Académique Documents
Professionnel Documents
Culture Documents
B.Tech.
in
Instrumentation and Control
by
Rajesh Sontakke
(GR N O. 132036)
Gaurav Pawar
(GR N O. 121665)
Akshay Dharmal
(GR N O. 132063)
Certificate
This is to certify that the project titled, Prototype development of small capac-
ity boiler and its instrumentation , submitted by Rajesh Munja Sontakke,
(GR.No:- 132036),Gaurav Sham Pawar, (GR.No:- 121665),Akshay Datta Dhar-
mal, (GR.No:- 132063) is a record of bonafide work carried out by them under my
guidance in partial fulfillment of the requirement for the award of the Degree of Bach-
elor of Technology in Instrumentation and Control with specialization in Process In-
strumentation.
Date:
Place: Pune
Examiner Certificate
This is to certify that the dissertation titled, Prototype development of small
capacity boiler and its instrumentation , submitted by Rajesh Munja Son-
takke, (GR.No:- 132036),Gaurav Sham Pawar, (GR.No:- 121665),Akshay Datta
Dharmal, (GR.No:- 132063) is approved for the award of the Degree of Bachelor of
Engineering in Instrumentation and Control of Vishwakarma Institute of Technology,
Pune.
Examiner Name:
Signature :
Date:
Place: Pune
Acknowledgement
We take this opportunity to express our deep gratitude and genuine respect to
wards our guide Prof.Tejas G.Patil for giving us support required during the course of
our project. He is being the constant source of inspiration and served us with moral
encouragement required for our project work. We would like to thank Prof. Dr.Shilpa
Y.Sondkar and Prof. J.A.Gaikwad for his kind co-operation. We are also thankful to
all staff member so Instrumentation Engineering Department, Lab assistants and all
other individuals.
Acknowledgement iv
1 Introduction 1
1.1 Problem statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Brief Introduction: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Advantages of Electric Boiler: . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Disadvantages of Electric Boiler: . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Electric Boiler Benefits: . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Boiler Basics 5
2.1 Brief description of Boiler types: . . . . . . . . . . . . . . . . . . . . . 5
2.2 Boiler accessories: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Safety Interlocks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Design Considerations 9
3.1 Boiler design introduction: . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Design Calculations: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Boiler diagram: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Detail working of boiler: . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Design Aspects: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6 General checks while startup: . . . . . . . . . . . . . . . . . . . . . . . 11
3.7 Bill of material: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Hardware Implementation 13
4.1 Details of equipment’s used: . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Software Implementation 15
5.1 PLC Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Why use PLC? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
v
5.3 PLC versus Relay Logic . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4 What makes PLC work? . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.5 Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7 Applications 20
9 ANNEXURE 22
9.1 PLC Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Bibliography 25
List of Figures
3.1 Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
vii
Chapter 1
Introduction
As our Boiler is electrically fired so it can be defined as, an electric steam boiler is
a type of boiler where the steam is generated using electricity, rather than through the
combustion of a fuel source.
Electric boilers are a fairly new invention, with many types of electric boilers still
on there is as more discoveries are made regarding their improvement. An electric
1
boiler can replace any other small to medium size boiler in the home, and are known to
be light, small and compact, often completely silent and, of course, boasting the main
benefit of a low running cost due to the price of electricity in comparison to oil or gas.
It is most common to need an electric powered boiler in rural areas where oil or
gas access may not be available, but also some new housing projects or flats are being
fitted with l centric boilers by choice due to its environmental and cost benefits.
Whereas gas boilers rely on burning gas to generate heat, electric boilers rely on the
electricity from the mains supply of the property to heat elements within the boiler.
Water get shutter as it passes over the see cements and one sufficiently heated the
water is then pumped to where it is required.
Electric boilers remain popular because they are considered to be around 99 effi-
cient to the end user. This is because electric boilers do not rely on the burning of
fossil fuels such as gas or oil to produce heat and there is therefore no chance of losing
valuable heat when releasing waste gases into the atmosphere.
These electric boilers are used to generate steam for process purposes in many lo-
cations, for example laundries, food processing factories and hospitals. Although they
are more expensive to run than gas-fired or oil-fired boilers they are popular because
of their simplicity and ease of use. Because of the large currents required, they are
normally run from a three-phase electricity supply. They convert electrical energy into
thermal energy with almost 100 efficiency but the overall thermal efficiency is variable,
depending on the efficiency with which the electricity is generated.
A traditional gas boiler system normally disposes of waste gases by taking it out
of the property via a fuel or chimney. As the flue is not required in an electric boiler
system.
Setup, this means that use full heat does not escape, helping the electric boiler to
run at around 99
2) Reduced installation costs:
If you do not currently have a gas pipe supply into your property it can cost a lot
of money to get this setup. An electric boiler is a cheaper solution. It is also beneficial
as you do not need to purchase a separate Flue or chimney as there is no requirement
to take waste emissions from the boiler to outside of the property, as with a gas boiler.
This will obviously save you money in the initial installation stage.
3) Space efficient:
The fact that a flue is not required benefits smaller properties where space is an
issue. There is also a lot more flexibility in where the electric boiler can be installed, as
it doesn’t necessarily need to be close to an outside wall. Unlike other types of boiler,
there is also no requirement for an additional fuel storage tank.
4) Quiet:
Electric boilers are not reliant on elements within the boiler moving to generate
heat. This means that electric boilers are renowned as being very quiet systems when
in use.
5) Maintenance:
Electric boilers generally don’t need to be serviced as regularly as gas and oil boil-
ers as they are considered to be like any other electrical appliance Generally they only
need maintaining if there is a problem with the boiler itself.
Electric boilers rely on electricity rather than the burning off fossil fuels to generate
heat. The electric boilers themselves are there for considered more environmentally
friendly than other types of boiler.
Electric boilers can only heat a certain amount of water at any one time, therefore a
more conventional boiler system may be more suitable to heat larger properties where
hot water usage levels maybe higher.
2) Environmental benefits:
Although the electric boiler units themselves are considered fairly environmentally
friendly heating systems, there are concerns that the actual process of creating elec-
tricity itself in power stations generates the same amount of pollution as gas and oil
boiler systems, therefore negating this benefit.
3) Cost of electricity:
Due to the higher cost of electricity over gas, electric boilers are considered as lightly
more expensive way to provide heat to a property.
Boiler Basics
In fire tube boiler, the fuel is burnt inside a furnace. The hot gases produced in
the furnace then passes through the fire tubes. The fire tubes are immersed in water
inside the main vessel of the boiler .As the hot gases are passed through these tubes,
the heat energy of the gasses is transferred to the water surrounds them. A results
team is generated in the water and naturally comes upon distorted up on the water in
the same vessel of fire tube boiler. This steam is then taken out from the steam outlet
for utilizing for required purpose. The water is fed into the boiler through the feed
water inlet.
E.g. .Lancashire boiler, locomotive 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 large utility boilers rely on the water-filled tubes
that make up the wall so the furnace to generate steam. E.g. Horizontal Straight Tube
Boiler (Babcock and Wilcox Boiler), Bent Tube Boiler.
B) Method of Firing
5
1. Internally Fired Boiler:
Internally fired boilers, the furnace form saint trial part of the boilers structure.
The vertical tubular, locomotive and the scotch marine boilers are well known exam-
ples.
2. Externally Fired Boiler:
Externally fired boilers have as separate furnace built outside the boiler shell and
usually below it. The horizontal return tube (HRT) boiler is probably the most widely
known example of this type. C) Pressure of Steam
Kgf/sq.cm and a temperature of about 650’C. One of the large modern steam power
plants in the world is in japan with a steam capacity of 1600Tonnes/hr. In India, the
tramway power plant has a steam generating capacity of 550 tones/hr, Ramagundam
power plant with 320 tones/hr. and bokaro plant with 160 tones/hr.
D) Circulation of Water:
1) Natural circulation:
General components of the boiler used for increasing efficiency and safe working
and they are as follows:
2.3.1 Boiler mountings:
These are machine components that are mounted over the body of boiler itself for
safety of boiler and complete control of process of steam generation.
Design Considerations
9
Figure 3.1: Boiler
Hardware Implementation
2. Electric heater:
Manufacturer’s name: OTMAX
Ratings: 1500W, 80VQuantity: 2
Function: Electric heaters have been used to heat the water stored in boiler tank to
required temperature and pressure. Water is heated up to 130degree Celsius.
3. Pressure gauge :
Manufacturer’s name: KAMAL
Ratings: 0-100 kg/cm2
Quantity: 1
Function: Pressure gauge was used to measure gauge pressure of steam in the boiler
.Recorded pressure for 130 degree Celsius.
13
5. Sight glass:
Material of construction: Borosilicate glass
Quantity: 1
Function: It was used to indicate the level of water inside the boiler tank.
Software Implementation
15
Figure 5.1: PLC System
5.5 Flowchart
The boiler prototype during its final test run gave the following results:-
4. No fluctuation in relay.
19
Chapter 7
Applications
1. Agricultural:
In agriculture, steam is used for soil sterilization to avoid the use of harmful chemical
agents and increase soil health.
2. Domestic:
Steam’s capacity to transfer heat is a used in the home: for cooking vegetables, steam
cleaning off a brigand carpets, and heating buildings.
3. Electricity generation (and cogeneration):
About 90 of all electricity is generate dousing steam as the working fluid , nearly all
by steam turbines in electric generation ,steam is typically condensed at the end of its
expansion cycle, and returned to the boiler for re-use.
4. Energy storage:
In other industrial applications steam is used for energy storage, which is introduced
and extracted by heat transfer, usually through pipes. Steam is capacious reservoir for
thermal energy because of water’s high heat of vaporization.
5. Steam in piping:
Steam is used in piping for utility lines .It is also used in jacketing and tracing of piping
to maintain the uniform temperature in pipelines and vessels.
6. Wood treatment:
Steam is used in the process of wood bending, killing insects and increasing plasticity.
7. Concrete treatment:
Steam is used to accentuate drying especially impure fabricates. Care should be taken
since concrete produces heat during duration and additional heat from the steam could
be detrimental to hard ensign reaction processes of the concrete.
8. Cleaning:
Used in cleaning offices, sometimes prior to painting.
20
Chapter 8
8.1 Conclusion
The boiler prototype inserted and checked for its safety and its desired results. It gives
a steam at a temperature of about130c. There is no risk or safety issues regarding
the function in go the boiler .It has been built taking into consideration lt he safety
procedures mentioned Indians
BoilerRegulations-1950(Reg.-321 to Reg.-326).
21
Chapter 9
ANNEXURE
22
Figure 9.2: Normal working condition
[1] Barron J.L, Fleet D.J, Beauchemin S.S,“Performance of Optical Flow Techniques”,
IJCV 12:1, pp 43-77, 1994
25