assembly" drawing.

Three phase, 415 V, 50 cycles A.C. electric supply with neutral and earth is required for
operating the Thermopac. The supply to the Thermopac should be given through a main
switch fuse having adequate capacity as mentioned in the following table. The back-up
fuse capacity to suit the total electric loading should also be maintained. The main switch
fuse capacity should be a little more, for safety.

No extra starter or switch is required for Thermopac TF circulating pump motor, blower
motors, etc. The panel board is pre-wired.

Switches for other pumps such as TF make up pump for pumping TF from storage tank to
the deaerator tank, etc. should be separately installed by the customer at points
convenient for operation.

The sizes of cables are given in Table E-1.

4.8.1 EARTHING OF THE EQUIPMENT

Earth wire of adequate cross section should be provided to link the heater, the electrical
control panel box, various motors etc. to a suitable earth plate.

Following size of earth conductors can be used :

Table E-1
[Link] Kw Rating Wire size
1 Upto 3.75 Kw 8 SWG GI wire
2 5.5 Kw to 30 Kw 3/8'' GI fine wire rope
3 37 Kw to 55 Kw 5/8'' GI fine wire rope

WHILE INSTALLING THE ELECTRICAL CABLES KEEP IN MIND THE RULES AND
REGULATIONS INVOLVED.

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COOLING & HEATING DIVISION 13 VTBB STD-I
THERMOPAC SECTION 1
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CHAPTER 4: TRANSPORTATION, UNLOADING & STORAGE

1. TRANSPORTATION AND UNLOADING

The heater dispatched from our factory is normally packed in wooden cases. During
transportation, care should be taken to keep the right side up as indicated on the wooden
cases by an arrow mark.

The heater should also be lifted for loading or unloading or shifting from one location to
other only by means of lifting hooks provided on the top of equipment. If lifting tackles are
not available, rollers, wooden slabs, or some skid should be placed beneath the frame of
heater / wooden cases & it should be carefully guided for unloading & shifting.

It is also advisable to unload and assemble the THERMOPAC, as close as possible to the
THERMOPAC house, preferably just outside the main door of the THERMOPAC house,
so that pushing the THERMOPAC into the THERMOPAC house for positioning it on the
foundation is easier. The place of unloading and the place where the gantry crane is
used, the soil should be hard enough to bear the loads of these otherwise, it may sink.
Likewise, when the THERMOPAC is being shifted to the THERMOPAC house, the
approach road to the THERMOPAC house should also be made of hard ground. Data
required for handling i.e. size & weight is provided on individual equipment drawing.

2. RECEIVING AND INSPECTION

On receipt of the heater, please check that all items as per delivery challen have been
received. For ease of checking one set of Packing slip is sent along with the transporter &
one set is nailed to one of the packing cases with clear marking of PACKING SLIP.

By careful inspection, determine whether any damage / loss has occurred in transit,
inspite of proper checking & loading of each equipment at our factory before dispatch.
Thermax / Insurance co. must be notified immediately in case of any loss or undelivered
parts, or transit damage for corrective action, as the case may be.
Timely assistance from our regional / area offices will be available.

3. STORAGE

If installation of any equipment is delayed and storage is made outdoors, provide

reasonable weather protection as dictated by the climate and period of exposure.

Electrical components, motors and bearings should be tightly covered to prevent entrance
of water and if the equipment or its parts are to be stored outdoors for any length of time it
should be completely covered with a tarpaulin. Periodically the unit should be inspected
to make sure no damage, such as corrosion, is occurring.

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COOLING & HEATING DIVISION 14 VTBB STD-I
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When equipment is stored or installed within a building still under construction, the
entrance of dirt and construction material to the motors, fans and electrical components
should be prevented. The critical components should be covered and sealed; preferably
they should be stored in covered building to prevent damage and corrosion.

The refractory bricks, insulation bricks and bonding material should be carefully stacked
in covered storage space with proper weather protection to prevent them from breakage
and loss.

Whenever assembled rotating equipment such as fans, pumps, gear boxes etc. is to
remain idle for any extended number of days, extra precaution has to be taken to avoid
rusting and jamming of bearings. The equipment can be rotated manually once a week to
prevent jamming.

N2 filling: If installation time from dispatch is going to exceed 2 to 2 1/2 months

then Nitrogen filling of the Thermic fluid heat exchanger and Water pre heater tubes
is essential. This will avoid corrosion of the tube material.

4. FOUNDATION

A rigid, level foundation is vitally essential for smooth, quite operation, good performance
and low maintenance cost of the THERMOPAC and other equipment. An improperly
constructed or inadequate foundation may cause vibration and possible misalignment of
the equipment. Foundation should be done as per loading given in foundation drawing.

Special attention must be given to ensure a permanently solid support for the rotating
equipment and bearing supports.

NOTE : ALL FOUNDATIONS MUST BE FLAT, LEVEL AND RIGID

The height of any foundation should be minimum 100 mm above the finish floor level
unless otherwise specified. This is to prevent the structure of equipment from getting in
contact with spilled water, oil etc. which may corrode and reduce the life of equipment and
foundation bolts.

An allowance must be made for a minimum of 25 mm of shimming and grouting

when determining the top surface of the foundation.

As a general practice, concrete foundations should have a minimum weight of six to eight
times the total weight of the equipment. Consult your Civil engineering expert for
designing the foundations based on soil condition of your plant and live weight on the
foundation. The foundation layout, height of each foundation and floor loading for
designing foundations of various equipment are given in Foundation layout drawing of the
THERMOPAC.

NOTE : PREFERABLY THE FOUNDATION WORK SHOULD BE COMPLETED PRIOR TO

ARRIVAL OF THERMOPAC TO SAVE TIME IN INSTALLATION.

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COOLING & HEATING DIVISION 15 VTBB STD-I
THERMOPAC SECTION 1
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5. HANDLING

If a hoist/crane is employed in handling the equipment, extreme care should be taken to

prevent distortion or damage to any part of the equipment. The handling of large sized
equipment will require extra precaution in this respect. Use lifting hooks or eyes where
provided.

It is advisable to use a spreader type sling when handling equipment.

THERMOPAC requires careful assembly and alignment at site. All equipment should be
moved to its foundation as a unit, with care being taken to prevent distortion of the
equipment. After the foundation holes in the unit are lined up with anchor bolts in the
foundation, the equipment should be lowered over the anchor bolts.

Since the THERMOPAC, feed pump and fan is mounted on separate foundations much
care and attention to alignment is required to match their inlets and outlets with pre-
fabricated steam/feed water/Thermic fluid pipe and air ducts.

Prior to placing any equipment on the foundation, the location of anchor bolts should be
checked against the drawing to ensure that these bolts are placed correctly. During
erection all parts should be carefully checked to see that they are in correct position as
indicated in the General Arrangement drawing.

6. GROUNTING AND LEVELING

For preventing the rotating equipment from vibrations etc. proper care needs to be taken
on selection of Anchor bolts, its size, shape and length and on proper leveling.

Anchor bolts in concrete should be L or T-shaped, and should be placed in sheet metal
sleeves approximately 50 mm larger in diameter then the anchor bolts to allow for
adjusting the bolts in case they move slightly when concrete is poured.

For leveling large area shims should be placed under the pedestal before tightening the
anchor bolts. Distortion of the equipment may occur when the bolts are not lightened
equally or if short thick shims providing only limited surface contact are used.

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COOLING & HEATING DIVISION 16 VTBB STD-I
THERMOPAC SECTION 1
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CHAPTER 5: GUIDELINES FOR INSTALLATION OF

THERMOPAC
The THERMOPAC and it's other components are required to be assembled at site.

After the heater, FD fan, ID fan, Air pre-heater, Dust collector, Thermic fluid and Water
pumps are placed, level and grout on the foundation. Thermax Engineer will help in
assembling the various accessories supplied separately with the unit. He will also help in
connecting the control panel box to various controls, safeties.

The refractory and insulation walls are built after completion of Open and Hydraulic
test of the THERMOPAC.

1. ERRECTION SEQUENCE OF THERMAL OIL HEATER

PRELIMINARY CHECKS

1. Check readiness of foundation as per drawing. Check orientation and Dimensions

of foundation.

2. All insertion plates should be in place as per the foundation drawing.

3. All foundation bolts for the equipments should be ready.

4. Boiler house area should be ready for installation i.e. removes all unwanted
material / parts.

5. Check readiness of trenches or cable trays.

6. Check availability of all utilities.

7. All ash hoppers should be ready duly inspected.

8. Check availability of equipments as per erection sequence / schedule.

9. Check foundation of chimney and ensure grouting of foundation bolts.

10. Ensure readiness of control room.

11. Ensure readiness of supporting structure (civil as well as mechanical) for all tanks.

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COOLING & HEATING DIVISION 17 VTBB STD-I
THERMOPAC SECTION 1
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ERECTION PROCEDURE (GENERAL SEQUENCE OF INSTALLATION)

The following procedure can be considered as a guide-line to complete the installation

activity.

1. Prepare the Thermopac house layout after referring to GATP and foundation
drawings. Locations of firing doors, air pre-heater, control panel, ID fan, FD fan,
Thermic fluid pump, D/Expansion tank, chimney etc. are to be decided in
consultation of site engineer after studying the system requirements & factory layout
and space availability. For air pre-heater, one typical location is shown.

2. Cast foundations as shown in foundation drawing of each equipment.

3. Erect main furnace structure (as per drawing) on the foundation, which should be
ready.

4. Erect radiant heat exchangers in its final position. Check the level and overall
height.

5. Place the convective heat exchanger on foundation.

a. Match the outlet connections of convective heat exchanger with the inlet
connections of radiant coil. If required, adjust the level of convective heat
exchanger. Refer GATP drawing for connections of radiant & convective coils
as maintaining Thermic fluid flow path as per GATP drawing is very important.

b. Check that top flanges of both the heat exchangers are in one level, by using
clear vinyl hose with water, and the center line distance is correct to ensure
fitting of top refractory duct.

c. Match the intermediate piping connections and weld the flanges ensuring that
the gaskets are fitted.

d. Grout the heat exchanger foundation only after ensuring above points.

Top Refractory Duct Assembly:

 Complete the top refractory duct lining before erecting in position.

 Put ceramic wool, as gasket, on the top flanges of both the heat exchangers
(for sealing refractory joint).
 Place the top flue gas duct pieces carefully on the respective heat exchangers
ensuring proper orientation. Bolt the flanges on radiant heat exchanger.
 Make a gasket of Ceramic wool blanket put it between two flanges of refractory
duct and bolt the mating flanges of two pieces of refractory duct.
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 Clamp the other end of refractory duct on convective heat exchanger top,
putting the gasket of ceramic wool in between.
Ensure that all the joints in flue gas path are air tight. Fill the gaps, if any with Fire
create super cement from inside the furnace, especially at top duct flange joint. .

6. Lay the refractory and insulation bricks as per the details given in the refractory
drawing of respective unit. For more information on refractory, refer to a separate
chapter on Refractory in this manual. Fix fire doors, ash doors, grates, secondary
air nozzles and FD duct end in the refractory.

7. Weld Orifice plate assembly ( if applicable in SOS , Pl. note it’s not a std. scope )
as per P & I in outlet piping .

8. Fix fans (ID & FD), ducting and dampers in position.

9. Fix pump assembly and diesel engine assembly in positions maintaining adequate
tension in `V' belts. (‘V’ belt should not be attached when diesel engine is not
working)

10. Position Air Pre-heater on it's foundation matching the inlet and outlets to incoming
duct from Thermopac and outlet duct to either Dust collector (optional) or I.D. fan.

11. Complete the cooling water lines for TF circulating pump gland and pedestal.

12. Erect the de-aerator cum expansion tank as per P & I Diagram and complete the
piping work.

13. Position electrical panels and complete the electrical cabling and connections.

14. Test the pipeline for leakage’s as explained in the manual.

15. Complete the coal/husk handling system.

16. Complete assembly and erection of chimney.

17. Erect all the junction box and field instruments on its respective locations.

18. Complete the power cabling, control cabling and instrument cables as per standard
practice of the customers and respective instruction given by Thermax.

19. Complete impulse piping for pressure gauge & junction box assemblly.

20. Compressed air piping for soot blower (if applicable) of convective heat exchangers
as per utility location.

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COOLING & HEATING DIVISION 19 VTBB STD-I
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21. Ensure readiness of fuel handling system (Customer scope).

22. Complete the insulation and cladding of all equipment’s, piping and ducting as per
insulation schedule.

23 Carry out final inspection as per P&I Diagram, GATP and respective drawing.

24. Start pre-commissioning checks.

NOTE:
This installation schedules will be indicative and will changed based on handling
equipment, readiness of items as per sequence and erection schedule prepared by
customer.

2. DO’S AND DON’TS FOR THERMOPAC INSTALLATION

Piping and fittings

Please check the piping for appropriate flow distribution, which otherwise affect the
Thermic fluid flow in the circuit. It’s recommended to do the piping stress analysis for 4” &
above pipe lines, which otherwise cause problem in developing stresses.

1. All water and Thermic fluid piping should be thoroughly flushed or blown out
(cleaned) before being connected to the system. This will prevent foreign matter
from blocking or damaging the piping system.

2. Use only Cast Steel valves and not Cast Iron valves in the Thermic fluid line. Cast
Iron cannot withstand the high temperature.

3. Use raised face flanges in the Thermic fluid piping.

4. Use flanged connections with valves.

5. Use 1/16" thick oil quality gaskets / spiral wound gaskets (as applicable). For all
flanges in the Thermic fluid piping.

6. Do not use elbows and sharp bends in the water, fuel oil and Thermic fluid lines as
far as possible to reduce frictional losses.

7. Do not use smaller diameter pipes than those specified for the Thermic fluid
system line as this pipe may not be capable of handling the quantity of Thermic
fluid being circulated in the process.

8. Do not use screwed connections anywhere in the Thermic fluid piping. Use only
welded construction and use a minimum number of flanged joints.
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COOLING & HEATING DIVISION 20 VTBB STD-I
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9. Provide a rise of about 1: 100 in the Thermic fluid outlet piping from the heater
towards the user equipment and a similar slope from the user equipment to the
heater in the return line or follow the piping drawing supplied by Thermax.

10. Do use expansion bends/bellows in the horizontal plane after every 30 meters of
straight run of piping or as specified by the expansion bellow manufacturer.

11. Do use vents to let out air and gases at all high points of pipe line. Air is a
contaminant for the Thermic fluid at high temperatures.

12. Use drain valves at one or more low points in the installation.

13. Do provide a strainer before the Thermic fluid pump in the return line to filter the
Thermic fluid.

14. Use gate valves in the water lines.

15. Never test the heater, piping or any heat exchanger hydraulically. Test them only
PNEUMATICALLY with an air pressure of about 5-7 kg/cm2g (70 psig). Testing
can be done with an inert gas like Nitrogen also. Ensure that water does not mix
with Thermic fluid. Testing above 5kg/cm2g can be done hydraulically, but follow
all complete procedure, ensure no water are remain in system after hydraulic
testing.

16. Do lag the lines and equipments after they have been tested completely.

17. Provide dry chemical or foam type fire extinguishers in the heater room for
emergencies. Never install soda acid or water jet type of extinguishers.

18. Make sure that vent pipe in the expansion tank is free of obstructions and is open
to the atmosphere. It should also prevent entry of water or foreign matters.

19. Do not lag the buffer vessel; inter connecting pipes & expansion tank.

20. Provide properly designed roller/sliding support for Thermic fluid pipe line to take
care of the thermal expansion. The expansion of pipe line is approximate 3
mm/mtr at 300°C.

21. The THERMOPAC and the Thermic fluid circulation pump set should be placed
side by side. The circulating pump set should preferably be placed on the same
side as the inlet of the THERMOPAC. While installing the circulating pump,
ensure that no part of the pump is at a distance of less than 1 meter from any of
the walls (This is applicable to all other machinery also as per Factory act.)

Flue gas circuit

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COOLING & HEATING DIVISION 21 VTBB STD-I
THERMOPAC SECTION 1
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1. Use correct diameter for chimneys and ducting as specified. Do not reduce the
diameter as this will pose combustion problems due to the frictional resistance
offered.

CONSULT SMOKE NUISANCE INSPECTOR WHEREVER THE ACT IS IN

FORCE.

2. Do lag the part of ducting and chimney inside the heater room.

3. Provide expansion joints on the suction and delivery side ducting of the I.D. fan.

3. As far as possible provides rectangular duct connection in chimney as the circular

duct connection reduces the strength of chimney at intersection point.

Furnace lining

1. First study the primary and secondary air arrangements and their respective
nozzles in refractory.

2. Use only specified qualities of refractory bricks, fire cement, and insulation
material. Broken pieces of bricks should not be used. All bricks should have
good sharp edges. Fire cement layer between the bricks should be as thin as
possible.

3. Brick surfaces facing to furnace should not be dressed.

4. Fallen bricks should be replaced immediately by proper shaped bricks or castable.

5. Provide the expansion gaps as per the refractory drawing (horizontally and
vertically) and fill them by asbestos mill board only (6 mm thick).

6. Do not use a piece of brick at the center of the Arch for Keying the Arch.

7. Provide asbestos mill board all around the fire and ash door frames.

8. Use only clean tap water for preparation of mortar.

9. Check whether there is any void in between joints and if so, fill up with fresh
mortar.

10. Stagger construction of the floor.

11. The refractory wall should be in plumb.

12. Use proper skew bricks for all arches.

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COOLING & HEATING DIVISION 22 VTBB STD-I
THERMOPAC SECTION 1
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COOLING & HEATING DIVISION 23 VTBB STD-I
THERMOPAC SECTION 1
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4. CHIMNEY

In view of pollution hazards, a chimney to discharge the products of combustion is

recommended. The minimum height of the chimney should be about 3 meters (10 feet)
above the highest point of the tallest building in a radius of about 300 meters.

Warning : WHEREVER SMOKE NUISANCE REGULATIONS ARE PREVALENT, IT IS

NECESSARY TO CONSULT THE SMOKE NUISANCE INSPECTOR

Note!
Follow IS 6533 for design fabrication for erection of chimney

In general, the following procedure is followed:

1. The chimney height is decided by the Smoke Nuisance Regulation applicable for
that site.

2. The flow rate of gas and the height of chimney primarily decide the diameter of
chimney. Velocity of gas can be about 7.5 ~ 8 m/s at full load.

3. The chimney drawings and strength calculations are to be approved prior to

starting the fabrication.

4. Prior to getting the approval of Smoke Nuisance Inspector, the "No Objection
Certificate" has to be obtained from the Air Pollution Prevention Department.

5. After the chimney is fabricated, it is offered for ground inspection and is allowed to
be erected only if the Inspector is satisfied.

6. The "No Objection Certificate" has to be obtained from the Civil Aviation Authority
also before the erection of the chimney.

The THERMOPAC is supplied with a suitable induced draught fan with a motor. The fan
is normally placed near the main chimney and the flue gas outlet of the heater is
connected to the suction side of the fan. To control the draught created by the ID fan, a
damper should be provided in the duct prior to the suction of the fan. The ID fan motor
set should be properly sheltered to protect it against sun, rain, etc. The ID fan shaft is air
cooled Chimneys with smaller diameters and chimneys with long cross-connections from
the flue gas outlet of the THERMOPAC to the ID fan and from the ID fan to the main
chimney should not be used.

Note ! Refer the chimney drawing for the minimum diameter of the main chimney stack
and height of the chimney. It is suggested that expansion joint may be provided on the
ducting of the suction and the delivery side of the ID fan. It is also recommended to have
45° angle between stack to ID fan, lower then 30° angle may be accepted, lesser then

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COOLING & HEATING DIVISION 24 VTBB STD-I
THERMOPAC SECTION 1
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that will affect heater performance. Also, chimney should be located within 10 m from
outlet of ID fan.

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COOLING & HEATING DIVISION 25 VTBB STD-I
THERMOPAC SECTION 1
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5. INDUCED DRAFT FAN

The following points may be born in mind before installing the ID fan. ID fan is site
assembled. Refer to assembly manual provided separately in addition to following points
(if applicable).

a. Before installation, inspect the fan and the motor closely to detect and eliminate
any defects, dents and other kinds of damages that might have occurred in transit.
b. Check the electric motor for proper insulation and have it dried if necessary.
c. Mount the ID fan motor set chassis strictly horizontally, checking it with a spirit
level.
d. Install the Fan on the foundation and secure it properly with bolts. Should the fan
be installed above ground or on an elevated structure, the use of vibration proof
beds and flexible or vibratory isolator connections between the fan and the ducting
is recommended.
e. Check the impeller for free rotation by hand.
f. See that the fan motor is properly earthed.
g. Provide suction damper and expansion joints at suction and discharge of the fan.

6. FORCED DRAFT FAN

FD fan equipped with control dampers is supplied along with the main unit. The canvas
duct for fan takes care of vibrations and alignment and is to be made at site.

The connecting ducts between primary F.D. fan to air pre-heater and air heater to furnace
is to be fabricated by user to suit the location of fan.

7. UTILISATION CIRCUIT

In order that optimum heat utilization takes place in the user equipment, it is important
that the complete circuit is properly designed taking into consideration the site conditions
and applications. In order to help the clients to ensure that the installations are made not
only as per layout drawings, but they also meet the important requirements for optimum
performance, we provide facilities for supervision by our experienced erection engineers.

Note :

If Thermic fluid line size exceeds more than 10” stress analysis of line needs to be done.

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COOLING & HEATING DIVISION 26 VTBB STD-I
THERMOPAC SECTION 1
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8. REFRACTORY AND INSULATION

After proper positioning of THERMOPAC Heat exchangers and the furnace structure on
foundation and after proper leveling and piping interconnection the refractory work is
done.
The combustion chamber and ash settling chamber inner lining is constructed using the
refractory bricks and the insulation bricks. The refractory bricks are Fire clay refractory
and contain Alumna Silica.

These are of two types

1. Plastic (China) Clay
2. Non-Plastic Clay

The Plastic clay improves cohesiveness and binding properties and Non-plastic lack it.

Alumina contents decide the purity of firebricks.

Plastic Clay has 20% to 35%
Non-Plastic Clay has 28% to 38%

Moderate heat duty fire bricks conforms to IS : 7 and IS : 6

High heat duty fire bricks conforms to IS : 8.

Bricks containing 45% to 90% Alumina can withstand temperatures 1750°C to 1950°C.

Selection of refractory brick depends on Operating temperature, Furnace size, Nature of

fuel, Location of the brick in the furnace construction etc.

[Link] Temperature °C Quality of Brick

1 Up to 750 Conforming to IS:7
2 750 to 1000 Conforming to IS:6
3 Conforming to IS:8 1000 to 1250
Please note the shelf life of refractory material from date of manufacturing

[Link] Description Shelf Life

1 Air settling morter 12 Months
2 Cement Whyteat K 9 Months
3 Cement insulyte 7 9 Months
4 Cement Firecreate 9 Months

Caution : Note the expiry date of above material from date of mfg., before use.
Conventionally the furnace wall is constructed with the Fire bricks on hot side (IS:8 or
IS:6 depending upon the furnace temperature calculation) followed by Insulation
bricks/Red bricks. Below GRATE BARS usually IS:6 is used.

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COOLING & HEATING DIVISION 27 VTBB STD-I
THERMOPAC SECTION 1
_______________________________________________________________________
Thickness of each wall is decided based on the heat transfer calculation. Mortar used for
construction usually contains 45% Alumina and Fireclay is used for insulating bricks.

While the refractory work is in progress following points need to be checked.

1. Use only specified qualities of refractory bricks, fire cement, and insulation
material. Broken pieces of bricks should not be used. All bricks should have good
sharp edges. Fire cement layer between the bricks should be as thin as possible.

2. Brick surfaces facing to furnace should not be dressed.

3. Provide the expansion gaps as per the refractory drawing (horizontally and
vertically) and fill them by asbestos mill board only (6 mm thick).

4. Do not use a piece of brick at the center of the Arch for Keying the Arch.

5. Provide asbestos mill board all around the fire and ash door frames.

6. The mortar should fill the gap between furnace and THERMOPAC flues.

7. Provide proper tie bricks for the wall as shown in the refractory drawing after every
eighth layer.

8. All mortars (for firebrick and insulation brick) to be used as per our specifications.

9. Use only clean tap water for preparation of mortar.

10. Check whether there is any void between joints and if so, fill up with fresh mortar.

11. Provide a lapping between the side wall and end wall at the corners.

12. Stagger construction of floor.

13. The refractory wall should be in plumb.

14. Use proper skew bricks for all arches.

8.1 Method of certifying a good refractory Job

1) Check the height along the plumb, 2 mm/meter out of plumb is allowed to the
extent of 5 mm for the height of the wall.

2) Check inside dimension of chamber with drawing.

3) Check the relative positions of pillars for grate bar supports or piers between two
supports, various door openings, baffle walls, external surface etc.
4) Check various arches on doors baffle wall etc. with drawing.

___________________________________________________________________
COOLING & HEATING DIVISION 28 VTBB STD-I
THERMOPAC SECTION 1
_______________________________________________________________________
5) Check the construction with reference to mortar, thickness, expansion joints,
staggering of joints, bonding etc.

6) Check whether pointing is properly done.

7) Check the primary and secondary air openings and their respective locations with
drawings.

8.2 Heating up schedule

1) Allow the construction of dry up for minimum 48 hours.

2) Heat up the refractory slowly using fire wood @ 50°C to 75°C/hour till the
temperature reaches 600°C.

3) Soak at this temperature for 2 to 3 hours by burning fire wood.

For measuring & controlling the temperature cycle for refractory, attach
thermocouple/ temp. indicator at the top most point of furnace inside refractory &
control the heating cycle.

Refractory should be cured within 3-4 days after construction to remove moisture,
in case it’s not done there will be cracks observed due to release of moisture,
causing air leakages during operation.

INSULATION

Following parts / equipments shall be insulated at site with mineral wool of 100 to 125 mm
thick and 64 or 96 kg/m3 density as per details shown on either GATP or P&I.

 Heat exchanger (main jacket)

 Air Pre-Heater (APH)
 Hot air and flue gas ducting
 Thermic fluid piping

___________________________________________________________________
COOLING & HEATING DIVISION 29 VTBB STD-I
THERMOPAC SECTION 1
_______________________________________________________________________

CHAPTER 6: FUEL SUPPLY

Depending upon the type of the fuel and its quantity in stock the storage and handling
should be arranged.

1. IMPORTED COAL/PETOCKE HANDLING

In case of a manually operated installation, it is necessary to provide sufficient space in

the heater room, for stocking coal required for one shift operation of the Thermopac. It is
advisable to build walls of about 1.8. meters height on two sides and a small wall of about
0.65 meter in front of the coal/ petcoke storing area for retaining coal.
Further to this service coal stock in the Heater Room, it is quite essential to store
coal/petocke required for three to four weeks operation of the Thermopac as close as
possible to the room. This will act as a buffer against interruption in coal/petcoke supply.
Storing coal on an unprepared ground causes high "Carpet losses" i.e. losses due to
layers of coal on the ground remaining untouched. About 4% - 5% of the coal/petcoke
may have to be written off as initial stockpiling on such sites. This can be avoided by
storing coal/petcoke on a leveled concrete surface. The concrete floor should be capable
of carrying vehicles and have self draining facilities.

While unloading, if the lorries dump the coal/petcoke haphazardly over the storage area,
the whole space may be covered with small heaps. Much of the ground may thus be
wasted and trimming needed to fill in the spaces between the heaps and to bring the
whole stack to an uniform height. Also it is difficult to assess the quantity of coal/petcke
held in stock when it is dispersed in a large number of irregularly shaped small heaps. In
order to enable better utilisation of the storage space and to reduce the frequency of
trimming the coal, the stockpile is divided into bays by brick or concrete retaining walls,
which are normally about 3 meters apart and about 1.5 meters high. Vehicles can bank
into such bays and fill them completely to a height of about 1.4 meters maximum. The
length of the retaining wall is usually around 3 meters and the bays are closed on one
side by retaining wall 1.5 meters high.
A thumb rule, to calculate the storage area required, is to provide 1.3 sq. meter of floor
area per tonne of coal laid in a layer 1 meter deep. To this, is to be added the space
required to maneuver the vehicles when unloading or removing the coal/petcoke. It is
necessary to construct an ash pit in the Heater Room as shown in the drawings
mentioned in first para. Care is to be taken to see that it is built in such a way that the
ash does not mix with the coal/petcoke. It is also necessary to build an ash storage pit of
about 5 meter x 5 meter x 2 meter deep outside the Heater Room. This ash pit can be
sized to suit the individual plant's requirements but generally a pit of dimensions
mentioned above will be quite adequate.

___________________________________________________________________
COOLING & HEATING DIVISION 30 VTBB STD-I
THERMOPAC SECTION 1
_______________________________________________________________________

2. ASH HANDLING/ CLEANING METHODS:

Depending upon soot type the ash cleaning methods needs to be selected

A) SOOT BLOWER: (IF PROVIDED)

Soot blowing can be done on line. It is done with the help of compressed air and sonic
nozzles. The minimum pressure required for this will be 7 Bar and capacity of receiver
should be 1.5 m^3. The receiver air is able to clean the soot till it’s pressure drops to 3.5
kg/cm2. The soot blowing time is 10 second wherein the pressure will fall from 7 bar to
3.5 bar.

For supplied soot blower, following parameters needs to be maintained.

Min capacity of receiver = 1.5 m3

Compressor capacity = 50 cfm
Working air pressure = 7 Kg/cm2
Duration of operation = 10 sec

Please refer to the GA drawing for the soot blower air piping arrangement. Please note
we have use one set of nozzles as provided connected on common 50 NB pipe. Ball
valve should be used as shown to regulate the air.

Frequency of cleaning:

To be done on line once or twice per shift (For lignite min. 3 times / Shift) depending upon
the type of fuel, ash content and unit load.

B) MECHANICAL BRUSH CLEANING:

The ash, which is deposited in cavities, cannot be cleaned with soot blower. For removing
this ash “Mechanical Brush” cleaning id to done.

The wire brush is to be attached to the flexible MS rod and then it is inserted between the
coil gaps to clean the ash. This will facilitate the cleaning of loose ash which is deposited
in cavities and which doesn’t get cleaned with “soot Blower”.

This is to be done if windows are available for cleaning access. If windows are not
provided then Top cover needs to be removed to do the mechanical cleaning. After
cleaning the assembly needs to be done properly i.e. use asbestos or ceramic rope
between the flanges to arrest the air leakage.

Frequency of cleaning

Considering the fouling nature we have to clean the unit once in 10 to 15 days time (For
lignite once in week) depending upon the unit load and type of fuel.

___________________________________________________________________
COOLING & HEATING DIVISION 31 VTBB STD-I
THERMOPAC SECTION 1
_______________________________________________________________________

C) HYDROJET CLEANING:
Hydrojet cleaning is to be done for removing the sticky matter, which normally doesn’t get
cleaned by neither soot blowing nor mechanical cleaning.

For doing this heater should be tripped and Thermic fluid temperature should be cooled
to 50~60 °C. It should be done with normal water and water should be taken out properly
so that it will not make the refractory wet. For this customer needs to consult Thermax
service engineer or concerned experts.

Frequency of cleaning

Considering the fouling nature we have to clean the unit once or twice in year (for lignite
once in two months ) depending upon the unit load and type of fuel.

CHAPTER 7 : LIST OF DRAWINGS

[Link] DESCRIPTION OF DRAIWNG DRAWING NOS.

1. Impulse piping scheme

- DP Switch across coil header PFVT 730134

- DP Switch across orifice ( if applicable ) PFVT 730124

- Valve connection for Pr. Gauge PFVT 730364

2. Thermic Fluid pump & Diesel Engine Arrangement PFVT 149014

3. Soot Blower & Piping Arrangement PFVT 730204

___________________________________________________________________
COOLING & HEATING DIVISION 32 VTBB STD-I
THERMOPAC SECTION 3
_______________________________________________________________________
INDEX

CHAPTER 1: PRE-COMMISSIONING, COMMISSIONING ............................................................................... 2

1. PRE-COMMISSIONING ............................................................................................................................ 2
2. COMMISSIONING OF THE SYSTEM ....................................................................................................... 3
3. WARMING UP THE SYSTEM ............................................................................................................................. 6
4. CHANGE OVER BY FUEL FIRING ........................................................................................................... 7
CHAPTER 2: CONTROLS AND SAFETIES ON THERMOPAC ......................................................................... 9
1. CONTROL AND SAFETIES ON THERMOPAC ........................................................................................ 9
2. CONROL & SAFETIES ON THE USER EQUIPMENT ............................................................................. 10
3. SETTING OF INSTRUMENTS FOR COMMISSIONING ......................................................................... 12
4. SECONDARY AIR SETTINGS ................................................................................................................ 12
CHAPTER 3: OPERATION................................................................................................................................... 14
1. BUBBLING BED COMBUSTION ............................................................................................................ 14
2. FUEL AND HANDLING IN OPERATION................................................................................................ 19
3. COMBUSTION METHOD........................................................................................................................ 20
4. WORKNG THE UNIT ON LESS LOAD (LOAD FLUCTUATION) FOR LONGER PERIOD..................... 24
5. AIR SUPPLY AND CONTROL ................................................................................................................. 25
6. PNEUMATIC SPREADER ....................................................................................................................... 25
7. CLEANING PROCEDURE FOR CONVECTIVE HEAT EXCHANGER ................................................... 26
8. START UP ................................................................................................................................................ 26
CHAPTER 4: TROUBLE SHOOTING ................................................................................................................ 28

CHAPTER 5: LIST OF DRAWINGS ................................................................................................................... 29

___________________________________________________________________
COOLING & HEATING DIVISION 1 VTBB STD-O
THERMOPAC SECTION 3
_______________________________________________________________________

CHAPTER 1: PRE-COMMISSIONING, COMMISSIONING

1. PRE-COMMISSIONING

PNEUMATIC TESTING OF PIPELINES

To carry out the pneumatic test, following procedure can be adopted.

1. Blank out suction and outlet points of the circulating pump.

2. Isolate combined expansion cum deaerator tank by blanking inlet and outlet
flanges. It is emphasised here that Expansion-cum-deaerator tank is not to be
subjected to pneumatic test.

3. Blank out Thermopac inlets and outlets so that the coil is isolated.

4. Close all vent and drain valves.

5. Check all the flanged joints for ring gaskets and clamp the flanges tightly.

6. After checking above points connect compressor to one of the drain or vent valves
with a flexible air hose and switch it ON.

7. Pressure will build in the system, the same can be observed at separate
pressure gauges installed in the line

8. In case the pressure fails to build up, check possible leakage points such as
flanges, vent valves and gland packings of the valves, etc. which are the points for
major leakage.

9. Once these are found to be correct, and yet the pressure fails to build up then one
should look out for a major leakage.

10. If observed minutely, the source of leakage can be determined easily by a hissing
sound of escaping air.

11. The source of leakage should be repaired after the system is depressurised.

12. Once again pressurise the system and minor leakage’s can be determined with the
help of soap solution test.

13. Apply soap solution to all the bends and joints (Welded, flanged or screwed).
Bubbles will be observed at the source of air leakage’s, however small the leak
may be.

___________________________________________________________________
COOLING & HEATING DIVISION 2 VTBB STD-O
THERMOPAC SECTION 3
_______________________________________________________________________
14. Maintain the air pressure in the system for at least one-hour with compressor
switched off and the air inlet valve closed. The test pressure can be between 5 to 6
kg/cm2g.

15. The pressure drop after one hour should not exceed 10% of the set pressure. 10%
of air pressure drop will be due to some leakage in glands of the valves, otherwise
even this pressure drop will not occur in case glands are leak proof.

16. Once satisfied with the pneumatic test, the blanked out points should be
removed and ring gaskets fitted in the flanged joints. Now the system is ready for
filling.

2. COMMISSIONING OF THE SYSTEM

After all the connections are completed and pneumatically tested, the unit is ready for
commissioning. Before commissioning, we suggest the following be done.

 Before filling the Thermal oil in the system please ensure the following :

1. Please check completeness of the piping as per P & ID and the piping drawing and
pipe supports are provided appropriately. Please check the hardware and gaskets
are of the right quality suitable for Thermal oil duty.

2. If the Thermic Fluid has been purchased by the client directly, ensure that this has
already been sent to us for analysis and confirmed fit for use by us. This will
ensure that the quality of the Thermic fluid is O.K. and that it is fit for use in the
system. (A sample of One Litre of Thermic fluid will suffice for analysis). If the
Thermic fluid is of bad quality, it may crack at higher temperatures and carbonise
and choke the system piping and the coil of the unit.

3. Ensure that the blank flanges used for blanking the circulating pump, de-aerator
tank, expansion tank, etc. for pneumatic testing are removed and the joints
tightened properly to prevent leakage.

4. Make arrangements for separate pump capable of pumping 1,000 Litres of oil per
hour against a head of 40 to 50 meters of liquid column depending upon the
highest point in the circuit viz. Expansion cum De-aerator Tank.

5. Connect outlet of this pump to the lowest point in the circuit. Always the Thermic
fluid must be pumped into the circuit from the lowest point in the circuit to ensure
that all the air escapes through vent points and no air remains trapped in the
circuit. The suction can be connected to the oil drums. In case motorised pump is
not available, use of hand operated semi-rotary gear oil pump can be made.

6. Open all the vent points to the atmosphere.

7. Start pumping the Thermic fluid and watch closely the vent valves.

___________________________________________________________________
COOLING & HEATING DIVISION 3 VTBB STD-O
THERMOPAC SECTION 3
_______________________________________________________________________

 Filling of the system with thermal oil:

1. Make sure that the filter element at the pump suction is of 80~100 mesh to arrest
the particle above the mesh size in the thermal oil.

2. Before filling open all the valves in the Thermal oil system. This will allow the
gases to escape during filling.

3. Start the Thermal oil transfer/make up pump. The pump generally should be of
8~10 m3/hr and of 60 mlc. Always the Thermic fluid must be pumped into the
circuit from the lowest point in the circuit to ensure that all the air escapes through
vent points and no air remains trapped in the circuit.

4. The filling time can be estimated based on the system hold up.

It will be observed that as the oil starts reaching the various levels in the circuit,
respective vent valves will start overflowing and these have to be shut and the
process continued till the last valve is shut. Now, one will have to observe closely
the level in the expansion tank. The desired level in the expansion tank is about
50 mm above the level of the bottom gauge glass valve. Since the system is being
filled up for first time, the possibility of air pockets is not ruled out. With the first
circulation of oil the level might fall down drastically and hence it is advised to fill
up the liquid to a level of 150 to 200 mm in the expansion tank. After this level has
been reached, the filling of oil should be stopped and the system be left for half an
hour for oil to settle. Then cold circulation of oil is to be started. The oil should be
passed through the strainer circuit in the piping for separating the unwanted solids
in the piping. If the strainer is not suitable for high temperature, this should be
done at ambient temperature only. Note the pump pressure and circuit pressure.
There should be practically no fluctuation of the needles of respective pressure
gauges. If fluctuation of these needles is observed, it is evident that either trapped
air is present or air is being sucked in through flanged joints or through glands of
the valves. In case of trapped air, this will be removed gradually by cold circulation
through de-aerator unit. The cold circulation should be continued until all the
trapped air is removed.

The flanged joints and the glands of the valves should be further tightened if found
leaking and a stage of constant pressure reached. In this process, it might be
necessary to start refilling of the thermic fluid in case the level in the expansion
tank falls below the required minimum level of 50 mm. Once the system is
balanced and the level is maintained for half an hour, then it is ready to be warmed
up. Check that the level switch in the tank operates properly.

5. As system start filling the Thermal oil will start coming out of the vent valves. As
soon as Thermal oil starts coming out close the respective valve.

6. Fill the system with Thermal oil till there is level in the expansion tank visible 1” in
level glass.
___________________________________________________________________
COOLING & HEATING DIVISION 4 VTBB STD-O
THERMOPAC SECTION 3
_______________________________________________________________________

7. After this check the readiness of main circulating pump. Start the circulating pump
and establish the flow in the circuit.

8. During starting filter element needs to be changed frequently to remove the

welding bur or insoluble impurities of the oil.

9. After establishing the flow and steady operations please change the filter element
to the size as recommended by the Thermal oil pump supplier. In absence of any
such data 80 mesh can be used.

The system is ready for commissioning.

 Charging the Thermal oil in the system, this is going to get connected to
existing heater in operation:

Before starting the filling of thermal oil in the system please ensure the following
points-

1. The isolation valves and bypass valves are provided as per mutually agreed hook
up and P&ID scheme.

2. The isolation valves are properly closed and bypass valves is open during starting.

3. The gas leg is provided with vent and isolation valve.

4. The tapping for expansion to be provided in the gas leg at the same level of
existing tapping of overflow of the expansion tank. This will allow the expansion for
the thermal oil during initial heating.

5. Please check completeness of the piping as per P & ID and the piping drawing and
pipe supports are provided appropriately. Please check the hardware and gaskets
are of the right quality suitable for Thermal oil duty.

6. Please check and ensure the weld joint quality by visual inspection and pneumatic
test.

7. Please check the cooling plan of the circulating pump as per the norms provided
by the pump supplier details.

8. Please checks and ensures the quality of the Thermal oil is as per the norms
provided by Thermax or Thermal oil supplier.

___________________________________________________________________
COOLING & HEATING DIVISION 5 VTBB STD-O
THERMOPAC SECTION 3
_______________________________________________________________________

3. WARMING UP THE SYSTEM

It is very important to follow the procedure detailed below in the process of

commissioning. After the Thermopac has been fired, the temperature of oil should be
gradually increased. The warming up should be done in the following stages.

1. Please refer the Scheme given in P & ID & hook up scheme.

2. The hook-up scheme needs to be finalized before the erection and should be
acceptable to both the user as well as supplier of the thermal oil heater.

3. Valves on vent line from Deaerator to expansion tank should be opened and T/F
expansion tank should be isolated.

4. Main T/F circulating pump provided for the unit should be started.

5. After establishing the Thermal oil flow, the system is ready for hookup.

6. Now bleed the hot oil from existing heater through isolation valve. The bleed from
the existing thermal oil system and make up from new system should be adjusted
in such a way that the unit outlet temperature variation is within acceptable limit
from process point of view. By this bleeding method the thermal oil temperature
should be raised till 250°C w/o firing. Existing heater needs to be operated slightly
at higher unit outlet temperature.

It is very important to follow the procedure detailed below in the process of

commissioning. After the Thermopac has been fired, the temperature of oil should be
gradually increased. The warming up should be done in the following stages.

1. Set the outlet temperature controller to 110°C.

2. Maintain return temperature for one hour.

4. Increase the outlet temperature controller settings to 120°C after making sure that
there is no cavitation in the system. If cavitation starts, stop the firing, switch off
the pumps, and immediately vent out the gases from vent points by opening the
vent valves. Steam and hot gases may come out of these valves and when oil
starts oozing out, the vent valves should be shut and circulation of oil be
commenced. When the pressure readings stabilize, the pumps can be re- started.

5. Maintain the return temperature for at least one hour so that all the vapors are
removed and observe that no cavitation occurs.

6. Increase the outlet temperature setting by 20°C and repeat the same procedure
detailed above until temperature of 160°C at the outlet is achieved.

___________________________________________________________________
COOLING & HEATING DIVISION 6 VTBB STD-O
THERMOPAC SECTION 3
_______________________________________________________________________
7. Maintain temperature of 160°C for at least one hour and closely observe for minute
fluctuations in the pump pressure and the level in the expansion tank. The level in
expansion tank should rise only as a result of expansion of oil, which is 7 Liters per
100 Liters of oil per 100°C rise. If it is greater than this, then it should be
concluded that some abnormal phenomena is on, such as back pressure due to
presence of moisture, trapped gases, etc. and these should be vented out.

8. Temperature between 160°C and 250°C should be achieved very gradually. In this
range of temperature, some ingredients of oil start separating out.

Sufficient time lag should be provided for de-aeration to remove these gaseous
ingredients.

9. After reaching the temperature of 250°C, further increase in the temperature up to

280°C can be done directly.

It should be noted here that the above procedure of warming up is only required in
the initial run of the unit and not every day. The temperature can be raised next
day directly up to 280°C.

10. It is necessary to check flanged joints for leakage at high temperature viz. 200°C
and above. If still found to be existing, then the flanges should be further tightened
with even pressure on diagonally opposite bolts. It might be necessary to add
gland packing to valves, to stop any leakage. This is known as “HOT BOLTING”.

11. Depending upon the process of bleeding, process load, it will take approx. 3-4 day
time to raise the new thermal oil temperature from 30°C to 250 - 280°C.
This needs to be discussed and finalized jointly at site as per site condition.

12. Now heater is ready for start up and firing.

4. CHANGE OVER BY FUEL FIRING

Now the thermal oil is attained the hot oil temperature of 250~280 °C by bleeding
as mentioned above and all the water vapors and other gases are driven out of the
thermal oil. Now heater can be taken into operation by fuel firing. Before
changeover please check and ensure the following.

1 The combustion side is ready in all respect with the pre-commissioning checks.

2 The fuel feeding measurements are established for calibration considering the fuel
density and GCV of site conditions.

3 All loop checking is done and working satisfactorily.

4 Now start the fuel firing and raise the temperature slowly to required operating
temperature. Since the load will be less and so unit will trip frequently.

___________________________________________________________________
COOLING & HEATING DIVISION 7 VTBB STD-O
THERMOPAC SECTION 3
_______________________________________________________________________
5 After acceptable performance and reliable operation start the changeover from old
unit to new unit.

6 Start the loading the unit by closing the bypass valve and opening the isolation
valve with equal percentage. It is suggested that the bypass valve should be
regulating control valve, which can be operated from the panel by inching.

7 As new unit starts taking over automatically the oil fired unit or earlier unit will go to
low firing automatically if control exists or needs to be done manually.

8 With the new unit observe the process at 50% load and after having satisfactory
operation slowly change it over to 100% load.

CAUTION : Every time, when the system is recharged with new thermic fluid or
when Thermic fluid is topped up, while recommissioning after cleaning, repairing or
changing the heat exchanger coil, the warming up procedure has to be followed
religiously.

___________________________________________________________________
COOLING & HEATING DIVISION 8 VTBB STD-O
THERMOPAC SECTION 3
_______________________________________________________________________

CHAPTER 2: CONTROLS AND SAFETIES ON THERMOPAC

1. CONTROL AND SAFETIES ON THERMOPAC

The following contribute for the safe operation of the unit.

A] DIFFERENTIAL PRESSURE SWITCH ACROSS THE ORIFICE PLATE. ( IF

APPLICABLE)

Differential Pressure Switch is used across an orifice plate to ensure that sufficient
quantity of flow is maintained through the system during normal operation above
150°C. In case the flow of Thermic fluid is less, the unit goes to electrical lock-out,
ID and FD fans will not start and alarm will be sounded. When the fluid
temperature is below 150°C, this safety is automatically bypassed through
thermostat set at 150°C.

B] RETURN AND OUTLET TIC

The return and outlet temperature TIC indicate and control the Thermic fluid
temperature at the Thermic fluid inlet and outlet of the unit respectively. The outlet
temperature TIC make the ID and FD fans work ON-OFF. Alarms are sounded if
outlet temperatures are high.

C] SWITCH IN THE EXPANSION TANK

When the level of Thermic fluid in the Expansion Tank drops too low, this level
switch stops the ID and FD Fans thereby stopping the combustion, and sounding
alarm.

D] D.P. SWITCH ACROSS INLET AND OUTLET HEADERS

This ensures minimum flow required in cold start condition, as well as during
continuous operation of system. (Extra safety).

E] FLUE GAS OUTLET TISH

The outlet temperature TIC indicates the heater outlet flue gas temperature is high.
This indicates the abnormal heat up in heater, and indicates that coil heat pick up
capacity decreases. This may happen because of choking in coil or over firing fuel.
The outlet temperature TISH makes the ID and FD fans work ON-OFF. Alarms are
sounded if outlet temperatures are high.

___________________________________________________________________
COOLING & HEATING DIVISION 9 VTBB STD-O
THERMOPAC SECTION 3
_______________________________________________________________________

2. CONROL & SAFETIES ON THE USER EQUIPMENT

It is advisable to have the following controlling devices on the User Equipment’s.

A] TEMPERATURE CONTROLLERS AND AUTOMATIC VALVES

The temperature in the user equipment is the main parameter, which needs to be
controlled. This temperature is sensed by the probe of temperature controller
which indicates and controls the temperature. When the temperature in the user
equipment exceeds the pre-set limit, the temperature

controller makes the automatic valve (2 way or 3 way pneumatic or motorised

valves) fitted in the thermic fluid line to close, thus regulating the circulation of
Thermic fluid through that equipment. The temperature controller makes the
automatic valves to open again as the temperature in the user equipment drops.

B] PRESSURE RELIEF VALVE

The purpose of a pressure relief valve is to relieve the components from pressure
when it builds up. In the thermic fluid system, whenever oil is filled in and firing is
started/unit is started, then thermic fluid expands due to coefficient of thermal
expansion. As the system is closed one, there is no space in between thermic fluid
pump to utility to accommodate this increased volume. So coil inside pressure will
increase due to heat addition. To protect the coil from over pressurization,
pressure relief valves are provided.

However, for part load operation, flow balancing has to be done either through two
ways control valve or three ways control valve which, is provided by the users.

In standard units, the pressure relief valves are set at 7 kg/cm2g which, is
maximum design pressure for coil. The relieving capacity is 7 m3/h, which will
cater to all VT units.

Note :- For the safety of circuit beyond our battery limit, the users has to
provide safety valve, 3 way control valve, based on his system requirement.
The safety valve requirement and purpose is summarized below.

C] SAFETY VALVE IN THE THERMIC FLUID CIRCUIT

The purpose of a safety valve in a Thermic fluid circuit is to maintain necessary

flow rate through the Thermopac by opening and bypassing some flow through it in
case of the increase in circuit resistance. The circuit resistance (circuit pressure)
may rise due to following reasons:

a. Too long piping, too many bends or smaller diameter piping.

___________________________________________________________________
COOLING & HEATING DIVISION 10 VTBB STD-O
THERMOPAC SECTION 3
_______________________________________________________________________
b. Choking of pipelines, heat exchanger tubes etc.

c. The isolating valves in various piping left partially/fully closed.

d. The 2 way valves controlling flow rate through the equipments are partially closed.

e. Even if a 3 way pneumatic valve is provided in the user equipment, it may not
satisfy the minimum flow requirements. This is particularly so when the unit
happens to be under utilized, particularly where a higher capacity unit is put into
operation for lesser heat loads with future expansions in mind or when it becomes
necessary to isolate one or two user equipments for repairs, modifications, etc

The adjustment of a safety valve may be done as follows :

i. Check up and note down the pump and circuit pressures when all the valves
connected across the user equipments are fully open. In standard units,
circuit pressure should be less than 2 kg/cm2g. Check the specifications for
that installation for circuit pressure.

ii. Now, close all the valves across all the user equipments and note down the
pump and circuit pressure.

iii. Adjust the safety valve to such an extent that the pump and circuit pressures
come down to the same initial reading. This will ensure the normal flow rate
as in the beginning.

NOTE :

IT SHOULD BE ENSURED THAT AT NO TIME THE UNIT WORKS WITH EITHER LESS
THERMIC FLUID OR NO THERMIC FLUID IN THE SYSTEM. THIS WILL RESULT IN
CAVITATION PROBLEMS AND IN EXTREME CASES EVEN CHOKING UP OF THE
COIL.

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3. SETTING OF INSTRUMENTS FOR COMMISSIONING

Sr.
Description Range Unit Switches
No.
H/HH(Design H/HH(Actua L/LL(Design L/LL(Actual
Values) l Values) Value) value)
Value Hyst Value Hyst Value Hyst Value Hyst
A TEMPERATURE CONTROLLERS/ PRESSURE SWITCHES
0
1 TIS1-1
TEMP IND SWITCH 0 -400 C 246 5 N.A N.A
0
2 TIS1-2
TEMP IND SWITCH 0 -400 C 280 5 N.A N.A
0
3 TIS6-1
TEMP IND SWITCH 0-400 C 340 5 N.A N.A
DPSL PRESSURE Kg /
3 0.3-4.5
1-3SWITCH FOR Cm2
VTB 04 “ N.A N.A 1.05
VTB 06 “ N.A N.A 1.05
VTB 10 “ N.A N.A 1.05
VTB 15 “ N.A N.A 1.05
VTB 20 “ N.A N.A 1.2
VTB 25 “ N.A N.A 1.2
VTB 30 “ N.A N.A 1.2
PRESSURE
DPSL SWITCH FOR
4 0-0.3 Bar 0.175
1-4 ORIFICE ( IF
APPLICABLE )

NOTE:

All above values are given on design condition. As per site conditions the set
values will get changed. Same values to be rated and recorded for monitoring the
trend of performance. For electrical components please refer electrical diagram
and switchgear table.

4. SECONDARY AIR SETTINGS

QUANTITY
The secondary quantity should be equal to volatile matter in the fuel.
Coal - 20~25 % of total air supplied.
Lignite - 35~45 % of total air supplied.
Husk/wood/baggase - 40~50 % of total air supplied.

SECONDARY AIR HEAD

The velocity & of the secondary air should be as below-
Furnace Width(mm) Velocity (m/sec) Sec air head (mmWc)
500~1000 20~25 50
1000~1500 30~35 75

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1500~2000 40~45 100
2000~2500 50~60 175
> 2500 60~70 225

For measuring the secondary air pressure, there should be provision in ducting and
manometer at site. This value to be set during commissioning.

For pneumatic spreader ( Only for husk firing ) the air requirement will be 8~10 % of total
air and head should be 180~200 mmWc.

For controlling the air quantity the dampers in secondary air ducting and spreading duct
should be good quality and leakage rate not more than 1~2%.

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CHAPTER 3: OPERATION

1. BUBBLING BED COMBUSTION

A] INTRODUCTION:

There are several methods adopted for firing solid fuels. The fuel can be hand fired on a
static grate or mechanical stokers such as Low Ram, Chain grate, Travagrate, etc. could
be used with or without spreader. Large boilers are fired by pulverised fuels wherein
finely ground fuel is burnt in a stream of air (like oil) in a special PF burner. For the fuel
having very high ash (up to 70%) high moisture (upto 45%) and low calorific value,
bubbling bed combustion technology is the most efficient and economical.

Solid particles could be moved by fast stream of air. The movement depends on the
velocity of air in the medium. If the velocity is to low, air will percolate through the bed of
solids. On the other hand, if the velocity is to large, the solids will be pneumatically
transported. If the velocity of the air stream passing through the bed is gradually
increased, a point is reached where individual particles are forced upwards with the rising
bubbles. As the bubble comes out of the bed and bursts, these particles are returned
back to the bed causing rapid mixing of particles. The surface is no longer well defined
and the bed in this state is called bubbling bed. The bubbling bed exhibits many
properties of liquids such as:

1. The bed finds its own level

2. Addition of solid powder to the bed is mixed uniformly through out the bed.
3. Objects can float or sink in the bubbling bed depending upon the density.
4. When heat is generated in one part of the bed it is transferred uniformly through out
the bed.
5. Mixing in bubbling bed causes the heat to be rapidly transferred to cooler surfaces
(such as water tubes) immersed in it.

This phenomenon of Bubbling Bed has been used in chemical engineering for years, but
its use for combustion of fuel is only two decades old. If the fuel is added continuously to
bubbling bed working at a temperature higher than ignition temperature of the fuel. The
combustion can be self-sustained. Because of high turbulence, rapid mixing of air and
fuel and heat stored by bed material, it is possible to achieve very high combustion
efficiency even with high ash, poor grade fuel. The bed temperature can be maintained
at a level much lower than the clinkering temperature making it sage and trouble free for
operation.

The fuel is crushed and sieved to 3 to 8 mm sizes and fed to the bed with a screw feeder
just above the expanded bed. Secondary air is added at this point which also helps in
spreading the fuel. The dust emission from the bubbling bed is rather high and it
requires dust-collecting equipment for cleaning the flue gases before passing them
through the chimney. A mechanical dust collector has therefore, been included in our
standard scope of supply.

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B] CONSTRUCTION FEATURES:

The Bubbling bed combustion chamber assembly consists of a plenum chamber. The top
plate of plenum chamber is fitted with number of specially designed nozzles to distribute
the air uniformly over the entire section of furnace. The top plate also supports the bed,
ash and fuel. One or more number of ash discharge ports of special design is
strategically located in the bed. The ash discharge can be operated manually with the
help of levers or automatically by ash discharge screw with geared motor. Fuel feeding
screw, driven by a variable speed motor through gearbox is fitted on the furnace.
Suitable capacity hopper is provided to contain & feed the sized fuel to screw feeder.
High-pressure secondary air connection is provided below the fuel feeding point to
spread the fuel over the bed. Access doors are provided on the furnace. To limit the
temperature of bed, a high temperature controller with special sensing element is also
provided in the bed.

The combustion chamber is lined with suitable quality firebricks backed up by insulation
bricks.

C] FUEL SUPPLY:

The Fuel feeding to the heater is by means of screw feeder. Its feeding rate can be
controlled depending upon the load on the heater.

Crushed fuel of adequate quantity has to be stored and to be conveyed to the hopper of
screw feeder by means of suitable fuel conveying system.

The screw feeder system has to be suitably supported near the boiler.

D] FUEL SIZE REQUIRED

OBF system
2 mm to 9 mm : More than 85%
Less than 2 mm : Less than 15%

E] START UP

1. Charge Imported coal/ petcoke of particle size as mentioned above, in the bed to
make 8 inch deep bed of uniform level.

2. Add 10 to 15 kg of charcoal per m2 of combustion bed area, wetted with diesel or

kerosene to the bed. To mix the charcoal thoroughly in the solid fuel. Air from F.D.
Fan for a short while with partial damper opening.

3. In case of petcoke firing lime stone bed height of ½” above the nozzle top to be
maintained and periodically Lime stone should be topped up manually. Lime stone

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quantity required is at least 50% of the fuel consumptions per hour. Lime stone
feeding is necessary to avoid sulfur corrosion of back end equipments.

Lime stone of size 10 to 12 mm (with minimum 80% purity) to be used.

3. Add second charge of 10 to 15 kg of wetted charcoal per m2 of combustion bed

area, uniformly spread over the bed. When the bed catches full fire, within 3-4
minutes start ID fan with 20% damper open, supply FD air, with controlled damper
at lower pressure of 100-150 mm WC to keep the bed in bubbling state. Charcoal
in the bed will start burning and the bed temperature will start rising gradually.

4. Add next charge of 5 to 10 kg of dry charcoal (no wetting) per m2 of combustion

bed area before the earlier charge is fully consumed and the bed temperature is
around 200°C Let the bed temperature rise further.

5. Gradually increase ID and FD fan dampers further to enhance combustion.

Excessive damper opening may cool the bed. Watch air pressure and bed
temperature.

6. At temperature around 500-600°C, the bed looks like a bubbling lava and is ready
for charging fuel.

7. Start fuel feeder with minimum feed rate when the bed temperature goes above
550°C. Raise the plenum chamber pressure to 350 mm WC. Adjust ID fan damper
for balancing the draught in furnace.

8. At 700°C bed temperature, dampers need final adjustment.

9. For normal operation, bed temperature is to be controlled within 800-900°C and air
pressure should be 350-375 mm WC and furnace draught around -3 to -6 mm WC.
The basic parameter to be set for a given load is the fuel feed rate. Hence first try
and set a correct feed rate for given load and then adjust FD, ID Fans, ash
discharge, secondary air pressure etc. to suit the optimum combustion and to
control bed temperature.

10. At steady, trouble free condition, note and mark the feeder speed, damper
positions, air pressure and bed temperatures corresponding to various loads.
Discharge ash at intervals to keep plenum chamber air pressure within 360-370
mm WC. The frequency will depend upon the load and the ash content of the fuel
fired. After 8 to 10 mm rise in plenum pressure the manual discharge is
recommended. The discharge frequency may be 2 to 4 times an hour, depending
upon the amount of ash in the fuel.

F] AIR CONTROL

The air and gas flow rates are controlled by dampers on FD and ID Fans. Following
features of these fans should be kept in mind during operation.

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1. Air and gas at lower temperature have higher density and hence the load on ID fan
drives motor increases. In our system, it is not required and not advisable to
operate the ID fans on full discharge at lower temperatures. The air required and
gas produced is proportional to the combustion rate. Full discharge is required
only at full load. Hence the motors are sized for full load (and working
temperature) condition. Opening dampers fully at lower temperatures will definitely
overload the motors. Therefore, it is necessary to open the ID fan damper
gradually, in steps, as the load and temperature rise.

2. FD fan provides air for combustion, via air pre-heater (if provided). A part of this
air is supplied through the nozzle below the fuel feeder to spread the fuel. This
also serves as secondary air. FD fan discharge is to be adjusted proportional to
fuel feeding rate and to maintain bed temperature within operating range.

3. ID fan is to be controlled only to the extent of maintaining the pressure in the

combustion chamber within -3 to -6 mm WC.

G] FUEL FEED CONTROL

Sized fuel is fed to the combustor above the bed level by means of a screw feeder. The
feed rate can be varied over a wide range by VFD.

During start-up of the combustor, keep the regulator speed at minimum and start the
feeder when bed temperature rises to around 500-550°C. The damper on secondary

air port should be gradually opened to spread the fuel falling through feeder outlet over
the bed. Reduce the damper opening if excessive carry over starts.

Increase the feeder speed at slower rate and if necessary, readjust the dampers to
maintain air pressure.

H] STOPPING

Stop the fuel feeder. Wait until the furnace temperature falls below 600°C Switch off ID
and FD fan. Keep ash doors and ID fan damper full open to facilitate cooling by natural
draught.

I] ASH DISCHARGE

In bubbling bed system, the ash discharge takes place through the outlets as given
below.

1. Ash collected in the ash settling chamber will remove periodically. Also ash over
the bed can be remove by racking pocking arrangement.

2. Dust collector arrests major part of ash, which is discharged continuously through
the rotary air lock valve. Place a wheel burrow under the discharge port.

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3. If bag filter is provided, then further separation of ash from flue gas takes place in
bag filters fitted with rotary air lock valves.

3. Little amount of ash is discharged through the stack.

5. Some fly ash settles at the bottom of main heat exchanger. It should be taken out
at necessary intervals. The accumulation here will choke the flue gas passage
affecting the system performance seriously.

6. Part of fly ash may settle at sharp bends in ducting. These locations should be
cleaned periodically.

J] LOAD FLUCTUATION

Normally, up to 60% load reduction, heat input can be controlled by fuel feed rate control
and corresponding FD and ID. Fan dampers resetting. For minor load variations (5 to
10%) feed screw speed control alone is sufficient.

If the load is reduced below 60% for short duration, ON-OFF operation of screw feeder
may be necessary. FD and ID fan dampers should be set corresponding to

70% load and be kept running continuously even if the fuel feed is stopped. (Else the
clinker formation may take place.)

If the unit is to be operated at lower load for a prolonged period, it is advisable to reduce
the grate area by laying refractory bricks inside the furnace up to 2 feet height. The air
nozzles on periphery will also be blocked. The reduction in grate area may be
proportional to the desired reduction in the capacity of the unit. This extra layer can be
removed and air nozzles re-installed if the full load operation is to be resumed.

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2. FUEL AND HANDLING IN OPERATION

The coal burnt at home and the coal burnt in Thermopac is much the same way. Once
the fire at home gets going, the coal gives off clouds of gas and smokes which soon light
up and burn as a flame. The other part of the coal does not turn into gas but burns as a
lump on the grate. Coal in the Thermopac burns in the same two ways.

The chimney at home pulls air through the fire to burn the lumps of coal and over the fire
to burn the gases. The coal in the furnace must have air too, both through the grate and
over it through the furnace doors.

How to add coal and how to adjust the supply of air, both through and over the fire, is the
art of stoking. THERE IS NO ALTERNATIVE TO A GOOD AND EXPERIENCED
FIREMAN. However, following are some hints on stoking coal.
The three best ways of hand firing are :

A. Sprinkling method,
B. Side or wing method, and
C. Coking method.

A] SPRINKLING METHOD

At each stoke, throw an even layer of coal over the grate (Drg. No. O-TC/040200).
Make sure that no part of the grate is bare and avoid the formation of dead patches.
When the flames are dying down, use the rake to level the fire.

Experience counts for more than strength. Almost at the end of the throw the handle of
the shovel is smartly tilted downwards so as to "Spray" the coal over a wide area. This is
a knack that comes only by practice. If the shovel is simply jerked away at the end of the
throw, the coal falls in a heap. So the fire becomes uneven and the results are bad.

B] SIDE OR WING METHOD

Throw the coal evenly over the right hand side of the fire door first (Drg. No. O-
TC/040200). Wait until the gases have burnt off this fresh coal, before firing on the left
hand side. This is a very popular method. Its advantage is that one half of the fire is
always bright enough to help burning the gases given off by the other half. Hence, it is a
good way to prevent black smoke. For both these methods, the general rules are :

a. Stoke little and often. The interval between stoking should not be more than 10
minutes. Only sufficient coal should be added to maintain the coal bed thickness.

b. Keep the fire doors open for the shortest possible time.

c. Keep the grate completely covered with coal. Do not forget the back of the grate
and the left and right corners of the fire doors.

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d. Adjust the dampers according to load.

C] COKING METHOD

Pile fresh coal on the front part of the grate to a depth of about 25 cms ([Link]. O-
TC/040300) when the gases have been driven off this pile, push the coal evenly over the
rest of the grate with the rake.

Make sure that there are no bare patches before stoking again. As long as too much coal
is not charged at one time, thick coking method produces very little smoke. Whilst "little
and often" is still the best practice, the coking method is useful when the fireman has
other duties to perform, because more coal can be charged at one time and the intervals
between stoking are longer. Points like these help to decide which method of stoking to
use; but a skilled fireman is able to use any method. He studies the kind of coal and
makes his choice of a stoking method accordingly.
One very important point to be remembered is to avoid over firing of coal. This has many
effects.

1. Bad combustion of coal which leads to heavy soot formation on the outer side of
tubes.

2. Unburnt loss

3. Clinker formation.

4. Reduced life of refractory, grates Thermic fluid, tube, ID fan etc.

5. Fuel consumption increased i.e. efficiency reduced.

Therefore, it is a must to strictly avoid over-firing.

3. COMBUSTION METHOD

A. FIRING TOOLS

There are many different types and designs of firing tools and [Link]. O-TC/040500
gives examples of those in general use which are as follows :

a. Shovel for stoking coal

b. Poker or pointed bar for poking the coal bed
c. Rake for leveling the bed
d. Hoe for removing clinker
e. Slice bar for separating clinker from the grate
f. Pricker bar for cleaning the spaces between the fire bars from below.

Tools should be as light as possible and they should be used as little as possible. Care
must be taken to avoid knocking the bed about and mixing the burning coal with ash.
When the rake has to be used, pass it lightly over the surface of the bed. Never drive it

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down to the fire bars and then push it along. It rubs soft clinker between the bars and
makes them burn. It also mixes up coal and ash, making it more difficult to clean the bed.
How much the poker has to be used depends on the kind of coal. If the lumps of coal
cake together, the poker must be used to stop the formation of masses of coke which are
slow to burn (sometimes it is easier to use the rake to crack the crust of the mass of coke)
for all other kinds of coal and for smokeless coal, the less the poker is used the better it
is.

B. THICKNESS OF FUEL BED

Success in operating a unit depends very much on how thick the coal bed is. The right
thickness has to be learnt from experience, because it depends on many factors, such as:

a. The size of the coal

b. Ash content of the coal
c. The load on the heater, etc.

The normal recommended size of coal for use in Thermopac is 12 mm to 50 mm. The
recommended coal bed thickness is about 100mm to 150 mm. However, when slacks of
size 1.2 to 1.5 cms are used, the thickness of coal bed can be reduced. When slackers
are used for stoking, wetting of coal is recommended. For every 10% of slack add 1%
moisture to the coal.

C. CLEANING OF FIRE BED

Cleaning the bed takes several minutes. First close the ID fan dampers part way. Let the
fire burn down, but not so low that there is no hot coal left after cleaning, to start quickly.
Indeed, when working with thin bed, it may be necessary to add fresh coal on the side to
be cleaned last.

The tools to use are the slice bar, the hoe and the rake. There are two methods of
cleaning - the side method and the front-and-back method.

D. SIDE METHOD

The side method is the better one. The steps illustrated in [Link]. O-TC/040400 are :

a. Push the coal from the left hand side, away from the ash and clinker beneath it, on
to the right hand side of the fire door.

b. Loosen the ash and clinker on the left hand side, with the slice bar. Then scrape it
out with the hoe.

c. Stoke in about 12 shovels of coal on the bare grate. Push the coal from the right
hand side back on to the left hand side. Add a few shovels of fresh coal if the fire
looks like burning out.

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d. Remove ash and clinker from the right hand side and stoke in about 12 shovels on
the bare grate.

e. Spread the fire evenly over the grate and build up with fresh coal.

E. FRONT AND BACK METHOD

The front-and-back method is quicker but not so thorough. The steps illustrated in Drg.
No. O-TC/ 040400 are :

a. Push the burning coal to the back against the brick wall with the rake or hoe.

b. Loosen the clinker with the slice bar and pull it out of the furnace with the rake.

c. Spread the fire evenly over the grate and build up with fresh coal.

The problem with the front and back method is that some clinker and ash is always left at
the back. This will put a part of the grate out of action. Also, the clinker may stick tightly
to the brick wall and it will be difficult to remove it later.

The front and back method may have to be used when the heat demand is high. If so,
give a thorough cleaning with the side method at the end of the day.

The times of cleaning should be arranged, if possible, to fit in with periods of low load.
But, sometimes, the bed becomes heavy with ash and it is not possible to clean it
thoroughly. Run the slice bar under the bed and twist the handle slightly while moving it
sideways. This will loosen the clinker and break it up to some extent. Be careful not to lift
the clinker into the upper part of the bed.

F. CLINKER PREVENTION

Clinker formation is caused by fusing or melting of the ash. Coals with high ash content
do not necessarily clinker badly. It depends upon the kind of ash present in the fuel. The
ash of some coals requires such a high temperature to melt it that no trouble is
experienced. With coals having low ash fusion temperature trouble is always
experienced.
Between these extremes, there are many types of coals that give little trouble when
properly fired, but clinker badly if they are carelessly handled.

The precautions to be taken to prevent clinker formation are :

a. avoid thick fire beds,

b. do not use tools more often than required

c. do not mix ash with the burning coal,

d. keep the bed level by careful stoking, and

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e. run as long as possible without disturbing the bed and then clean out thoroughly.

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G. BANKING FIRES

Fires are banked when a continuous though small supply of heat is needed overnight or
at the weekend. Sometimes, it is the practice of banking, even when no heat is required
so that the unit can be restarted and brought to full capacity quickly.

In banking, the fuel left on the grate is allowed to burn away very slowly indeed. The
amount burnt during the banked period should only be just sufficient to make up for
natural cooling and to produce in addition small amount of heat if required.

To do this, a small amount of air that enters the unit must pass through the hot part of the
bed. Any air which does not pass through the hot part of the fuel bed comes in cold and
leaves hot. The heat has been taken away from the unit and is a direct waste of coal.

The bulk of the fuel should be red hot before starting to bank. The back of the grate is
then cleaned and all the good, live fire is pushed on to the back against the brick wall.
The fire is then built up with fresh fuel. Any clinker on the rest of the grate is loosened
but left on the front and middle of the grate.

All dampers are then nearly closed, leaving ; they open only enough to prevent the
escape of fumes into the Unit Room. The air grids on the fire doors are also closed. It is
usually possible to close the dampers further, about half an hour later. When starting up
again after banking, or after the dampers have been closed for any length of time, take
care to open the ID fan damper first and then open the fire doors. It allows unburnt gases
to be swept out of the furnace and avoids the risk of backfiring and a dangerous
explosion. But after starting the ID and Secondary Air fans again, the fire and ash doors
should be closed.

4. WORKNG THE UNIT ON LESS LOAD (LOAD FLUCTUATION) FOR

LONGER PERIOD
Normally, up to 60% load reduction, heat input can be controlled by fuel feed rate control
and corresponding FD and ID. Fan dampers resetting. For minor load variations (5 to
10%) feeding control alone is sufficient.

If the load is reduced below 60% for short duration, FD and ID fan dampers should be set
corresponding to 60% load and be kept running continuously even if the fuel feed is
stopped. (Else the clinker formation may take place.)

When it is expected that the demand for heat will be much less, for a long time than the
designed rating of the unit, it is advisable to shorten the grate. This can be done by
covering part of the grate, near the walls with fire bricks. These bricks can easily be
removed if necessary, whilst the unit is in operation.

When to shorten the grate, depends on how much coal is being burnt in relation to the
size of the grate. Burning rates are given in kgs of coal burnt per square meter per hour.

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If the burning rate should fall to 60 kg per square meter of grate per hour, or lower, the
efficiency will be considerably reduced. There is also a possibility of smoke emission,
due to the low temperature in the furnace and not due to lack of air. The remedy is to
shorten the grate sufficiently to raise the burning rate to 90 to 100 kg per square meter
per hour.

5. AIR SUPPLY AND CONTROL

To find the correct draught, first make sure that the fires are in good condition. The coal
bed must be of right depth for the type of coal used and the grate must be evenly covered
from front to rear. The dampers can then be regulated so that the load on the unit is met
easily and there is no visible smoke at the top of the chimney.

This draught will only be correct for the particular load and fuel. For greater loads, the
draught must be increased, for lesser loads, it must be reduced.

More draught will be required for thicker fuel beds, for fuels needing more primary air, for
more fines in the fuel, for dirty fuels, or for air leakages. Make sure that all leakages are
stopped.

If the load is variable, alter the damper setting to match the load. Adjust the secondary
air supply from time to time to burn off the gases rising from the fuel bed.

6. PNEUMATIC SPREADER
The fuel is continuously fed from the fuel receiving hoppers, advanced across the
specially designed trajectory plate and floated in a fine and light density fuel well into the
furnace. The fuel distribution, front to rear and laterally within the furnace is controlled by
the combination of high pressure air and the trajectory plate setting. Strategically located,
over fire air jets provide turbulence and thorough mixing of the fuel and air to ensure
complete combustion. Fine particles of fuel are rapidly burned in suspension while
coarser, heavier particles are spread either on a stationary air cooled grate or a moving
Travagrate, forming a fast burning fuel bed. In the case of a stationary grate, ash formed
may be cleaned manually by using ash rakes through the standard doors provided for this
purpose. In the case of Travagrate the ash formed is continuously discharged into the
ash pit.

Features :

1. The fuel feeding chute of the fuel distributor is constructed for large capacity and
for continuous flow.

2. A high pressure air duct continually supplies air for movement of the fuel.

3. The air distributor directs the volume of fuel being fired.

4. A setting device determines the position of the fuel deflector plate.

5. The fuel distributor opening is designed for large or small volume feeding.

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6. A metering damper allows adjustment of air flow for proper front to rear fuel
distribution.

7. The deflector plate determines the lateral and longitudinal curve of the fuel.

7. CLEANING PROCEDURE FOR CONVECTIVE HEAT EXCHANGER

If fuel contains either high moisture on ash content then it starts depositing on the coil
surface. So these surfaces needs to be cleaned periodically which vary from fuel to fuel.

For cleaning purpose of convective bank access doors are provided on the top plate of
convective heat exchanger. Put off the firing and FD fan. Run ID Fan and circulating
pump for 2 - 3 hours (minimum) till the thermic fluid temperature drops to 100C. While
cleaning, remove the top covers of access door. Put compressed air pipe inside and with
jet of air remove the ash from coil surface. In case cleaning frequency is higher due to
fuel nature, the permanent air piping from compressor air point to access door can be
made from IS : 1239 tubes and suitable platform can be provided to stand there while
cleaning. Only end portion of air pipe should be kept flexible.

After cleaning put back access door and tight the nut - bolts properly to avoid leakage.
Then unit is ready for use.

Cleaning frequency and time is governed by type of fuel.

8. START UP

The combustion starts only after fuel reaches a particular temperature called the "Ignition
temperature". Hence to start with, a bed of fuel mixed with other easily combustible
material like pieces of wood and cloth soaked in oil is prepared on the fire grate. This
bed is put to fire with the help of a live torch. The lighter substances like wood, cloth and
oil immediately catch fire and start heating the fuel mass around, which start burning after
a little while. More fuel is then added to the firing bed which gets heated and starts
burning. This is how the combustion becomes self-sustaining.

The ID and FD fans make available necessary air for combustion. The FD fan supplies a
part of the combustion air (primary air) through the grate bars to help burn char and also
to avoid over heating of grate bars. The secondary air fan supplies air above the bed
(secondary air) which helps in burning gases and volatiles given off by the fuel. It is
necessary to keep the fire and ash doors properly closed to obtain proper combustion.
The ID fan draws the flue gases from the combustion chamber and delivers it to the
chimney.

It is very important to regulate the fuel feeding continuously and exactly proportional to
heat demand. If the fuel feeding is not continuous, every time when the feeding starts,
there will be excessive amount of volatile matter liberation, leading to back firing & dark
smoke through chimney. This situation is unsafe and leads to damages to equipment,
loss of heat and excessive pollution.

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COOLING & HEATING DIVISION 26 VTBB STD-O
THERMOPAC SECTION 3
_______________________________________________________________________
Maintain furnace draft within -3 to -6 mm. It should be noted that, ID fan damper should
be adjusted based on the heat load and FD fan based on the furnace draft.

Supply of sufficient amount of secondary air is necessary for complete combustion of

volatile matter (which is very high in these fuels) which will otherwise go unburnt & lead to
black smoke.

Bed should be levelled periodically to have uniform primary air distribution. Periodic
raking of the bottom of bed will discharge part of ash to ash pit. Don't let the bed
thickness build to more than 700 mm.

DON'T FORGET TO CLOSE FD FAN DAMPER BEFORE OPENING ANY DOOR ON

THE FURNACE.

___________________________________________________________________
COOLING & HEATING DIVISION 27 VTBB STD-O
THERMOPAC SECTION 3
_______________________________________________________________________

CHAPTER 4: TROUBLE SHOOTING

SYMPTOM CAUSE REMEDY

THERMIC FLUID SYSTEM:
Pressure gauges Air or vapour trapped in Remove all the air/vapour
fluctuating thermic fluid
Slow heating to remove the vapour
from thermic fluid
Low level of TIF in Check and correct the expansion tank
expansion tank level
TIF not developing Check the TIF pump inlet Clean the filter strainer
pressure filter strainer for choking
Improper impeller size Check the correct impeller size
fitted in the TIF pump
Very low circuit pressure Throttle the valve pump outlet line
High pressure drop Choking of one of the Check the tuns for choking and if
across coil turn of the coil required carryout full passing test
Higher flow in the system By throttling the valves on TIF pump
than designed out. Let line, adjust the design flow in
the system
Expansion tanks level TIF heating rate very Follow the warm up procedure in the
lowing continuously high manual
Water ingracement in Allow the water vapours to come out
the Thermic fluid of the system and then continue
further heating
Check and stop if there is
ingracement of water from any other
point to the Thermic fluid system
COMBUSTION SYSTEM :
No fuel feeding even No fuel from service Check the fuel conveyor system
screw in rotating. (If hopper
applicable)
Screw in jammed and Check and rectify the fault.
hence not delivering fuel
ID Fan drawing excess Under voltage condition Set relay accordingly
current during starting
Inlet dampers are not ID fan should be started with max 30
closed during starting % suction damper opening .
Higher flue gas Check the Convective Heat
temperature causing the Exchanger for fouling with ash and if
higher gas volume required do the cleaning
Fuel feeding screw not TIF unit inlet and outlet Check the RTD and transmitter
operating (if TIC not sensing properly signals
applicable)
High furnace outlet Check fuel feed rate and unit load. If
temperature found overload, reduce fuel feed rate

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COOLING & HEATING DIVISION 28 VTBB STD-O
THERMOPAC SECTION 3
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CHAPTER 5: LIST OF DRAWINGS

[Link] DESCRIPTION OF DRAIWNG DRAWING NOS.

1. Methods of Stoking Coal ( Sprinkling & Side firing ) O-TC/040200

2. Methods of Stoking Coal (Coaking) O-TC/040300

3. Methods of Cleaning Fires O-TC/040400

4. Tools for coal firing & Cleaning O-TC/040500

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COOLING & HEATING DIVISION 29 VTBB STD-O
THERMOPAC SECTION 4
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INDEX

CHAPTER 1 MAINTENANCE ........................................................................................... 2

1.1 THERMIC FLUID .................................................................................................... 2
1.2 TRAINING............................................................................................................... 2
1.3 LOG BOOK ............................................................................................................. 3
1.4 SPARE PARTS ....................................................................................................... 6
1.5 ROUTINE MAINTENANCE SCHEDULE ................................................................. 4
1.6 LIST OF RECOMMENDED SPARES ...................................................................... 6

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COOLING & HEATING DIVISION 1 VTBB STD-M
THERMOPAC SECTION 4
_______________________________________________________________________

CHAPTER 1 MAINTENANCE

The performance of a Thermic fluid heater depends very greatly on the maintenance
carried out. The unit and its surroundings should be kept clean and maintain proper fluid
flow to the unit so that it works efficiently.

Please read the chapter on Safety before doing any type of maintenance.

Manuals of standard components like Pressure switch, Temp. controller, Pr. Gauge
etc. are available with Technical services ( Head office ), can be provided on
request if required.

In the following paragraphs, the maintenance to be carried out are listed down as Daily,
Weekly, Monthly, etc. It is also necessary to check up whether all the parts of the unit are
working properly. PLEASE NOTE THAT IT IS TOTALLY UNSAFE TO SHORT CIRCUIT
SAFETIES AND WORK THE UNIT.

1.1 THERMIC FLUID

As thermic fluid is costly, it is very essential to take care that it is not contaminated with
any other oil or foreign matter. It should be kept in a clean container. The thermic fluid
leaked out from the system should not be reused unless it is made sure that it is
uncontaminated.

It is advised that the thermic fluid (1 Litre) is sent for analysis once every three months.
This can be done by THERMAX LIMITED, PUNE, and by THERMAX SERVICE
FRANCHISE (TSF) of your area at nominal charges. In order that the thermic fluid is
clean, it is advisable to circulate it through the strainer provided in the return line, each
time the level in the expansion tank is topped up and also at least once a week.

1.2 TRAINING

Training is important to understand the product completely and to carry out routine
maintenance on the product. Apart from the excellent After Sales Service offered to the
customers through our branches all over India, a brief training is imparted to the
customers by the Service Engineers while installing and commissioning the units.
Training is imparted to customers' trainees in THERMAX LIMITED, PUNE, by our able
and experienced engineers.

Customers are requested to make use of this and benefit themselves. It is beneficial for
those who have been trained up if the knowledge acquired is imparted to other people
also in their places, connected with the unit.

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COOLING & HEATING DIVISION 2 VTBB STD-M
THERMOPAC SECTION 4
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1.3 LOG BOOK

Record of daily checks and servicing operation as well as other checks and servicing
operation must be kept in an operating log book and signed daily by the responsible
operating personal. Recurring tests carried out by the technically competent person must
also be entered in this operating log book. All the units are dispatched from our factory
with this Log Books, extra copies can also be obtained at nominal cost.

Operator must enter details of various temperatures, pressures etc. at brief intervals (at
least every Hour) in this log book along with the details of date and time.

The operator's superior must convince himself at least weekly of proper operation and
servicing of the Thermopac installation and other accessories and equipment and must
note this on the operating log book along with his signature and date.

It is suggested that these Log Books are maintained religiously and regularly, so that
deviations, if any, from standard/normal readings, may be noted and attended to
immediately, this can avoid major breakdowns and unwanted stoppage of the plant.

Please refer attachment of Daily Log Book Format

DAILY LOG BOOK FORMAT

Para- 8 9 10 11 12 1 2 3 4 5 6 7
Location Tag No Unit
meter am am am am pm pm pm pm pm pm pm pm
P Pump In
P Pump out
P Unit in
P Unit Out
P Orifice out
T/F Kg /
( If Applicable ) 2
Pressure cm g
P Process In
P Process Out
T Unit IN
T unit OUT
T Stack
T.F Pump
Motor
FD Fan Amp
Current
ID Fan
Voltages Supply Volt
Size Hopper mm
Fuel
Consumption Avg. Kg/hr
Ambient
Lab °C
Site Temp
conditions Relative
Lab %
Humidity
Flue gas Stack Temp °C

Note: Please make sure that all readings are taken properly to find out the trend of performance. In absence of this
data it is very difficult to diagnosis the problem and provides the solution.

___________________________________________________________________
COOLING & HEATING DIVISION 3 VTBB STD-M
THERMOPAC SECTION 4
_______________________________________________________________________

WEEKLY LOG BOOK FORMAT

Para-
Location Unit Date Date Date Date Date Date Date Date Date Date Date
meter
P ID Fan in
ID Fan P APH in
mmWc
Pressure P PCE in
P HE Out
P FD Fan Out
FD Fan P APH Out
mmWc
Pressure P Furnace in
P Sec. Duct
CO2 %

Kcal/
GCV
Fuel Kg
Moisture %

1.4 ROUTINE MAINTENANCE SCHEDULE

1.4.1 DAILY (or every 8 hours of operation whichever is earlier).

 Clean the external furnace off the remnant fuel, ash and fly ash.

 Clean the grate bars.

 Check diesel and lubricating oil levels in diesel engine. Check and maintain it for
single stroke starting.

 Check the lubricating oil in the thermic fluid pump.

 Check the level of thermic fluid in the expansion tank and top it up, if required.

 Check the level of water in IBH headers.

NOTE:

After filling the thermic fluid, it should be circulated through the strainer provided in
the return line so that dirt if any, can be filtered. Also note that this should be done
only at ambient temperature, as the strainer provided cannot withstand high
temperatures.

 Check and tighten the gland of the circulating pump if necessary. If packing cannot be
tightened further, replace the gland packing with a new one. The gland should be
gradually tightened with increase in temperature of thermic fluid.

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COOLING & HEATING DIVISION 4 VTBB STD-M
THERMOPAC SECTION 4
_______________________________________________________________________
 Check the level of lubricating oil in the bearing housing of the thermic fluid circulating
pump. Top it up, if required. Use lubricating oil SAE-40.

1.4.2 WEEKLY or every 50 hours of operation, whichever is earlier

(All the Daily instructions plus the following)

 Check the working of differential pressure switches.

 Check the working of all TIC by lowering their settings. Reset them to their original
settings.

 Check the calibration of all instruments.

 Check the time delay relays for their operation.

 Check the working of overload relays of motors. Reduce their settings and see if the
unit cuts off. Reset them to their original settings.

 Check and tighten foundation bolts of pump, Primary air fan ID fan, etc if necessary.

 Clean the strainer in the return line of the thermic fluid line.

1.4.3 MONTHLY or every 200 hours of operation, whichever is earlier

(All Daily and Weekly instructions plus the following).

 Check the coupling and alignment of the circulating pump.

 Clean the blades of ID fan and Primary Air fan (for Coal firing)

 Check the tension and alignment of V Belts of ID fan.

 Tighten all flanges of the thermic fluid and fuel pipelines to stop leakage, if any.

 Filter the thermic fluid by circulating it through the strainer provided in the return oil
line. Close the valve in the return line and open valves in the bypass strainer line.
This should be done when the thermic fluid is at atmospheric temperature.

 Tighten screws connecting wires to the terminal strip, to various relays, to various
motors, etc.

 Check silver contacts of relays. Clean with Carbon Tetra Chloride (CTC) or with thick
paper only, if required. Rough emery paper or wire brush should never be used.

 Check the working of various temperature controllers and automatic valves.

1.4.4 QUARTERLY or every 600 hours of operation, whichever is earlier

(All Daily, Weekly and Monthly instructions plus the following).
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COOLING & HEATING DIVISION 5 VTBB STD-M
THERMOPAC SECTION 4
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 Drain and change the lubricating oil in the oil sump of thermic fluid circulating pump.

 TAKE OUT A SAMPLE OF THERMIC FLUID (1 LITER) FROM THE THERMIC FLUID
LINE, FROM THE BOTTOM MOST POINT IN THE LINE AND SEND IT TO OUR
FACTORY FOR ANALYSIS. SAMPLE SHOULD BE TAKEN ONLY AT
TEMPERATURE BELOW 70°C.

1.4.5 HALF YEARLY or every 1200 hours of operation, whichever is earlier

(All Daily, Weekly, Monthly and Quarterly instructions plus the following)

 Check the condition of the refractory wall of the external furnace.

 Clean the entire coil with wire brush and compressed air.

 Check all valves for leakage and lap them with lapping paste, if necessary.

1.4.6 YEARLY or every 2400 hours of operation, whichever is earlier.

(All Daily, Weekly, Monthly, Quarterly and Half Yearly instructions plus following).

 Check the condition of the refractory wall of the external furnace. Get it repaired, if
required.

 Remove the coil. Clean it thoroughly with wire brush and compressed air.

 Clean the inside portion of flue gas outlet.

 Grease electric motors.

 Check the condition of the grate bars. Replace damaged ones, if any (for Coal firing).

NOTE:
Increase the routine maintenance schedule on prorata basis, if the number of
working hours exceeds 8 hours a day.

WARNING:

DO NOT TAMPER WITH THE SETTINGS OF CONTROLS AND SAFETIES

UNNECESSARILY.

1.5 SPARE PARTS

It is suggested that certain spares may be kept in stock to avoid idle time due to
unpredictable breakdowns particularly in places which are far away from branches and
not easily approachable in a short period. If there is any breakdown, it is better to replace
the defective component and repair the defective component, if repairable, at leisure, as
replacement is faster and easier. The list attached at the end may to be followed.

___________________________________________________________________
COOLING & HEATING DIVISION 6 VTBB STD-M
THERMOPAC SECTION 4
_______________________________________________________________________
IMPORTANT: While ordering spares please give complete NAME PLATE details of
your THERMOPAC and of the equipment for which the spares are required.

LIST OF RECOMMENDED SPARES

While ordering spares, please give complete NAME PLATE DETAILS of unit model, Sr.
No. and other relevant information.
Sr. No. Description Quantity (No.)
THERMIC FLUID PUMP
1. Set of gaskets 2
2. Gland packing 1
3. Oil seal set 1
4. Shaft sleeve 1
5. Ball bearing 2
6. Spider for Love joy coupling 2
7. Impeller nut 1
8. Washer for impeller nut 2
9. Pump pressure gauge 1
CIRCUIT SAFETY VALVE
10. "O" Ring 4
EXPANSION TANK
11. Gauge glass(Part no : RM01T01002) for Expansion tank 2
FUEL SYSTEM
12. Grate bars 530 mm long (part no : PXX0050030) 12
Grate bar 730 mm long (part no: PXX0050023) 12
13. Grate bar supports 1066 mm long (part no: PXX0050033) 2

FUEL SYSTEM ( for screw feeder if applicable )

14. Coal feeding screw 1
15. I.D. Fan bearing set 1
SAFETY & CONTROL
16. Differential pressure switches (Part No. P41PS10090 ) 1
17. RTD ASSLY-PT100,1/2"NPTx220LG (Part No. P44TE10100 ) 1
18. RTD ASSLY-PT100,1/2"NPTx400LG (Part No. P44TE10130 ) 1
19. PR. GAUGE, 0-10Kg, D100, 3/8 BSP, BT (Part No. 1
P41PG10070)
20. [Link] / CONT-2SP, I/P-RTD, TC (Part No. P42G190610 ) 1
21. [Link] / CONT-1SP, 0-999 DC (Part No. P42G190180 ) 1
22. Safety valve (Part No. P36SR1046M) 1
ELECTRICALS
23. * Thermic fluid pump motor contactor 1
24. * Thermic fluid pump motor overload relay 1
25. * Thermic fluid pump motor fuse – HRC 3
26. * ID fan motor contactor 1
27. * ID fan motor overload relay 1
28. * ID fan motor fuses – HRC 3
29. * FD Fan motor contactor 1
30. * FD Fan motor overload relay 1

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COOLING & HEATING DIVISION 7 VTBB STD-M
THERMOPAC SECTION 4
_______________________________________________________________________
31. * FD Fan motor fuses -HRC 3
32. * To be procured by Customer from open market make SIEMENS

___________________________________________________________________
COOLING & HEATING DIVISION 8 VTBB STD-M
THERMOPAC SECTION 5
_______________________________________________________________________

INDEX
APPENDIX A: SOLID FUELS AND COMBUSTION................................................................................... 2
A.1 PROXIMATE ANALYSIS............................................................................................................... 2
A.2 ULTIMATE ANALYSIS .................................................................................................................. 3
A.3 COMPARISON OF SOLID FUELS ................................................. ERROR! BOOKMARK NOT DEFINED.
A.4 COMBUSTION ............................................................................................................................. 4
A.5 USEFUL INFORMATION ON COAL.............................................................................................. 5
APPENDIX B: HUSK COMBUSTION ............................................. ERROR! BOOKMARK NOT DEFINED.
B.1 HUSK AS FUEL ............................................................................. ERROR! BOOKMARK NOT DEFINED.
B.2 CHARACTERISTICS OF HUSK COMBUSTION ............................ ERROR! BOOKMARK NOT DEFINED.
B.3 BURNING HUSK IN EXCESS AIR .................................................. ERROR! BOOKMARK NOT DEFINED.
B.4 AIR SUSPENDED COMBUSTION ................................................. ERROR! BOOKMARK NOT DEFINED.
APPENDIX C: CASTABLE REFRACTORIES............................................................................................ 7
C.1 STORAGE .................................................................................................................................... 7
C.2 MIXING......................................................................................................................................... 7
C.3 FORMWORK................................................................................................................................ 8
C.4 ANCHORING ................................................................................................................................ 8
C.5 PLACING OF CASTABLE ............................................................................................................. 9
C.6 CURING ....................................................................................................................................... 9
C.7 INITIAL HEATING ....................................................................................................................... 11
APPENDIX D: PUMPS, PIPING AND FLOW DISTRIBUTION ................................................................. 12
D.1 SYSTEM RESISTANCE ............................................................................................................. 12
D.2 RESISTANCE OF PIPING AND FITTINGS ................................................................................. 15
D.3 PIPING NETWORK RESISTANCE AND FLOW .......................................................................... 16
D.4 NPSH ......................................................................................................................................... 17
D.5 ESTIMATING FLOW RATE IN OPERATING SYSTEM ............................................................... 17
D.6 EFFECT OF LIQUID VISCOSITY ................................................................................................ 18
D.7 PUMPS IN SERIES AND PARALLEL .......................................................................................... 18
APPENDIX E: THERMIC FLUID ............................................................................................................... 19
E.1 PROPERTIES OF THERMIC FLUID ........................................................................................... 19
E.2 SPECIFICATIONS OF NEW THERMIC FLUID ........................................................................... 20
E.3 DETERIORATION OF THERMIC FLUID ..................................................................................... 20
E.4 TESTS ON THERMIC FLUID AND ITS CAUTION/ ACTION LIMITS ............................................ 22
E.5 WHEN TO REJECT THE THERMIC FLIUD IN USE ..................................................................... 22
E.6 RECOMMENDED THERMIC FLUID ........................................................................................... 23
APPENDIX F: PROCEDURE FOR FILLING/ CHANGING OIL IN A THERMIC FLUID SYSTEM ............. 24

APPENDIX G: CLEANING OF THERMIC FLUID SYSTEM ..................................................................... 27

G.1 METHOD 1: ................................................................................................................................ 27
G.2 METHOD 2: ................................................................................................................................ 27
G.3 METHOD 3: ................................................................................................................................ 28
APPENDIX H: PROCEDURE FOR DESCALING ..................................................................................... 30

APPENDIX I: OPERATOR TRAINING & THERMIC FLUID TESTING ..................................................... 34

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COOLING & HEATING DIVISION 1 VTBB STD-A
THERMOPAC SECTION 5
_______________________________________________________________________
APPENDIX A: SOLID FUELS AND COMBUSTION
For effective utilisation of solid fuels, the knowledge of their constituents and their
combustion properties as discussed below is very essential.

A.1 PROXIMATE ANALYSIS

Proximate analysis of a fuel gives following constituents on percentage weight basis.

i. Moisture
ii. Ash
iii. Volatile matter
iv. Fixed carbon

i. Moisture:

Moisture in the fuel has following effects. It absorbs a part of heat liberated in the
combustion process. As a result,

a. Net useful heat available from fuel is reduced,

b. Furnace temperature is lowered and
c. Heat loss from stack is increased. If stack temp. is below 150°C the chances of
vapour condensation are higher. If the fuel contains Sulphur then the risk of
H2SO4 corrosion of heat recovery unit, ID fan, ducting & chimney is higher.
Moisture also lowers the rate of combustion, particularly so in case of larger size of
fuel pieces. High amount of moisture may pose problems in fuel sizing, conveying,
feeding etc.

ii. Ash:

Ash is the incombustible solid mineral matter in the fuel. It mainly contain Silica (SiO2),
Alumina (Al2O3), Iron oxides (FeO, Fe2O3), CaO, MgO etc. At higher temperature, the
ash fuses/softens and forms clinkers, which entraps combustible matter and prevents
proper air distribution. This lowers combustion efficiency. It sticks to grates & refractory
walls and causes damage. Fuel firing and ash removal also becomes difficult.

The ash fusion & clinker formation depends upon -

a. Melting point of the lowest melting point component,

b. The distribution of minerals in the coal,

c. Reaction condition in the furnace. (In reducing atmosphere, Fe2O3 is reduced to

FeO, which reduces ash fusion temperature at the surface of coal particle causing
agglomeration & clinker).

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COOLING & HEATING DIVISION 2 VTBB STD-A
THERMOPAC SECTION 5
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d. Extent of mixing of fuel & ash (If burning fuel and ash are mixed then the chances
of clinker formation increase).

e. Duration for which fuel/ash is exposed to high temperature. Longer the duration of
exposure, higher the chance of clinker formation.

f. Supply of pre-heated primary air increases bed temperature, leading to clinker

formation.

iii Volatile Matter :

On heating of solid fuels, Volatile matter (flammable gas and smoke) is liberated. This
burns as visible flame on supply of sufficient air, time, temperature & turbulence. If
volatile matter in the fuel is higher (e.g. wood & agro wastes), then large amount of
secondary air with high pressure need to be supplied at strategic location for effective
combustion. Incomplete combustion of volatile matter leads to dark smoke, heat loss,
pollution hazard and soot deposition on boiler surfaces.

iv Fixed Carbon:

Fixed carbon is the part of total carbon in the fuel, that remains as solid carbon mixed up
with ash. This burns with glow on supply of sufficient amount of air. As the most of the
fixed carbon, along with ash burns on the bed, proper amount and distribution of primary
air passing through bed is essential.

A.2 ULTIMATE ANALYSIS

Ultimate analysis of fuel gives its chemical constituents such as Carbon, Hydrogen,
Oxygen, Nitrogen, Sulphur and total mineral matter. This analysis helps in estimating.

a. Stoichiometric (theoretical) air required for complete combustion.

b. Flue gas generated per kg of fuel fired.

c. Water vapour content in the flue gas,

d. Sulphur content of flue gas (that leads to corrosion), and

e. Calorific value of fuel, as it depends upon carbon and Hydrogen content of fuel.

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COOLING & HEATING DIVISION 3 VTBB STD-A
THERMOPAC SECTION 5
_______________________________________________________________________

A.3 COMBUSTION

The mechanism of solid fuel combustion is quite complex and varies with type of fuel
constituents of proximate analysis, type of furnace & grate, method of stoking, thickness
of bed, distribution of air, temperature in the furnace and fuel bed, residence time,
reducing or and oxidising atmosphere, amount of excess air, sizing and segregation of
fuel, skill of operator, etc., etc.

Broadly, there are three stages of combustion :

i. Evaporation of moisture from fuel

ii. Distillation of volatile matter from fuel and its subsequent combustion in the
furnace space.

iii. Combustion of fixed carbon

Chemistry of combustion:-

Typical chemical reactions involved are :-

C + O2 = CO2 (+ 8050 kcal/kg of carbon)

C + 0.5 O2 = CO (+ 2410 kcal/kg of carbon)

CO + 0.5 O2 = CO2 (+ 2410 kcal/kg of carbon)

H2 + 0.5 O2 = H2O (+ 33865 kcal/kg of H2)

S + O2 = SO2 (+ 2210 kcal/kg of S)

These calculation help estimating stoichiometric air required. Calorific values are
estimated in laboratory. (Some empirical formulae may be used for approximate
estimates of cal-values for different fuels).

Amount of stoichiometric air required is proportional to gross calorific value (GCV).

Approximately 1 kg air is required per 745 kcal of GCV.

In practice, certain amount of excess air has to be supplied in order to compensate for the
lack of contact between fuel and oxygen. This amount will vary from 30 to 80%
depending upon fuel and furnace design. In some cases (e.g. external refractory lined
furnaces) further excess air needs to be supplied to limit furnace temperature below
caking/ash softening temperature. The total amount of air should be judiciously
distributed as primary and secondary air. It shall be noted that secondary air is very
effective for combustion of gaseous products (including the CO generated in the reducing

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COOLING & HEATING DIVISION 4 VTBB STD-A
THERMOPAC SECTION 5
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zone of thick bed of low volatile matter fuels like coke). Pressure required for primary air
needs to be just sufficient to push it upto the top of fuel bed, without pressurising the
furnace. Secondary air should be supplied at high pressure through jets, which will
penetrate through the cross section of gas across it.

On complete combustion of solid fuels, amount of CO2 gas generated, on stoichiometric

basis by volume is between 18 to 20% for most of the fuels. However, with practical
amount of excess air, best CO2 could be between 13 to 14%. More than 14% CO2 may
be associated with incomplete combustion and presence of CO in flue gas. If furnaces
need extra air for cooling, the CO2 may reduce to 7 to 10%.

A.4 USEFUL INFORMATION ON COAL

Conclusion from visual appearance of coal

Sr. Inference on coal quality (Probable limits

Observation
No given for relative estimation)
1. Very bright shining coal jet black, in 1. Caking coal (brighter the luster, stronger the
section all layers appear shining, the caking)
coal does not leave stain on palm 2. Ash fusion (1000-1100C)
fairly light, can be easily broken by 3. Lower ash content (10-20%)
hand. 4. Low volatiles (15-20%)
5. Low inherent moisture (1-2%)
6. High calorific value (5500 to 6500 kcal/kg)
2. Moderately bright, jet black. In 1. Medium caking
section alternate layers are shining 2. Ash fusion little more (1100 to 1200 C)
and dull, does not leave stain or 3. Ash content (15-20%)
palm, heavier than (1) above, not so 4. Volatiles (20-25%)
easy to break by hand. 5. Inherent Moisture (1-2%)
6. Calorific value (5000 to 6000 kcal/kg)
3. Moderately bright, in section 1. Medium caking
alternate layers are bright and dull, 2. Lower ash fusion (1000 to 1100 C)
but white streaks seen between 3. Higher ash content (20-30%)
layers. Does not leave stain. 4. Volatiles (20-25%)
Reasonably light, not easy to break. 5. Inherent moisture (1-2%)
6. Calorific Value (4500 to 5000 kcal/kg)
7. More unburnt expected.
4. Quite dull brown appearance. In 1. Weakly caking or even non-caking.
section, no layers seen bur uniform 2. High ash fusion (above 1200C)
smooth grain structure, curved 3. High ash content (25-35%)
surface acquired on breaking. Hard 4. High volatiles (25-35%)
to break, fairly heavy. Does not 5. Higher inherent moisture (3-5%)
stain hand. 6. Calorific Value (4800 to 5800 kcal/kg)
5. Dull black appearance. All fibrous 1. Non-caking
structure, Very light. Looks exactly 2. Low ash fusion (1100-1200 C)
like charcoal. Leaves heavy black 3. High ash content (25-30%)
stain on hand. Very soft to break. 4. Low volatiles (20-25%)
5. Moisture (1-25%)
6. Calorific Value (4500 to 5500 kcal/kg)
7. Very heavy fine formation on grate
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COOLING & HEATING DIVISION 5 VTBB STD-A
THERMOPAC SECTION 5
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6. Dull brown colour. In section rough 1. This is no coal at all, but either a shale piece.
gains. Breaks with flat surface. 2. Very high ash (70-80%)
Very heavy. Leaves no stain. 3. Ash fusion (above 1100 C)
Cannot be broken easily. 4. No volatiles
5. Little inherent moisture
6. Difficult to ignite and burn.
7. Very low Calorific Value (1200 to 1500
kcal/kg)

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APPENDIX B: CASTABLE REFRACTORIES

Castable refractors are mixtures of the fire-brick grog, calcined high alumina grog and the
binder or cement in certain proportions. These are hydraulic setting in nature and can
become hard very quickly. Castable are best suited for places that are difficult to
approach. These can be cast or moulded to any shape and thus obviate the need for
specially shaped bricks. Presently we are using a mixture of firecrete and caladium in
proportion 9:1 as castable. Even if proper care is not taken while placing the castable;
caladium helps to develop hydraulic bond in a short period. Under such circumstances
though we get a hard casting at room temperature, when pressed in to service, casting
may develop cracks, which lead to eventual failure. The following write-up aims at giving
a detailed procedure of installation of castable.

B.1 STORAGE

Store the bags of castable in a dry place where rainwater will not fall on them. Do not set
bags on damp ground and avoid storing in a damp basement. All castable have a certain
shelf life. Even if it is stored in a dry place, it will deteriorate in properties with the
passage of time. Usually all castable are designed to be stored for a period of six to eight
months. Hard lumps definitely mean that castable has set up in the bag and is unsuitable
for use. There is no way to reclaim the castable, once it has deteriorated in storage.

B.2 MIXING

Some segregation of the fine and coarse particles may have taken place during
transportation and handling. If a portion of castable is taken out without premixing all the
material in the bag, the part used may not have the proper percentage of aggregate and
binder and may result in non-uniformity of end product. It is necessary to premix the entire
contents of the bag before the usage. It should be done on a clean non-absorbing
surface. Any contamination of alkalis, salts, ordinary Portland cement, lime etc. will cause
the castable either to set up too early or too slowly or not to set at all. It will also reduce
the strength of castable. Add cold water in the crater formed in the castable after dry
mixing. As a guide line, the water used for hand ramming may vary from 8% to 13% for
firecrete. Allow half a minute for absorption of water thus poured. Next, with vigorous
over- lapping and folding actions of shovel, ensure good mixing of castable. Do not allow
even part of the binder to get washed away with the water that escapes. Small lots may
be mixed in buckets or in trays or in wheelbarrows.

It may be pointed out that addition of water in excess of the recommended will increase
the work ability of the mix, but it will have adverse effects on strength and volume
stability. While on the other hand, too dry a mix will not have sufficient moisture and will
not develop a proper hydraulic bond. The ball in hand test offers a convenient method of
checking most castable for the proper water content. A handful of material tossed about
25-30 mm into air a dozen times should form a ball. It is too dry if it breaks and too wet if it
sags down through the fingers. The quantity of water required can be adjusted a little
either way to obtain best workability. The mixing time is equally important and the mixing
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operation should be completed within 3-4 minutes for firecrete and within 2-3 minute for
insulating castable.

B.3 FORMWORK

The wet mixed castable should be transported immediately in pans to the site of
placement, preferably within 15 minutes. The shuttle ring and the formwork should be
rigid and strong to take up the pressure induced by wet mix. It should, also be waterproof.
It is important to note that a castable develops its strength and becomes hard because of
a chemical reaction between the hydraulic binder and the water added for mixing. If
sufficient water is not available this reaction cannot go to completion and the castable
cannot develop its full strength. Wood form or a back-up wall will absorb water from the
castable.

One method of preventing the water from being pulled out of the castable is to coat the
form work lightly with oil or grease. Where this method is not practical for water proofing
on old refractory surface, it may be sprayed several times with a fine spray of water to
saturate it. Of course, there should not be puddles of water remaining when the castable
is poured.

While making refractory on the seal plate, the case is exactly reverse than above. In this
case the castable should stick to the sheet metal form. Therefore, care should be taken
to see that sheet metal is clean, rust free and free from any oil or grease stains.

While repairing the old refractory construction, ensure that the surface on which castable
is to be placed is free from oil stains, soot, dust, ash etc. Wherever possible scratches the
old surface randomly so that newly placed castable will adhere to the old one strongly.

B.4 ANCHORING

Where castable are to be placed as roofing material or as spanning material between

supports or as short cantilevers suitable anchors should be firmly secured to the
supporting shell or frame.

The use of anchors should be restricted to the minimum necessary number. The
differential Thermal expansions and poor bond between the anchors and the castable
may lead to cracks instead of reinforcement. To obviate this, stainless steel anchors are
used for reinforcement, because of its low coefficients of thermal expansion and
resistance to oxidation. The anchors are of V shape or Y shapes made from 5-6 mm dia
wire. The castable cover over the top of the anchors should be approximately 30-40 mm.
Sometimes strip of 10-12 mm width and 1-1.5 mm thickness is used for anchors. Apply a
thin coat of bitumen on anchors to provide allowance for thermal expansion of steel.

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B.5 PLACING OF CASTABLE

Mostly castable set considerably faster than ordinary structural concrete. If too long a
time elapses before installing the castable, it starts to set up and looses part of its
strength. Throw that batch away and mix new material.

Some castable stiffen in a few minutes after mixing because of gelling action. It will return
to a good working consistency by simply remixing. In no case extra water should be
added to achieve workability once mixture is ready.

Immediately after the castable is poured into the forms, it should be rodded and/or
vibrated to ensure effective consolidation. The best practice is to resort to internal and
external vibration. Wherever vibrations cannot be employed, employ roding or ramming.
The castable should be rammed/ vibrated as quickly as possible, preferably within 15
minutes after placing. The thickness of the layer should not exceed 50 mm between
consecutive ramming operations. For insulating castable, however, instead of ramming
only trowelling or pudding should be done otherwise the light weight vermiculite particles
may get broken down losing its porous nature. With good damping/vibrating, the castable
becomes solid, homogeneous and without voids.

Although inadequate ramming is a more frequent cause of trouble, too much of ramming
causes segregation and binder comes to the surface and impairs hydraulic bond setting.
This is particularly true for insulating castable. Do not trowel the castable to a slick finish.
This causes fines to come to the surface, sealing it off and results in slower drying.

B.6 CURING

All castable are hydraulic setting and need the presence of moisture for the setting
process. It is therefore, necessary to ensure that the castable does not dry out due to
exposure or due to heat produced within the mass. It should not be allowed to dry during
first 24 hours after it has been placed.

Moist condition can be maintained by covering the castable with wet sack or by frequent
sprinkling of fine mist of cold water on all exposed surfaces. This sprinkling should start
after the castable has set partially. Otherwise water may wash out the binder from the
surface. The setting of the castable can be judged by pressing a thumb. If there is no
thumb print left on the castable we can say that it has partially set. It is generally
advisable to spray water on dense castable every 45 minute to an hour until the end of
the 24 hour period.

When lining small vessels or shells, it is often possible to seal the entire opening to
prevent the moisture from escaping. The humidity quickly rises to 100% and prevents
any further loss of moisture from the surface.

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The curing period should be extended in cold weather. After the castable has fully
developed the hydraulic bond, it may be allowed to air dry for 3-4 days before heat is
applied.

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B.7 INITIAL HEATING

Proper attention should be given during initial heat up. The castable should be heated up
slowly for two reasons. They have considerably lower permeability than comparable brick
and it is more difficult for the water to pass through the castable and escape as the
refractory is heated. If the moisture is heated too rapidly, it will develop high-pressure
steam within the body of the material, which will rupture the lining.

Secondly rapid heating may cause a pattern of cracks to develop on the cold face which
extend through the lining to the hot face. Rapid heating will cause the hot face to dry up
and heat up while the rest of castable is still cool comparatively because of the process of
evaporation of moisture. This will lead to expansion of hot face and hence development
of crack on cold face. Ideally the rate of rise of temperature should not exceed 50°C/hr
upto a temperature level of 500°C. At 500°C, soak the castable for 6-8 hours and later
rate of rise in temperature may be increased to 100°C /hr. till service temperature is
reached.

In practice, however, it may not be possible to maintain the rate of rise of temperature as
specified. This is particularly true for field jobs. In such cases the castable may be
heated up by gas torches and skin temperature may be measured by surface pyrometer.
Care should be taken to see that the flames do not impinge the castable continuously.
After the first heat up, the subsequent heating cycles can be faster and the rate of heating
need not be restricted.

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COOLING & HEATING DIVISION 11 VTBB STD-A
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APPENDIX C: PUMPS, PIPING AND FLOW DISTRIBUTION

The total system resistance is the total head to be developed by pump. Since the
centrifugal pump flow-head characteristics are drooping, when the head increases, the
flow rate reduces. To ensure sufficient flow rate from pump, the system resistance should
be minimum.

C.1 SYSTEM RESISTANCE

The system Resistance (Ref. fig. 1a) consists of following:

a. Resistance of total length of piping

b. Resistance of valves, bends and fittings

c. Elevation of open discharge point from suction point.

d. Discharge velocity head.

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C.2 RESISTANCE OF PIPING AND FITTINGS

PRESSURE DROP

Pressure Drop (mlc) = f * L * v² / (2 * g * di) = K * Q²..(1)

Where,
K = f * L/(12.1 * di5) ... (2)

f = Darcy's friction factor (Moody's Diagram)

Pipe NB 15 20 25 32 40 50 65
Friction 0.027 0.025 0.023 0.022 0.021 0.02 0.019
Factor, f
Pipe NB 80 100 150 200 250 300 350
Friction 0.018 0.017 0.015 0.0145 0.014 0.0135 0.013
Factor, f

v = Fluid velocity in given section (m/s)

L = equivalent length of given section (m), including equivalent length of fittings. #

di = Piping ID (m)

Q = Fluid flow rate (m3/s)

g = 9.81 (m/s²)

# (Note : For equivalent lengths of fitting , refer fig 2)

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COOLING & HEATING DIVISION 15 VTBB STD-A
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C.3 PIPING NETWORK RESISTANCE AND FLOW

Method for piping Network Resistance and Flow Distribution

2.1 Draw a schematic line diagram of piping network to represent parallel & series
connections (Refer Figure 4)

2.2 Convert the resistance’s of valves, fittings, bends, etc to the equivalent lengths of
respective branches. #

2.3 Indicate the path resistance’s of different sections of network by of variables Ki (i =

1,2, .....,.n) on the respective lines of diagram.

2.4 Calculate the values of each of the path resistance’s (Ki) using equation (2). In
case of coils, multiply K by coil resistance factor.

2.5 Calculate the resultant (K's) of various groups of network as follows :

K9 = K2 + K3
1/K10 = 1/K9 + 1/K4
K11 = K10 + K5
1/K12 = 1/K11 + 1/K6
K13 = K1 + K12 + K7 + K8

2.6 If the total flow rate is not known accurately, then, it can be calculated by
rearranging equation (2) i.e

Q = (/\ Pa-e/K13) /\Pa-e can be obtained by measuring pressures at

the suction (Hs) and outlet (Ho) of the pump.
Thus, /\Pa-e = Ho - Hs

(The total flow rate (Q) may also be assumed initially and then iterated with the
help of pump characteristic).

2.7 Calculate the flow rates through different branches as follows :

/\Pb-d = K12 * Q²

Q3 = (/\Pb-d/K6)

/\Pb-c = K10 * (Q-Q3)²

Q2 = (/\Pb-c/K4)

Q1 = (/\Pb-c/K9) or Q1 = Q - (Q3 + Q2)

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C.4 NPSH

If the suction head created by the pump impeller at its entry is more than the vapour
pressure of liquid at pumping temperature, then vapour bubbles will form. This
"cavitation" has two fold adverse effects.

1. Interruption in flow rate with loss of head, and

2. Damage to the metal surface of impeller and casing when the bubbles collapse at
these surfaces, releasing large amount of energy.

To avoid cavitation the available "Net Positive Suction Head" (NPSH) should be
more than that required by the pump. (Normally 2 to 3 meters) Ref fig. 1a)

NPSHa = Atm. pressure

+ Suction static head
- Suction line resistance
- Vapour pressure of liquid at pumping temp.

C.5 ESTIMATING FLOW RATE IN OPERATING SYSTEM

4.1 By Motor Power consumption or current:

Power consumed by pump = Power supplied by motor

Q*H*S = 3V * I* Cos * Em

367 * Ep 1000
Where,
V = Existing voltage (Volts)

I = Current drawn by motor (Amp)

Cos  = Power factor at actual load

Em = Motor efficiency at actual load (fraction)

Q = Pump flow rate (m3/h)

H = Head developed by pump (mlc)

S = Specific gravity of liquid at pumping temp

Ep = Pump efficiency (fraction)

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C.6 EFFECT OF LIQUID VISCOSITY

(Refer Figure 1b)

In case of THERMOPAC systems, pump is started at room temperature when liquid
viscosity is around 60 cst. When the firing is started, the liquid temp. starts increasing
and viscosity starts reducing. At 100°C, viscosity is nearly 5 cst and at 250°C it is nearly
1cst (equal to water).

When the viscosity is more, system resistance is more.

Pump flow rate and efficiency are also reduced when viscosity is higher. Thus the higher
viscosity leads to much reduced flow and increased motor power.

C.7 PUMPS IN SERIES AND PARALLEL

PUMPS IN PARALLEL

When more than one pump discharges into the same pipe line the resultant Q-H line for
the performance of the group is found by totaling the individual flow rates at the same
head. As in the case with the pump working alone, the operating point is at the
intersection of resultant Q-H with the system resistance curve. (Ref. Fig. 3/a & 3/b). By
drawing a horizontal line through established operating point for parallel operation, it is
possible to find flow rates of individual pumps & efficiencies. Each pump does not have
to carry the same flow, but it will operate at its own characteristic curve and must deliver
the required head. At a common tie point on discharge of all the pumps, the head will be
the same for each pump, regardless of its flow.

The characteristic curves of both the pumps must be continuously dropping, otherwise
with looped curves, there may be two flow conditions for each head, and the pumps would
"hunt" back & forth with no means to become stabilised.

PUMPS IN SERIES

Sometimes it is advantageous or economical to use two or more pumps in series to reach

the desired discharge pressure. In this situation the capacity is limited by the smaller
capacity of any one of the pumps (if they are different) at its speed of operation. The total
discharge pressure of the last pump is the sum of the individual discharge pressures of
the individual pumps. For identical pumps, the capacity is that of one pump, and the
discharge pressure of the last pump is the sum of the individual heads of each pump
acting as a single unit. Thus, for two identical pumps the discharge head is twice that of
the rated pressure of one pump at the designated flow rate (Ref. Fig. 3/c). The pump
casing of each stage (particularly the last) must be of sufficient pressure rating to
withstand the developed pressure.

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COOLING & HEATING DIVISION 18 VTBB STD-A
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APPENDIX D: THERMIC FLUID

D.1 PROPERTIES OF THERMIC FLUID

A good Thermic fluid should have the following properties -

1.1 A reasonably low pour point of approximately -10°C. If the fluid is derived from
paraffin base it should have been well de-waxed during refining process, so that at
low winter temperatures it does not get wax clogged.

1.2 It should have specific heat of about 0.45 kcal/Kg ºC, at ambient conditions and
this value should not preferably exceed 0.7 kcal/Kg ºC at the highest working
temperature (300°C), so that its heat transfer properties are reasonably well
maintained.

1.3 The oil must be thermally stable.

1.4 The oil must possess adequate stability to oxidation.

1.5 The oil must not be too viscous at ambient temperatures or otherwise the pump
motor may be subjected to heavy draw of current during cold start. We may thus
have to, unnecessarily resort to installing large HP motor, just for cold working.

1.6 The oil during its hot run must not lose its viscosity too much.

1.7 The oil must have a fairly high boiling point at atmospheric pressure (320 - 340°C)
i.e., must have low vapour pressure. This property will ensure lower circulation
pressure, and lesser possibilities of vapour lack effects, in the system.

1.8 The oil must be completely free from water, and any insoluble substance within it.

1.9 The oil must be free from any acidic reaction, to avoid corrosion.

1.10 The oil should have low corrosion tendency for the materials of the apparatus.

1.11 The oil should be non-toxic and non-smelly.

1.12 The oil should have low sensitivity to impurities (e.g. oxygen).

1.13 The oil should have a low co-efficient of expansion so that its volume does not
increase much at higher temperatures.

1.14 The oil should have a low fire risk, high flash point and high auto ignition
point.

1.15 Low risk to the environment in case of leakage

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D.2 SPECIFICATIONS OF NEW THERMIC FLUID

The important specifications of a new Thermic Fluid are:-

a. Specific gravity in range 0.86 - 0.90 at 15 º C.

b. No impurities.

c. Specific heat not to exceed 0.7 k cal/Kg ºC at 300°C.

d. Boiling point not less than 330°C.

e. Thermal conductivity K, at temperature t°C should confirm the relation.

0.101 (1 - 0.00054 t)
K= --------------------------------
Specific gravity
Kcal per meter hour per °C

f. Thermal expansion, preferably in range of 0.0007 to 0.0008 per °C.

g. Adequate resistance to oxidation. This means that during the refining process, all
such unstable hydrocarbons, having low resistance to oxidation, must have been
removed. An oil which indicates no insoluble, with Hexane and Benzene shows
that it has adequate resistance to oxidation.

h. Adequate thermal stability, flash point to be minimum 200°C when tested as per
COC method.

i. There should be no ash and water in oil, to guard against corrosion.

j. Pour point below -10°C.

D.3 DETERIORATION OF THERMIC FLUID

Reasons for deterioration of Thermic Fluid are:

3.1 Water finding way into the system and forming emulsion. Such emulsion reduces
life of fluid. Moreover water induces rapid corrosion of tubes. Further, even a small
quantity of water present will change to steam under pressure and push out
Thermic fluid through the expansion tank.

3.2 Ingress of contaminants like solvents, process fluids, etc. depending on end user
industry may deteriorate Thermic fluid in operation. In case of aromatic, benzoic
and hydrocarbon based solvents, irreversible chemical reaction in Thermic fluid
may cause thinning or thickening of the Thermic fluid. This may lead to indirect

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effect on flash point of the lubricant. Users are advised to monitor the Thermic fluid
regularly to check and contain this phenomenon.

3.3 Ash formation due to oxidation. Ash may also be present due to additives in
Thermic fluid. Ash induces corrosion.

3.4 Overheating of Thermic fluid:-

i) Hot spots on pipes may result in raising the film temperature above the
cracking temperature. This results in release of lighter and inflammable
hydrocarbons.
ii) Therefore flash point and viscosity gets reduced.
iii) These newly released lighter hydrocarbons polymerize and tend to form
deposits which cling to the inner surfaces of tubes; clog filters or settles
down as sludge.
Lowering of flash point thus serves as a warning, indicating that the oil has
started cracking down. For mineral Thermic fluids 170°C is the critical flash
point temperature below which, due to further cracking, rate of deposition
becomes faster, more sludge formation takes place, more insoluble cling to
the surface of tubes, resulting in greater obstruction to heat transfer. Hence
progressive overheating takes place resulting in accelerated cracking,
choking of tube passage and tube puncture. Then Thermic fluid will come in
contact with outside air and ignite causing fire.

3.5 Oxidation of Thermic Fluids:

Thermic fluids tend to get oxidised in the presence of oxygen and temperature.
Since a Thermic fluid system operates at very high temperature, the fluid tends to
get oxidised rapidly in presence of oxygen and forms products of oxidation like
acids and sludge. Sludge increases insoluble and gets deposited in the system.
The acids are corrosives in nature.
Rate of oxidation of Thermic fluids approximately doubles for every 10°C rise in
temperature. Therefore at high temperatures, the tendency of oxidation is very
high. Even though de-aeration is provided in the system to push out as much
oxygen as possible, at high temperatures, what ever little oxygen is in a dissolved
state will attach to hydrogen atoms to form unstable peroxides, which produce
soluble acidic products as well as insoluble sludge and gum deposits. High
temperatures in de-aeration tank increases risk of oxidation exponentially (i.e. 10 º
C rises in temperature beyond 60ºC doubles rate of oxidation)
3.6 Contaminations: External contaminants can increase insoluble in systems that can
affect thermal stability of the oil and can get deposited in system.
3.7 Topping up with incompatible oils can lead to reaction between both oils and the
system oil can loose its properties.

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D.4 TESTS ON THERMIC FLUID AND ITS CAUTION/ ACTION LIMITS

The main parameters to be monitored for regular oil check of Thermic fluids are given
below along with the suggested rejection limits.

Sr. No. Parameter Fresh Caution Reject

1 Flash point, ºC >200 185 160
2 Viscosity @ 40ºC ~27 cSt +/-15 % +/-25%
3 TAN mg of KOH/g of oil <0.1 1.2 2
Insoluble in Pentane and
4 Toluene Nil Present 1.5
5 Millipore solids( 0.8 micron) Nil 60 mg/L 150 mg/L

D.5 WHEN TO REJECT THE THERMIC FLIUD IN USE

It is therefore, imperative that the Thermic fluid users should necessarily get sample of oil
from circulation tested every three months. These tests will help keep close check on the
degree of deterioration. If the degree of such deterioration exceeds the following limits,
the entire oil quantity in the system is liable to be replaced by fresh new oil. (It should be
noted that the parameters mentioned here are for guidance only and the user needs to
consult appropriately before arriving at decision)

1. Flash point below 180 deg C when tested as per ASTM D 92(COC)
2. Insoluble exceed 1.5% when tested as per ASTM D 893
3. Any acidity beyond 0.10 gram of KOH neutralization per gram of oil when tested as
per IP 139

As mentioned it is the overheating of oil, hot spots on tubes, etc. that bring about thermal
instability and oxidation of oil within tubes, which may finally lead to cracking, sludge
deposits, gum deposits, corrosive acidity, choking possibilities, viscosity increase, and
decrease of flash point. The puncturing of tube is due to accelerated rate of cracking,
soon after the flash point reaches 170°C and also due to intensified corrosion rapidly
progressing. Even if the oil has been subject to severe oxidation and hence increased
deposits and gumming state, so long as the flash point is maintained above 160°C we
need not change the oil from the entire system. We can effectively filter off the oil, to
remove all deposits, sediments, water, etc. and reuse the same oil. In such events, it is
desirable to get a sample of filtered oil tested in a Laboratory for confirming clearance
against corrosion, viscosity and flash temperature.

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D.6 RECOMMENDED THERMIC FLUID

Thermax Limitd recommends the use of SHELL HEAT TRANSFER OIL S2 manufactured
by Shell India Markets Private Limited for its Thermic Fluid heaters.

TECHNICAL SPECIFICATIONS OF THERMIC FLUID- SHELL HEAT

TRANFER OIL S2

Following are typical test properties and technical specifications of Thermic Fluid
manufactured by M/s. Shell India Markets Private Limited and recommended by Thermax
Limited.

Shell Heat
Sr. No. Parameters Unit Standard
Transfer Oil S2
1 Thermic Fluid Bulk Temperature Deg C 300
2 Kinematic Viscosity @ 40 deg. C cSt. ISO3104 25
3 Kinematic Viscosity @ 100° C cSt. ISO3104 4.7
4 Viscosity Index ISO 2909 105
5 Density @ 15 DeG c Kg/ltr ISO 3675 0.866
6 Pour point Deg C ISO3016 -12
7 Flash Point COC Deg C ISO2592 220
8 Fire point Deg C ISO2592 255
9 Initial boiling Point Deg C >355
ASTM
10 Autoignition Temperature Deg C 360
D2155
11 Coefficient of thermal Expansion Per Deg C 0.0008
12 Neutralisation Value mg KOH/gm IP139 <0.05

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APPENDIX E: PROCEDURE FOR FILLING/ CHANGING OIL IN A
THERMIC FLUID SYSTEM
1. It is necessary to remove all of the old oil in the system to ensure that any oxidised
or cracked/polymerised products do not accelerate the deterioration of the new oil.
The system should therefore be drained fully, taking care to ensure that any low
points in the system are also empty. It may be necessary to run a flushing charge
through the system to remove any sludge deposits which may have collected e.g.
against flanged joints or low points. The necessity for this can be judged from the
condition of the oil to be removed.

2. The oil removed should be collected in suitable containers, sealed and disposed of
in a responsible, safe and environmentally acceptable manner. (It may be
necessary to keep sufficient no. of empty oil drums/containers for this purpose.)

3. When filling with new oil it is best to fill from the lowest point in the system, usually
near the pump suction. During filling all vents must be opened and manned ready
to be closed as soon as oil appears.

4. When the system is filled to the lower mark in the expansion tank, the circulation
pump should be started and the oil gently circulated cold for several hours to
remove air pockets and flush any loose debris into the strainer. The oil level should
be made up where necessary; the filters cleaned and pump re-started.

5. The heater can then be turned on and the temperature slowly increased. Initially
some entrained moisture may boil out, causing bumping in the system. However
gentle heating with regular venting will enable the oil to be dried out without
mishap. (To minimize this problem, pressure testing or flushing of the system using
water, or water based fluids, before re-commissioning should be avoided.) The
upper limit of heat input for oil and gas fired systems is normally 5 W/cm2 (43000
kcal/m2h) to negate the risk of thermal cracking. Oil flow velocity through the
heating zone should not be below 1.5 m/s at temperatures up to 200°C, and 2.5
m/s at higher operating temperatures. Above 300°C, a flow velocity greater than
3.0 m/s is necessary.

6. When the system has stabilized, readings should be taken of all measuring
devices, e.g. gauges, flow meters, to establish reference points for future
reference.

7. A sample of oil should also be taken for analysis to establish a reference against
which future analyses can be compared.

8. Having established a reference line for oil properties during commissioning, a

second sample should be taken after three months to check that no rapid
deterioration is taking place. If this shows that all is well, that the system is
operating according to its design parameters, sampling should be carried out

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regularly every six months for the following properties to build up a complete
picture of oil condition and to plot rates of deterioration.

 Viscosity @100°C (ASTM D 445): Increase of 10%

 Flash Point (PMCC - ASTM D 93): Decrease by 50°C
 TAN (ASTM D 664): Increase of 1.0 mg KOH/g
 Insolubles (ASTM D 983): Increase of 1.0% by mass

9. The oil condition will change by slow and gradual deterioration. If any
sudden changes in the analysis take place, the reasons for the same
should be investigated.

Precautions to be taken at the time of adding oil into the system

1. A thermal fluid always contains a small amount of dissolved water (up to ~150
ppm). The water can, and must, be removed from the system in order for stable
operation to occur. This is typically done upon start-up of a new system, when oil is
added or when the oil is replaced. The process is commonly referred to as boil-out,
and is accomplished by heating the oil in the system to approximately 120°C and
holding it there for a period of time while the water is evaporated from the system.
The temperature can be adjusted up or down based on the amount of water in the
system and the level of boiling that is occurring.

2. Often during this process, the temperature starts out near 100°C and is increased
upwards as water is removed from the system. Once the water is all removed, the
temperature of the oil can be raised to the desired operating temperature, and the
system will operate satisfactorily without any water boiling conditions.

3. The system must be vented to the atmosphere during any boil-out operation. If new
oil is added to the system, or if the system is shut down while vented to the
atmosphere, water may get re-introduced into the system, and a boil-out operation
will be necessary to again dehydrate the oil. For shutdown situations, this can be
avoided by providing an inert gas (dry nitrogen) purge on the expansion
tank/reservoir. The inert gas blanket will prevent the ingress of atmospheric water
(humidity) during shutdown periods. Having an inert gas blanket provides an
additional benefit - the added pressure of the gas will add pumping distance and
head pressure to the oil, which makes the system a little more efficient. The gas
pressure is typically fairly low - a few psi. This will also prevent the venting of oil
vapor from the system.

4. Oil vapour that comes out an atmospheric vent usually condenses on nearby
surfaces, causing a housekeeping problem. Oily surfaces can be slippery, and
they also seem to act as a magnet for airborne dirt particles. Both these problems
can be prevented by adding the inert gas blanket to the system.

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5. Recharging of leaked fluid is also a source of oxidation and therefore should be
avoided.

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APPENDIX F: CLEANING OF THERMIC FLUID SYSTEM
Three proven methods of cleaning partially/fully choked Thermic fluid systems are
explained hereunder. While carrying out the cleaning job, it is advisable to take utmost
precaution as recommended by the chemical manufacturer.

F.1 METHOD 1:

Using Shell ARGINA X 30 MANUFACTURED BY Shell India Markets Private Limited:

The method described below is useful for removal of carbon from hot oil system with
severely oxidized oil.

1. Add Shell Argina X 30 into the system (after removing sufficient oil) at 20 -25%
treat rate depending on the severity of carbon contamination.
2. This is left for at least 2 weeks and the system run as normal.
3. The additives in Argina X 30 will allow the carbon to be removed from the pipes.
Deposited carbon reduces heat conduction, fluid flow and begins the degradation
of the new oil.
4. After the system is drained, flush out the system with fresh Shell Thermia /Flushing
Oil.
5. Thereafter top up system with fresh Shell Heat Transfer oil S2.

The method described above has following advantages over other cleansers:

o This is much safer then using ester based system cleaners as an ester-based
product might dramatically reduce the flash point.
o To remove the traces of cleansers, sometimes it takes 3-8 flushes or more.
o If water based cleanser is used, traces of water may create problem in the system.
o There is no need to stop the system which helps in system changeover with
minimum down time.

F.2 METHOD 2:

Using "GREESKILLA" Compound made by Castrol :

1. Drain out the Thermic fluid from the system.

2. Open any bend or pipe to check the extent of carbon deposition.

3. Make solution of “Greeskilla” with water at 5% concentration by weight. Preferably,

use DM or condensate water.

4. Pump the solution in the system with separate charging pump.

5. Replace “Metaflex” gland packing of Thermic fluid pump with ordinary gland
packing, to avoid leakage from the gland of the Thermic fluid pump.

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6. Start circulation of solution with Cyclotherm circulating pump.

7. The Thermic fluid system without the utility should be cleaned first. Further, take
up individual utilities. This procedure is adopted to avoid choking of pipelines and
utility.

8. Maintain solution at 70° to 80°C with low-pressure steam.

9. Circulate the solution for 12 hrs. in the system. (Duration of circulation mentioned
here is for 1/4" coating of carbon inside the pipeline).

10. Inspect the system pipeline at any convenient point to check effectiveness of
cleaning.

11. After ensuring cleaning, drain out the solution from the system.

12. Recharge fresh solution of “Greeskilla” at 2.5 to 3% concentrations by weight.

Maintain temperature of solution at 70° to 80°C and circulate for 24 hours and
drain out the solution.

13. Rinse the system with water 6 to 8 times to remove traces of “Greeskilla”. Each
circulation of water should be for duration of 6 to 8 hours. However, the rinsing
should be continued till the pH of inlet and outlet water coincides.

14. Inspect the pipeline again. Get all the air vents and valves cleaned.

15. Dry the system with low-pressure steam and compressed air.

16. Get the circulating pump overhauled.

17. Charge new oil, carry out normal checks and recommission the unit.

F.3 METHOD 3:

Using "SANDOCLEAN-TW" Compound made Sandoz

1. Drain out the Thermic fluid from the system.

2. Open any bend or pipe to check the extent of carbon deposition.

3. Make solution of "SANDOCLEAN-TW" in the ratio of 15 to 25 gm of “Sandoclean-

TW” per liter of hot water (say about 45° - 50°C). Preferably use DM or
condensate water.

4. Pump the solution in the system with separate charging pump.

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5. Replace “Metaflex” gland packing of Thermic fluid pump with ordinary gland
packing, to avoid leakage from the gland of the Thermic fluid pump.

6. Start circulation of solution with Cyclotherm pump.

7. The Thermic fluid system without the utility should be cleansed first. Further take
up individual utilities. This procedure is adopted to avoid choking of pipelines and
utility.

8. Maintain solution at 45° - 50°C.

9. Circulate the solution till all carbon deposits are removed. Frequent changes of
solution may be required.

10. Inspect the system pipeline at any convenient point to check effectiveness of
cleaning.

11. After ensuring cleanliness, drain out the solution from the system.

12. Rinse the system with water about 6 times to remove traces of “Sandoclean-TW”.

13. Inspect the pipeline again. Get all the air vents and valves cleaned.

14. Dry the system with low pressure steam and compressed air.

15. Get the circulating pump overhauled.

16. Charge new oil, carry out normal checks and recommission the unit.

The compound "SANDOCLEAN-TW" is available with all "SANDOZ" Office.

NOTE:

It is important that all the precautions governing safe operation of Cyclotherm be duly
observed during cleaning period.

If considerable carbon or oil sludge is found to be still adhering to the internals of

pipelines, the entire process should be repeated, until the pipe lines are free from all
impurities.

CAUTION:
When working with caustic liquids or chemicals, it is imperative that the relevant accident
prevention regulations are observed and made accessible to the persons carrying out the
work.

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COOLING & HEATING DIVISION 29 VTBB STD-A
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APPENDIX G: PROCEDURE FOR DESCALING
Descaling should be carried out by qualified personnel only and following method to be
adopted very carefully.

PROCEDURE FOR CLEANING WATER SIDE DEPOSITS FROM BOILERS USING

MAXCLEAN - 04, 05 AND 06

The descaling method for any boiler depends much upon boiler design and nature of
scales. The general procedure to be followed while descaling with maxclean-05 and 06 is
given below for scales having following typical analysis (as reported by Electricity and
heating system board in "NADIM GASPROM."

Silica - 42%
Calcium Oxide - 36%
Magnesium - 13%
Iron & Aluminium - 10%

STEP – 1 FLUSHING:

Allow boiler to cool. Open manholes and flush with plain water to remove loose
sludge/deposits. For complete removal of loose sludge use pressure jets or any similar
mechanical arrangement. At the end flushing loose scales, mud is removed facilitating
easy descaling with chemicals. Inspect tubes for complete blocking and try to clean them
mechanically to make passage for circulating descaling chemicals.

STEP – 2 MAXCLEAN-06 TREATMENT

Fill boiler up to normal water level with 5% solution of Maxclean-06. Keep steam valve or
safety valve. Open and heat slowly till boiling. Boiling of water will ensure good
circulation of descalant solution within the boiler. Continue slow boiling for 8 - 12 hours.
Make-up with fresh solution to maintain water loosened sludge accumulated in mud drum.
Check concentration of residual descalant using test kit.

STEP – 3 FLUSHING

Drain the Maxclean-06 solution in separate holding tank for reuse. Flush boiler with plain
water as given in Step-1. Cleaning with pressure jets with remove loosed scales.

STEP – 4 MAXCLEAN-05 TREATMENT 1

Fill boiler with 5% solution of Maxclean-05. Keep steam valve/safety valve open to vent
off produced gases. Fire boiler slowing to raise temperature of solution to 60-80°C.
Heating in boiler will ensure circulation of Maxclean-05 solution within boiler. Continue
slow heating for 8 hours. Give blowdown periodically to remove accumulated mud.
Make-up with fresh solution to maintain level in boiler. Check concentration of residual
Maxclean-05 every hour using test kit.
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STEP – 5 FLUSHING

Drain Maxclean-05 solution in separate tank for further use RINSE BOILER with fresh
water till pH of rinse water is above 5.0. Use pressure jets, if necessary to remove loose
scales.

STEP – 6 INSPECTION

After thorough flushing as in step-5, inspect boiler tubes and internals. If scales are still
found, repeat Step-2 to Step-6. If boiler is free of scales flush boiler with fresh make up
water or condensate.

STEP – 7 PASSIVATION

After thorough flushing of boiler with condensate or fresh make-up, fill boiler with make up
water. While filling, add 100 ppm of MAXTREAT-3011 and 100 ppm of MAXTREAT-3100
and caustic to boost pH of boiler water to 10.5 to 11.5. Boiler may be kept filled up with
above solution till it is commissioned.

STEP- 8 COMMISSIONING

After passivation as given above for 8 hours, fire boiler slowly. Use normal make-up
water and internal treatment chemicals. Give heavy blowdown till normal conditions are
obtained.

NOTE - 1

MAXCLEAN 05 or 06 SOLUTIONS should be circulated in boiler either by firing boiler or

by using external pump. When external pump is used; pass solution from the steam drum
and take out from mud drum.

NOTE - 2

Maxclean-05 and 06 solutions should never be mixed. They are not comparable.
Therefore STEP 3 AND STEP 5 SHOULD BE FOLLOWED RELIGIOUSLY.

NOTE - 3

Time required for descaling depends much on nature of scales. Test kit will help to adjust
time of descaling.

NOTE - 4

Quantity of descalant consumed depends on quantity of scales and nature of scales in

boiler. For 1 kg. of hardness scales, 1.5 kg. of Maxclean-05 is required while 1 Kg, of
Maxclean-06 is consumed for 1 Kg. of silica scales.

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PREPARATION OF SOLUTIONS:

MAXCLEAN-08

Use Carbon steel or HDPE tank equipped with stirrer or similar mixing arrangement.
Take sufficient quantity of make-up water in this tank to fill the boiler. (Generally 10%
excess of hold up volume of boiler). Add about 5 kgs of Maxclean-06 powder 95 ltrs. of
water taken in the tank. Add power slowly while mixing. Maxclean-06 produce heat while
dissolving and therefore, powder should be added slowly (esp. when HDPE tank is used).
Mix well to dissolve.

CAUTION:

Maxclean-06 is highly alkaline in nature. Use hand gloves and goggles while preparing
solution. Normal precaution of handling caustic solutions should be taken while making
Maxclean-06 solution. For further safety information, refer to materials Safety Data.
Maxclean-06 solution can be stored under normal conditions for 1 year and it can be
reused.

MAXCLEAN-05

Use HDPE tank equipped with stirrer or any similar mixing arrangement. Take sufficient
quantity of make up water in this tank to fill the boiler (Generally take 10% excess of hold
up volume of the boiler). Add about 5 kgs of Maxclean-05 per 95 ltrs of water in tank.
Add power slowly while mixing in the tank. Mix well to dissolve completely. Heat to 60°C
for dissolving it quickly.

CAUTION:

Maxclean-05 is highly acidic in nature. Use hand gloves, goggles and masks while
preparing solution. Normal precautions of handling acid solution should be taken while
preparing Maxclean-05 solution, for further information refer to material Safety Data.

Maxclean-05 solution can be stored in HDPE tank for 30 days under normal storage
conditions and it may be refused.

Please note that descaling procedure may be varied to suite boiler design and for ease of
handling. Kindly contact THERMAX for any further queries.

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COOLING & HEATING DIVISION 33 VTBB STD-A
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APPENDIX H: OPERATOR TRAINING & THERMIC FLUID TESTING

H.1 APPLICATION FOR TRAINING COURSE

To, From :

The Training Officer, _______________________________________

Process Heating Division,
Thermax Limited., _______________________________________
MIDC, Chinchwad,
Pune - 411 019 _______________________________________

Dear Sirs,

We wish to send the following participants for the training course at your factory.
____________________________________________________________________________
Training on Tick Model Sr. No.
____________________________________________________________________________
1. Revomax
2. Cyclotherm/Thermopac Oil/Coal
3. Revotherm/Shellmax
4. Multitherm
____________________________________________________________________________
Tick whichever is applicable.
____________________________________________________________________________
Name Designation

____________________________________________________________________________
Technical Qualifications
____________________________________________________________________________
Present duties in the organisation
____________________________________________________________________________
Practical experience in Boiler/ Period :
Thermopac maintenance Make :
____________________________________________________________________________
Languages known Read Write Speak
English
Hindi
____________________________________________________________________________
Yours faithfully,

Customer's Signature

IMPORTANT: Please go through the instructions given on the next page before filling in
the particulars.
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INSTRUCTIONS FOR APPLICATION FOR TRAINING COURSE

THERMAX LIMITED

CHINCHWAD, PUNE - 411 019

1. The course covers operation, maintenance, electrical circuits and trouble shooting
aspects of boilers/Cyclotherm.

2. The course is generally conducted in English and hence we suggest that you
depute a person who knows English and has some electrical background.

3. The clients should send the detailed particulars of the participant as required in the
application form.

4. If you have any problem on operation and maintenance or any clarification on your
unit, please prepare a list and send it through your participant so that the same can
be discussed and a solution provided.

5. Training charges of Rs. 2500/- per participant are required to be paid in advance
by a demand draft in favor of Thermax Limited, Pune. Please check with our
nearest office for training schedules.

6. The duration of the course is three days.

7. The participants should contact our Training Officer at our Chinchwad factory at
9.30 AM on the day of commencement of the course.

8. The participants shall make their own arrangement for lodging and boarding.
Decent hotel accommodation is readily available in Chinchwad / Pimpri area within
3 to 4 kms from our factory. Some of the hotels are Prince, Mayur, Casino,
Suryakiran, Panchshil and Emerald Park.

9. Lunch and tea/coffee will be served during training sessions.

10. Our factory is located on the east of Bombay-Poona Road, and is about two kms.
from Chinchwad Railway Station, and about 23 kms. from Pune Railway Station.
Buses and auto rickshaws are available.

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H.2 PROCEDURE FOR SENDING THERMIC FLUID SAMPLE FOR ANALYSIS

1. Draw sample from the system in the cold condition when system is at ambient
temperature. The sample should be drawn from the lowest point. The sample
should contain minimum 1 liter.

2. Fill it in a plastic airtight container and seal it properly to avoid leakage.

3. Put a label on the container indicating your full address and brand name of thermic
fluid and date on which sample is drawn.

4. Pack this container neatly with a plastic cover and insert a copy of duly filled Data
Sheet along with a covering letter mentioning details of payment by Demand Draft
towards analysis charges.

5. On the packing clearly write your full address, enabling us to identify the same.

6. Send the sample by registered post parcel or by courier service only.

7. At the same time send us a letter intimating dispatch of sample along with a copy
of Data sheet and payment towards thermic fluid analysis by demand draft in favor
of `Thermax Ltd' payable at Pune. (For present analysis changes, contact our
nearest office).

8. Please insure that the thermic fluid sample and analysis charges are sent
simultaneously, enabling us to process the samples immediately.

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H.3 DATA SHEET FOR ANALYSIS OF THERMIC FLUID

1. Customer's Name & Address:

_________________________________________________________________

_________________________________________________________________

2. Model and serial No. of Thermic Fluid Heater:

____________________________________

3. Date on which the sample was drawn:

______________________________________

4. Quality/Brand Name of Thermic Fluid sent:

______________________________________

5. If mixed with any other brand of Thermic Fluid, State Brand:

_________________________________________________________________

6. When was the sample of Thermic Fluid last tested?

Report No. and date:
_________________________________________________________________

7. When was the Thermic fluid last replace? State the Brand name of there placed
Fluid:

_________________________________________________________________
8. Unit Inlet
Temperature:______________________________________________________

9. Unit Outlet Temperature

:________________________________________________________________

IMPORTANT NOTE:

1. Sample should be sent in clean leak proof plastic container with identification
marks by Registered Post Parcel or courier. We need minimum one liter thermic
fluid for testing, accompanied by DATA SHEET duly filled in and payment towards
thermic fluid testing by demand draft towards testing charges. If the sample is
handed over to our Branch / Area offices, there will be an extra charge of Rs. 100/-
per sample as handling charges.

2. Invoice/Bill will not be raised. We will issue you receipt after receiving
testing charges. Please send testing charges in advance.

Date: _________________ Signature: ____________

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H.4 COMPLAINT INFORMATION FORM

In case of any complaints please furnish following information for arranging prompt After-
Sales-Service.

Name of Company
_____________________________________________________________________

Address _______________________________________________________________

Phone No. Telex No. Fax No.

Unit Model ___________________________________Sr.No._____________________

Design pressure/Temperature _________________________Year of make___________

Defective equipment _________________________________ Make ________________

Model No._______________________________Sr.

No.___________________________________

Date of Installation
______________________________________________________________________

Date of Commissioning
______________________________________________________________________

Contact Person
Mr.____________________________________________________________________

Plant/Department
______________________________________________________________________

Weekly Off _____________________________________________________________

Nature of Complaint ______________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

Name of person:-

Designation:-

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COOLING & HEATING DIVISION 39 VTBB STD-A
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Date:-

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COOLING & HEATING DIVISION 40 VTBB STD-A