1 INTRODUCTION TO COMPANY Leader in Manufacturing Process Steam & Power Generation Equipment Cheema Boilers Limited, popularly known

as CBL is a trusted name in the field of Indian Boiler Industry. It is known for its commitment, competence and compliance. CBL was established in the year 1999 to provide complete solution to steam generation needs. The company's origin in the boiler industry goes back to founding of it's sister concern Cheema Engineering Services (P) Limited engaged in manufacturing of Steam Boilers, Pollution Control equipment, Fluidized Bed Conversion and energy saving devices since 1991. It's visionary Mr. Harjinder Singh Cheema, currently CBL Managing Director along with his three brothers, now CBL Directors started this company with Boiler services and very soon CBL moved to manufacturing of full-fledged Process Boilers. Presently company is manufacturing all types of boiler to meet the requirement of process and power industry. CBL has got its own manufacturing facilities at Kurali 25 kms from Chandigarh, near Ropar and Corporate Office at Mohali, (Chandigarh). In last 8 years of operation, the company has established its name in Boiler Industry with internal core competency in Engineering, Manufacturing and Project commissioning. A dedicated and multi-skilled manpower has taken this company to a new height of business excellence. Its operation facilities, technology, manpower competency and customer base are expanding every year, which has resulted in doubling the company's turnover year over year. Company has already drawn an ambitious short and long term plan to meet growing demand of energy in India and abroad. CBL is already exporting to Asian and European countries. CBL has sizeable manufacturing facilities that produce 'A' grade quality goods. The Company has extensive experience in the manufacturing of boilers and boiler house auxiliaries. Producing through three plants, located one at Nalagarh (HP) and two plants at Kurali (near Chandigarh), CBL supplies the nation the cost-effective power solutions. The Nalagarh plant produces process boilers while the Kurali Unit-I produce power boiler parts like boiler drums, headers and larger process boilers. The Kurali Unit-II manufactures tubular products for power boilers and boiler auxiliaries like ESP, Fans and Air Pre-Heaters etc. The CBL plants are well equipped with destructive and non-destructive testing, and work with proven quality management systems like ISO 9001 2000 and ASME code stamp.
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1.1 CBL CERTIFICATION: ISO 9001, ISO 14001, OHSAS 18001. It implies Passport for International Market. Professional Image. Increased customer confidence. Improved quality cut in costs owing to rejection control Clarity of responsibility and authority. Better and Defined system. Consistent Quality. Improved Cycle Time.

1.2 ASME Certification Cheema Boilers has received ASME (American Society of Mechanical Engineers) Certification for "U" & "S" stamps. It implies Complete traceability of raw materials All design meets the A.S.M.E. code All pressure vessel tests is witnessed by an A.S.M.E. third party Unsurpassed quality assurance Quality Manager and an Authorized Inspector actually travel with each project through all phases of the work Final inspection where units are hydrostatically tested at 1.5 times the working pressure

Total area: 122000 sq. mtrs

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Covered area: 16000 sq. mtrs. Open metalled space: 12000 sq. mtrs. For storage 1.3 ANNUAL TURNOVER: Annual turnover of Cheema boilers limited is 250 crore. 1.4 CLIENTS: SPONGE IRON CUSTOMER

PLACE

Shyam SEL Limited Crest Steel & Power Ltd. Asian Color Coated Ispat Ltd Jai Balaji Jyoti Steels Limited Umang Oils Pvt Limited Haldia Steels Limited

Kolkata Bhillai Bawal Rourkela Varanasi Durgapur

FOOD CUSTOMER

PLACE

Riddhi Siddhi Gluco Biols Ltd Agro Dutch Inds. Ltd. Ruchi Soya Industries Ltd Sukhjit Strach & Chemicals Ltd. Fast Foods (Nepal) Pvt Ltd Induss Food Prod. & Equip Ltd MC.Roller Flour Mills (P) Ltd. Shivambu International Bronze Powder Ltd Ram Niwas Flour Mills Pvt.Ltd. Faizah Coconut Oil Ltd Gurudev Foods Shivalik Foods HSF Foods Limited Dollon Food Products (P) Ltd Harish Chandra Food Products M&M Coca Products Ltd.
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Rudarpur Lalru Nagpur Phagwara Kathmandu Pakistan Shahjhanpur Una (HP) Faridabad Delhi Dhaka (Bangladesh) Moga Kurali Sirsa Kolkata Farukhabad Baddi

Richerster Foods R. S. Foods Vadilal Industries Varshney Bandhu Foods Pvt Ltd VRS Foods Limited Goyal Proteins Limited DAIRY CUSTOMER

S.Africa Rajnandgaon (CG) Ahmedabad Delhi Bulandshahar Kota

PLACE

Milkfood Limited Parul Foods Ltd Shree Warna Dudh Karnal Milkfoods Limited Haryana Milk Foods Limited Sterling Agro Industries Limited S.N. Milk Products Pvt Limited Rana Milk Foods Pvt. Limited Prabhu Jee Dairy Food Processor

Bahadurgarh Kurkshetra Kolhapur Karnal Pehowa Nawab Ganj Agra Samrala Jaipur

Tirumala Milk Products DSPI Milk foods Ltd Punjab Milk Food Co Pasupati Dairies Pvt.Ltd. Ganga Dairy Products (P) Ltd. Delight Dairy Limited CHEMICALS CUSTOMER

Nellore (AP) Shahbad Amritsar Saharanpur Delhi Indore

PLACE

Solaris Bio-Chemicals Ltd (BILT) India Organics Limited (Trident) SRF Limited Citurgia (Bombay Dying unit) Bhatinda Chemicals Ltd Kashyap Organics (P) Ltd Gujarat Ambuja Exports Ltd. Sukhjit Strach & Chemicals Ltd. HPL Chemicals N.B.Welcome Chemicals (P) Ltd.
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Baroda Barnala Bhiwadi Rishikesh Jalalabad Ghaziabad Gujarat Phagwara Faridabad Faridabad

Gandhar Petrochemicals Ltd. Saurav Chemicals Ltd Bee Chems Industries Leena Organics (P) Limited Deccan Chromates Ltd Reliance Chemotex Industries Chemical Resouces

Faridabad Derabassi Kanpur Ghaziabad Hyderabad Udaipur Panchkula

2. PRODUCT DETAIL OF CHEEMA BOILERS: Various types of boilers manufactured at cheema boilers limited are 2.1 AFBC Boilers: Atmospheric fluidized bed combustion boiler 2.1.1 PRODUCT FEATURES

Bi-drum / Single Drum, Water Tube Natural circulation design Provision for Hot air for better combustion Suitable for saturated and super heater steam for Co-generation and Captive power plants Multifuel firing possible Underbed / Overbed fuel feeding options available High residence time for proper combustion design Optimum fluidizing velocity Low excess air
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Single pass and two pass boiler bank

2.1.2 OPERATING RANGE Capacity: upto 175 TPH Pressure: upto 105 kg/cm2 Temperature: upto 525 C Firing fuels: Rice husk, Coal, lignite etc.

Figure 2.1 AFBC BOILER 2.2 INPAC BOILER: Inpac is a packaged, three-pass smoke tube, with fully wet back boiler. Inpac comes in two series for Wood & Biomass and other for Coal. It can also be customized to a completely skid mounted unit on customer demand. 2.2.1 PRODUCT FEATURES Three-pass smoke tube with fully wet back boiler. Multi-fuel option Wood/Briqutte/Baggase/Coal. High efficiency of about 70% to 74%. High dryness fraction steam increases usable heat.
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Large water holding capacity. Plain Single furnaces for boiler upto 4 TPH capacity.

2.2.2 OPERATING RANGE Capacities: In the range of 1 TPH to 5 TPH Pressure: In the range of 10.54 to 17.54 Kg/cm2 (g) Temperature: Up to 75C Firing fuels: Wood, Briquettes, Baggase, Coal

Figure 2.2 INPAC BOLIER 2.3 OIL PAC BOILER: 2.3.1 PRODUCT FEATURES Standard design integral furnace boiler suitable for burning heavy and light fuel, oils including gas Multipass fire tube design Three pass, fully automatic, wetback design Designed to give overall efficiency of 88% on NCV
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Dryness fractions to the order of 0.985 achievable

2.3.2 OPERATING RANGE Capacities: In the range of 1 TPH to 20 TPH Pressure: In the range of 10.54 to 17.54 Kg/cm2 (g) Temperature: Up to 75C Firing fuels: Oil, gas

Figure 2.3 OIL PAC

2.4 EFFY PAC BOILER: 2.4.1 PRODUCT FEATURES: Plug & Steam Unit need only water, power & Chimney. Skid mounted design not requiring any structure, Water tank, insulation, ducting, refractory etc. Compact design suitable for industries with less space. Inbuilt HRU for high efficiency.

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Cyclone included in package for controlling outlet dust concentration.

2.4.2 OPERATING RANGE Capacity: 500,1000,1500,2000 Kg/hr Pressure: Up to 17.5 Kg/cm Fuel: Coal, Wood, Agro Waste, Briquettes etc.

Figure 2.4 EFFYPAC BOILER

2.5 HYPAC BOILER: 2.5.1 PRODUCT FEATURES: Water cum smoke tube boilers Capacity upto 15 TPH Easily takes the variation of load fluctuations Burn agriculture residue and other high volume low density fuels
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Can be equipped with fluidized bed, moving and stationery grate furnace Four side water wall design available

2.5.2 OPERATING RANGE: Capacity: upto 15 tph Pressure: upto 25 kg/cm2 Fuel: rice husk, coal, pet coke, lignite etc.

Figure 2.5 HYPAC BOILER 3. INTRODUCTION OF BOILERS A steam generator or boiler is, usually, a closed vessel made of steel. Its function is to transfer the heat produced by the combustion of fuel to water, the ultimately to generate the steam. The steam produced may be supplied. 1. To an external combustion engine 2. At low pressure for industrial process work in cotton mills, sugar factories, breweries etc. 3. For producing hot water, which can be used for heating installation at much lower pressure
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A boiler is an enclosed vessel that provides a means for combustion heat to be transferred to water until it becomes heated water or steam. The hot water or steam under pressure is then usable for transferring the heat to a process. Water is a useful and inexpensive medium for transferring heat to a process. When water at atmospheric pressure is boiled into steam its volume increases about 1,600 times, producing a force that is almost as explosive as gunpowder. This causes the boiler to be an equipment that must be treated with utmost care. The boiler system comprises of: a feed water system, steam system and fuel system. The feed water system provides water to the boiler and regulates it automatically to meet the steam demand. Various valves provide access for maintenance and repair. The steam system collects and controls the steam produced in the boiler. Steam is directed through a piping system to the point of use. Throughout the system, steam pressure is regulated using valves and checked with steam pressure gauges. The fuel system includes all equipment used to provide fuel to generate the necessary heat. The equipment required in the fuel system depends on the type of fuel used in the system. The water supplied to the boiler that is converted into steam is called feed water. The two sources of feed water are: (1) Condensate or condensed steam returned from the processes and (2) Makeup water (treated raw water) which must come from outside the boiler room and plant processes. For higher boiler efficiencies, an economizer preheats the feed water using the waste heat in the flue gas.

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Figure 3.1 SCHEMATIC DIAGRAM OF BOILER ROOM 3.1 TYPE OF BOILERS This section describes the various types of boilers: Fire tube boiler, Water tube boiler, Packaged boiler, Fluidized bed combustion boiler, Stoker fired boiler, Pulverized fuel boiler, Waste heat boiler and Thermic fluid heater. 3.1.1 Fire Tube Boiler In a fire tube boiler, hot gases pass through the tubes and boiler feed water in the shell side is converted into steam. Fire tube boilers are 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 12,000 kg/hour and pressures 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 of packaged construction (i.e. manufacturer erected) for all fuels.
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Figure 3.2 SECTIONAL VIEW OF A FIRE TUBE BOILER 3.1.2 Water Tube Boiler In a water tube boiler, boiler feed water flows through the tubes and enters 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 designs are within the capacity range 4,500 120,000 kg/hour of steam , at very high pressures. Many water tube boilers 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 draft provisions help to improve combustion efficiency. Less tolerance for water quality calls for water treatment plant. Higher thermal efficiency levels are possible Most modern water boiler tube designs are within the capacity range 4,500 120,000 kg/hour of steam, at very high pressures. Many water tube boilers 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.

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Figure 3.3 SIMPLE DIAGRAM OF WATER TUBE BOILER 3.1.3 Packaged Boiler The packaged boiler is so called because it comes as a complete package. Once delivered to a site, it requires only the steam, water pipe work, fuel supply and electrical connections to be made to become operational. Package boilers are generally of a shell type with a fire tube design so as to achieve high heat transfer rates by both radiation and convection. The features of packaged boilers are: Small combustion space and high heat release rate resulting in faster evaporation. Large number of small diameter tubes leading to good convective heat transfer. Forced or induced draft systems resulting in good combustion efficiency. Number of passes resulting in better overall heat transfer. Higher thermal efficiency levels compared with other boilers.

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These boilers are classified based on the number of passes - the number of times the hot combustion gases pass through the boiler. The combustion chamber is taken, as the first pass after which there may be one, two or three sets of fire-tubes. The most common boiler of this class is a three-pass unit with two sets of fire-tubes and with the exhaust gases exiting through the rear of the boiler.

Figure 3.4 A TYPICAL 3 PASS, OIL FIRED PACKAGED BOILER 3.1.4 Fluidized Bed Combustion (FBC) Boiler Fluidized bed combustion (FBC) has emerged as a viable alternative and has significant advantages over a conventional firing system and offers multiple benefits compact boiler design, fuel flexibility, higher combustion efficiency and reduced emission of noxious pollutants such as SOx and NOx. The fuels burnt in these boilers include coal, washery rejects, rice husk, bagasse & other agricultural wastes. The fluidized bed boilers have a wide capacity range- 0.5 T/hr to over 100 T/hr. When an evenly distributed air or gas is passed upward through a finely divided bed of solid particles such as sand supported on a fine mesh, the particles are undisturbed at low velocity. As air velocity is gradually increased, a stage is reached when the individual
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particles are suspended in the air stream the bed is called fluidized. With further increase in air velocity, there is bubble formation, vigorous turbulence, rapid mixing and formation of dense defined bed surface. The bed of solid particles exhibits the properties of a boiling liquid and assumes the appearance of a fluid bubbling fluidized bed. If sand particles in a fluidized state are heated to the ignition temperatures of coal, and coal is injected continuously into the bed, the coal will burn rapidly and the bed attains a uniform temperature. The fluidized bed combustion (FBC) takes place at about 840OC to 950OC. Since this temperature is much below the ash fusion temperature, melting of ash and associated problems are avoided. The lower combustion temperature is achieved because of high coefficient of heat transfer due to rapid mixing in the fluidized bed and effective extraction of heat from the bed through in-bed heat transfer tubes and walls of the bed. The gas velocity is maintained between minimum fluidization velocity and particle entrainment velocity. This ensures stable operation of the bed and avoids particle entrainment in the gas stream. 3.1.4.1 Atmospheric Fluidized Bed Combustion (AFBC) Boiler Most operational boiler of this type is of the Atmospheric Fluidized Bed Combustion. (AFBC). This involves little more than adding a fluidized bed combustor to a conventional shell boiler. Such systems have similarly being installed in conjunction with conventional water tube boiler. Coal is crushed to a size of 1 10 mm depending on the rank of coal, type of fuel fed to the combustion chamber. The atmospheric air, which acts as both the fluidization and combustion air, is delivered at a pressure, after being preheated by the exhaust fuel gases. The in-bed tubes carrying water generally act as the evaporator. The gaseous products of combustion pass over the super heater sections of the boiler flowing past the economizer, the dust collectors and the air pre-heater before being exhausted to atmosphere. 3.1.4.2 Pressurized Fluidized Bed Combustion (PFBC) Boiler In Pressurized Fluidized Bed Combustion (PFBC) type, a compressor supplies the Forced Draft (FD) air and the combustor is a pressure vessel. The heat release rate in the bed is proportional to the bed pressure and hence a deep bed is used to extract large amounts of heat. This will improve the combustion efficiency and sulphur dioxide absorption in the bed. The steam is generated in the two tube bundles, one in the bed and one above it. Hot flue gases drive a power generating
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gas turbine. The PFBC system can be used for cogeneration (steam and electricity) or combined cycle power generation. The combined cycle operation (gas turbine & steam turbine) improves the overall conversion efficiency by 5 to 8 percent. 3.1.4.3 Atmospheric Circulating Fluidized Bed Combustion Boilers (CFBC) In a circulating system the bed parameters are maintained to promote solids elutriation from the bed. They are lifted in a relatively dilute phase in a solids riser, and a down-comer with a cyclone provides a return path for the solids. There are no steam generation tubes immersed in the bed. Generation and super heating of steam takes place in the convection section, water walls, at the exit of the riser. CFBC boilers are generally more economical than AFBC boilers for industrial application requiring more than 75 100 T/hr of steam. For large units, the taller furnace characteristics of CFBC boilers offers better space utilization, greater fuel particle and sorbent residence time for efficient combustion and SO2 capture, and easier application of staged combustion techniques for NOx control than AFBC steam generators.

Figure 3.5 CFBC BOILER 3.1.5 Stoker Fired Boilers Stokers are classified according to the method of feeding fuel to the furnace and by the type of grate. The main classifications are spreader stoker and chain-gate or traveling-gate stoker.
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3.1.5.1 Spreader stokers Spreader stokers utilize a combination of suspension burning and grate burning. The coal is continually fed into the furnace above a burning bed of coal. The coal fines are burned in suspension; the larger particles fall to the grate, where they are burned in a thin, fastburning coal bed. This method of firing provides good flexibility to meet load fluctuations, since ignition is almost instantaneous when the firing rate is increased. Due to this, the spreader stoker is favored over other types of stokers in many industrial applications.

Figure 3.6 SPREADER STOKER BOILER

3.1.5.2 Chain-grate or traveling-grate stoker Coal is fed onto one end of a moving steel grate. As the grate moves along the length of the furnace, the coal burns before dropping off at the end as ash. Some degree of skill is required, particularly when setting up the grate, air dampers and baffles, to ensure clean combustion
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leaving the minimum of unburnt carbon in the ash. The coal-feed hopper runs along the entire coal-feed end of the furnace. A coal gate is used to control the rate at which coal is fed into the furnace by controlling the thickness of the fuel bed. Coal must be uniform in size as large lumps will not burn out completely by the time they reach the end of the grate.

Figure 3.7 VIEW OF TRAVELING GRATE BOILER 3.1.6 Pulverized Fuel Boiler Most coal-fired power station boilers use pulverized coal, and many of the larger industrial water-tube boilers also use this pulverized fuel. This technology is well developed, and there are thousands of units around the world, accounting for well over 90 percent of coal-fired capacity. The coal is ground (pulverized) to a fine powder, so that less than 2 percent is +300 micrometer (m) and 70-75 percent is below 75 microns, for a bituminous coal. It should be noted that too fine a powder is wasteful of grinding mill power. On the other hand, too coarse a powder does not burn completely in the combustion chamber and results in higher unburnt losses. The pulverized coal is blown with part of the combustion air into the boiler plant through a series of burner nozzles.
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Secondary and tertiary air may also be added. Combustion takes place at temperatures from 1300-1700 C, depending largely on coal grade. Particle residence time in the boiler is typically 2 to 5 seconds, and the particles must be small enough for complete combustion to have taken place during this time. This system has many advantages such as ability to fire varying quality of coal, quick responses to changes in load, use of high pre-heat air temperatures etc. One of the most popular systems for firing pulverized coal is the tangential firing using four burners corner to corner to create a fireball at the center of the furnace.

Figure 3.8 TANGENTIAL FIRING FOR PULVERIZED 3.1.7 Waste Heat Boiler Wherever the waste heat is available at medium or high temperatures, a waste heat boiler can be installed economically. Wherever the steam demand is more than the steam generated during waste heat, auxiliary fuel burners are also used. If there is no direct use of steam, the steam may

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be let down in a steam turbinegenerator set and power produced from it. It is widely used in the heat recovery from exhaust gases from gas turbines and diesel engines.

Figure 3.9 A SIMPLE SCHEMATIC OF WASTE HEAT BOILER

4 VARIOUS PARTS OF BOILERS MANUFACTURED AT CHEEMA BOILERS: 1. 2. 3. Economizer Super heater Air Preheter
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4. 5. 6. 7.

Deaerator Electrostatic precipitator Cyclone Fans and blowers

4.1 ECONOMIZER An economizer is a device used to heat feed water by utilizing the heat in the exhaust flue gases before leaving through the chimney. Economizer improves the economy of the steam boiler.

Figure 4.1 SCHEMATIC DIAGRAM OF LOCATION OF ECONOMISER Most of the sensible heat is absorbed in the Economiser. These are a set of coils made from steel tubes located in the tail end of a boiler. The hot gases leaving the boiler furnace heat the water in the coils. The water temperature is slightly less than the saturation temperature. From the 24economizer the water is fed to the drum.

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Figure 4.2 ECONOMIZER COILS 4.2 SUPER HEATER A super heater is a device found in steam boilers that is used to convert wet, saturated steam into dry steam. Super heaters are a very beneficial part of the steam cycle, because dry steam contains more thermal energy and increases the overall efficiency of the cycle

Figure 4.3 LOCATION OF SUPER HEATER Types of super Heater 4.2.1 Radiant super heaters 4.2.2 Convection super heaters 4.2.1 Radiant super heaters Radiant super heaters are located directly within the combustion chamber of the boiler itself. This arrangement allows for the burner from the boiler to heat both the boiler tubing and the super heater tubes, making radiant super heaters highly effective devices. These are most commonly found in steam power plants 4.2.2 Convection super heaters Convection super heaters are most commonly found on locomotives. Much like a convection oven, this type of super heater utilizes the hot gases from the burner to reheat the steam. A
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convection super heater can be extremely efficient, because most of the thermal energy is given only to the boiler tubing, and what would normally be exhaust instead heats the super heater tubes. These are also found in power plants, but they were mostly implemented in steam locomotives. 4.3 AIR PREHEATER An air pre heater (APH) is a general term to describe any device designed to heat air before another process (for example, combustion in a boiler) with the primary objective of increasing the thermal efficiency of the process. They may be used alone or to replace a recuperative heat system or to replace a steam coil. The purpose of the air preheater is to recover the heat from the boiler flue gas which increases the thermal efficiency of the boiler by reducing the useful heat lost in the flue gas. As a consequence, the flue gases are also conveyed to the flue gas stack (or chimney) at a lower temperature, allowing simplified design of the conveyance system and the flue gas stack. It also allows control over the temperature of gases leaving the stack

4.3.1 Tubular type 4.3.1.1 Construction features Tubular preheaters consist of straight tube bundles which pass through the outlet ducting of the boiler and open at each end outside of the ducting. Inside the ducting, the hot furnace gases pass around the preheater tubes, transferring heat from the exhaust gas to the air inside the preheater. Ambient air is forced by a fan through ducting at one end of the preheater tubes and at other end the heated air from inside of the tubes emerges into another set of ducting, which carries it to the boiler furnace for combustion. 4.3.1.2Problems The tubular preheater ductings for cold and hot air require more space and structural supports than a rotating preheater design. Further, due to dust-laden abrasive flue gases, the tubes outside the ducting wear out faster on the side facing the gas current. Many advances have been made to eliminate this problem such as the use of ceramic and hardened steel.
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Many new circulating fluidized bed (CFB) and bubbling fluidized bed (BFB) steam generators are currently incorporating tubular air heaters offering an advantage with regards to the moving parts of a rotary type. 4.3.2 Regenerative air preheaters There are two types of regenerative air preheaters: the rotating-plate regenerative air preheaters (RAPH) and the stationary-plate regenerative air preheaters 4.3.2.1 Rotating-plate regenerative air preheater The rotating-plate design (RAPH)[2] consists of a central rotating-plate element installed within a casing that is divided into two ( bi-sector type), three (tri-sector type) or four (quad-sector type) sectors containing seals around the element. The seals allow the element to rotate through all the sectors, but keep gas leakage between sectors to a minimum while providing separate gas air and flue gas paths through each sector. Tri-sector types are the most common in modern power generation facilities In the tri-sector design, the largest sector (usually spanning about half the cross-section of the casing) is connected to the boiler hot gas outlet. The hot exhaust gas flows over the central element, transferring some of its heat to the element, and is then ducted away for further treatment in dust collectors and other equipment before being expelled from the flue gas stack. The second, smaller sector is fed with ambient air by a fan, which passes over the heated element as it rotates into the sector, and is heated before being carried to the boiler furnace for combustion. The third sector is the smallest one and it heats air which is routed into the pulverizes and used to carry the coal-air mixture to coal boiler burners. Thus, the total air heated in the RAPH provides: heating air to remove the moisture from the pulverised coal dust, carrier air for transporting the pulverized coal to the boiler burners and the primary air for combustion. The rotor itself is the medium of heat transfer in this system, and is usually composed of some form of steel and/or ceramic structure. It rotates quite slowly (around 3-5 RPM) to allow optimum heat transfer first from the hot exhaust gases to the element, then as it rotates, from the element to the cooler air in the other sectors. 4.3.2.1.1 Construction features

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In this design the whole air preheater casing is supported on the boiler supporting structure itself with necessary expansion joints in the ducting. The vertical rotor is supported on thrust bearings at the lower end and has an oil bath lubrication, cooled by water circulating in coils inside the oil bath. This arrangement is for cooling the lower end of the shaft, as this end of the vertical rotor is on the hot end of the ducting. The top end of the rotor has a simple roller bearing to hold the shaft in a vertical position. The rotor is built up on the vertical shaft with radial supports and cages for holding the baskets in position. Radial and circumferential seal plates are also provided to avoid leakages of gases or air between the sectors or between the duct and the casing while in rotation. For on line cleaning of the deposits from the baskets steam jets are provided such that the blown out dust and ash are collected at the bottom ash hopper of the air preheater. This dust hopper is connected for emptying along with the main dust hoppers of the dust collectors. The rotor is turned by an air driven motor and gearing, and is required to be started before starting the boiler and also to be kept in rotation for some time after the boiler is stopped, to avoid uneven expansion and contraction resulting in warping or cracking of the rotor. The station air is generally totally dry (dry air is required for the instrumentation), so the air used to drive the rotor is injected with oil to lubricate the air motor. Safety protected inspection windows are provided for viewing the preheater's internal operation under all operating conditions. The baskets are in the sector housings provided on the rotor and are renewable. The life of the baskets depend on the ash abrasiveness and corrosiveness of the boiler outlet gases.

4.3.2.2 Stationary-plate regenerative air preheater The heating plate elements in this type of regenerative air preheater are also installed in a casing, but the heating plate elements are stationary rather than rotating. Instead the air ducts in the preheater are rotated so as to alternatively expose sections of the heating plate elements to the upflowing cool air.

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4.4 DEAERATOR Oxygen is the main cause of corrosion in boilers. If carbon dioxide is also present then the pH will be low, the water will tend to be acidic, and the rate of corrosion will be increased. Typically the corrosion is of the pitting type where, although the metal loss may not be great, deep penetration and perforation can occur in a short period. The essential requirements to reduce corrosion are to maintain the feedwater at a pH of not less than 8.5 to 9, the lowest level at which carbon dioxide is absent, and to remove all traces of oxygen. The return of condensate from the plant will have a significant impact on boiler feedwater treatment - condensate is hot and already chemically treated, consequently as more condensate is returned, less feedwater treatment is required. Water exposed to air can become saturated with oxygen, and the concentration will vary with temperature The first step in feedwater treatment is to heat the water to drive off the oxygen. Typically a boiler feedtank should be operated at 85C to 90C. This leaves an oxygen content of around 2 mg / litre (ppm). Operation at higher temperatures than this at atmospheric pressure can be difficult due to the close proximity of saturation temperature and the probability of cavitation in the feedpump, unless the feedtank is installed at a very high level above the boiler feedpump. If a liquid is at its saturation temperature, the solubility of a gas in it is zero, although the liquid must be strongly agitated or boiled to ensure it is completely deaerated. This is achieved in the head section of a deaerator by breaking the water into as many small drops as possible, and surrounding these drops with an atmosphere of steam. This gives a high surface area to mass ratio and allows rapid heat transfer from the steam to the water, which quickly attains steam saturation. This releases the dissolved gases, which are then carried with the excess steam to be vented to atmosphere. (This mixture of gases and steam is at a lower than saturation temperature and the vent will operate thermostatically). The deaerated water then falls to the storage section of the vessel. A blanket of steam is maintained above the stored water to ensure that gases are not reabsorbed.

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4.5 ELECTROSTATIC PRECIPITATOR Electrostatic precipitation removes particles from the exhaust gas stream of an industrial process. Often the process involves combustion, but it can be any industrial process that would otherwise emit particles to the atmosphere. In many industrial plants, particulate matter created in the industrial process is carried as dust in the hot exhaust gases. These dust-laden gases pass through an electrostatic precipitator that collects most of the dust. Cleaned gas then passes out of the precipitator and through a stack to the atmosphere. Precipitators typically collect 99.9% or more of the dust from the gas stream. Precipitators function by electrostatically charging the dust particles in the gas stream. The charged particles are then attracted to and deposited on plates or other collection devices. When enough dust has accumulated, the collectors are shaken to dislodge the dust, causing it to fall with the force of gravity to hoppers below. The dust is then removed by a conveyor system for disposal or recycling. Depending upon dust characteristics and the gas volume to be treated, there are many different sizes, types and designs of electrostatic precipitators. Very large power plants may actually have multiple precipitators for each unit.

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Figure 4.4 ELECTROSTATIC PRECIPITATOR 4.6 CYCLONES In C-Cyclones, dust laden gas enters the upper cylinder tangentially and moves down the conical section in a spiral path. The centrifugal force thus developed makes the dust particles move radially outward. They then strike the wall and drop out of the gas stream into the hopper. Clean gas flows out through central the exit tube. Specific application parameters like the dust load, gas velocity, dust characteristics, particle size distribution and the overall system decide the optimum cyclone geometry and the internals. Factors such as length of the outlet tube inside the cyclone, length of the cylindrical portion, inlet and outlet areas, deflectors, length of conical portion etc. play an important role in determining
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the performance of the cyclone. Proper consideration of all these ensures high collection efficiency and very low emission levels, which is not possible in conventional cyclones. For boiler applications it is possible to achieve emissions as low as 300 - 350 mg/Nm for agrowaste (husk) firing, which makes the C-Cyclones suitable as a final dust collector. This equipment from the was instrumental in providing an economical answer to the problem of handling fly-ash in husk fired fluidised bed boilers in the Punjab-Haryana belt, when norms of the above order were first introduced. 4.6.1 TYPES OF C-CYCLONES With increasing gas volumes, it is difficult to obtain the desired dust collection efficiency in a single cyclone construction. We can configure high efficiency cyclones into various versions twin (two cyclones), quad (four cyclones) and double quad (eight cyclones) with the help of computer aided simulations to achieve higher efficiencies. For special applications like the fertiliser industry, individual collection hoppers with each cyclone in twin/quad version are provided instead of common hoppers. This prevents dust reentrainment and facilitates free dislodging of dust from the hoppers. Dust discharge is affected through a motorized leak proof double flap dump valve or a rotary air lock valve.

Figure 4.5 CYCLONE 4.7. FANS AND BLOWERS 4.7.1 Introduction

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Fans and blowers provide air for ventilation and industrial process requirements. Fans generate a pressure to move air (or gases) against a resistance caused by ducts, dampers, or other components in a fan system. The fan rotor receives energy from a rotating shaft and transmits it to the air. 4.7.2 Difference between Fans, Blowers and Compressors Fans, blowers and compressors are differentiated by the method used to move the air, and by the system pressure they must operate against. As per American Society of Mechanical Engineers (ASME) the specific ratio the ratio of the discharge pressure over the suction pressure is used for defining the fans, blowers and compressors 4.7.3 Fan Types Fan and blower selection depends on the volume flow rate, pressure, type of material handled, space limitations, and efficiency. Fan efficiencies differ from design to design and also by types. Fans fall into two general categories: centrifugal flow and axial flow. In centrifugal flow, airflow changes direction twice - once when entering and second when leaving (forward curved, backward curved or inclined, radial) (see Figure 14). In axial flow, air enters and leaves the fan with no change in direction (propeller, tube axial, vane axial)

Figure 4.5 CENTRIFUGAL FAN

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Figure 4.6 AXIAL FAN 4.7.3.1 Centrifugal Fan: Types The major types of centrifugal fan are: radial forward curved and backward curved Radial fans are industrial workhorses because of their high static pressures (upto 1400 mm WC) and ability to handle heavily contaminated airstreams. Because of their simple design, radial fans are well suited for high temperatures and medium blade tip speeds. Forward-curved fans are used in clean environments and operate at lower temperatures. They are well suited for low tip speed and high-airflow work - they are best suited for moving large volumes of air against relatively low pressures. Backward-inclined fans are more efficient than forward-curved fans. Backward-inclined fans reach their peak power consumption and then power demand drops off well within their useable airflow range. Backward-inclined fans are known as "non-overloading" because changes in static pressure do not overload the motor.
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Figure 4.7 Types of Centrifugal Fans Forward Curved, Backward Curved 4.7.3.2 Axial Flow Fan: Types The major types of axial flow fans are: tube axial, vane axial and propeller Tube axial fans have a wheel inside a cylindrical housing, with close clearance between blade and housing to improve airflow efficiency. The wheel turn faster than propeller fans, enabling operation under high-pressures 250 400 mm WC. The efficiency is up to 65%. Vane axial fans are similar to tubeaxials, but with addition of guide vanes that improve efficiency by directing and straightening the flow. As a result, they have a higher static pressure
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with less dependence on the duct static pressure. Such fans are used generally for pressures upto 500 mmWC. Vaneaxials are typically the most energy-efficient fans available and should be used whenever possible. Propeller fans usually run at low speeds and moderate temperatures. They experience a large change in airflow with small changes in static pressure. They handle large volumes of air at low pressure or free delivery. Propeller fans are often used indoors as exhaust fans. Outdoor applications include air-cooled condensers and cooling towers. Efficiency is low approximately 50% or less.

5 TRAINING DEPARTMENT OVERVIEW Training department: Process Boilers Division Marketing and Sales. 5.1 INTRODUCTION TO PROCESS BOILERS.
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Operating range: Capacity: upto 15 tph Design pressure: upto 21 kg/cm2 Steam temp: upto Saturated Fuel: Rice husk, coal, lignite, washery rejects, char, Indian/imported coal, pet coke, pith, wood etc. Process boilers are designed to meet the process steam requirement of a wide spectrum of industries like rice, solvent, food, textiles, distilleries, paper, rubber, pharmaceutical, steel etc. CBL process boilers are highly efficient & more reliable and incorporate the best features that a process industry needs. Be it turn down capability, multiple compartment, proper fuel distribution, automatic boiler controls, usage of wide range of fuels etc. CBL has always been a trend setter since 1999. Customers can be rest assured, since these boilers are being designed with a rich experience of more than decades and vast database of more than 1000 boilers already in operation. The varieties of configuration include combined fire tube & water tube design (hybrid boilers), water tube boilers, package type internal combustion & external combustion boilers. CBL can offer with the state of the art instrumentation & control system to simplify the boiler operation, efficient & reliable pollution control system in addition to safety & electrical interlocks which will give an entrepreneur the peace of mind.

5.2 TYPE OF PROCESS BOILERS. The different types of process boilers that CBL offers are as follows 1. Effypac boiler 2. Energypac boiler 3. Inpac boiler 4. Oilpac boiler 5. Hypac boiler
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6. Hypac smart

Figure 5.1 TYPE OF PROCESS BOILERS The above classification is done on different criterias. In which Capacity, fuel options, furnace type and structure being the main criterias. The process boilers which cover capacity upto 14 tph and presssure till 17.5 kg/cm2 are the ideal choice for all the smal and mid sized industries with steam requirement like rice mills, breweries, food and plywood industries etc. The special feautered skid mounted boilers are recently introduced by CBL which are direct plug and use boilers. Products like hypac smart and effypac are are skid mounted, hence does not needs any foundations at the site for erection. These boilers minimize erection efforts and reduce costs substantially. The oilpac boiler offers the option of using an oil as an fuel. It may be HSD (high speed diesel) or any other efficient liquid fuel and inpac being an boiler with a integral furnace is a three pass boiler, hence a less space consuming boiler for special cases. Hypac gives an multifuel option, higher efficiency and an FBC (fluidized bed combustion) to keep the maintenance cost low along with the operational cost.
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5.3 CBL MARKET BREAK-UP. CBL's impetus towards growth is a result of its team being unfettered of limitations. With a strong belief in surmounting limits, CBL was incorporated in the year 1999. Since then it has extended its reach and client base to across the nation. It has been because of the synergy among its various departments that work dedicatedly in the best interest of its clients. The market break up of the company according to its different product and services is shown in fig 5.2.

Figure 5.2 CBL MARKET BREAK-UP LP Boilers HP Boiler Others Upgradation Low pressure process boilers High pressure Co-generation and IPPs WHRBs for Sponge iron plants, slop fired boilers, ESPs and Hot Air Generators Retrofitting, capacity enhancement, etc.

The diagram shows the % wise share of the high pressure, low pressure, Upgradation and other services. Here low pressure (LP) boilers are the process boilers and they take up about 38% of the total whereas high pressure boilers have the maximum of 46% and Upgradation and other services take up 3% and 13% respectively.

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Hence, due to the large market scope of the process boilers and their unprecedented functioning. The process boilers of CBL make have the top most priority in the business. Now the process boilers are again sub divided on the basis of the different type of industries in which they are used and installed. The main of the industries are rice, sugar, dairy & food and solvent etc. The fig. 5.3 shows the mentioned division.

Fig 5.3 TYPES OF PROCESS BOILER INDUSTRIES 5.4 MARKETING AND SALES The Marketing and Sales department delivers customized material and offers expert advices in the best interest of the client to give the competitive edge. Fully understanding the clients' needs it offers the right product. Since CBL's business is conducted with complete transparency, the products are offered with complete specifications and techno-commercial clarity. Team of highly skilled marketing professionals analyzes the target market and the needs of the clients, determining the corporate and product positioning and the marketing objectives and integrating these goals into serving the clients. The Proposal team understands the commercial brief and clients' requirements, taking negotiations to superior levels. Adept at drafting and making proposals the team is responsible
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for

making

the

proposal

comprehensive,

transparent

and

cost-effective.

Comprising specialists from relevant fields the team capable of providing not only what is required but add that something extra which will be of tremendous value to clients. That is superior, cost effective and performance enhancing alternatives. Process boilers marketing and sales team is responsible from the enquiry generation to the dispatch of the boiler to the client after manufacturing. The marketing engineer at CBL holds the ample technical and production knowledge along with a impeccable communication skills to communicate with the customer and meet their needs with the best technical solutions for their problem and needs. The marketing engineer is the ambassador of the company as, He is the one who lays the foundation for all the production and after sales by taking the orders and submitting technical offers to the customers. The result of the efficient marketing and sales team can be seen in the forms of the turnover of the company over the years. As shown in the fig. 5.4 below.

Fig 5.4 YEAR WISE ANNUAL TURNOVER 5.5 PROJECTS UNDERTAKEN ON TRAINING During the 6 months of on and off field training as an marketing engineer. Following tasks and projects were taken care of. Receiving and understanding customers requirement from the level 1.

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Preparation of techno-commercial offers for process boilers. Preparation of different technical data charts like fuel comparison charts and others. Techno commercial Meetings with customers for CBL. Plant visits at different industries and CBL plant with clients and for internal purposes. Active participation in many achieved offers from the starting to the execution of the order.

Checking on all the technical aspects of the received order and making sure that the correct execution of it is done.

5.5.1 Corporate Communication Corporate communication is the set of activities involved in managing and orchestrating all internal and external communications aimed at creating favorable point-of-view among stakeholders on which the company depends. It is the messages issued by a corporate organization, body, or institute to its audiences, such as employees, media, channel partners and the general public. Organizations aim to communicate the same message to all its stakeholders, to transmit coherence, credibility and ethic. Corporate Communications help organizations explain their mission, combine its many visions and values into a cohesive message to stakeholders. The concept of corporate communication could be seen as an integrative communication structure linking stakeholders to the organization. Three principal clusters of task-planning and communication form the backbone of business and the activity of business organizations. These include management communications, marketing communications, and organizational communications. Management communications are between management and its internal and external audiences. To support management communications, organizations rely heavily on specialists in marketing communications and organizational communications. Marketing communications get the bulk of the budgets in most organizations, and consist of product advertising, direct mail, personal selling, and sponsorship activities.
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Organizational communications consist of specialists in public relations, public affairs, investor relations, environmental communications, corporate advertising, and employee communications.

The responsibilities of corporate communication are: To flesh out the profile of the "company behind the brand (corporate branding) To minimize discrepancies between the company's desired identity and brand features To delegate tasks in communication To formulate and execute effective procedures to make decisions on communication matters To mobilize internal and external support for corporate objectives To coordinate with international business firms

A corporate brand is the perception of a company that unites a group of products or services for the public under a single name, a shared visual identity, and a common set of symbols. The process of corporate branding consists creating favorable associations and positive reputation with both internal and external stakeholders. The purpose of a corporate branding initiative is to generate a positive halo over the products and businesses of the company, imparting more favorable impressions of those products and businesses. In more general terms, research suggests that corporate branding is an appropriate strategy for companies to implement when:

There is significant information al symmetry between a company and its clients, that is to say customers are much less informed about a company's products than the company itself is;

Customers perceive a high degree of risk in purchasing the products or services of the company. Features of the company behind the brand would be relevant to the product or service a customer is considering purchasing.

5.5.2 Corporate Responsibility

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Corporate responsibility (often referred to as corporate social responsibility), corporate citizenship, sustainability, and even conscious capitalism are some of the terms bandied about the media and corporate marketing efforts as companies jockey to win the trust and loyalty of constituents. Corporate responsibility (CR) constitutes an organizations respect for societys interests, demonstrated by taking ownership of the effects its activities have on key constituencies including customers, employees, shareholders, communities, and the environment, in all parts of their operations. In short, CR prompts a corporation to look beyond its traditional bottom line, to the social implications of its business. The below fig.5.5 shows the flow chart of the process of corporate communication.

Fig. 5.5 CORPORATE COMMUNICATION

6 CONCLUSION

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Cheema boilers limited ensures the quality of both work and products. Being an intern here is a great opportunity to learn as much as possible with the perfect work environment provided by the company. Its beneficial for both the students and the company to work creatively together. Interns are given full opportunity to participate in the problems and are always welcome to valuable suggestion. Because CBL team considers all the suggestions and change for kaizen which Is always good. KAI-ZEN is a Japanese term implemented at CBL which means change for good means CBL implements every possible change for the further betterment of the company.

7 BIBLIOGRAPHY
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www.cheemaboilerslimited.com www.eren.doe.gov www.oit.doe.gov/bestpractices www.pcra.org www.energy-efficiency.gov.uk www.actionenergy.org.uk www.cia.org.uk www.altenergy.com

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