DECLARATION

I here by declare that the internship work being presented in the dissertation

entitled “A Study on Boiler Unit at MYMUL” is an authentic work that has

been carried out at Mysore District co-operative Milk Producers Societies

Union Limited, Mysuru under the guidance of Mr. Sriharsha A D, Assistant

Manager, Engineering Division MYMUL, Mysuru, as part of my study for the

award of degree of Bachelor of Engineering in Mechanical Engineering of

Visvesvaraya Technological University, Belgaum, Karnataka. The work contained

in the report has not been submitted in part or full to any other University or

Institution or Professional body for the award of any degree or any other

fellowship.

Date: 06/02/2020 RANJITH PS NAIK

Place: Mysuru (4NN15ME055)

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 ACKNOWLEDGEMENT

The success of any hard work comes from the constant encouragement and
support of the people apart from the effort of the person who has done it. The
satisfaction and the euphoria that accompanies the successful completion of any task
would be incomplete without the mention of the person who made it possible. The
only way in which we can express our gratitude to these people is by mentioning their
name in the report.

I express my deep sense of gratitude to Mr. Raghu H R (General Manager,

Engg), Mr.SriHarsha A D (Assistant Manager, Engg), Mr. Manjunath,
Mr Aravind and all Engineers and Staff, in the organization for their cooperation
and valuable suggestion and guidance throughout this training.

RANJITH P.S NAIK

(4NN15ME055)

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 CONTENTS

DECLARATION i
ACKNOWLEDGEMENT ii
TABLE OF CONTENTS iii
LIST OF FIGURES vi
LIST OF TABLES vii
NOMENCLATURE vii

CHAPTER- 1 INTRODUCTION 1-5

1.1 Development of Dairy Industry in India 1
1.2 National Dairy Development Board NDDB 1
1.3 Objectives of NDDB 3
1.4 Services Rendered by NDDB 3
1.5 Introduction Karnataka Milk Federation 4
1.6 Vision 5
1.7 Mission 5
1.8 Objectives 5
CHAPTER- 2 COMPANY PROFILE 6-11
2.1 Introduction 6
2.2 Vision 8
2.3 Mission 8
2.4 Objectives 8
2.5 Quality Policy 9
2.6 Functional Departments 9
2.7 Function of procurement Department 10
2.8 Processing And Production Activities 10
2.9 Function of Engineering Department 10
2.10 Section of Engineering Department 11
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2.11 Function of Boiler Section 11

CHAPTER- 3 BOILERS 11-30

3.1 Operating Principle 11
3.2 Working Of ComBloc Ultra Hybrid Boiler In Mega Dairy Unit 12
3.2.1 Pressure Part Assembly 13
3.2.2 The Furnace 14
3.2.3 Heat Recovery System (Economizer) 14
3.3 Operational Features Of ComBloc Ultra Hybrid Boiler 15
3.3.1 Combustion and steam Generation. 15
3.3.2 Steam Pressure switch 16
3.3.3 Flue Gas Temperature Control 16
3.4 Technical Data 16
3.5 Working Principle Of Energy Pack Boiler 17
3.6 Working Principle Of Thermax Boiler 18
3.7 Fuel Supply And Ash Handling System 19
3.7.1 Boiler Fuel 19
3.7.2 Briquettes/Coal/Coconut Shell Handling System 22
3.7.3 Ash Handling System 23
3.7.4 Dust Collector 23
3.8 Draught System 24
3.8.1 Chimney 25
3.8.2 Flue Gas Ducting 25
3.9 Boiler Feed Water 26
3.9.1 Impurities in Water 27
3.9.2 Effect of impurities in the boiler Water 27
3.9.3 Hardness removal by Softening 28
3.9.4 De- alkalization Process 29
3.9.5 Demineralization Process 30

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3.10 Boiler Safety and Maintenance 31
3.10.1 Steps involved in periodic boiler maintenance 31
3.10.11 Some operations performed during maintenance 32

DESCRIPTION OF TASK PERFORMED 34

SPECIFIC OUTCOMES 35

REFLECTION NOTES 36

CONCLUSION 37

REFERENCE 39

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 LIST OF FIGURES

FIGURE PAGE
TITLE
NO NO

1.1 Nandini Brand Logo 04

2.1 MYMUL 06

2.2 Mega Dairy Plant 07

2.3 Organization Chart 09

3.1 Principal of Fire Tube Boiler 12

3.2 ComBloc Ultra Hybrid Boiler 13

3.3 Furnace without flame and with flame 14

3.4 Economizer 14

3.5 Flow diagram of Boiler operation 15

3.6 Integral Furnace Boiler & Conventional Hybrid Boiler 15

3.7 Working Circuit of Energy Pack Boiler 17

3.8 Energy Pack Boiler 17

3.9 Working Circuit of Thermax Boiler 18

3.10 Thermax Boiler 18

3.11 Fuel & Ash Handling Operation 19

3.12 Briquette and Wood Chip 20

3.13 Belt Conveyor 21

3.14 Magnetic Separator 21

3.15 Impact Crusher 22

3.16 Boiler overhead Bunker & Dosing Bin 22

3.17 Submerged Ash Conveyor 23

3.18 Bag House & Cyclomax Ash Collector 24

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3.19 FD & ID fans 24

3.20 Chimney 25

3.21 Boiler Feed water system 26

3.22 Feed Water Drum & Dearator 27

3.23 Softening process 28

3.24 Softener Drums 29

3.25 De- alkalization Process & Demineralization Process 30

3.26 Demineralization Process 30

3.27 Water gauge 32

3.28 Water gauge mounted on boiler 32

3.29 Ash inside furnace chamber 32

3.30 Ash removed from furnace chamber 32

3.31 Safety valve 33

3.32 Safety valve mounted on boiler 33

LIST OF TABLES

TABLE PAGE
TITLE
NO NO

3.1 Specifications of ComBloc Ultra Hybrid Boiler 16

3.2 Specifications of Energy Pack and Thermax boiler 19

3.3 Fuel conditions 20

3.4 Specification Of Feed Water And boiler water 28

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 NOMENCLATURE

SL NO ACRONYM EXAPANSION

1 NDDB National Dairy Development Board

2 KMF Karnataka Milk Federation

3 KDDC Karnataka Dairy Development Corporation

4 DCS Dairy Cooperative Societies

5 TLPD Thousand Liters Per Day

6 LTS Liters

7 WPH Water Pre Heater

8 MDC Mechanical Dust Collector

9 hrs Hours

10 °C Degree Centigrade

11 F Fahrenheit

12 J/g Joule Per Gram

13 kg Kilogram

14 K Kelvin

15 T Ton

16 rpm Revolution Per Minute

17 cm3 Cubic Centimeter

18 kg/cm2 Kilogram Per Centimeter Square

19 kW Kilowatt

20 mm Millimeter

21 kJ Kilo joule

22 kg/hr Kilogram Per Hour

23 lph Liters Per Hour

24 m3/s Meter Cube Per Second

25 ms Mass Flow Rate Of Steam

26 Q Heat Transferred

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