My practicum presentation

1. WELCOME
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2. FINAL PRESENTATION
Title of Presentation
A Study on Operation and Maintenance of Fire Tub Steam Boiler At
Shine Textiles Ltd
Presenter
Mohammad Mehedi Hasan
ID: 13207016
Department of Mechanical Engineering
Supervisor: Mr. Nayem Hossain
Lecturer, Dept of Mechanical
Engineering
Industrial Guide: Mr. Diau
Maintenance Engineer
IUBAT-International University of Business Agriculture and Technology 2

3. CONTENT
• Introduction
• Objective
• Limitations
• Company overview
• Fire tube boiler
• Construction and Working Principle of Fire
Tube Boiler
• Boiler Draught & Types of draught
• Boiler Mountings
• Boiler Accessories
• Operation
• Maintenance
• Problems Finding and Solution
• Conclusion
• Recommendation
• References
•
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4. INTRODUCTION
Boiler or more specifically steam boiler is an essential part of textile industries. Here I’m
going to discuss about fire tube boiler, boiler draught, mountings, accessories. Also,
operation and maintenance of boiler.
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5. OBJECTIVES
The objective of this internship are:
• To Study the components of fire tube Steam Boiler.
• To know operation process of fire tube Steam Boiler.
• To know about maintenance of fire tube Steam Boiler.
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6. LIMITATIONS
 Sufficient records are not available.
 Unavailability of machine catalogue due to fire accident.
 I did not get any assembly or installation of a new boiler.
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7. COMPANY OVERVIEW
Ring Shine Textiles Ltd. was established in 1998. It is Bangladesh’s largest fully integrated textile company
with a dominant presence in the Cotton and Polyester segments. It is the most modern composite mill in
the region.
Ring Shine Textiles Ltd. is located at Dhaka Export Processing Zone Extension Area, Ganakbari,
Savar, Dhaka. The site enjoys excellent infrastructure like good road communication, gas, power, water,
telecommunication and manpower.
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8. Vision
We are the leading Textiles solution provider in Bangladesh achieving our business vision
through growth in market reach, increasing operation size, international distribution,
total service and consistent branding activities by the being most customers focused &
Innovative, cost effective & efficient, environmentally responsible & quality concerned
company in the business.
Mission
We manufacture superior import-substitute consumer and industrial products. Our
cutting-edge precision leads to greater public utility and hygiene, with a great care for
the environment and human inhabitation. It is the very ingredient that gives our
organization the integrity upon which our reputation is built and we zealously guard it
every day. Many a thousand minds contributed their gathered knowledge to keep the
wheels rolling that in turn leads us to our goal. This cumulative strength of knowledge is
required, today, to find new solutions for the manifold problems of fast- changing 8

9. FIRE TUBE BOILER
A fire-tube boiler is a type of boiler in which hot gases pass from a fire through one or (many)
more tubes running through a sealed container of water. The heat of the gases is transferred
through the walls of the tubes by thermal conduction, heating the water and ultimately creating
steam.
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10. Different types of fire tube boiler :
1. Cornish Fire Tube Boiler
2. Lancashire Fire Tube Boiler
3. Locomotive Fire Tube Boiler
4. Vertical Fire Tube Boiler
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11. WORKING PRINCIPLE OF FIRE TUBE
BOILER
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12. Advantages of fire tube boiler:
• The water is supplied in shell and outside tubes while hot gas is supplied inside tubes
so the water volume cannot be shaken easily when the fire tube boiler is running.
• It is so easy to use, operate, clean and maintain
• It can be used in small scale industries.
• It is relatively cheaper than water tube boiler.
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13. BOILER DRAUGHT & TYPES OF
DRAUGHT
Boiler draught is defined as the small difference between the pressure of outside cold
atmospheric air and that of gases within a furnace or chimney.
Type of draught:
1. Natural Draught
2. Artificial or Mechanical Draught
i. Induced draught
ii. Forced draught
iii. Balanced draught
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14. BOILER MOUNTINGS
Boiler mountings are the devices which are necessary for the safe and satisfactory operation
of the boiler. These devices are mounted over the shell or drum of the boiler.
There are seven important boiler mountings:
1. Pressure gauge
2. Water level indicator or water gauge
3. Safety valve
4. Steam stop valve or Junction valve
5. Feed check valve
6. Fusible plugs
7. Blow off cock (Blow off valve)
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15. Pressure gauge
The function of the pressure gauge is to measure the pressure of steam inside the boiler.
The gauge is usually mounted on the front top of the shell or drum such that it should be
clearly visible to the operator.
The pressure gauges generally used are of Bourden type.
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16. Water Level Indicator
The function of a water level indicator is to indicate the level of
water in the boiler constantly.
It is also called water gauge.
It helps the operator in keeping the level constant from outside
through a glass tube. In case of need, if the level falls down,
water will be pumped by the operator.
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17. Safety valve
• Safety valves are attached to the steam boiler chest.
• Generally, two safety valves are present on a boiler.
• It is used to prevent explosion due to excessive internal pressure.
pressure. When the internal pressure inside the boiler exceeds its
its working pressures than the safety valves blow off the steam
and maintains the internal pressure.
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18. Steam stop valve
It is usually fitted to the highest part of the shell by means of a flange.
It is used to control the flow of steam from the boiler to the main steam pipe.
Also, to shut off the steam completely when required.
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19. Feed check valve
It is fitted to the shell slightly below the normal water level of the boiler. It is a non-
return valve, fitted to a screwed spindle to regulate the lift.
It is used to regulate the supply of water, which is pumped into the boiler by the feed
pump.
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20. Fusible plug
It is fitted to the crown plate of the furnace or firebox.
Its function is to extinguish fire in the furnace when the
water level in the boiler falls to an unsafe limit. This
avoids the explosion that may takes place because of the
overheating of the furnace plate.
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21. Blow off cock
It is located at the bottom of the boiler.
To empty the boiler whenever required & To remove the mud, scale or sediments
accumulated at the bottom of the boiler.
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22. BOILER ACCESSORIES
These are the devices which are used as integral parts of a boiler and help in running
efficiently.
1. Feed pump
2. Superheater
3. Economiser
4. Air Preheater
5. Injector
6. Pressure reducing valve
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23. Feed pump
It is used to deliver water to the boiler. A feed pump
may be of centrifugal type or reciprocating type. But a
double acting reciprocating pump is commonly used
as a feed pump.
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24. Superheater
 It is an important device of a steam generating unit. Its purpose is to increase the
temperature of saturated steam without raising its pressure. It is generally an integral part
of a boiler and is places in the path of hot flue gases from the furnace.
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25. Economiser
An Economiser is a device used to heat feed water by utilizing the heat in the exhaust
flue gases before leaving through the chimney. It improves the economy of the steam
boilers
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26. Air Preheater
It is used to recover heat from the exhaust gases. It is installed between the economiser
and the chimney.
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27. Injector
Function of the injector is the same as that of feed pump i.e.; to
deliver feed water to boiler under pressure.
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28. Pressure reducing valve
The function of the pressure reducing valve is to maintain constant pressure on its
delivery side of the valve irrespective of fluctuating demand of steam from the boiler.
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29. Others devices
Feed water regulator
Feed water regulator is device to control feed water that be supplied and maintain water
level in the steam boiler at normal condition, so reduce excess of fuel consumption.
Gas system
Gas system is a group of devices that consist of control valve, solenoid valve, gas
regulator, and mechanism control to arrange mixture ratio between air and gas in the
furnace of steam boiler, so combustion can take place completely.
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30. FD fan
Forced Draft Fan is a type of a fan supplying pressurized air
to a system. In case of a Steam Boiler Assembly, this fan is
of a great importance.
ID fan
Induced Draft fan is used to extract the air from boiler post
combustion via (Electrostatic Precipitator if present) to
exhaust through the chimney.
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31. OPERATION
Before going to light up the boiler certain checks shall be done
All manhole doors on the boiler and ducts are to be closed.
All dampers in the flue gas path, primary air path, & secondary air path shall be
checked for their correct position.
Power supplies for all electrically operated dampers shall be switched on.
Breakers of all auxiliaries shall be kept in service position.
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32. DC control supplies shall be ensured for all auxiliaries.
Local push buttons shall be kept released.
All breakers shall be selected for remote operation.
Valves status shall be checked on the boiler.
Fuel oil pump shall be kept in service.
Fuel oil heating system shall be kept in service and the fuel oil shall be kept under
circulation to raise its temperature.
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33. Control Panel
The plug should be inserted at the control panel. And step by
by step switch on all the plugs of control board. It will show
the green light when it will work well. When it found the
yellow light, we have to realize that, there is something
wrong.
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34. Switching on boiler
1. Switch on main ON/OFF switch and the boiler fills automatically. The filling time is
approximately 10-20 minutes (depending on the size of the boiler), until the water is
visible in the sight glass.
2. When both low water level lights come on, press the re-set button which releases the
the locking relays and the boiler is ready for operation.
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35. Boiler shut down
When a boiler has to be removed from service for maintenance, inspection, or layup, the
following procedure should be followed:
1. Before shutting the boiler down, give it a good blowdown to remove as much sediment as
possible. Stop when the drain runs clear.
2. Put the boiler steam pressure control in manual mode, and slowly reduce the firing rate.
Watch the main steam header pressure to make sure that the other boilers are taking up
the load. Do not reduce the firing rate below that necessary to maintain a stable flame.
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36. 3. Allow the fan to post-purge the furnace with a reduced air flow, and then shut
the fan down. Be particularly careful not to let the fan supply large amounts of cold
air into the furnace in the winter.
4. Close the boiler header stop valve.
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37. MAINTENANCE
A well-planned maintenance program avoids unnecessary down time or costly repairs.
There are several types of maintenance-
1. Daily Maintenance
2. Weekly Maintenance
3. Monthly Maintenance
4. Annual Maintenance
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38. Daily Maintenance
Check feed water quality.
Clean the gauge glass externally.
Clean the fuel filters and strainers.
Drain slightly the oil line bucket filter.
Nozzle cleaning.
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39. Weekly Maintenance
Check the working of low level & extra low-level alarm by reducing the water level.
Ensure proper lubrication of all moving parts.
Clean the flame sensor and viewing glass.
Check the conditions of door seals.
Check that there are no variations in the fuel pressure as compared with that at
commissioning time.
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40. Monthly Maintenance
Clean electrical contacts of all relays and tighten loose connections if any. Rough
emery paper should not be used for cleaning contacts.
Check water pump gaskets and non-return valve.
Lubricate the modulation motor linkages.
Clean the burner nozzle and ignition electrodes.
If need check and clean the furnace.
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41. Yearly Maintenance
Clean the smoke tubes with the help of wire brush.
Clean the combustion chamber of boiler and, super heater. However, quality of fuel
and burner efficiency will determine the frequency of cleaning this.
Lubricate the motors. Burner should be over hauled at least once a year & regulated to
ensure perfect combustion.
Check the door refractory for any damage. Repair as necessary.
Clean the water side of the boiler thoroughly. Descaling, if required, should be carried
out as given in the section on “De-scaling”.
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42. PROBLEMS FINDING AND SOLUTION
1. Problem: Dosing pump hose pipe
teardown.
Reason: The hose pipe of dosing pump
teardown because its use of long time also
temperature.
Solution: At first dosing pump turned off and
we took off the damaged hose. Then we cut
down two (2 meter) hose pipe from hose reel.
One hose connected to the dosing pump
suction to dosing tank another hose
connected to dosing pumps discharge to feed
water line. After completion of hose
connection, we turn on the dosing pump. 42

43. 2. Problem: Steam leakage through flange.
Reason: Gasket damaged due to long time use and temperature.
Solution: Replace the damaged gasket by new one
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44. 3. Problem: Soft Scale on tube
Reason: Scaling is mainly due to the presence of calcium and magnesium salts in water.
Solution: Clean the tubes with wire brush and high-pressure water.
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45. 4.Problem: Feed pump bearing damage.
Reason: Corrosion of bearing.
Solution: Replace the damaged bearing by new one.
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46. CONCLUSION
Industry like Ring Shine Textiles Ltd. has a very good impact in the sector of our main
economy. Boiler is an important part for Garments industries. Doing this practicum of
steam boiler, I acquired practical knowledge about boiler, its starting and shutdown
system and maintenance &troubleshooting. My experience during the short time stay at
Ring Shine Textiles Ltd. has not only increased my depth of knowledge, but also has
given me the feeling of challenges in engineering profession. I hope it will help me in my
service life a lot.
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47. RECOMMENDATION
1. They do not use proper PPE during working, so they should use proper PPE.
2. There is no economizer for waste heat recovery. Economizer could be used for waste
heat recovery.
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48. REFERENCES
1. R. Dean Wilson (2008), Boiler Operator's Workbook (4, illustrated). American
Technical Publishers
2. R.S. Khurmi , J.K.GUPTA ,Thermal Engineering, New Delhi, S. Chan & Company Ltd,
2007.
3. Ring Shine Textiles Ltd. Boiler operation and maintenance catalogue.
4. Frederick M. Steingress (2001). Low Pressure Boilers (4th ed.). American Technical
Publishers.
5. R. Dean Wilson (2008), Boiler Operator's Workbook (4, illustrated). American
Technical Publishers
6. Robert D. Port, Harvey M. Herro (1991) The Nalco guide to boiler failure analysis, 2nd
edn., American : McGraw-Hill.
7. Prabir Basu, Cen Kefa, Louis Jestin (1999) Boilers and Burners: Design and Theory,
2000th edn., New York: Springer
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49. THANK YOU
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50. ANY QUESTION?
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