BUDGE BUDGE INSTITUTE OF TECHNOLOGY DEPARTMENT OF MECHANICAL

ENGINEERING, 4TH YEAR -: PRESENTATION ON :- CASE STUDY OF A CONDEMNED BOILER &

METHODS TO RE-ESTABLISH IT.

SUBMITTED BY:Aditya Bhattacharjee- Roll No: 27600712006Argha Das - Roll No: 27600712016Indranil Chakraborty - Roll No: 27600712038Sudipta Raha - Roll No: 27600711053

DATE: 11/06/2016

UNDER GUIDENCE OF: Prof. Mr. DEBAJIT BANERJEE

CONTENTS Acknowledgement Introduction Abstract of HSDCL Definition of Boiler Specification of Boiler Flow Diagram of the process Boiler Accessories Scope of work for Boiler maintenance & repairing

I. Dismantling of Boiler & its accessories II. Pressure test of Ducts & stream pipeline

Scope of work after renovation I. Flue Gas AnalysisII. Boiler Tuning

Conclusion Bibliography

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ACKNOWLEDGEMENTWe are using the opportunity to express Ours's gratitude to everyone who supported us throughout this project. We are thankful for their aspiring guidance, invaluable constructive criticism and friendly advice during project work. We are sincerely grateful to them for sharing their truthful and illuminating views on a number of issues related to this project. I expressed my warm thanks to Director Mr. ALOK SARAF ; Project Co-ordinator Mr. VEDANT SARAF ; GM Mr. S.C.CHANDRA & engineers Mr. Natwar Gupta ; Mr. Debabrata Das ; Mr. Anway Chakraborty for their support and guidance at Hindustan Storage & Distribution Co. Ltd. I would also like to thank my project guide Mr. Debajit Baneerjee from the Budge Budge Institute of Technology and all the people who provided me with the facilities and conductive conditions for this project. Thanking You,Aditya BhattacharjeeArgha DasIndranil Chakraborty Sudipta Raha

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INTRODUCTIONBoiler is one of the most important devices in a power plant or in industries where a source of stream is required as a source of heat.It is the a device used to create stream by applying heat energy to water and the heat is supplied from the combustion of fuel. Hence brake down of boiler at any time may leads to severe damage to the industrial processes. Hence our project reflects the detail procedures to re-establish and start-up a condemned boiler such that it fulfil the industrial need by maximizing the economy while maintaining fuel economy.

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ABSTRACT ON HSDCLHindustan Storage & Distribution Company Ltd is a Public

incorporated on 07 December 1982. It is classified as Non-govt. company and is registered at Registrar of Companies, Kolkata.Directors of Hindustan Storage & Distribution Company Ltd are Alok Saraf, Sawarmal Agarwal. This company is basically a oil storage & distribution company which import and exports a various kind of edible oils, lub oils and chemicals. The products are stored in several tank with capacity range 500 kl to 8000 kl. The company have pipelines of 2.5 Km almost from Jetty to their storage tank.Product type: CPO- Crude Palm Oil RBDPO- Refined Bleached Deodorized Palm Oli LAB- Linear Alkyl Benzine LUBE- Lubricant Oil Ketrul D-80 SUPER SPIRIT

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REQUIREMENT OF BOILER AT HSDCLDefination Of Boiler: A boiler is an enclosed container that provides a mean fro heat of combustion

to be transferred to the working medium(water) until it become heated or convert in steam.

The heated steam can be utilized for transferring the heat in several processes that consume the heat of the stream and turns in work or just to heat another substance.

Requirement of Boiler: The products like CPO & RBDPO which are stored in the company have slip

melting point at about 35 degree centre grade .That means during winter seasons as the atm. temperature falls below 35 degrees they starts solidifying and about 15-16 degrees of atmospheric temperature the oils get solidified. Hence hot steam under pressure is used to melt the oils. To generate the hot stream a package boiler REVOMAX PLUS is installed in the site.

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SPECIFICATION OF BOILER

REVOMAX PLUS (STEAM GENERATOR)Model: R*D-850/164Type: Package stream generatorManufacturing Year: 2003Fuel: Furnace Oil Rating: 415V ; 3 Phase ; 50 HZCapacity: 850 kg/hrDesign pressure: 10.54 -17.50 kg/cm^2Fuel Firing System: Pressure Jet-Reverse Flue,Dual BlockMake: Thermax Ltd.

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(A) Study of the Boiler Accessories Combustion Chamber: It internal space of

the boiler where combustion take place. Steam coil: The coil through which the

water circulates and heats up to form stream .It is made up of mild steel .

Economizer: Heat exchanger(shell tube type) to preheat the feed water before it enters the combustion chamber by recovering the heat of flue gas.

Heat Optimizer: Preheat the water entering the economizer and optimize the temperature of water leaving the economizer and entering the feed water pump.

Feed water pump: 3 cylinder ,positive displacement, reciprocating pump to feed the water to the steam coil at desired pressure and rate.

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Combustion Chamber

Economizer

COIL

Feed Water Pump

Burner Gun: It is a heating device which burns the fuel oil. The fuel is atomized through the nozzle under pressure and it is ignited by electric sparks generated by 2 sets of electrodes.

Oil Filter: They minimize the dirt and water that can enter into the boiler fuel system. This not only maximizes the efficiency of your furnace but its longevity as well.

Water Softeners: Removes the minerals calcium, magnesium and metal cations from hard water. This is very essential to eliminate the formation of scales on the equipments.

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OIL FILTER BURNER GUN

(A) Study of the Boiler Accessories

WATER TANK

WATER SOFTNER

ANION

CATION

HEAT OPTIMIZER

BOILER

ECON

OM

IZERFEED

WATER PUMP

CHIM

NEY

FUEL TANK

FILT ER

FUEL PUMP

OIL PREHEAT

ER

STEAMLINE TO TANKS

FILT ER

WATERFUELFLUE

FLOW CHART OF THE PROCESS 10

(B)Scope of work for Boiler maintenance & repairing

(1)Dismantling of Boiler & its accessories: Boiler parts and accessories were dismantled using overhead chain-pulley & gas cutter.

(2)Pressure test of Ducts and Steam Line:Commenced by using compressor, manifolds, pressure gauges, temperature recorder.

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Results of Dismantling of Boiler & its Accessories

Results after Dismantling of Boiler & its accessories EQUIPMENT OBSERVATION TEST STATUS

OUTER JACKET Damaged due to rusting Replaced

INTERMEDIATE JACKET Ceramic insulations are damaged To be renewed

STEAM COIL Rusting & Scales Pressure Tested Found OK

ECONOMISER Outer Cover & Inside Cover damaged due to rusting Complete set-up was replaced

CONTROL PANEL All circuits are intact Checked by Electricians Found OK

PUMPS(Reciprocating Water Pump & Fuel Pump ) Unused since long days Operated on No Load

conditionShaft was moving at required speed(rpm). Hence it is found

OK.

SENSORS Damaged due to no longer use Checked by Electricians Replaced with the new one.

INSULATIONS Glass wool insulations are totally damaged Replaced

BURNER ASSEMBLY In good shape Found OkPRESSURE GAUGES Working Found OK

WATER SOFTNERS Anion and cation exchanger are damaged

Tested by specialized technicians Replaced

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Images of damaged parts of Boiler13

14Images of damaged parts of Boiler

(B)Scope of work for Boiler maintenance & repairing

(2)Pressure Test of Ducts & Streamline:Pressure test of Ducts & streamline are conducted.Process: Compressed hot air at around 50 degree centigrade was allowed to pass through the stream line while all the valves were closed.Pressure gauges and temperature recorder were installed at the inlet and outlet of the pipelines.The operation was commenced at 1.5 times higher than the design pressure of the system. RESULT:Pressure drop, temperature drop & several leakages were found. Therefore hence total insulation has to be replaced & the pipeline has to be repaired by arc welding.

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(C)Scope of work after Renovation:

Flue Gas Analysis

Boiler Tuning

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Flue Gas Analysis

PURPOSE: Increase fuel economy. Decrease undesirable emissions. Improve safety of burning equipments.

OBJECTIVE: Combustion analysis involves the measurement of gas concentrations, temperatures

and pressure for boiler tune-ups, emissions checks and safety improvements. Parameters that are commonly examined include:

Oxygen Carbon Monoxide & Carbon Dioxide Exhaust gas temperature Supplied air temperature Nitric Oxide Nitrogen Dioxide & Sulfur Dioxide

FLUE GAS ANALYSIS

THE ORSAT ANALYZEROBJECTIVE: To manually sample CO2,O2 & CO from the flue of a combustion system.

PROCEDURE: The sample of gas extracted from flue is allowed to bubble out through the

solution of reagents that selectively absorb each gas. The amount of gas absorbed is indicated from which stack gas concentration

is calculated.

ABSORBENTS: Potassium Hydroxide absorbs Carbon dioxide Alkaline pyrogalic acid absorbs Oxygen Cuprous Chloride absorbs Carbon monoxide

(A) MANUAL GAS MEASUREMENTS

COMBUSTION ANALYSIS CALCULATOROBJECTIVE: To analyze combustion routinely for tune-up, maintenance & emission monitoring

PROCEDURE: This instrument are extractive. The remove the sample from

stack or flue by vacuum pressure and the analyze the sample using electro chemical sensors.

Thermocouple used for the stack and flue temperature. Pressure transducer is used for draft measurement. On board computer performs the combustion calculations.

(B)PORTABLE ELECTRONIC EQUIPMENT:

OBJECTIVE: To measure exhaust stack gas and temperature continuously.

PROCEDURE: CEMS uses extractive as well as internal stack sensors a along with various electronic technologies for gas detections. CEMS are often used in larger installations.

(C)CONTINUOUS EMISSION MONITORS

COMBUSTION PARAMETERS THAT ARE EXAMINED

Excess Air Carbon Dioxide Concentration Combustion Efficiency Emission Rate Calculation

DEFINATION: The percentage of excess air needed above the theoretical

amount for complete combustion of fuel.

REQUIREMENT: To ensure complete combustion of fuel as insufficient

combustion air causes a reduction in combustion efficiency, produce highly toxic carbon monoxide and produce soot.

CALCULATION: Excess air can be calculated by measuring the amount of non-

reacted O2 in flue gas.

(A)EXCESS AIR

FORMATION: Carbon dioxide forms when the carbon in the fuel combines with the

oxygen of the combustion air. Maximum possible CO2 concentration depends on the carbon content of

the fuel.

REQUIREMENT: CO2 concentration is required for the calculation of combustion

parameters and to monitor the amount of CO2 in the exhaust as CO2 is a pollutant.

CALCULATION: CO2 concentration is determined using o2 concentration.

(B)CARBON DIOXIDE CONCENTRATION

REQUIREMENT: The combustion efficiency determine how effectively the energy from fuel is converted

into useful energy to produce required amount of steam. Cost effect way to improve equipment operation. Reduce fuel expenses.

CALCULATION:

STACK/FLUE HEAT LOSS = Lg+Lh+Lm+Lco Lg = heat loss due to dry gas Lh = heat loss due to moisture from burning hydrogen Lm = heat loss due to moisture in fuel Lco = heat loss from the formation of carbon monoxide

FUEL HEATING VALUE - Heigher heating value(HHV) or Lower heating value(LHV)

DETAILES ARE PROVIDED IN THE REPORT

(C)COMBUSTION EFFICIENCY

CALCULATION:

E=Emission Rate(KJ/kg) Cg=Gas Concentration(PPM) Ft=Emission Rate Conversation Factor

CORRECTED GAS CONCENTRATION:

(D)EMISSION RATE CALCULATION

BOILER TUINING

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BOILER TUNE-UPWhat is Boiler tune-up?• Boiler tune up refers different aspects of improving and

starting up the boiler operations.• The tune –up activity is the act of re-establishing the

air-fuel mixture for the operating range of boiler, oxygen and unburned fuel are balanced to provide safe and efficient combustion

Primary Objective: • To improve the boiler efficiency with economically

consumption of fuel while providing the desired effect.

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STEPS OF TUNE-UPPREPERATIONS:• Study on the boiler & its accessories, operation process.• Assemble boiler & burner drawings, data sheets ,combustion

control information, environmental regulations and limitations and other important data.

• Renovation strategy and tests.

OBSERVATION: on the basis of tests performed• Examine the combustion control components, boiler general

components & burner internal components and fix up the defect found.

• Measure and record the CO,CO2 ,O2 & emission content for proper control of combustion.

• Maximum utilization of flue gas for maximum heat recovery.

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STEPS OF TUNE-UPTUNE – UP:• Tune – up each operating position of combustion control system.• Establish steady operation for the target operating point• Adjust combustion control position relationship to achieve

desired combustion characteristics. • Flue gas O2,CO & NOx content should be within manufacturer’s

specifications & limits specified in environmental laws.• Adjustments for emissions control are generally completed after

combustion adjustments are established. DOCUMENTATION :• Documentation of test results before and after tune up.

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CONCLUSIONBoiler or steam generator is an integral part of most of the core industries like power plant, steel plant etc. As machines are always susceptible to damages ,any problem related to boiler will hampers the total process of production or service in an industry.We are highly honoured to be part of the project which deals with immediate steps to repair, renovate and re-establishment of small industrial package boilers. From the project we have learned basic ideas about stream generator ,its working processes, requirement in industries, individual parts and their functions and the means to improve the efficiency of the boiler while maintaining the environmental laws and pollution act.The project has immensely helped us to use our theoretical knowledge and skills in practical field while dismantling the boiler parts and analysis for any defects and needful works for their repair.Overall it has been a great learning experience and gain a lot of experience which we can utilize in practical field in future.

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BIBLIOGRAPHY Brochure on REVOMAX PLUS by Thermax ltd. “Stream Generator Unites", American society of Mechanical

Engineers, New York,1991 “Flue and exhaust gas analysis", American society of Mechanical

Engineers, New York,1981 R. k. Raj put, thermal engineering S. Domkundwar , A. v domkundwar, s. c Arrora, power plant engineering P. c Sharma, power plant engineering Thermal engineering- R.S Khurmi/J.s gupta/s.chand Thermal engineering-M.L. Mathur &Mehtal/join bros

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