CBL Industrial Training Report

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CHEEMA BOILER LIMITED
INDUSTRIAL TRAINING REPORT
Submitted By:
Akshay Kumar(14BME8004)
in partial fulfillment for the award of the degree
of
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING DEPARTMENT
at
CHANDIGARH UNIVERSITY
GHARUAN(MOHALI),PUNJAB(INDIA)-140413
UGC
JUNE-2016

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ACKNOWLEDGMENT
No Endeavour can be successful without the active cooperation of the people
concerned with it, which was fourth coming in full during this study. It is
extremely difficult to find words which can do justice to this sort of cooperation.
I am deeply indebted to CBL PLANT KURALI who allowed me feel lucky to
complete my training under the table and competent guidance .
I am extremely grateful faculty members for their whole hearted co-operation.
I extend my deepest gratitude to all those persons who supported me all through
my training. My interaction with all these people has left a long lasting impression
in my mind that will influence my project and my behavior for all times to come.
Akshay
14BME8004
ME (7TH
SEM)

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INDEX
S.No. CONTENT PAGE No.
1 Introduction 4
2 Safety Guidelines 5
3 Machine in Manufacturing Unit 6
4 Boiler 9
5 Classification Of Boiler 10
6 Boiler Mountings 11
7 Description of Boiler Mountings 11
8 Specification Of Boiler 12
9 Boiler Pressure Parts 13
10 Description Of Pressure Parts 14
11 Conclusion 20
12 Bibliography 21

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INTRODUCTION
Cheema Boilers Limited is one of India's premier engineering solutions company
serving industry's energy requirements. CBL has been manufacturing boilers and
allied products for the last two decades and has earned recognition as a research
driven organization that sets benchmarks for innovative technologies. CBL's
customer centric business practices uncompromising quality approachand
continuous thrust on technological up-gradations are the key factors contributing to
its multi-fold growth.
Cheema Boilers Limited builds high capacity boilers for steam-generation power
generation & process heating and provides turnkey integrated power plant
solutions. Besides there are packaged boilers designed, manufactured and tested at
CBL s facilities located near Chandigarh in the northern part of India. In addition
CBL also offers supportservices for existing boilers and process furnaces.

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SAFETY GUIDELINES
To avoid accidents & to keep them from happening following safety guidance
should be allowed.
• Provide your attention at most to the job & work quietly.
• Keep the tools with in your convenient reach. Arrange neatly without
scattering them around.
• Be serious about your never including in horseplay or other foolish activities
to avoid injury to other.
• Never put sharp objects like screwdriver in your pocket otherwise you will
cut yourself or get stabled or ruin the up hot slay of a vehicle.
• Always wear suitable clothes for the job serious injuries are liable be caused
by cleaning sleeve or lies getting caught the machining sandals or open to be
worn full leather with non skid rubber heel & shoe or steel to safety shoe
should be worn.
• To provide good grip on tool or part always wipe excess oil and grease up
fly our hand tool.
• Compressed air should, never be used to below dust from your clothes.
Compressed a hose should never be pointed to any person because fling
particles may harm him.
• Wheel welding and grinding always water out for flying speak which can set
your clothes on fire.

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Machines In Manufacturing Unit
Training period I have worked on various machines in cheema boiler.
 Bending Machine
 Rolling Machine
 Pipe cutter Machine
 welding Machine
I was only in manufacturing unit because the trainees are not allow to entered in a
assembly line and steam unit.
In the manufacturing unit many of workers are perform welding operation on the
boiler joint. And I was also performed the welding operation on the boiler joint.

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Bending machine: This machine is used to bend the pipes of the boiler at
certain angle. This machine is run by the computer. In the computer I was entered
the required angle and required force and specific point where to start the bending.
And run that command and the machine was perform the operation according to
my requirement.
Rolling Machine: This machine is used for the boiler plates. This machine is
worked manually. In which 3 rollers are placed and the plate is rolled by these 3
rollers and a crane is move upward that rolled plate with the help of the safety
joints.

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Pipe cutter Machine: This machine is perform the cutting operation on the
pipes. This machine is run on the computerized technique. In the computer
software putt the total length of the pipe and the length to cut the pipe and material
of the pipe and force required and give the command to the machine and machine
is cut the pipe.
Welding machine: To joint the boiler pipe this is the basic common operation
to be performed. In company maximum Arc welding is to be used to joint the
boiler plates.

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BOILER
In General, A boiler is a closed pressurevessel strongly constructed of steel or iron
where water is converted to steam by application of heat.
According Indian Boilers Act, 1923,
“Boiler" means a pressurevessel in which steam is generated for use external to
itself by application of heat which is wholly or partly under pressure when steam is
shut off but does not include a pressure vessel,-
(i) with capacity less than 25 litres (such capacity being measured from the feed
check valve to the main stream stop valve)
(ii) with less than one kilogram per centimetre square design gauge pressure and
working gauge pressure.
(iii) in which water is heated below one hundred degrees centi-grade;
Usage of Boiler
 In Power Sectors
 In Independent Power Plant (IPP) & Captive Power Plant (CPP).
 In Process Plants
 In Oil Refineries, Paper Industry, Sugar Industry, Chemical Industry,
Rice mill, Steel Industry etc.

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Classification of Boiler
Criteria Types
Content of Tube Fire Tube Boiler, Water Tube Boiler
Type of firing Solid, Liquid & Gas Fired
Type of Circulation Natural Circulation, Natural Assisted or
Controlled Circulation, Forced
Circulation
Steam Pressure Sub Critical Boiler, Super Critical
Boiler
Draught Natural Draught, Mechanized
Draught(Forced, Induced, Balanced)
Content of Tubes
 Fire Tube
 In fire tube boiler hot flue gas will be moved inside the tubes & water
outside the tube.
 In fire tube boiler mode of firing is generally internally fired.
 In fire tube boiler operating pressure limited to 25 kg/cm²
 Water tube
 In water tube boiler water will be moved inside the tube & hot flue gases
outside the tubes.
 Mode of firing is externally fired.
 Operating pressure can exceed 125 kg/cm² or more

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Boiler Mountings
 Safety Valves
 Feed Check Valves
 Pressure Gauge
 Drum Water Level gauge
 Blow Down Valve
 Main Stop Valve…etc
Boiler Mountings are basically used for safe operation of Boiler.
Description of Boiler Mountings
 SafetyValve: The Function of a safety valve is to blow off steam when the
pressure in the boiler exceeds the working pressure.
 FeedCheck Valve: A feed check valve is used to control the supply of feed
water to boiler & also to act as a non-return valve.
 Pressure Gauge:Pressuregauge indicates the pressure of steam in a boiler.
 Drum Water Level Gauge: The Function of water gauge glass is to
indicate the water level in the Drum.
 Blow down Valve: Blow down Valves are designed for continuous use to
control the concentration of dissolved solids in boiler water.
 Main Stop Valve: Function of a steam stop valve is to stop or allow the
flow of steam from the boiler to Main Stream line.

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Specification of Boiler
 Maker : Bharat Heavy Electricals Ltd
 Boiler Maker No : 0675,0676
 Type: Controlled Circulation, Sub Critical,
Two Pass, Single Reheat, Balance draught,
Tangential PC Fired.
 Boiler Rating : 51793 m2
 Boiler Drum Design Pressure : 210 kg/cm2(g)
 Boiler Hydro test Pressure : 315 kg/cm2(g) ,(ForRH-78 kg/cm2(g)
)
 Boiler Drum Design Temp : 369 OC
 Steam flow at SHO: 1700TPH
 Steam pressure at SHO: 192.2 kg/cm2(g)
 Steam temperature at SHO: 540OC
 Reheat Steam flow: 1468.1TPH
 Steam pressure at RHI: 52.4 kg/cm2(g)
 Steam temperature at RHI: 337OC
 Steam pressure at RHO: 52.4 kg/cm2(g)
 Steam temperature at RHO: 540OC
 Boiler Efficiency: 86 %

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Boiler Pressure parts
The Following parts generally comes under this category –
• Drum
 Economizer
 Water Walls
 Radiant RoofTubes
 Steam Cooled Walls
 LTSH Coil
 Platen SH
Reheated Coil Assay

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Boiler Drum
 In a Sub-Critical re-circulation boiler, the drum plays an important role. In
the erection of a Power Boiler, the lifting of the Boiler Drum is the first mile
stone activity.
 The Functions of Drum are
 Separation of saturated steam from the steam- water mixture produced
by evaporating tubes.
 Mixing feed water from economizer and water separated from steam-
water mixture, and re-circulate through the evaporating tubes
 Carrying out blow down for reduction of boiler water dissolved solid
concentration.
 Treatment of Boiler Water by chemicals.

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Economiser System
 Application of economisers is to capture the heat from flue gas and transfer
it to the feed water. This raises the temperature of the boiler feed water,
lowering the needed energy input, in turn increases efficiency.
 Total System Consists of ECO feed line, Eco I/L Header, ECO Coil Assy,
ECO O/L Hdr, ECO Link to Drum.
Water Wall System
 The water walls are tube panels through which the water for steam
generation will be circulated. In Water Wall only heat is added to evaporate
the feed water to steam.
 It also forms the major part of furnace enclosure.
Super Heater System
 Superheated is a component of a boiler that superheats steam i.e. heats steam
above its saturation temperature. Superheated steam contains more thermal
energy and increases the overall efficiency of the cycle.
 There are 3 stages of Super Heaters – LTSH, Divisional Panelist SH &
Platen Super Heater.
Reheater System
 Reheated is a boiler component in which heat is added to intermediate-
pressure steam, which has lost some of its energy in expansion through the
high-pressure turbine.
 Reheated System comprises of : RH Inlet Header, RH Front Platen Coil
Assay, RH Rear Spaced Assay, RH Outlet Header.

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Forced Draught Fan
 These fans supply air necessary for fuel combustion for properburning of
the specific fuel. These are generally axial type.
 The FD fans supply secondary& over fire air, which is preheated in
secondarysector APH.
 Over fire air can be admitted to the furnace through the upper levels of
furnace wind boxnozzle to assist in reducing the amount of NOx formed in
furnace.
 Control of airflow to WB is effected by FD fan blade pitch control &
distribution of secondaryair to WB compartments is controlled by
secondaryair damper.
 Steam Coil Air Pre Heater(SCAPH) are provided in the by pass ducts before
each APH to prevent corrosionof cold end of APH normally at start up &
low load operation.

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Primary air fan
 These fans supply the air needed to dry & transport coal from coalmills to
the furnace. These fans are generally axial type of fan.
 To achieve the required temperature at mill inlets(For ProperDrying of
Coal) , part of air(Tempering air) by passes the APH & is mixed with hot air
coming out of APH.
 The PA Fan blade pitch is modulated to maintain a pre determined pressure
in pulverize hot air bus duct.
 Mill Air flow is maintained by adjusting the hot air regulating damper while
the mill outlet temp is maintained by adjusting the cold air regulator damper.
Ventura is provided in the mill inlet duct to measure the individual mill air
flow.

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Air Pre Heater
 The purposeof APH is to recover heat from the boiler flue gas & heat air
before another process and so as to increase the thermal efficiency.
 The basic componentof Ljungstrom APH is a continuously rotating
cylinder, called rotor, that is packed with thousands of square feet of
specially formed sheets of heat transfer surface.
 As the Rotorrevolves, waste heat is absorbed from the hot flue gas passing
through one half of the structure. The heat transfer cycle is continuous as the
surface are alternatively exposed to the outgoing gas & incoming air stream.

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Soot blowers
Wall blower
 As the flue gas moves over the heat transfer areas of boiler, the ash deposits
on the heating surfaces. This is known as sootdeposit. Soot Blowers are
installed to blow away these sootdeposits to facilitate smooth heat transfer.
 There are two types of SootBlowers-Wall Blowers & Long Retractable Soot
Blowers.
 Wall Blowers are used to blow off soots deposited in water walls in furnace
 LRSB are used in Super Heaters, Economiser & Reheater Zone.
Electrostatic Precipitator : An electrostatic precipitator (ESP) is a highly
efficient filtration device that removes fine particles, like dust and smoke, from a
flowing gas using the force of an induced electrostatic charge minimally impeding
the flow of gases through the unit.

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CONCLUSION
Industrial training is the way for us to get the practical knowledge of the entire
theoretical concept studied in college session. In college workshop we are not able
to give proper time for practical work as in industrial training. So as a Mechanical
Engineering student I think this training is very useful for us and we learn enough
things in the training period and our knowledge level will be increased.
We enjoy the training and maintain discipline in workshop and the entire
mechanics are impressed with our attitude and sense of learning and they give us
best wishes for our future and say that you must be hard work as an engineering
student to make your future bright.
So, at last I would like to thanks once again to all workshop members, work
manager and HOD of Mech. Engg..

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BIBLIOGRAPHY
• S. Chand publications R .S. Khurmi
• www.google.co.in
• http://cheemaboilers.com/overview.php