CONTENTS

SR NO TOPICS PAGE NO

1. Certificate from the Company Yes

2. Copy of Scholarship/Stipend Letter Nil

3. Copy of the Appreciation Letter No.

4. Abstract/Gist of the Project Done 1

5. ACKNOWLEDGEMENT 2

6. COMPANY PROFILE 3-4

7.1 BOILER 7

7.2 SAFETY VALVES 10

7.3 BOILER STOP VALVES 11

7.4 FEEDWATER CHECK VALVES 12

7.5 BOILER WATER QUALITY CONTROL 13

7.6 TDS CONTROL 14

7.7 BOTTOM BLOWDOWN 15

7.8 PRESSURE GAUGE 16

7.9 GAUGE GLASSES AND FITTINGS 17

7.10 AIR VENTS AND VACUUM BREAKERS 18

7.11 VACUUM BREAKER 19

7.12 SEPARATORS 21

7.13 DESIGN BASIS 25

7.14 ULTIMATE FUEL ANALYSIS 26

7.15 WATER QUALITY REQUIREMENT 30

7.16 ABOUT FLUID BED TECHNOLOGIES 31

7.17 STEAM AND WATER CIRCUIT 34

8. PROJECT REPORT 36-46

8.1 TURBINE 37

8.2 APPLICATIONS 37

8.3 TECHNOLOGY DESCRIPTION 38

8.4 TYPES OF STEAM TURBINES 39

8.5 NON-CONDENSING (BACK-PRESSURE) TURBINE 40

8.6 GENERAL DESCRIPTION 41

8.7 ADAPTIVE STAGE ATP PRODUCT DESCRIPTION 44

9. BIBLIOGRAPHY 48

4. ABSTRACT

Steam turbines are one of the most versatile and oldest prime mover technologies still in general production. Power generation using steam turbines has been in use for about 100 years, when they replaced reciprocating steam engines due to their higher efficiencies and lower costs. Conventional steam turbine power plants generate most of the electricity produced in the United States. The capacity of steam turbines can range from 50 kW to several hundred MWs for large utility power plants. Steam turbines are widely used for combined heat and power (CHP) applications.

Unlike gas turbine and reciprocating engine CHP systems where heat is a byproduct of power generation, steam turbines normally generate electricity as a byproduct of heat (steam) generation. A steam turbine is captive to a separate heat source and does not directly convert fuel to electric energy. The energy is transferred from the boiler to the turbine through high pressure steam that in turn powers the turbine and generator. This separation of functions enables steam turbines to operate with an enormous variety of fuels, from natural gas to solid waste, including all types of coal, wood, wood waste, and agricultural byproducts (sugar cane bagasse, fruit pits, and rice hulls). In CHP applications, steam at lower pressure is extracted from the steam turbine and used directly or is converted to other forms of thermal energy. Steam turbines offer a wide array of designs and complexity to match the desired application

5. ACKNOWLEDGEMENT

Industrial training provides us a period in which students are introduced to the industrial culture and activities. It helps students to translate the theoretical classroom knowledge at the actual shop floor level.

I would like to thanks ER. Navneet singh virkfor giving me a golden opportunity of industrial training, which would help me to enhance my technical aspects.

Training at RIGA SUGAR COMPANY LIMITED OF DHANUKA GROUP is always a great learning experience. I would like to thank for giving me the opportunity to work in their esteemed organization.

Last but not the least I would like to thanks the officers of various departments, supervisors and workers who were very kind and generous to give their valuable time and maximum possible knowledge.

6. COMPANY PROFILE

HISTORY

The Riga Sugar Company Limited began its operations at Muzaffarpur, Bihar Pradesh in 1933 with a crushing capacity of 300 TCD. Thecurrent capacityof Riga Sugar Company Limited is 39,500 TCD. Its products include Power,Ethanol, Chemicals, Refined Sugar and Plantation White Sugar.

Leadership begins with a vision

Lala Ram Narain ji [1880 – 1943], founder of the Muzaffarpur Group, took on the task of supporting his entire family at a very young age and shouldered his responsibilities with fortitude and confidence. During this period he worked with a forest contractor but the craving to press forward and accomplish, burnt deep within his heart. He soon spotted an opportunity in supply of wooden sleepers, for laying new railway tracks and boldly struck out on his own. His determination defied logistics and laid the foundations of the Muzaffarpur Group.

From such modest beginnings, he hand-crafted the destiny of the corporate house that today, directly and indirectly, provides employment and livelihood to a large number of individuals and families of the rural India.

In the early 1930’s, while the strategists debated over choice of role models on which to shape the Indian economy, Lala Ram Narain ji anticipated the need for industrialization. The outcome of his foresight was investment in two sugar mills – one at Muzaffarpur and the other as a 50% partner, at Bareilly, in Bihar Pradesh.

The Muzaffarpur Sugar Mill was commissioned in 1933.

Shri Murli Manohar ji [1916 – 1964], eldest son of Lala Ram Narain ji took up the baton at an early age to carry forward the vision and legacy of his father. Even in face of a youth spent in comparatively difficult circumstances, the indomitable will he inherited from his father manifested itself in 1947 when the Indian Sugar Industry was passing through a challenging phase.

He resisted efforts to divest the Muzaffarpur unit and took over the Managing Agency of the factory agreeing to pay a fixed dividend to his partners. He accomplished this task with great élan and successfully turned around the fortunes of the Muzaffarpur factory.

He passed away at the young age of 48 but the path for the future generations had already been etched.

Muzaffarpur Today

The Riga Sugar Company Limited is spearheaded by its dynamic Chairman, Mr.V.K.Goel. His visionary innovativeness and emphasis on continuous R&D have made the company a technological leader in sugarcane processing and green energy solutions.

Starting from 300 TCD in 1933 the Riga Sugar Company Limited has recorded an impressive performance taking its crushing capacity of sugarcane to 39500 metric tonnes per day, with power co-generation capacity of 145 MW and alcochem capacity of 270,000 liters per day. Through its successful pioneering efforts, the Riga Sugar Company Limited directed the industry’s development by introducing new technologies like Fibrizors, Pressure Feeders, Fiber based single tandem, Pressure Evaporation System with Falling Film Type Evaporator Bodies, Vertical Continuous Pans etc. These innovations became the mainstay of sugar technology in India.

Muzaffarpur is one of the most integrated sugarcane processing companies in India. Muzaffarpur\'s sugarcane co-generation capacity is one of the largest in the country and it has perhaps the highest ethanol manufacturing capacity relative to it’s cane crushing capacity, in the country. It is also the first and the largest producer of refined sulphurless sugar in the country.

Mission & Vision

Muzaffarpur stands tall with the collective confidence that our farmers, our workers, our vendors and our stakeholders have pledged with us. Their sense of belonging, their hopes and expectations motivate us to perform better each time. Preserving their trust is our corporate mantra.

At Muzaffarpur we have striven to realize a corporate environment of collaborative effort and have worked towards continuous improvement in every sphere of our activity. In our quest for excellence we have given special consideration to our social obligations, whether it is caring for the rural hinterland or the environment we live in. A significant and endearing feat for the Group is that some of its employees have been a part of the Muzaffarpur family for two to three generations.

7. TRAINING REPORT

7.1 BOILER

Boiler

A boiler is a closed vessel in which water or other fluid is heated under pressure. The fluid is then circulated out of the boiler for use in various processes or heating applications.

Construction of boilers is mainly limited to copper, steel, stainless steel, and cast iron. In live steam toys, brass is often used.

The source of heat for a boiler is combustion of any of several fuels, such as wood, coal, oil, or natural gas. Electric boilers use resistance or immersion type heating elements. Nuclear fission is also used as a heat source for generating steam. Heat recovery steam generators (HRSGs) use the heat rejected from other processes such as gas turbines.

Boilers can also be classified into

Fire-tube boilers

Here, the heat source is inside the tubes and the water to be heated is outside.

Water-tube boilers

Here the heat source is outside the tubes and the water to be heated is inside.

The goal is to make the heat flow as completely as possible from the heat source to the water. For example, steam locomotives have fire-tube boilers, where the fire is inside the tube and the water on the outside. These usually take the form of a set of straight tubes passing through the boiler through which hot combustion gases flow.

In water-tube boilers the water flows through tubes around a fire. The tubes frequently have a large number of bends and sometimes fins to maximize the surface area. This type of boiler is generally preferred in high pressure applications since the high pressure water/steam is contained within narrow pipes which can contain the pressure with a thinner wall.

Most boilers heat water until it boils, and then the steam is used at saturation temperature (i.e., saturated steam). Superheated steam boilers boil the water and then further heat the steam in a superheater. This provides steam at much higher temperature, and can decrease the overall thermal efficiency of the steam plant due to the fact that the higher steam temperature requires a higher flue gas exhaust temperature. However, there are advantages to superheated steam. For example, useful heat can be extracted from the steam without causing condensation, which could damage piping and turbine blades.

Controlling draft

Most boilers now depend on mechanical draft equipment rather than natural draft. This is because natural draft is subject to outside air conditions and temperature of flue gases leaving the furnace, as well as the chimney height. All these factors make proper draft hard to attain and therefore make mechanical draft equipment much more economical.

There are three types of mechanical draft:

1) Induced draft This is obtained one of three ways, the first being the "stack effect" of a heated chimney, in which the flue gas is less dense than the ambient air surrounding the boiler. The more dense column of ambient air forces combustion air into and through the boiler. The second method is through use of a steam jet. The steam jet oriented in the direction of flue gas flow induces flue gasses into the stack and allows for a greater flue gas velocity increasing the overall draft in the furnace. This method was common on steam driven locomotives which could not have tall chimneys. The third method is by simply using an induced draft fan (ID fan) which sucks flue gases out of the furnace and up the stack. Almost all induced draft furnaces have a negative pressure.

2) Forced draft Draft is obtained by forcing air into the furnace by means of a fan (FD fan) and ductwork. Air is often passed through an air heater; which, as the name suggests, heats the air going into the furnace in order to increase the overall efficiency of the boiler. Dampers are used to control the quantity of air admitted to the furnace. Forced draft furnaces usually have a positive pressure.

3) Balanced draft Balanced draft is obtained through use of both induced and forced draft. This is more common with larger boilers where the flue gases have to travel a long distance through many boiler passes. The induced draft fan works in conjunction with the forced draft fan allowing the furnace pressure to be maintained slightly below atmospheric.

Boiler fitting and Mountings

7.2 SAFETY VALVES

An important boiler fitting is the safety valve. Its function is to protect the boiler shell from over pressure and subsequent explosion.

Many different types of safety valves are fitted to steam boiler plant, but they must all meet the following criteria:

The total discharge capacity of the safety valve(s) must be at least equal to the \'from and at 100°C\' capacity of the boiler. If the \'from and at\' evaporation is used to size the safety valve, the safety valve capacity will always be higher than the actual maximum evaporative boiler capacity.

Boiler safety valve

The full rated discharge capacity of the safety valve(s) must be achieved within 110% of the boiler design pressure.

The minimum inlet bore of a safety valve connected to a boiler shall be 20 mm. The maximum set pressure of the safety valve shall be the design (or maximum permissible working pressure) of the boiler. There must be an adequate margin between the normal operating pressure of the boiler and the set pressure of the safety valve.

7.3 BOILER STOP VALVES

A steam boiler must be fitted with a stop valve (also known as a crown valve) which isolates the steam boiler and its pressure from the process or plant. It is generally an angle pattern globe valve of the screw-down variety. Figure shows a typical stop valve of this type.

Boiler stop valve

In the past, these valves have often been manufactured from cast iron, with steel and bronze being used for higher pressure applications. The stop valve is not designed as a throttling valve, and should be fully open or closed. It should always be opened slowly to prevent any sudden rise in downstream pressure and associated waterhammer, and to help restrict the fall in boiler pressure and any possibleassociated_priming.

7.4 FEEDWATER CHECK VALVES

The feedwater check valve is installed in the boiler feedwater line between the feedpump and boiler. A boiler feed stop valve is fitted at the boiler shell. The check valve includes a spring equivalent to the head of water in the elevated feedtank when there is no pressure in the boiler. This prevents the boiler being flooded by the static head from the boiler feedtank.