Week two report about boiler and chiller

operating principle

Prepared by:
1.Mistireselassie Taddese
2.Melkamfrie Adane
Submitted to: Wogderes Bayou
Submitted date: Friday, June 18, 2021
Outline
1. Acknowledgement
2. Introduction
3. Challenges and problems
4. Recommendations
5. Conclusion
Acknowledgement
From this week rotation we have inquired almost three personnel’s,
Mulugeta, Ermias and Tringo who have supported a lot and we
acquired the required information for our internship project, not only
how the machineries operates but also how much problems happened
before and which of them are still the problems of this company, since
our main concern is also solving these problems and enhancing the
productivity of the company. The company seems without problems,
but these operators shows these problems from the root causes, so we
have to give a special thanks. Thank you all!
Introduction
What is a chiller and it’s working principle?

Compressor

Evaporator

Condenser

A chiller is a device which is used to remove waste heat from a liquid, specifically from water and
reduce the temperature in to the required value.
A chiller have four main components, evaporator which is used for removing the waste heat from
water, condenser which is used to condense the refrigerant gas in to liquid state, compressor which is
used to do the required work allowing to transfer heat from the cold matter to the hot matter,
expansion valve which is used to allow the movement of the refrigerant from the condenser to the
evaporator.
 Ambient air to cool water

Cont.…
Soft water in
Flow diagram of the chiller
Soft water out Expansion Cold water in Cooling tower
Water to be cooled valve
evaporator
cycle
Soft Chilled Cooling water
water water Chilled
Refrigerant cycle
water out condenser
cycle Hot cooling
water out Additive chemicals
Additive chemicals 1. Anti corrosion
1. Anti corrosion compressor
2. Anti scalant
2. Anti scalant

Syrup room for

Line for cooling the
filler and dissolved sugar

mixer
Cont.… Cooling tower is a heat exchanger for
which direct contact between the
ambient air and the water needed for
cooling the required refrigerant from the
evaporator

The cooling tower pump which

is used to pump the water
needed for cooling the
refrigerant

Anti scalant and anti corrosive chemical

syringes.
Cont.…
Buffer tank for storing both the
water from the soft water and
that of the chilled water which
should be supplied to the
required places

The valve should be opened and

closed for allowing the water to
Gauge pressure for be overflow from the buffer tank.
reading the pressure of
the chilled water to be
pumped into the lines
Cont.…

Gauge pressure which is a

mechanical pressure display for the
water from the buffer tank

The secondary pumps of the chiller

which pumps the chilled water to
the required places.

The primary pumps which pumps

from the buffer tank the water to
be chilled into the evaporator.
 Cont.…
Water cooled chiller display
board , which is specially used for
controlling water chiller operation.

The working principle for water cooled chiller

The soft water from the buffer tank if infeed into the evaporator through the pipes by using the primary
pump forces.
The water then get cooled from the evaporator and return into the chilled water section of the buffer tank.
Even though the water is cooled from the evaporator, the evaporator chiller chemical has its own four
cycles. From the compressor the refrigerant is pumped in to the condenser. The condenser reduces the
temperature of the refrigerant and the water from the cooling tower get hot. The water from the cooling
tower enters with 24oC but the water from the condenser outflows into the cooling tower with 20oC.
The refrigerant then flows into the evaporator through the expansion valves.
Cont.…
What a boiler is and the working principle of it?
A boiler Is a device which induces a steam from the liquid form of water
with in a serious of steps.
The steps followed while a steam is induced are, first the water from
the water make up tank flows through the pipes by using a mechanical
forces of the pumps, simultaneously the fuel from the fuel tank flows
into the boiler with the surrounding air along the burner, and then the
spark igniter ignites a spark in the furnace and then flows through the
pipes and the reversal chamber reverses the direction of the ignition.
And finally the smoke out through the chimney.
Cont.… Boiler shell which covers the boiler furnace,
and boiler tubes, the boiler tube for the
water and fire ignition.
Boiler conductivity electrode/sensor, which
sends detects what is happened with respect to
the conductivity of water.

Boiler conductivity controller,

controls the productivity level by
sending a message to the actuator.

Boiler AOX Actuator, gives a mechanical

action for the message send from the
controller.
 Burner display board, which
Cont.… displays the burners status
like fuel quality, and
controlling the solenoid valves

The fuel pump, which is the main

component of the boiler for pumping the
oil.

The fuel flow through this

pipe( plastic pipe.

Fuel tank

Block
valves/solenoid Motor, which are
which are used as a fun for air
blowing into the Fuel level eye glass
blocked and open
as what amount burner and giving a
of fuel and air is mechanical force for
needed the fuel pump.
Cont.…
Dual switch, indicating the
water level and starting the
pump.

Boiler display control

board, which displays
the boilers steam The eye glass for fire type and
pressure and the level of quality. Which allow the
water. operators to give the type of
the Compressor fire, what is
needed.

Steam level eye glass,

Makeup tank for
which indicates and
storing the water
controls dry firing.
forming a steam,
and accepts from
soft water vessels.
 Condensate
return back

Cont.…
Boiler working flow diagram
Sugar dissolving
Smoke out

Makeup boiler Washer, mixer and

tank filler
burn
er

CIP & Others

Chemicals added needing steam
1. Anti-scalant
2. Anti- Air from the
Fuel tank
corrosion surrounding
3. Oxygen
scavengers
Cont.…
Mechanical terms used in both boiler and chiller.
1. Pipe is a long, hollow tube for carrying water, steam, gas
2. A pump is a device that moves fluids (water, fuel and steam) by mechanical action
3. Fan is used in cooling tower to reduce the waters temperature
4. Motor is any of a class of devices that convert electrical energy to mechanical energy,
usually by employing electromagnetic phenomena.
5. Compressor is a mechanical device that increases the pressure of a gas by reducing its 
volume. 
6. Evaporator functions as a heat exchanger such that heat captured by the process coolant
flow transfers to the refrigerant.
7. Condenser is collecting all the unwanted heat from the building and transferring it
over into the condenser water loop where it will be rejected from the building
via the cooling tower.
8. Valves for passing fluids and also blocking them.
Cont.…
Electrical terms used for chiller and boiler.
1. sensors, actuators and controllers.
2. Wires for electrical connection.
3. Sparking plug/ the fire igniter for inducing fire from the electrical
volts energy and converts it into the required heat energy.
Sensors like level and conductivity sensors have their own controllers
and actuators so as to function properly.
The wires for voltage carriers and the proper functioning of the
required machines, chiller and boiler.
Challenges and problems
1. The level indicator glasses are blurred
2. Power fluctuation and the main issue too
3. Buffer tank sensor is pointed at the top, once the water level is
below that sensor, which stops the pumps automatically.
4. Leakage of the evaporator external cover the dew to be overflow
into the surrounding room. Plus to that the leakage of boiler water
pipes and the oil pipes.
Recommendations
1. Adequate maintenance of the required matters, like proper
cleaning of the level indicator glasses.
2. Appropriate and constant supply of electric should be used, like
reusage of the waste matters as a source of electricity and
continuous supply of energy.
3. Proper sensor position for removing unwanted blockages when safe
working conditions are around.
4. Proper corrective maintenance of fuel pump, chiller condenser, and
any matter which leaks, and also an adequate preventive
maintenance, so as to argue the stoppage of works.
Conclusion
In this week we, Mistireselassie and Melkamfrie want to conclude that
there are problems in this international company, solving them with a
minimum cost should be our concern. The 80% of the unproductivity
level of the company rely on the 20% of major problems as the pareto
analysis tells us, by analyzing these major problems we want to
enhance the productivity level of the COCA-COLA.

THANK YOU