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Industrial Training

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Industrial Training

Letter from the department for training, along with the list of

topics for the training

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Industrial Training

Introduction to Thermax, Ltd.

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Industrial Training

1. Industry: Energy and Environmental Engineering

2. Products: Vapor Absorption Machines, Boilers, Water Treatment

Plants, Solar Based Cooling, etc

3. Founded: 1980 in Dadar, Mumbai

4. Divisions: C&H, B&H, Power, Enviro, Chemical & Water, Solar energy

5. Headquarters: Pune, India

Training at Thermax Energy House, Chinchwad MIDC in Solid Fuels

section of B&H division

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Industrial Training

P&ID

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Industrial Training

1. Piping and instrumentation diagrams are the schematic used in the

field of instrumentation and control or automation

2. P&IDs are used by field technicians, engineers, and operators to

better understand the process and how the instrumentation is

interconnected

3. P&IDs use symbol and circles to represent each instrument and how

they are inter-connected in the process

Instrument Tags

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Industrial Training

1. Tags are the letters and numbers placed within or near the

instrument to identify the type and function of the device

2. First letter is used to designate the measured variable such as

Pressure, Temperature, Level, Flow, Vibration, etc.

3. Succeeding letter(s) are used to designate the function of the

component or to modify the meaning of the first letter such as

Indicator, Recorder, Controller, Transmitter, Measuring Element,

Switch, Alarm, Valve, etc.

4. These letters are used against the standards for P&ID of

Instrumentation Standards Association (ISA S5.1) as shown in figure

1.1

Figure 1.1: ISA S5.1 Identification Letters

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Industrial Training

Instrument Location

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Industrial Training

1. The horizontal line in the circle indicates the mounting location of

instrument

2. No line: Mounted in the field near the process for monitoring

3. Solid line: Mounted in the control room accessible to the operator

4. Dashed line: Located out of sight not accessible to the operator

5. A circle in a Square: The display of the instrument is in the control

room of DCS

Piping and Connection Symbols

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Industrial Training

A dashed line is used to

indicate the

interconnection between

instruments on field to

DCS

Valve Symbols

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Industrial Training

1. Valves are used to control the flow of air, water, steam, fuel, gases,

etc.

2. These valves are controlled by either manually by hand or

automatically by electric or pneumatic signals from DCS/PLC

Types of Valves

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Industrial Training

Gate Valve Globe Valve Check Valve

Piston/ Lift check valve Swing Check Valve Butterfly Valve

Instrument Specification

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Industrial Training

1. Tag ID of instrument

2. Type of instrument

3. Loop sequence number

4. Service in overall process

5. Alarms

6. Normal and design temperature and pressure

7. Scale unit and ranges

8. Control set point

9. I/O type

10.Signal level and type

Instrument Index & DCS I/O List

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Industrial Training

1. The list which consists all the instruments and their specifications in

a process plant is called Instruments Index

2. It consists all instruments including field Gauges & Measuring

Elements

3. A list consisting all the instruments connected from field to DCS or

vice versa is known as the DCS I/O List

4. It contains specifications such as transmitter tag name, DCS tag

name, loop service, signal type, I/O type, instrument calibration

range and DCS range, digital states (if present), alarms, etc.

Instrument Index & DCS I/O List

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Industrial Training

Instrument Index

DCS I/O List

Instrument Erection Drawing

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Industrial Training

Boiler Major Equipment

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Industrial Training

1. Feed water system

2. Feed water heater

3. Deaerators

4. Economisers

5. Boiler drum

6. Boiler tubes

7. Superheaters

8. Attemperators

9. Condensate systems

10.Fuel system

Feed water system

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Industrial Training

1. The water supplied to the boiler, which is converted into steam, is

called feed water

2. The two sources of feed water are condensate or condensed steam

returned from the process and makeup water (treated raw water)

which must come from outside the boiler room and plant processes

3. DM water is used in boiler to avoid scaling

Feed water heater

1. Heaters are shell and tube heat exchangers with the feed water on

the tube side (inside) and steam on the shell side (outside)

2. Boiler efficiency is improved by the extraction of waste heat from

spent steam to preheat the boiler feedwater

Deaerators

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Industrial Training

1. The oxygen is mechanically removed in a deaerator

2. Oxygen is decreasingly soluble as the temperature is raised

3. This is done by passing a stream of steam through the feed water

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Industrial Training Economizers

A feed water economizer reduces steam boiler fuel requirements by

transferring heat from the flue gas to incoming feed water

Boiler drum

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Industrial Training

1. A boiler system consists of a steam drum and a mud drum

2. The steam drum is the upper drum of a water tube boiler where the

separation of water and steam occurs

3. The lower drum, called the mud drum, is a tank at the bottom of

the boiler that collects solids such as salts formed from hardness

and silica or corrosion products carried into the boiler

Boiler tubes

1. Boiler tubes are usually fabricated from high-strength carbon steel

2. The tubes are welded to form a continuous sheet or wall of tubes

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Industrial Training

Superheaters

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Industrial Training

1. The purpose of the superheater is to remove all moisture content

from the steam by raising the temperature of the steam above its

saturation point

2. The steam leaving the boiler is saturated, that is, it is in equilibrium

with liquid water at the boiler pressure (temperature)

Attemperators

1. Attemperation is the primary means for controlling the degree of

superheat in a superheated boiler

2. Attemperation is the process of partially de-superheating steam by

the controlled injection of water into the superheated steam flow

Condensate systems

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Industrial Training

1. Condensate tanks and pumps are major points for oxygen to enter

the condensate system and cause corrosion

2. These points should be monitored closely for pH and oxygen ingress

and proper condensate treatment applied

Fuel system

1. Their primary functions include transferring the fuel into the boiler

and distributing the fuel within the boiler to promote uniform and

complete combustion

2. The type of fuel influences the operational features of a fuel system

Boiler Safety Interlocks

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Industrial Training

1. Purge

2. Low Air Flow

3. Low Fuel Supply

4. Loss of Flame

5. Fan Interlock

6. Low Water

7. High Combustible content

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Industrial Training

Boiler Process