This document provides an overview of boiler training for an Asian Paints plant, including descriptions of the main parts of a boiler like feed pumps, burners, and safety valves. It discusses the different types of boilers like solid fuel boilers and low pressure boilers. The document also outlines the purpose and functions of key components in the boiler system like the forced draft fan, air preheater, modulation unit, and various sensors and switches used for safety interlocks.

1. BOILER TRANNING
ASIAN PAINTS KHANDALA PLANT
1MIS | Site Name | 2017-MM-DD

2. WHAT IS BOILER AND ITS USES .
It is a steam generation device .
Fire tube and water tube .
Types of Boiler –
1. Solid:- Coal, Rice Husk, Begas, wood .
2. Liquid :- Diesel , Furnace Oil .
3. Gases :- Bio gas , Cng .
Three Pass Boiler ( Air change direction)
Three Ton Capacity (3000 Ltr Steam ) .
2MIS | Site Name | 2017-MM-DD

3. SOLID BASE BOILER
3MIS | Site Name | 2017-MM-DD
1. Solid:- Coal, Rice Husk, Begas, wood .
2. 140 Ton steam Generating steam boiler .

4. LOW PRESSURE BOILER
MAIN PARTS
4MIS | Site Name | 2017-MM-DD
1. FEED WATER PUMPS .
2. DIESEL PUMPS .
3. FORCED DRAFT FAN .
4. AIR PRE HEATER .
5. BURNER .
6. FIRE TUBES .
7. SAFETY VALVES .
8. ELCTRICAL PANEL.

5. BOILER SLD
5MIS | Site Name | 2017-MM-DD

6. 6MIS | Site Name | 2017-MM-DD
FEED PUMPS USED FOR MAINTANNING WATER IN TANK.
MAINTAIN WATER FOR STEAM GENRATION IN BOILER .
THREE TON WATER PER HOURS .
3000 LTR WATER = 3000 LTR STAEM .
MAX PRESSURE =10.5 KG .
FEED PUMPS

7. DIESEL PUMPS AND ITS VALVES
7MIS | Site Name | 2017-MM-DD
IT IS USED FOR DIESEL SUPPLY TO BURNER
1 2 3

8. FORCED DRAFT FAN
8MIS | Site Name | 2017-MM-DD
FIRE = AIR + FUEL + IGINATION .
THREE PASS BOILER ( BURNER , TUBES, APH ) .``
``

9. AIR PRE HEATER
9MIS | Site Name | 2017-MM-DD

10. BURNER
10MIS | Site Name | 2017-MM-DD
BURNER FIRE = AIR + FUEL + IGINATION
1 2

11. UV QRA2
11MIS | Site Name | 2017-MM-DD
ULTRA VIOLET CELL USE FOR FLAME SENSE .
SAFETY DEVICE IN COMBUSTION CHAMBER .
UV QRA2 IS USED FOR LFL-1.335 .
IT CAN CAPABLE TO DETECT FIRE AND
EXPLOSIONS WITHIN 3-4 MILLISECONDS ,
A TIME DELAY OF 2-3 SECONDS .
FAULTS:- SENSING ,COMBUSTION FLAME ,FIRING
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12. IGINATION TRANSFORMER
12MIS | Site Name | 2017-MM-DD
IT IS USED FOR BURNER SPARKING .
INPUT = 220VAC , OUTPUT = 2X7KV FOR 4 SEC .
IT INCREASE THE VOLTAGE FOR IGINATION .
STEP UP TRANSFORMER .
FAULTS:- SPARKING , FIRING

13. MODULATION UNIT
13MIS | Site Name | 2017-MM-DD
SERVO MOTOR , MEHANICAL MECHANISM , POSITIONER,
PCM2-6 PRESSURE CONTROLLER MODULATION .
1 MOTOR UNIT 2 FOR DIESEL 3 FOR GAS
3

14. MAIN GAS VALVES
14MIS | Site Name | 2017-MM-DD
1. MAIN GAS LINE VALVE 2. GAS LINE VALVE 3.PILOT VALVE
3

15. Modulation unit controller – Pressure Troll
15MIS | Site Name | 2017-MM-DD
Capacity 3 Ton/ Hour .
Max Pressure = 10.5 kg .
Max Cut off = 8.5kg .

16. Steam Pressure switch for Boiler Cutoff
16MIS | Site Name | 2017-MM-DD
Capacity 3 Ton/ Hour .
Max Pressure = 10.5 kg .
Minimum Cut off = 7 kg .

17. Air Pressure Switch
17MIS | Site Name | 2017-MM-DD
IT IS FOR COMBUSTION BLOWER MAIN AIR LINE .
FIRE = AIR + FUEL + IGINATION .
SUPPLY 220VAC , ONE NO AND ONE NC .
AIR PRESSURE FOR NO TO NC 5 BAR .
INTERLOCKING WITH COMBUSTION BLOWER

18. BOILER INTERLOCKING
18MIS | Site Name | 2017-MM-DD
1. LEVEL - IF DIESEL TANK LEVEL LOW BOILER WILL TRIP OR WILL NOT START .
2. LEVEL - IF WATER LEVEL IN STORAGE TANK IS LOW , BOILER WILL TRIP OR NOT START .
3. MOBERY - IF LEVEL INSIDE DRUM FALL BELOW 25% BOILER WILL TRIP .
4. STACK TEMP – FLUE GASES RAISE ABOVE 270deg BURNER WILL TRIP .
5. COMBUSTION AIR SWITCH FOR COMBUSTION BLOWER .
6. PRESSURE SWITCH - IF PRESSURE INSIDE THR DRUM IS HIGH , BOILER WILL CUT OFF .
7. PHOTO CELL – IF FLAME IS NOT GENRATED IN BURNER , BOILER WILL TRIP .
8. MODULATION UNIT – IF MODULATION UNIT FEED BACK IS NOT RECEIVED , BOILER TRIP .
9. PRESSURE – IF GAS IS LESS THEN 30mbar , BOILER WILL TRIP .

19. Water level gauge and Mowbray Switch
19MIS | Site Name | 2017-MM-DD
1 low water level 2 Extra water low level 3 Gauge Glasses

20. Sequence Controller LFL-1.335
20MIS | Site Name | 2017-MM-DD
1. 24 TERMINALS , 220VAC SUPPLY.
2. PRE PURGE TIME -31 Sec .
3. PILOT TRIAL FOR IGINATION – 4 Sec .
4. MAIN TRIAL FOR IGINATION - 4 Sec .
5. MODULATION UNIT – 10.5 Sec .
6. POST PURGE TIME – 12 Sec .
7. FLAME FAILUR RESPONSE TIME – 1 Sec .
OLS , LGP , HGP,LWS , HIGH LIMIT , POC , CAB , CAS , LOW AND HIGH FIRE.
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21. FLUE GAS TEMPURATOR SENSOR
21MIS | Site Name | 2017-MM-DD
STACK TEMP – FLUE GASES RAISE ABOVE
270deg BURNER WILL TRIP .
1. IT USED TO SENSE HEAT TRANSFER SYSTEM .

22. END OF SEASSION
22MIS | Site Name | 2017-MM-DD
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