VISVESVARAYA TECHNOLOGICAL UNIVERSITY

JNANASANGAMA, BELAGAVI - 590018

An Internship Report on
OPERATION AND MAINTENANCE OF BOILER

In
MARINE ENGINEERING

Submitted in partial fulfilment for the award of the degree

BACHELOR OF ENGINEERING
Submitted By

T A PRAJWAL AIYAPPA
4SN15MR032
Internship Carried Out at

CAMPCO
PUTTUR
Internal Guide External Guide
Dr. SHANKAR K S Mr. RADESH KUNDALPADI
Head of the Department Production Manager
SIT, Mangaluru CAMPCO, Puttur

DEPARTMENT OF MARINE ENGINEERING

SRINIVAS INSTITUTE OF TECHNOLOGY
VALACHIL, MANGALURU - 574 143
2018-2019
 SRINIVAS INSTITUTE OF TECHNOLOGY
MANGALURU - 574143, KARNATAKA

DEPARTMENT OF MARINE ENGINEERING

CERTIFICATE

Certified that the Internship work entitled

“OPERATION AND MAINTENANCE OF BOILER” is a bonafide work carried out by T A PRAJWAL
AIYAPPA, bearing USN 4SN15MR032, in partial fulfillment for the award of degree of Bachelor of
Engineering in Marine Engineering of the Visvesvaraya Technological University, Belagavi during the year
2018-2019. It is certified that all corrections/ suggestions indicated for Internal Assessment have been
incorporated in the report deposited in the departmental library. The Internship report has been approved as it
satisfies the academic requirements prescribed for the degree of Bachelor of Engineering.

_____________ ___________ ______________

Dr. Shankar K S Mr. Tony K Sebastian Dr. Shankar K S
Internal Guide Internship coordinator Head of the department

EXTERNAL VIVA
Name of Examiners Signature with Date

1. 1.

2. 2.
 DECLARATION

I T A PRAJWAL AIYAPPA , bearing USN 4SN15MR032, student of Eighth semester B.E in

Marine Engineering, Srinivas Institute of Technology, Mangaluru, hereby declare that the
Internship work entitled " OPERATION AND MAINTENANE OF BOILER" has been carried out
and duly executed by me at CAMPCO,PUTTUR, under the guidance of Dr.SHANKAR K S, Head
of the Department, Department of Marine Engineering, Srinivas Institute of Technology,
Mangaluru and Mr. RADESH KUNDALPADI, PRODUCTION MANAGER, CAMPCO
PUTTUR, submitted in partial fulfill-ment of the requirements for the award of degree of Bachelor
of Engineering in Marine Engineering by Visvesvaraya Technological University, Belagavi during
the academic year 2018-2019.

Date: 18/03/2019 T A PRAJWAL AIYAPPA

Place: Mangaluru 4SN15MR032

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 Acknowledgement

The internship opportunity that I had in CAMPCO, Puttur was a great chance for learning and
professional development. Therefore, I consider myself as a very lucky individual as I was
provided with an opportunity to be a part of it. I am also grateful for having a chance to meet so
many wonderful people and professionals who led me though this internship period.

Bearing in mind previous I am using this opportunity to express my deepest gratitude and special
thanks to the MD of CAMPCO Sri Suresh Bhandary who in spite of being extraordinarily busy
with his duties, took time out to hear, guide and keep me on the correct path and allowing me to
carry out my internship at their esteemed organization and extending during the training.

I express my deepest thanks Mr. Prahallad, maintenance engineer and Mr. Rajesh, external
guide for taking part in useful decision & giving necessary advices and guidance and arranged all
facilities to make life easier. I choose this moment to acknowledge their contribution gratefully.

I owe my deep gratitude to our internship internal guide Dr.Shankar K S and internship
coordinator Mr. Tony K Sebastian, who took keen interest on our Internship work and guided us
all along, till the completion of our internship work by providing all the necessary information for
developing a good practical experience.

I would like to thank Head of the Department, Marine engineering, SIT, Mangalore for
providing the opportunity to do internship in CAMPCO, Puttur and also for his encouragement and
support during the internship period.

I would like to thank Dr. Shrinivasa Mayya D, principal, SIT, Mangalore for providing us this
opportunity and for allowing me to do internship.

I perceive as this opportunity as a big milestone in my career development. I will strive to use
gained skills and knowledge in the best possible way, and I will continue to work on their
improvement, in order to attain desired career objectives.

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 Summary

This internship was carried in CAMPCO Ltd, Puttur from 07 th January 2019 to 06thFebruary 2019
for a period of 30 days under maintenance and operation of boiler department which comes under
Campco Chocolate Factory. There I was admitted as an internship trainee under maintenance and
operation department and was insisted to observe the work of operators who look after the
operation and maintenance of the boiler. The factory boiler plant consists of two boilers one is fire
tube and the other one is combined. The main objective of this internship was to have a practical
knowledge regarding various parts of the boiler and it’s working. Plants maintainer gave the
practical knowledge of the boiler. He always took us along the boiler plant to show the various
work carried out as a routine. By doing this I gained some practical knowledge in the field of
maintenance of various boiler mountings and its operations. In this internship I also gained
experience regarding how the works are assigned to operators and how that works are done and
what are the daily, weekly and monthly checks and maintenance works that has to be done on the
boiler plant and also how to rectify various problems that arises during the operation of the boiler.

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SL.NO CONTENT PAGE NO

Chapter 1 - Company profile

1.1 Factory manufactures

1.2 Working hours
1.3 Organizational structure
1.31 Organization and management
1.32 List of department
01 1.33 Functional department 08 - 12
1.34 Preventive Maintenance department
1.35 Account Department
1.36 Administrative Department
1.37 Quality and control Department
1.38 Stores Department
1.39 Marketing Department

Chapter 2 – Description

02 2.1 Fire Tube Boiler

2.2 Combined Boiler 13 - 22
2.3 Boiler Accessories
Boiler layout
Chapter 3 - Internship Discussion

3.1 Skills observed during internship period 23 - 24

03 3.2 Challenges experienced during internship

04 Conclusion 25

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SL.NO Tables & Figures PAGE NO

1. Organizational structure 10
01 2. List of departments of Campco sales 11

2.1 Fire Tube Boiler 13

2.2 Combined Boiler 14
Boiler layout 15
2.38 Steam stop valve 18
02 2.39 Gauge glass 18
2.310 water level alarm 19
2.311 Pressure gauge 19
2.313 Safety valve 21

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CHAPTER - 1

COMPANY PROFILE
Central Areca nut and Cocoa Marketing and Processing Cooperative Limited (CAMPCO) is
having a success story in cooperative movement.

CAMPCO was established in the year 1973 to help the arecanut farmers in the Dakshin Kannada
district of Karnataka. At that time price of areca nut was very low and farmers faced problems of
areca nut marketing. For this reason, CAMPCO was founded, which established itself as a
multistate co-operative, joint venture with the states of Karnataka and Kerala.

1.1 The Factory Manufactures

 Cocoa mass, cocoa butter and cocoa powder-industrial products for internal and export
markets.
 Moulded chocolates, enrobed chocolates, chocolate éclairs, sugar coated chocolate buttons
and instantized drinking chocolates, finished products for internal market & export
potential.
 Keeping pace with the consumer needs of the new products, CAMPCO has recently
exported instantized milk flavoring beverage products and chocolate eclairs to Australia,
that are formulated at product development cell of chocolate factory export of cocoa butter
to European countries also takes the cue.

1.2 Working hours at CAMPCO

As per information revealed by the employees of CAMPCO there are four shifts including
general shifts of eight hours per day.

The shift is made in such a way that it is not overlapping

The timings of the 4 shifts are as follows:

 1st shift 6 AM to 2 PM
 2nd shift 2 PM to 10 PM

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  3rd shift 10 PM to 6 AM
 General shift 9 AM to 5.30 PM

1.3 Organizational structure

Board of directors

President

Managing director

General Manager

Account & Finance Marketing Administration

Chocolate Dy. Areca nut Dy. Dy. GM

Dy. GM GM
GM
Assistant GM Assistant GM Assistant GM
Assistant GM

Chief
Chief Manager Chief Manager
Chief Manager Manager
Senior Senior
Senior Senior Manager
Manager Manager
Manager

Officers Officers Officers

Officers

Fig1. Organizational structure

1.31 Organization and Management

The Management of CAMPCO vests in the boards of directors consisting of 17 directors. These
directors are elected or nominated as per the provisions of Bye laws. The managing director is
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appointed by the Government of Kerala. The day today activities are conducted by the managing
directors. The Executive committee and business committee will devote more time to scrutinize
and decide about the financial and business transaction of the factory.

1.32 List of department of CAMPCO sales

Owned Rent
Ponkunnam Ahmedabad Cuttack Nagpur
Dhamapuram Hubli Delhi Adimali
Indore Kanpur Perumbvoor
Jaipur Mumbai Thamarassery
Table2. List of department of Campco sales

1.33 Functional departments at CAMPCO Chocolate factory

There are several functional departments in CAMPCO chocolate factory, which are handling
various operations.

They are:

 Maintenance department
 Accounts department
 Administrative department
 Production department
 Quality control department
 Stores department
 Marketing department
 Security department

1.34 Preventive Maintenance department

Preventive maintenance refers to take care of machinery before breakdown. Under this system the
machines are frequently checked and required.

1.35 Account department/ financial department

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The CAMPCO chocolate factory has maintained an accounts department. The chief accountant is
in charge of this department. Under him are the senior office assistants and junior office assistants
working in the department. A report has to be sent to the head office about the day-today work and
expenses incurred.

1.36 Administrative department

The administrative department looks after the day-today administration activities in the factory. At
the top level there is an administrative manager. Normally the General Manager carries over day-
today administrative activities in the factory.

He is also assisted by the various departments in the factory. The General Manager is accountable
to the head office that is in Mangalore.

1.37 Quality and Control Department

The quality control department is headed by the quality control manager. Under him/her there are
three supervisors. In this department there is one micro biologist. There are few technical assistants
to help the microbiologists. They check the quality of raw materials and also the quality of
products. In CAMPCO, production is carried quickly according to quality standards. The quality of
product manufactured is of international standards. The function is to check the quality of products
after production.

1.38 Stores Department

The stores department is headed by store manager. Under him/her there are supervisors. The main
function of the store is divided into 3 units. These three functions are: receiving the raw materials
for manufacture of chocolates and also packing materials and sending it into go down. The stores
managers are responsible to provide the raw materials to required department and store the finished
goods in the store. The store’s activities are carried out in shifts by rotation. There are four
department maintained by the stores department. They are:

 Material inward registers

 Daily stocks report
 Material register note

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  Return note book

1.39 Marketing department

To promote and develop Areca and Cocoa cultivation, marketing and processing. Campco has
chocolate manufacturing factory at puttur. It processes cocoa and manufactures large quantity of
semi-finished and finished products with a capacity of 18,000 tons per annum. The Arecanut/
Supari/Betelnut so purchased in various Branches are brought to main centers. Here it is
garbled/graded and processed as per the requirement of the consuming markets. CAMPCO has
appointed Selling Representatives (S. R’s) for marketing its supari. These representatives canvass
for CAMPCO supari and place orders and arrange the supply of supari to their customers and
arrange the payments to CAMPCO. The goods are dispatched through CAMPCO approved
transporters by holding security deposits of both the transporters and S. R’s.

CAMPCO has opened Sales Depots at Bombay, Ahmedabad, Indore, Jaipur, Delhi, Nagpur, Patna,
Calcutta, Cuttack, Bangalore, Rajkot and Chennai and caters to the requirements of the local
customers, in the respective states. The customers can also directly contact the Branches for Supari
and their requirement will be met without the middlemen. There are about 1000 varieties of supari
marketed by CAMPCO.

CHAPTER – 2

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 DESCRIPTION
A boiler is a closed vessel in which fluid (generally water) is heated. The fluid does not
necessarily boil. The heated or vaporized fluid exits the boiler for use in various processes or
heating applications.

In campco chocolate factory we studied about briquette fire tube boiler and combined boiler (fire
tube and water tube). A briquette (or briquet) is a compressed block of coal duster
other combustible biomass material such as charcoal, sawdust, wood chips, peat, or paper used
for fuel and kindling to start a fire.

A fire-tube boiler is a type of boiler in which hot gases pass from a fire through one or (many)
more tubes running through a sealed container of water. The heat of the gases is transferred
through the walls of the tubes by thermal conduction, heating the water and ultimately
creating steam.

2.1 Fire tube boiler

Fig 2.1 Fire tube boiler

Manufacturer: THERMAX Ltd.

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Boiler capacity: 4TPH

Boiler rating: 154 m2

2.2 Combined boiler (Fire tube and water tube boiler)

Fig 2.2 Combined boiler

Manufacturer: THERMAX Ltd.

Boiler capacity: 4TPH

Boiler rating: 146 m2

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 1. Boiler Layout
Steam for the plant
Chimney

Deaeration
Return line tank
Service
tank

Steam manifold

2
2

ID FAN

5 5 6
Feed water pump DUST
6

3 3

4 4
Feed water tank Fire tube boiler
Fire tube boiler

Water treatment 7
chemicals
8

7
8 8
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Parts mentioned in the boiler layout

Water line

Steam line

Exhaust line

Air line

1. Multi stage centrifugal pump

2. Isolating valve
3. Feed water pumps
4. Feed check valves
5. Steam stop valves
6. Air preheaters
7. FD (Forced draft) Fans
8. Blow down valve

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2.3 Boiler accessories

1. Settling tank: It is a tank which collects the water from condensate steam used by the
chocolate factory plant through the condenser.

2. Fusible plug:  Fusible plug is a fitting used in Steam boilers to enhance the safety during
operation. It's working depends upon the water level in the boiler shell. A Fusible plug is a
threaded metallic cylindrical object, with a tapered hole in it which goes through its entire
length.

3. Service tank: It is tank which supplies water to the boilers and it contains two pumps to
suck the water from settling tank.

4. Deaerator: It is present above the service tank; in this the air is removed from the water.

5. Feed water pump: A boiler feed water pump is a specific type of pump used to pump feed
water into a steam boiler.

6. Feed check valve: It is used in boilers to regulate the supply of feed water and to maintain
the water level. It is fitted close to the boiler shell and in the feed pipe line.
The valve prevents water from being returned to the supply line, due to steam pressure in
the boiler.

7. Fuel: Briquettes are used as fuel in this boiler, a briquette (or briquet) is a compressed

block of coal dust or other combustible biomass material such as charcoal, sawdust, wood
chips, peat, or paper used for fuel and kindling to start a fire.

8. Chimney:
A chimney is a structure that provides ventilation for hot flue gases or smoke from a boiler
to the outside atmosphere.

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9. Steam stop valve:  It is used to regulate the flow of steam from boiler to the steam pipe or
from one steam pipe to the other.

Fig 2.38 Steam stop valve

10. Gauge glass: Gauge glass is nothing but a water level indicator. Its top side is in steam
side of boiler and bottom side is in water side. Both side pressure equalizes and indicates
the correct level.

Fig 2.39 Gauge glass

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11. Water level alarm: An external float chamber with balance connection to steam drum is
mounted on the way of the drum water level. A float within the chamber then relates to this

. Fig2.310 Water level alarm

Water level and moves an attached magnet up and down in response to any changes of
water level within the steam drum. Four micro switches with magnetically operated arms
are fitted on the outside the balance chamber. They are arranged so that when the internal
magnet comes level with one of these external magnets like poles are presented and so
repelling each other operate the micro switch and gives the alarm.
12. Pressure gauge: A pressure gauge is used to indicate the steam pressure of the boiler. It is
also called as steam gauge. It is usually mounted in the front top of the steam drum.

Fig 2.311 Pressure gauge

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13. Blower or FD fan: Forced Draft Fan is a type of a fan supplying pressurized air to a
system. In the case of a Steam Boiler Assembly, this fan is of a great importance.
As we know, for a Steam Boiler to generate steam, combustion must occur, be it any fuel
(wood/coal/rice husk/pet coke/LDO/Furnace oil) and for combustion to exist one of its
three main requirements, is the air. And this requirement is compensated by a Forced
Draft Fan.

14. Blow down valve: Boiler blowdown is the removal of water from a boiler. Its purpose is to
control boiler water parameters within prescribed limits to minimize scale, corrosion,
carryover, and other specific problems. Blowdown is also used to remove suspended solids
present in the system.

15. Air pre heater:

An air preheater (APH) is any device designed to heat air before another process (for
example combustion in a boiler) with the primary objective of increasing the thermal
efficiency of the process. They may be used alone or to replace a recuperative heat system
or to replace a steam coil.
The purpose of the air preheater is to recover the heat from the boiler flue gas which
increases the thermal efficiency of the boiler by reducing the useful heat lost in the flue gas.
As a consequence, the flue gases are also conveyed to the flue gas stack (or chimney) at a
lower temperature, allowing simplified design of the conveyance system and the flue gas
stack. It also allows control over the temperature of gases leaving the stack.

16. ID(Induced draft) fan:

Induced Draft: - A fan is used to extract the air from boiler post combustion via
(Electrostatic Precipitator if present) to exhaust through the chimney.

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 17. Safety valve: Safety valve is a valve that acts as a protection of equipment from exploding
or damaging and it is mainly installed in pressure vessels such as chemical plants, electric
power boilers and gas storage tanks. ... When the pressure becomes higher than the set
pressure, "Disc" starts to lift and discharge the fluid.

Fig 2.313 Safety valve

2.4 Boiler Maintenance

A well planned maintenance program avoid unnecessary down time or costly repairs.

2.41 Shift maintenance:

 Include checking the boiler water level in the gauge glass.
 Checking the boiler steam pressure on gauge glass.
 Chemical feed treatment.

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2.42 Daily maintenance:

 Steam pressure.
 Visual appearance.
 Test the boiler low level alarms and low water cutoff.
 Maintain a daily schedule of soot blowing.

2.43 Monthly maintenance:

 Checking the condition of refractory for damage or cracking.

 Patch and repair the refractory as required.
 Safety valve inspection and testing.
 Check for all the valves.
 Check for corrosion

2.44 Annual maintenance:

 If possible, the unit has to be inspected and checked by a service representative

from the manufacturer.
 Clean the boiler, with clean water at high pressure.
 Use hand scraper to remove accumulated sludge and scale.
 Inspect and clean the tubes.

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CHAPTER - 3

INTERNSHIP DISCUSSION
Our objective of getting practical knowledge about fire tube boiler used in the Campco ltd Puttur
are achieved.

 In Campco chocolate factory we learned more about the boiler operation and maintenance.
 We saw how the workers burn the briquettes in the boiler initially and time to time removal
of ash from the combustion chamber.
 Before putting the briquettes in the combustion chamber they are used to weigh the weight
of the briquettes.
 Fuel feeding system is manual which is done by the workers directly, they are using ramp
and sliding system.
 We can easily find out the lines of boiler that from where the water is coming and which
and all components present in the lines and the output steam line.
 Boiler water treatment plays important role in avoiding failure of the boiler functions or
decrease in the efficiency.
 Hardness, sludge and air are the parameters which will affect the boiler for scale formation,
corrosion, decrease in efficiency etc.,
 In order to remove the parameters mentioned in last point , in campco they are adding
different chemicals and chemical feeding system
Chemicals used
NALCO 2584 - In order to remove the hardness of boiler feed water they are using
this chemical for maintaining the pH to avoid scale formation and corrosion.
NALCO 7208 - Sludge removal to increase the thermal efficiency.
NALCO 2548 - Air removal to avoid erosion and vacuum inside the boiler.

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3.1 Skills observe during internship period

 Operating boiler auxiliary equipments

 Read gauges, digital meters and charts to track the boiler lines
 Monitor boiler water, chemicals and fuel.
 Checking of safety equipments regularly
 Record data and keep logs operation and safety activity.
 We got practical knowledge of the theories that we had studied.

3.2 Challenges experienced during internship

 We had only theoretical knowledge about boiler so it was initially difficult to identify the
parts
 It was challenging internship since the strength of students came for internship are more,
they could not concentrate on each one of us.
 There was no particular trainer in company to guide us, we ourselves went near boiler and
learned from workers who are working in boiler section.
 We faced some difficulties while tracing the line diagram of boiler as it was complicate in
its presence.

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Conclusion

It was completely useful experience working with the friendly welcome operators and the space
that has created for the intern allowed me with full opportunity to learn and know myself as a
worker. The experience brought out my strength and also a strong positive attitude and taught me
how to to work in such conditions. The primary objective of an internship is to gather a real life
working experience and also to put the theorectical knowledge to practice, and I have did that here
with perfections. My experience in the campco campus was highly educative one. I went to boiler
plants and equipments in the campus and got a lot of varied experience. I noticed many changes in
my attitude towards work and I am more confident and more likely to do any work now.

As a student of marine engineering after completion of my studies I or we the marine engineers

work on ship as a maintenance engineers i.e. we operate and maintain various machineries and
plants that I learnt here boler maintance and operation. In that perspective this internship was a
boon to me and I throughly enjoyed the challenges that came along every single day.

I learned that this is just the beginning of the road and I have to travel a long distance to be a
succesful person in my field. But I must say that this experience will prove an objective in my
career in shipping field.

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