SUMMER TRANNING REPORT

AT

JK TYRE AND INDUSTRY LIMITED

TITLE:-BOILER

SUBMITTED TO: SUBMITTED BY:

Mr. Sanjay Aher Aditya Mishra

Chief manager 0901ME161010

JK tyre industry Madhav institute of

Technology and science

 CERTIFICATE

This is to certify that this Vocational training Entitled “Study of

Boiler and Thermal Plants” at JK Tyre industry, gwalior from 10 June
2019 to 10 July 2019 , is a bonafide record presented by Mr. Aditya
Mishra ,Enroll no: 0901ME161010, in fulfilment of Vocational
training under B.E. Curriculum in Madhav institute of Technology
and science, Gwalior, Madhya Pradesh.

Mr. Sanjay Aher

Chief manager
JK tyre industry
 ACKNOWLEDGEMENT

With profound respect and gratitude, I take opportunity to convey my

thanks to Mr. Abhishek Harshdeep Sir, for permitting me to complete
my training in JK Tyre industry. and to be the part of this esteemed
organisation.
I extend my heartful thanks to Mr. Sanjay Aher Sir, for providing me
the proper guidance during my training period.
I am extremely grateful to all the operation and guidance that has
helped me a lot during the course of training. I have learnt a lot under
them and I will always be indebted to them for this value addition in
me.
At last I would like to convey my thanks to all the members of
Madhav institute of technology and science, and my parents for their
cheerful encouragement, unfailing patience and consistent support.

Aditya Mishra
Vocational Trainee
10.06.2019 – 10.07.2019
 Contents
1. Certificate (I)
2. Acknowledgement (II)

3. Introduction (1)
4. History of Boiler (2-3)
5. Types of Boiler and its classification (3-7)
6. Basic components of Boiler (8)
(i) Economiser (9)
(ii) Pre-heater (10)
(iii) Super-heater (10)
(iv) Re-heater (11)
(v) De-super heater (11)
(vi) Condenser (12)
(vii) Cooling Tower (13)
(viii) Fan & Draught system (13)
(ix) Ash handling system (14)
Introduction

 Boiler: A Boiler or steam generator essentially is a container into

which water can be fed and steam can be taken out at desired pressure,
temperature and flow. For that the boiler should have a facility to burn a
fuel and release heat. Thus the function of a boiler can be stated as:-
 To convert chemical energy of the fuel into heat energy.
 To transfer this heat energy to water for evaporation as well to
steam for superheating.

 Block diagram of Boiler:

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 History of Boiler

The steam-generating boiler’s roots go back to the late 1700s and early
1800s with the development of the kettle-type boiler, which simply boiled
water into steam. The water was placed above a fire box and then boiled
into steam. It wasn’t until around 1867, with the development of the
convection boiler that the steam-generating industry began.

It may be debated who developed the first steam-generating boiler;

however, most will agree that George Babcock and Steven Wilcox were
two of the founding fathers of the steam-generating boiler. They were the
first to patent their boiler design, which used tubes inside a firebrick-
walled structure to generate steam, in 1867, and they formed Babcock &
Wilcox Company in New York City in 1891. Their first boilers were
quite small, used lump coal, fired by hand, and operated at a very low rate
of heat input. The solid firebrick walls that formed the enclosure for the
unit were necessary because they helped the combustion process by
reradiating heat back into the furnace area.

The Stirling Boiler Company, owned by O.C. Barber and named for the
street (Stirling Avenue) the facility was on in Barberton, Ohio, also began
making boilers in 1891. Their eighth Stirling boiler design was called the
H-type boiler (“h” being the eighth letter in the alphabet) and had a brick
setting design. The Stirling boiler was much larger than the Babcock &
Wilcox boiler and used three drums to help circulate the water and steam
flow throughout the boiler.

In 1907, the Stirling Boiler Company merged with the Babcock &
Wilcox Company. They renamed their boiler the H-type Stirling, and it
became one of best-selling boilers of its time, probably because of its
ability to produce up to 50,000 pounds of steam per hour.

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 However, they were not the only boiler manufacturers during the late
1800s. The Grieve Grate Company and the American Stoker Company
were also making boilers of similar all-brick-wall design. They both used
a travelling or screw-type grate at the bottom of the boiler to transport the
fuel (lump coal) across the inside of the boiler. As the fuel traveled across
the inside of the boiler, it was burned and the ash or un-burned fuel would
drop into a hopper. These two companies later formed the Combustion
Engineering Company in 1912. The new Combustion Engineering
Company offered their version of the Grieve and American Stoker boilers
and called it the Type E stoker boiler.

 Types of Boiler and its classifications

There are two general types of boilers: ''fire-tube'' and ''water-tube''.
Boilers are classified as "high-pressure" or "low-pressure" and "steam
boiler" or "hot water boiler." Boilers that operate higher than 15 psig are
called "high-pressure" boilers.

A hot water boiler, strictly speaking, is not a boiler. It is a fuel-fired hot

water heater. Because of its similarities in many ways to a steam boiler,
the term ''hot water boiler'' is used.
 Hot water boilers that have temperatures above 250° Fahrenheit or
pressures higher than 160 psig are called ''high temperature hot water
boilers''.
 Hot water boilers that have temperatures not exceeding 250° Fahrenheit
or pressures not exceeding 160 psig are called ''low temperature hot water
boiler’s.

Heating boilers are also classified as to the method of manufacture, i.e.,

by casting (cast iron boilers) or fabrication (steel boilers). Those that are
cast usually use iron, bronze, or brass in their construction. Those that are
fabricated use steel, copper, or brass, with steel being the most common
material.

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Fire-tube Boilers
In fire-tube boilers, combustion gases pass through the
inside of the tubes with water surrounding the outside of
the tubes. The advantages of a fire-tube boiler are its
simple construction and less rigid water treatment
requirements.
The disadvantages are the excessive weight-per-pound of
steam generated, excessive time required to raise steam
pressure because of the relatively large volume of water,
and inability to respond quickly to load changes, again,
due to the large water volume.

The most common fire-tube boilers used in facility heating

applications are often referred to as ''scotch'' or ''scotch
marine'' boilers, as this boiler type was commonly used for
marine service because of its compact size (fire-box
integral with boiler section).

The name "fire-tube" is very descriptive. The fire, or hot

flue gases from the burner, is channelled through tubes
that are surrounded by the fluid to be heated. The body of
the boiler is the pressure vessel and contains the fluid. In
most cases, this fluid is water that will be circulated for
heating purposes or converted to steam for process use.

Fire-tube boilers are:

 Relatively inexpensive
 Easy to clean
 Compact in size
 Available in sizes from 600,000 btu/hr to 50,000,000 btu/hr
 Easy to replace tubes
 Well suited for space heating and industrial process applications

Disadvantages of fire-tube boilers include:

 Not suitable for high pressure applications 250 psig and above
 Limitation for high capacity steam generation

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Water-tube Boilers
In a water-tube boiler, the water is inside the
tubes and combustion gases pass around the
outside of the tubes. The advantages of a water-
tube boiler are a lower unit weight-per-pound of
steam generated, less time required to raise
steam pressure, a greater flexibility for
responding to load changes, and a greater ability
to operate at high rates of steam generation.

A water-tube design is the exact opposite of a

fire-tube. Here, the water flows through the
tubes and is encased in a furnace in which the
burner fires. These tubes are connected to a
steam drum and a mud drum. The water is
heated and steam is produced in the upper drum.

Large steam users are better suited for the water-

tube design. The industrial water-tube boiler typically produces steam or hot
water primarily for industrial process applications, and is used less frequently
for heating applications. The best gauge of which design to consider can be
found in the duty in which the boiler is to perform.

Water-tube boilers:

 Are available in sizes far greater than a fire-tube design , up to several

million pounds-per-hour of steam
 Are able to handle higher pressures up to 5,000 psig
 Recover faster than their fire-tube cousin
 Have the ability to reach very high temperatures

Disadvantages of the water-tube design include:

 High initial capital cost

 Cleaning is more difficult due to the design
 No commonality between tubes
 Physical size may be an issue

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Other types of Boiler are:
1. Cast iron boilers.
2. Steam and Condensate boiler system.
3. Hydronic (Hot water) boiler system.

Cast Iron Boilers

Cast iron boilers are made in three general types: horizontal-sectional, vertical-
sectional, and one-piece. Most of the sectional boilers are assembled with push
nipples or grommet type seals, but some are assembled with external headers
and screw nipples. Horizontal-sectional, cast iron boilers are made up of
sections stacked one above the other, like pancakes, and assembled with push
nipples. Vertical-sectional, cast iron boilers are made up of sections standing
vertically, like slices in a loaf of bread. One-piece cast iron boilers are those in
which the pressure vessel is made as a single casting.

Steam and Condensate Boiler System

Boilers are generally used to provide a source of steam or

hot water for facility heating and process needs.
In steam and condensate systems, heat is added to water
in a boiler causing the water to boil and form steam. The
steam is piped to points requiring heat, and as the heat is
transferred from the steam to the building area or process
requiring heat, the steam condenses to form condensate.
In some very low-pressure saturated steam heating
applications, the steam distribution piping may be sized
to slope back to the boiler so that the steam distribution
piping also acts as the condensate return piping (single-
pipe system).

In other low-pressure applications, there may be steam

supply piping and condensate return piping (two-pipe
system), although the condensate system is open to the steam system. In typical
packaged steam boiler operations, the boiler system may generate steam at
about 150 psig for distribution throughout the facility and may be lowered to the
operating pressure of equipment supplied through point-of-use pressure
reducing stations. As heat is transferred from the steam, condensate is formed
which collects in discharge legs until enough condensate is present to operate a
trap that isolates the steam distribution system from the condensate system.

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In common facility heating applications, the condensate system is at
atmospheric pressure and the system is arranged to drain the condensate to a
central condensate receiver, or into local smaller receivers that pump the
condensate back to the central condensate receiver.

Hydronic Boiler System

A boiler is used to heat water that is circulated through a

closed loop piping system for general facility and
service water heating. Low-temperature systems
generally operate below 200° Fahrenheit Medium-
temperature systems generally operate at temperatures
between 200 and 250° Fahrenheit.
A feature of hot water systems' is an expansion tank to
accommodate the expansion of the water in the system
as the water is heated. The expansion tank, when piped
into the system on the suction side of the circulating
pumps, also pressurizes the system to prevent flashing in
the circulating pump, piping, and piping components. In
many low- and medium-pressure systems, pressurization
is maintained by flash steam in the expansion tank. In a
few hot water systems, pressurization is maintained by
maintaining a compressed gas blanket above the water
level in the expansion tank.

High-temperature hot water systems, which operate

above 250° Fahrenheit, are basically the same as hot water systems that operate
below 250°F. High-temperature systems are generally installed when a process
requires the higher temperature, a number of locations require small quantities
of low-pressure steam that the high-temperature hot water can generate in a
local converter, or high-temperature drop equipment can be used at end use
points to minimize the size of water circulation piping required.
Most facility boiler systems are fired using a combustible gas (typically natural
gas or propane) or fuel oil. In many facilities, the boilers are designed to fire
both a combustible gas fuel and a fuel oil. In these facilities, the combustible
gas fuel is generally natural gas that is considered the primary fuel, and fuel oil
is considered to be the backup fuel.

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 Basic components of Boiler are:
 Furnace
 Economiser
 Air – Preheater
 Super Heater
 Re-heater
 De-Super heater
 Condenser
 Cooling tower
 Fan or draught system
 Ash handling system
 Furnace: A boiler furnace is the first pass of the boiler in which the
combustible products pass to the super heater
and second pass of boiler. The
combustion process is a
continuous process, which
takes place in the first pass of
the boiler and control by the
fuel input through coal
feeders. It is a radiant type and
water cooled furnace and
enclosure is made up of water
wall.

The furnace is open at the

bottom to allow ash linkers to
freely into the furnace bottom
ash hopper (through a furnace
throat) and at the top of its rear
wall, above the arch, to allow
hot gases to enter rear gas
pass.

[Image by: http://wiki.zero-emissions.at]

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Requirement should be satisfied by the furnace:
1. Proper installation, operation and maintenance of fuel burning equipment.
2. Sufficient volume for combustion requirement.
3. Adequate refractoriness and insulation.

 Economiser:

[Image by: Cleanboiler.org]

It is located below the LPSH in the boiler and above pre heater. It is there to
improve the efficiency of the boiler by extracting heat from flue gases to heat
hot water and send it to the boiler drum.

Advantages:
1. Fuel economy: It is used to save fuel and increase overall efficiency of
the boiler plant.
2. Reducing size of the boiler: A the feed water is preheated in the
economiser and enter boiler tube at elevated temperature. The heat
transfer area required for evaporation reduced considerably.

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  Air-preheater: The heat carried
out with the flue gases coming out of
economiser are further utilize for
preheating the air before supplying
to the combustion chamber. It is
necessary equipment for supply of
hot air for drying the coil in
pulverized fuel system to fascinate of
fuel in the furnace.
[Image by:slideshare.net]
 Super-heater:

[Image by:slideshare.net]

The steam generated by the boiler is usually wet or at the most dry saturated
because it is in direct contact with water. So, in order to get superheated
steam, a device known as super heater has to be incorporated with the boiler.
The function of the super-heater system is to accept dry saturated steam from
the steam drum and to supply superheated steam at the specific final
temperature of 540°C by means of a series of heat transfer surfaces arranged
within the boiler gas passes.
A super-heater is a surface type heat exchanger generally located in the
passage of hot flue gases.
The dry saturated steam from the boiler drum flow inside the super-heater
tubes and in this way its temperature is increased at same pressure.
Types of super-heater:
1. Primary super-heater
2. Secondary super-heater
3. Final super-heater

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  Re-heate r:
Power plant furnaces may have a
re-heater section containing tubes
heated by hot flue gases outside
the tube. External steam from the
high pressure turbine is re-routed
to go inside the re-heater tube to
pick up more energy to go drive
intermediate or lower pressure
turbines.
[Image by: cleanenergysystem.org]
 De-super heater:

[Image by: mechanicalenggineerings.wordpress.net]

(A) Super heater – De super heater:

The super heater de-super heater is fitted after 10 th coil to control the super
heated steam at the specified terminal temperature of 540°C . The maximum
design temperature reeduction at the super heater de-super heater is from
446°C to 388°C.
(B) Re-heater de-super heater:
The re-heater de-super heater is only brought into use when the re-heater
outlet temperature rises above the normal temperature.

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  Condenser:

[Image by: ohio.edu]

The condenser condenses the steam from the exhaust of the turbine into the
liquid to allow it to be pumped. If the condenser can be made is reduced and
efficiency of the cycle increases.

Functions:
1. To provide lowest economic heat rejection temp for steam.
2. To convert exhaust steam to water for reserve thus saving on feed water
requirement.
3. To introduce make up water.

We normally use surface condenser although there is one direct contact

condenser as well. In direct type exhaust steam is mixed with directly with De-
mineralized cooling water.

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 Cooling tower:

[Image by: power-en g.com]

The cooling towerr is a semi-enclosed device for evaporrative cooling of

water by contact with air. The hot water coming out from the condenser
is fed to the tower on the top and allowed to tickle on form of the thin
sheets or drops. T he air flows from bottom of the tower or perpendicular
to the direction of water flow and then exhausts to the atmosphere after
effective cooling.

The cooling towers are of four types:

1. Natural Draft cooling tower.
2. Forced Draft coooling tower.
3. Induction Draftt cooling tower.
4. Balanced Draft cooling tower.

 Fan or Draught system:

In the boiler, it is essential to supply a controlled amountt of the air to the
furnace for effecttive combustion of fuel and to evacuate hot gases
formed in the furrnace through the various heat- transfer area of the
boiler. This can be done using a chimney or mechanical device such as
fans which acts as a pump.

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 Ash handling system:
The dispersed of ash from a large capacity power station is of same
importance as ash is produced in large quantities. Ash handling is a
major problem:
1. Manual handling: While barrows as used for this. The ash is collected
directly through the ash outlet door from the boiler into the container
from manually.
2. Mechanical handling: Mechanical equipment is used for ash disposal,
mainly bucket elevator, belt conveyer. Ash generated is 20% in the
form of bottom ash and next 80% through flue gases so called fly-ash
and collected in ESP.
3. Electrostatics precipitator: From air pre-heater, this flue gases (mixed
with ash) goes to ESP. The precipitator has plate blanks (A-F) which
are insulated from each other between which the flue gases are made
to pass. The dust particles are ionized and attracted by charged
electrodes. The electrodes are maintained at 60KV.
 Conclusion

Industrial training being an integral part of engineering curriculum provides not

only easier understanding but also aspect of all things which differ considering
from theoretical models.

During my training, I gained a lot of practical knowledge which otherwise could

have been exclusive to me. The practical exposure required here will pay rich
dividends to me when I will set my foot as an engineer.

The training at JK tyres, was altogether an exotic experience, since work,

culture and mutual co-operation was excellent here. Moreover fruitful result of
adherence to quality control, awareness of safety and employees were fare
which is much evident here.

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 References
 Modern power station practice-Volume B & Volume C.

 Power plant engineering- by PK Nag.

 Control and Instrumentation

 Operation & Maintenance Manual (MTPS) – Volume H.

 www.ntpc.co.in

 http://indianpowersector.com/home/powerstation/thermal-power-plant/

 https://en.wikipedia.org/wiki/Boiler

 https://en.wikipedia.org/wiki/Thermal_power_station

 https://en.wikipedia.org/wiki/Rankine_cycle

 nptel.ac.in/courses/112106133/Module_5/2_Rankinecycle.pdf

 en.wikipedia.org

 www.mechanicalengineerings.wordpress.com

 www.electrical4u.com

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