Visit Report Rakhoh Boiler

Dear Sir: Following are the details for 9 days training conducted at Rakhoh Boiler.

Visited By:
Sanket S Koyate Projects and Marketing 9! 9"#9#9$"%" projects@seplindia.co.in

Project Details:
Company Name: Rakhoh enterprises, Pune Rakhoh Boiler& S'!!& (' Block& M)D* Bhosari '+!!%$" Pune. Name of Project: Visit Report to Rakhoh Boilers Location& Date when isite!: Bhosari& Pune "#,"$,%",%%,%&,%$ No an! '%,'(,'& Dec %'"( Project Coor!inator Name: Mr. ,ikhil Patil Marketing De-art.ent

Visit Details:
Following is the details of 9 days /isit to Rakhoh Boilers and also F01 which is understood D02 ! (i.e: !!.3% to !4.3% 5n !#6!!6$%!3 ) /isited to Rakhoh Boilers& for the -ur-ose of 9'!% days training to learn the conce-ts of 7oilers. 0s Mr. ,ikhil was on site /isit he was not a/aila7le. So& ) .et Mr. *haughule who is ser/ice engineer in the co.-any. 8e referred Mr. Sharan who took .e to the .anufacturing unit where .any ty-es and si9es of 7oiler where -re-ared. Mr. Sharan was ser/ice engineer with e:-erince& so he e:-lained according to his knowledge. 8e showed 0P8 i.e. air -reheater& furnace& inner no99les of furnace. ) found it /ery interesting and so.e ;uestions were unanswered as he was ser/ice engineer with less than a year of e:-erience. First day of /isit was less -rofita7le. ) learnt .any things and so.e things which were taught 7y Mr. <ikrant sir during Bangladesh /isit were shar-en 7y seeing it actually in Rakhoh co.-any. Many ;uestions were neither answered correctly nor satisfactory. But in co.ing "'= days that ;uestions will 7e cleared and also .any ;uestions to 7e asked. Such as 8usk consu.-tion& Boiler losses& efficiency& etc. D02 $ (i.e: !!.3% to !4.3% >(hese ti.ings are when ) reached Rakhoh *o.-any and left fro. there.? 5n !96!!6$%!3 Mr. *haughule with his junior Mr. Sharan was out on site /isit. 0lso .arketing de-art.ent -ersons were una/aila7le. Day $ was non -roducti/e. ) was on sho- floor where ) saw .any different ty-es of 7oilers as "%%%kg6hr of Kenya& 4%%%kg6hr internal furnace of synergy& etc ) saw sheet rolling techni;ue with se.i auto.atic .achine& which ) ha/e ca-tured in /ideo. D02 3 (i.e: !!.3% to !4.3%

5n $!6!!6$%!3 Mr. ,ikhil Patil was a/aila7le in office and he hel-ed .e understanding .any conce-ts related to 7oilers. 8e e:-lained .e e/ery ;uestion of .ine with drawings where/er re;uired. 0lso when on sho- floor Mr. (ushar fro. -roduction de-art.ent e:-lained .e conce-ts of 7oiler. (here were lifters fro. 4 ton to $% ton ca-acity. @/ery .achine was a/aila7le such as -ress .achine& drill .achine& welding .achine& etc Day + (i.e: !!.3% to !".3% 5n $$6!!6$%!3 Mr. ,ikhil cleared .e conce-ts of husk consu.-tion& 7oiler efficiency& 0nnual fuel cost etc. 8e e:-lained .e 0uto*0D Drawings where/er necessary. Day 4 (i.e: !!.3% to !4.3% 0s there was office work for drawings of Mr. Mag7ul Mir ) did not attend training for $ days. 5n $"6!!6$%!3 Mr. ,ikhil was not a/aila7le. ) was on sho- floor with trainee of Rakhoh Mr. Sagar& where he showed .e different ty-es of de-art.ent of Rakhoh such as Design& Production& Marketing& etc. Day " A Day = (i.e: !3.+% to !=.3% 5n $96!! A %$6!$6$%!3 ) was at design de-art.ent of Rakhoh where ) learnt the .any conce-ts in the foundation layout drawings of Boiler fro. the -ersons of the design de-art.ent. Day # (i.e: !!.3% to !".3% 5n 36!$6!3 ) was on sho- floor looking out for different -rocesses like -ressing& rolling& welding. 0lso saw the ongoing work for insulation .aterial which is like ce.ent. Day 9 (i.e: !3.3% to !=.3% 5n %"6!$6!3 ) was on sho- floor for final re/ision of whate/er ) learnt and also was going through .y notes which ) -re-ared. ) learnt .any things related to Boiler and this training was useful

FAQ BOIL R
FBR(8@R 1B@S()5,S C)DD B@ BPD0(@D 0S (R0),),E )S S()DD E5),E 5,. (8)S C@R@ 1B@S()5, 0,D 0,SC@R C8)*8 ) 0SK@D 0,D B,D@RS(55D. !" #hat is Boiler$ Boiler is a closed /essel in which soft water is heated 7y any 7urna7le fuel which gi/es saturated stea.. Sanket S Koyate

%" #hat is F.D Fan$ F.D. fan is used for forcing -ressure into furnace. Forced draft fan is used to create -ositi/e -ressure. Fan te.-erature is around 3% degree *elsius.

&" #hat is ID Fan$ )nduced draft fan is to transfer flue gases fro. furnace to chi.ney. Fan te.-erature is around $%% degree *elsius. )t created negati/e -ressure.

'" #hat is (l)idi*ed +ed co,+)stion$ Fluidi9ed 7ed co.7ustion e.-loys a distri7utor -late& a 7ed of sand. (he 7ed of sand is ke-t fluidi9ed state 7y the FD fan. 0 P0 fan is used to trans-ort and inject the rice husk into the 7ed. (he 7ed of sand is initially heated 7y charcoal 6 or rice husk. 5nce the sand is heated and .aintained in fluidi9ed condition& the rice husk is continuously injected to .aintain the co.7ustion and to gi/e the heat re;uired for generating the stea. in the 7oiler. (he ash after co.-lete co.7ustion lea/es

the 7ed and gets collected in ash ho--ers of the 7oiler A in the dust collector. 0n )D fan is used to .aintain the negati/e draft in the furnace. Pollution is the 7ig issue here. 5ne should ha/e -ro-erly designed A installed MD* cones. -" Role o( .ater so(tener$ )t re.o/es the hardiness >calciu.& Magnesiu.? in raw water >hard water? and changes the hard water to the soft water. )f the water contains hardness& the hardness is condensed in the 7oiler as heating 7eco.es scale for.ation and it then adheres inside the water tu7es. (hen heat efficiency declines 7ecause of the scale adhesion. /" #hat is IBR$ )ndian Boiler Regulations& which has created in !94% in e:ercise of -owers& conferred 7y section $# and $9 of the )ndian Boiler 0ct. )t was for.ed to consolidate and a.end the law relating to stea. 7oilers. 0" #hat are +oiler ,o)ntin1s$ Boiler .ountings are generally .ounted on the 7oiler for safety o-erations -ur-ose. Different .ountings are Cater le/el indicator& safety /al/e& -ressure gauge& stea. sto- /al/e& Feed check /al/e& Manhole& etc 2" #hat are +oiler accessories$ (his is de/ice which is installed with a 7oiler. )t is used to increase efficiency of the 7oiler. Different ty-es of accessories are Feed water -u.-& injector& -ressure reducing /al/e& air -reheated& su-er heater& econo.i9er& stea. drier6se-arator& etc #? 3ypes o( +oiler s)pplied +y Rakhoh 4o,panyF a? Bio'dru. co'generation 7oiler 7? Bi'dru. D ty-e high -ressure 7oiler c? Solid fuel fired internal furnace

d? 5il6Eas fired 7oiler e? Multi fuel e:ternal furnace + .e.7rane wall >fluidi9ed 7ed? f? Package ty-e twin furnace 7oiler g? 8usk fired -ackage ty-e 7oiler h? Boiler for s.all industry i? Caste heat reco/ery unit j? (her.ic Fluid heater k? *oded -ressure /essel

5" #hat is (ired t)+e +oiler$

0 fire'tu7e 7oiler is a ty-e of 7oiler in which hot gases fro. a fire -ass through one or .ore tu7es running through a sealed container of water. (he heat of the gases is transferred through the walls of the tu7es 7y ther.al conduction& heating the water and ulti.ately creating stea..

%!" #hat is .ater t)+e +oiler$

0 water tu7e 7oiler is a ty-e of 7oiler in which water circulates in tu7es heated e:ternally 7y the fire. Fuel is 7urned inside the furnace& creating hot gas which heats water in the stea.'generating tu7es. )n s.aller 7oilers& additional generating tu7es are se-arate in the furnace& while larger utility 7oilers rely on the water' filled tu7es that .ake u- the walls of the furnace to generate stea..

%%" #hat is ' pass in +oilers$

0s indicated in drawing three'-ass wet7ack design has a rear water wall& which se-arates the -ri.ary heating surface of the co.7ustion cha.7er fro. rear tu7e sheet. (he water jacket eli.inates the need for a refractory wall and rear door s-acing 7ehind the 7oiler& as well as costly refractory .aintenance.

(he rear wall eli.inates the need for gasketing & which is /ulnera7le to the te.-erature generated in the rear of the turnaround area. )t has great o/erall efficiency.

%&" #hat is 6eat 7chan1er$

Bsed for heat transfer fro. one .ediu. to another .ediu.. (his .edia .ay 7e se-arated 7y solid walls to -re/ent .i:ing or they .ay 7e in direct contact. Cidely used in s-ace heating& refrigeration& air conditioning& -ower -lants& -etroleu.& natural gas -rocessing. Mostly shell and tu7e ty-e is used.

%'" 3ypes o( chi,neys in Boiler$ a? Self su--orted chi.ney 7? Structural su--orted chi.ney c? Ro-e su--orted chi.ney d? Call Su--orted chi.ney

%-" 6o. to calc)late ()el operatin1 cost$

Fuel 5-erating *ost G Fuel *onsu.-tionHFuel *ostH!.%$ Chere& !.%$ is considered as electricity A other factors in -roduction.

%/" 6o. to calc)late ann)al cost o( F)el$ 0nnual Fuel *ostG Fuel *ost6hr H ,o of hrs6day H ,o of days6yrs

%0" 8o,e de(inition (or +oiler accessories$

(he de/ice which are installed with a 7oiler A used to increase efficiency of 7oiler. >a? Feed #ater P),p : (o feed water to 7oiler. >7? Injector : (5 feed water under -ressure. >c? Press)re red)cin1 9al9e: (he function of -ressure reducing /al/e is to .aintain constant -ressure on deli/ery side of the /al/e irres-ecti/e of the fluctuating su--ly of stea. fro. 7oiler. >d? Air Pre heater: (o heat the air 7efore it enters the co.7ustion cha.7er. >e? 8)per heater: Bsed in stationery 7oiler. Function is to con/ert dry saturated stea. into su-erheated stea. at the desired te.-erature. )t is used to increase the te.-erature of saturated stea. without raising its -ressure. >f? cono,i*er: *onsidera7le a.ount of heat of the -lant is carried away 7y flue gases& so to utili9e this waste heat. 0n econo.i9er is -laced in the -ath of flue gases to -reheat the feed water. 0n econo.i9er increases the stea. raising ca-acity of a 7oiler. >g? 8tea, drier or separator: (o se-arate the water -articles fro. stea. 7efore it is su--lied to the -oint of a--lication

%2" #hat is 9apori*ation$ )t is -hase transition fro. li;uid -hase to gas -hase.

%:" 8o,e de(inition (or Boiler ;o)ntin1s: a? #ater Le9el Indicator: )ndicates e:act water le/el of 7oiler tu7e. 7? 8a(ety 9al9e: Mechanical de/ice used as safeguard for 7oiler& in case the -ressure inside the 7oiler rises a7o/e its nor.al working at.os-here. c? Press)re <a)1e : )ndicates the -ressure d? 8tea, 8top Val9e: Sto- or o-en the stea. su--ly fro. 7oiler to the -oint of a--lication. e? Feed 4heck Val9e: (o regulate the flow of water. f? ;an 6ole: )t is the o-ening on the to- -ro/ided for cleaning and ins-ection. %5" Boiler 4lassi(ication$ Following is the classification of 7oiler Accordin1 to the position o( ()rnace:

a? )nternally fired 7oiler 7? @:ternally fired 7oiler Accordin1 to the a7is o( ()rnace

a? <ertical Boiler 7? 8ori9ontal Boiler c? )nclined Boiler Accordin1 to ,ethod o( circ)lation o( .ater

a? ,atural *irculation Boilers 7? Forced *irculation Boilers Accordin1 to stea, press)re

a? Dow > !4 ' $% 7ar? 7? Mediu. >$% I #% 7ar?

c? 8igh > More than #% 7ar ? Accordin1 to so)rce o( heat:

a? Cater (u7e Boiler 7? Fired (u7e Boiler

$%? Eeneral na.es for the different -arts of 7oilerF

)hat are the stren*ths, opportunities within the Rakhoh Company+ )hat positi es !i! you notice !urin* your isit+ (here were different -eo-les for different de-art.ent such as design& -roduction which .ade there work easy. Marketing de-art.ent was technically sound. . @/ery 7oiler and its other -arts were .anufactured with accuracy. @/ery -art was checked 7y .aking asse.7ly of it with res-ecti/e -art. (he fa7rication work and the welding were done well. (he finishing work like grinding& coloring was done with care. Positi/es ) noticed were

they were ha/ing good e:-erience of -re-aring different ty-es of 7oiler& which were good for us& so their e:-erience would create no .istakes while 7oiler is .anufactured.

Post=project Visit:
,a e you contacte! the project coor!inator after your isit+ 2es& ) ha/e contacted Mr. Eurjar Sir and Mr. <ikrant Sir ,a e you took support !ocumentation that you may ha e collecte! -like photo*raphs taken, reports, !ocuments, etc./+ 2es& ) ha/e taken -hotogra-hs of 7oiler and also /ideo of sheet rolling .achine. 0? 4t-h husk fired 7oiler