REPORT

ON

INTERNSHIP

IN

BOILER HOUSE

&

COAL PLANT
AT

AUROBINDO PHARMA LTD. UNIT V

PASHMYLARAM

BY

[Link]

DEPT: MECHANICAL ENGINEERING

VNR VJIET

BACHUPALLY

FROM

19-06-2018 TO 02-07-2018

MENTOR: P.N.V. SRINIVAS RAO

AIM:

The aim of my training is to seek the answers to the following questions

1. What is boiler and what are the devices present in boiler system?
2. How energy is developed in boiler?
3. How steam is generated in boiler?
4. How energy is saved to reduce the fuel and feed water consumption?

DETAILED EXPLANATION AND OBSERVATIONS:

Boiler is a closed vessel where the fluid(water) is heated and converted to its gaseous
phase(steam). Boilers are mainly used in chemical and power plant industries. There are
various types of boilers depending upon various factors like nature of use, position of water
and flue gases, nature of fuel used etc. Boiler which I observed was a bi-drum water tube
fluidised bed boiler of maximum capacity of 24TPH. Fluidised bed means sand in the bed will
be in fluidised state. This fluidised state is acquired by passing the air into bed through air
nozzles. Fuel used in the boiler house is imported coal. The reason behind the usage of imported
coal is most of the Indian coal produced have low calorific value, higher ash content and high
moisture content when compared to imported coal which means before the usage of Indian
coal, it should to be dry in order to improve the quality of coal which brings the loss of time
and money when compared to the usage of imported coal.

Pocket feeding is the type of fuel feeding is done in this boiler.

In this type small pockets of coal are sent into the boiler using pressurised air which is generated
by pa fan which is discussed later in the report. Externally fired type of boiler is used in our
plant as the furnace is neither wholly nor partly surrounded by water. High pressure boiler with
maximum pressure range of 10-12 kg/cm2 is used in our plant. Dimensions of boiler bed is
around 4000*[Link] is observed that the in heating surface, area of integral economic assy-
198m2 , bank tube assy-273m2 , water wall assy-165m2 . Two safety valves are located at steam
drum with orifice of 100/150 m, set pressure of 11.50 kg/cm2 and 12 kg/cm2 and reliving
capacities of 15468 kg/hr and 16085 kg/hr.

Designing boiler mountings is a part of boiler design which explains about the
mechanical appliances which are essential for operating a boiler smoother and safer. These
appliances are mounted on the surface of the boiler.
Function of each boiler mounting is given below as follows:-

 Water level indicator: It indicates the level of water inside the boiler drum.
 Main steam stop valve: It regulates the flow of steam from boiler to steam pipe or one
steam pipe to another one.
 Safety valves: They guard the boiler against the excessive high pressure of steam inside
the drum. If the pressure of steam in the boiler drum exceeds the working pressure, then
the safety valve allows blow off the excess quantity of steam to atmosphere.
 Pressure gauge: It indicates the pressure of steam in boiler.
 Blow off cock: It is used to discharge the sediments deposited in the bottom of water
space in the boiler.
 Feed check valve: It controls the supply of water from the boiler when the feed pump
pressure is less than boiler pressure or pump is stopped.
 Fusible plug: It is use to protect the boil against damage due to overheating caused by
low water level in the boiler.

My mentor then explained about the boiler accessories which are

the crucial part for running of boiler. Boilers Accessories are those appliances which are
installed along with the boiler to improve the operating condition and overall efficiency of
the boiler plant.

Feed pump: It is one of the crucial part which delivers feed water to the boiler. The water
sent into the feed pump may be freshly supplied or returning condensate i.e. after
condensate recovery the water is again used as feed water. To force the water into the boiler
the pressure in the pump must be greater than boiler pressure hence most of the feed pumps
are of centrifugal type. The pump is shaft coupled with a motor where the motor helps in
driving the pump with some electrical power. When there is minimum flow of water it
returns the water to deaerator tank. Even condensate pump can also be used as feed pumps.
Feed check valves are attached to feed pump to regulate the flow. The water supplied must
have a pH of 7(approx.) so as avoid corrosion in the pump. In our plant I have observed
feed pump which is connected to steam drum through economiser. These pump are high
pressure pumps comparative to pumps in our apartments or houses as they draw huge
amount of water for example drawing 12KL with the pressure of more than 10.5kg/cm2.
 As the pump is centrifugal type mathematically efficiency of pump is given by

ηpump = Hydraulic power/Shaft power

ρghQ
=
𝑚𝑜𝑡𝑜𝑟 𝑝𝑜𝑤𝑒𝑟∗𝑚𝑜𝑡𝑜𝑟 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦∗1000

Where ρ = density of fluid(water) = 1000 kg/m3 h = height of water column in mm

g = acceleration due to gravity = 9.8056 m/s2 Q = flow rate of water in m3/s

h = height of water column in mm

Economiser: Before entering into the steam drum, feed water is preheated in the economiser
i.e. temperature of feed water is increased with exchange of heat energy with flue gases when
both passes through the economiser. This equipment is mainly used in saving the heat energy
which are lost with flue gas. Economiser mainly lowers the temperature of flue gases and
increases the temperature of feed water. By using this mechanical device efficiency of boiler
increases about 3-6% approximately. Economisers must be corrosion resistant as they condense
the flue gas which may also contain some acidic combustion gases which leads to equipment
damage due to corrosion.

Air pre-heater: APH is the device designed to heat air before delivering the air to boiler for
heating of the fuel. Air produced gives an additional boost to the heat energy produced by
charge during the starting process. APH recovers the heat from the flue gas by transferring it
to ambient air. APH inlet is connected to FD fan outlet and outlet is connected to the air box.
Ambient air is drawn into APH through FD fan which are high pressure fans and then air is
heated in air preheater. Later the heated air enters into the air box where the combustion of fuel
takes place. This device improves the efficiency of boiler to a higher extent reducing the heat
loss caused by flue gases.

Mechanical dust collector and Bag filters: These are environment protective devices of boiler.
They try to reduce the air pollution caused by flue gas as it contains many harmful particles
while leaving the boiler it reacts with atmosphere and causes air pollution. consists of a Four-
sided hollow metallic body which is conical at the downside. Also, a vertical squirrel cage type
arrangement is there for supporting and holding the filter bags.
These squirrel type cages are covered by filter bag material. After covering these cages with
filter bags, it appears as a pipe like geometry. Before leaving into atmosphere flue gases enters
the bag filter and passes through the filter bags. Continuous suction of flue gas is done by ID
fan. Dust particles stick to the surface of filter and the separated flue gas is sent into atmosphere
through chimney. Pressurised air is then passed through filter bags to remove the dust particles
at the bottom of bag filter.

Coal feeder: Coal is one of the most important material in development of heat energy in our
boiler plant. To feed coal into the boiler bed fuel feeders are used. Crushed coal from coal plant
is sent into the feeder through belts. Outlet of the coal feeder is connected to boiler bed through
air box. Variable frequency drives are installed with coal feeder to adjust the flow of coal into
boiler bed. Small amount of combustion air drawn by forced draft fans is tapped and sent into
primary air fan where the air is pressurised and sent to the feeder. This gives an additional boost
for feeder to feed the coal into the boiler.

Other accessories of boiler system include forced draft, induced draft and primary air fans.

Forced Draft fan: These fans supply the air necessary for fuel combustion by pushing the air
through the combustion air supply system and into the furnace. These fans are centrifugal fan
utilizing radial aerofoil blading or variable pitch axial fans. These fans are mainly placed at
inlet of the system near APH.

Induced Draft fan: These fans are placed at the outlet of boiler system to remove all gaseous
combustion products from boiler by suction within the furnace. Generally, these fans are more
susceptible to corrosion as they handle hot flue gases. They are also centrifugal fans similar to
FD fans. These fans have greater wear resistance to handle hard particles without any material
loss.

Primary Air fan: These are high pressure fans used to supply air for pneumatic fuel feeding. In
these combustion air drawn by FD fan is tapped and pressurised it to use for coal feeding. These
are generally aerofoil centrifugal fans or multistage axial fans which are similar to FD fans.

Boiler parts are essential for working of boiler. They include furnace and steam drum. Boiler
mountings and accessories are attached to these parts. The whole constitutes a system.

Boiler furnace: It is also called as the combustion chamber of the boiler. It is the place where
the heat energy is developed. Fuel from the feeder enters into the combustion chamber reacts
with the preheated air developed from APH.
The reaction results in the formation of flue gases which are nothing but the combustion
products. The flue gases from C.C. circulates over the boiler system and leaves the boiler
system at the chimney through bag filters. In detail of process in boiler furnace is given in
energy development section. Ceramics are used in the design of boiler furnace as they sustain
high temperature produced by the reaction in it. Ceramics were again covered with some foils
in order to reduce the heat exchange with the atmosphere. Most of the boiler mountings are
attached to boiler furnace. Proper care must be taken while operating the boiler furnace as they
are the one of the root cause for blasting of boilers.

Steam drum: It is the place where both steam and feed water exists. This drum is the main part
of water and steam circuit where both entering of feed water and exit of steam takes place
simultaneously. Feed water enters to the steam drum through economiser and then goes to mud
drum through bank tubes where the feed water is surrounded by flue gas. Here exchange of
heat energy occurs between flue gas and feed water and thus feed water turns into steam.
Produced steam enters the steam drum again whereas feed water enters mud drum. After
entering into mud drum the water gets purified from impurities and again sent into steam drum
using riser tubes. A phase separator is used to separate both steam and water. Produced steam
is sent to required areas through steam pipes.

How energy is developed in boiler?

Let us assume theoretically that there are three phase in development of heat energy in boiler.
They are ignition phase, uncontrolled combustion phase and controlled combustion phase. In
ignition phase initially small amount of charge is ignited and sent to combustion chamber.
Further proper amount of air and fuel is sent into the boiler to spread the fire created by the
charge sent into the C.C. to heat the boiler to burning temperature of fuel. This phase is called
as uncontrolled combustion. In this phase reaction rate and temperature increases rapidly until
the required temperature is reached. After the required temperature is reached when fuel is
added continuously reaction occurs rapidly releasing some energy with product obtained. This
product is known as flue gas which carries the heat energy throughout the system by circulating
the overall boiler system.

But in practical ignition phase and uncontrolled combustion phase is regarded as boiler light
up and compartmental transfer. Before light-up certain precautions need to be taken as they
leading to damaging of boiler. Light up is done only for one compartment.
Check the following before light up

 All the access doors are closed.

 All personnel cleared.
 All foreign materials are removed from furnace and pressure parts.
 Starting equipment and interlocks are in position.
 Boiler is filled with soft water above low level limit.
 For adequate lubrication and readiness for service check fans, drives, pumps, feeders
and controllers.
 Dry fuel (0-6mm) available in bunker.
 Instrument air is available at required pressure.
 Feed control valve, bypass valves, blowdown valve and main steam stop valve are
closed.
 Air vent on top of drum, gauge isolations valves and valves on the feedline connecting
to feed pump in operation must be closed.
 Furnace and fluidisation study is complete.

Procedure for light up:

Fixed quantity of dry charcoal is spread uniformly over the start-up compartment. Then fixed
quantity of kerosene mixed charcoal is spread uniformly over the dry charcoal layer. Fire is
initiated with swab. Further by proper air flow control fire can be spread and heat released by
charcoal is utilised to heat the bed material. Further the fuel feed rate is adjusted to maintain a
bed temp of 800 oC to 850 oC.

Compartmental transfer of heat:

After stabilizing the first compartment open that PA line damper of next compartment and
ensure that the lines are clear. Open the FD line damper of the required compartment an
increase the air flow to fluidisation level. At the mixing the bed temperature ensure that the
temperature of running compartment never go down below the fuel ignition temperature. Here
temperature of running compartment goes down while mixing compartment rises. Then adjust
the fuel feeding rate such that the bed temperature be above the fuel ignition temperature.
In practical controlled combustion phase takes place when boiler runs continuously.

Clinker formation is the most common problem while operating the boiler. Clinkers are the
stony residue of burnt coal. Formation of clinkers results in decrease in bed temperature and
reaction rate in the furnace. Clinker formation must be avoided in every part of energy
development. Ensure that proper amount of fuel and air is passed to the boiler. Clinkers even
form if the fluidisation velocity is low. Excess fuel feeding also cause clinkers. Avoid delay in
mixing which reduces formation of clinkers.

How steam is generated in boiler?

Energy developed in the boiler is stored in the form of flue gas. First the flue gas enters the
economiser where water is heated and sent to the steam drum. Here we observe the temperature
change of feed water at economiser inlet and outlet. Next the flue gas enters the air preheater
where the air is preheated to send it to boiler for combustion. Later the flue gas enters MDC
and bag filter where it leaves the boiler system. Meanwhile the heated water produced at
economiser reaches steam drum through riser tubes. Then from the steam drum it goes to down
comer. From there it reaches a narrow tube section called water wall where the phase change
of water occurs by heat exchange between flue gases and water. Saturated steam produced
enters the steam the drum where both water droplets and steam is separated by separator. Then
the steam is passed to required area through steam pipes whereas the water droplets are again
sent to down comer for phase change. To get superheated steam, a superheated is installed in
between steam pipes and steam drum in order to reduce moisture content in steam.

How energy is saved to reduce the fuel and feed water consumption?

Flue gases generated carry high heat energy. Most of the energy is lost to atmosphere. To
overcome this situation, Energy should be converted to some useful work. APH and
economiser are the basic requirements to conserve energy. Even steam generated can be used
to conserve feed water. This process is called as condensate recovery. Condensate recovery is
a process to reuse the water and sensible heat contained in the discharged condensate. In this
process steam condenses by losing it latent heat and changes into water. Produced water is
again used as feed water. This leads to reduction in consumption of fuel and feed water.
Condensate recovery is an environment favourable process which reduces the emission of NOx,
SOx, CO2.
CALCULATION AND ANALYSIS: -

My mentor then helped me in analysing the report of month may to get an idea how efficient
the plant boiler is working by giving required parameters

Given

Feed water = 10,185KL Steam Temperature = 180 oC

Steam = 9675.75 Tonnes Feed water Temperature = 73 oC (Tsat)

Condensate Recovery = 6783 KL Pressure = 10.5 kg/cm2 (Psat)

Coal = 1967.28 Tonnes

From Rankine cycle (As boiler follows this cycle)

ηb = (ms*(hs-hw))/(mf*gcv) -------------(1)

where ms = amount of steam produced

hs = enthalpy of steam

hw = feed water enthalpy

mf = amount of fuel required

gcv = gross calorific value of fuel (coal) = 4200 kcal/kg

From steam table at saturated temperature of 73oC

hw = 73.023 kcal/kg

At saturated pressure of 10.5 kg/cm2

hs = 664.335 kcal/kg

from (1)

Relative ηb = (9675.75(664.335-73.023))/ (1967.28*4200)

= (9675.75*591.312)/ (1967.28*4200)

= 69.24%
Heat energy utilised to convert water to steam per kg of fuel = (ms*(hs-hw))/ mf

= (9675.75(664.335-73.023))/ 1967.28

= (9675.75*591.312)/ 1967.28

= 2908.27 kcal/kg

Average evaporation rate = steam produced per hour

= 9675.75/ (24*31) =13000 kg/hr

Determination of value of condensate return in rupees:

1. Determination of fuel cost:

Each kilogram of condensate not returned to the boiler feed tank must be replaced by 1 kg of
cold make-up water (15°C) that must be heated to the condensate temperature of 100°C. (ΔT
= 85°C).

Calculating the heat required to increase the temperature of 1 kg of cold make-up water by
85°C,

Q = mw*cpw*ΔT

= 1*4.187*85 = 355.90 kJ/kg = 85.06 kcal/kg

Energy required to replace the heat in make-up water is 9675.75*1000*85.06 = 823.019 Gcal

If the average boiler efficiency is 69.24%, the energy supplied to heat the make-up water is:

823.019/0.6924 = 1188.64 Gcal

With a fuel cost of Rs.X/Gcal, the value of the energy in the condensate is:

X*1188.64 = Rs. 1188.64X

2. Determination of water cost:

Water is sold by volume, and the density of water at normal ambient temperature is about 1000
kg /m3. The total amount of water required replacing non-returned condensate is therefore:

(9675.75*1000)/1000 = 9675.75 m3
If water costs are Rs. Y per m³, water cost is:

Water cost = 9675.75 m3 * Rs. y/m3 = Rs. 9675.75Y

3. Determination of effluent cost:

The condensate that was not recovered would have to be discharged to waste, and may also
be charged by the water authority. Total amount of water to waste also equals 9675.75 m³ If
effluent costs are Rs. Z per m³, the effluent cost is:

Effluent cost = 9675.75 m3 x Rs. Z/m3 = Rs.9675.75Z

Total value = fuel cost + water cost + effluent cost

= 1188.64X + 9675.75(Y+Z)

This is when there is 100% condensate return

% condensate return = (condensate recovery*100)/steam produced

= (6783*100)/9675.75 = 70.1%

Value of condensate return = Total value*0.701

If Rs. A is invested on the boiler then the payback period is given by

A/((1188.64X+9675.75(Y+Z)) *0.701)

Actual costs aren’t mentioned on the basis of company’s policy.

Analysis: Higher the condensate recovery, higher will be the savings

Determination of optimum feed water temperature among 30oC, 70oC, 100oC

Given

Steam produced = 24TPH

Steam pressure = 10.5 kg/cm2

Boiler efficiency = 80%

Gcv of coal = 4200 kcal/kg

From saturated steam pressure table at P = 10.5 kg/cm2 , hs = 664.335kcal/kg

From saturated steam temperature table at T = Tsat required hw is obtained.

(i) At 30oC

mf = (ms*(hs-hw))/(ηb*gcv)

= (24*(664.335-30.059))/ (0.8*4200) = 4.53TPH

Heat utilised in converting water into steam per kg of fuel = (ms*(hs-hw))/mf

= (24*(664.335-30.059))/4.53 = 3360.4 kcal/kg

(ii) At 70oC

mf = (ms*(hs-hw))/(ηb*gcv)

= (24*(664.335-70.019))/ (0.8*4200) = 4.24TPH

Heat utilised in converting water into steam per kg of fuel = (ms*(hs-hw))/mf

= (24*(664.335-70.019))/4.24 = 3364.05 kcal/kg

(iii) At 100oC

mf = (ms*(hs-hw))/(ηb*gcv)

= (24*(664.335-100.148))/ (0.8*4200) = 4.02TPH

Heat utilised in converting water into steam per kg of fuel = (ms*(hs-hw))/mf

= (24*(664.335-100.148))/4.02 = 3368.28 kcal/kg

Analysis:

 At 30oC heat utilised is less compared to other two cases but coal consumption is more.
 At 100oC heat utilised is more compared to other two cases but coal consumption is
less.
 At 70oC optimum conditions are met.

Among 30oC, 70oC, 100oC, 70oC is the optimum feed water temperature.

Optimum feed water temperature is calculated in the order to obtain highest boiler
efficiency.
Conclusion:

During my internship I have learned practical operations of 24TPH boiler and understood the
practical problems while running like no load on boiler, defective display indicators, effect of
clinker formation. I have learned how to maintain operational log books to observe operational
trends of boiler. It was also taught by my mentor to calculate the efficiency of boiler and
optimum feed water temperature where I got a relative efficiency of boiler of 69.24% at the
month of May and optimum feed water temperature of 70oC which gives higher efficiency than
other temperatures.

Vote of thanks:

Finally, I am thankful to Mr. N. Karunasagar Sir (DGM), my mentor Mr. P.N.V. Srinivas Rao
(Deputy Manager), the team H.R. APL-V, Mr. Ravi Suresh (Corporate H.R.) for their extended
support during my internship at Aurobindo Pharma Unit-V.

Best Regards

[Link]