TRAINING SEMINAR ON BOILER DEPARTMENT. Training at BANAS DAIRY, IMT, FARIDABAD

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INTRODUCTION

 Boiler is a closed vessel in which water is converted into steam by utilising the heat of fuel combustion.

 _{The steam under pressure is then usable for}

transferring heat to process.



_{Type :}

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Fire Tube Boiler

 A fire-tube boiler is a type of boiler in which

hot gases from a fire, pass throug tubes running through a sealed container of water.

 The heat of the gases is transferred through the

walls of the tubes by thermal conduction,

heating the water and ultimately creating steam.

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BOILER DETAILS

 Type: 3 pass Fire tube boiler, fully wet back  Quantity : 2 nos.

 Model : SM-80DH/10.54KG/CM²

 Fuel Used : Furnace Oil (F.O.) / PNG  Capacity : 8000 kg/hr

 Design pressure : 10.54 kg/cm²

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Boiler installed at our plant BURNER

BOILER

OPH

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Boiler System Consist Of

1. Feed water system 2. Fuel system

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Feed Water System

 provides water to the boiler and regulates it automatically to meet

the steam demand. Various valves provide access for maintenance and repair.

 Flow diagram:

Soft water from WTP at pre. 3-4

kg/cm²

15 KL feed water storage tank

Feed water pumps 2 nos. (1W+ 1S)

BOILER

Feed water Quality: Hardness : <10 ppm

pH: 8.5 to 9.5 TDS: 100 ppm

Steam supply for water heating Flow:850 kg/hr

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F.O. Fuel System

 Flow diagram:

Unloading tank 1 KL

Ring main pump Capacity: 1.5KLPH 2 nos. (1W+1S) Transfer Pump Capacity : 5 KLPH 2 nos. (1W+1S) Burner F.O. Storage tank

2X50 KL

Return fuel oil from burner

Service (Day) tank 4.5 KL

Closed small tank

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Steam system

 collects and controls the steam produced in the boiler. Steam is

directed through a piping system to the point of use.

 Flow diagram: BOILER Steam to production unit Steam to boiler PRS Main steam header

Steam stop valve

To process PRS

To CIP PRS To PACKING PRS

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BURNER

Function:

- Mixing oil and air in proper proportions. - To produce heat by combustion of fuel & air. - Forced Draft air is forced in to combustion

chamber.

_Design:

 Fully automatic & step less modulating (20 to 100%)

 High pressure atomizing (jet), means oil is atomized by nozzle

and vaporization occurs in combustion space.

 Forced draught combustion air blower with motor  Nozzle

 Ignition transformer with electrode  Solenoid valve

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COMBUSTION

 High speed fuel oxidation that produces light, heat & flame.

 Three necessary components require for combustion:

1. Oxygen ( Air) 2. Ignition

3. FUEL

 Four important factors that control combustion

1.Air supply

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BOILER MOUNTINGS

 Boiler mounting are required for

 the complete controlling of steam generation,

 measurement of some of the important properties of steam,

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 According to IBR following mountings should be fitted to the boiler,

1. Two safety valve:

Function : To blow off steam when the pressure in the boiler

exceeds the working pressure.

2. Two water level indicators:

Function: Indicate the water level in boiler.

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3. Pressure gauge:

Function : Indicates the pressure of steam in boiler.

4. Steam stop valve:

Function: To stop the flow of steam from the boiler to main steam header.

5. Feed check valve:

Function: Control the supply of feed

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6.Blow down valve:

Function: continuous use to control the concentration of dissolved

solid in boiler water.

7.Fusible plug:

Function: To protect the boiler against damage due to over heating

caused by low water level in boiler.

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BURNER TRIP

 Mobery controller : boiler water level

low & extra low

 Photocell : flame failure  Flue gas temp. high

 Burner return oil pressure high  Ring main pressure low

 Furnace oil temp. low- OPH outlet  Flue gas outlet damper closed

 Instrument air pre. Low

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BOILER CONTROLS

 Sequence control

 Feed water level control  Pressure (firing ) control  Trim control

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Performance Evaluation of Boilers

• The performance parameters of boiler, like

efficiency and evaporation ratio reduces with

time due to

– poor combustion,

– heat transfer surface fouling and – poor operation and maintenance.

• There are two methods of assessing boiler efficiency.

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EFFICIENCY

1. Direct method:

Efficiency = Q X (hs – hf) X 100 % q X GCV

Q= Quantity of steam generated per hour (kg/Hr) q = Quantity of fuel used per hour (kg/Hr)

hs = Enthalpy of Dry saturated steam ( kcal/kg) hf = Enthalpy of feed water (kcal/kg)

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2. Indirect method :

ɳ = 100 – (L1+L2+L3+L4+L5) L1= Stack Loss

L2= Un-burnt loss L3= Enthalpy loss

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THANK YOU

Prepared By : ARIF UMATIYA