A

REPORT
ON

BOILER UTILITY

For
Partial fulfilment of the requirements
of GET’s training program

Under the guidance of

Mr. Naishadh Ajagaonkar

By
Sudeep Gupta
Dattaprasad Bochare
Prashil Wankhede
Avinash Shinde

GALAXY SURFACTANTS LTD.

13 TH AUGUST, 2012

1
Table of Contents
1.Introduction.............................................................................................................................................. 5
1.1 Boiler .............................................................................................................................................. 5
1.1.1 Fire Tube Boiler...................................................................................................................... 5
1.1.2 Water Tube Boiler................................................................................................................... 6
1.1.2.1 Type of Water Tube Boiler ......................................................................................... 8
1.2 Ideal Boiler Emission Standards by CPCB ................................................................................. 10
2. Boilers Present in Galaxy ..................................................................................................................... 10
2.1Coal Boiler..................................................................................................................................... 10
2.1.1Component of Coal Boiler ..................................................................................................... 10
2.1.2 Working of Coal Boiler ........................................................................................................ 12
2.1.2 Coal Boiler Safety Precautions ............................................................................................. 13
2.2 Oil-Fired Boilers ........................................................................................................................... 13
2.2.1 Working of Oil Boiler........................................................................................................... 14
2.3 Waste Heat Recovery Boilers (WHRB) ....................................................................................... 14
3. Distribution, Piping, Insulation, Valves & Steam Traps ................................................................... 15
3.1 Distribution ................................................................................................................................... 15
3.2 Piping ............................................................................................................................................ 15
3.3 Insulation ...................................................................................................................................... 15
3.4 Valves ........................................................................................................................................... 16
3.5 Steam Traps .................................................................................................................................. 16
3.5.1 Types of Steam Traps ........................................................................................................... 18
3.5.1.1 Thermostatic Traps ................................................................................................... 18
3.5.1.2 Mechanical Traps...................................................................................................... 18
3.5.1.3 Traditional Thermodynamic Steam Traps ............................................................... 19
4. Coal ....................................................................................................................................................... 20
5. Specifications & PFD of Boilers........................................................................................................... 22
5.1 Coal Fired Boiler .......................................................................................................................... 22
5.1.1 Specifications........................................................................................................................ 22
5.1.2 PFD of Coal Fired Boiler...................................................................................................... 26

5.2 Oil Fired Boiler............................................................................................................................. 27

5.2.1 Specifications........................................................................................................................ 27
5.2.2 PFD of Oil Fired Boiler ........................................................................................................ 30

2
 5.3 EOU WHRB ................................................................................................................................. 31
5.3.1 Specifications........................................................................................................................ 31
5.3.2 PFD of EOU WHRB............................................................................................................. 32

5.4 V-23 WHRB ................................................................................................................................. 33

5.4.1 Specifications........................................................................................................................ 33
5.4.2 PFD of V-23 WHRB............................................................................................................. 34

5.5 DG WHRB.................................................................................................................................... 34
5.5.1 Specifications........................................................................................................................ 34
5.5.2 PFD of DG WHRB ............................................................................................................... 35

6. Calculations .......................................................................................................................................... 36
6.1 Coal Boiler Calculations ............................................................................................................... 36
6.1.1 Steam Cost Calculations ....................................................................................................... 36
6.1.2 Efficiency of Coal Boiler ...................................................................................................... 39
6.1.3 Efficiency of WHRBs .......................................................................................................... 41
7. Steam Distribution Network ................................................................................................................ 43

7.1 Boiler to Main Steam Line............................................................................................................ 44

7.2 EOU Plant Steam Distribution...................................................................................................... 45
7.3 V-23 Plant Steam Distribution...................................................................................................... 46
7.4 MED Plant Steam Distribution ..................................................................................................... 47
7.5 Analysis of Steam Distribution Network ...................................................................................... 48
7.6 Conclusion .................................................................................................................................... 51
8. Fugais ..................................................................................................................................................... 53

9. Past Improvements (MP Sheets - Boiler) ............................................................................................ 54

9.1 Steam Header................................................................................................................................ 54

9.2 Automated ON/OFF Valve ........................................................................................................... 54
9.3 Personal Safety ............................................................................................................................. 55
9.4 Air Blower .................................................................................................................................... 55
9.5 Flow Meter.................................................................................................................................... 55
9.6 Effluent Spillage ........................................................................................................................... 56
9.7 Steam Purging............................................................................................................................... 56
9.8 Proper Routing of Condensate ...................................................................................................... 57
9.9 Feed Water Drain Valve ............................................................................................................... 57

3
 9.10 Local Temperature Indicator....................................................................................................... 58
10. Suggestions .......................................................................................................................................... 59
10.1 Suggestions - Coal Boiler .......................................................................................................... 59
10.1.1 Automization of Ash Conveying System............................................................................ 59
10.1.2 Efficiency Improvements.................................................................................................... 60
10.2 Suggestions - WHRB ................................................................................................................. 61
10.2.1 Efficiency Enhancement of V-23 WHRB .......................................................................... 61
10.2.2 Utilization of hot exhaust gas of WHBR for heating of water in hot water tank............... 62
10.3 Suggestions - Steam Distribution System .................................................................................. 63
10.3.1 V-23 Condensate Recycle................................................................................................... 63
10.3.2 Condensate recovery of all the plants ................................................................................ 63
10.3.3 Modification in Ethoxylation steam distribution network .................................................. 64
11. Safety Related Suggestions ................................................................................................................ 65
11.1 Temperature of the Coal heap rises due to high storage height .................................................. 65
11.2 Safety Suggestion related to cyclone clogging .......................................................................... 66
12. Observations ....................................................................................................................................... 67
References

4
1. INTRODUCTION
1.1 Boiler
Boiler is a closed vessel in which water or other fluid is heated. The heated or vaporized fluid
exits the boiler for use in various processes or heating applications, including boiler-based power
generation, cooking, and sanitation.
Boilers can be classified as follows
I. According to the flow of water and hot gases: fire tube (or smoke tube) and water tube
boilers.
In fire tube boilers, hot gases pass through tubes which are surrounded with water.
Examples: Vertical, Cochran, Lancashire and Locomotive boilers. There may be single
tube as in case of Lancashire boiler or there may be a bank of tubes as in a locomotive
boiler.
In water tube boilers, water circulates through a large number of tubes and hot gases pass
around them. Examples: Bobcock & Wilcox boiler.
II. According to the axis of the shell: vertical and horizontal boilers.
III. According to location or position of the furnace: Externally and internally fired boilers.
In internally fired boilers, the furnace forms an integral part of the boilers structure. The
vertical tubular, locomotive and the scotch marine boilers are well known examples.
Externally fired boilers have a separate furnace built outside the boiler shell and usually
below it. The horizontal return tube (HRT) boiler is probably the most widely known
example of this type.
IV. According to the application: stationery and mobile boilers. A stationary boilers is one of
which is installed permanently on a land installation.
A marine boiler is a mobile boiler meant for ocean cargo and passenger ships with an
inherent fast steaming capacity.
V. According to steam pressure: low and high pressure boilers. Steam pressure range up to
5 kg/ cm2 in steam boilers, or as long as the temperature of the water does not exceed
121ºC (250ºF) is called low pressure boiler.
1.1.1 Fire Tube Boiler
The name fire tube is very descriptive. The fire, or hot flue gases from the burner, is channeled
through tubes that are surrounded by the fluid to be heated. The body of the boiler is the pressure
vessel and contains the fluid. In most cases this fluid is water that will be circulated for heating
purposes or converted to steam for process use.
Every set of tubes that the flue gas travels through, before it makes a turn, is considered a "pass".
So a three-pass boiler will have three sets of tubes with the stack outlet located on the rear of the
boiler. A 4-pass will have four sets and the stack outlet at the front.

5
Advantages of Fire Tube Boiler

 Relatively inexpensive

 Easy to clean

 Compact in size

 Available in sizes from 600,000 btu/hr to 50,000,000 btu/hr

 Easy to replace tubes

 Well suited for space heating and industrial process applications

Disadvantages of Fire Tube Boilers

 Not suitable for high pressure applications 250 psig and above

 Limitation for high capacity steam generation

1.1.2 Water Tube Boiler
A Water tube design is the exact opposite of a fire tube. Here the water flows through the tubes
and are incased in a furnace in which the burner fires into. These tubes are connected to a steam
drum and a mud drum. The water is heated and steam is produced in the upper drum. Large
steam users are better suited for the Water tube design. The industrial water tube boiler typically

6
produces steam or hot water primarily for industrial process applications, and is used less
frequently for heating applications.

Advantages of Water Tube Boiler

 Available in sizes that are far greater than the fire tube design. Up to several million
pounds per hour of steam.

 Able to handle higher pressures up to 5,000 psig.

 Recover faster than their Fire Tube cousin.

 Have the ability to reach very high temperatures.

Disadvantages of the Water Tube Boiler

 High initial capital cost.

 Cleaning is more difficult due to the design.

 No commonality between tubes.

 Physical size may be an issue.

7
1.1.2.1 Type of Water Tube Boiler

a) Longitudinal Drum Boiler

The longitudinal drum boiler was the original type of water-tube boiler that operated on the
thermo-siphon principle. Cooler feed water is fed into a drum, which is placed longitudinally
above the heat source. The cooler water falls down a rear circulation header into several inclined
heated tubes. As the water temperature increases as it passes up through the inclined tubes, it
boils and its density decreases, therefore circulating hot water and steam up the inclined tubes
into the front circulation header which feeds back to the drum. In the drum, the steam bubbles
separate from the water and the steam can be taken off.

Typical capacities for longitudinal drum boilers range from 2 250 kg/h to 36 000 kg/h.

b) Cross Drum Boiler

The cross drum boiler is a variant of the longitudinal drum boiler in that the drum is placed cross
ways to the heat source as shown in figure. The cross drum operates on the same principle as the
longitudinal drum except that it achieves a more uniform temperature across the drum. However
it does risk damage due to faulty circulation at high steam loads; if the upper tubes become dry,
they can overheat and eventually fail.

8
The cross drum boiler also has the added advantage of being able to serve a larger number of
inclined tubes due to its cross ways position.

Typical capacities for a cross drum boiler range from 700 kg / h to 240 000 kg/h.

c) Bent tube or Stirling boiler

A further development of the water-tube boiler is the bent tube or Stirling boiler shown in figure.
Again this operates on the principle of the temperature and density of water, but utilizes four
drums in the following configuration.

Cooler feed water enters the left upper drum, where it falls due to greater density, towards the
lower, or water drum. The water within the water drum, and the connecting pipes to the other
two upper drums, are heated, and the steam bubbles produced rise into the upper drums where
the steam is then taken off.

The bent tube or Stirling boiler allows for a large surface heat transfer area, as well as promoting
natural water circulation.

9
 1.2 Ideal Boiler Emission Standards by CPCB

Sr. Emission Measurement Methods Emission Limit

No. Parameters (ppm)

1. Particulates Gravimetric 50

2. SO2 Barium Perchlorate – Thorin indicator method 200

3. NOx Chemiluminescence, Non Dispersive Infra Red, 400

Non Dispersive Ultra-Violet (for continuous
measurement), Phenol disulphonic method

4. CO Non Dispersive Infra Red 100

5. O2 Paramagnetic, Electrochemical Sensor

6. NMHC Gas Chromatograph-Flame Ionisation Detector 50

2. BOILERS PRESENT IN GALAXY

a) Coal boiler
b) Oil fire boiler
c) WHRB
2.1 Coal Boiler
Coal is used for the combustion purpose to produce steam or electricity through steam.
2.1.1 Component of coal boiler
 Steam and water drum (boiler shell): One half of the drum which is horizontal is filled up
with water and steam remains on the other half. It is about 8 meters in length and 2 meter in
diameter.
 Water tubes: Water tubes are placed between the drum and furnace in a vertical position (at
an angle to promote water circulation. These tubes are connected to the uptake-header and
the down-comer.
 Uptake-header and down-corner (or down take-header): The drum is connected at
middle section of top to the uptake-header by pipe and at the other bottom side two end to the
down-corner by long pipes for water circulation inside the tubes.
 Furnace: Coal is burned in furnace.
 Baffles: The fire-brick baffles, two in number, are provided to deflect the hot flue gases.
 Deaerator: Deaerator is a device that is widely used for the removal of oxygen and other
dissolved gases from the feed water to steam-generating boilers. In particular, dissolved
oxygen in boiler feed waters will cause serious corrosion damage in steam systems by

10
attaching to the walls of metal piping and other metallic equipment and forming oxides
(rust). Dissolved carbon dioxide combines with water to form carbonic acid that causes
further corrosion. Most deaerators are designed to remove oxygen down to levels of 7 ppb by
weight (0.005 cm³/L) or less as well as essentially eliminating carbon dioxide.

 Inspection doors: Inspection doors are provided for cleaning and inspection of the
boiler.
 Coal Feeders (rotary valve): Fuel flow is controlled using the feeders by adjusting the
speed of the feeder.
 Coal Crushers: The coal feeds in through the center of the mill onto a circular trough.
Large, heavy wheels (called rollers) roll around the trough and crush the cola. At the top
is a classifier, which is used to send larger pieces back down for more grinding. The
finely crushed coal (passing through a 2 mesh screen) sent to the coal bunker.
 FANS (Primary Air, Forced Draft, Induced Draft): Axial fans are often used for
forced draft (secondary air) and induced draft duty. The pitch of the blades can be
hydraulically controlled to vary the flow without wasting energy in dampers, much like
using a variable speed motor.
 Waterwalls, Interior and Exterior: The waterwalls are tubes that are welded to spacers
between the tubes to form a gas-tight wall. The water flows up through the walls as it
turns to steam.
 Bed Ash Coolers: The bed ash is at 1600° F, so it must be cooled before disposal. There
are several types of coolers for this job. Some use water-cooled surface, some just use
water-cooled screw conveyors and others use air (called stripper coolers).
 Economizer: An economizer is a forced-flow, once-through, convection heat-transfer
device to which feed water is supplied at a pressure above that in the steam-generating
section and at a rate corresponding to the steam output of the unit. The economizer is in
effect a feed water heater, receiving water from the boiler feed pump and delivering it at

11
 a higher temperature to the steam generator or boiler. Economizers are used instead of
additional steam-generating surface because the feed water, and consequently the heat-
receiving surface, is at a temperature below that corresponding to the saturated steam
temperature; thus, the economizer further lowers the flue gas temperature for additional
heat recovery.

2.1.2 Working of Coal Boiler

Combustion

Coal is a heterogeneous material consisting of a composite of: Hydrocarbons (referred to as

volatiles), Non-volatile combustible material (referred to as charcoal; this is mostly carbon in
solid form), Ash, which doesn’t really play much of a part in combustion. To burn the coal, there
must be sufficient oxygen, sufficient mixing of the fuel and oxygen, sufficient temperature for
ignition, and sufficient time to complete the process. For combustion to take place, the coal
particle must heat up, and it can’t really do that until the moisture is vaporized and removed. As
the particle continues to heat up, the volatile hydrocarbons are released as a gas, and they burn
very readily. Finally, the coal burns. This process can take several seconds, and some of it never
does burn and just becomes part of the ash.

Air flow

Air is delivered in two parts: primary air and secondary air. Primary air flow is roughly the same
as the full-load coal flow on a mass basis. Secondary air flow is much higher (approximately 8
times more). The total air supplied is regulated to maintain the target oxygen content in the flue
gas, which indicates the amount of excess air. Part of the primary air is heated, and part is not.
The tempering air (unheated) flow is controlled to maintain the target outlet temperature. Too
cold can lead to problems with insufficient drying, and too hot can lead to mill fires.

Water circulation

That portion of water tubes which is just above the furnace is heated comparatively at a higher
temperature than the rest of it. Water, its density being decreased, rises into the drum through the
uptake-header. Here the steam and water are separated in the drum. Steam being lighter is
collected in the upper part of the drum. The water from the drum comes down through the down
–comer into the water tubes. A continuous circulation of water from the drum to the water tubes
and water tubes to the drum is thus maintained. The circulation of water is maintained by
convective currents and is known as “natural circulation”.

The boiler is fitted with necessary mountings. Pressure gauge and water level indicator are
mounted on the boiler at its left end. Steam safety valve and stop valve are mounted on the top of
the drum.

12
2.1.3 Coal Boiler Safety Precautions

A coal boiler is a machine that uses the heat generated by burning coal to boil water into steam.
The steam can be used for a variety of purposes, including generating electricity. However, there
are a variety of procedures that must be observed where coal boilers are concerned.
Inspection
Coal boilers have to be inspected and declared safe on a regular basis, depending on local and
county law.
Pressure
A coal boiler should never be over-pressurized. Doing so can damage the pipes, and could cause
an explosion that would cause injury.
Coal Dust
If people are going to be exposed to the coal, they should wear proper protective equipment for
their mouths, noses and eyes. Coal dust can be very aggravating, and possibly harmful if inhaled
for too long.
Exhaust
Once the coal is burned, the fumes need to be pumped away from the workers. Inhaling the
fumes that come from a coal boiler is a decided safety hazard.
Heat
Safety boards should be erected, and a barrier should be kept to stop people from coming into
accidental contact with these hot areas.
2.2 Oil-Fired Boilers

2.2.1 Working of Oil Boiler

The oil burner then pumps oil at high pressure from a holding tank through a fuel line to a burner
nozzle. The nozzle sprays the oil into a fire chamber, separating it into small droplets so that it

13
will vaporize quickly and thus be susceptible to combustion. The oil burner has both a high
voltage ignition system that sends sparks and an air intake blower that provides air into the fire
chamber. This provides all that is necessary to efficiently ignite the oil vapor. Hot gases from the
burning oil pass through metal tubes or sections in the boiler, heating them in the process. These
hot pipes in turn heat the water in the boiler up to the safe maximum temperature of the system.
This water is stored in the boiler until the system is put into action again by the thermostat in the
building.
2.3 Waste Heat Recovery Boiler (WHRB)
These boilers may be either fire tube or water tube design and use heat that would otherwise be
discarded to generate steam. Typical sources of heat for WHRBs include exhaust gases or high
temperature products from an external manufacturing process in refineries and chemical
manufacturing facilities, or combustion of a waste fuel in the Boiler furnace.

14
3. DISTRIBUTION, PIPING, INSULATION, VALVES AND STEAM TRAP
3.1 Distribution The distribution system transports steam from the Boiler to the various end
uses. Although distribution systems may appear to be passive, in reality, these systems regulate
the delivery of steam and respond to changing temperature and pressure requirements.
Consequently, proper performance of the distribution system requires careful design practices
and effective maintenance. The piping should be properly sized, supported, insulated, and
configured with adequate flexibility.

Pressure-regulating devices such as pressure reducing valves and backpressure turbines should
be configured to provide proper steam balance among the different steam headers. Additionally,
the distribution system should be configured to allow adequate condensate drainage, which
requires adequate drip leg capacity and proper steam trap selection. Steam distribution systems
can be broken down into three different categories: buried pipe, above-around, and building
sections, and selection of distribution components (piping, insulation, etc.) can vary depending
on the category.

3.2 Piping

Steam piping transports steam from the boiler to the end-use services. Important characteristics
of well-designed steam system piping are that it is adequately sized, configured, and supported.
Installation of larger pipe diameters may be more expensive, but can create less pressure drop for
a given flow rate. Additionally, larger pipe diameters help to reduce the noise associated with
steam flow. As such, consideration should be given to the type of environment in which the
steam piping will be located when selecting the pipe diameter. Important configuration issues are
flexibility and drainage. With respect to flexibility, piping (especially at equipment connections),
needs to accommodate thermal reactions during system start-ups and shutdowns. Additionally,
piping should

Piping is equipped with a sufficient number of appropriately sized drip legs to promote effective
condensate drainage. Additionally, the piping should be pitched properly to promote the drainage
of condensate to these drip lines. Typically, these drainage points experience two very different
operating conditions, normal operation and start-up; both load conditions should be considered in
the initial design.

3.3 Insulation

Thermal insulation provides important safety, energy savings, and performance benefits. In terms
of safety, insulation reduces the outer surface temperature of the steam piping, which lessens the
risk of burns. A well-insulated system also reduces heat loss to ambient workspaces, which can
make the work environment more comfortable. Consequently, the energy saving benefits include
reduced energy losses from the steam system and reduced burden on the cooling systems that
remove heat from workspaces. In addition to its safety and energy benefits, insulation increases

15
the amount of steam energy available for end uses by decreasing the amount of heat lost from the
distribution system. Important insulation properties include thermal conductivity, strength,
abrasion resistance, workability, and resistance to water absorption. Thermal conductivity is the
measure of heat transfer per unit thickness. Thermal conductivity of insulation varies with
temperature; consequently, it is important to know the right temperature range when selecting
insulation. Strength is the measure of the insulation’s ability to maintain its integrity under
mechanical loads. Abrasion resistance is the ability to withstand shearing forces. Workability is
a measure of the ease with which the insulation is installed. Water absorption refers to the
tendency of the insulation to hold moisture. Insulation blankets (fiberglass and fabric) are
commonly used on steam distribution components (valves, expansion joints, turbines, etc.) to
enable easy removal and replacement for maintenance tasks. Some common insulating materials
used in steam systems include calcium silicate, mineral fiber, fiberglass, perlite, and cellular
glass.

3.4 Valves

In steam systems, the principal functions of valves are to isolate equipment or system branches,
to regulate steam flow, and to prevent over pressurization. The principal type of valves used in
steam systems include gate, globe, swing check, pressure reducing, and pressure relief valves.
Gate, globe, and swing check valves typically isolate steam from a system branch or a
component. Pressure reducing valves (PRV) typically maintain certain downstream steam
pressure conditions by controlling the amount of steam that is passed. These reducing valves are
often controlled by transmitters that monitor downstream conditions. Pressure relief valves
release steam to prevent over pressurization of a system header or equipment.

3.5 Steam Trap

The duty of a steam trap is to discharge condensate while not permitting the escape of live steam.
No steam system is complete without that crucial component 'the steam trap' (or trap). This is the
most important link in the condensate loop because it connects steam usage with condensate
return. A steam trap quite literally 'purges' condensate, (as well as air and other incondensable
gases), out of the system, allowing steam to reach its destination in as dry a state/condition as
possible to perform its task efficiently and economically.

The quantity of condensate a steam trap has to deal with may vary considerably. It may have to
discharge condensate at steam temperature (i.e. as soon as it forms in the steam space) or it may
be required to discharge below steam temperature, giving up some of its 'sensible heat' in the
process.

The pressures at which steam traps can operate may be anywhere from vacuum to well over a
hundred bar. To suit these varied conditions there are many different types, each having their
own advantages and disadvantages. Experience shows that steam traps work most efficiently
when their characteristics are matched to that of the application. It is imperative that the correct

16
trap is selected to carry out a given function under given conditions. At first sight it may not
seem obvious what these conditions are. They may involve variations in operating pressure, heat
load or condensate pressure. Steam traps may be subjected to extremes of temperature or even
water hammer. They may need to be resistant to corrosion or dirt. Whatever the conditions,
correct steam trap selection is important to system efficiency.

It will become clear that one type of steam trap can not possibly be the correct choice for all
applications.

Considerations for steam trap selection

 Air venting
At 'start-up', i.e. the beginning of the process, the heater space is filled with air, which unless
displaced, will reduce heat transfer and increase the warm-up time. Start-up times increase and
plant efficiency falls. It is preferable to purge air as quickly as possible before it has a chance to
mix with the incoming steam. Should the air and steam be mixed together they can only be
separated by condensing the steam to leave the air, which must then be vented to a safe place.
Separate air vents may be required on larger or more awkward steam spaces, but in most cases
air in the system is discharged through the steam traps. Here thermostatic traps have a clear
advantage over some types of trap since they are fully open at start-up. Float traps with inbuilt
thermostatic air vents are especially useful, while many thermodynamic traps are also quite
capable of handling moderate amounts of air. However, the small hole in fixed orifice
condensate outlets and the bleed hole in inverted bucket traps both vent air slowly. This could
increase production times, warm-up times, and corrosion.
 Condensate removal
Having vented the air, the trap must then pass the condensate but not the steam. Leakage of
steam at this point is inefficient and uneconomical. The steam trap has to allow condensate to

17
pass whilst trapping the steam in the process. If good heat transfer is critical to the process, then
condensate must be discharged immediately and at steam temperature. Water logging is one of
the main causes of inefficient steam plant as a result of incorrect steam trap selection.

3.5.1 Types of Steam Trap

Three different type of trap available:

3.5.1.1 Thermostatic Traps

Operate in response to the surrounding steam temperature. The operation and benefits of 3
different types are considered here - liquid expansion traps, bimetallic and balanced pressure
thermostatic traps. Each operates in a different way and is suited to specific types of application.

3.5.1.2 Mechanical Steam

Traps rely on the difference in density between steam and condensate in order to operate. They
can continuously pass large volumes of condensate and are suitable for a wide range of process
applications. Types include ball float and inverted bucket steam traps.

 Ball Float Steam Trap

The ball float type trap operates by sensing the difference in density between steam and
condensate. In the case of the trap shown in Figure, condensate reaching the trap will cause the
ball float to rise, lifting the valve off its seat and releasing condensate. As can be seen, the valve
is always flooded and neither steam nor air will pass through it, so early traps of this kind were
vented using a manually operated cock at the top of the body. Modern traps use a thermostatic air
vent. This allows the initial air to pass whilst the trap is also handling condensate.

 Inverted Bucket Steam Trap

The inverted bucket steam trap is shown in Figure. As its name implies, the mechanism consists
of an inverted bucket which is attached by a lever to a valve. An essential part of the trap is the
small air vent hole in the top of the bucket. Figure shows the method of operation. In (i) the
bucket hangs down, pulling the valve off its seat. Condensate flows under the bottom of the
bucket filling the body and flowing away through the outlet. In (ii) the arrival of steam causes the

18
bucket to become buoyant, it then rises and shuts the outlet. In (iii) the trap remains shut until the
steam in the bucket has condensed or bubbled through the vent hole to the top of the trap body. It
will then sink, pulling the main valve off its seat. Accumulated condensate is released and the
cycle is repeated.

In (ii), air reaching the trap at start-up will also give the bucket buoyancy and close the valve.
The bucket vent hole is essential to allow air to escape into the top of the trap for eventual
discharge through the main valve seat. The hole, and the pressure differential, is small so the trap
is relatively slow at venting air. At the same time it must pass (and therefore waste) a certain
amount of steam for the trap to operate once the air has cleared. A parallel air vent fitted outside
the trap will reduce start-up times.

3.5.1.3 Traditional Thermodynamic Steam Trap

The thermodynamic trap is an extremely robust steam trap with a simple mode of operation. The
trap operates by means of the dynamic effect of flash steam as it passes through the trap, as
depicted in as shown in Figure. The only moving part is the disc above the flat face inside the
control chamber or cap.

On start-up, incoming pressure raises the disc, and cool condensate plus air are immediately
discharged from the inner ring, under the disc (Figure i).

19
Hot condensate flowing through the inlet passage into the chamber under the disc, drops its
pressure and releases flash steam moving at high velocity. This high velocity creates a low
pressure area under the disc, drawing it towards its seat (Figure ii).

At the same time, the flash steam pressure builds up inside the chamber above the disc, forcing it
down against the incoming condensate until it seats on the inner and outer rings. At this point,
the flash steam is trapped in the upper chamber, and the pressure above the disc equals the
pressure being applied to the underside of the disc from the inner ring. However, the top of the
disc is subject to a greater force than the underside, as it has a greater surface area.

Eventually the trapped pressure in the upper chamber falls as the flash steam condenses. The disc
is raised by the now higher condensate pressure and the cycle repeats (Figure, iv).

The rate of operation depends on steam temperature and ambient conditions. Most traps will stay
closed for between 20 and 40 seconds. If the trap opens too frequently, perhaps due to a cold,
wet, and windy location, the rate of opening can be slowed by simply fitting an insulating cover
onto the top of the trap.

4. COAL
Currently we import coal from Indonesia. Table given below shows various coal providers and
their coal specification with cost. Out of this Galaxy import coal from Bhatia International
Limited. Steaming (Non Coking) coal is loaded in ship and dispatched from Dharmtar port of
Indonesia to the J.N.P.T. port of India. From J.N.P.T the Mayur industries distribute coal at

20
taloja site. Quarterly 1000 metric ton of coal is purchased and it is being supplied during the
period of one month.

Coal Provider KATARIA NISHA BHATIA HARKANI

Type of Coal Lignite Lignite Lignite Lignite
Gross Calorific Value Kcal/kg. 5800+-200 5800+-100 5800+-200 5800+-200
Size in M.M. 0-50mm 0-50mm 0-50mm 0-50mm
Total Moisture (+-5%) 31% 37% +/-2% 30+/-2% 30+/-2%
Inherent Moisture (+-5%) 18% 14% +/-2% 23+/-2% 23+/-2%
Ash (+-2%) 6% 5% 6% 6%
Sulphur 1% 1% 1% 1%
Rate per ton in Rupees/ Ton. 6050 5800 6000 5930
Vat applicable 5% 5% 5% 5%
Port / Dispatch from DHARMTAR DHARMTAR DHARMTAR DHARMTAR
Transport rates in rupees per ton Rs 450 Rs 630 Rs 630+175 as per rate

Coal Storage

Coal is stored in two godowns having capacity of 400 MT each. The maximum permissible coal
storage height is 8 feet. From this godowns coal is supplied to boiler as per daily requirement.
The table shows 2012 coal import and its uses record:

Month In, Kg Used, Kg Remaining, Kg

January - (Stock remaining from 2011 is 356536 396003

752500)
February 19490 373284 42209
March 470990 437142 76057
April 527170 395740 207487
May 379700 353363 233824
June 743240 375942 601122
July - 410649 190473

Ash

Ash from boiler is sold to local brick manufacturing factories at rate of 1000 Rs. per truck.
Monthly ash production from coal fired boiler is nearly 10 ton.

21
5. SPECIFICATIONS &PFD OF BOILERS
Boiler Capacities
1. Coal fired boiler - 5000 kg/hr
2. Furnace Oil boiler - 2500 kg/hr (2 Numbers)
3. EOU sulphonation WHRB - 800 kg/hr
4. V23 sulphonation WHRB - 600 kg/hr
5. CPP WHRB - 1200 kg/hr

5.1 Coal Fired Boiler

5.1.1 Specifications

Manufacturer Transparent Energy Systems Pvt. Ltd.

Boiler Tag MR-13621
Model TEJASWEE-V-5000
Type Water tube coal fired boiler with economizer
Steam condition Dry & saturated
Installation Vertical
Safety valve set pressure 10.54 Kg/cm2
Steam generation 5 TPH
Steam outlet pressure 10.2 Kg/cm2
Fuel Coal
Type of grate Water cooled vibrating grate
Mode of ash removal Belt conveyor
Total heating surface of boiler 79.85 m2
Total heating surface of economizer 273.46 m2
Final temp. of steam 186oC

Feed Water Pump (2 Nos.)

Make Groudfos
Model CR5-36 A
Suction Horizontal
Flow rate 5.7 m3/hr

22
Head 189.2 mlc
Feed Pump Motor
KW 5.5
RPM 2900
Insulation Class B/F

Bag Filter Assembly

Flow Rate 7850 m3/hr at 1200 C
Head 250 mm at 1200 C

Grate Vibrating
Make Crompton
Frame ND 112
KW 7.5
HP 5
Insulation Class B/F
RPM 2830
Gear Box for
Size 30
Ratio 8
Type 3
Sr. No. 14437
Oil 320
Max. 1700F

Belt Conveyor for ash BC-3 BC-4

Make Crompton Greaves Crompton Greaves
KW 3.7 5
HP 2.2 3
RPM 940 1440
Bearing no. 6308/6208 6308/6208
BC-1,2 for Coal 3.7 KW

23
Vibrating Grate (VG) Circulation Pump
Make Kirloskar Brothers Ltd.
Flow Rate 18 m3/hr
Impeller Diam. 144 mm
Head 22 mlc
HP 3
RPM 2900
Model MEGA
VG Pump Motor
Make Crompton Greaves
HP 3
RPM 2900
Bearing No. 6205 ZZ & 6203 ZZ

Forced Draft (FD) Circulation fan

Type Centrifugal
Head 250 mm at 1200 C
Flow Rate 7850 m3/hr at 1200 C
Type of outlet 450 Up Blast
Make Own
FD Fan Motor
Make Crompton Greaves
KW 7.5
HP 10
RPM 2890
Bearing no. 6308 ZZ & 6208 ZZ
FD Secondary Fan
Make Crompton Greaves
KW 1.5
HP 2

24
RPM 1400
Bearing no. 6306
Insulation Class B/F
Induced Draft (ID) Fan Motor
Make Crompton Greaves
KW 30
HP 23
RPM 2945

25
5.1.2 PFD of Coal Fired Boiler
To steam header

To atmosphere
1

9
2

Water
from
Deaerator

1 11

26
 Tag No. Details
1 Steam Drum
2 Coal Bunker
3 Vibrating Grate
4 Furnace
5 Economizer (2 Pass)
6 Bag Filter
7 Cyclones
8 Exhaust fan
9 Chimney
10 Trough for submerged ash (Belt) conveyor
11 FD Fan (Primary & Secondary)

Deaerator, Conveyor Belt (to transport coal & ash), Coal Feeder and Feed Water Tank are also
present.

5.2 Oil Fired Boiler

5.2.1 Specifications

Capacity 2*2.5 TPH (From & at 1000 C)

No. of tubes 122
Shell Side Fluid Water
Tube Side Fluid Air

Feed Water

Hardness like CaCO3(mg/l) < 5 ppm

Oxygen 0.2 mg/l

Silica 5 mg/l

TDS 108 mg/l

pH 8.5 -9.5

27
Turndown Ratio 3:1

Boiler Water

Sodium Sulphite as SO3 30-60 ppm

Alkalinity as CaCO3 800 ppm

Hardness as Ca < 5 mg/l

Silica < 5 ppm

Phosphate as PO4 20 - 40 ppm

TDS < 3500 ppm

pH 9.5-11

Chemical Dosing Compound

Trade Name Tri Sodium Phosphate

Proportion 50 ml/1000 liters.

Fuel Oil

Name High Speed Diesel (HSD)

GCV 10200 Kcal/Kg

Density at 150 C 0.825

Stoichiometric air required 11.4 m3/Kg

Fuel Oil Pump (Gear Pump)

Make Prakash Fuel Pump

Type Gear Pump

Capacity 450 LPH

Port Size 1/2" * 1/2"

HP 2

KW 3.4

28
RPM 1410

Equipment Nos. Power F.L. Current O/L Relay

rating (kW) (amps) Setting (amps)

Feed Water Pump Motor 2 7.5 14 12

Fuel Pump motor 2 1.5 3.5 3

Blower Motor 1 7.5 14 12

Dosing Motor 2 0.75 1.8 1.5

29
5.2.2 PFD of Oil Fired Boiler
To atmosphere
Steam to EOU header
2
7

1
11
9

3 13

4
5

6
8

10
12

30
 Tag. No. Details
1 Furnace Oil Tank
2 Water Tank
3 Oil Filter
4 Oil Heater
5 Gear Pump
6 Modulator
7 Water Pump
8 Horizontal Boiler
9 Steam Header
10 Air preheater
11 FD Fan
12 Cyclone
13 Chimney
5.3 EOU WHRB

5.3.1 Specifications

Type Single Pass

Shell side fluid Hot gas

Tube side fluid Water

Inlet Hot Gas Temp. 2960 C

Outlet Hot Gas Temp. 1680 C

Inlet Water Temp. 970 C

Outlet Steam Temp. 1780 C

Hot Gas Flow Rate 14000 Kg/hr

Water Flow Rate 550 Kg/hr

Feed Water Pump

Make Bhide-RPD pump

Type Triplex P-3 piston with SS ball v/v NRV

Flow Rate 850 Liter/hr

Pressure 28 Kg/cm2

31
 Pump Motor

Make Crompton Greaves

Frame SD 908

KW 0.75

RPM 935

5.3.2 PFD of EOU WHRB

Steam
Spray Water from W TP 4 To EOU Plant
5
To atmosphere

Hot Gases

Tag No. Details

1 Water Preheater
2 Reciprocating Piston Pump
3 One pass WHRB
4 Steam Drum
5 Steam Header
6 Chimney

32
5.4 V-23 WHRB

5.4.1 Specifications

Make Transperant Energy Systems Pvt. Ltd.

Equipment MR 13050
Type Horizontal WHRB
Length Overall 3380 mm
Design Pressure of Boiler 10.54 Kg/cm2
Hydraulic Test Pressure 15.81 Kg/cm2
Shell Side Fluid Water
Tube Side Fluid Hot gas
Total Heating Surface 100.25 m2
Evaporation (MCR) 600 Kg/hr
Final Steam Temp. 1830 C
Mode of Heat Recovery Steam Generation
Steam Condition Dry & Saturated
Installation Horizontal
Safety Valve Set Pressure 10.2 to 10.4 Kg/cm2
Exhaust Gas Inlet Temp. 3000 C
Exhaust Gas Outlet Temp. 1850 C
Feed Water Pump
Type RPD Feed Unit (2 Nos.)
Serial No. 75909
Model PS 3
RPM 200
Rated Flow 454 Liter./hr
Rated Pressure 28 Kg/cm2

33
 5.4.2 PFD of V-23 WHRB

Hot Gases from 12E 2,

12E 3,12 E 5 Exhaust Gases
Water from WTP

Saturated
Steam
Preheated by
Coils
Horizontal WHRB

5.5 DG WHRB

5.5.1 Specifications

Make Transperant Energy Systems Pvt. Ltd.

Type 3 Pass Shell & tube

Design Pressure 10.5 Kg/cm2

Tube Side Fluid Water

Shell Side Fluid Hot Gases

Flue Gas Flow Rate 4230 Kg/hr

Flue Gas inlet Temp. 3800 C

Flue Gas Outlet Temp. 2200 C

Water Preheater Inlet Water Temp. 970 C

Economizer 1 Inlet Water Temp. 153.6 0 C

Economizer 1 Outlet Water Temp. 187 0 C

Economizer 2 Inlet Water Temp. 79 0 C

Economizer 2 Outlet Water Temp. 29.5 0 C

34
5.5.2 PFD of DG WHRB

To
atmosphere

Steam at 10.5 8

Feed Water

1
5

Flue Gases 7

35
 Tag No. Details

1 Feed Water Pump

2 Water Header

3 Steam Drum

4 3 Pass WHRB

5 Economizer 1

6 Economizer 2

7 Diversion Valve

8 Chimney

9 By pass Exhaust Gas

6. CALCULATIONS

6.1 Coal Boiler Calculations

6.1.1 Steam Cost Calculations

The following costs need to be considered to calculate the cost of steam (per Kg basis)

a) Electricity consumption cost

b) Cost of coal

c) Chemical cost

d) Man power cost

e) Maintenance cost

f) Makeup water cost

36
a) Electricity Consumption Cost

Electricity is consumed by the following equipments in the coal fired boiler unit

Equipments Power Consumed

1 Conveyor Belt Motor (BC-1) 3.7 kW

2 Conveyor Belt Motor (BC-2) 3.7 kW

3 Conveyor Belt Motor (BC-3) 3.7 kW

4 Conveyor Belt Motor (BC-4) 2.2 kW

5 VFD for Boiler Coal Feeder Motor 4 kW

6 Vibrating Motor 7.5 kW

7 Vibrating Grate Circulation Pump 2.23 kW

8 Feed Water Pump 5.5 kW

9 Deaerator Pump 5.5 kW

10 Dust collector motor 2.2 KW

11 FD Fan 7.5 kW

12 Secondary Fan 5 kW

13 ID Fan 22 kW

Generally all instruments don't draw electricity simultaneously.

Average electricity consumed by coal boiler (data collected from maintenance department) = 950
KW/Day = 39.59 KWh

Cost of electricity = 39.59 * 10.5 = 415.7 Rs/h

b) Cost of Coal

Coal cost = 6000 Rs/ton

Transportation cost = 805 Rs/ton

Total coal cost = 6.8 Rs./Kg

Coal used (for the month of July 2012) = 410649 Kg

37
Coal used = 570.3 Kg/h

Cost of coal = 3878.35 Rs/h

c) Chemical Cost

Coal Fired Boiler

Chemical Composition

price
S.N. Product QTY/DAY QTY/MONTH /Kg Price/month

1 NALCO-22341 0.7 20 152 3040

2 ALKTRAT-2 0.4 12 93 1116

3 NALCO-2548 0.3 9 129 1161

4 TRIACT-1800 0.5 15 228 3420

TOTAL 8737

*(data collected from maintenance department)

Chemical Cost = 12.13 Rs./hr

d) Man Power Cost

Daily operational activities of coal boiler plant are managed by Trimurty Company. Galaxy pays
18.22 lac/annum to the company.

Man power cost = 208 Rs./hr

*(data collected from maintenance department)

e) Maintenance Cost

Maintenance cost = 6.795 lac/annum = 77.57 Rs/hr

*(data collected from maintenance department)

f) Makeup and Raw Water Cost

Makeup water consumption = 1199.7 Kg/hr = 1.2 m3/hr

Cost of makeup water = 25 Rs/m3

Makeup water cost = 30 Rs/h

38
Raw water consumption = 0.0264 m3/h

Cost of raw water = 20 Rs/m3

Raw water cost = 0.527 Rs/h

Total water cost = 30.53 Rs/hr

Net cost associated with coal boiler unit = 4622.3 Rs/h

Steam generated = 3646.8 Kg/h

Cost of steam = 1.27 Rs/Kg

6.1.2 Efficiency of Coal Boiler

Data used in calculation

GCV of coal (Kcal/kg) 5800

Steam produced (Kg/hr) 3646.7

Coal Consumed (Kg/hr) 570.3

Condensate recycled (Kg/hr) 2491.3

Additional Soft Water (Kg/hr) 1155.4

Feed Water to WHRB (Kg/hr) 600

Feed Water to boiler (Kg/hr) 3646.7

Cp of air (KJ/kg OC) 1.0234

Air Flow rate (m3/hr) 5500

Moisture in coal (%) 24

Humidity of air (Kg/Kg dry air) 0.028

Cp of dry ash (KJ/kg OC) 0.8

Ambient temp. (oC) 28

Ash content in coal (%) 6

Radiation Loss (%) 2

39
 Enthalpy of water
Temperature (KJ/kg)
(oC)
Liquid Vapor

28 137.8

65 272

100 414.1 2676

173 732 2770

a) Direct Method

Direct method compares the energy gain of the working fluid (water and steam) to the energy
content of the fuel. This is also known as ‘input-output method’ due to the fact that it needs only
the useful output (steam) and the heat input (i.e. fuel) for evaluating the efficiency. The
efficiency is than estimated using equation below

Direct Method

Heat of
Given to
Heat of Heat of Heat of DG Input Output
Steam Condensate Soft water WHRB Heat Heat
(KJ/Hr) (KJ/Hr) (KJ/Hr) (KJ/Hr) (KJ/Hr) (KJ/Hr)

10101359 677633.6 159214.12 248460 13826353 9512971

% Efficiency 68.80

b) Indirect Method

Here the efficiency is estimated by summing the losses and comparing with the heat input. The
major heat losses from boiler are due to:

1. High temperature flue gas leaving the stack

40
2. Moisture in fuel and combustion air

3. Heat in un-burnt combustibles in refuse

4. Radiation from the boiler surfaces

Sum up the losses and calculate the efficiency using equation:

Efficiency (% E) = 100 – Σ Losses

Indirect Method

1.Heat losses due to stack gases 405266.4

2.Heat losses due to moisture in air 390882.8

Losses in 3.Heat losses due to moisture in coal 34740.9

Coal
4.Heat losses due to dry ash 10183.3
Boiler
(KJ/Hr) 5.Radiation heat Loss 276527.1

6.Heat loss due to WHRB feed water 1522920.0

Total Losses (KJ/Hr) 2640520.4

Total Heat generated in boiler (KJ/Hr) 13826353

% Efficiency 80.90

6.1.3 Efficiency of WHRBs

Enthalpy of steam (KJ/kg) 2676

Cp (KJ/kg oC) 1.013

Equipment Hot Gas Water Hot Gas Water Enthalpy Efficiency

Flow Flow of
Rate Rate Ti To Ti To water
o o
(kg/hr) (kg/hr) ( C) ( C) (oC) (oC) (KJ/kg)

DG
WHRB 11000 625 380 220 90 183 390 0.80

41
Equipment Hot Gas Water Hot Gas Water Enthalpy Efficiency
Flow Flow of
Rate Rate Ti To Ti To water
o o
(kg/hr) (kg/hr) ( C) ( C) (oC) (oC) (KJ/kg)

EOU
WHRB 14000 550 296 168 97 178 400 0.69

V-23
WHRB 9000 250 300 185 65 183 295 0.57

42
7. STEAM DISTRIBUTION NETWORK

43
 7.1 Boiler to Main Header Steam Line

Coal
Fired
Boiler

Bypass
To MED

E
O
U To V‐23

From Coal Boiler

H From DG
e WHRB

a
To EOU
d

44
 7.2 EOU Plant Steam Distribution

EOU $ 61 Z 1 Section 1
Gate

$ 61 Z 2

NECA Project
$ 61 Z 3 GOLD

R series $
Sanitization
S Melter
R 21,22
$ SHE Flaker

S ESP Scrubber
u R 23
l R 17
f Washing at
H changeover
e WHRB R 24
a
d
e R18 PHE 17 R2

Hot
Water
Tank
E
O
U

H
e
a Section 2
d $

Tanker Washing
Tank Farm

$ indicates the PRV along with bypass.

45
7.3 V-23 Plant Steam Distributions

V‐23
Gate

FO header

Oil Fired Boiler

E
O
U

H
e
a
d

DEE

52 $
&
53
Z1
$

$ 51 Z1

WHRB

Sulfonation Header

Ethoxylation S Melter S Tracing 14C1 14K1

$ indicates the PRV along with bypass.

46
7.4 MED Plant Steam Distribution

V‐23 E
Gate O
U

H
e
a
d

EOU
Gate

Air S
Comp
Melter

MED Header $

Recirculating
CW

ESP

Scrubber

47
7.5 Analysis of Steam Distribution Network Study

Pipe Surface Condensate loss in Heat

Line Insu. Pipe No. of length area Ts-Tamb distribution Lines loss
No. From To Dia (inch) section (m) (m2) (0C) (Kg/hr) (W)
V-23
1 Steam drum EOU header 8 110 88 56.15 8 27 4491.858
2 EOU header Diversion Point 8 78 62.4 39.81 10 19 3981.42
3 Diversion Point FO header 10 62 49.6 39.56 8 15 3243.836
4 FO split point New Dryer 6 63 50.4 24.12 8 16 1881.221
5 FO split point DEE 6 45 36 17.23 8 11 1292.047
6 FO split point VAHP 6 10 8 3.83 8 2 306.263
V-23 sulfonation
7 Diversion Point header 8 74 59.2 37.77 7 18 2644.071
V-23 sulfonation Sulfur Melter
8 header area 6 25 20 9.57 11 6 1052.779
V-23 sulfonation
9 header 14C1 & ESP 6 10 8 3.83 8 2 306.263
V-23 sulfonation Tank
10 header Sanitization 6 53 42.4 20.29 8 13 1542.034
V-23 sulfonation
11 header Dryer 51Z1 6 45 36 17.23 7 11 1171.456
12 FO header Ethoxylation 8 166 132.8 84.73 9 41 7880.148
EOU
13 EOU header F-2 PRV 10 82 65.6 52.32 8 20 4185.595
14 Diversion Point tanker unloading 4 40 32 10.21 5 10 510.4384

48
 Pipe Surface Condensate loss in Heat
Line Insu. Pipe No. of length area Ts-Tamb distribution Lines loss
2
No. From To Dia (inch) section (m) (m ) (0C) (Kg/hr) (W)
15 Diversion Point tanker washing 3 57 45.6 10.94 5 14 547.2
16 Diversion Point Section 1 8 44 35.2 22.46 6 11 1347.557
17 Diversion Point Section 2 8 34 27.2 17.35 6 8 1041.294
Sulphonation
18 F-2 PRV header 10 71 56.8 45.30 3 18 1359.042
Sulfur Melter
19 Sulphonation header area 6 10 8 3.84 8 2 307.2
ESP, Scrubber
20 Sulphonation header and R series 6 60 48 23.04 6 15 1382.4
21 Sulphonation header Dryer header 10 67 53.6 42.75 5 17 2137.461
22 Dryer header Dryer 4 45 36 11.48 5 11 574.2432
23 Dryer 63Z1 NECA 4 50 40 12.76 5 12 638.048
24 Sulfur Melter area Hot water tank 3 46 36.8 8.83 2 11 176.64
25 Hot water tank tanker washing 3 44 35.2 8.45 2 11 168.96
MED
26 EOU header MED header 8 117 93.6 59.72 8 29 4777.703
27 MED header Sulphur melter 6 8 6.4 3.06 5 2 153.1315
ESP Diversion
28 MED header point 6 41 32.8 15.70 4 10 627.8392
29 ESP Diversion point Scrubber 6 6 4.8 2.30 5 1 114.8486
Recirculating
30 ESP Diversion point cooling Water 6 7 5.6 2.68 3 2 80.39405
31 MED header Bed Reg. 4 14 11.2 3.57 4 3 142.9228

49
 Pipe Surface Condensate loss in Heat
Line Insu. Pipe No. of length area Ts-Tamb distribution Lines loss
No. From To Dia (inch) section (m) (m2) (0C) (Kg/hr) (W)
Tank
Sanitization &
32 MED header 33D1 4 52 41.6 13.27 4 13 530.8559
Total 1308.8 406 50597.17

Note: Line No. marking can be referred from the AutoCad drawing shown in the starting of the section 7.

Tamb (0C) 30

h (W/m2 0C) 10

Condensate per 30m (Kg/hr) 9.3

Length of each section (m) 0.8

50
7.6 Conclusion

a) Ethoxylation Steam Consumption (basis July 2012)

MW of LA 194
Heat Capacity (KJ/(mol.K) of LA 438
LA Tin (oC) 40
LA Tout (oC) 165
Latent heat of steam (KJ/(kg) 2096

ETLA used (Tons) ETLA Moles of Steam used

S.N. ETLA
V-23 EOU MW LA (T)
1 1M 1086 0 238 4563.03 119.19
2M
2 (C1214) 637.4 580.7 282 4319.50 112.83
2M
3 (C1216) 204.2 165.8 284 1302.82 34.03
4 2.2M 0 182.5 290.8 627.58 16.39
5 3M 27.8 0 326 85.28 2.23
6 3M JD 18.3 0 326 56.13 1.47
7 MW 257 438.3 0 502 873.11 22.81
MW 257
8 JD 38.3 0 502 76.29 1.99
9 MW 259 9.2 0 590 15.59 0.41
Total Steam consumed (Ton/month) 311.35
Total Steam consumed (Kg/hr) 432.43

b) Steam Calculations

Accounted Steam
Steam
Plant Process required
(Kg/hr)
Sulfonation 350
Ethoxylation
(basis July 2012) 432
52Z1 188
V-23 New Dryer
53Z1 163
Old Dryer 51Z1 313
DEE 114
VAHP 708
EOU Sulfonation 400

51
 Accounted Steam
Steam
Plant Process required
(Kg/hr)
61Z1 270
Dryer 62Z1 270
63Z1 320
F-2 278
NECA 23
MED Sulfonation 250
Total (Kg/hr) 4079

Unaccounted Steam
Plant Sections
Tank Sanitization
V-23 Recirculating CW
FO preheater
Bed Regeneration
Hot Water Tank
FO heater (DG)
Hot Water Tank
Tanker Unloading
33D1 (Cooling Jacket)
16R1 (Cooling Jacket)
EOU Tank farm
33MX2
Tank Sanitization
R series Sanitization
Bed Regeneration
MED 33D1 (Cooling Jacket)
Recirculating CW

Net steam Loss (Kg/hr)

Coal Boiler (basis July 2012) 3600
EOU WHRB 550
V-23 WHRB 250
DG WHRB 625
Total Steam Produced 5025
Total Steam Consumed 4079

52
 Net steam Loss (Kg/hr)
Condensate Loss in Distribution Lines 406
Steam Loss 540

8. FUGAIS
Coal Boiler
 Floor is broken at many places
 Cables are not properly fixed on trays
 Very congested economizer and is not easily accessible
 Water belt conveyor: wear and tear to belt causing water leakages
 Water leakage in godown from broken glass of the window and broken shutter
 Ash mud spread out from conveyor near the gear box
 Outlet of cyclone is not properly fixed in drums
 Outlet of bag filter is placed on belt conveyor, the particles may sleep over drain
 Heat loss from coal bunker feeder to coal boiler
 No PLC
 There is tag of CO2-15 on the wall but the fire extinguisher cylinder is absent
 Refractory linings are damaged
 Flue gas release at the flange joint of blower
 Godown shutter is broken

Waste Heat Recovery Boiler (WHRB)

a) DG WHRB
 No proper insulation
 Wet floor
 Tank above WHRB is not in use, yet it is lying there in this rainy season
 Temperature indicator not working
 Corrosion is very high on pipe and valve

b) EOU Sulfonation WHRB

 Leakages of hot gases at the top of WHRB
 Valves are open to air
 Disappearance of tags
 Floor is not clean
 Rust and corrosion on pipes and valves
 No insulation on pipes and valves

c) V-23 Sulfonation WHRB

 No proper insulation

53
  Floor broken at various places
 Pressure gauges not covered with polythene

9. PAST IMPROVEMENTS (MP SHEETS - BOILER)

9.1 Steam Header

Task: Piping layout with proper slope to steam header
Problem: Accumulation of condensate in steam line header
Cause
 If steam header or lines are with 0 slope then condensate will collected at the bottom side
of the header.
 As the steam flow rates are high this condensate will carry over to the system.
 This will results in low performance of system.
Solution: Given proper slope to steam header pipe

9.2Automated ON/OFF Valve

Task: Automated ON/OFF valve at feed water pump discharge to avoid backpressure.
Problem: If there is no ON/OFF valve, the back pressure effect can’t be handled.
Cause:
 Feed water pump will operate depending upon the Mobary level of the tank.
 So this Level Switch can take care of level but it can’t withstand backpressure coming on
pump.
 So instead of giving directly the interlock for pump, lets operate the ON/OFF valve at the
discharge first and then stop the respective pump which is in remote.
 Sine the ON/OFF valve is closed during LSH; there is no issue of back pressure.
Solution: Implementation of automated ON/OFF valve at feed water pump discharge

54
9.3 Person Safety
Task: Elimination of Near miss and improve person safety.
Problem: : Near miss, hard to access & dangerous place area for boiler operator while checking
water level in feed water tank.
Cause:
 Boiler feed water tank is at approx 8 meter height. Operator goes at top for checking
water level. There is possibility of person slipping from top. To take care of this Han
railing is provided on 4 sides of water tank. The distance between railing & tank edge is
only 0.4 m which is very less. Hence the area is hard to access. & dangerous place to
work.
Solution: Elimination of Near miss improves person safety

9.4 Air Blower

Task: Filter at the suction of combustion air blower
Problem: Dust accumulation on boiler tube surface reduces heat transfer area.
Cause:
 Combustion air blower without filter is the path for dust or sand to enter the boiler.
 This dust accumulates on the tube surface of the boiler.
 It will results in decreasing heat transfer area and efficiency of the boiler.
Solution: Implementation of filter at the suction of combustion air blower.

9.5 Flow Meter

Task: Flow meter for boiler feed water and condensate

Problem: No idea regarding how much condensate water is used in boiler
Cause:
 Daily soft water consumption has to be noted down.
 For boiler due to absence of flow meter actual quantity of soft water is not getting.
 With the help of flow meter we can record the actual quantities of soft and condensate
water used in the boiler
Solution: Implemented flow meter at boiler feed water and condensate

55
9.6 Effluent Spillage
Task: Improvement in GHK & effluent spillage control.
Problem: Bad housekeeping & effluent spillage during yearly cleaning of feed water tank.
Cause:
 During yearly cleaning of feed water tank bottom valve is opened using rod & cleaning
water is allowed to spill from 8 m height on ground, Same gets spread all over the area.
Solution: Implemented piping route to effluent pit

9.7 Steam Purging

Task: Heating of boiler feed water by purging live steam using control valve.
Problem: Electric heater is provided to increase feed water temperature to 70 0C
Cause:
 The soft water has to be heated to 70 0C in feed tank so that further it is preheated in
economizer from 70 to 90 0C.
 If electric heater is used then massive KW is required and chances of electric shock are
there.
 Steam purging using CV is best effective method to adopt

56
Solution: Steam purging in tank using control valve

9.8 Proper Routing of Condensate

Task: Proper routing of condensate pit to effluent pit
Problem: The condensate from the pit is spread on the surface causing slippery area formation
Cause:
 The condensate trap provided at regular interval are having individual pit on ground
level.
 But these pits are not properly routed to gutters.
 So the water gets spread on the surface causing slippery area formation
Solution: Routing of condensate pit to effluent pit

9.9 Feed water drain valve

Task: Safe condition for valve opening.
Problem: Feed water tank is located at 8 m height. Bottom valve is given to tank to drain water
during yearly cleaning. This valve is operated by using steel rod. Valve is required to hammer
some times due to choking problem.

57
Cause:
 Wrong valve location creating unsafe condition for valve operation.
Solution: Changed bottom valve location

9.10 Local Temperature Indicator

Task: Local temperature indicator to feed water tank
Problem: If the feed water temperature drops then performance of boiler decreases.
Cause:
 Feed water temperature (70 0C) affects drastically on the performance of the boiler.
 If it falls due to the malfunctioning of the Control valve then it will affect the process.
 So there must be local temperature indicator so that operator will have continuous watch
on it
Solution:

Before Improvement After Improvement

Difficulty in operation can occur due to the Continuous watch on the feed water
malfunctioning of the CV of steam. It will temperature. So any malfunction in
affect the efficiency of the boiler. operation can be controlled immediately.

58
10. SUGGESTIONS
10.1 Suggestions - Coal Boiler

10.1.1 Atomization of Ash Conveying System

Belt conveying system is used in the conveying of ash from the furnace to outside the plant. This
conveying system runs the whole day irrespective of the Vibrating Grate's vibration fashion. It
has been noted that maximum times belt is running empty and company is loosing money in
running the BC3 & BC4 belt conveyor's motor.
It is found that Vibrating Grate's vibration fashion varies according to the coal firing rate. But in
general it vibrates at an interval of 12 minutes. Two set of experiments have been done to find
out the electricity saving. BC3 & BC4 were started for 1 minute and then they were kept off for
12 minutes. This cycle continues till 2 hours experiment time. Quantity of ash collected is
measured after the experiment and it is compared with the quantity of ash collected in a normal
belt conveyor operation of 2 hours.

BC3 motor rating (KW) 3.3

BC4 motor rating (KW) 2.2

Experiment-1
BC3 Total
BC3 & & BC3 &
One BC4 BC4 Total BC4 Total
Cycle off on Exp. run ash Electricity Cost Cost
Time time time Time Time collected Cosumed associated associated
(min) (min) (min) (min) (min) (Kg) (KW/hr) (Rs./hr) (Rs./yr)
(A)
Discontinueous
13 12 1 120 9.00 26.05 0.41 4.33 37941.75
operation of
BC3 & BC4
(B)
Continueous
13 0 12 120 120 23.55 5.50 57.75 505890
operation of
BC3 & BC4
Annual Electricity Saving 467948.25
Experiment-2
(A)
Discontinueous
13 12 1 120 9.00 52.55 0.41 4.33 37941.75
operation of
BC3 & BC4
(B)
Continueous
13 0 12 120 120 49.2 5.50 57.75 505890
operation of
BC3 & BC4
Annual Electricity Saving 467948.25

59
Note: Both experiments were done on different days.

10.1.2 Efficiency Improvements

At present coal boiler efficiency is:

By Direct Method = 68.8 %

By Indirect Method = 80.9 %

Total losses (KJ/Hr)

(indirect method) 2640520.4
Associated Coal (Kg/Hr) 108.9
Associated Cost (Rs/Hr) 740.6
Associated Cost (Rs/yr) 6398938.1

These losses can be minimized by the following modifications:

(i) Moisture present in the inlet air is very high and associated heat losses are also high.

Heat Loss due to

air moisture 390882
Associated Coal (Kg/Hr) 16.1
Associated loss (Rs/Hr) 109.6
Associated loss (Rs/yr) 960405.0

To reduce the heat loss due to moisture, this moisture should be removed by using chiller at the
inlet of air to condense the moisture.

(ii) Minimizing the scale formation in the Economizer

The hot flue gases from boiler furnace sent to economizer for preheating of feed water. It is
observed that there is large scaling occurs on the tubes of economizer. This is because the flue
gas contains more fly ash. High scale formation lead to the lower heat transfer coefficient thus
less efficiency.

This problem can be solved by arranging the sequence of economizer & cyclones. There are two
cyclones in coal boiler. If we put one cyclone before the economizer , the flue gases from
furnace can directly be sent to one of the cyclone. So that the fly ash is removed before it goes to
economizer & hence the corrosion & scaling of economizer tubes can be reduced.

60
 Present Setup

Furnace Economizer Cyclone (2 nos.)

Proposed Setup

Furnace Cyclone Economizer Cyclone

(iii) Reducing the inlet coal particles size

Presently 2-mesh size (7.01mm) sieve is used for the coal particles after the grinder. It is well
known fact that as coal particle size decreases combustion efficiency increases. If the coal
particle size is reduced, the surface area will be more for the combustion thus higher the
efficiency.
Company should experiment this once by installing the 4-mesh size (5.89mm) sieve and should
observe the effect of it on the efficiency and steam production.

10.2 Suggestions - WHRB

10.2.1 Efficiency Enhancement of V-23 WHRB

Existing facility: Cross Current WHRB
Proposed facility: Counter Current WHRB

Enthalpy of water (KJ/kg) 176

Enthalpy of steam (KJ/kg) 2676
Cp (KJ/kg oC) 1.013

Equipment Hot Gas Water Flow Hot Gas Water Enthalpy Efficiency
Flow Rate Rate Ti (o C) To (oC) Ti (o C) To (oC) of water
(kg/hr) (kg/hr) (KJ/kg)
EOU
WHRB 14000 550 296 168 97 178 400 0.69
V-23
WHRB 9000 250 300 185 65 183 295 0.57

61
Assumptions:
1) Efficiency of new WHRB = 70 %
2) Outlet temp. of hot gas for New WHRB = 168 o C

Heat available for steam generation in New WHRB

= efficiency x specific heat of gas x flow rate gas x ( Ti –To)
= 0.70 x 1. 013x 9000 x (300 – 168)
= 842410 KJ/hr

New capacity of WHRB

= Heat available for steam generation / (Enthalpy of steam - Enthalpy of water)
= 842410 /(2676-176)
= 336 kg/hr

Increased steam generation capacity

= New capacity of WHRB - Existing capacity of WHRB
= 336 – 250
= 86 kg/hr

Cost saving = Cost of 1 kg of steam x Increased steam generation capacity

= 1.24 x 86
= 109.22 Rs./hr
= 2621.28 Rs/day
= 786384 Rs / year on the basis of 300 day operation

10.2.2 Utilization of hot exhaust gas of WHBR for heating of water in hot water tank
Temperature of hot water tank is 65 0C. Presently water temperature is increased from 32 0C to
65 0C using steam. Hot exhaust gas of WHBR can be utilized to heat the water and steam can be
saved . Hot exhaust gas outlet temperature is around 168 0C. Assume it looses its heat up to 100
0
C.
Energy saving calculation has shown below,

V-23 WHRB = Specific heat of gas x flow rate gas x ( To –Tassume)

= 1. 013x 9000 x (185 – 100)
= 774945 KJ/hr

EOU WHRB = Specific heat of gas x flow rate gas x ( To –Tassume)

= 1. 013x 14000 x (168 – 100)
= 964376 KJ/hr

62
Total energy loss in stack gas =1739321 KJ /hr

This energy can utilized for the heating of water in hot water tank by passing hot gasses through
the tube in water tank.

10.3 Suggestions - Steam Distribution System

10.3.1 V-23 Condensate Recycle

V-23 Presently V-23 sulfonation dose not have condensate recovery system. It produces 350
Kg/hr of condensate. This condensate is presently sent to V-23 cooling tower as water
conservation. But it is the double loss of plant because load on cooling tower increases and one
also loose heat present in the condensate. It is advised that this condensate should be recycled to
the V-23 WHRB feed water line. By this way heat present in the condensate can be utilized and
feed water requirement will also decrease.

10.3.2 Condensate recovery of all the plants

There is a large amount of condensate formed after the process equipment. This condensate is
not recovered or recycled in most of the processes. If we recovered this condensate, then there is
large utilization of heat of condensate.

Plant Process Condensate CRS available

formed
Sulfonation 350 No
V-23 Ethoxylation 450 Yes
Dryer 660 Yes
VAHP 700 Yes
Sulfonation 400 Yes
EOU Dryer 860 Yes
F-2 280 No
NECA 23 No
MED Sulfonation 250 Yes

The condensate is of same quality as that of makeup water. Hence no requirement of chemical
dosing.
Approximate unrecovered condensate=1053 Kg/hr

Assumption: Temperature of condensate=1000C

Cp of water=4.187 KJ/Kg 0C
Ambient Temp.=35 0C

63
So, Heat loss = m*Cp*dT
= 1053*4.187*(100-35)
= 286579.21 KJ/hr
= 68560 Kcal/hr
Hence it is suggested that condensate recovery system must be present in all of these processes.

10.3.3 Modification in ethoxylation steam distribution network

The steam line from EOU header first diverted into two parts. One line goes to FO header &
another to V-23 Sulfonation. A new steam line is placed from FO header to ethoxylation plant.
This is an excess pipeline which causes heat loss through insulation & condensate losses.
Instead of a excess line from FO header to ethoxylation, it is suggested that a line should be put
up from diversion point itself along with a valve to assure a constant steam flow.

V23
Proposed Modification Gate

FO header

Oil Fired Boiler

E DEE
O Existing line
U

H
e
a Dryer
d
e
r

Ethoxylation

To sulfonation

64
11. SAFETY RELATED SUGGESTIONS

11.1 Temperature of the Coal heap rises due to high storage height

Moisture content change and size degradation

In its natural state within a seam, coal is always more or less completely saturated with water and
mined coal when exposed to air will therefore tend to lose moisture until on equilibrium between
it and the ambient atmosphere has been established . If the relative atmospheric humidity
increases, the coal will reabsorb moisture; and this cycle of desorption and reabsorption of
moisture can be repeated many times.
During drying, desorption of moisture from the external surfaces of a coal lump will always be
faster than desorption from its interior; and since desorption is accompanied by some volume
shrinkage. Similar stresses are set up during reabsorption of moisture which will also be faster at
the surface than in the interior and so lead to differential expansion. the disintegration is usually
termed "decrepitating" or "slacking" and will, among other matters, substantially increase the
total surface area which the coal present which coal present to air.

Oxidation
While losing or absorbing moisture when exposed to air, cola will also chemisorb oxygen and so
become increasingly "oxidized". There is still some uncertainty about chemical mechanism
which this process entails but it is generally agreed that the first stages of the oxidation create
active peroxide complexes at the coal surface which subsequently decompose to yield water and
oxides of carbon and to leave oxygen- bearing functional groups (such as hydroxyl, carboxyl,
carbonyl, ethers, enols and antihydrides). Further oxidation appears to cause progressively more
extensive molecular degradation, forming so called humic acid which in turn, degrade into
simpler molecular species (and ultimately water soluble coal acids).
Because oxidation is a surface reaction, its rate under otherwise constant conditions will depend
upon the rate at which oxygen can diffuse into a coal lump and this, in turn, is largely determined
by the surface area of the coal to which oxygen can have access.
In this connection, it is important to note that rates of oxidation depend also on
temperature - generally doubling with every 10 °C rise in temperature - and that oxidation is
itself and exothermic reaction which generates heat (14100 btu/lb of carbon oxidized to carbon
dioxide). Accumulation of this heat of wetting in the coal mass will consequently lead to
progressively faster oxidation and cause so called autogenous heating which may, ultimately, end
in "spontaneous” ignition of coal.
Safety limit for coal storage is up to 8 feet while storing in storage pile. This will minimize the
chances of spontaneous ignition of coal. But currently we are storing as high as 12-13 feet. And
it is found that temperature of coal after digging 2 feet is 65 oC. So it will be way higher at the
bottom parts of the coal godown.

65
11.2 Safety Suggestion related to cyclone clogging

Fine particles from economizer are separated in cyclone separator. With time particles are
aggregate on bottom portion of cyclone which has very higher temperature. This clogging of
particle prevents further particles dropping outside the cyclone at cyclone bottom outlet. This
clogging is removed manually by operator which is not safe and it can cause injury to operator.
So there should be some hammering or vibrating adjustment at the bottom of the cyclone so that
particles fall automatically after some time.

66
12. Observations
During the 2 week of boiler training program, we visited all boilers in the plant. Our
observations regarding these boilers are:

 Insulation to DG WHRB

There is no proper insulation from all sides of a boiler which imparts a huge heat loss.

67
  Condensate recovery

The condensate produced in most of the processes is not recovered or recycled to a boiler.
Also, there is a bad situation of condensate pits. The condensate water is contaminated which
increases its TDS. This activity increases the cost of chemical treatment & makeup water.

 Losses at control valve

68
During the steam line tracing we observed a lot of leakages near the control valve (PRV).
The surface of a control valve is exposed to atmosphere. So, a large heat loss is found.

69
REFERENCES

 Chemical data sheets provided by NALCO Chemicals

 Boiler documents present in the maintenance department

 MP Sheets of Boiler

 PFD and process data provided by V-23, EOU & MED sections

 World Wide Web

70