3. Letter from the
department for
training, along
with the list of
topics for the
training
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
3
4. Introduction to Thermax, Ltd.
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
4
1. Industry: Energy and Environmental Engineering
2. Products: Vapor Absorption Machines, Boilers, Water Treatment
Plants, Solar Based Cooling, etc
3. Founded: 1980 in Dadar, Mumbai
4. Divisions: C&H, B&H, Power, Enviro, Chemical & Water, Solar energy
5. Headquarters: Pune, India
Training at Thermax Energy House, Chinchwad MIDC in Solid Fuels
section of B&H division
6. P&ID
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
6
1. Piping and instrumentation diagrams are the schematic used in the
field of instrumentation and control or automation
2. P&IDs are used by field technicians, engineers, and operators to
better understand the process and how the instrumentation is
interconnected
3. P&IDs use symbol and circles to represent each instrument and how
they are inter-connected in the process
7. Instrument Tags
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
7
1. Tags are the letters and numbers placed within or near the
instrument to identify the type and function of the device
2. First letter is used to designate the measured variable such as
Pressure, Temperature, Level, Flow, Vibration, etc.
3. Succeeding letter(s) are used to designate the function of the
component or to modify the meaning of the first letter such as
Indicator, Recorder, Controller, Transmitter, Measuring Element,
Switch, Alarm, Valve, etc.
4. These letters are used against the standards for P&ID of
Instrumentation Standards Association (ISA S5.1) as shown in figure
1.1
8. Figure 1.1: ISA S5.1 Identification Letters
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
8
9. Instrument Location
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
9
1. The horizontal line in the circle indicates the mounting location of
instrument
2. No line: Mounted in the field near the process for monitoring
3. Solid line: Mounted in the control room accessible to the operator
4. Dashed line: Located out of sight not accessible to the operator
5. A circle in a Square: The display of the instrument is in the control
room of DCS
10. Piping and Connection Symbols
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
10
A dashed line is used to
indicate the
interconnection between
instruments on field to
DCS
11. Valve Symbols
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
11
1. Valves are used to control the flow of air, water, steam, fuel, gases,
etc.
2. These valves are controlled by either manually by hand or
automatically by electric or pneumatic signals from DCS/PLC
13. Instrument Specification
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
13
1. Tag ID of instrument
2. Type of instrument
3. Loop sequence number
4. Service in overall process
5. Alarms
6. Normal and design temperature and pressure
7. Scale unit and ranges
8. Control set point
9. I/O type
10.Signal level and type
14. Instrument Index & DCS I/O List
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
14
1. The list which consists all the instruments and their specifications in
a process plant is called Instruments Index
2. It consists all instruments including field Gauges & Measuring
Elements
3. A list consisting all the instruments connected from field to DCS or
vice versa is known as the DCS I/O List
4. It contains specifications such as transmitter tag name, DCS tag
name, loop service, signal type, I/O type, instrument calibration
range and DCS range, digital states (if present), alarms, etc.
15. Instrument Index & DCS I/O List
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
15
Instrument
Index
DCS I/O
List
17. Boiler Major Equipment
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
17
1. Feed water system
2. Feed water heater
3. Deaerators
4. Economisers
5. Boiler drum
6. Boiler tubes
7. Superheaters
8. Attemperators
9. Condensate systems
10.Fuel system
18. Feed water system
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
18
1. The water supplied to the boiler, which is converted into steam, is
called feed water
2. The two sources of feed water are condensate or condensed steam
returned from the process and makeup water (treated raw water)
which must come from outside the boiler room and plant processes
3. DM water is used in boiler to avoid scaling
Feed water heater
1. Heaters are shell and tube heat exchangers with the feed water on
the tube side (inside) and steam on the shell side (outside)
2. Boiler efficiency is improved by the extraction of waste heat from
spent steam to preheat the boiler feedwater
19. Deaerators
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
19
1. The oxygen is mechanically removed in a deaerator
2. Oxygen is decreasingly soluble as the temperature is raised
3. This is done by passing a stream of steam through the feed water
20. Industrial
Economizers Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
20
A feed water economizer reduces steam boiler fuel requirements by
transferring heat from the flue gas to incoming feed water
21. Boiler drum
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
21
1. A boiler system consists of a steam drum and a mud drum
2. The steam drum is the upper drum of a water tube boiler where the
separation of water and steam occurs
3. The lower drum, called the mud drum, is a tank at the bottom of
the boiler that collects solids such as salts formed from hardness
and silica or corrosion products carried into the boiler
Boiler tubes
1. Boiler tubes are usually fabricated from high-strength carbon steel
2. The tubes are welded to form a continuous sheet or wall of tubes
23. Superheaters
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
23
1. The purpose of the superheater is to remove all moisture content
from the steam by raising the temperature of the steam above its
saturation point
2. The steam leaving the boiler is saturated, that is, it is in equilibrium
with liquid water at the boiler pressure (temperature)
Attemperators
1. Attemperation is the primary means for controlling the degree of
superheat in a superheated boiler
2. Attemperation is the process of partially de-superheating steam by
the controlled injection of water into the superheated steam flow
24. Condensate systems
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
24
1. Condensate tanks and pumps are major points for oxygen to enter
the condensate system and cause corrosion
2. These points should be monitored closely for pH and oxygen ingress
and proper condensate treatment applied
Fuel system
1. Their primary functions include transferring the fuel into the boiler
and distributing the fuel within the boiler to promote uniform and
complete combustion
2. The type of fuel influences the operational features of a fuel system
25. Boiler Safety Interlocks
Industrial
Training
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
25
1. Purge
2. Low Air Flow
3. Low Fuel Supply
4. Loss of Flame
5. Fan Interlock
6. Low Water
7. High Combustible content
26. 26
[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
Industrial
Training
Boiler Process
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[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
Industrial
Training](https://image.slidesharecdn.com/ranviramolsitlowsize-140919042017-phpapp01/85/Ranvir-amol-sit-lowsize-1-320.jpg)
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[2011BIN001] Ranvir Desai
[2011BIN044] Amol Dudhate
Industrial
Training](data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7)