Rental Boiler Specifications (Nebraska Boiler) ESI's 72,000 pph trailer-mounted watertube steam boilers are designed and built in accordance with ASME Code. Each boiler is arranged for natural gas or #2 oil firing, complete with standard boiler trim, low NO x burner, FGR capability, and combustion controls. Boiler Data: Steam Flow Design Pressure Maximum Operating Pressure Minimum Operating Pressure Steam Temperature 72,000 pph 350 psig 325 psig 125 psig Saturated Requirements for Gas Firing: Gas Consumption (100% MCR) 96,720 scfh based on 1,000 btu/ft 3 Minimum Gas Pressure Required at Connection (Regulated) 20 psig Maximum Gas Pressure Required at Connection (Unregulated) 35 psig Requirements for #2 Oil Firing: Oil Consumption (100% MCR) 660 gph based on 140,100 btu/gal Minimum Oil Pressure at Pump Inlet Positive pressure Maximum Oil Pressure at Pump Inlet 30 psig Pilot Gas Pressure Required for Oil Start-Up 2.0 psig Oil Atomization (Air) Minimum Air Pressure 80 psig Maximum Air Pressure 120 psig Air Consumption 85 acfm Minimum Capacity Required for Steam Atomization 25% Oil Atomization (Steam) - Steam Pressure Required 125 psig minimum Feedwater Requirements: Minimum Feedwater Pressure 75 psig above operating pressure Maximum Feedwater Pressure 100 psig above operating pressure Minimum Feedwater Temperature 228 F Pressure Drop Across Feedwater Regulator Valve 25 psi (approximate) Electrical Requirements - Single Point Connection: Electrical Amps - Gas Firing 100 Electrical Amps - Oil Firing 125 FD Fan 75 hp, 60 Hz Oil Pump (#2 Oil) 3 hp, 60 Hz Voltage 480V/3 phase/60 Hz Motor Starter Included for both FD fan and oil pump Dimensions Trailer Height 14'5" Trailer Width 10'7" Trailer Length 52' Shipping Weight 94,000 pounds (approx) Operating Weight 115,000 pounds (approx) Stack Diameter 3'
Scope of Supply Summary (Nebraska Boiler) Item Description Supplied By: Installed By: ESI Lessee ESI Lessee Trailer X X Boiler X On trailer Burner/fuel trains X On boiler/trailer Gas pressure reducing valve X On trailer Oil pump X On trailer FD fan and drive X On boiler FGR duct X On boiler Propane pilot Only Required if Natural Gas is not Available Safety valves X X Nonreturn valve X X Economizer X X Second stop valve X X Controls X On boiler Instruments X On boiler Burner management X On burner Feedwater regulator X On boiler Stack X X Feedwater pumps/supply X X Deaerator X X Water conditioning system X X Chemical feed system X X Utilities to trailer limits X X Steam flow meter X X Heat tracing X X Cribbing for trailer X X Foundations X X
Item Description Supplied By: Installed By: ESI Lessee ESI Lessee FD motor starter X On boiler Oil pump motor starter X On boiler Blowdown valves X X Remote drum level indicator X X Disconnect switch between rental boiler and power feed X X Pipe supports X X Atomizing media Only Required if Natural Gas is not Available Blowdown separator X X Platforms, ladder, handrail X Handrail only Safety valve vents X X Natural gas vent X X Nuts, bolts, gaskets, etc. X X Transportation permits Operational permits Freight charges Field supervisor Start-up representative X Per Diem Per Diem X X
Temporary Boiler Field Connections and Auxiliary Equipment to be Mounted (Nebraska Boiler) Field Connections Steam 8" Flanged Feedwater 2½" Flanged Natural gas 4" Flanged #2 oil 1½" Flanged Oil return ½" Flanged Atomizing air 1½" Flanged Blowdown 1½" Flanged Continuous Blowdown 1" NPT Chemical feed 1" NPT Electrical 480 V / 3 ph / 60 Hz 150 amps Auxiliary Equipment to be Field Mounted by Lessee One 6'6" high stack and transition assembly One 8" 300# steam nonreturn valve One 8" 300# main steam second stop valve Two 1½"bottom blowdown valves and piping Two ASME safety relief valves set at 350 psig One (1) flanged upper FD fan housing Handrails
Mobile Boiler Emissions Natural Gas #2 Oil NO x without FGR (lbs/mmbtu input) 0.15 0.20 NO x with 5% FGR (lbs/mmbtu input) 0.10 0.125 CO (ppm) 200 200 The above predicted emissions are valid only with the below listed assumed fuel analyses. Emissions using a different, specific fuel analysis can be provided upon request. Constituent Natural Gas (% Vol) #2 Oil (% wgt) CH 4 90 C 2 H 6 5 N 2 5 0.02 S 0.30 H 2 12.50 C 87.17 O 2 0.01 Btu/lb 21,746 19,460 Btu/scf 1,000
System Components Description Trailer The transportation and support trailer for the rental boiler is a 35-ton capacity tri-axle assembly with an air-ride suspension and manual override system. The trailer has dimensions of 52'-0" overall length by 8'-6" overall width by 26'-0" deck length. The main deck width is 54" and has a loaded fifth wheel height of 48" and a loaded deck height of 22½" (ground to top of rail). Four two-speed landing gear assemblies with cranks are installed at the front and rear of the deck of the trailer to provide support when the unit is in storage. The landing gear assemblies are not to be used for leveling the trailer/boiler. The trailer meets all DOT guidelines. Boiler The boiler is an "O" type design, watertube unit specifically designed for rental boiler applications. The unit is constructed with a welded membrane furnace and outside wall assembly, membrane water-cooled rear wall, and membrane water-cooled front wall. The unit is designed for operation between 125-325 psig with a system design pressure of 350 psig. Maximum capacity is 72,000 pph saturated steam based on an inlet feedwater temperature of 228 F at an operating pressure of 325 psig. The unit is manufactured by Nebraska Boiler, built in 1997. Burner and Fuel Trains The burner and windbox attached to the front wall of the boiler is a low NO x design, capable of firing natural gas or #2 fuel oil. The burner assembly includes the capability for air or steam atomization with air atomization being used for cold start-up on #2 fuel oil. The burner pilot system includes the provision for propane pilot in the event natural gas is not available. The natural gas burner system is a ring type burner with multiple spuds for optimum burner performance. The fuel oil and the atomizing steam trains are all welded construction as much as possible to prevent leakage and is constructed with steel valves wherever possible for longevity purposes. The main gas fuel train includes a PRV to regulate supply pressure for proper burner performance. The system can bypass the PRV if desired. The burner is manufactured by Todd Combustion, built in 1997. Forced Draft Fan and Electric Motor Drive The combustion air requirements are supplied by a windbox-mounted forced draft fan and 75 hp 480 volt electric motor. An inlet damper provides control of the combustion air based on firing rate requirements. The top portion of the forced draft fan housing is removable for shipment purposes and must be installed before fan operation. The fan is manufactured by Chicago Blower and includes static pressure provisions for addition of a future economizer. Flue Gas Recirculation System A flue gas recirculation system is included to extract flue gas from the boiler outlet and induce flue gas into the fan inlet to minimize nitrous oxide emissions. The flue gas recirculation system consists of a 10" diameter carbon steel duct and manually positioned butterfly damper.
Controls and Instrumentation The trailer-mounted boiler system includes all required combustion controls and instrumentation for automatic operation. The control system is a jackshaft positioning system. A steam pressure signal from the steam drum pressure transmitter is sent to the Moore Fieldpac master controller. Essentially, the Moore Fieldpac in turn sends a signal to the Beck actuator to adjust the firing rate in order to maintain steam pressure. The Beck actuator is connected via mechanical linkage to a jackshaft system which connects the fuel control valves and forced draft fan damper. The relative positions of the forced draft fan damper and fuel control valves are field adjustable by qualified service personnel to optimize operation throughout the boiler operating range. Burner Management System The flame safety or burner management system provided is a Fireye E100 system including an E300 annunciator for burner limits. The Fireye E300 will annunciate all alarms including low water alarm. Further, it will indicate the cause of a boiler trip and will display the reason for the trip until the unit is reset. This will assist plant operations personnel in troubleshooting. The burner management system is in full compliance with NFPA 8501. Feedwater Control System Control of the boiler feedwater supply is accomplished with a boiler-mounted electronic feedwater control valve. A transmitter responding to drum level conditions in the temporary boiler system sends a signal to the Moore Fieldpac which in turn opens or closes the control valve. The response of this valve is field set in accordance with the requirements at the specific site. An optional steam flow correction feature can be provided to enable two-element drum level control with both drum level and steam flow as inputs. Fuel Oil Pump and Drive A #2 fuel oil supply booster pump is provided, mounted to the trailer including a 3 hp electric motor drive. The pump is capable of supplying the required burner fuel flow at a discharge pressure of 150 psig based on an inlet supply pressure of 30 psig maximum and 0 psig minimum. Platforms and Access Ladder OSHA-approved platforms and access ladder are provided for the boiler rear drum head and right-hand side of the steam drum. Removable handrails (for shipment) are provided and required to be installed at the site for proper operation. Access to these platforms is via an uncaged ladder extending from the trailer main deck area. Electrical System A complete electrical system is included to receive 480 volt, three phase, 60 Hz power from an external source at the main electrical control panel mounted on the side of the windbox. A 480 volt to 120 volt transformer is included for operation of electrical auxiliaries requiring 120 volt power including burner front lighting and auxiliary electrical outlets for maintenance purposes. The motor starters for both the forced draft fan electric motor and fuel oil pump electric motor are included as are fusible disconnects as required. Grounding of the trailer is accomplished by a connection on the trailer deck to an appropriate site ground source.
Stack A single-wall 36" diameter by 6'6" high carbon steel stack and transition is included to be mounted on the boiler outlet flange. The stack includes four 1" instrument connections. Nonreturn Valve and Main Steam Stop Valve One Edwards 8" nonreturn valve is provided for mounting on the main steam outlet and connecting to the process steam supply. One 8" gate valve is provided, including vent port and shut-off valve. Safety Relief and Blowdown Valves Field-mounted safety relief valves are provided to be mounted to several of four potential connections on the steam drum for proper relief and installation of the temporary boiler system. Likewise, tandem blowdown valves are supplied to be mounted to the bottom drum blowoff connection. Valves All valves to the first valve point of the temporary boiler are included and installed for proper isolation and shutoff of drains, supply pressures, instrumentation, etc. All valves provided are fabricated from cast steel material included all welded piping as required.