This presentation report describes about steam boiler,classification of boiler ,boiler mounting, boiler accessories, operation & maintenance of boiler, boiler starting & shut downing systems, and safety operation of boiler. some common problems that occurred during boiler operation have been also presented in the presentation report along with solutions . Finally some recommendations are being suggested.

1. WelcomeWelcome
to Everyoneto Everyone
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2. 2
Presenter
Lipon Islam
ID # 14207082
Department of Mechanical Engineering
IUBAT—International University of Business
Agriculture & Technology
26th
April 2018

3. A Study on Operation &
Maintenance of Steam Boiler at
DK knitwear Ltd.
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4. 4
Contents
 Introduction
 Objectives
 Company Overview
 Boiler
 Types of Boiler
 Boiler Auxiliaries
 Operation
 Maintenance
 Problem and Solution
 Safety
 Limitation
 Recommendation
 Conclusion

5. Introduction
I am going to discuss about Introduction of boiler , Type of
Boiler ,Operation & Maintenance, Problem & solution and
also objectives of this internship.
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6. 6
ObjectivesObjectives
The main objective of this internship is to gather practical
knowledge, experience and understand the pros and cons of
the steam boiler and understanding the basic operation and
maintenance of steam fire tube boiler.

7. Specific Objectives
To learn operation process of Steam Boiler.
To know about maintenance of Steam Boiler.
To gather knowledge about boiler controlling system.
To Study on components of Steam Boiler.
To learn about troubleshooting of fire tube boiler.
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8. 8
Company Overview
Front view of DK knitwear Ltd.

9. DK. Knitwear Ltd. is a 100% export oriented knit
fabric & garments manufacturing & export
industries in Bangladesh. It started to walk since
2004. It has a well trained and experienced member
of staff. Committed to top quality, best price
negotiate, on time delivery.They Always caring for best
quality.
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10. Company Address
Corporate Head office
House# 15, Road# 68/A, Gulshan 1,
Dhaka-1111, Bangladesh.
Tel: 8801-8814070, 9898107
Email: info@dkgbd.com
Web: www.dkgbd.com
Factory
Zamgara, Savar, Dhaka, Bangladesh
Email: dkkl@dkgbd.com Web: www.dkgbd.com
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11. Vision statement
To be the most preferred garment, home textile, bags and other
sourcing agency for global clients and to provide automated
warehousing and re-distribution solutions to global clients.
Mission statement
To conduct the business of DK Group so as to maintain there
reputation for credibility and integrity with there clients,
vendors, and employees.To provide customized sourcing and
logistic solutions to global clients having unique requirements.
To achieve consistent high quality levels and on-time delivery
schedules, through a team of committed personnel and a proven
set of vendors with World Class, systematic manufacturing
facilities. To open window for new avenue of business
diversity.
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12. Main Production Items of Dk Knitwear Ltd
They produce all kinds of men, ladies, and children's polo, basic
t-shirt, fancy t-shirts along with embroidery, print, sequence
etc.They also do all kinds of pigment wash, stone wash,
garment wash t-shirt.Finally they produce T-shirt, feeder stripe
and Eng stripe t-shirt.
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Production Capacity of Dk Knitwear Ltd
Name of Products Pcs. / Day
Basic Tee shirt 40000 pcs
Fancy Tee 10000 pcs
Polo Shirt 10000 pcs

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Organogram of Employees

15. Boiler
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16. Boiler is a closed vessel made of steel. Its function is to transfer
the heat produced by the combustion of fuel (Solid, liquid,
gaseous) to water, and ultimately generated steam.
Specification of Boiler
Produce of steam 6 ton/h
Pressure 10.5 bar
Steam condensed 600 kg/h
Fuel used 450 m3/h
Temperature of the boiler house 280
c
Feed water temperature 500
c
Saftey valve pressure 7.5 kg/cm 2 16

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History of boiler
It may be debated who developed the
first steam-generating boiler; however,
most will agree that George Babcock
and Steven Wilcox were two of the
founding fathers of the steam-generating
boiler. They were the first to patent their
boiler design, which used tubes inside a
firebrick-walled structure to generate
steam, in 1867.

18. Materials of Boiler
 Steel /alloy steel
 Wrought iron
 Ferritic stainless steel
 Copper
 Brass
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19. Steam uses is Dk knitwear Ltd.
 Steam use in Yarn Dying Machine for colour the Yarn.
 Steam use in Knit Dying Machine for colour and
washing the Knit.
 For colour and Chemical Mixture.
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20. Important Terms of Boiler
1. Boiler Shell
2. Combustion Chamber
3. Grate
4. Furnace
5. Heating Surface
6. Mountings
7. Accessories
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Types of Boiler
According to the axis of the Shell
Vertical Boiler Horizontal Boiler

22. Stationary Boiler
Mobile Boiler
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According to the use

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Fire Tube BoilerWater Tube Boiler
According to the contents in the tube

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According to the position of the furnace
Internally Fired Boiler Externally Fired
Boiler

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Fire Tube Boiler
Fire tube boiler is a boiler where the flue gasses is inside the tube
and water is surround from furnace.Actually it is uses in small
power plant and small and medium sized industrial installations.

26. Fire tube boiler can be classified into following types
1. Lancashire boiler
2. Marine scotch boiler
3. Locomotive boiler
4. Cornish boiler
5. Vertical boiler
6. Cochrane boiler
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27. Operation of Fire Tube Boiler
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Advantages of Fire tube boiler
 Fire tube boiler is so easy to use, operate, clean and
maintenance.
 Fire tube boiler can be used in small scale industries.
 Fire tube boiler is relatively cheaper than water tube
boiler.

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Disadvantages of Fire tube boiler
 From the furnace combustion side, required time to
fill water is longer than to increase temperature and
pressure.
 The fire tube boiler can not produce steam at a
pressure higher than 24.5 bar
 Capacity of generated steam is limited.

30. Boiler Auxiliaries
Boiler auxiliaries are-
1.Boiler mountings
2.Boiler accessories
3.Another equipment’s
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Boiler Mountings
These are the fittings, which are mounted on the boiler for
its proper and safe functioning.
The boiler mountings are
 Water level indicator
 Pressure gauge
 Safety valves
 Steam stop valve
 Feed check valve

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Boiler Mountings
A water level indicator (gauge
glass) shows the current level of
water in the boiler, regardless of the
boiler's operating conditions. It is an
important fitting.
Water level Indicator

33. Blow Off Cock
It is fitted at the bottom of the boiler drum.
The functions of blow off cock is
(i)To empty the boiler whenever required.
(ii)To discharge the scale, mud and
sediments which gets collected at the
bottom of the boiler.
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34. 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.
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Pressure Gauge
Pressure gauge is used to
measure the Pressure of Steam
inside the steam boiler.
It is fixed in front of the steam
boiler.
Pressure gauges are connected
to the steam spaces in the boiler.

36. Safety Valves
 Safety valves are attached to
the steam chest for
preventing explosions due to
excessive internal pressure of
steam.
 These are directly placed on
the boiler.
 Its function is to blow off the
steam when the pressure of
steam inside the boiler
exceeds the working
pressure.
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37. Steam Stop Valve
It is the largest valve on the
steam boiler. Principle
function of a stop valve are:
 To control the flow of steam
from the boiler to the main
steam pipe.
 To shut off the steam
completely when required.
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38. Feed checked valve
 It is a non return valve
 This valve must have its
spindle lifted before
the pump start.
 Feed checked valve
distribute the water in
uniformly
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Boiler Accessories
These are the devices which are used as integral parts of a
boiler, and help in running efficiently.
The boiler accessories are
 Feed pump
 Economizer
 Super heater
 Air pre-heater

40. Boiler Accessories
Feed Pump
A feed pump may be centrifugal
type or reciprocating type .Thus
we need a feed pump to deliver
water to the boiler.
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Economizer
An economizer is a device
used to heat the feed water by
utilizing the heat in the
exhaust flue gases before
leaving through chimney.
The economizer improves the
economy of the steam boiler.

42. Super Heater
A super heater is a
device used to convert
saturated steam or wet
steam into superheated
steam or dry steam.
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Air Pre-heater
Air pre heater is a heat recover
unit. An air pre heater is used to
recover the heat from the exhaust
flue gases.
 The preheated air gives higher
furnace temperature.
 Its results in better combustion
with less smoke.

44. Another Boiler equipment
Boiler drum
A boiler drum is a pressurized
vessel where saturated steam and
feed water gets separated .It is a
pressure vessel because high
pressure feed water is pumped to
the boiler drum .it’s a most critical
element in the boiler.
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45. Furnace Chamber
A furnace chamber is a device used for
high temperature heating .
FD fan
FD fan is basically mentioned here for
forced draft fan. A fan is used to force air
into the boiler to provide more air for
combustion. This is called FD fan.
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46. Id fan
ID fan is basically mentioned here
induced forced draft fan .A fan is
used to extract the air
from boiler post combustion via to
exhaust through the chimney. This
is called ID fan.
Chimney
A chimney is a structure that
provides vemtilation for hot flue
gases for smoke from a boilers to
outside atmosphere.
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47. Operation
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48. Boiler Starting System
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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49. 
D C 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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Control Panel Board
The plug should be inserted at the
control panel. And step by step switch
on all the plugs of control board. If it
will show the green light then it will
work well. If it found the yellow light,
there is something wrong.

51. Switching on Boiler
1.Switching on main ON/OFF switch and
the boiler fills automatically. The filling
time is approx 10-20 minutes, until the
water is visible in the sight glass.
2. When both low water level lights come
on, pressing the re-set button which
releases the locking relays and the boiler is
ready for operation.
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52. Boiler shut downing system
1.Before shutting the boiler down, giving it a good blowdown to
remove as much sediment as possible. Stoping when the drain
runs clear.
2. Puting the boiler steam pressure control in manual mode, and
slowly reduce the firing rate. Watching he 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. 52

53. 3. Allowing the fan to the furnace with a reduced air flow, and
then shut the fan down. Being particularly careful not to let the
fan supply large amounts of cold air into the furnace in the
winter.
4. Closing the boiler header stop valve.
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54. Maintenance
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steam boiler problems typically occur over a long period of time,
regular monitoring and maintenance go a long way in avoiding
failures or catastrophic disasters. In the maintenance of boiler is
a part of scheduled maintenance. There are several types of
maintenance-

56. Operation and maintenance at running condition
1. Keep the room clean
2. Inspect boiler drum level.
3. Inspect fans. Air heaters periodically
4. Ensure water quality
5. Maintain constant pressure and temperature of steam
Scheduled maintenance
1. Daily maintenance
2. Weekly maintenance
3. Monthly maintenance
4. Yearly maintenance
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57. Daily Maintenance
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1.Checking feed water quality.
2.To ensure water level.
3.To ensure water quality.
4.To ensure steam temperature and pressure .
5.To ensure fuel gas temperature .
6.To ensure quantity of blow down.
7.To ensure the working environment clean.

58. Weekly Maintenance
1.Checking the working of low level & extra low level alarm by
reducing the water level.
2.Ensure proper lubrication of all moving parts.
3.Cleaning the flame sensor and viewing glass.
4.Checking the conditions of door seals.
5.Checking that there are no variations in the fuel pressure as
compared with that at commissioning time.
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59. Monthly Maintenance
1.To ensure function ability of all safety valves .
2.Checking water pump gaskets and non-return valve.
3.Lubricate the modulation motor linkages.
4.Cleaning the burner nozzle and ignition electrodes.
5.Checking and clean, if necessary, the furnace.
6.To ensure the opening of drain valves .
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60. Yearly Maintenance
1.To inspect boiler tube inside for scale ,corrosion.
2.To inspect and tightening bolts
3.To inspect and repair of all manhole ,Connection points and headers
for crack, corrosion or erosion .
4.To perform hydraulic test for pressure parts .
5.Cleaning the water side of the boiler thoroughly.
6.To Review boiler log book .maintenance register and water quality log
book.
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61. Boiler Blowdown
Boiler blow down is done to
remove the scale from the Boiler
Drum. when boiler is shut down
the remaining water in Boiler
drum create solid & chemical
layer. It is called scale.
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Boiler Blowdown Benefits
• Less maintenance and repair cost.
• Saves manual supervision for other tasks.
• Reduced operating cost.

63. Problem & Solution
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SI.
No.
Problem Cause Solution
01 Leaking
and
dripping
broken internal
component, such as a
pump seal or pressure
valve.
pump seal may
have become worn out
and need replacing.
02. Strange
banging,
whistling
or gurgling
noises
a. the water pressure is
too low.
b. kettling. Imminent
pump failure.
the pressure relief
valve needs replacing
and increasing water
pressure of the boiler.
03. Flame
failure.
Air flow high. Adjusting air flow.

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SI.
No.
Problem Cause Solution
04 Furnace
vibration
Incomplete combustion Adjusting air, fuel
ratio.
05 Steam
quality
low
Insufficient blow
down.
Check & action.
Increasing blow down.
06 Very loud
explosive
noise on
ignition
A lot of gas in the
chamber which causes
explosive ignition.
Replaced the ignition
leads and the flame
sensor.

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SI.
No.
Problem Cause Solution
07 Boiler fails to
ignite
when dirt and carbon
build up on the ignition
and flame sensor .
Boiler must be
stripped down and
should clean.
08 Boiler doesn’t
switch on
Internal problem in
power control board
Power control
board need to
replace .
09 Boiler keeps
switching
itself off
Low water pressure
problem with
thermostat and lacks
of water supply.
Checked the water
pressure and water
supply and taking
necessary action .

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Safety for Boiler Room
The safety should be followed during operating the boiler at
boiler room are-
Used Apron , Hand gloves, Shoe , Ear plug properly .
Following fire alarms, Pressure regulator,
Checking electric connection, safety tools of boiler .
Used the Fire extinguisher bottle to quench the fire.
Actually it contains CO2 gas.

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Fire extinguisher bottle Fire alarm
Head phone type Ear plug

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Limitation
DK knitwear Ltd has provided me the best opportunity to
learn about Fire Tube Boiler. But there are some limitations.
The limitations are
 I did not get some information because of company privacy.
 During my practicum I didn’t face any big trouble. So I have
missed the study about big trouble shooting.
 I did not get any assembly or installation of a new boiler.

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Recommendation
.
1. During the practicum period , I noticed that they did not
check the regulator and gas line properly . The regulator and
gas line properly should be checked.
2. I saw that they did not check safety components
regularly .It may be dangerous that’s why safety
components should be checked.
3. There is no economizer for waste heat recovery.
Economizer could be used for waste heat recovery .

71. 4. I noticed that they did not use insulate and sheet to cover
hot line. Reducing heat loss by insulating & sheet covering of
hot line should be used.
5. They do not maintain the maintenance schedule.Weekly
report should be checked for taking necessary action for
maintenance
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Conclusion

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Industry like DK Knitwear 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 much practical knowledge about boiler, its starting and
shutdown system and maintenance & troubleshooting . My
experience during the short time stay at DK Knitwear Ltd. has
not only increased my depth of knowledge, but also has given
me the feeling of challenges I faced in engineering profession. I
hope it will help me in my service life a lot .

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Thanks to allThanks to all

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