Cheema Boilers: Boiler Upgrade Project - Proposal Engineer's Report

This report documents the experience of a Proposal Engineer at Cheema Boilers Ltd. during a project to upgrade a 12 TPH rice husk fired boiler to a 14 TPH petcoke fired boiler. The project's objective was to provide a techno-commercial offer to the client, including technical details for replacing or modifying boiler components. The engineer's responsibilities included tender activities, understanding steam requirements, preparing lists of components, costing, reviewing vendor prices, analyzing technical specifications, participating in meetings, estimating project costs, and providing technical support for thermal analysis. The report details the process of offer preparation, revisions based on client feedback, cost estimation, and addressing discrepancies in the purchase order, highlighting the engineer's role in ensuring project alignment and successful execution. The report also covers the scope of supply, technical meetings, and coordination with various departments.

C.E. 1.1 INTRODUCTION
Employer CHEEMA BOILERS LTD.
Place CBL head office, Mohali, Punjab
Duration 11 June 2013 – 30 July 2013
Position Proposal Engineer
CE 1.2 BACKGROUND
CE 1.2.1 OBJECTIVE OF THE PROJECT
This project involved the upgradation of 12 TPH, 45 kg/cm² rice husk fired boiler into 14
TPH, 45 kg/cm² petcoke fired boiler. Due to rise in demand of steam and increasing price of
rice husk, client wanted to upgrade the capacity of boiler and change the fuel feeding system.
As petroleum coke (petcoke) is a by-product in fossil fuel refining process, it was decided to
change the fuel of new boiler from rice husk to petcoke. The higher heating value of petcoke
ensure more efficiency in the plant and better utilisation of waste streams. The main aim of
this project was to provide a detailed techno-commercial offer to client. The offer included all
the technical details of the parts of the boiler that needed to be replaced or changed during
this modification. So, I worked on the technical offer with the help of my team members.
CE 1.2.2 ORGANISATIONAL STRUCTURE
Vice President
(Engineering)
Proposal
Manager
Proposal
Engineer (My
Role)
Junior Engineer Draftsman

CE 1.2.3 MY JOB RESPONSIBILITIES
1. To govern the tender activities for in-depth understanding of modification as per the
requirement of client.
2. To understand the steam requirement of the plant and technical details of the existing
boiler.
3. To prepare a detailed list of the boiler pressure parts and other components needs to
be replaced or changed during modification of boiler.
4. To prepare the technical offer for the modification as per the requirement of customer.
5. To do the costing of the modification as per terms and conditions mentioned in the
proposal.
6. To review all the prices of components and material from our registered vendors.
7. To analyse the technical specifications of different components such as fans, pumps,
water wall and layout and instrument drawings.
8. To be a part of meetings for submission of proposal.
9. To analyse the drawings and layout of boiler pressure parts and other instruments.
10. To estimate the complete cost of the project
11. To submit the final offer with general arrangement drawing and technical datasheets.
12. To assist the design department with technical support for thermal analysis of boiler.
13. After we got this order, I have gone through the purchase order and matched it with
my technical offer to check the scope and commercial terms and found few terms not
as per our offer. So, I made a deviation list and submitted to marketing department.
14. After that, I made the order check list and circulated to the relevant departments.
CE 1.3 PERSONAL ENGINEERING ACTIVITY
CE 1.3.1
Upon joining CHEEMA BOILERS LIMITED, I was assigned for an in-plant training. After
the completion of training, I was allotted the proposal department of company to utilise the
technical knowledge I gained during my studies and internship programs. There was dire
need of mechanical engineer with sound understanding of thermal design and offer-making
skills such as tender evaluation, cost estimation, proposal preparation and submission with
strong communication and inter-personal skills. Hence, I was designated as Proposal
Engineer reporting to proposal manager. I was responsible to work autonomously for
technical and commercial aspects of proposals and bidding of different projects and

instruments in our organisation. I was also accountable for drafting the offers, getting them
reviewed from manager and then submitting to marketing department. The project I worked
upon was to analyse the technical and commercial specifications for upgradation of 12 TPH,
45 kg/cm² rice husk fired boiler into 14 TPH, 45 kg/cm² petcoke fired boiler at M/s KBK
BIOTECH PVT. LTD.
CE 1.3.2
The main objective of project was to submit offer to increase the capacity of boiler from 12 to
14 TPH and change the fuel from rice husk to petcoke. The client aimed to upgrade the steam
generation plant with an efficient power generation source as per the increasing demand of
steam in plant for maintaining the quality and quantity. The requirement of upcoming steam
generation plant was to bear the load of different departments. The project demanded tender
preparation with overall documentation of technical and commercial details. So, after
analysis of tender, I forwarded electrical portion of the tender to electrical department as I
had to do the mechanical part in the tender. I was assigned limited time to complete the
project. For first few days, I went through the whole tender documents and drawings given by
client to get acquainted with different components of boiler. This enabled me to pass over
information to relevant personnel in the organisation and to get the project completed in
stipulated time.
CE 1.3.3
The project was of turnkey nature, so it comprised of all aspects such as design, Thermal
design, detailed engineering analysis, manufacturing, assembly and erection of different
parts, inspection of the boiler and equipment supplied and finally followed by testing and
commissioning. In the first stage of project, I went through the mechanical aspects of the
tender to understand the key factors for proposal and cost analysis. I concluded that
requirement of steam at full load, operating conditions of boiler such as pressure and
temperature, power system for fuel, supply methodology were important. I prepared a list of
existing items which were not suitable for use after the modification of boiler and needs to be
replaced these components were: -
 Boiler downcomers & Risers.
 Boiler Bank tubes.
 Air box assembly with Primary air nozzles, fuel nozzles drain pipes etc.
 Bed Coil assembly with inlet & outlet Headers.

 Bag filters for dust collection.
 Air pre-Heater assembly.
 Economizer coils with headers.
 FD & ID fans with Base frame & coupling hardware.
 Super Heater assembly along with headers.
 Water wall assembly.
 All Dampers & Expansion joints in Air & Flue gas ducting.
The following were the additional items or new items that were required for the
modification: -
 Screw Feeders along with motor and VFD and fuel spreading nozzle.
 Strengthening of fuel bunker.
 Air nozzles made from SS 310.
 High grader refractory made from Molite bricks.
 Auto as re-injection system.
 Petcoke disintegrator.
 Secondary combustion chamber for re burning of ash.
 Electrostatic precipitator for pollution control.
CE 1.3.4
Upon completing the technical offer, I started working on the scope of supply as per the
tender requirement. After analysation, I found out that some of the components that can be
used without any changes required.
 Mud drum.
 Steam drum with internals and all its mountings (i.e. Level gauges, Safety valves,
Blow down valves etc.).
 De-aerator with storage tank.
 LP & HP dosing system.
 De-aerator Pressure & Level control valves.
 Sample coolers.
 Blow down tank.
 All Isolation, By-pass, Check valves & drain valves for Boiler & accessories.
 Steam line Flow nozzle, & feed line orifice flow meter.

The major specifications I observed were: multi-stage feed water pumps, boiler shell and
water wall, draught control systems, motor control centre and control panel, types and
number of valves required, dust collectors, instrumentation required. Further, I concluded that
miscellaneous accessories such as supporting platform, duct installation for air and flue gas,
cladding and insulation of pipes and wires, refractory, water storage tank, water softener and
painting at final stage. Finally, erection and commissioning of project was required. I was
told to figure out the use of the existing equipment. So, I prepared a list of components which
can be used as it is without any modification to reduce the time and cost of the project. The
major existing components for boiler were chimney, Mud drum and steam drum. For
preparation of technical datasheet and industrial drawing, I coordinated with junior engineer.
He provided the required information in due time also supervised the draftsman for
preparation of drawings. I reviewed the drawing and data sheets thoroughly before being
submitted to client. Also, electrical engineer and commercial department gave me their
deviation list and I combined all the deviations in the technical offer.
CE 1.3.5
I submitted the technical offer to our Hyderabad office. Upon the submission, I had technical
meeting with client to clarify the technical points and scope of supply. Following were the
outcomes of the first meeting.
1. Implementation of belt weighing system to check the weight of fuel in fuel storage
system.
2. To incorporate the installation of Electrostatic precipitator in CBL scope of supply.
3. The material of secondary super heater should be changed to SA213 T-22 rather than
SA 213 T-11 as it gives more life to super heater tubes.
4. Dampers and Expansion bellows of FD and ID fan to be supplied by CBL.
5. Steam Pressure at secondary super heater should be 45 Kg/cm².
CE 1.3.6
The next stage involved cost estimation and I worked on the various aspects such as
approximate weight of boiler shells, water wall, pre-heaters, fuel feeding systems, supporting
platforms, ducted systems and exhausts. Then, I researched on the cost of different metallic
components and tubes such as SA 210 Gr. A1 tubes for bed coils, SA 515 / 516 grade 70
plate for casings, SA 106 grade B for headers, SS 310 for Air nozzles, Sa 213 T-22 for Super

heater coils and IS 2062 for chimney and platform. Further, I acquired quotations for other
accompanying instruments such as valves, motors and pumps to understand the variability in
price. I revised the technical offer and resubmitted to our Hyderabad office. Further, I helped
the marketing team with some technical issues raised in the meeting such as prominent heat
transfer areas, size of water wall height increased to 9950mm, height of boiler. Upon
receiving the approval on technical offer, I submitted the price bid with commercial wing of
organisation. I also included taxes and duties involved on different components with
assistance of commercial wing. The steam pressure at outlet was kept at 45 kg/cm2. The inlet
temperature of feedwater was kept at 105 °C.
CE 1.3.7
In addition, cooling water and piping, Ash hoppers, Refractory was in client scope. To
understand the number of vehicles required for transportation of material, I worked with
draftsman to prepare the drawings for stacking of boilers in the vehicle. This results in
detailed information about:
1. Number of transportation vehicle required for moving whole material.
2. Approximation of transportation cost.
3. Arrangement of material in the vehicle i.e. dimensions of different components during
transportation.
In the next step, I drafted the costing sheets and submitted to my project manager. I was
suggested to raise the Electrostatic precipitator costs due to variation of prices internationally.
Thus, I increased the price with a small value to avoid any loss due to volatility in market.
Thereafter, I combined all the documents into a single proposal and made the techno-
commercial offer. I submitted the final documents to our Hyderabad office, which was later
forwarded to client by them.
CE 1.3.8
I received some suggestions from marketing office regarding costing, so, I revised the bid
document accordingly. The document was submitted to client for clearance. Finally, I
received the acquired the offer and was asked to work on installation and commissioning. I

figured out some errors in purchase order by client and communicated the same with
marketing office and client.
1. It was suggested initially to incorporate all the gas and air ducting in CBL scope, but
it was considered in client scope.
2. Dismantling of Existing components mentioned as responsibility “CBL”, whereas it
was responsibility of client.
3. Similarly, Ash conveying pipelines were mentioned as responsibility of “CBL”,
which was not the case actually.
I communicated these issues with marketing office and asked to make amendments in the
purchase order. Upon receiving the revised purchase order, I started working on my checklist
as per scope of supply and communicated same with various departments such as design,
project, production, marketing and purchase. The seismic co-efficient of horizontal design
was kept as IS-1893-2002. The furnace of boiler consisted Air box, fire doors, nozzles etc.
CE 1.3.9
The project required high levels of coordination and professionalism to get work done in a
timely manner. I worked with other team members coherently and assisted with technical
expertise when required. My subordinates commended me for guidance. Because of in-depth
understanding of technical aspects and project management skills, I was able to complete the
project in required time and minimum cost. I supervised the junior engineers and draftsman at
regular periods and reviewed the work to have error free drawings. I helped draftsman for
issues, he was facing in AutoCAD. I used MS Project for planning the different activities in
the project. Also, I reported to my manager every week for project progress. I performed the
performance testing of boiler in PTC 4.1 software.
CE 1.3.10
I was aware that even though the project demanded autonomous work, the importance of
subordinates and fellow colleague was also crucial for successful delivery of project. Further,
I was careful about small mistakes which could result in not receiving the purchase order. To
maintain the professional integrity and I worked with other colleagues in best manner to
conclude the project as per standard technical parameters and competitive cost.

CE 1.4
SUMMARY
Upon the completion of project, I was able to showcase the management of limited resources,
client management and negotiation, interpretation of information and time management for
successful delivery of project. My result-oriented approach was commended by project
manager and I was appreciated for completing the project in a timely manner.
C.E. 2.1 INTRODUCTION
Employer CHEEMA BOILERS LTD.
Place CBL head office, Mohali, Punjab
Duration 17th August 2015 – 29th September 2015
Position Proposal Engineer
C.E. 2.2 BACKGROUND
C.E. 2.2.1 OBJECTIVE OF THE PROJECT
The main objective of this project to setup a new 6 TPH (From and at 100°C) water cum
smoke tube boiler plant near Delhi with the all the accessories required for the boiler plant to
work. The aim of the project was to provide the company with the technical-commercial
offers of the 6 TPH boiler with all the required documentation in a particular period of time.
The team was included in the process of tender making and with the expertise of the whole
team, I was able to complete the techno-commercial bids. The boiler was to be installed in
M/s Relaxo Footwears Ltd.
C.E. 2.2.2 ORGANISATIONAL STRUCTURE

C.E. 2.2.3 JOB RESPONSIBILITIES
My job responsibility in this project were relating to these activities:
15. To study the enquiry very carefully to understand the requirement of the client.
16. After Detailed analyse, Distribution of work to team members as per their experience
in the related field.
17. To coordinate within a large team and make them understand the requirements of the
project.
18. To understand the steam requirement of the plant and technical details of the boiler.
19. To prepare a deviation list, the items which were not required for a petcoke fired
boiler.
20. To calculate the appropriate capacity for fans, pumps water and boiler wall.
21. To prepare the technical offer for the boiler as per the requirement of customer.
22. To do the costing as per terms and conditions mentioned in the proposal.
23. To review all the prices of components and material from our registered vendors.
24. To analyse the technical specifications of different components such as fans, pumps,
water wall and layout and instrument drawings.
25. To be a part of meetings for submission of proposal.
Vice President
(Engineering)
Proposal
Manager
Proposal
Engineer (My
Role)
Junior Engineer Draftsman

26. To analyse the drawings and layout of boiler pressure parts and other instruments.
27. To estimate the complete cost of the project
28. To submit the final offer with general arrangement drawing and technical datasheets.
29. To assist the design department with technical support for thermal analysis of boiler.
30. To attend the technical meetings with client and resolve some client’s doubts and
make list of items to be included in revised offer.
31. To make the revised offer based on our meeting with client.
32. To help my juniors and draftsman to prepare the project drawings in given time
period.
33. After we got this order, I have gone through the purchase order and matched it with
my technical offer to check the scope and commercial terms and found few terms not
as per our offer. So, I made a deviation list and submitted to marketing department.
34. After that, I made the order check list and circulated to the relevant departments.
C.E. 2.3 PERSONAL ENGINEERING ACTIVITY
C.E. 2.3.1
After realizing my technical skills form the previous project work, the management has given
the sole responsibility of the project. This episode describes one such opportunity that I was
granted by the management. This was my fourth project in the industry which included the
six TPH system generation for the boiler that was supplied to the other city and state. After
receiving the enquiry documents from the marketing manager, I started to go through the
requirements for the project. It took me three days to breakdown the tender in three different
parts. These three parts included the mechanical, electrical and commercial sides of the
project. This helped the project to operate smoothly with better sight into the requirements. I
considered high head for ID fan to accommodate the pressure drop of wet bath scrubber. I
decided to keep flow rate of steam was 6000 kg/hr and steam pressure of 10.54 kg/cm2. The
fuel feeding system of boiler was selected to be petcoke with net calorific value of 8000
kcal/kg.

C.E. 2.3.2
The next part of the project was to establish the in-depth study of the client requirement. It
involved recognizing the department with respect to the requirements. The electrical work
was sanctioned to electrical department and mechanical and commercial part of the enquiry
was managed by me. I chose to select atmospheric fluidised bed combustion for boiler
system. Further a horizontal shell type water cum smoke tube boiler was chosen. My junior
helped me with the detail datasheets for the mechanical part of the tender.
The cost estimation and other offers were made on the rigorous and detailed study of the
enquiry document for mechanical department. I understood factors required for the project
which were important for the convincing execution of the project, these factors are as
follows:
 Technical specs of the boiler with the accessories included.
 Limits of the battery, supply scope and exclusion items.
 The fuelling system required by the client, over bed or under bed fuel.
C.E. 2.3.3
After carefully reading the document’s mechanical part, I came up with a nonconformity list
that has few points which were not related to the boiler project. I identified few terms and
items such as 70% of the humidity level, de-aerator, boiler bank, economizer which were not
required in process boiler. I also collected the nonconformity list from other departments such
as electrical and commercial, to put together the techno-commercial deal for the client. After
the completion of the technical and commercial documents, I forwarded it to the office in
Delhi for people to handle the commercial side of the deal with insight from the customer.
For water wall construction, I chose fin welded member wall construction and shell was
designed as per IBR 1950 and I chose the over bed fuel feeding system for this boiler.
C.E. 2.3.4
After the customer gave the clearance on the documents of deviation, my team and I started
to build the strategy to reduce the time by making few decisions and started making
important documents. Drawing were prepared, data sheets and cost was setup and calculated
for the project. My role was towards the mechanical side of the project, which included the
setting up of boiler shell, water wall and APH sizing. I also helped in calculating the flow,
head, and motor rating for ID, FD and PA pumps. After the calculations were finished, I took

part and collaborated in making the boiler size and also prepared the general arrangement
drawing and piping and instrumentation diagram of the boiler. The boiler was laid out as
demanded by customer with all the specifications mentioned in the tech-commercial
documents. I also guided the draftsman to prepare the general arrangement drawings as
required and scoped for the particular project. For scope of supply, I excluded following
items:
 Air & flue gas ducting with required supports.
 All insulation / lagging wherever required.
 Steam and feed water piping, drain and blow down, vent piping.
 Boarding and lodging of our staff at site.
 Chimney, Water tank, Water treatment plant & its related piping.
 Fuel storage Bunker.
 Ash handling systems.
C.E. 2.3.5
When finished entire method of computation, data sheet tops off, diagrams and so on, I had
begun to set up an appropriate specialized proposal in Microsoft word file. I had contained all
remark and illuminations, technical parameters, information sheet, extent of supply, rundown
of battery limits, water quality, eliminated things and so forth in offer. My manager had
checked every technical parameter, information sheet and significant calculations before
sending it to client. After the preparation of the technical documents I had forwarded them to
the Delhi marketing office, which was set to be shown to the client for their approval on the
boiler scope. It laid the key points for the clients to give them overall picture for the project.
The few of them are: Air and water pre-heater, boiler drum with membrane wall of water,
PA, FD and ID fans, under bed fuelling system for feeding, all valves and mountings, sonic
soot blower, boiler steam drum, electrical panel to control power, dust collector, commission,
erection, maintenance and operation spares.
C.E. 2.3.6
During the first meeting with the client, the client mentioned that the company will be
burning petcoke as their primary fuel. So, if the petcoke gets moisturised, it can make some
hard lumps, which can chock the fuel feeding lines. So, I told client to install a petcoke
disintegrator in order to solve this problem. Also, client wants to install the wet bath scrubber
as an additional dust control. So, I figured out that an ID fan of high head is required in order