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GEETANJALI INSTITUE of TECHNICAL STUDIES a Practical GEETANJALI INSTITUE OF TECHNICAL STUDIES (Affiliated to Rajasthan Technical University Kota, Rajasthan) A Practical Training Report On Types of Boilers & Mounting In Mechanical Engineering Session 2012 From 12june-11 july Training at HINDUSTAN ZINC LTD., DEBARI Submitted To: Submitted By: Mechanical Department Bhupendra Singh Jhala Geetanjali Inst. Of Technical Studies B-Tech IV Year Dabok Udaipur VII Semester ACKNOWLEDGEMENT I wish to acknowledge the encouragement received from Mr A.Raman( Principal Of G.I.T.S., Udaipur) ,Mr Vishnu Agarwal (HOD Mech. Department) and special thanks to Mr. Vijendra Sankhala and Mr. Pankaj Ahir for initiating my interest in training. Their mastery & work helped me in covering out this work smoothly. I am also grateful to all the faculty of mechanical departments who helped me to improve my thinking as well as the practical knowledge Bhupendra Singh Jhala CONTENTS 1. Introduction 2. Preface 3. Classification Of Boilers 4. Types Of Boilers 5. Boilers Mounting And Accessories INTRODUCTION Boiler is a metal container in which a liquid is heated and changed into a vapor. Most boilers change water into the vapor steam. Steam is used to heat buildings and processes. It changes from vapor to liquid form as it delivers heat into a room or building, giving off even more heat as a result. Some heating systems, called hydronic systems, circulate hot water rather than steam. However, the heat source in these systems is still referred to as a boiler. Steam produced in boilers is also used in steam turbines and for refining oil or drying paper.The process of heating a liquid until it reaches it's gaseous state is called evaporation Heat is transferred from one body to another by means of (1) radiation, which is the transfer of heat from a hot body to a cold body through a conveying medium without physical contact, (2) convection, the transfer of heat by a conveying medium, such as air or water and (3) conduction, transfer of heat by actual physical contact, molecule to molecule. The heating surface is any part of the boiler metal that has hot gases of combustion on one side and water on the other. Any part of the boiler metal that actually contributes to making steam is heating surface. The amount of heating surface a boiler has is expressed in square feet. The larger the amount of heating surface a boiler has the more efficient it becomes. The heat required to change the temperature of a substance is called its sensible heat. In the teapot illustration to the left the 70 oF water contains 38 Btu’s and by adding 142 Btu’s the water is brought to boiling point. In the illustration to the left, to change the liquid (water) to its gaseous state (steam) an additional 970 Btu’s would be required. This quantity of heat required to change a chemical from the liquid to the gaseous state is called latent heat. The saturation temperature or boiling point is a function of pressure and rises when pressure increases. When water under pressure is heated its saturation temperature rises above 212 oF. This occurs in the boiler. In the example below the boiler is operating at a pressure of 100 psig which gives a steam temperature of 338 oF or 1185 Btu’s. Latent Heat When heat is added to saturated steam out of contact with liquid, its temperature is said to be superheated. The temperature of superheated steam, expressed as degrees above saturation, is referred to as the degrees of superheat. PREFACE Practical training is a way to implement theoretical knowledge to practical use to become a successful engineer it is necessary to have a sound practical knowledge because it is only way by which one can acquire proficiency & skill work successfully different industries. It is proven fact bookish knowledge is not sufficient because things are not as ideal in practical field as they should be. Hindustan Zinc Ltd. Is one of the best examples to understand the production process & productivity in particular of Zinc. This report is an attempt made to study the overall production system & related action of Zinc Smelter, Debaria HZL.It is engaged in production of high grade zinc metal & other by- products viz. Cd, sulphuric acid etc. Since 1968 by adopting Hydro metallurgical technology. Classification of Boilers: Boilers can be classified as follows: 1. 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. Eg.bobcock& Wilcox boiler. 2 According to the axis of the shell – vertical and horizontal boilers. 3. 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. 4. 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. 5. According to steam pressure – low, medium and high pressure boilers. Types of Boilers: Firetube Boilers: Firetube boilers consist of a series of straight tubes that are housed inside a water- filled outer shell. The tubes are arranged so that hot combustion gases flow through the tubes. As the hot gases flow through the tubes, they heat the water surrounding the tubes. The water is confined by the outer shell of boiler. To avoid the need for a thick outer shell firetube boilers are used for lower pressure applications. Generally, the heat input capacities for firetube boilers are limited to 50 mbtu per hour or less, but in recent years the size of firetube boilers has increased. Firetubeboilers are subdivided into these groups. Horizontal return tubular (HRT) boilers typically have horizontal, self-contained firetubes with a separate combustion chamber. Scotch, Scotch marine, or shell boilers have the firetubes and combustion chamber housed within the same shell. Firebox boilers have a water-jacketed firebox and employ at most three passes of combustion gases. Most modern firetube boilers have cylindrical outer shells with a small round combustion chamber located inside the bottom of the shell. Depending on the construction details, these boilers have tubes configured in either one, two, three, or four pass arrangements. Because the design of firetube boilers is simple, they are easy to construct in a shop and can be shipped fully assembled as a package unit. These boilers contain long steel tubes through which the hot gases from the furnace pass and around which the water circulates. Firetube boilers typically have a lower initial cost, are more fuel efficient and are easier to operate, but they are limited generally to capacities of 25 2 tonnes per hour and pressures of 17.5 kg per cm . Watertube Boilers: Watertube boilers are designed to circulate hot combustion gases around the outside of a large number of water filled tubes. The tubes extend between an upper header, called a steam drum, and one or more lower headers or drums. In the older designs, the tubes were either straight or bent into simple shapes. Newer boilers have tubes with complex and diverse bends. Because the pressure is confined inside the tubes, watertube boilers can be fabricated in larger sizes and used for higher-pressure applications. Small watertube boilers, which have one and sometimes two burners, are generally fabricated and supplied as packaged units. Because of their size and weight, large watertube boilers are often fabricated in pieces and assembled in the field. In watertube or “water in tube” boilers, the conditions are reversed with the water passing through the tubes and the hot gases passing outside the tubes. These boilers can be of a single- or multiple-drum type. They can be built to any steam capacity and pressures, and have higher efficiencies than firetube boilers. Almost any solid, liquid or gaseous fuel can be burnt in a watertube boiler. The common fuels are coal, oil, natural gas, biomass and solid fuels such as municipal solid waste (MSW), tire-derived fuel (TDF) and RDF. Designs of watertube boilers that burn these fuels can be significantly different. Coal-fired watertube boilers are classified into three major categories: stoker fired units, PC fired units and FBC boilers. Package watertube boilers come in three basic designs: A, D and O type. The names are derived from the general shapes of the tube and drum arrangements. All have steam drums for the separation of the steam from the water, and one or more mud drums for the removal of sludge. Fuel oil-fired and natural gas-fired watertube package boilers are subdivided into three classes based on the geometry of the tubes. The “A” design has two small lower drums and a larger upper drum for steam-water separation. In the “D” design, which is the most common, the unit has two drums and a large- volume combustion chamber. The orientation of the tubes in a “D” boiler creates either a left or right-handed configuration.
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