SUPERVISED INDUSTRIAL TRAINING REPORT

SALVA OIL AND GENERAL INDUSTRIES

(PVT) LIMITED

BSc MECHANICAL ENGINEERING TECHNOLOGY

SUBMITTED BY
Muhammad Atiq
2018-GCUF-88800
8650
Training Period
10-08-21 to 24-10-21
DEPARTMENT
OF MECHANICAL ENGINEERING TECHNOLOGY
GOVT. COLLEGE UNIVERSITY FAISALABAD
SAHIWAL CAMPUS
2022
 SUPERVISED INDUSRIAL TRAINING REPORT
SALVA OIL AND GENERAL INDUSTRIES
(PVT) LIMITED

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR

THE AWARD OF THE DEGREE OF

BSc MECHANICAL ENGINEERING TECHNOLOGY

SUBMITTED TO

THE FACULTY OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING TECHNOLOGY

GOVT. COLLEGE UNIVERSITY FAISALABAD, SAHIWAL CAMPUS

SAHIWAL

SUBMITTED BY

Name of Student Roll No

Muhammad Atiq 8650

Training Period

10-08-2019 to 24-10-2021

GOVERNMENT COLLEGE UNIVERSITY FAISALABAD

SAHIWAL CAMPUS
2022
 CERTIFICATE
I hereby certify that I have completed the Twelve Weeks Training in partial fulfillments of
requirements for the award of BSC Mechanical Engineering Technology. I did my Training in
Salva Oil and General Industries (Pvt) Limited from 10-08-2021 to 24-10-2021.The matter
presented in this report has not been submitted by me for the award of any other degree
elsewhere.

Signature of Student
Muhammad Atiq

Examined by:
Engr. Syed Muhammad Raza

INCHARGE/HOD
Engineering and Technology Department
 ACKNOWLEDGEMENT
Praise and glory be almighty God who is creator of the universe, who enables us to fulfill the
required functionalities of this report. I would like to sincerely thank my report supervisor
Engr. Syed Muhammad Raza or his ideas, contribution and guidance and throughout the report
duration and this all was not possible without his guidance and mortal support. I would like to
thanks HOD Engr. Muhammad Adeel Aslam for his guidance. He was always there whenever
his help and ideas. We acknowledge the help of all our teaching faculty, report director
mechanical department and library staff for providing the require resources, with provided us
every opportunity to work in healthy atmosphere.

Signature of Student

Muhammd Atiq (8650)

i
 TABLE OF CONTENTS

Title Page No

Acknowledgement i

Table of Content iii

List of Figures v

ii
 TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION ............................................................................ 1

1.1 ESTABLISHMENT .................................................................................................... 1

1.2 LOCATION.............................................................................................................. 1
1.3 PROJECTS AND PRODUCTS ..................................................................................... 1
1.3.1 SALVA OIL AND GENERAL INDUSTRIES ............................................................... 2
1.3.2 FAZAL PAPER MILLS .......................................................................................... 2
1.3.2.1 PURCHASE MARKET ........................................................................................ 2
1.3.3 FATIMA VEGETABLE OIL MILLS ....................................................................... 2
1.3.3.1 MAJOR MARKET OF INDUSTRY ....................................................................... 3
1.3.4 SALVA FOOD MILLS PVT LTD ........................................................................... 3
1.3.4.1 MAJOR MARKET ............................................................................................. 3
1.3.5 NEMAT FOODS PVT LTD ................................................................................... 3
1.3.5.1 MAJOR MARKET OF THE INDUSTRY ................................................................. 3
1.3.5.2 PRODUCTION CAPACITY .................................................................................. 4
1.3.6 RAVI RICE MILLS............................................................................................... 4
1.3.7SALVA THERMAL POWER PLANT......................................................................... 4
1.4 SALIENT FEATURES ............................................................................................... 4
1.4.1 INTEGRITY .......................................................................................................... 4
1.4.2 ACCOUNTABILITY ............................................................................................... 4
1.4.3 DIVERSITY ......................................................................................................... 5
1.4.4 QUALITY............................................................................................................. 5
1.5 ORAGANO GRAM OF INDUSTRY ............................................................................. 5
CHAPTER 2 TRAINING WORK ................................................................................ 6

2.1 THERMAL POWER PLANT ....................................................................................... 6

2.2 SAFETY .................................................................................................................. 6
2.3 WATER TREATMENT .............................................................................................. 6
2.4 RO PLANT ............................................................................................................. 7
2.4.1GROUND WATER ................................................................................................. 7
2.4.2 RAW WATER PUMP ............................................................................................ 7
2.4.3 DUAL MEDIA FILTER .......................................................................................... 7
2.4.4 BACK WASH FILTER ........................................................................................... 8
2.4.5 SOLENOID OPERATING VALVE ........................................................................... 8
2.4.6 CARTRIDGE FILTER............................................................................................. 9
2.4.7 HIGH PRESSURE PUMP ........................................................................................ 9
2.4.8 SEMI PERMEABLE MEMBRANE ......................................................................... 10
2.5 DEMINERALIZATION PLANT ................................................................................. 10
2.5.1 CATION FILTER ................................................................................................. 10
2.5.2 ANION FILTER .................................................................................................. 11
2.5.3 MIXED BED FILTER .......................................................................................... 11
2.5.4 REGENRATION .................................................................................................. 11
2.6 FUEL USE IN POWER PLANT................................................................................. 12
2.7 BOILER AND ITS TYPES ........................................................................................ 12
2.7.1 FIRE TUBE BOILER............................................................................................ 12
2.7.2 Water Tube Boiler ......................................................................................... 12

iii
 2.8 BOILER PARAMETERS ......................................................................................... 13
2.9 MANUFACTURING HISTORY ................................................................................ 13
2.10 BOILER EQUIPMENT .......................................................................................... 14
2.10.1 FUEL PROVIDING UNIT .................................................................................. 14
2.10.1.1 FUEL ........................................................................................................... 14
2.10.1.2 FUEL PROCESSING UNIT .............................................................................. 14
2.10.1.2.2 FUEL CHAMBER ........................................................................................ 14
2.11 FUEL DELIVERY SYSTEMS ................................................................................. 14
2.12 DEAERATOR ..................................................................................................... 15
2.13 FEED WATER PUMP ............................................................................................ 15
2.14 FURNACE OF BOILER ......................................................................................... 16
2.15 STEAM DRUM .................................................................................................... 17
2.16 MUD DRUM ....................................................................................................... 17
2.17 BOILER TUBE ..................................................................................................... 18
2.18 VALVES USED IN BOLIER................................................................................... 18
2.18.1 GATE VALVE .................................................................................................. 19
2.18.2 GLOBE VALVE ................................................................................................ 19
2.18.3 FEED CHECK VALVE ....................................................................................... 20
2.18.4 DIAPHRAGM VALVE ....................................................................................... 20
2.18.5 NRV ............................................................................................................... 20
2.18.6 VENT VALVE .................................................................................................. 21
2.18.7 SAFETY VALVE .............................................................................................. 21
2.18.8 MOTOR OPERATING VALVE............................................................................ 22
2.18.9 AC VALVE...................................................................................................... 22
2.18.10 BALL VALVE ................................................................................................ 22
2.19 VALVE SYMBOLS ............................................................................................... 23
2.20 GAUGES USED IN BOILER .................................................................................. 23
2.20.1 PRESSURE GUAGE........................................................................................... 23
2.20.2 TEMPERATURE GUAGE .................................................................................. 24
2.20.3 GUAGE GLASS ................................................................................................ 24
2.21 ASH CONVEYS ................................................................................................... 25
2.22 CYCLONE SEPERATOR....................................................................................... 25

CHAPTER 3 SKILL ATTAINED............................................................................... 26

3.1 PLANT CYCLE AND WORKING PRINCIPLES ......................................................... 26

3.2 MECHANISM OF PLANT ...................................................................................... 26
3.3 FUEL PROCESSING .............................................................................................. 26
3.4 FUEL TRANPORTATION ....................................................................................... 26
3.5 FUEL STORAGE IN BOILER ................................................................................. 27
3.6 FUEL DELIVERY TO THE FURNACE ..................................................................... 27
3.7 PROCESSED WATER SUPPLY ............................................................................... 27
3.8 WORKING PRINCIPLE OF DE AERATOR .............................................................. 27
3.9 ECONOMIZER ...................................................................................................... 28
3.10 SOOT BLOWER RETRACABLE ............................................................................. 28
3.11 STEAM DRUM .................................................................................................... 29
3.12 DEMISTER WORKING MECHANISM .................................................................... 30
3.13 BANK OF TUBES ................................................................................................ 30
3.14 MUD DRUM ....................................................................................................... 30
3.15 SUPER HEATER WORKING PRINCIPLE ................................................................ 30

iv
 3.16 W.P OF FURNACE .............................................................................................. 31
3.17 W.P OF FD FAN ................................................................................................. 31
3.18 W.P Of Air Pre Heater...................................................................................... 32

CHAPTER 4 CONCLUSION, FEEDBACK & RECOMMENDATIONS ............. 33

4.1 CONCLUSION OF INTERNSHIP AT INDUSTRY ................................................... 33

4.2 CONCLUSION OF THEORETICAL CONCEPTS .................................................... 33
4.3 FEEDBACK FOR INDUSTRY ............................................................................. 33
4.4 FEED BACK FOR UNIVERSITY ............................................................................ 33
REFRENCES ...................................................................................................................

v
 LIST OF FIGURES
Figure Page
1.1 ................................................................................................................................................ 1
1.2 ................................................................................................................................................ 1
1.3 ................................................................................................................................................ 2
1.4 ................................................................................................................................................ 2
1.5 ................................................................................................................................................ 3
1.6 ................................................................................................................................................ 4
2.1 ................................................................................................................................................ 6
2.2 ................................................................................................................................................ 7
2.3, 2.4, 2.5 .................................................................................................................................. 8
2.6, 2.7 .......................................................................................................................................... 9
2.8, 2.9 ........................................................................................................................................ 10
2.10, 2.11 .................................................................................................................................... 11
2.12 ............................................................................................................................................. 12
2.13 ............................................................................................................................................. 13
2.14 ............................................................................................................................................. 14
2.15, 2.16 .................................................................................................................................... 15
2.17, 2.18 .................................................................................................................................... 16
2.19a, 2.19b................................................................................................................................. 17
2.19c, 2.20 ................................................................................................................................... 18
2.21, 2.22 .................................................................................................................................... 19
2.23, 2.24 .................................................................................................................................... 20
2.25, 2.26, 2.27 ........................................................................................................................... 21
2.28, 2.29 .................................................................................................................................... 22
2.30 ............................................................................................................................................. 23
2.31, 2.32, 2.33 ........................................................................................................................... 24
2.34, 2.35 .................................................................................................................................... 25
3.1 ............................................................................................................................................... 27
3.2 ............................................................................................................................................... 28
3.3, 3.4 ........................................................................................................................................ 29
3.5 ............................................................................................................................................... 30
3.6, 3.7 ........................................................................................................................................ 31
2.32 ............................................................................................................................................. 23
vi
TABLE PAGE

2.1 ............................................................................................................................................... 12
2.2 ............................................................................................................................................... 13
3.1 ............................................................................................................................................... 32
3.2 ............................................................................................................................................... 32

vii
CHAPTER 1: INTRODUCTION
1.1 Establishment

Fig 1.1 Monogram of Salva Group of Industries

Salva Group of industries was established in the era of 1980 with trading of commodities and
gradually entered the manufacturing of various products. The Group has success story spread
over 3 decades , expanding its horizon from trading to manufacturing company

1.2 Location

Fig 1.2 Location

The Company is located on Faislabad Road at the distance of 10-KM from Okara .

1.3 Projects & Products

• Salva Group of Industries consists of following projects:-

• Salva Oil & General Industries Pvt Ltd
• Fazal Paper Mills Pvt Ltd
• FatimaVegetable Oil Mills Pvt Ltd
• Salva Feed Mills Pvt Ltd
• Nemat Food Pvt Ltd
• Ravi Rice Mill Ltd.

1
1.3.1 Salva Oil & General Industries
Salva Oil & General industries is one of the oldest ghee manufacturing unit in Salva group
of Industries with its high quality and brand Salva Oil and General Industries is providing
export quality edible oil and Ghee. Olive oil and extension is one of the planned project of
salva oil and general industries .currently it is producing following brands

• Nemat Banaspati
• Nemat Cooking Oil
• Nemat Soap

1.3.1.1 Major Market of the Industry

Salva Oil & General Industries covers vast area of the Southern Punjab with its demanding
brand Nemat Banaspati ,Nemat Cooking Oil & Nemat Soap. With the passage of time
area of Northern Punjab has also covered with these brands

1.3.1.2 Sales Market

Sales market of the industry is within the Punjab but it works for broadening their marketing
scope up to the country level.

1.3.1.3 Purchase Market

The raw material for ghee and cooking oil is mainly being import from Malaysia .And the
total volume of imports of the industry is 40,000 MT(2016) on yearly basis.

1.3.2Fazal Paper Mills Pvt Ltd

Fig 1.3 Fazal Paper Mill

2
 Fazal Paper Mills was established in September 2008 with a single plant of packing
Material having capacity of 10tons per day. Now company is producing world class paper
board wiring paper & packing paper having capacity of 140 tons a day.

• Neeli Bar
• Top Rider
• Ravi Super
• Ravi Special

1.3.2.1 Purchase Market

The raw material for paper and board is mainly imported from America ,Middle East and
Taiwan.The total volume of waste and chemical import of industry is 3016.18 MT on
yearly basis(2014)

1.3.3 Fatima Vegetable Oil Mills Pvt Ltd

Fig 1.4 Fatima Vegetable Oil

Fatima vegetable oil industry was established in 2011 producing high quality cooking oil
and banaspati with the name of

• Salva banaspati
• Salva Cooking oil
• Salva Canola Cooking Oil
• Salva Sunflower oil
• Salva Soap

3
1.3.3.1 Major Market of the industry
Fatima vegetable oil mills targeted rural areas of Punjab where other brands are un
reacheable.

1.3.4 Salva Feed Mills Pvt Ltd

Salva feed mills was established in 2014 and started commercial production of poultry feed
in April-2016

Fig 1.5 Salva Feed

1.3.4.1 Major Market

Salva Feed targeted rural areas of Centeral Punjab

1.3.5 Nemat Foods Pvt Ltd

Nemat food is the lates addition in the salva group of industry established in September
2014 producing high quality blend of black tea with the name Namet Gold Label Tea.

1.3.5.1Major Market of the Industry

Nemat Food ( a tea manufacturing industry) targeted mostly southern and centeral areas of
Punjab however it is working for broadening sales market throughout the country

4
1.3.5.2 Production Capacity and Current Production
Currently company is producing 10 tons per day but the production capacity is 50 tons per
day which will be increase gradually.

1.3.6 Ravi Rice Mills Pvt Ltd

Fig 1.6 Nemat Rice

Salva Group of Industry has started this business in 1965 and now the Ravi Rice Mill is one
of the main rice processing plant in Pakistan and exporting the products to Europe and
UAE.

1.3.7 Salva Group of Industries Thermal Power Plant

In 2014 there was a huge shortage of electricity in Pakistan which was resulting in bad
shutdown of industries across the country due to unsuffcient power supply.Salva Group
decided to establish its own thermal power production unit of 8MW so that all industries
can run smoothly.In this regard Cheema Boilers(India) and Triveni Turbines(India) were
hired and installation of plant completed in 2016.

1.4 Salient Features

1.4.1 Integrity
The company admire and respect its stakeholders they are driving force behind our success that
spread over the period of three decades

1.4.2 Accountability
The Company is passionate about its protection, prevention & the progress of the people connected
with it.Its exceptional services & innovative products help its business to grow in the righteous
direction

5
 1.4.3 Diversity
The people are the most valuable asset to have and the company has mission to build an inclusive
environment that acknowledges everyones opinion.Salva is commited to inclusion and diversity.

1.4.4 Quality
The company is commited to continous improvement in quality and has established a quality
management system that provide a framework of measuring continous improvement and
enforcement of quality principles.

1.5 Organogram of Industry

CEO

Administrator

General Manager

Production HR Plant Manager

Manager Manager

Workers and Engineers

Team Leader
Clerks

Foreman

Worker

6
CHAPTER 02 : TRAINING WORK
2.1Thermal Power Plant
A thermal power station is a power station in which heat energy is converted to electricity.
Typically, water is heated into steam, which is used to drive an electrical generator. After it passes
through the turbine the steam is condensed in a steam condenser and recycled to where it was
heated. This is known as a Rankine Cycle. The greatest variation in the design of thermal power
stations is due to the different heat sources: fossil fuel, nuclear energy, solar energy, biofuels, and
waste incineration are all used. Certain thermal power stations are also designed to produce heat
for industrial purposes, for district heating, or desalination of water, in addition to generating
electrical power.

Fig 2.1 Thermal Power Plant

2.2 Safety
Safety is one of the priorities of the plant. The safety equipment includes safety shoes, goggles,
earplugs and helmets. Other equipment, like safety harnesses and aprons are also used for some
jobs.
Outside the plant the walkways are indicated. The danger signs are installed wherever necessary.
The sign of high noise is also installed where needed. The whole plant is house kept regularly. The
awareness boards are installed to encourage safety and housekeeping.
2.3 Water Treatment
Water treatment is any process that improves the quality of water to make it appropriate for a
specific end-use. The end use may be drinking, industrial water supply, irrigation, river flow
maintenance, water recreation or many other uses, including being safely returned to the
environment.
7
It has two methods of water treatment.
1. RO Plant
2. Demineralization Plant
2.4 RO Plant (Reverse Osmosis)
Reverse osmosis plants require a variety of pre-treatment techniques including softening,
dechlorination, and anti-scalent treatment. Following pre-treatment, high levels of pressure send
water through a semi-permeable membrane, which retains all contaminants but lets pure water pass
through. Energy requirements depend on the concentration of salts and contaminants in the influent
water; higher concentrations requires more energy to treat.
2.4.1 Ground Water
In the process of groundwater Total Dissolved Salt (TDS) membrane is selected base upon the
(TDS) value obtained in the raw water.
TDS value can be majority calculated by using these two methods:
• Using and electrical conductivity meter
• Using filter paper and a scale

2.4.2Raw Water Pump

Raw-water pump This pump does the bulk of the engine’s cooling. It draws raw water (this may be
seawater, fresh water or whatever mixture of the two the boat is floating in) into the engine’s open
or raw-water cooling circuit using a rubber impeller.

Fig.2.2 Raw Water Pump

2.4.3 Dual Media Filter

Water treatment plants now use rapid dual-media filters following coagulation and sedimentation.
A dual-media filter consists of a layer of anthracite coal above a layer of fine sand. The upper layer
of coal traps most of the large floc, and the finer sand grains in the lower layer trap small
impurities.

8
 Fig.2.3 Dual Media Filter

2.4.4 Backwash Filter

A Backwashing filter will collect any particles that flow through your water. As water flows
through the tank, the backwash system will reverse the flow and drain it out of the filter media.
Next, it will use compressed air to suspend any particles in the filter media.

Fig.2.4 Backwash Filter

2.4.5 Solenoid Operating Valve

Solenoid valves are electrically activated valves, typically used to control the flow or direction of
air or liquid in fluid power systems. The most basic solenoid valves are two-way, two-position
poppet valves, which simply open and close, modifying their flow path when their coil is
energized.

Fig.2.5 Solenoid Operating Valve

9
2.4.6 Cartridge Filter
A cartridge filter is a piece of tubular filtration equipment that can be used across various
industries for an array of filtration requirements. A cartridge is encased within a housing or a
casing and used to remove unwanted particles, pollutants, and chemicals from liquids.

Fig.2.6 Cartridge Filter

2.4.7 High Pressure Pump
High-pressure pumps are used to feed water and/or chemical liquids to the pressurized
environment or to flow water using pressure. The following paragraphs introduce three
typical high- pressure pumps that play an active role in thermal power plants, steelworks, and
desalination plants.

Fig.2.7 High Pressure Pump

10
2.4.8 Semi Permeable membrane
Semi Permeable membranes are used for reverse osmosis where an applied
pressure selectively forces water from a solution through the membrane to separate it from solute.
Strong synthetic membranes are required for effective, i.e., high pressure, purification.

Fig 2.8 Semipermeable Membrane

2.5 Demineralization Plant
Demineralization is the removal of dissolved solids in the water through ion exchange. A
demineralizer from EUROWATER requires no special pre-treatment of the inlet water to achieve
demineralized water quality. The plants are used for many applications, including production of
rinse water, process water, boiler water, and more.The demineralization plants are two-column
systems, where the water first passes through a cation exchange column and then next passes
through an anion exchange column.

2.5.1 Cation Filter

One resin will remove positively charged ions and the other will remove negatively charged ions.
In a dual bed system, the cation resin is always first in line. As city water enters the tank filled
with cation resin, all positively charged cations are attracted to the cation resin bead and exchanged
for hydrogen.

Fig 2.9 Cation Filter

11
2.5.2 Anion Filter
Anion exchange devices remove anions (negatively charged ions such as arsenic and nitrate) and
replace them with chloride.

Fig 2.10 Anion Filter

2.5.3 Mixed Bed Filter

A method of mixed-bed filtration and demineralization for removing suspended impurities from
the primary cooling water in a power plant by means of a demineralizer having a mixed bed
formed of a particulate cation and anion exchange resin that have such a surface layer structure that
granules are seen to bind with one another under microscopic examination, being able to be
operated in a safe and yet economical manner by virtue of established conditions for operating
processes, such as regeneration of the demineralizer by backwashing and by passage of chemicals
and also, replacement of the demineralizer.

Fig 2.11 Mixed Bed Filter

2.5.4 Regenration

• Cation exchange resins are generated by treatment with HCL then washing with water.
• Anion exchange resins are generated by treatment with caustic soda then washed with
water

12
2.6 Fuel Use in Power plant
Table 2.1 Fuel Used
Fuel Type Bio mass and coal
Fuel (Imported/Indigenous) Indigenous
Fuel Suppliers Local Contractors/Suppliers
Supply Arrangement Trucks/Roads
Storage Area 15000m2

2.7 Boiler and Its Types

A boiler is a closed vessel in which working 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, including water heating, central heating, boiler-based power
generation, cooking, and sanitation.

2.7.1 Fire Tube Boiler

A fire-tube boiler is a type of boiler in which hot gases pass from a fire through one or 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.

Fig .2.12 Fire Tube Boiler

2.7.2 Water Tube Boiler

A water tube boiler (also spelled water-tube and water tube) is a type of boiler in which water
circulates in tubes heated externally by the fire. Fuel is burned inside the furnace, creating hot gas
which boils water in the steam-generating tubes. In smaller boilers, additional generating tubes are
separate in the furnace, while larger utility boilers rely on the water-filled tubes that make up the
walls of the furnace to generate steam.

13
 Fig 2.13 Water Tube Boiler

2.8 Boiler Parameters

Table 2.2 Boiler Parameters
Boiler Type Water Tube
Orientation Vertical Type
Steam Production Capacity 50 ton/h
Steam Pressure 65 bar
Fuel Type Coal & Biomass
Boiler Control Semi Automatic (PLC)
Manufacturer & Installers Cheema Boilers (Mohali India)
Year of Installation 2014

2.9 Manufacturer History

Cheema Boilers Limited is a leading resource for design, innovation, manufacture and
commissioning of boilers and auxiliaries, with decades of experience in serving diverse industries.
CBL has the necessary presence, competence and solutions to provide a broad range of
technologies across major industries. Whatever be your field of industry, CBL can help you meet
your energy demands with improved cost efficiencies. CBL can also efficiently partner you for
waste heat recovery, incinerators for hazardous waste and a wide array of air pollution control
equipment.

14
2.10 Boiler Equipment
2.10.1 Fuel Providing Unit

2.10.1.1 Fuel
Fuel is the most important element of power plant .Different type of fuel require different type of
equipment and it can change the whole working mechanism and machinery of plant.Generally
Coal and Biomass is used as a fuel in the boiler.Coal is used as main fuel and corn straw is used to
make process economical due to low cost.

2.10.1.2 Fuel Processing Unit

2.10.1.2.1 Fuel Crusher

A crusher is a machine designed to reduce large Coal stones into smaller Coals particles, gravel, or
rock dust. Crushers are machines which use a metal surface to break or compress materials.

Fig 2.14 Fuel Crusher

2.10.2.1.2 Coal Separator

A size based coal separator machine is used to separate larger particles and stones of coal and
small fine particles.Small fine particles can burn easily along with corn straw.The larger separted
particles are again passed through crusher machine.

2.11 Fuel Delivery System

Coal and biomass is delivered to fuel feeder unit in boiler through conveyer belt. An alternative to
conveyer belt is elevator . Fuel is mixed and placed on conveyer belt through a machine and then
conveyed to feeder

15
 Fig. 2.15 Conveyer Belt

2.12 De Aerator
Thermal de aerators are commonly used to remove dissolved gases in feed water for steam-
generating boilers. Dissolved oxygen in feed water will cause serious corrosion damage in
a boiler by attaching to the walls of metal piping and other equipment and forming oxides (like
rust).

Fig 2.16 De aerator

2.13 Feed Water Pump

A boiler feed water pump is a specific type of pump used to pump feedwater into a steam boiler.
The water may be freshly supplied or returning condensate produced as a result of the
condensation of the steam produced by the boiler

16
 Fig 2.17 Feed Water Pump

2.14 Furnace of Boiler

Furnaces heat air and distribute the heated air through the house using ducts. Boilers heat water,
and provide either hot water or steam for heating. Steam is distributed via pipes to steam radiators,
and hot water can be distributed via baseboard radiators or radiant floor systems, or can heat air via
a coil

Fig. 2.18 Furnace of Boiler

17
2.15 Steam Drum
A steam drum is a standard feature of a water-tube boiler. It is a reservoir of water/steam at the top
end of the water tubes. The drum stores the steam generated in the water tubes and acts as a phase-
separator for the steam/water

Fig 2.19a Steam Drum at Plant

Fig 2.19b Steam Drum

2.16 Mud Drum

The mud drum is the lower drum in a boiler. The steam drum is the upper drum of a boiler where
all of the generated steam is collected. The mud drum and water tubes are filled completely with
water, while the steam drum is only partially full
18
 Fig 2.19c Mud Drum

2.17 Boiler Tubes

Boiler Tubes are metal tubes located inside of boilers that heat water in order to produce steam.
There are two major types of tube boilers. Water-tube boilers and fire-tube boilers. In water-tube
boilers, water circulates inside the tubes and is heated externally by hot gases generated by the
furnace. Alloy Steel & Carbon Steel is used to make tubes.

Fig.2.20 Boiler Tubes

2.18 Valves Used in Boilers

Following are some types of valves used in boilers

• Gate Valve
• Globe Valve
• Feed Check valve
• Non Return Valve

19
 • Vent Valve
• Safety Valve
• Motorized Operated Valves
• Auto Control Valves
• Valve Symbols

2.18.1 Gate Valve

Gate valve, also known as a sluice valve, is a valve that opens by lifting a barrier (gate) out of the
path of the fluid. Gate valves require very little space along the pipe axis and hardly restrict the
flow of fluid when the gate is fully opened.

Fig 2.21 Gate Valve

2.18.2 Globe Valve

A globe valve is a linear motion valve used to stop, start, and regulate the fluid flow. The globe
valve disk can be removed entirely from the flow path, or it can completely close the flow path.
During the opening and closing of the valve, the disc moves perpendicularly to the seat.

Fig 2.22 Globe Valve

20
2.18.3 Feed Check Valve
Feed Check Valves are one of the most important components of boiler which control the flow of
water from feed pump to the boiler and further prevents the backflow of water from boiler to pump
when the boiler pressure is more than the pump pressure or when feed pump stops working.

Fig 2.23 Feed Check Valve

2.18.4 Diaphragm Valves

They are used to control fluid flow by regulating the area with which media can enter and exit
the valve, effectively changing its speed and velocity. They are so-called
“diaphragm” valves because a thin, flexible membrane is used to control the opening and closing
of the valve.

Fig 2.24 Diaphragm Valve

2.18.5 Non Return Valve

A non-return valve allows a medium to flow in only one direction and is fitted to ensure that the
medium flows through a pipe in the right direction, where pressure conditions may otherwise cause
reversed flow.

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 Fig 2.25 NRV

2.18.6 Vent Valve

The radiator's air valve, or radiator air vent or steam valve as it is sometimes called, is used only in
one-pipe steam boiler systems. It is usually located at the end of the radiator opposite the supply
pipe, about halfway up or higher towards the top.

Fig.2.26 Vent Valve

2.18.7 Safety Valve

A safety valve is a device that automatically relieves pressure and is actuated by pressure upstream
of the valve. .This type of valve will fully open at a set pressure and remain fully open until
the boiler pressure reaches a preset pressure. This preset pressure is set lower than the lifting
pressure

Fig 2.27 Safety Valve

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2.18.8 Motor Operated Valve
Motor operated valves are typically used in process plants as on-off valves. So instead of fluid
flow control, they simply turn the flow of process fluid on or off, with .

Fig 2.28 MOV

2.18.9 Auto Control Valve

A flow control valve regulates the flow or pressure of a fluid. Flow Control valves normally
respond to signals generated by independent devices such as flow meters or temperature gauges.
Control valves are normally fitted with actuators and positioners. Pneumatically-actuated globe
valves are widely used for control purposes in many industries, although quarter-turn types such as
(modified) ball and butterfly valves are also used.

Fig 2.29 ACV

2.18.10 Ball Valve

A ball valve is a form of quarter-turn valve which uses a hollow, perforated and pivoting ball to
control flow through it. It is open when the ball's hole is in line with the flow and closed when it is
pivoted 90-degrees by the valve handle

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 Fig 2.30 Ball Valve

2.19 Valve Symbols

2.20 Gauges Used In Boilers

Mostly three types of gauges are used in boilers

• Pressure Gauge
• Temprature Guage
• Guage Glass

2.20.1 Pressure Gauge

Steam boiler use pressure gage to measure pressure at some places either for water fluid or steam
fluid. Pressure gauge is useful for the operator or personnel who working in steam boiler area to
see working pressure and try to control the pressure under MAWP (Maximum Allowable Working
Pressure).

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 Fig 2.31 Pressure Gauge

2.20.2 Temperature Gauge

Temperature gauges operate on the gas-actuated, bimetal or expansion principle. They can measure
temperatures between -200 … +700 °C. All instruments are also suitable for operation in thermo
wells.

Fig 2.32 Temprature Gauge

2.20.3 Gauge Glass

The glass tube of a water gauge by which the water level in a boiler or tank is observed .

Fig.2.33 Gauge Glass

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2.20.4 Sight Glass
A sight glass or water gauge is a type of level sensor, a transparent tube through which the operator
of a tank or boiler can observe the level of liquid contained.

Fig 2.34 Sight Glass

2.21 Ash Conveyer

Ash conveyors are devices that help move ash from one system to the next. The most common of
these conveyors use a giant screw inside a tube. One end of the tube is inside the ash that needs to
move out.

Fig.2.35 Ash Conveyer

2.22 Cyclone Separator

Cyclone separators or simply cyclones are separation devices (dry scrubbers) that use the principle
of inertia to remove particulate matter from flue gases. Cyclone separators is one of many air
pollution control devices known as pre cleaners since they generally remove larger pieces of
particulate matter.

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CHAPTER 03: SKILLS ATTAINED
3.1 Observation of Plant Cycle and Working Principles
Following is the complete lay out of thermal power plant

3.2Working mechanism of Plant

All the procedures and practices involve in efficient and continous working of whole power plant
is discussed with original parameters and principles.

3.3 Fuel Processing

The fuel used for this plant consist of coal and biomass .Biomass is used to reduce cost of fuel
however it has some disadvantages but neglected due to high cost reduction .The coal is filtered
through a machine which uses set of perforated trays moving in a reciprocating manner so that fine
coal can be separated and delivered toward conveyer belt using a conveyer belt .

3.4Fuel Transportation
The fine coal and corn straw and Pedi straw is mixed in well and then coal is mixed through the
coal processor discussed above. Fuel is transported through conveyer belt moving on rollers. The
fuel is collected in hopper .

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3.5 Fuel Storage in Boiler
Fuel is stored in hopper store so that in case of shortage due to any fault it can work continuously
for 1 hour without more external fuel supply. The quantity of fuel is supervised by the operator
sitting in control room with the help of sensors and a manual operator deployed at hopper. In case
of negligence of manual operator, PLC operator can stop conveyer belt to stop further supply of
fuel .PLC operator can inform manual operator through a siren.

3.6 Fuel delivery to the furnace

Fuel is delivered to the furnace through set of screw conveyers and coal feeders. Coal feeder is
used only in case of pure coal usage otherwise screw conveyers are used.

3.7 Processed Water Supply

Feed water from the feed water tank is supplied to the de aerator .

3.8 Working Principle of De- Aerator

Thermal de aeration relies on the principle that the solubility of a gas in water decreases as the
water temperature increases and approaches its boiling point. In the de aerator, water is heated up
to close to its boiling point with a minimum pressure drop and minimum vent. De aeration is done
by spraying feed water into a chamber to increase its surface area, and may involve flow over
multiple layers of trays. This scrubbing (or stripping) steam is fed to the bottom of the de aeration
section of the de aerator. When steam contacts the feed water, it heats it up to its boiling point and
dissolved gases are released from the feed water and vented from the de aerator through the vent.
The treated water falls into a storage tank below the de aerator. The excess water flows out of tank
through a over flow valve. The whole process is monitored by the PLC operator and a manual
worker deployed at de aerator which can examine process and level through gauge glass and sight
glass.Chemical such as Hydrazine is dosed through a reciprocating dosing pump into the de aerator
tank for further removal of remains of gases.

Fig.3.1 Working of De Aerator

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3.9 Economizer

Working principle
The Economizer in Boiler works on the principle of Heat Transfer. Heat transfer usually takes
place from high temperature to low temperature. In the case of Boilers, flue gases or exhaust from
the boiler outlet are at high temperature and water that needs to be preheated is at low temperature.
Generally, If the required water temperature is above the normal boiling point at atmospheric
pressure, then the Boiler Economizers are needed to be pressurized and if they are below the
boiling point they can be made non-pressurized

Fig 3.2 Economizer

3.10 Soot Blower Retractable in Economizer

Retractor soot blower is used for economizer. Soot blowing is performed after every 8 hours at
temperature of about 100C having pressure 6 bar.

Working Mechanism of Soot Blower

Soot blowers are placed in the flue gas path to clean some portion of the tube. When blowing is
starting this high pressure steam comes out at high velocity from the nozzle of blower. This high
velocity steam clean the soot deposits on the tube. The blower rotates by 360 degree by means of
electrical motor

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 3.3 Soot Blower Working

3.11 Steam Drum

The temperature of feed water is further increased and from economizer it moves toward steam
drum.

Working Principle
The steam and water mixture enters the steam drum through riser tubes, drum internals consisting
of demister separate the water droplets from the steam producing dry steam. The saturated water at
the bottom of the steam drum flows down through the down comer pipe, normally unheated, to
headers and water drum.

Fig.3.4 Steam Drum Working

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3.12 Demister working mechanism
As the name indicates the demister is used for removal of the mist from gaseous phase.
The demister pads work by coalescing smaller liquid droplets by obstructing their path.

Fig 3.5 Working of Demister

3.13 Bank of Tubes

Number of Tubes are used for the water movement from steam drum to mud drum .The tubes used
in the boiler under observation have 65mm diameter. The tubes are directly in contact with flue
gases which convert the water in down comer tubes into steam

3.14 Mud Drum Working Principle

The flow of hot water at the base of the steam drum will be supplied into mud drum via down
comer tube as well as to heat the water in the mud type drum. Whenever cooler supply water is
initiated into steam type drum due to the high concentration of cool water, and it moves down in
the down comer type tube near mud drum. When transferring hot water from the mud type drum to
steam type drum using riser tubes then it consequences in normal water circulation in the water
tube type boiler. As additional steam is generated in the boiler then the force in the drum enhances
& the water supply into the drum reduces which tend for decreasing the flow of steam. In the same
way, when the production rate of steam reduces the force in the water-tube boiler reduces, & the
water supply into the boiler enhances which tends to enhance the production rate. Like this, the
water tube boiler controls the production of steam

3.15 Super Heater Working Principle

Steam from tubes and mud drum is rised up due to low density than water and collected into steam
drum but still steam is saturated .It is further moved toward super heater and then become
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superheated.It superheats the steam generated by the boiler and increases the temperature steam
above saturation temperature at constant pressure. It superheats the steam generated by the boiler
and increases the temperature steam above saturation temperature at constant pressure

Fig 3.6 Working of Mud Drum

3.16 Working Principle of Furnace

Furnace is the most important part of boiler. Above furnace there is a super heater which uses flue
gas to super heat saturated steam. Similarly banks tubes use flue gases to convert water in the tubes
to steam. Furnace consist of a chain grate which is used for movement of fuel .Chain grid consist
of number of stokers. Fuel is dropped and well spread on the surface of moving stoker. Chain
containing stokers moves at 0.2 rpms. A motor having 700 rpms is used along with gearbox to run
the chain grate. Fuel is spread well with the help of air from down side of chain and air is moved
up through holes in stoker. The air is preheated to achieve complete combustion of fuel during
cycle. The Ash falling from Chain grid is extinguished through water and then transported to truck
through a conveyer belt.

Fig 3.7 Working of Furnace

3.17 Working Principle of FD fan

Forced draft fan is used to intake air for combustion. FD fan under observation have 797 rpm and
the air is moved toward air pre heater

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 Table 3.1 FD Fan Parameters

RPMs 797 (max 1500)

Air Pressure 174.8 mm of H2O

Air Flow rate 733861.7 ton/hour

3.18 Working Principle of air pre heater

Primary air pre heater is used increase temperature of air and then again moved toward Secondary
air pre heater air duct where its temperature is further increased and air is supplied through divider
ducts .The flow of air is controlled through damper

• Secondary air for front wall

• Secondary air for rear wall

• Secondary air for stoker

• Secondary air for fuel feeding

Table 3.2 Air Pre heater Parameters

Sec. FD Rpms 1150 rpms

Pressure 325.9 mm of H2O

Temperature of air of front wall 135.1 C

Temperature of air of rear wall1 135.7

Temperature of air of stoker 131.7

Temperature of air of fuel 136.7

feeding

Air flow rate 232119.0 ton/h

33
Rpms of Primary FD 850 rpms

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CHAPTER4:CONCLUSION, FEEDBACK RECOMMENDATION
4.1 Conclusion of Internship at Industry
From whole internship it is concluded that the system at the plant is latest and working efficiently.
There is a wonderful mechanism to control each system associated with plant. Water tube boiler is
installed of capacity 50 ton /h steam having 65 bar pressure and approx 491 degree Celsius
temperature. The boiler is equipped with accessories such as super heater , air pre-heater and
economizer to increase efficiency of boiler and make it economical. After passing through turbine
steam is condensed using a condenser and water moves toward cooling tower where its
temperature is further decreased and returns back to absorb temperature of steam which is just
entered to condenser ,now the water is moved toward feed water tank and from there it will be
again move toward boiler after mixing with makeup water .There is supply line of water from
cooling tower to the generator to cool it and the water after cooling the generator is then exhausted
through a pipeline.This was the whole system which was under consideration during internship.

4.2 Conclusion of theoretical concepts during study at University

During study we went through all the concept related to the equipment deeply. We studied their
working principles ,work done, merits/demerits and efficiency .We are aware about all the system
under observation during internship and the knowledge delivered by our hardworking teachers
proved extremely helpful during internship.

4.3 Feedback for Industry

First of all I am very thankful to the industry administration especially general manager for giving
me opportunity to learn at their plant when number of industries refused due to worst pandemic
situation. All of the employees were very cooperative and guided me & other internees very well.
Every worker was well aware about his job .

4.4 Feedback for University

Firstly, I am very thankful to my supervisor Engr. Adeel Aslam who guided us about internship
very well. Due to Corona Virus there was a long term closure of educational institutes but our
hardworking faculty was available to guide us virtually.

Secondly , I am very thankful to all other teachers for there attention toward us during our study
period and their hard work on us made us competent despite limited sources. They delivered more
than that they paid for.

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4.5 Recommendation for Industry
All the workers are very cooperative and sincere to their task . I found some lags to manage them.
Quality Management System is a detailed management system to deal with workers. According to
a clause of this system employee should be provided with a proper chance to discuss complexities
and hurdles he is facing during his task. The problem and recommendations of worker should be
forwarded to the higher authorities and endorsed without any discrimination. Every worker should
be provided with a healthy environment so that he can work well .Competition regarding quality
working, quality behavior and sincerity should be arranged so that a very supportive and free
environment can be maintained. This will not only increase interest of worker but also make whole
management system very effective and efficient.

• OSHA Standard for Worker Safety should be introduced & implemented immediately.
• ISO 9001:2015 Quality Management System should be implemented.

4.6 Recommendations for University

Alhamdulillah, our faculty is second to none in term of knowledge ,hardwork, focus, and character
building. Campus should arrange all the required equipment for mechanical lab and so that
students can perform all the practical during their study period . University administration should
provide funds to student groups for making project which can work efficiently and follow all the
parameters & standards once in a year and this project should be stored for juniors so that they can
study about them and mini project in each semester should be necessary.

36
References
1.https://en.wikipedia.org/wiki/Deaerator

2. https://www.thermodyneboilers.com/economisers

3. https://www.askpowerplant.com/what-is-soot-blowing-in-boiler-operation-

4. https://www.google.com/search?q=steam+drum+working+Mechanism

5. https://www.google.com/search?q=demister+in+boiler&source=

6.https://www.google.com/search?bih=625&biw=1366&hl=en-

7.https://www.google.com/search?q=Tubes+of+water+tube+boiler&tbm

8.https://www.elprocus.com/water-tube-boiler-working-principle-types-of-water-t

9.https://www.google.com/search working+principle+of+s

10. https://www.google.com/search?q=Surface+condenser+working+mechanism

11.https://www.google.com/search?q=tsurumi+vacuum

12. https://www.thermodyneboilers.com/boiler-safety-precautions

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