[Fives combustion system]

A PROJECT REPORT
Submitted by

Ahjoliya Om Prakash Bhai

[190170117002]
BACHELOR OF ENGINEERING
In
Instrumentation and control

Vishwakarma government engineering collage

- Chand Kheda, Ahmedabad

Gujarat Technological University, Ahmedabad

[ month, year]

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 Vishwakarma government engineering collage

CERTIFICATE

This is to certify that the project report submitted along with the project entitled
internship in Fives combustion system pvt. ltd. in has been conducted by Om
ahjoliya under my guidance in partial fulfillment for the degree of Bachelor of
Engineering in control and instrumentation department 8th Semester of Gujarat
Technological University, Ahmadabad during the academic year 2021-22.

PROF. M.D KHEDIA DR. M.K SHAH

Internal Guide head of department

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 [Industry Letter Head]

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 DECLARATION

We hereby declare that the Internship report submitted along with the Internship
entitled in fives combustion system pvt. Ltd submitted in partial fulfillment for
the degree of Bachelor of Engineering in instrumentation and control to Gujarat
Technological University, Ahmedabad, is a bonafide record of original project work
carried out by me at fives combustion system under the supervision of Hardik
Panchal (HOD & manager of C&I department) and that no part of this report
has been directly copied from any students’ reports or taken from any other source,
without providing due reference.

Om ahjoliya MR. Hardik Panchal

(Student name) ( external guide)

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 Acknowledgement

I would also like to express my appreciation to my colleagues and the staff at fives
combustion system for their warm welcome and assistance during my internship. It
was a pleasure to work with such a talented and supportive team.
From the moment I arrived, my colleagues were quick to introduce themselves and
make me feel welcome. They were always willing to share their knowledge and
expertise and were patient in answering my questions and helping me to understand
the company and industry.
In addition to my colleagues, the staff at the Company were always helpful and
efficient in assisting me with any needs or questions I had. I am grateful for the
opportunity to work with such a dedicated and professional team.
I am deeply grateful to Mr. Hardik Panchal as my mentors and Haresh Vala,
Mayan dholu, and Akshar Panchal as advisors during this internship, for their
invaluable advice and guidance. Their industry experience and expertise helped me
to better understand the company and the industry also allowed me to make the most
of my internship.
Throughout the internship, Mr. Hardik Panchal provided me with valuable insights
and guidance that helped me to navigate my tasks and responsibilities. They were
always available to answer my questions and provide support, and their wisdom and
expertise helped me to grow as a professional. I am thankful for their time and
support, and for sharing their valuable insights with me.

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 Abstract

This internship report serves the purpose of recording the details of my industrial
training which was conducted in fives combustion system pvt. Ltd. Which is a big
name in combustion burner industries. This report will cover the details of my
internship in the control and instrumentation department for a duration of three
months which began from 23 January 2023 till 23 April 2016 at fives company
which is located at Vadodara.

Students who are undertaking the accounting degree in Gujrat technological

University (GTU) are compulsory to undergo industrial training at one company for
a period of three months prior to graduating. Students are allowed to make their own
choices to enter any company to do their internship, The objectives of having this
industrial training are to give exposure to the students to the real working life, enable
the students to develop a deeper understanding on the course which they are
undertaking and to provide the appropriate work-related trainings to them in the field
of instrumentation.
Here I gained great experience in the burner and combustion industry as well as
control and instrument. Also, I learned about burner philosophy and how burners are
used in all kinds of industries. I also learned all documentations and working process
of any EPC company.

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 1.Fives group introduction

Fives group has about 8000 employees throughout 30 countries also it is 200 years
old company.
Fives designs and supplies machines, process equipment and production lines for
various industries: steel, aerospace and special machining, aluminum, the
automotive and manufacturing industries, cement, energy, logistics and glass.
Based on a portfolio of proprietary technologies, Fives products and solutions
anticipate the needs of industrial companies in terms of profitability, performance,
quality, safety and environmental protection.
To optimize synergies and propose a more legible offer of its organization and
services, the Group is organized around three Major Activities - High Precision
Machines, Process Technologies, and Smart Automation Solutions.

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 1.1. fives combustion system

Fives Combustion Systems, formerly known as Coen Bharat Limited and CBL
Combustion Systems, was founded in 1981 to answer a significant demand for
efficient industrial combustion equipment and burner systems in the country.
In 2012, Fives Combustion Systems joined the Fives group and is today the leading
actor in the cement and pelletizing industries in India. It is part of Fives’ Energy |
Combustion activity with other great names in combustion including Fives Pillared
(Mineral & Energy), Fives ITAS (Oil & Gas) and Fives North American
Combustion (Aluminum & Steel)
We have the full infrastructure to design, engineer, manufacture, supply, and
commission Pillard and North American combustion equipment and burner systems
in a wide range of solid, liquid, and gaseous fuels.
We have 4 main branches for combustion works in the world.
1) fives combustion system (India)
2) fives north America combustion (north America)
3) fives itas (Italy)
4) fives Pillard(France)

Our 3,800 m2 workshop follows the highest standards for quality and safety in
compliance with the European, North American, and Middle East markets.

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 2. What is the burner industry?

It is the industry that make all industries upgrade to next level combustion process
and used to simplify control system and other combustion processes to get desire
temperature according to applications and try to get the same at minimum fuel and
energy resources. The main part of this industry is ‘good combustion’ so this word
is making this industry to must desire application of every industry.

There are many types of applications of this industry.

1. Cement plant
2. Steel plant
3. Boiler
4. Power plant
5. Hrsg (heat recovery steam generation)
6. Mining
7. Metals
8. Food industry
9. More other applications where we need elevated temperature.

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In the burner industry, there are main term is combustion that has many types
according to client application and requirement we can consider it. Here three types
are described.
1. Forced draft combustion.
FD Fan is there which is used to suck air from atmosphere and push it into boiler
through Air Preheater where it will be preheated with the help of flue gases and then
it will help in carrying the coal to the Boiler (PA Fan) and support for addition
Combustion & Turbulence
2. Natural draft
A natural draft furnace is one that uses natural atmospheric pressure to force the
waste gasses of combustion out through the ventilation system. For this work the
chimney is there for providing natural draft air as the fuel in the furnace burns, it
creates hot air as well as combustion byproducts.
3. Negative draft combustion.
Induced draft fans or id fans remove flue gases from the combustion chambers and
create a vacuum of negative air pressure with a blower to suck the air out of the
combustion chamber. These air or flue gases are discharged from the boiler through
a stack or chimney.
The system that used for burner industry is called burner management system.it is
most important for burner industry. And should learn to familiarize yourself with the
burner industry. For combustion need three main things like home applications it Is
igniter & burner , fuel and its skid , air( blower ) . By referring to this sequence
further report is made. Also, the system that is needed for burner operation as well
as start and stop is BMS system that also described.

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 3. Fives products
Product name Applications

(1) startup burner To warm up to self-ignition temperature of

coal
(2) GRC standard burner Uses as load burner for boiler

(3) GRC simplified burner Uses with hot gas generator

(4) GRC low NOx burner Uses as load burner. Main aim to control
emission within limit
(5) GRC induct burner Continuous oil / gas firing HRSG burner .

(6) induct burner (duct burner ) Continuous gas firing HRSG burner .

(7) low btu burner (KFT/ bio To utilize low energy fuel for considerable
flam/scroll) energy output
(8) HGG For generating hot gas used for drying out
process also used in steel plant.
(9) kiln burner ( cement & Continuous firing burner in cement kiln and
minerals ) used in boiler.
(10)coal fired HGG(vertical) For cement plant and WHRB

(11)thermic fluid heating system Liquid to liquid heat transfer unit

(12)molten salt heating system To heat salt

(13)vertical furnace for test To evaluate different type of burner at test

center Italy center before commercial launch

(14) FNA small burners Various application like conveyor belt or level
base burning system.
(15) indurating Furnace Used for producing iron ore pellets.

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 4.Burner philosophy
“ Burner Is a device or group of devices for the introduction of fuel and air into a
combustion chamber at the velocity, turbulence and concentration required to
maintain ignition and combustion of fuel.”

Burner operating sequence :

Electric
power

Fuel gas
By-pass stack
Steam turbine generator

HRSG
Gas turbine generator

Fresh air fan

TEG FIRING
FRESH AIR FIRING (auxiliary mode)

Mode Selection Ignition

Interlocks Pilot Light-up

Check

Leak Test Main Burner

Light-up
Purge Burner Release
for Modulation
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 4.1. working process of burner

The working process of burner starts from mode selection, first we must select
control mode from there we have to control whole bms system. User must select one
mode out of ‘bms mode , local mode dcs mode’ according to selection user can
control whole process by this location.
Then interlock check is the most important part , it’s part of bms system so we
described it farther. If all kinds of interlock are healthy then manually, we must
check leakage problem. If it’s ok, then we can press the push button of purge start.
In control of the burner system a logic system is there in that we must give the set
point of purge and all others. According to the logic purge is start. This logic and all
are part of the bms system, so we learn it in brief in farther discussions . After 5 min
purge is done and then ignition command is given by the controller, so ignitor is on
and gives pilot flame.
And then according to plc logic the ssov and other valve is open for pass the fuel to
the burner. The ignitor lights up the burner when the actual fuel meets the pilot
aflame. We can take feedback from the scanner to show whether the burner is start
or not.
After main burner light up, we can modulate the burners temperature by giving air
by blower And some other conditions according to our temperature requirement.
The terms I use in this description like purge , interlock , pilot and for combustion
there are many things that are important like logic , control system, control panels
fuel , oil and gas skids , instruments , bms system , ignitors , air blowers, scanners
engineering documents , drawings etc. These are all terms you learn in this report
after that you learn the actual processes of burner.

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 4.2. Process sequence terms

Mode selection :
Operators may choose from either of the three available modes (‘ local mode, Bms
mode, dcs mode’ ) and its respective interlocks will then be monitored by BMS.
Interlocks :
A device, or an arrangement of devices, in which the operation of one part or one
mechanism of the device or arrangement controls the operation of another part of
another mechanism.
Leak test :
Leak Test is carried out to ensure tightness for main line safety shut off valves. This
is carried out in two stages, one with pressurized condition (for 2nd Block Valve) and
another in zero pressure condition (for 1st Block Valve)
Purge :
A flow of air or an inert medium at a rate that will effectively remove any gaseous
or suspended combustibles and replace them with the purging medium.
Ignition :
For ignition ignitor is used it is A permanently installed device that provides proven
ignition energy to light off the main burner.
Logic System :
The decision making and translation elements of the burner management system. A
logic system provides outputs in a particular sequence in response to external inputs
and internal logic.
Fuel Trip :
The automatic shutoff of a specific fuel as the result of an interlock or operator action

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 4.3. Burner Management System
Bms stands for burner management system and its heart of the burner philosophy
burner is working according to these systems rules and regulations. We cannot call
this system is about burner work principle and process, but it is for safety purpose,
so it also called the part of safety instrumentation system. A Burner Management
System or BMS is a safety system used to assure safe start-up, operation and shut
down of process burners.
BMS is the system that monitors the fuel burning equipment during startup,
shutdown, operation, and transient conditions. It is designed to present the status of
all fuel burning equipment to the operator in a concise format. The BMS initiates a
safe operating condition or shutdown procedure to prevent an explosion if an unsafe
condition exists, thus protecting equipment from damage and people from injury or
death.

The burner management system essentially is an on/off control system that permits
firing of a boiler at any load when safe conditions exist. If an unsafe condition
occurs, the BMS automatically shuts off fuel or causes the boiler to go to a safe state.
The code authority that covers practices in this area is the National Fire Protection
Association (NFPA). The published documents are the 85 series.

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The major steps in boiler burner management system are :

• checking boiler self-protection for startup,

• pre-purging, pilot trial and ignite,
• main burner trial and ignite, maintaining air/fuel ratio according to the load
demand.
• post-purging after burner stops.

A burner management system (BMS) is a safety solution that manages a combustion

system and is responsible for :

• Start-up and main flame detection

• Control and monitoring
• Shutdown sequences

❖ The purpose of a BMS :

• To inhibit / stop startup when unsafe conditions exist.

• To protect against the unsafe operating conditions and admission of improper
quantities of fuel to the furnace.
• To provide the operator with status information – operator assistance
• To initiate a safe operating condition or shutdown interlock if unsafe condition
exists.
• The BMS is a control system dedicated to boiler furnace safety and operator
assistance.
Burner Management Systems have been typically designed in the past through
applying the prescriptive requirements contained in codes / standards.

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 ❖ BMS system important terms :

4.3.1. Interlocks system

4.3.2. Purging sequence
4.3.3. Flam detection, monitoring, and tripping system.
4.3.4. Scavenging sequence ( for oil fired burners)
4.3.5. Bms Logics
4.3.1. interlock system
As we show in working process of burner the interlock takes main role in burner for
creating its logic for proper working.there are basically 3 types of interlocks
1. System interlock
2. Burner starts interlocks.
3. Burner trip interlocks.

❖ System interlock:
It is interlock that must be always healthy like in example of car there are some
things that must be important to drive the car (like air in tire).
In burner also some things are most important for combustion and its always need
to check up weather burner is in running condition or not. So that kinds of interlocks
called system interlock. Here some interlocks are described.
• tank level should be not low.
• PHF unit any pump should be running (if there is PHF unit available).
• Burner mode selection
• Coffee pot or hoisting damper is in open position (in hgg burner).
• Fuel selection.
• Emergency stop should not be pressed.
• Instrument and automizing air pressure should not be low then given set point.
• Combustion and dilution air fan running
• Input and output check. (Not fail)
• Coffee pot or hoisting damper open position
This all interlock should be healthy in every condition of burner. If any interlock is
in unhealthy condition, it will terminate running sequence, operator has to check and
resolve it before starting sequence.

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 ❖ Burner starts interlocks:
This is the interlock that always be healthy when burner is start and before start. If
this all interlocks are healthy then we can press ‘burner start’ button. Here mentions
some interlocks.
• System interlocks are ok.
• Purge startup interlocks ok.
• Skid inlet pressure and temperature ok.
• Combustion air low fire position
• Purge complete.
• No purge fails.
• Burner trip interlocks ok.
After these interlocks are healthy then we can press burner start button then burner’s
ignitor will ON that provide ignition spark to the burner fuel for combustion.
❖ Burner trip interlock:
This is the interlocks that most important according to NFPA rules it is for safety
purpose, basically these interlocks are tripping interlocks when some undesired
things are occur then our burner will trip (burner OFF). Here some interlocks are
described.
• Systems interlocks not healthy.
• Main burner flame fail.
• Flame discrepancy.
• Main skid outlet pressure high.
• Fuel not selected.
• Dilution air pressure low.
• Hgg outlet temperature and pressure high
• Emergency stop button pressed.
BMS will continuously monitor the following interlocks after opening the fuel line
shut off valves respected burner and failure of any would lead to tripping of the
burner.
Here the word we heard flame discrepancy, it is moment in that flame scanner detect
the flame without fuel line valve in open condition it will give an alarm for the flame
discrepancy.

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4.3.2. purging sequence
Purge is the process to remove any gaseous or suspended combustibles by using Air
flow. This process is needed every time we start the burner because some undesired
particles are there, and some fuel particles are also there so every time we must
remove it. There are some conditions for starting the purging sequence. Here some
of them are mentioned.
• Skid outlet SSOV is in a close position.
• Main skid return line ssov in open position.
• Ignitor damper is in retract position.
• No flame on feedback from scanner.
• System interlocks are healthy.
Once the above conditions are fulfilled. We can press the purge start button. After
finish purge within 10 min signal Is given to the burner start interlocks and after
checking burner start interlock, we can press the burner start button. If any reasons
purge will fail, then we have to do rework on this process and do purging from
starting.

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