Training Report

1

CONTENTS

1. Site Visit Training .................................................................................................................................. 2

2. Site location and product details .......................................................................................................... 3

3. WWS division product specifications and learning’s ............................................................................ 4

3.1 DM Plant (Site: Shankar SSK, Akluj) ............................................................................................. 4

3.2 RO PLANT (DYNAMIX DAIRY, BARAMATI) ................................................................................... 6

3.3 STP PLANT (AMANORA, MAGARPATTA, PUNE) .......................................................................... 8

4. Heating division product specifications and learning’s ........................................................................ 9

4.1 COMMISIONING PROCEDURE FOR BOILERS ............................................................................... 9

4.2 SHELLMAX SX 06 (Deluxe Laundry, Pune) ................................................................................. 10

4.3 SHELLMAX SM 1 TPH/10.54 (purple textile,Baramati) ............................................................. 11

4.4 HUSKPAC HP 50BB/10.54 (Ganesh Agro, Moregaon Arjuni) .................................................... 12

4.5 THERMOPAC(Alpha Foam Ltd., Chakan) ................................................................................... 13

4.6 REVOMAX (Angio Pharma) ........................................................................................................ 14

4.7 NEOTHERM(Forstar Foods, Taloja) ............................................................................................ 15

4.8 SHELLMAX (Hindustan Antibiotics Ltd., Pimpri) ........................................................................ 16

4.9 AQUAMATIC ( Hotel Ashiyana, FC road, pune) ......................................................................... 17

5. Enviro division product specifications and learning ........................................................................... 18

5.1 BAG FILTER 8000m3/hr (PIX Transmission Pvt. Ltd., Nagpur) .................................................. 18

6. Chemical Dosing .................................................................................................................................. 19

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1. Site Visit Training

The purpose of site visit at various customers’ location was to analyze and visualize the product actual

functioning and its operating conditions in addition to understand its erection time and space

requirement. To understand the customer’s demand for the product and its purpose. Also to be able to

recommend the customer the best suitable product according his input parameters and resources.

After moving through various sites we are now able to understand the work flow of the product function

and also to judge the input resources for the product and to provide valuable suggestions for product

based on that.

3

Site location and product details

Site Product Purpose

Shankar SSK, Akluj DM Plant For demineralize water for cogen boiler

Dynamix dairy, Baramati RO Plant with UF Water for dairy products

Amanora, Magarpatta, Pune

STP For treating sewage water using FAB

Alpha Foam Ltd., Chakhan Thermopac 06 For heat exchange by thermic fluid in foam

production

Angio Pharma, Pune Revomax .85 TPH For pharmaceutical use

Deluxe Laundry, pune SX 06 For Drying and ironing clothes

Purple Textiles, Baramati Shellmax 1TPH For Drying textile cloth

Hindustan Antibiotics, Pune Shellmax 6TPH For Chemical Process

Forstar Fisheries, Taloja Neotherm 0.5TPH For Drying fishes

Ashiyana Hotel, Pune Aquamatic 2Million kcal/hr For Hot water in hotel use

PIX Transmission Ltd., Nagpur

BagFilter 8000m3/hr For Carbon black removal from outlet gases.

Ganesh rice Mill, Moregaon Arjuni

Huskpac 5TPH For drying rice

Yash Agro Energy Ltd., Biwapur

ESP For cleaning flue gases from boiler outlet

Inventies Research Chemical dosing Dosing for boiler water and cooling water

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Dual Media Filter

Activated Carbon Filter

Stong Acid

Cation

Storage for

Degasser

Degasser Tower

Strong Base

Anion

Mixed BedRaw Chlorinated Water

WWS division product specifications and learning’s

3.1 DM Plant (Site: Shankar SSK, Akluj)

UNIT FLOW

(m3/hr)

OPERATING

PRESSURE

(kg/cm2)

ANALYSIS/CHECK OBR

(m3)

OBR

TIME

(Hr)

CHEMICAL CONSUMPTION

PER REGENERATION

(100% conc.)

RESINS In LITERS

DMF 45 3.5 Cl2 > 1 ppm - -

ACF 45 3.0 Cl2 = 0 ppm - - - -

SAC 36 2.5 Hardness = 0 ppm

pH = 2-3

720 20 278 kg HCl 3997 T42H

DEGASSER - Gravity Removal of CO2

SBA 36 3.5 pH = 8-9.5 Conductivity < 36

720 20 288.3 kg NaOH 4810

A27MP

MB 36 2.5 pH = 6-7 conductivity < 2

22 kg HCl

24.5 kg NaOH

275 T42H

350 A27MP

CONSTITUENTS RAW WATER ANALYSIS TREATED WATER ANALYSIS

COD 15 ppm < 15 ppm

BOD NIL NIL

TSS 20 ppm < 5 ppm

TDS 300 ppm < 0.2 ppm

pH 7.3 6-7 (before pH correction)

Conductivity 450 µmhos/cm < 1 µmhos/cm

Silica 10 ppm < 0.02 ppm

Colloidal Silica NIL NIL

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KEY POINTS:

General P & I diagram of the plant

Sea Sand should be used because of its alkalinity and coagulation properties which avoids sand block

formation

Everyday do backwash for filter

Raw should be chlorinated by NaOCl (Sodium Hypochlorite) and polyelectrolytes.

Erection of plant and available space evaluation

Operating Conditions:

Regneration Cycle: ACID-ALKALI Injection should be carried out for 30 mins, slow rinse for 25 mins and fast

rinse for 30 mins.

Air flow through blower in MB should be 86. 39 m3/hr @ 0.45 kg/cm2 for 2-3 mins

Air Flow in degasser should be 848.23 m3/hr @ 100 mm wc

pH of output water from MB should be corrected by using suitable alkali such as Morpholine/Hydrazine.

DESIGN PARAMETERS:

DMF is designed for maximum load of 50 NTU turbidity to produce outlet water of less than 5 NTU turbidity, if

turbidity is greater 50 NTU, then suitable coagulants are added.

APPLICATION:

For Boiler feed water treatment.

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• DMF

25 m3/hr

• ACF

25 m3/hr• Softner

(1640 litres of T40Na)

18m3/hr

• Basket Strainer (100 micron)

18 m3/hr• 6 UF's

15 .5 m3/hr

• UF permeate

ANTI scalant and SMBS dosing/

14m3/hr • Cartiridge Filter (5 micron)

14 m3/hr

• RO

10 m3/hr

Chlorinated raw water RO Permeate to process

3.2 RO PLANT (DYNAMIX DAIRY, BARAMATI)

PROPERTIES FEED WATER TREATED WATER

Iron < 0.05 mg/lit 0 mg/lit

Hardness 500 mg/lit < 5 mg/lit

pH 7.62 7-7.5

TDS 1100 < 75

SDI 10 NIL

Alkalinity 165 < 50

Organic matter 0.8 NIL

Chloride 158 mg/lit 25 mg/lit

Nitrates > 1.03 < 1.03

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UNIT Operating Pressure

(kg/cm2) Capacity (m3/hr) Treatment

DMF 3.5 25 Removes Turbidity

ACF 3.5 25 Removes Chlorine,

colour and odour

Softner (1640 ltrs of

T42Na) 3.5 18

Hardness reduced to < 5

ppm from 500 ppm

UF membrane Unit 3.0 15.5

Permeate = 14 m3/hr,

also removes colloidal

silica

SMBS dosing unit 3.5 6 Does dechlorination

Anti scalant Unit 3.5 6

Avoid formation of

scales in RO membrane

by MAXTREAT 9001

pH correction Unit 3.5 6 Maintain pH by

MAXTREAT 3006

Cartridge filter 3.5 14 Removes particles

greater than 5 micron

RO Unit 3.5 14 Permeate = 10 m3/hr

KEY POINTS:

General P & I diagram of RO Plant

Operation of plant by understanding controls and readings on control unit.

Erection phase of RO plant

OPERATING CONDITIONS:

Back wash to be done once a day for 15 mins @ 2 kg/cm2 with flow of 75m3/hr

Quantity of NaCl required for one regeneration phase is 263 kg

DESIGN PARAMETERS:

Y strainer is used before raw water feed pump to restrict large size particles to enter the DMF

Steam line is attached to ACF for sanitization at 80◦C to avoid fungal and bacterial growth.

APPLICATION:

RO permeate for dairy process.

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Sweage water Sweage

water sumpBar screen

Equilization tank

FAB 1 and FAB 2

Tube Settler DMF ACF Treated water

3.3 STP PLANT (AMANORA, MAGARPATTA, PUNE)

KEY POINTS:

General P & I diagram of the plant

Construction phase of plant

Visual inspection of FAB media rings

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Heating division product specifications and learning’s

4.1 COMMISIONING PROCEDURE FOR BOILERS

1. Check process line setup according P & I diagram

2. Check proper rotation of motor direction

3. Check power supply unit

4. Inspect mobery installation and its working

5. Adjust proper pressure and temperature of fuel

6. Check operation of feed water pump and its operating conditions

7. Set Burner for firing and start fire after checking all valves and fittings

8. Leave steam upto pressure of 2kg/cm2 for shell boiler and 5kg/cm2 for coil boiler

9. Setting of pressure switch according to required pressure at outlet

10. At stack check O2 and CO2 levels according to standard norms

11. If O2 and CO2 instruments doesn’t work or malfunction, then alternatively check levels of CO2 by

colour of flue gases

12. Check safety i.e. photocell, water level safety i.e. mobery, pressure switch etc.

13. Stack temp. should not be more than 220◦C

14. Finally check the temp. of flue gases at the outlet of the chimney

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4.2 SHELLMAX SX 06 (Deluxe Laundry, Pune)

KEY POINTS:

General P & I diagram

Heat Output of SX 06 is 600 kg/hr at 10.34 kg/cm2

Fuel used is FO

Operating controls and readings on control unit

18 seconds is ideal time for blow down.


Fuel oil inlet pressure is 18 kg/cm2 at temp. of 120◦C

Outlet steam temp. is 180◦C approx.

Per minute outlet water is 10.4 liters before steam generation

Fuel consumption is 38 kg/hr

Economizer operating temp. is 48◦C which extracts heat from flue gases at 220◦C.

DESIGN PARAMETERS:

Economizer is used for feed water heating

Fuel pre heater is used which heats it up upto 120◦C

Ortili burner for combustion

APPLICATION:

Steam for drying and ironing clothes in laundry.

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4.3 SHELLMAX SM 1 TPH/10.54 (purple textile,Baramati)

KEY POINTS:

General P & I diagram.

Operating pressure is kept at 10.54kg/cm2

Fuel used is LPG.

Working of 3 pass shell boiler

OPERATING conditions:

Inlet gas pressure is 0.3 bar and outlet is 100 milli bar

Minimum and maximum gas flow rate is 0.25 m3/hr and 40 m3/hr respectively

Gas required at low flame and high flame phase is 14-18 kg/hr and 38-40 kg/hr

Flue gas outlet temp. is 290◦C

DESIGN PARAMETERS:

ACTARAS FLOW meter for measuring gas flow

Mobery controller for water control at inlet of boiler at 3 different levels

APPLICATIONS:

Steam for textile process and drying clothes.

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4.4 HUSKPAC HP 50BB/10.54 (Ganesh Agro, Moregaon Arjuni)

KEY POINTS:

General P & I diagram.

Heat Output of HP 50 is 5000 kg/hr at 10.34 kg/cm2

Fuel used is husk

Water inlet flow is 1000 lit/hr and feed of husk is 100 kg/hr for generation of 5 TPH


Flue gas temp. is maintained at 250◦C

Blowdown should be done twice a day.

DESIGN PARAMERTERS:

Cool air provision with the help of air duct for keeping watch glass cool at combustion chamber

door.

Boiler designed for bore well water properties.

Hot condensed water from process outlet is also used as feed water.

APPLICATION:

For drying of rice and for process in rice mill.

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4.5 THERMOPAC(Alpha Foam Ltd., Chakan)

KEY POINTS:

Study of P & I diagram

It is a 3 pass, coil type, thermic fluid boiler (TPC-06).

Fuel used is furnace oil.

Ortili burner is used for firing.


Heat output is 600,000 kcal/hr

Thermic fluid flow rate is 30 m^3/hr

Fuel temp at inlet - 120°c

Maximum temperature of thermic fluid used for process is 280°c

DESIGN PARAMETERS:

Distance between outer and inner coil is approximately 20mm.

Diameter of coil is 40 NB.

Fuel pressure is 22kg/cm^2

Deaerator tank elevation should be 0.6m above the highest point in thermic fluid system

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4.6 REVOMAX (Angio Pharma)

KEY POINTS:

Study of P & I diagram.

It is a 2 pass, coil type boiler(RXD-850)

Fuel used is LDO.

Ortili burner is used for firing.

Optimizer and water preheater is used.


Pressure of LDO pump is 23-24 kg/cm^2

Working pressure is 10.34 kg/cm^2

Output generated is 0.531MW

Connection load is 3.5 KW

Heat output is 850 kg/hr

DESIGN PARAMETERS:

At the steam outlet SPH(steam pressure high) switch is given. At the water preheater LSL (Level switch low) is provided. At the outlet 2 safety valves are given at 10.3kg/cm^2 and 10.5 kg/cm^2

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4.7 NEOTHERM(Forstar Foods, Taloja)

KEY POINTS:

Study of P& I diagram

It shell type 3 pass boiler (NEO-05/7/3).

Fuel used is LO.

Pilot burner is used for firing.


Heat output is 600,000 kcal/hr

Output power generated is 0.3 MW

Heat generated is 500 kg/hr

Operating pressure is 7 kg/cm^2

Fuel pump- 60l/hr, pressure- 28 kg/cm^2

Water pump - flowrate- 1 m^3/hr, pressure- 17 kg/cm^2

DESIGN PARAMETERS:

For water level safety mobri is used.

Pressure is set in between 6-6.75 for outlet of steam.

For steam output globe valve is used for pressure adjustment.

At stack outlet stack temperature high switch is provided for temperature 220°C

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4.8 SHELLMAX (Hindustan Antibiotics Ltd., Pimpri)

KEY POINTS:


It is a 3 pass shell type boiler.

Fuel used is FO

Turndown ratio of 1:4 is provided.


Heat output is 6000 kg/hr

Power generated is 3.76KW

Design pressure is 10.54 kg/cm^2


Water pump - Power- 4KW, flowrate- 5.8 m^3/hr, temp- 120°c, pressure- 25 bar, Hmax- 177.4 m, Hact -

133 m.

Water:conductivity - 10 micro siemens/cm, pH - 8.5 - 9.5

DESIGN PARAMETERS:

Back pressure regulating valve is provided.

Eccentric reducer is provided so that NPSH is created.

40 mm insulation is provided.

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4.9 AQUAMATIC ( Hotel Ashiyana, FC road, pune)

KEY POINTS:


It is a coil type hot water generator

Fuel used is HSD

Calorifier is used

Monobloc burner is used


Heat output is 200000 kcal/hr

Power generated is 0.232 MW


Flame temp - 1200-1300°C

Soft water in boiler - 500l

Calorifier capacity - 1000 - 1200 l of water

DESIGN PARAMETERS:

Initially water in calorimeter is at 40°C

Outlet temperature of water from boiler is 90°C

This water is used to heat up the water in the calorimeter to 50°C by circulation through coil in calorimeter which is then sent for general use in hotel.

The water in calorimeter coil is again sent to the boiler as it temperature reduces with the help of circulating pump.

Set point of circulation pump at inlet and outlet are maintained at 57 and 70°c respectively.

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Enviro division product specifications and learning

5.1 BAG FILTER 8000m3/hr (PIX Transmission Pvt. Ltd., Nagpur)

KEY POINTS:

Capacity of bag filter is 8000 m3/hr

Working and operating controls of bag filter

Setting of purging pressure and purging frequency according to load on bags

Setting rpm of Air Lock Rotary Valve

Inspection of bag fabric material and its handling conditions.


Purging pressure for purging the air bags is set at 7 kg/cm2.

The rpm of Air Lock Rotary valve is maintained between 5-20

Air flow to the atmosphere is done by blower which is set at 5.7 kg/cm2 and is being powered by

motor of 20 hp

Suction pressure for sucking the air containing carbon particles from the process is set at 0.5

kg/cm2

DESIGN PARAMETERS:

Total bags used were 72 in a matrix of 12*6 with size of bag as 3000 mm length and diameter of

149 mm.

High Level sensor is provided near hopper to indicate the load variation near hopper walls and

inside the hopper.

Automatic Pressure switch is there if the purging pressure falls below 3 kg/cm2, which cut offs

the circuit and stops the bag filter operation.

APPLICATION:

Bag filter is used to avoid flow of minute carbon black particles to atmosphere, from the

incoming air from the factory’s process.

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Chemical Dosing

Boiler water chemical dosing:

The boiler water dosing is done by testing the water at blowdown

The blowdown is checked per shift

The storage tank is of 8 KL. The dosing is done as 500 l/hr.

The chemicals used are:-

Maxtreat : 3100 - oxygen scavenger

3004 - pH booster

3221 - Antiscalant

After chemical dosing the water parameters at blowdown are as follows:-

pH - 10.5 - 12.5

p- Alkalinity - 300 ppm

m- Alkalinity - 700 ppm

chloride - App. 1000 ppm

TDS - <3500 ppm

Phosphate - 15-30

Sulphite - 40-50

Cooling water chemical dosing :

The cooling water chemical dosing is done based on the bio-organic growth

The chemicals used are:-

Maxtreat:611 biocycle - dosing is done weakly (40-50 ppm)

608 biocycle - Alternate day ( 40-50 ppm)

25210 antiscalant - daily dosing (40 - 60 ppm)

After dosing of chemicals the water parameters are :-

Hard or soft - nil <200 ppm

TDS - <2000 ppm

pH - 8.5

Phosphate - 5 ppm

Chloride - <50 ppm

p- Alkalinity , m-Alkalinity - 200-250 ppm

Documents

Training Report