Visit Report Rakhoh Boiler

Dear Sir:

Following are the details for 9 days training conducted at Rakhoh Boiler.

Visited By:

Sanket S Koyate

Projects and Marketing

+91 9689892606

projects@seplindia.co.in

Project Details:

Company Name:

Rakhoh enterprises, Pune

Rakhoh Boiler,

S-11, T- Block, MIDC

Bhosari -411026

Pune.

Name of Project:

Visit Report to Rakhoh Boilers

Location& Date when visited:

Bhosari, Pune

18,19,21,22,26,29 Nov and 02,03,06 Dec 2013

Project Coordinator Name:

Mr. Nikhil Patil

Marketing Department

Visit Details:

Following is the details of 9 days visit to Rakhoh Boilers and also FAQ which is

understood

DAY 1

Time: 11.30 to 15.30

On 18/11/2013 I visited to Rakhoh Boilers, for the purpose of 9-10 days training to learn

the concepts of boilers. As Mr. Nikhil was on site visit he was not available. So, I met

Mr. Chaughule who is service engineer in the company. He referred Mr. Sharan who took

me to the manufacturing unit where many types and sizes of boiler where prepared. Mr.

Sharan was service engineer with experince, so he explained according to his knowledge.

He showed APH i.e. air preheater, furnace, inner nozzles of furnace. I found it very

interesting and some questions were unanswered as he was service engineer with less

than a year of experience. First day of visit was less profitable. I learnt many things and

some things which were taught by Mr. Vikrant sir during Bangladesh visit were sharpen

by seeing it actually in Rakhoh company.

Many questions were neither answered correctly nor satisfactory. But in coming 6-7 days

that questions will be cleared and also many questions to be asked. Such as Husk

consumption, Boiler losses, efficiency, etc.

DAY 2

Time: 11.30 to 15.30

(These timings are when I reached Rakhoh Company and left from there.)

On 19/11/2013 Mr. Chaughule with his junior Mr. Sharan was out on site visit. Also

marketing department persons were unavailable. Day 2 was non productive. I was on

shop floor where I saw many different types of boilers as 6000kg/hr of Kenya, 5000kg/hr

internal furnace of synergy, etc I saw sheet rolling technique with semi automatic

machine, which I have captured in video.

DAY 3

Time: 11.30 to 15.30

On 21/11/2013 Mr. Nikhil Patil was available in office and he helped me understanding

many concepts related to boilers. He explained me every question of mine with drawings

wherever required. Also when on shop floor Mr. Tushar from production department

explained me concepts of boiler. There were lifters from 5 ton to 20 ton capacity. Every

machine was available such as press machine, drill machine, welding machine, etc

Day 4

Time: 11.30 to 16.30

On 22/11/2013 Mr. Nikhil cleared me concepts of husk consumption, boiler efficiency,

Annual fuel cost etc. He explained me AutoCAD Drawings wherever necessary.

Day 5

Time: 11.30 to 15.30

As there was office work for drawings of Mr. Magbul Mir I did not attend training for 2

days. On 26/11/2013 Mr. Nikhil was not available. I was on shop floor with trainee of

Rakhoh Mr. Sagar, where he showed me different types of department of Rakhoh such as

Design, Production, Marketing, etc.

Day 6 & Day 7

Time: 13.40 to 17.30

On 29/11 & 02/12/2013 I was at design department of Rakhoh where I learnt the many

concepts in the foundation layout drawings of Boiler from the persons of the design

department.

Day 8

Time: 11.30 to 16.30

On 3/12/13 I was on shop floor looking out for different processes like pressing, rolling,

welding. Also saw the ongoing work for insulation material which is like cement.

Day 9

Time: 13.30 to 17.30

On 06/12/13 I was on shop floor for final revision of whatever I learnt and also was going

through my notes which I prepared. I learnt many things related to Boiler and this

training was useful

FAQ BOILER

FURTHER QUESTIONS WILL BE UPDATED AS TRAINING IS STILL

GOING ON. THIS WERE QUESTION AND ANSWER WHICH I ASKED

AND UNDERSTOOD.

- Sanket S Koyate

0) What is Boiler?

Boiler is a closed vessel in which soft water is heated by any burnable fuel which

gives saturated steam.

1) What is F.D Fan?

F.D. fan is used for forcing pressure into furnace. Forced draft fan is used to

create positive pressure. Fan temperature is around 30 degree Celsius.

2) What is ID Fan?

Induced draft fan is to transfer flue gases from furnace to chimney. Fan

temperature is around 200 degree Celsius. It created negative pressure.

3) What is fluidized bed combustion?

Fluidized bed combustion employs a distributor plate, a bed of sand. The bed of

sand is kept fluidized state by the FD fan. A PA fan is used to transport and inject

the rice husk into the bed. The bed of sand is initially heated by charcoal / or rice

husk. Once the sand is heated and maintained in fluidized condition, the rice husk

is continuously injected to maintain the combustion and to give the heat required

for generating the steam in the boiler. The ash after complete combustion leaves

the bed and gets collected in ash hoppers of the boiler & in the dust collector. An

ID fan is used to maintain the negative draft in the furnace. Pollution is the big

issue here. One should have properly designed & installed MDC cones.

4) Role of water softener?

It removes the hardiness (calcium, Magnesium) in raw water (hard water) and

changes the hard water to the soft water.

If the water contains hardness, the hardness is condensed in the boiler as heating

becomes scale formation and it then adheres inside the water tubes. Then heat

efficiency declines because of the scale adhesion.

5) What is IBR?

Indian Boiler Regulations, which has created in 1950 in exercise of powers,

conferred by section 28 and 29 of the Indian Boiler Act. It was formed to

consolidate and amend the law relating to steam boilers.

6) What are boiler mountings?

Boiler mountings are generally mounted on the boiler for safety operations

purpose.

Different mountings are Water level indicator, safety valve, pressure gauge, steam

stop valve, Feed check valve, Manhole, etc

7) What are boiler accessories?

This is device which is installed with a boiler. It is used to increase efficiency of

the boiler.

Different types of accessories are Feed water pump, injector, pressure reducing

valve, air preheated, super heater, economizer, steam drier/separator, etc

8) Types of boiler supplied by Rakhoh Company?

a) Bio-drum co-generation boiler

b) Bi-drum D type high pressure boiler

c) Solid fuel fired internal furnace

d) Oil/Gas fired boiler

e) Multi fuel external furnace 4 membrane wall (fluidized bed)

f) Package type twin furnace boiler

g) Husk fired package type boiler

h) Boiler for small industry

i) Waste heat recovery unit

j) Thermic Fluid heater

k) Coded pressure vessel

9) What is fired tube boiler?

A fire-tube boiler is a type of boiler in which hot gases from a fire pass through

one or 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.

10) What is water tube boiler?

A water tube boiler is a type of boiler in which water circulates in tubes heated

externally by the fire. Fuel is burned inside the furnace, creating hot gas which

heats water in the steam-generating tubes. In smaller boilers, additional generating

tubes are separate in the furnace, while larger utility boilers rely on the water-

filled tubes that make up the walls of the furnace to generate steam.

11) What is 3 pass in boilers?

As indicated in drawing three-pass wetback design has a rear water wall, which

separates the primary heating surface of the combustion chamber from rear tube

sheet. The water jacket eliminates the need for a refractory wall and rear door spacing

behind the boiler, as well as costly refractory maintenance.

The rear wall eliminates the need for gasketing , which is vulnerable to the

temperature generated in the rear of the turnaround area. It has great overall

efficiency.

12) What is Heat Exchanger?

Used for heat transfer from one medium to another medium. This media may be

separated by solid walls to prevent mixing or they may be in direct contact.

Widely used in space heating, refrigeration, air conditioning, power plants,

petroleum, natural gas processing. Mostly shell and tube type is used.

13) Types of chimneys in Boiler?

a) Self supported chimney

b) Structural supported chimney

c) Rope supported chimney

d) Wall Supported chimney

14) How to calculate fuel operating cost?

Fuel Operating Cost = Fuel Consumption*Fuel Cost*1.02

Where, 1.02 is considered as electricity & other factors in production.

15) How to calculate annual cost of Fuel?

Annual Fuel Cost= Fuel Cost/hr * No of hrs/day * No of days/yrs

16) Some definition for boiler accessories?

The device which are installed with a boiler & used to increase efficiency of

boiler.

(a) Feed Water Pump :

To feed water to boiler.

(b) Injector :

TO feed water under pressure.

(c) Pressure reducing valve:

The function of pressure reducing valve is to maintain constant pressure on

delivery side of the valve irrespective of the fluctuating supply of steam from

boiler.

(d) Air Pre heater:

To heat the air before it enters the combustion chamber.

(e) Super heater:

Used in stationery boiler. Function is to convert dry saturated steam into

superheated steam at the desired temperature. It is used to increase the

temperature of saturated steam without raising its pressure.

(f) Economizer:

Considerable amount of heat of the plant is carried away by flue gases, so to

utilize this waste heat. An economizer is placed in the path of flue gases to

preheat the feed water. An economizer increases the steam raising capacity of

a boiler.

(g) Steam drier or separator:

To separate the water particles from steam before it is supplied to the point of

application

17) What is vaporization?

It is phase transition from liquid phase to gas phase.

18) Some definition for Boiler Mountings:

a) Water Level Indicator: Indicates exact water level of boiler tube.

b) Safety valve: Mechanical device used as safeguard for boiler, in case the

pressure inside the boiler rises above its normal working atmosphere.

c) Pressure Gauge : Indicates the pressure

d) Steam Stop Valve: Stop or open the steam supply from boiler to the point of

application.

e) Feed Check Valve: To regulate the flow of water.

f) Man Hole: It is the opening on the top provided for cleaning and inspection.

19) Boiler Classification?

Following is the classification of boiler

According to the position of furnace:

a) Internally fired boiler

b) Externally fired boiler

According to the axis of furnace

a) Vertical Boiler

b) Horizontal Boiler

c) Inclined Boiler

According to method of circulation of water

a) Natural Circulation Boilers

b) Forced Circulation Boilers

According to steam pressure

a) Low ( 15 - 20 bar)

b) Medium (20 – 80 bar)

c) High ( More than 80 bar )

According to source of heat:

a) Water Tube Boiler

b) Fired Tube Boiler

20) General names for the different parts of boiler?

What are the strengths, opportunities within the Rakhoh Company? What positives did

you notice during your visit?

There were different peoples for different department such as design, production which

made there work easy. Marketing department was technically sound. . Every boiler and

its other parts were manufactured with accuracy. Every part was checked by making

assembly of it with respective part. The fabrication work and the welding were done well.

The finishing work like grinding, coloring was done with care. Positives I noticed were

they were having good experience of preparing different types of boiler, which were good

for us, so their experience would create no mistakes while boiler is manufactured.

Post-project Visit:

Have you contacted the project coordinator after your visit?

Yes, I have contacted Mr. Gurjar Sir and Mr. Vikrant Sir

Have you took support documentation that you may have collected (like photographs

taken, reports, documents, etc.)?

Yes, I have taken photographs of boiler and also video of sheet rolling machine.

A) 5tph husk fired boiler