Sugar Factory Internship Report

INDEX
CHAPTERS CONTENTS
Introduction
1 Location and Plan
Organization Profile
Organization Chart
Plant Processing Layout
Departments and its Function
Cogeneration Plant
2 De-mineralized Water Plant (DM
plant)Effluent Treatment Plant
Water and Steam Flow System

3 Gas Flow System
Operation and Maintenance of Boiler
Boiler-Calculation
My own Experience and Assessment

4 Specific Technical Outcomes
Specific Non-Technical Outcomes
Conclusion
DAYANAND SAGAR COLLEGE OF ENGINEERING Page 1

CHAPTER-01

ABOUT THE COMPANY
1.1 Introduction
Fig1.1-Bilagi Sugar mill limited Badagandi
Bilagi Sugar Mill Limited is situated in Badagandi village of Bilagi taluk and
district Bagalakot of north Karnataka. Shri S. R. Patil is the founder and chairman
of this mill. Shri Sureshgouda Patil and Shri Laxman. R. Nirani are working as
directors of this mill. Bilagi Sugar Mill Limited was registered on 19 November
2001. Sugar projects supplied science 15 march 2006. Bilagi Sugar Mill Limited's
Corporate Identification Number (CIN) is U1542KA2001PLC029788, Registration
number is 029788. Their registered address on file is KH B Colony Bagalakot,
Bagalkot District Karnataka, India. The mill is double Sulphitation type and milling
capacity is 35000 tons crushing per day. Bilagi Sugar Mill Limited is currently in
active status.
1.2 Location and Plan
Bilagi sugar mill is located in the district of Bagalakot, and taluk is Bilagi.
This factory nearest railway station is Bagalakot. And is located in the highway of
Vijayapur and Hubli. This factory has an area of about 20 acres.
1.3 Major Milestone of the Company
Bilagi Sugar Mill Limited is awarded as 1" prize for "Best Technical
Efficiency in 43 annual Convention of the "South Indian Sugarcane and Sugar
Technologist's Association (SISSTA)" for the academic year of 2013-13.

1.4 Organization Profile
Name of the company: Bilagi Sugar Mill Ltd, Badagandi
Address : Bilagi Sugar Mill Ltd, Badagandi-587116 Tq: Bilagi Dist: Bagalkot -
Karnataka, India.
Register office : Bilagi sugars Ltd, Badagandi-587116 Tq:Bilagi Dist:Bagalkot
Email :bilagisugarmill@yahoo.co.in
Corporate identification number: U15429KA2001PLC029788
Executive vice president : Mr. K.A. AZIZ
Status of the company concern: Active status , Sole Trading Concern.
Constitution of the firm: Registered Under Companies Act 1956
Auditor Of Company CA. Charantimath, Hubli
Bankers of the company: DCC bank, Bagalkot and Belgaum
Axis bank, Bagalkot
Bank of India, Bagalkot
Product:White crystal sugar, Byproducts as Molasses, Baggase and Press mud
1.5 Products and Services of the Company

The main product of the factory is White crystal sugar and because the cane
is wholesome raw material every part of it is utilized by the sugar industries in one
or the other way. A part from the main product there are some by products which
are:
• Molasses -Fed to the distilleries.

• Bagasse - Fed to the boiler as fuel.
• Press mud - Used as the fertilizers
• Sugar -Used as food.

1.6 Organization chart
BILAGI SUGAR MILL LTD, BADAGANDI.
ORGANISATION CHART
1.7 Man power and time shifts of the factory

Man power is the main source for an industry. BSML has total man power of 530
include permanent and outside source.
Permanent workers – 330
Outside workers - 200
The factory working as three shifts per day in season time. But in off season only
general shift works.
1 shift-5AM to IPM
2nd shift IPM to 9PM
3rd shift-9PM to SAM
General shift-9AM to 6PM (Include lunch time)

1.8 Plant processing layout
Fig 1.3 - Process chart of BSML
Process Flow Chart

1.9 MANUFACTURE OF SUGAR
Sugar commonly is white crystalline in shape. Flow diagram and outline of
manufacturing operations
1.9.1 STAGES OF SUGAR MANUFACTURING

• Extracting juice from sugarcane by milling
• Clarification of juice
• Concentration of juice by evaporation to syrup
• Crystallization of sucrose by vacuum pan boiling
• Centrifugal separation of sugar and molasses from the massecuites
• Drying cooling of sugar
• Sugar grading and packing
1.9.2 SUGARCANE MILLING

Sugarcane received at the factory level is weighed on platform scale and fed
in to cane carrier by mechanical devices such as mechanical imlonders of grab type
or sling type with feeder table arrangement or tippler arrangement ete. During its
travel to milling. The cane is prepared for crushing by the preparatory devices.
The preparatory devices consist of a Kicker, Levelers and a Cutter and a

Fibrizors or Shredders. The leveler and shredders consist of knives whose number
depend upon the width of the carrier. The knives rotate at about 600 rpm for cutting
the cane traveling on the carrier. The knifed cane delivered to the Fibrizor or
Shredder for being finely prepared for milling. The quantity of preparation has a
very significant role in the capacity and efficiency of the milling tandem The milling
plant usually consists of five mills each of 3 rollers which are hydraulically loaded.
The prepared cane passes through these mills where it is subjected to repeated
application of high pressure. The spent cane is discharged from the last mill and juice
is collected from mills and pumped to the Boiling House for processing
In the process of milling hot water is applied on the mills to increase the
extraction of sugar. Compound maceration is followed by application Dilute juice
on penultimate mills. In this system water is spread over blanket of cane before last
mil The diluted Juice from this mil is spread on the blanket to the proceeding mil

and so on Hence, the system gives a counter current process, thus improving he
extraction of sucrose.
Milling in this manner gives about 92.95% extraction The discharged bagasse
from the last mill contains fiber, sugar and about 50% moisture. This bagasse is
elevated by bagasse conveyor to a height convenient for being finally discharged in
to boiler furnace for burning. Heat is utilized to generate steam at required pressure
and temperature. The steam produced is used for generation of power and the direct
steam drives prime movers. The exhaust steam available from the prime movers is
utilized for process heating and evaporation etc.
1.9.3 CLARIFICATION OF JUICE

The juice as extracted out cane is composed of primary juice expressed by
first crushing unit called first mill and diluted juice from second crushing unit called
as secondary juice, Hoth these juices are combined together and termed as mixed
juice. The mixed juice Is a sugar solution which consists of about 84% water, 13%
sucrose, 30 non-Sugar (impurities). The principal non-sugars are invert sugars
(1.5%) and inorganic ash 0.5%. The mixed juice when sent for processing is termed
as raw juice and its pll ranges from 4,7 to 5.7. At this pll, the juice is prone to
microbial as well as chemical inversion. It is advisable to process the juice as quickly
as possible to loss of crystallizable sugar, to avoid oxidation which causes coloration.
In order to achieve maximum recovery of Sugar, it is essential that the juice must be
free from all non-sucrose solids. The presence of each part of non-sugar in juice
causes 0.4 part of sucrose to be non-crystallizable. To get rid of the impurities, the
juice is subjected to clarification treatment.
Essentially the good clarification process to be adopted is one that enables

maximum removal of impurities. The juice is strained at the mills and sent to the
juice weighing scales where juice is weighed and its weight is recorded
There are three different types of clarification processes for sugarcane juice
a) Defecation
b) Sulphitation
c) Carbonation

First method is often used for producing raw sugar for subsequent refining.
While the other two are generally used when it is desired to make direct consumption
plantation of white sugar. Essentially, the treatment of cane juice in any of the
different method aims at neutralizing the natural acidity and precipitating as much
non-sugars as possible out of it to obtain a neutral, clear amber colored juice. Many
different products like phosphates, magnesia was tried for clarification of raw cane
juice but still lime remains the most economical agent juice clarification. Sugar mills
in India mostly follow sulphitation process as described below.
1.9.4 SULPHITATION PROCESS

This is the standard and conventional process followed with various
modifications such as pre sulphitation pre-liming tor obtaining good quality of white
sugar. The juice is heated at 70°C after making up its P₂ Os level to 300 PPM.
Optimum dose milk of lime is added and sulphur dioxide gas is Simultaneously is
applied to bring down the pH to7.0. during this process phosphate and calcium salts
are formed and the floes absorb the impurities and color.
The sulphited juice is heated again tol00°C in the secondary Juice heaters and
is allowed to settle in the continuous clarifier. The effect heat and precipitation of
Ca SO, results in settling of most of the impurities. The clarified juice is drawn out
of clarifier and the mud is filtered in the continuous rotory filters. The consumption
of lime, TSP and sulphur on cane is 0.11 0.02%. 0.001 to 0.01% and 0.04 to 0,10%,
respectively.
1.9.5 EVAPORATION
The juice as received from clarification station contains water and sucrose
together with water added to the mills for the purpose of maceration and water used
for washing the filter cake. The clear juice is about 100% on cake with solid about
15% while temperature is increased to 110-112°C. The clear juice is stored in a clear
juice tank from where it is pumped to the evaporator through pre-heater le clear juice
heater.
The function of pre-heater is to raise the temperature of clear juice to boiling

point temperature of the first vessel. In this way, pre-heater plays an important role

in augmenting evaporator capacity. Otherwise, the initial heating has to take place
in the lower part of tube in the first vessel of evaporators.
The evaporation is carried out in multiple-effect evaporators (quite often

single or double effect vapor cells. All modern multiple effects are vertical tube
evaporators based on Rillieux's principles. The saturated steam (exhaust of the of the
prime movers) is admitted in the calandria (steam space) of the first vessel where its
parts with its latent heat to the juice inside the vertical tubes and gets condensed. The
vapor thus liberated by the boiling juice passes through pipe in to steam space of
next vessel and juice evaporated for the second time by the vapor from the preceding
vessel i.e by its own vapor. The process is repeated in subsequent vessels generally
comprising of tour effects thus known as Quadruple effects.
The vapor space of the first quadruple effect is connected to the condenser
where vapors are condensed by bringing them in to intimate contact with cold water.
The non-condensable gases are removed from the calandrias under vacuum to save
condensers or ejectors.
The condensate of the first calandria which has higher temperature and is from
Sugar traces is Sent to the boiler feed tank through the pump. The condensates from
the second, third, and fourth calandria are removed by means of pump through
equalizing System, since these Calandrias work under vacuum. The second
condensates may at times contain some sugar traces and are as such used for process
and maceration. The high density (60-65° brix) syrup accumulating in the last vessel
is evacuated under vacuum by means of a pump and is sent to the storage tanks on
the pan floor after sulphitation.
1.9.6 CRYSTELLIGATIONPAN BOILING

A sphited syup is subjected to boiling in the Vacuum part where its
Concentration leads to the supersaturation and formation of sugar crystals. A three
or four stage boiling scheme is selected keeping in view the size of sugar crystals
desired and exhaustion of the mother liquor.
Various massecuites i e. A, B, and (massccuites are after boiling in the pans

treated in the crystallizers where residual salting out of sugar to exhaust the mother

sugar takes place, three or four stages exhaustion minimizes the sugar loss in final
mother liquor which is called final molasses and is sent out to storage and disposal
1.9.7 CENTRIFUGING
The curing A, B, and C massecuttes is done in centrifugals to separate the
respective molasses from sugar crystals. A massecuite where from commercial sugar
is received is cured in verticals hatch type machines with automated and recycling
controls, sugar in the basket is washed with water/steam and molasses is fractionated
in to heavy and light fractions
B Massecuite is cured in vertical continuous machines where B molasses is

separated. B sugar is magmised to be used as footing for A or melted and melt used
for building A massecuite.
C massecuite is also cured in continuous centrifugals, mostly in two stagesto

obtain final molasses, which is sent out and C light molasses is used back in boiling.
C sugar Is melted and is used for A boiling.
1.9.8 DRYING AND COOLING OF SUGAR

If this wet sugar is sent to warehouse it deteriorates considerably during
storage by the action of bacteria on the film of molasses which envelopes it. This
inversion reduces the polarization. It is therefore essential to condition the sugar
before being bagged and ultimately sent from factory to sugar warehouse. By sugar
conditioning it is meant to lower the moisture content of sugar to 0.02to 0.05% to
cool down the sugar for packing. In the process of conditioning, the sugar crystals
produced in the centrifugal machine dries in the basket and cools on the hopper
conveyor. This conveyor discharges the sugar in the foot of sugar elevator which
delivers it in to the graders.
1.9.9 SUGAR GRADING

Sugar discharged from the elevators is fed to the graders where it is screened
into different size grades before storage in warehouse. There are two types of
vibrating screens in use for this purpose in one type, the vibrating frame is mounted
on the springs and belt driven rotating shaft is mounted on the vibrating frame. The
core of solenoid works against adjustable spring tension due to which the vibration

of desired magnitude can he achieved. Both the type of units are composed of three
to four decks. In each deck, the wire screen of desired opening is held in position
under tension by clamp at the slope 35° to the horizontal. The sugar obtained from
elevators is fed on the top of grader and is collected in bags from different spouts for
different sizes.
1.9.10 STORAGE
The sugar packed in 100 kg. Twill gunny bags are stacked in the sugar godons
to prevent its deterioration in storage, the godons are constructed in such a manner
to provide storage facilities free from humidity. Humidity is maintained below 50%
for deterioration free storage.
1.10 Departments and its Functions

1. Human Resource Department
2. Technical Department
3. Manufacturing Department
4. Cane development Department
5. Administrative Department
6. Marketing Department
7. Civil Department
1.10.1 Human Resource Department

In all industry, Human Resource department plays very important role. This
department has some important functions. Man power planning recruitment,
placement, training and development. Providing welfare activities, canteen and
medical security. The IIR Managers are to be motivate to the workers in order to get
efficient work from the workers.
1.10.2 Technical Department

All the mechanical process that running in the plant is controlled by the
technical department. This department has one general manager and engineers. Any
technical problem in the processing time of the factory is to be cleared by technical
department.

1.10.3 Manufacturing Department
The products of the industry is manufactured to get desired objective. In sugar
industry sugar is manufactured from sugarcane to form different grain size of sugar.
In manufacture department processing of products takes place.
1.10.4 Cane Development Department

The main important function of the cane development department is to be the
surveying where the sugar cane is grown and providing them to the fertilizers, to
improve the growth rate of sugar cane. This department has one General manager
and few members of field assistants. This department provide facilities to the
formers, that are, providing harvesting charges (sending people for the harvesting),
registration of cane load during the time of crushing and helps in the plantation of
sugarcane.
1.10.5 Administrative Department

Administrative department is the back bone of the industry. The main job
responsibility of an administrator is to ensure the efficient performance of all
departments in the industry. They act as the connecting link between the senior
management and employees. They provide motivation to the work force and make
them realize the goals of an industry. In BSML the time office, sales and purchase
is controlled by the administrative department.
1.10.6 Marketing Department

The main goal of the marketing department is to be sale the product of the company.
Department held shall be responsible and authorized for ensuring understanding and
implementation of the company's quality and objectives within the marketing
department. Collection and acceptance of order from customers and final terms and
condition with the customer in consulting with zonal manager prizing committee.
1.10.7 Civil Department

Any constructions in the industry is to be done by civil department. The supporting
beam, column in the industry is designed by civil engineers

CHAPTER-02

ABOUT THE DEPARTMENT
Bilagi sugar mill limited has four different departments in its sugar production
1. Cogenerations plant
2. De-mineralized water plant
3. Effluent treatment plant
4. Mechanical system
PRINCIPLE OF OPERATION OF TURBINE OF COGENERATION PLANT
The Wiley's India limited mule, back pressure steam turbine is an impulse
turbine usually with one two-row velocity (Curtis) wheel and three Rateau (pressure
compounded) stages (shown in fig. 4 in Appendix-111). The steam supply to the
turbine is lead through an emergency valve and a control valve (which is controlled
by the governing system) to the high-pressure nuzzles. The nozzle plate is bolted to
steam belt formed at the steam end of the turbine cylinder. Steam passes through the
Curtis wheel which includes a row of fixed (guide) blades between the moving rows
to direct steam on to the next one and then through the remaining two or three Rateau
stages consisting of nozzles mounted in inter stage diaphragms, and successive rows
of blades mounted on the turbine rotor. Finally, it exhausts to the low-pressure steam
main.
Pressure balancing holes through the turbine rotor wheels ensure that each
rotor wheel is surrounded by steam at uniform pressure and is turned only by the
impulse action of nozzle jets, the steam expansion taking place in the nozzle only.
Consequently, under normal circumstances, no large thrusts are developed.
Speed controls and emergency over speed governors are provided. The hydro
mechanical type speed control governor controls the opening of the steam control
valve, in order to maintain a substantially constant speed irrespective of load on the
turbine. The emergency trip gear protects the turbine in the event of failure of the
normal speed governor by closing the independent emergency valve and completely
shutting off steam Supply to the turbine if the turbine speed exceeds the normal
speed by 10-12percent. The emergency trip gear may also be operated manually or
by the solenoid trip valve, which is itself associated with protection system for the
unit, Lubricating oil for the unit is provided from a main oil pump driven from the

slow speed shaft of the reduction gearbox. An A.C. auxiliary motor-driven oil pump
is also provided for flooding the bearings before starting and for maintaining an
adequate supply while running up and shutting down. A pressure switch fitted in the
lubrication oil system starts the auxiliary oil pump as the turbine slows down, either
during stopping or after oil supply failure, to safeguard the bearings. It is not
intended that the turbine should run the auxiliary oil pump. The pumps provide
lubricating oil turbine, gear and alternator bearings. The lubricating oil is water
cooled in a Dellis design shell and tube types cooler.
The driven equipment is driven through a single helical reduction gear. The
turbine rotor as well as driven equipment rotor is coupled to the gearbox pinion and
gear wheel respectively through all metallic flexible element’s spacer type
couplings.
2.1 Cogeneration plant

Cogeneration is the simultaneous generation of heat and power, both which
are used in industry. As the centricity generated by cogeneration plant is normally
used locally and hence the transmission and distribution losses are negligible.
There are several industries such as paper mills, textile mills, chemical
factories, jute mills, rice mills and so on where saturated steam at the desired
temperature is required for heating, drying etc. for constant temperature heating (or
drying), steam is very good medium since isothermal condition can be maintained
by allowing saturated steam to condense at that temperature and utilizing latent heat
released for heating purpose. Apart from the process heat, factory also needs power
to drive various machines, for lighting and other purposes.
2.1.1 Steam power plant

A steam power plant is continuously converts the energy stored in fossil fuels
or fissile into shaft work and ultimately into electricity. The working fluid is water
which some times in the liquid phase or vapour phase during its cycle of operation.
The steam power plants which are operated on the principle of Rankine Cycle.

Rankine cycle
Fig 2.1-Rankine cycle.
For each process in the vapour power cycle, it is possible to assume a

hypothetical or ideal process which represents the basic intended operation and does
not produce any extraneous effect. for the steam boiler, this would be a reversible
constant pressure heating process of water to form steam, for the turbine the ideal
process would be a reversible adiabatic expansion of steam, for the condenser it
would be a reversible constant pressure heat rejection as the steam condenses till it
becomes saturated liquid and for the pump the ideal process would be the reversible
adiabatic compression of this liquid ending at the initial pressure. When all these
four processes are ideal, the cycle is an ideal cycle, called a Rankine cycle.
2.1.2 Steam generator (Boiler)

Boilers are the basically a closed vessel into which water is heated until the
water is converted into steam at required temperature and pressure. Steam produced
in a boiler is primarily used to,
✓ Generate electrical power.

✓ Industrial process heating.
Fig 2.2-working principle of boiler

Working principle of boiler
The basic working principle of boiler is very simple and easy to understand.
The boiler is essentially close vessel inside which water is stored. These hot gases
come in contact with water vessel where the heat of these hot gases transfer to the
water and consequently steam is produced in the boiler. Then this steam is piped to
the turbine of the power plant.
2.1.3 Classification of boiler

1. Relative position of hot gas and water
I. Fire tube boiler

II. Water tube boiler
i. Fire tube boiler
Fig 2.3-Fire tube boiler.
As it indicates from the name, the fire tube boiler consists of number of tubes
through which hot gases are passed. These fire tubes heated up the water and convert
the water into steam. As the water and steam both are in same vessel a fire tube boiler
cannot produce steam at very high pressure. Ex-Lancashire boiler, Cochran boiler
and locomotive fire box.
ii.Water tube boiler
A water tube boiler is such a kind of boiler where the water is heated inside tubes
and hot gases surround them. These type boilers are used in high steam demand and
pressure requirement. Ex-
Babcock and Wilcox boiler, sterling boiler and La-mount boiler.

2. Method of firing
i. Lancashire boiler
ii. Locomotive boiler
iii. Scotch boiler
3. Pressure of steam
i. High pressure boiler (<80 kg/cm²)

ii. Low pressure boiler (>80 kg/cm²)
4. According to the axis of shaft
i. Vertical tubular boiler

ii. Horizontal tubular boiler
5. Method of circulation of water
i. Natural circulation
ii. Forced circulation
6. Nature of service to be performed
i. Land boiler
ii. Portable boiler
iii. Mobile boiler
Bilagi sugar mill limited has the water tube boiler and capacity of 55 ton per
hour and pressure of 45 kg/cm². Followings are the details of the boiler.
Boiler number KTK-2847
Boiler make Thermodyne
Boiler type Bi-drum boiler
Boiler capacity 55 TPH
Working pressure 45 kg/cm ^2
Steam temperature 485±5 C

Total heating surface 3473 m²
Type of fuel Type of grate Bagasses
Type of gate Dumping
Table 2.1-Details of boiler in BSML
2.1.4 Boller Mountings
Mountings are required for proper and safe functioning of the boiler which are
generally mounted over the boiler shell,
1. Water level indicator
The water level indicator is needed to ascertain the water level of a boiler. It should
he fitted for each boiler in such a place that the water level can be constantly seen.
2. Pressure gauge
A pressure gauge is an instrument by means of which the pressure exerted inside a

vessel can be measured. There are two types of pressure gauges, one is Bourdon tube
pressure gauge and the other is diaphragm type gauge.
3. Safety valve
The safety valve (pressure relief valve) is used in a boiler to relieve the pressure of
steam when it is above the working pressure. Its function is to discharge a portion of
the steam from the boiler automatically when the steam pressure exceeds the normal
limit. It is mounted on the top of the shell.
4. Fusible plug
The function is to extinguish the fire in the event of water level in the boiler shell
falling below a certain specified limit.
5. Feed check valve
The feed check valve is used to control the supply of water to the boiler and to
prevent the escaping of water from the boiler when the pump pressure is less or the

pump is stopped. It is fitted over the shell slightly below the normal water level of
the boiler.
6. Steam stop valve
The function of the stop valve or junction valve is to regulate the flow of steam from
the boiler to the main steam pipe. To shut off the steam completely when required.
7. Blow-off cock
It may empty the boiler when necessary for cleaning, inspection and repair. It may
discharge a portion of water when the boiler is in operation to blow out mud, scale
or sediments periodically.
2.1.5 Boiler Accessories
The boiler accessories are required to improve the efficiency of steam power plant
and to enable for the proper working of boiler. The accessories are not mounted
directly on the boiler
Roller Mountings
Mountings are required for proper and safe functioning of the boiler which arc
generally mounted over the boiler shell.
1. Water level indicator
The water level indicator is needed to ascertain the water level of a boiler. It should
Refitted for each boiler in such a place that the water level touch of a boiler, it shou
2. Pressure gauge
A pressure gauge is an instrument by means of which the pressure exerted inside a

Vessel can be measured. There are two types of pressure he pressure exerted inside
a pressure gauge and the other is diaphragm type gauge.
3. Safety valve
The safety valve (pressure relief valve) is used in a boiler to relieve the pressure of
steam when it is above the working pressure. Its function is to discharge a portion of

the steam from the boiler automatically when the steam pressure chored the romal
limit. It is mounted on the top shell.
4. Fusible plug
The function is to extinguish the fire in the event of water level in the boiler shell
falling below a certain specified limit.
5. Feed check valve
The feed check valve is used to control the supply of water to the boiler and to
prevent the escaping of water from the boiler when the pump pressure is less or the
pump is stopped. It is fitted over the shell slightly below the normal water level of
the boiler.
6. Steam stop valve
The function of the stop valve or junction valve is to regulate the flow of steam from
the boiler to the main steam pipe. To shut off the steam completely when required.
7. Blow-off cock
It may empty the boiler when necessary for cleaning, inspection and repair. It may
discharge a portion of water when the boiler is in operation to blow out mud, scale
or sediments periodically.
2.1.5 Boiler Accessories
The boiler accessories are required to improve the efficiency of steam power plant
and to enable for the proper working of boiler. The accessories are not mounted
directly on the boiler.
1. Economizer Fig 2.5 - Economizer tubes

The function of an economizer in a steam generating unit is to absorb heat from the
flue gases and add this sensible heat to the feed water before the water enters
evaporation circuit of the boiler. Provision of this additional heating surface
increases the efficiency of steam generating unit saving in fuel consumption, thus it
is called by the name economizer.
It is useful to locate the economizer ahead of air heaters and following the
super heaters and boiler bank tubes. Counter flow arrangement is normally selected
so that heating surface requirement is kept minimum for the same temperature drop
in the flue gas. The economizer tubes are placed in line arrangement. With higher
feed water temperature, low temperature corrosion or bonded deposits in economizer
will seldom encountered. For on load cleaning the most common arrangement is to
provide soot blowers at gas inlet of the economizer. Even though on load cleaning
is sufficiently effective, it is usual to water wash economizer during each off-season.
Table 2.2-Economizer tube data
Tube size 50.8*3.25mm thick
Tube material BS 3059 P1 ERW 320
Header size OD 168.3 * 10.97 MM THICK
Header material SA 106 Gr.B
Heating surface of the economizer 423 m²
Water inlet temperature 105 c
Water outlet temperature 165 – 180 c
2. Super heaters
Super heaters are meant to raise the steam temperature above the saturation
temperature by absorbing heat from the flue gas. By increasing the temperature of
the medium(steam) the useful energy that can be recovered increases, thus the
efficiency of the cycle also. Super heating the steam also eliminates the formation
of condensate during the transportation of steam in pipelines and inside the early
stage of turbine, which is harmful to the turbine blades and pipelines. The metal
temperature at all the locations should be kept within the permissible value. This can
be accomplished by keeping the steam temperature at the outlet of the super heaters
within the particular value. Super heaters are to be steam blown to kept them
reasonably clean. Fly ash with high moisture content may stick to the heat transfer
surfaces resulting in low super heater outlet steam temperature. Super heaters have
two type coils that are primary super heater coils and secondary super heater coils.
Steam flows first to the primary super heating coils and then to the secondary super
heater coils.
Primary Secondary
Tube size OD 38.1*3.66 mm thick OD 38.1*3.66 mm thick
Tube material SA 213 T11 SA213 T11
Number of coils 50 50
Header size OD 219*12.70 mm thick
Heating surface area of 293 m²
super heater tubes
3. Air Pre-heater
Air pre-heater is a heat transfer surface in which air temperature is raised by
transferring heat from flue gas. Science air pre-heater can be successfully employed
to reclaim heat from flue gas at lower temperature levels than is possible with
economizer, the heat rejected to chimney can be reduced to higher extent thus
increasing the efficiency of boiler. This pre-heater consists of large number of steel
tubes expanded into tube plates at the ends. Flue gas flows through the tubes and air
flows outside the tube. Ate air pre-heater is divided into two blocks for easy
maintenance. The air which is pass across the tube is forced draft air, due to heating
this air the efficiency of the boiler increases and also reduces the flue gas temperature
at the outlet.
Tube size OD63.5*2.04 mm thick

Tube material BS6323
Number of tubes 1148
Tube height 4000
Heating surface of air pre-heater 1355 m²
4. Feed Pump
The pump will have their suction from the deaerator and delivered the feed water to
the boiler. The pump will be provided with minimum circulation control
arrangement to protect the pump under low load operation. Feed pump outlet
pressure is 48.5 kg/cm²

Make KSB
Type HAD 65-13
SL>NO> 0218079-75 2003/0218080-75 2003
Discharge 65 M^3/hr
Head 600m
Speed 2960 rpm
Rating 147 KW
Motor HP 240 HP
Table 2.5-Feed pump details
5. Steam Drum
Fig 2.7-Steam Drum

The boiler is equipped with a large steam drum to provide adequate steam storage
capacity and minimize water level fluctuation resulting from sudden changes in
steam drum. To achieve quality of steam required for industrial boilers, separators
and driers are provided inside the boiler drum as a part of boiler internals. The drum
internal design combines simplicity and efficiency to produce low maintenance cost
and high steam quality. The steam and water mixture entering the drum from the
raiser tubes and the bank tubes are collected in a separate chamber formed by baffle
panels inside the drum. The baffling is done in the drum to separate the down comer
tubes from the raiser tubes. The steam water mixture passes via the baffle before
entering the secondary separators.
The secondary steam dryer consists of several layers of screens stacked one above
the other where the entering moisture in steam is removed.

The water thus separated is returned to the water side of the drum. The drum is
maintained half level of water.. Dry steam leaves the drum through the top steam
outlet.
2.1.6 Deaerator
Fig 2.8(a)-Block Diagram of Deaeractor Fig 2.8(b)-Deaerator

The water to the boiler should be free from oxygen, otherwise it will form oxides
in the boiler parts. In the deaerator tank removal of oxygen takes place.
Working principle:
Feed water enters the deaerator from the top and evenly distributed, by means of
the distributing device, into the perforated trays fitted at the bottom. Water fills the
perforation and rains down and comes in contact with the heating steam delivered
into the lower portion of the deaerator column through the steam distributor. As a
result of heat exchange between the steam going up and the feed water stream
flowing down the water gets heated up to its boiling point and the gases (O2& CO2)
dissolved in it are transferred to the gas phase. These gases together with non-
condensing vapor are vented into the atmosphere through a vent valve. The de
aerated water storage tank which is fitted with gauge glass, pressure gauge and avoid
the formation of high pressure or vacuum in the deaerator. S streams of water may
by pass or not get fully degasified in the deaerator colum, thereby carrying

dissolved oxygen and carbon dioxide into the storage tank. Therefore, removal of
these dissolved gases takes place in the storage tank that affords enough space above
the water level for desorption to takes place.
2.1.7 Wet Scrubber
Fig 2.9(a)-Wet scrubber Fig 2.9(b)-working of wet scrubber

Wet scrubber is the main part of a team power plant. It will helps in the reduction of
ash content in the flue gas. In this wet scrubber two parts are present, one is venture
and another is wet scrubber tank.
The flue gas that enters the venture part in that small jet of water sprayed to flue gas
and then it enters to the wet scrubber. While flue gas is moving fine jet of water is
sprayed. That helps in the removing ash particle that come along with the flue gas.
Those ash particles are collected at the bottom of the tank and that is flows along the
drainage. That water along with ash is collected in the ash pit, where the filtration of
water takes place. The ash is used for the making of civil bricks and pure water is to
be again recirculation to the wet scrubber.
2.1.8 Fans
Fans are used in the steam power plant is to provide draft for the burning of fuel and
also the movement of the flue gas.

There are three different types of fans are present in power plant.
➢ Forced draft fan
➢ Secondary air fan
➢ Induced draft fan
A. Forced draft fan
This forced draft is to be provided in the power plant is due to increase the burning
rate of fuel. By using the atmospheric air forced draft is produced. This forced draft
air is first heated in the air pre-heater to a temperature of 170 ^ 0 * C and this air is
supplied to the furnace from the bottom of the furnace. This forced draft lifts the fuel
and helps in the complete burning of the fuel.
Medium handled Air

Medium temperature 30°C
Density 1.165kg / (m ^ 3)
Volume of air 24m ^ 3 / s
Head required 250 mmwe
Fan make Industrial system & equipment's limited
Fan model IERB/ 2 - 1000
Fan speed 1440 rpm
Motor rating 90 W
Table 2.6-FD fan details

B. Secondary air fan
Fig 2.11-Secondary air fan

Secondary air is to be provided for the proper burnin secondary air is not heated;
the cold air is to be supplied 30/49 air helps in the spreading of fuel though out the
area of the system is provided on the four sides of the furnace.
Medium handled Air
Medium temperature 30 deg * C
Volume of air 6.7m ^ 3 / s
Head required 700 mmwc
Fan make Industrial system &equipment Itd
Fan model JERB-1300
Fan speed 1440 rpm
Motor rating 55 W
Table -2.7 SA fan details.
C. Induced draft fan
Fig 2.12-Induced draft fan

This fan is used in the power plant is due to the remove of flue gas from the
furnace. This fan sucks the flue gas generated in the furnace and passes to the
chimney.
Medium handled Flue gas
Medium temperature 170 deg * C
Density 0.749kg / (m ^ 3)
Volume of air 29m ^ 3 / s
Head required 320WC
Table 2.8-ID fan details.
2.1.9 Steam Turbine

A steam turbine is heat engine converting the energy of steam supplied to it, into
useful work. Steam flows at high velocity results from expansion of the steam
through a series of nozzle which converts the heat energy into kinetic energy. This
kinetic energy is transformed into useful work as the steam mass progresses through
the turbine. The change in the direction experienced by the steam as it impinges on
the moving blades imparts a reactive force on the blades- producing torque on the
rotor shaft. In order to convert large amount of energy into useful work with
maximum efficiency, it is necessary to expand the pressure energy of the steam flow
in series or stages. Each stage comprises of set of nozzles followed by a fully bladed
disc or wheel.
Classification of steam turbine
1. According to the action of the steam
(a) Impulse turbine
(b) Reaction turbine
(c) Impulse and reaction turbine
2. According to the direction of steam flow

(a) Axial flow turbine-steam flows in direction of axis of turbine.
(b) Radial flow turbine-steam flow in perpendicular to the axis of the turbine.

3. According to the exhaust condition of steam
(a) Condensing turbine - steam at a pressure less than atmosphere is exhausted in
to the condenser
(b) Non-condensing turbine atmosphere - pressure of exhaust steam greater than
the
4. According initial conditions

(a) Low pressure turbines (1.2 to 2 bar)
(b) Medium pressure turbines (up to 40 bar)
(c) High pressure turbines (above 40 bar)
5. According to number of stages

(a) Single-stage turbine
(b) Multi-stage turbine
6. According to use
(a) Stationary turbine - used in power plants, and for turbo-blower and pumps.
(b) Non-stationary turbines - used to drive ships.
BSML has the turbine of the type Back-pressure turbine (non-condensing turbine).
This type of turbine is most widely used for process steam applications at Sugar
plants. Refineries, pulp and paper plants, and desalination facilities where large
amount of low-pressure process steam are needed. The exhaust pressure may be
controlled by a regulating valve to suit the needs of the process steam pressure. The
following table shows the specification of the turbine in BSML.

Fig 2.13-Steam Turbine
Back pressure turbine Type
Make Triveni turbines
Power rated 7840 kW
Inlet steam pressure & Temperature 45kg / c * m ^ 2 & 485 deg * C
Inlet steam flow 53000kg / h * r
Exhaust steam pressure 2.5 Kg/cm^2
Turbine speed 8226 rpm
Alternator speed 1500 грm
Turbine trip speed range 9134-9549 грm
Direction of rotation from output end Counter clockwise
Table 2.9-Specification of the steam turbine.
Make TEIL- Mysore
Type Double helical
Model N2219C
Output speed 1500 rpm
Table 2.10 Gear box details.

2.2 De-mineralized water plant (DM Plant)
Purpose of water treatment
Water treatment is required for satisfactory operation of the boiler. It must be
devised to prevent depositing of scale and to prevent corrosion from acids, oxygen
and other such harmful elements that may be in the water supply. A qualified water
treatment chemist should be consulted and the water systematically treated.
Objectives
The basic objectives treatment of water treatment are:
➢ Prevent the accumulation of scale and deposits in the boiler.
➢ Remove dissolved gases from the water.
➢ Protect the boiler against corrosion.
➢ Maintain the highest possible boiler fuel efficiency.
➢ Decrease the amount of boiler down time from cleaning.
Bilagi Sugar Mill, Boiler required following properties:

1. pH 9.5 to 10.5
2. TDS-Nil
3. Conductivity of water - less than 1 micro-ohms/cm
4. Total hardness - Nil
5. Sulphate - Nil
6. Sugar trace – Nil
7. Fluoride – Nil

Steps involved in de-mineralization process
A. Sand filter
Fig 2.15-Sand filter

The raw water from the bore well is passed to the sand filter. It get
cleared in sand filter, because it contain different size of sand particles
that removes the dust particles present in the water. In this sand filter no
suspended particles is cleared.

After passing to the sand filter, water that is in hard condition. That is,
this water contain cat-ion and an-ion casing hardness impurities in it. So
that hardness of water is removed before it entering to the boiler by cat-
ion bed and an-ion bed.
Cast iron bed
Fig 2.16-Cast iron bed

This removes the cat-ion contain hardness suspended particles in water. That
hardness causing chemicals are, Magnesium, Calcium and Sodium. These present in
water is removed with the help of cat-ion regime. This Mg, Ca, and Na are attached
to the regime, and cleared water is obtained. This regime is treated with 33% HCl,
that rinse the regime and make that regime clear. The hardness causing cat-ion
impurities are separate out.
B. Degasser Fig 2.17-degasser.

Degasser used in the de-mineralization process for the purpose of removing
Carbon di-oxide (C*O_{2}) present in the water.
C. An-iron bed
Fig 2.18-An-iron saparator.

This removes the an-ion contain hardness suspended particles in water. Hardness
causing chemicals are C*l_{2} S*O_{4} and N*O_{3} This present in water is
removed with the help of an-ion regime. These an-ion hardness causing impurities
are attached to the regime and cleared water is obtained. This regime is treated with
Caustic soda (NaOH), that rinse the regime and make that regime clear. The hardness
causing an- ion impurities are separate out.
D. Mixed Bed
Fig 2.19-Mixed bed

This bed acts as both cat-ion and anion bed. Tis bed has 1 / (3 ^ (nd)) portion acts
as cat-ion bed and 2 / (3 ^ (rd)) portion acts as Anion bed. After this step water is to
be demineralized and pH of the water is reduced, in order to increase the pH of the
water pH boaster chemical is used. In this step water conductivity reduces to less
than 1 micro ohms/cm. The demineralized water is stored in a tank, after it is
supplied to the feed water tank.
2.3 Effluent treatment plant

The effluent generated through leakages of pumps, massecuites, molasses, juices
and oil etc. is contaminated and are not fit to use directly.Therefore, this is collected
and taken to effluent treatment plant. Where oil, grease content is removed and water
processed through stabilizer, anaerobic digester, aerators and settlers. The final
water which meets the standards of pollution control board is given for land
irrigation. These solids deposited in settlers is dried in beds and given to formers as
manure.
Flue gases from boiler are pass through Mechanical dust collectors or Wet Scrubber
or Electro static precipitators to remove fly ash content so outlet gas meets the
standards prescribed by pollution control board to maintain surrounding atmosphere
clean.

CHAPTER-03

TASK PERFORMED
3.1-Water and steam flow system
Feed water from deaerator storage tank /feed water tank fed into the boiler through
a feed pump. From feed pump water is passes to economizer inlet header, tubes and
outlet header and fed into the steam drum. Flue gases produced in the furnace passes
through secondary super heater & primary super heater and economizer. Economizer
tubes exposed to flue gas pick up the heat and increases the water temperature. From
steam drum water passes to evaporator through down comer. Steam water mixer
enters to the steam drum through riser tubes, water particles are separated in the
drum with screen separators, dry steam is passed to primary & secondary super
heater in which the steam temperature is increased to the required conditions. Steam
generated in the boiler is accumulated in the steam header and given to turbine for
power generation /process heating.
Steam is to be expanded in the turbine and its pressure and temperature is reduced.
Bilagi sugar mill has back pressure turbine, the steam from the turbine is passed to
the pressure regulation distribution station, where its pressure is reduced and
converted into saturated water. This saturated water is used for the process heating
in boiling house. After this it is again fed into the deaerator tank.
3.2 Combustion System

Fuel from the mill or bagasse yard is fed to the combustor through feeders. Burners
are provided to ignite the fuel. Wind box receives the air from FD fan after passing
through A.P.H. and supplies air to combustor for combustion. Combustion control

system is established to maintain the steam pressure constantly. Fane air ducti
dampers, control equipment & flow measuring devices are combustion system to
monitor the combustion.
3.3 Gas flow system
Air supplied from FD fan passes to A.H. and heated-up with the waste gas leaving
the boiler and fed into the combustor through wind box. The fuel is supplied from
fuel feeders to the furnace. Fuel & air supplied to the combustor are undergoes
combustion when the ignition temperature to burn the fuel is already available in the
combustor. Flue gas is produced after combustion of the fuel in the furnace passes
through primary & secondary super heaters, bank, economizer and A.P.H. then it
passes through ID fan the gas is let into the chimney.
3.4 Operation and Maintenance of boiler

During the operation maintenance time following procedures is taken into account.
This helps in the efficient use of boiler.
3.4.1 Key points for operation and maintenance crew
• Whenever the equipment released for inspection & maintenance the work
permit to be cleared in writing to ensure safety.
• The written permission should contain necessary precaution to be taken by
maintenance crew.
• Necessary boards are to be kept to prevent unauthorized entry and starting of
the equipment.

• Control & power fuses are to be removed to prevent accident.
• After inspection and maintenance, written permit to be duly discharged
competent authority of a maintenance crew and returned t before starting the
equipment. `aut'
• If the equipment released for maintenance work ensure t. cle and closing of
man holes and ensure the equipment is free and it is made for regular
operation.
• Ensure the power and control supply are made ready.
• Ensure connected instruments and controls are working.
• Ensure protection interlocks are normal.
• Ensure the dampers, valves, ete in the connected system are ready for
operation.
• Ensure the filling of lubricants.
• To avoid over loading of the equipment it is recommended to start with no
load or minimum load.
3.4.2 Boiler filling
Acceptable water quality to be used to avoid corrosion and deposition in boiler.
All the vents are kept opened to avoid formation of air pockets.
3.4.3 Hydraulic Testing
• Hydraulic test is to be conducted above the operating pressure and the
safety valve are to be gagged. It is recommended to use treated water with
recommended water quality for hydraulic test.
• Use water temperature above 25°c.
• Check the supports and arrest all the spring-loaded hangers to take-up
additional load due to water.
• If the main steam piping is included in the hydraulic test, ensure no water
can enter in the turbine.
3.4.4 Steam line Charging
• While clearing the steam line from cold with steam, regulated quantity of
steam to be charged to ensure gradual raise of metal temperature. This
may be ensured by using integral bye-pass valve available in the main
steam stop valve.

• Keep all the vents and drains in the line open to remove air pockets and
condensate water. Otherwise, water hammer can occur in the system if
the condensate water is not fully drained.
3.4.5 Drum level

• Most important operating parameter to be maintained during boiler operation.
If the drum level drops below the gauge glass visibility it can endanger the
water wall and drum causing permanent damage.
• If the drum level rises above operating range, the steam quality will deteriorate
causing high carry over and deposits in super heater and turbine.
• Drum level normally maintained by controlling the feed water quantity and
the quantity required will be equal to steam output + blow down and
leakages. However, during load variation transient period there may be
variation in the feed water quantity.
• Drum water level gauge glasses provided on the drum are most reliable
level indicator. In high pressure boilers drum level indicated by gauge glass
may be slightly less than the actual due to sub-cooling.
• To click the gauge glass is indicating properly crack open the drain valve
and then close. The level in the gauge glass initially will go down when the
drain is closed it will be restored to its original position
• The instrument level indicators provided in the control room to be cross
checked with local level indicator once in shift. During starting & shut
down and low-pressure operation, local level indicator to be taken into
account and the instrument indicators eon he relied nacre ensuring correct
comparison with diet water level gauges.
3.4.6 Furnace Draft

• a balance drain unit important parameter to be maintained is furnace draft.
Maintaining slightly legatine pressure is necessary to avoid flame and gas
corning out of the furnace.
• In order to protect furnace walls and buck stays from damage duc to excess
pressure safety protections are normally provided for high and low furnace
drans.

• Any change or fluctuation in the furnace draft clearly indicates that there are
variation in the combustion condition inside the furnace. Due to tube failure
also the furnace draft can fluctuate at times. Furnace draft is maintained by
an induced draft fan.
3.4.7 Steam Pressure

• S.H. Steam pressure is maintained by rate of fuel firing which depends on the
loading of the turbine /steam consuming demand.
• The S.H. steam pressure is affected by steam drawn from the boiler. In a
Steady state condition steam pressure and temperature will be maintained
constantly or there will not be any significant variation in the steam
parameters.
• Due to abnormal pressure increases during load surging, safety valves are
provided to release the excess pressure and to avoid damage to the pressure
parts.
• Drum safety valves are set at higher pressure than line safety valve because
drum safety valve lifting earlier to line safety valve will cause reduction in
Steam flow through super heater and failure of super heater due to
overheating.
• It is essential to check before firing the boiler that the safety valves are not
gagged or prevented from operating.
3.4.8 Steam Temperature
S.H. steam temperature is normally controlled by De-super heating water spray.

The steam temperature is however affected by different operating parameters.
The following conditions the steam
a. Low feed water temperature

b. High excess air
c. High slagging in the furnace
d. Due to high secondary combination

Steam temperature will drop when
a. Feed water temperature increases

b. Excess air level reduces
c. Combination is in complete
d. Water entry to supper heater from drum
3.4.9 Operating parameters control

• Boiler pressure. level. O2 in flue gas and furnace pressure are the important
parameters to be maintained fairly at a constant value throughout all the
range.
• The parameters like feed Water quantity. fuel input air supply and ID fan
load are to be varied by the operator to control the above parameters.
• Subsequent change in the Water. fuel and air supply will have proportionate
change in the boiler pressure steam output and O2 in flue gas.
• Normally steam pressure. temperature, combustion control and drum level are
operated in automatic control.
3.4.10 Boiler Cold start-up Sequence

• Ensure no line clear permit is pending on boiler, auxiliaries & associated
system
• Ensure boiler and auxiliaries are ready for normal start-up.
• Ensure instruments & controls are working and instrument air supply is
available.
• Ensure protection interlocks are in line.
• Ensure normal water level in the drum.
• Ensure dampers are in shut condition before starting the fans.
• Ensure soot blowers are ready for operation
• Ensure fuel feeders / pulverizer are ready for operation
• Ensure closing of D.S.H. steam temperature control valve
• Ensure opening of vents and drains
• Start the boiler as per the start-up procedure.
• Close the drum vent when the pressure increases to 2 to 5 kg/cm2
[DAYANAND SAGAR COLLEGE OF ENGINEERING Page 44

• When the unit is heated-up boiler expansion movement to be checked, Check
the loading of spring hangers in the boiler.
• Increase the firing rate and raise the pressure,
• Line charging shall be made as per charging procedures
• Steam turbine rolling shall be carried out once the steam parameters are
acceptable to the turbine manufacturer recommendation.
• During turbine start-up, synchronizing and loading, steam parameters like
pressure, temperature are to be maintained constantly to ensure smooth startup
of turbine.
• Turbine load shall be increased by increasing steam generation in boiler by
adjusting fuel and air in the boiler.
• Once turbine loaded all the vent and drains in the boiler and steam line shall
be closed
• The continuous blow down shall be kept open according to boiler water solids
concentration
• When the steam temperature, pressure reaches a steady state, it can be put in
automatic control.
3.4.11 Boiler shut down procedure
• Gradually reduce the firing rate and allow the boiler pressure. Temperature to
drop
• Pressure, temperature reduction should be in the acceptable limit to turbine
while reducing the load
• Different parameters and system which are working in auto control to be taken
into manual control at appropriate condition and monitored carefully.
• Close the de-super heater isolating valves when de-super heater is not required
• Open the start-up vent, drains of super heater outlet.
• Continuous water feeding to be ensured to maintain normal drum level.
• Open the drum vent when drum pressure reaches to 2 kg/cm^2
• Boiler can be completely drained if necessary when the water temperature
reaches to 85’c
• Boiler pressure parts to be preserved during shut down to avoid corrosion and
preservation procedure to be followed.

3.4.12 Trouble Shooting in boiler operation
Generally, any incident which disturbs the boiler operating ability is called boiler
failure.
Boiler failure can happen due to
a. Internal disturbance
b. External disturbance
Internal disturbance which can lead to boiler failure are
a. Feed water flow

b. Feed water temperature
c. Fuel flow and combustion
d. Combustion air flow
External disturbance which can lead to boiler failure is load on alternator/reduction

in steam consumption
3.4.13 Emergency Shut down

During the following cases, emergency shutdown to be taken.
• Failure of boiler feed pump

• Deformation or failure of boiler pressure parts
• Explosion Of furnace
• Failure to ensure reliable operation
• Failure of water level gauges
• Non-permissible raise of S.H. temperature
• Failure of feed water flow meter for once through boiler
• Very low drum level on account of safety interlock
• Rupture of tube
• In case of re-heater, if there is no steam flow to re-heater then the boiler is
to be stopped

3.4.13 Boiler tube failure
Tube failures can be detected by noise and difference between steam & water
flows.
Major causes for tube failure
a. Over heating
b. Internal corrosion
c. External corrosion
d. Stress corrosion
3.5 Boiler Calculations

Boiler calculations include the following calculation
3.5.1 Evaporation ratio

Evaporation ratio is given by
Evaporation ratio = Steam produced / Fuel consumed
= (55 ton/hr) / (25 ton/hr)
=2
3.5.2 boiler efficiency

Boiler efficiency is defined as the ratio of heat actually utilized in generation of
steam to the heat supplied by the fuel in the same period.
i.e., Boiler efficiency = (Heat output / Heat input) * 100
= Mass flow rate of steam * (hg - hf ) / Bagasse Consumption * Gross calorific value
hg = Enthalpy of superheated steam at 45 kg/cm2 and 4850 C
hf = Enthalpy of feed water at 900 C
Efficiency = 55*(3439.3 – 376.9) / 25*9500
= 0.7091
= 70.91%

3.5.3 Total heating surface
The heating surface is nothing but actual heat transfer takes place between two
media. Either it may be water and flue gas or air and flue gas. In the boiler total
heating surface includes furnace bank tubes. water valves, superheat tubes (primary
and secondary), economizer and air pre-heater.
Following table shows the heating area of the boiler,
Table 3.1 – Total heating surface details
sl no Description Heating surface area in

m2
1 Furnace 227
2 Boiler bank 1175
3 Super heater 293
4 Economizer 423
5 Air pre-heater 1355
Total 3473

CHAPTER NO 04

REFLLECTION NOTES (SPECIFIC OUTCOMES)
4.1 my own experience and assessment
internship to the person gives the practical knowledge of machinery equipment.
What the theoretical is there come to experience in the internship process. I had
gone Internship in Sugar Mill Ltd Badagandi. the experience of the internship
was very good theoretical knowledge of subjects are Come in practically how
that are work.
• practical knowledge is more effective than theoretical knowledge.

• All machinery equipment in the industry is seen by us and I conclude that
the working of the machinery equipment.
• How the working is little bit different than theory procedure of work.
• Systematic operational steps included in the production process, from the
raw material to the desired object of the industry.
• How the organization structure of the industry is present. And different
department of the industry, what are the role of different departments.
• How the sugar production process is to be done in the industry is to be
known from the raw sugarcane to the different grain size of sugar.
• How the authority is present in the industry from top management to the
lower management.
• Time management is an important tool for an industry.
• I understand the financial details of the industry and customers to the
industry, transportation of the products in industry.
• What is the employee role in the industry is to be concluded.
• How the relation is between with the higher authority and lower authority.
• How the employee may be part in the celebration of festivals come in
industry.
• Where the products of the industry is stored.
• I understand the complete information about the boiler and its working
procedure.
• I understand the complete information about the steam turbine, and how
it will work.
• What are the safety precautions used in the industry is to be known.

4.2 Specific Technical Outcomes
The experience of internship is to be get technical knowledge of the work.
How technology is involved in the industry for the operation of machinery
equipment. Being an engineer technical knowledge is more important than
theoretical knowledge. The followings are the some of important technical
knowledge I get in the industry.
• Initially I went to the industry I first understand the milling process.

How the juice is extracted from the mill tandem. Helical groves are cut
on the miller tandem. so that complete extraction of juice takes place.
• The byproduct after crushing the sugar cane bagasse is obtained. This
is to be used as a fuel to the boiler.
• This bagasse is lifted by menace of elevators called by bagasse carrier.
• The heat energy is produced by the fuel is to used to boiler to produce
steam at required pressure and temperature.
• I Understood what are the boiler mountings and how that are operate to
control the boiler operations.
• Controlling of operation is by the boiler mounting equipment. The
super heat temperature crosses beyond the required level, then
attempters are use to control the temperature.
• Knowledge of back pressure turbine come in understood.
• Knowledge of working of pressure reliving distribution station (PRDS).
It is used to reduce the steam pressure and temperature for the process
heat application of steam.
• I understood the process of de-mineralization of water. What happen, if
raw water is directly used in the boiler.
• I understand the hydraulic testing of the boiler before it is starting of fire.
• The pressure for the hydraulic test is kept more than that of the normal
pressure of boiler. Near about I .5 of the boiler pressure.
• I understand the principle of working of wet scrubber. How the ash is
removed from the flue gas.
• I made calculation of efficiency of boiler, total heating surface of boiler
and total amount of fuel input to the furnace.
• Manual control of safety valves.

• What is the safety precautions are to be taken during the time of
maintenance.
• I understood how low quality of a steam will affect the Turbine blade.
• I came to Know How fixed and moving blades are arranged.
• Difference between FD fan and ID fan.
• Maintenance of pH, conductivity of Feed water, condenser water and
main steam.
• All control valves are made auto mode and these are controlled in a
control room, program logic control system helps to know exact values
and regulate the working condition.
• Importance of Soot blower.
• Importance of secondary air fan.
4.3 Specific non-technical outcomes

Following are the non-technical skills learn from the internship
❖ Managing Employees
During shutdown time the work is more and all work should complete in time.
So the managing employees to get particular work with their skill is very
important i observe from supervisors how they extract work from employee with
a clam mind.
❖ Improvement in verbal and written communication
During of internship, I enhanced my verbal and written communication Skill.
With the employees I share Iny experience about the student life as well as
experience I got by observing the company and I hear their experience and
ongoing difference between their initial career with present carrier. and also
present running situations day by day this made mine verbal Communication to
improve. From higher authorities anything want we get by giving letter for a
particular aspect. Typing request letters. report writing has improved my written
communication skill during the internship.
❖ Personality Development
During internship I observed higher authorities of co-generation where well and
good with their knowledge and management skills. WQ1ile discussion with

them made me improve Professional behavior. And also by observation of these
peoples made me to develop my intellectual skills, so which lead me into
develop mine personality.
❖ Time management
Department Turnover depends upon working days of co-generation. So
companies each work is bounded with Time. I observe each work is carried
within a point of time. By observing this it made me know the importance of
Time management.
❖ Resource utilization Skills
In circular, I completely read how power plant work i.e. Basics of power plant
and what are the types of equipment for enhancing the efficiency of plant.

CONCLUSION
Power plant is the most developing field in the present day. In BSML well
experienced staff members in their particular field of power plant. I have learned
about power plant, and I come to know the complete information about the power
plant and various process of the company. How the steam generator are to be
work in the power plant. And working of steam turbine to be understood. The
safety preventions are to be taken during the maintenance time. Got the
information about the technology involved in the power plant.

Sugar Factory Internship Report

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Sugar Factory Internship Report

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INDEX

Water and Steam Flow System

My own Experience and Assessment

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Fig1.1-Bilagi Sugar mill limited Badagandi

1.2 Location and Plan

1.3 Major Milestone of the Company

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Name of the company: Bilagi Sugar Mill Ltd, Badagandi

Register office : Bilagi sugars Ltd, Badagandi-587116 Tq:Bilagi Dist:Bagalkot

Corporate identification number: U15429KA2001PLC029788

Executive vice president : Mr. K.A. AZIZ

Status of the company concern: Active status , Sole Trading Concern.

Constitution of the firm: Registered Under Companies Act 1956

Auditor Of Company CA. Charantimath, Hubli

Bankers of the company: DCC bank, Bagalkot and Belgaum

Axis bank, Bagalkot

Bank of India, Bagalkot

Product:White crystal sugar, Byproducts as Molasses, Baggase and Press mud

1.5 Products and Services of the Company

• Molasses -Fed to the distilleries.

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1.7 Man power and time shifts of the factory

2nd shift IPM to 9PM

3rd shift-9PM to SAM

General shift-9AM to 6PM (Include lunch time)

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Fig 1.3 - Process chart of BSML

Process Flow Chart

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1.9.1 STAGES OF SUGAR MANUFACTURING

1.9.2 SUGARCANE MILLING

The preparatory devices consist of a Kicker, Levelers and a Cutter and a

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1.9.3 CLARIFICATION OF JUICE

Essentially the good clarification process to be adopted is one that enables

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1.9.4 SULPHITATION PROCESS

The function of pre-heater is to raise the temperature of clear juice to boiling

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The evaporation is carried out in multiple-effect evaporators (quite often

1.9.6 CRYSTELLIGATIONPAN BOILING

Various massecuites i e. A, B, and (massccuites are after boiling in the pans

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B Massecuite is cured in vertical continuous machines where B molasses is

C massecuite is also cured in continuous centrifugals, mostly in two stagesto

1.9.8 DRYING AND COOLING OF SUGAR

1.9.9 SUGAR GRADING

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1.10 Departments and its Functions

1.10.1 Human Resource Department

1.10.2 Technical Department

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1.10.4 Cane Development Department

1.10.5 Administrative Department

1.10.6 Marketing Department

1.10.7 Civil Department

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PRINCIPLE OF OPERATION OF TURBINE OF COGENERATION PLANT

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2.1 Cogeneration plant