Sabardairy Industrial Training Report

1. A
Practical Training Report
On
Submitted in partial fulfillment for the award of the degree of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted by:-
DESAI NIRAV M.
MECHANICAL-A
SEM-VII
(15012031009)
GANPAT UNIVERSITY
DEPARTMENT OF MECHANICAL ENGINEERING
U. V. PATEL COLLEGE OF ENGINEERING
KHERVA, MEHSANA

2. 1.COMPANY PROFILE
Introduction of company:-
General Information:-
Unit of Glance:-
SABAR DAIRY, At-Post: Boria, Ta: Himmatnagar, Dist: Himmatnagar,
Pin-code: 383006.
Telephone No: (02272) 226051, 226060

3. Vision
Sabar dairy has only one vision and it is “TO SELL THE PRODUCT TO
OTHER OWN BRAND NAMES RATHER THAN AMUL”.
Product
 The manufactured by Sabar dairy is below,
1. Amul spray powder
2. Amul butter
3. Amul instant milk food
4. Amul pure ghee
5. Amul Shrikhand
6. Amul Shakti milk
7. Amul gold milk
8. Amul butter milk
9. Amul skimmed milked powder

4. Overview of plant:-
 The Sabar dairy produce different milk product. There are two main plants
for mechanical site,
(1) Refrigeration plant,
(2) Boiler plant
Refrigeration plant:-
 Principle of Refrigeration:-
Refrigeration is defined as “the transfer of the heat from a lower
temperature region to a higher temperature one”. Refrigeration device that
produce refrigeration operate using for the vapour compression cycle
(reversed Carnot cycle). Some examples of refrigeration device are heat
Pumps, Refrigerators, Automotive air-conditioners, residential/commercial
air-conditioners. All of these devices have one thing in common, to reduce
the temperature of an enclosed environment. The ideal vapour-
compression cycle uses refrigerant as the working fluid to absorb and reject
heat energy. The energy transfer allows the vapour-compression cycle
assumes that the system is perfect based on thermodynamic theory,
therefore neglecting any losses associated to performance.

5. REFEIGERATION CYCLE:-
 Types of basic parts in a mechanical refrigeration system,
1. COMPRESSOR
2. CONDENSER
3. EXPANSION VALVE
4. EVAPORATOR
5. RESERVOIR
6. ACCUMULATOR
7. ECONOMIZER

6. COMPRESSOR :-
The compressors are the heart of the mechanical
refrigeration system. It circulates the refrigerant around the system. And
creates the pressure differential required for system operation.
 Screw compressor is used in the sabar dairy refrigeration system. It is the
rotary type of the compressor.
 Screw compressor:- They are based on a mechanism made up of two
threaded rotor (screws) that are couple together. The gas is compressed
due to the progressive overlapping of the lobes, causing a reduction in the
volume occupied by the gas.
CONDENSORS:-
In a cooling cycle of a refrigeration system, heat is
absorbed by the vapour refrigerant in the evaporator followed by the
compression of the refrigerant by the compression . The high pressure and high
temperature state of the vapour refrigerant is then converted to liquid at the
condensers. It is designed to condense effectively the compressed refrigerant
vapour.

7. (1) Air cooled condenser:-
(a)Natural convection air-cooled condensers,
(b)Forced convection air-cooled condensers,
(2)Water cooled condenser:-
(a)Tube-in-tube or double tube condensers,
(b)Shell and coil condensers,
(c)Shell and tune condensers,
(3)Evaporative condensers:-
 Evaporative condensers is used in the sabar dairy refrigeration system.
EVAPORATIVE CONDENSER:-

8. Principle of operation:-
An evaporative condenser is a condenser
integrated into a cooling tower which rejects the latent heatof condensation of
refrigerant (Ammonia/Freon) through a coil to the surroundings by means of
evaporation. Water sprayed onto the coil exchanges heat with the refrigerant. A
small quantity of water is evaporated into the air thereby cooling the remaining
water cascading to the basin at the bottom. Post evaporation the saturated air
passes through the drift eliminators and then forced out using a fan.
EXPANSION DEVICES:-
The expansion device is also known as metering
or throttling device. The expansion device is an important device that devices the
high pressure side and low pressure side of refrigerating system. It is connected
between the receiver and the evaporator device performs the following function.
1. It reduce the high pressure liquid refrigerant to low pressure liquid
refrigerant before being fed to evaporator.
2. It maintains the desire pressure difference between the higher and low
pressure side of the system, so that the liquid refrigerant vaporises at the
designed pressure in the evaporator.
3. It controls the flow of refrigerant according to the load on the evaporator.
The expansion devices used with dry expansion evaporators are usually
called expansion valves whereas the expansion devices used with flooded
evaporators are known as float valve.

9. Boiler plant:-
 Introduction:-
 A boiler is closed vessel in which water or other fluid is heated. The heated
or vaporized fluid exits the boiler for use in various processes or heating
applications, including boiler-based power generation, cooking, and
sanitation.
 Boiler is a device used for generation steam which is used for driving prime
movers or industrial purposes like process heating.
 According to IBR a boiler is a closed pressure vessel with capacity exceeding
22.75 liters for generating steam under pressure.
 At atmospheric pressure water volume increase 1,600 times when converts
into steam.
 In boiler plant 6 boilers are produce steam for milk products. Detail of the
boiler is an under,
Sr. No. Boiler No. Boiler Name Heating Surface Capacity –
Tone
1 GT 1630 AVB Ltd. 126.7 Sq Meter 4.5
2 GT 1641 AVB Ltd. 128.7Sq Meter 4.5
3 GT 1810 Western work
boiler
267 Sq Meter 10
4 GT 1984 Western work
boiler
267 Sq Meter 10
5 GT 2381 AVB Ltd. 216.7 Sq Meter 8
6 GT 3174 Thermal
boiler
164.25 Sq Meter 10

10. • Types of boiler:-
 There are main two types of boiler,
1. Water Tube boiler,
2. Fire Tube boiler
1. Water tube boiler:-
In water tube boiler feed water feed through the tubes and enter to the
boiler drum. The circulated water is heated by the combustion gases and
converted into steam at the vapour space in the drum. These boilers are
selected when the steam demand as well as steam pressure requirements
are high as in the case of process cum power boiler / power boilers.
Most modern water boiler tube design are within the capacity range
4,500-1,20,000 kg/hr of steam, at very high pressures. Many water tube
boilers now a days are of “packaged” construction if oil and /or gas are to
be used as fuel. Solid fuel fired water tube designs are available but
packaged designs are less common.
 The Features of water tube boilers are ,
•Forced, induced and balanced draught provisions help to improve
combustion efficiency.
•less tolerance for water quality calls for water treatment plant.
•Higher thermal efficiency levels are possible.

11. 2. Fire tube boiler:-
In fire tube boiler, hot gases pass through the tubes and
boiler feed water in the shell side is converted into steam. Fire tube boiler
generally used for relatively small steam capacities and low to medium
steam pressures. As a guideline, fire tube boilers are competitive for steam
rates up to 12,000kg/hr and pressure up to 18 kg/cm2. Fire tube boilers are
available for operation with oil, gas or solid fuels. For economic reasons,
most fire tube boilers are nowadays of “packaged” construction for all
fuels.
 BOILER MOUNTINGS:-
These are different fittings and devices which are
necessary for the necessary for the operation and safety of a boiler.
Normally these devices are mounted over boiler shell.
 Mountings of fire tube boiler:-
1) Two safety valve
2) Mobery
3) Two Water Level Indicator
4) Pressure gauge
5) Steam stop valve
6) Top feed
7) Feed check valve]
8) Bottom blow of cock
9) Flash tank
10) Hand hole
11) Man hole
12) Mud hole
13) Air vent valve
14) Fusible plug
15) Controlling draught
Now see the details of mountings,

12. Safety valve:-
 Function:-
 The faction of safety valve is to blow off the steam from boiler to
atmosphere when pressure of steam exceeds the rated pressure. The
safety valve automatically opens and excess steam rushes out from boiler
to atmosphere till the pressure in boiler drops down to working pressure or
rated pressure.
 The blow off steam through the safety valve creates a noise which serves as
warning to the operator. As per boiler regulation every boiler must be fitted
with two safety valves.
 In plant SPRING LOADED SAFETY VALVE is used.
Spring Loaded safety valve:-
 Function :-
 Its function is to maintain constant steam pressure inside the boiler. Apart
from this function, the discharge capacity should be equal to evaporative
capacity so that frequent built up of pressure does not occur which is
placed in boiler.
 The flange of body of valve is bolted to a mounting block of boiler shell at
top of shell.
 LOCATION :- It is fitted on mounting block on top of the boiler shell.

13. Mobrey :-It is a magnetic control switch:-
 Function:-
 It also automatically maintains constant water level inside the boiler. If the
water level in the boiler goes below the certain required level, then steam
automatically discharged into atmosphere. This raiser alarm so that
corrective action can be taken by pumping in water.
 Location:- It is fitted on mounting block on top of the boiler shell with
safety valve.
Water level indicator(Gauge glass):-
 Function:-
 It shows the operator the level of fluid in the boiler constantly.
 It is also known as a sight glass, water gauge or water column is provided.
 Location :- It is mounted in front of boiler in such a way that it is visible to
the operator. Generally two water level indicators are used in boiler having
capacity 135 kg/hr of steam or more.
 Why boilers provided with, water level indicator:- If one fails to accidental
breakage the other one will continue to be in line and show the water level.
Pressure gauge:-
 Function:-
 The function of pressure gauge is to indicate the steam pressure of the
boiler in pound/inch2(kg/cm2) or bar.
 It reads pressure of steam above atmosphere.
 The actual pressure of steam=gauge pressure+ barometer reading
 Common type of pressure gauge used is known as bourdon pressure gauge.
 Location:- It is fixed in front of steam boiler and in steam space in drum.

14. Steam stop valve ( Junction valve):-
 Function:-
 To control the flow of steam from boiler to the main team pipe.
 To shut off the steam completely when required.
 Location:- steam stop valve is usually fitted to highest part of boiler shell
i.e., Top of shell.
Top feed:-
 Function:-
 In this design for feed water injection, the water is fed to the top of the
boiler. This can reduce boiler fatigue caused by thermal stress. By spraying
the feed water over a series of trays the water is quickly heated and this
can be reduce lime scale.
Feed check valve or clack valve:-
 Function:-
 Its function is to allow and control flow of boiler feed water from feed
pump to boiler at a higher pressure than boiler continuously, secondly to
prevent back flow of water from boiler to the pump as pressure is less than
boiler pressure or when it is not working.
 Location :-A non return stop valve in the feed water line. This may be fitted
to the side of the boiler, just below the water level. Inlet end of flange is
connected to delivery end of feed pump while the outlet end of flange is
connected to the pipe which leads to boiler.

15. Bottom blow off cock:-
 Function :-
 To empty the boiler when necessary for cleaning, repair and inspection.
 To discharge the mud and sediments carried with feed water and
accumulated at bottom of the boiler.
 Location:-As the name implies, this valve is usually located directly on the
bottom of the boiler, and is occasionally opened to use the pressure in the
boiler to push these particulates out.
 Blow of cock should be operated only when boiler is working and if
sediment are to be removed. This is because the sediments are forced out
quickly due to the high steam pressure in the boiler.
Flash Tank:-
 Function :-
 High pressure blow down enters this vessel where the steam can ‘flash’
safely and be used in a low-pressure system or be vented to atmosphere
while the ambient pressure blows down flows to drain.
Hand holes:-
 Function :-
 They are steel plate installed in opening in ”header” to allow for inspections
& installation of tubes and inspection of internal surfaces.
Man hole:-
 Function :-
 It is a hole provided on the boiler so that a workman can go inside the
boiler for inspection, cleaning and maintenance.

16. Mud hole:-
 Function :-
 Ti collects all impurities present in the water. It is at the bottom or shell.
These impurities are removed time to time by help of blow of cock.
Air vent valve:-
 Function :-
 It isused to release the air from the boiler for safely starting the boiler.
 Location:- It is located on boiler or on steam pipe.
Fusible plug(Low-water cut-off):-
 Function :-
 The function of fusible plug is to put-off the fire in furnace of the boiler,
when water level in the boiler falls below an unsafe level and thus avoids
the explosion which may takes place due over heating of tubes and shell.
 Location:-It is fitted near crown of furnace.
Controlling draught:-
 Function :-
 Most boilers now depend on mechanical draught equipment rather than
natural draught. This is because natural draught is subjected to outside air
conditions and temperature of flue gases leaving the furnace, as well as the
chimney height. All these factor make proper draught hard to attain and
therefore make mechanical draught equipment much more economical.
 There are three types of mechanical draught:-
1) Induced draught ,
2) Forced draught ,
3) Balanced draught

17. Boiler accessories:-
 These are auxiliary plants or parts required for steam boilers for their
proper operation and increase efficiency of the boiler.
 According to Indian Boiler Regulation (IBR) the following mountings should
be fitted to the boilers.
 In plant no one accessories planted.
 Advantages of Fire tube boiler used in dairy plant:-
 Chances of explosion are less due to low pressure.
 Less skill required for efficient and economic working.
 For producing process steam.
 No problem of scale deposition.
 Less problem of overheating.
 Well suited for space heating and industrial process applications.
 Easy maintenance.
 Corrosion is effect less.