Parabolic Drugs Limited

BOILER
BRIEF DESCRIPTION-
Three boilers having capacity of 6, 3 and 1.5 tons are installed and operational in our
plant. Both are water and smoke type boilers , this means the water is first heated in
furnace side in tubes which increases its temperature and after this water is passed to
boiler shell where it is heated by flue gases present in tubes converting it into steam.
Wood is used as a fuel for both boilers.
The 3 ton boiler has a air preheater unit installed and 1.5 ton has a heat recovery unit
installed increasing their performance characteristics, Now these boilers are not in service
& Husk fire boiler having capacity-6 ton/ hr is operational.

Scope:
Sr.no. Equipment No. Location Supply To Capacity

1 BLR/003 Boiler House All plants 6 ton/Hr

Steps taken to ensure proper functioning of system-

-Preventive maintenance procedure being followed.
- De scaling of boiler tubes being done at regular intervals.
- Regular blow downs are given to maintain parameters like TDS.
-Chemicals are used to maintain the feed water parameters in boiler.
Functions of chemicals are-
-Ph booster
-Corrosion Inhibitor
-Oxygen Scavenger

Efficiency

Efficiency of boiler is given by=output/input

= mw x (hs – hw )
mf x L ev
Where,
mw= Mass of water
hs= enthalpy of steam
hw= enthalpy of water
mf= mass of fuel
L ev= calorific value of fuel

For ideal operation-

75 % = mw x (660-80)/ (mf x 3000)
.75x 3000/560= mw
mf
mw = 4.01 ideally ratio of water to steam should come 4.01
mf

Results:
Sr. No. Equipment Mass of water to fuel Reference Remarks
Name ratio

1 BLR/003 3.93 Annexure 01

Annexure-01
Mass of water- 20590Ltr
Mass of fuel used- 81000 Kg
Ratio= 81000/21000 = 3.93
 Parabolic Drugs Limited
BOILER
BRIEF DESCRIPTION-
Two boilers having capacity of 3 and 1.5 tons are installed and operational in our plant.
Both are water and smoke type boilers , this means the water is first heated in furnace
side in tubes which increases its temperature and after this water is passed to boiler shell
where it is heated by flue gases present in tubes converting it into steam. Wood is used as
a fuel for both boilers.
The 3 ton boiler has a air preheater unit installed and 1.5 ton has a heat recovery unit
installed increasing their performance characteristics.

VARIOUS IMPROVEMENTS

PURPOSED
- 6 ton boiler using husk as a fuel has been installed and will be operational soon.
- Boiler to be charged with DM water for cost saving.
- Co2 analyzer with variable feed drive to be provided.
- Td to be replaced by FD
- Steam leakage to be checked and stopped.
In operation
- Pure steam condensate recovery is taken in process .
- Various chemicals are used to maintain the feed water parameters in the boiler.
Functions of Chemicals used are
- Ph booster
- Corrosion inhibitor
- Oxygen scavenger
Regular blow downs are given to maintain parameters like TDS(total dissolved solids)
TA( total alkanity) and TH(total hardness)
 Parabolic Drugs Limited
COOLING TOWERS
BRIEF DESCRIPTION-
A cooling tower is a heat rejection device, which extracts waste heat to the atmosphere
though the cooling of a water stream to a lower temperature. The type of heat rejection in
a cooling tower is termed "evaporative" in that it allows a small portion of the water
being cooled to evaporate into a moving air stream to provide significant cooling to the
rest of that water stream. The heat from the water stream transferred to the air stream
raises the air's temperature and its relative humidity to 100%, and this air is discharged to
the atmosphere. Cooling tower in utility is used for water and brine chillers, air
compressor, and nitrogen compressor and for process requirements in the plant. All the
cooling towers are induced draft type cooling towers. Induced draft cooling towers are
constructed such that the incoming circulating water is dispersed throughout the
cooling tower via a spray header. The spray is directed down over baffles that are
designed to maximize the contact between water and air. The air is drawn through the
baffled area by large circulating fans and causes the evaporation and the cooling of the
water.

COOLING TOWER LOCATIONS AND CAPACITY

SR. EQUIPMENT LOCATION SUPPLY TO RATED

NO. NO. (UTILITY) CAPACITY(TR)
1. UA\CLT\001 1 BRINE CHILLER 150
2. UA\CLT\002 1 NOT OPERATIONAL 100
3. UB\CLT\001 2 BRINE CHILLER 150
4 UB\CLT\002 2 BRINE CHILLER 300
5. UC\CLT\001 3 FOR PLANT 500
6. UC\CLT\002 3 CHILLERS,AIR 500
COMPRESSOR AND
NITROGEN PLANT
7. UC\CLT\003 3 CHILLERS,AIR 500
COMPRESSOR AND
NITROGEN PLANT
 Parabolic Drugs Limited

Before calculating the efficiency of the cooling tower following steps were taken to
ensure the proper functioning of the tower. The steps are as follows-
- Dosing of chemicals is regularly done and the parameters of water were regularly
checked to ensure that they were maintained as per or norms.
- A float valve was installed at make up water side and regularly adjusted to ensure
that there was no water loss due to overflow.
- Leaks were regularly checked.
- Aluminum\brick bending was installed to stop the water loss due to air drift.
- Damaged fins of tower were replaced by new\cleaned ones to ensure maximum
efficiency is obtained.
- Monthly maintenance checks are made at cooling towers to ensure their proper
functioning.
- Strainer is checked at regular intervals and cleaned.
- Soft water being charged as a make up water.
 Parabolic Drugs Limited

NOW EFFICIENCY OF COOLING TOWER IS GIVEN BY=HWT-CWT*100

HWT-WBT

AND ALSO APPROACH IS GIVEN BY =CWT –WBT

WHERE,
HWT=CONDENSOR RETURN WATER TEMPERATURE
CWT=COOLING TOWER SUMP TEMPERATURE
WBT=AMBIENT WET BULB TEMPERATURE

EQUIPMENT NO. AVERAGE APPROACH AVERAGE EFFICIENCY

(%)
UA\CLT\001 1.82* 75.57*

UB\CLT\001,002 2.54* 65.44*

UC\CLT\001,002,003 2.43* 66.51*

*=REFER ANNEXURE
 Parabolic Drugs Limited

EFFIECIENCY OF AIR COMPRESSOR

UTILITY-3
EQUIPMENT NO.-UC/ARC/001

*FORMULAS USED FOR VOLUME-

VOLUME OF CYLINDER- 22/7{r} ^2*h
VOLUME OF SPHERICAL CAP -22/42{(3r^2+ (H) ^2} H
*refer annexure for spherical cap volume

V1-Volume of pipeline
V2-Volume of heat exchanger
V3-Volume of pipeline
V4-volume of receiver (small)
V5-volume of pipeline
V6-volume of receiver (big)
V7-volume of pipeline

V1 Volume of pipeline

Total Length of pipeline=.09

Diameter = .05 m
Volume =22/7*4{(.05)^2}.09 = .0017 m^3

V2 Heat exchanger volume

Volume of spherical caps

V=22/42*{3(.1)^2/4 +(.035)^2}(.035)=.023 m^3
Volume of both side = 2* .023= .046 m^3
Volume of heat exchanger = 22/28[{.2*.1*.1}+ {.235*.1*.1}+{.14*.1*.1}]=.0143 m^3
Total heat exchanger volume =.0143 + .046 =0.156 m^3

V3+V5+V7-Total pipeline volume

Total length of pipeline=8.34 m

Diameter = .05 m
V = 22/28{.05*.05}8.34 =.016 m^3

V4 Volume of receiver (small)

Volume of spherical caps or dish area = 22/42{3(.25)^2/4 +(.075)^2}.075 =.002 m^3

Volume of both sides = 2*.002 =.004 m^3
Volume of cylinder =22/28*.25*.25*.49 =.024 m^3
Total volume =.024 +.004 =.028 m^3

V6 Volume of receiver (big)

Volume of cylinder=22/28(.82*.82)1.49 =.787 m^3

 Parabolic Drugs Limited

Volume of dish area or spherical cap =22/42{3(.82)^2/4 +(.15)^2}(.15) = .041 m^3

Total volume =.787 +2*(.041) = .815 m^3

Total volume of system

V1+V2+V3+V4+V5+V6+V7
= .0017 +.156+.016+.028+.815 =1.015 m^3

Now time taken to fill this volume is 47 seconds

By using the following relation we find the FAD of system
Free Air Delivery (FAD) = (P2 – P1) (V)/T
Where P1 =initial pressure (0.8)
P2= final pressure (6.8)
V = volume of system (1.015)
T = time taken to fill this volume in minutes
using the above relation we get
Calculated FAD = (6) (1.015)*60/43 = 8.49 kg m^3/min

Efficiency of the system = Actual /rated discharge * 100

= 8.49/9.41 * 100 = 90.3 %
{*rated discharge =332 Cfm
= 332/ (3.28) ^3
=9.41kgm 3/min}
 EFFIECIENCY OF NITROGEN PLANT AIR COMPRESSOR

EQUIPMENT NUMBER- UC\NAC\001

UTILITY- 3
FORMULAS USED
VOLUME OF CYLINDER-22\7r^2h
VOLUME OF SPHERICAL CAP-22\42[3{r}^2+{h}^2] h*
*=REFER ANNEXURE

V1-VOLUME OF PIPELINE
V2-VOLUME OF HEAT EXCHANGER
V3-VOLUME OF PIPELINE BEFORE RECIEVER
V4-VOLUME OF AIR RECIEVER
 Parabolic Drugs Limited

V1
Length of line-3.95 m
Diameter- .05 m
Volume- 22\28*.05*.05*3.95
= .007 m^3

V2
Number of columns in heat exchanger= 5
Number of rows in heat exchanger= 7
Length of column = .324 m
Diameter of pipeline = .05 m
Length of row = .9 m
Volume of heat exchanger = volume of row +volume of column
=22\28 {5*.05^2 *.324}{7*.05^2*.9}
= .0132 m^3

V3
Length of line=1.45 m
Diameter = .05 m
Volume = 22\28 *.05 .05*1.45
= .0029 m^3

V4
Length of cylinder= 1.2 m
Diameter = .44 m
Volume = 22\28 *.44*.44*1.2 = .182 m^3
Volume of dish area or spherical cap
Height of cap = .025 m
Volume = 2 *22\42{3[.44]^2\4 + [.025]{.025) =. 054 m^3
Total volume = .182 + .054
=. 236 m^3
EFFICIENCY OF AIR COMPRESSOR ATTACHED TO THE SYSTEM

Volume filled by air compressor till air receiver = V1+V2+V3+V4

= .007+.0132+.0029+.236 = .2591 m^3
Time taken to fill this volume is 29 sec at pressure of 6.3 bar
By using relation for FAD(Free air delivery)= (p2 –p1)V\T(in minutes)
=6.3*.2591*60\29
 Parabolic Drugs Limited

=3.37 m^3 per minute

Therefore
Efficiency = FAD\RATED FAD * 100 = 3.37/4.05* 100 = 83.38 %

EFFIECIENCY OF NITROGEN PLANT AIR COMPRESSOR

EQUIPMENT NUMBER- UB\NAC\001

UTILITY- 2
FORMULAS USED
VOLUME OF CYLINDER-22\7r^2h
VOLUME OF SPHERICAL CAP-22\42[3{r}^2+{h}^2] h*
*=REFER ANNEXURE

V1-VOLUME OF PIPELINE
V2-VOLUME OF PIPELINE
V3-VOLUME OF AIR COOLER
V4-VOLUME OF AIR RECIEVER

V1
Length of line- 2.9 m
Diameter- .075 m
Volume- 22\28*.075*.075*2.9
= .012 m^3

V2
Length of line = 2.8
Dia of line = 2.8
V= 22\28..05*.05*2.8
=.005m^3

V3
Diameter = .15
Height of air cooler = 1.2 m
Volume of cylinder = 22\28 *.15 .15*1.2= .0212 m^3
Dish volume= 2 *22\42{3[.15]^2\4 + [.05]^2 }.05 =.0010 m^3
Total volume = .0212 + .0010
= .0222 m^3

V4
Diameter of receiver =.93 m
 Parabolic Drugs Limited
Height of receiver=1.25 m
Volume f cylinder= 22/28*1.25(.93)^2= .849 m^3
Volume of dish
Height of dish=.1
Volume = 2 *22\42{3[.93]^2\4 + [.1}^2}{.1}=.069 m^3
Total volume = .849 + .069
=.918 m^3

EFFICIENCY OF AIR COMPRESSOR ATTACHED TO THE SYSTEM

Volume filled by air compressor till air receiver = V1+V3+V4

= .012+.0222+.918 = .9522 m^3
Time taken to fill this volume is 81 sec at pressure of 5 bar
By using relation for FAD(Free air delivery)= (p2 –p1)V\T(in minutes)
=5*.9522*60\81
= 3.52 m^3 per minute
Efficiency of compressor = actual fad*100=3.52*100 = 78.22 %
Rated fad 4.5

EFFICIENCY OF AIR COMPRESSOR (ETP)

PLANT NAME- ETP

EQUIPMENT NO. - UB\ARC\001

VOLUME OF SYSTEM= 500 L\MIN (GIVEN)

RATED FAD OF SYSTEM= 1225 L\MIN

EFFICIENCY OF AIR COMPRESSOR IS GIVEN BY= ACTUAL FAD*100

RATEDFAD

Where rated FAD =V*(P2-P1)

T
Where,
FAD= free air delivery
V= volume in m^3/min
P2= final pressure
P1= final pressure
T=time taken to achieve from initial to final pressure

System achieved a pressure of 5 bar in 133 seconds.

Therefore, by using the above relation FAD= 5(500)*60 =1127.8 l\m
133
Now efficiency= 1127.8 *100=92.06 %
1225
 EFFIECIENCY OF NITROGEN PLANT

EQUIPMENT NUMBER- UC\ARC\001

UTILITY- 3
FORMULAS USED
VOLUME OF CYLINDER-22\7r^2h
VOLUME OF SPHERICAL CAP-22\42[3{r}^2+{h}^2] h*
*=REFER ANNEXURE

V1-VOLUME OF PIPELINE
V2-VOLUME OF HEAT EXCHANGER
V3-VOLUME OF PIPELINE BEFORE RECIEVER
V4-VOLUME OF AIR RECIEVER
V5- VOLUME OF PIPELINE
V6-VOLUME OF PSA (PRESSURISED SQUARE ABSORBER) TOWER
V7- VOLUME OF FLANGE OF PSA TOWER
V8- VOLUME OF PIPELINE
V9- VOLUME OF RECIEVER
V10- VOLUME OF PIPELINE
V11- VOLUME OF END RECIEVER

V1
Length of line-3.95 m
Diameter- .05 m
Volume- 22\28*.05*.05*3.95
= .007 m^3

V2
Number of columns in heat exchanger= 5
Number of rows in heat exchanger= 7
Length of column = .324 m
Diameter of pipeline = .05 m
Length of row = .9 m
Volume of heat exchanger = volume of row +volume of column
=22\28 {5*.05^2 *.324}{7*.05^2*.9}
= .0132 m^3

V3
Length of line=1.45 m
Diameter = .05 m
Volume = 22\28 *.05 .05*1.45
= .0029 m^3
 V4
Length of cylinder= 1.2 m
Diameter = .44 m
Volume = 22\28 *.44*.44*1.2 = .182 m^3
Volume of dish area or spherical cap
Height of cap = .025 m
Volume = 2 *22\42{3[.44]^2\4 + [.025]{.025) =. 054 m^3
Total volume = .182 + .054
=. 236 m^3

V5
Length of line =5.5 m
Volume = 22\28*.05*.05*5.5
=.0104 m^3

V6
Height of psa tower = 1.22 m
Diameter = .61
Volume = 22\28 *(.61)^2 *1.22 =
.35 m^3

Volume of dish =22\42{3{.61}^2\4 + {.025}^2}.025 =.0044 m^3

Total volume for one psa tower = .35 +2(.0044) = .3588 m^3
Total volume for both psa tower as dimensions are same = 2(.3588)
=.7176 m^3

V7
Height of flange = .5 m
Diameter of flange = .1 m
Volume = 22\28*.1*.1*.5
= .0039 m^3

Total volume of both flanges = 2*(.0039)

= .0078 m^3

V8
Length of line = 1.4 m
Volume = 22\28 (.05)^2* 1.4
=. 0026 m^3

V9
Height of receiver =1.6 m
Diameter = 1.1 m
Volume = 22\28(1.1)^2*1.6=1.52 m^3
Volume of dish =22\42{3{1.1}^2\4 +{.1}^2}.1=.048 m^3
Total volume =1.52 + 2(.048)
=1.616 m^3

V10
Length of line = 5.6 m
Diameter = .25
Volume =22\28 5.6(.25)^2
=.274 m^3

V11
Height of cylinder = 5.28 m
Diameter = 1.6 m
Volume = 22\28 *5.28(1.6)^2 = 10 .62 m^3
Dish volume =22|42{3(1.6)^@\4 +(.3)^2}.3= 1.22 m^3
Total receiver volume = 10.62 + 2(1.22)
= 13 .062 m^3

Total volume of the system =V1+V2+V3+V4+V5+V6+V7+V8+V9+V10+V11

= 15 .94 m^3

*FIRST WE CALCULATE THE EFFICIENCY OF AIR COMPRESSOR

ATTACHED TO THE SYSTEM

Volume filled by air compressor till air receiver = V1+V2+V3+V4

= .007+.0132+.0029+.236 = .2591 m^3
Time taken to fill this volume is 29 sec at pressure of 6.3 bar
By using relation for FAD(Free air delivery)= (p2 –p1)V\T(in minutes)
=6.3*.2591*60\29
=3.37 m^3 per minute
Therefore
Efficiency = FAD\RATED FAD * 100 = 3.37/4.05* 100 = 83.38 %

NOW EFFICIENCY OF NITROGEN SYSTEM

Volume filled by system in110 minutes at 5 bar = 15.90 m^3

FAD = 5(15.90)\110
=. 72 m^3\ min
Rated discharge of system=50 Nm^3\hr
Efficiency of system =