CONTENTS

1. Site Visit Training .................................................................................................................................. 2

2. Site location and product details .......................................................................................................... 3
3. WWS division product specifications and learning’s ............................................................................ 4
3.1 DM Plant (Site: Shankar SSK, Akluj) ............................................................................................. 4
3.2 RO PLANT (DYNAMIX DAIRY, BARAMATI) ................................................................................... 6
3.3 STP PLANT (AMANORA, MAGARPATTA, PUNE) .......................................................................... 8
4. Heating division product specifications and learning’s ........................................................................ 9
4.1 COMMISIONING PROCEDURE FOR BOILERS ............................................................................... 9
4.2 SHELLMAX SX 06 (Deluxe Laundry, Pune) ................................................................................. 10
4.3 SHELLMAX SM 1 TPH/10.54 (purple textile,Baramati) ............................................................. 11
4.4 HUSKPAC HP 50BB/10.54 (Ganesh Agro, Moregaon Arjuni) .................................................... 12
4.5 THERMOPAC(Alpha Foam Ltd., Chakan) ................................................................................... 13
4.6 REVOMAX (Angio Pharma) ........................................................................................................ 14
4.7 NEOTHERM(Forstar Foods, Taloja) ............................................................................................ 15
4.8 SHELLMAX (Hindustan Antibiotics Ltd., Pimpri)........................................................................ 16
4.9 AQUAMATIC ( Hotel Ashiyana, FC road, pune) ......................................................................... 17
5. Enviro division product specifications and learning ........................................................................... 18
5.1 BAG FILTER 8000m3/hr (PIX Transmission Pvt. Ltd., Nagpur) .................................................. 18
6. Chemical Dosing .................................................................................................................................. 19

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1. Site Visit Training

The purpose of site visit at various customers’ location was to analyze and visualize the product actual
functioning and its operating conditions in addition to understand its erection time and space
requirement. To understand the customer’s demand for the product and its purpose. Also to be able to
recommend the customer the best suitable product according his input parameters and resources.

After moving through various sites we are now able to understand the work flow of the product function
and also to judge the input resources for the product and to provide valuable suggestions for product
based on that.

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Site location and product details

Site Product Purpose

Shankar SSK, Akluj DM Plant For demineralize water for
cogen boiler
Dynamix dairy, Baramati RO Plant with UF Water for dairy products
Amanora, Magarpatta, STP For treating sewage water
Pune using FAB
Alpha Foam Ltd., Chakhan Thermopac 06 For heat exchange by
thermic fluid in foam
production
Angio Pharma, Pune Revomax .85 TPH For pharmaceutical use
Deluxe Laundry, pune SX 06 For Drying and ironing
clothes
Purple Textiles, Baramati Shellmax 1TPH For Drying textile cloth
Hindustan Antibiotics, Pune Shellmax 6TPH For Chemical Process
Forstar Fisheries, Taloja Neotherm 0.5TPH For Drying fishes
Ashiyana Hotel, Pune Aquamatic 2Million kcal/hr For Hot water in hotel use
PIX Transmission Ltd., BagFilter 8000m3/hr For Carbon black removal
Nagpur from outlet gases.
Ganesh rice Mill, Moregaon Huskpac 5TPH For drying rice
Arjuni
Yash Agro Energy Ltd., ESP For cleaning flue gases from
Biwapur boiler outlet
Inventies Research Chemical dosing Dosing for boiler water and
cooling water

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 WWS division product specifications and learning’s

3.1 DM Plant (Site: Shankar SSK, Akluj)

Dual Activated Stong Storage Strong

Degasser Mixed
Raw Chlorinated Water Media Carbon Acid for Base
Tower Bed
Filter Filter Cation Degasser Anion

CONSTITUENTS RAW WATER ANALYSIS TREATED WATER ANALYSIS

COD 15 ppm < 15 ppm

BOD NIL NIL

TSS 20 ppm < 5 ppm

TDS 300 ppm < 0.2 ppm

pH 7.3 6-7 (before pH correction)

Conductivity 450 µmhos/cm < 1 µmhos/cm

Silica 10 ppm < 0.02 ppm

Colloidal Silica NIL NIL

UNIT FLOW OPERATING ANALYSIS/CHECK OBR OBR CHEMICAL RESINS In

(m3/hr) PRESSURE (m3) TIME CONSUMPTION LITERS
(kg/cm2) (Hr) PER
REGENERATION
(100% conc.)
DMF 45 3.5 Cl2 > 1 ppm - -
ACF 45 3.0 Cl2 = 0 ppm - - - -
SAC 36 2.5 Hardness = 0 ppm 720 20 278 kg HCl 3997 T42H
pH = 2-3
DEGASSER - Gravity Removal of CO2
SBA 36 3.5 pH = 8-9.5 720 20 288.3 kg NaOH 4810
Conductivity < 36 A27MP

MB 36 2.5 pH = 6-7 22 kg HCl 275 T42H

conductivity < 2 24.5 kg NaOH 350 A27MP

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KEY POINTS:

 General P & I diagram of the plant

 Sea Sand should be used because of its alkalinity and coagulation properties which avoids sand block
formation
 Everyday do backwash for filter
 Raw should be chlorinated by NaOCl (Sodium Hypochlorite) and polyelectrolytes.
 Erection of plant and available space evaluation

Operating Conditions:
 Regneration Cycle: ACID-ALKALI Injection should be carried out for 30 mins, slow rinse for 25 mins and fast
rinse for 30 mins.
 Air flow through blower in MB should be 86. 39 m3/hr @ 0.45 kg/cm2 for 2-3 mins
 Air Flow in degasser should be 848.23 m3/hr @ 100 mm wc
 pH of output water from MB should be corrected by using suitable alkali such as Morpholine/Hydrazine.

DESIGN PARAMETERS:

 DMF is designed for maximum load of 50 NTU turbidity to produce outlet water of less than 5 NTU turbidity, if
turbidity is greater 50 NTU, then suitable coagulants are added.

APPLICATION:
 For Boiler feed water treatment.

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 3.2 RO PLANT (DYNAMIX DAIRY, BARAMATI)

ANTI scalant and

25 m3/hr 18 m3/hr SMBS dosing/ 10 m3/hr
• DMF • Softner • 6 UF's 14m3/hr • Cartiridge
Chlorinated raw water • ACF (1640 litres • Basket • UF Filter (5 • RO RO Permeate to process
of T40Na) Strainer permeate micron)
(100 micron)
25 m3/hr 18m3/hr 15 .5 m3/hr 14 m3/hr

PROPERTIES FEED WATER TREATED WATER

Iron < 0.05 mg/lit 0 mg/lit

Hardness 500 mg/lit < 5 mg/lit

pH 7.62 7-7.5

TDS 1100 < 75

SDI 10 NIL

Alkalinity 165 < 50

Organic matter 0.8 NIL

Chloride 158 mg/lit 25 mg/lit

Nitrates > 1.03 < 1.03

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 Operating Pressure
UNIT Capacity (m3/hr) Treatment
(kg/cm2)

DMF 3.5 25 Removes Turbidity

Removes Chlorine,
ACF 3.5 25
colour and odour

Softner (1640 ltrs of Hardness reduced to < 5

3.5 18
T42Na) ppm from 500 ppm

Permeate = 14 m3/hr,
UF membrane Unit 3.0 15.5 also removes colloidal
silica

SMBS dosing unit 3.5 6 Does dechlorination

Avoid formation of
Anti scalant Unit 3.5 6 scales in RO membrane
by MAXTREAT 9001

Maintain pH by
pH correction Unit 3.5 6
MAXTREAT 3006

Removes particles
Cartridge filter 3.5 14
greater than 5 micron

RO Unit 3.5 14 Permeate = 10 m3/hr

KEY POINTS:

 General P & I diagram of RO Plant

 Operation of plant by understanding controls and readings on control unit.
 Erection phase of RO plant

OPERATING CONDITIONS:
 Back wash to be done once a day for 15 mins @ 2 kg/cm2 with flow of 75m3/hr
 Quantity of NaCl required for one regeneration phase is 263 kg

DESIGN PARAMETERS:
 Y strainer is used before raw water feed pump to restrict large size particles to enter the DMF
 Steam line is attached to ACF for sanitization at 80◦C to avoid fungal and bacterial growth.

APPLICATION:

 RO permeate for dairy process.

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 3.3 STP PLANT (AMANORA, MAGARPATTA, PUNE)

Sweage Equilization FAB 1 and Treated water

Sweage water Bar screen Tube Settler DMF ACF
water sump tank FAB 2

KEY POINTS:

 General P & I diagram of the plant

 Construction phase of plant
 Visual inspection of FAB media rings

8
 Heating division product specifications and learning’s

4.1 COMMISIONING PROCEDURE FOR BOILERS

1. Check process line setup according P & I diagram

2. Check proper rotation of motor direction
3. Check power supply unit
4. Inspect mobery installation and its working
5. Adjust proper pressure and temperature of fuel
6. Check operation of feed water pump and its operating conditions
7. Set Burner for firing and start fire after checking all valves and fittings
8. Leave steam upto pressure of 2kg/cm2 for shell boiler and 5kg/cm2 for coil boiler
9. Setting of pressure switch according to required pressure at outlet
10. At stack check O2 and CO2 levels according to standard norms
11. If O2 and CO2 instruments doesn’t work or malfunction, then alternatively check levels of CO2 by
colour of flue gases
12. Check safety i.e. photocell, water level safety i.e. mobery, pressure switch etc.
13. Stack temp. should not be more than 220◦C
14. Finally check the temp. of flue gases at the outlet of the chimney

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4.2 SHELLMAX SX 06 (Deluxe Laundry, Pune)

KEY POINTS:
 General P & I diagram
 Heat Output of SX 06 is 600 kg/hr at 10.34 kg/cm2
 Fuel used is FO
 Operating controls and readings on control unit
 18 seconds is ideal time for blow down.

OPERATING CONDITIONS:
 Fuel oil inlet pressure is 18 kg/cm2 at temp. of 120◦C
 Outlet steam temp. is 180◦C approx.
 Per minute outlet water is 10.4 liters before steam generation
 Fuel consumption is 38 kg/hr
 Economizer operating temp. is 48◦C which extracts heat from flue gases at 220◦C.

DESIGN PARAMETERS:
 Economizer is used for feed water heating
 Fuel pre heater is used which heats it up upto 120◦C
 Ortili burner for combustion

APPLICATION:

 Steam for drying and ironing clothes in laundry.

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4.3 SHELLMAX SM 1 TPH/10.54 (purple textile,Baramati)

KEY POINTS:
 General P & I diagram.
 Operating pressure is kept at 10.54kg/cm2
 Fuel used is LPG.
 Working of 3 pass shell boiler

OPERATING conditions:
 Inlet gas pressure is 0.3 bar and outlet is 100 milli bar
 Minimum and maximum gas flow rate is 0.25 m3/hr and 40 m3/hr respectively
 Gas required at low flame and high flame phase is 14-18 kg/hr and 38-40 kg/hr
 Flue gas outlet temp. is 290◦C

DESIGN PARAMETERS:
 ACTARAS FLOW meter for measuring gas flow
 Mobery controller for water control at inlet of boiler at 3 different levels

APPLICATIONS:

 Steam for textile process and drying clothes.

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4.4 HUSKPAC HP 50BB/10.54 (Ganesh Agro, Moregaon Arjuni)

KEY POINTS:
 General P & I diagram.
 Heat Output of HP 50 is 5000 kg/hr at 10.34 kg/cm2
 Fuel used is husk
 Water inlet flow is 1000 lit/hr and feed of husk is 100 kg/hr for generation of 5 TPH

OPERATING CONDITIONS:

 Flue gas temp. is maintained at 250◦C

 Blowdown should be done twice a day.

DESIGN PARAMERTERS:
 Cool air provision with the help of air duct for keeping watch glass cool at combustion chamber
door.
 Boiler designed for bore well water properties.
 Hot condensed water from process outlet is also used as feed water.

APPLICATION:

 For drying of rice and for process in rice mill.

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4.5 THERMOPAC(Alpha Foam Ltd., Chakan)

KEY POINTS:

 Study of P & I diagram

 It is a 3 pass, coil type, thermic fluid boiler (TPC-06).
 Fuel used is furnace oil.
 Ortili burner is used for firing.

Operating Conditions:
 Heat output is 600,000 kcal/hr
 Thermic fluid flow rate is 30 m^3/hr
 Fuel temp at inlet - 120°c
 Maximum temperature of thermic fluid used for process is 280°c

DESIGN PARAMETERS:

 Distance between outer and inner coil is approximately 20mm.

 Diameter of coil is 40 NB.
 Fuel pressure is 22kg/cm^2
 Deaerator tank elevation should be 0.6m above the highest point in thermic fluid system

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4.6 REVOMAX (Angio Pharma)

KEY POINTS:

 Study of P & I diagram.

 It is a 2 pass, coil type boiler(RXD-850)
 Fuel used is LDO.
 Ortili burner is used for firing.
 Optimizer and water preheater is used.

Operating Conditions:
 Pressure of LDO pump is 23-24 kg/cm^2
 Working pressure is 10.34 kg/cm^2
 Output generated is 0.531MW
 Connection load is 3.5 KW
 Heat output is 850 kg/hr

DESIGN PARAMETERS:

 At the steam outlet SPH(steam pressure high) switch is given.

 At the water preheater LSL (Level switch low) is provided.
 At the outlet 2 safety valves are given at 10.3kg/cm^2 and 10.5 kg/cm^2

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4.7 NEOTHERM(Forstar Foods, Taloja)

KEY POINTS:

 Study of P& I diagram

 It shell type 3 pass boiler (NEO-05/7/3).
 Fuel used is LO.
 Pilot burner is used for firing.

Operating Conditions:
 Heat output is 600,000 kcal/hr
 Output power generated is 0.3 MW
 Heat generated is 500 kg/hr
 Operating pressure is 7 kg/cm^2
 Fuel pump- 60l/hr, pressure- 28 kg/cm^2
 Water pump - flowrate- 1 m^3/hr, pressure- 17 kg/cm^2

DESIGN PARAMETERS:

 For water level safety mobri is used.

 Pressure is set in between 6-6.75 for outlet of steam.
 For steam output globe valve is used for pressure adjustment.
 At stack outlet stack temperature high switch is provided for temperature 220°C

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4.8 SHELLMAX (Hindustan Antibiotics Ltd., Pimpri)

KEY POINTS:

 Study of P & I diagram

 It is a 3 pass shell type boiler.
 Fuel used is FO
 Turndown ratio of 1:4 is provided.

Operating Conditions:
 Heat output is 6000 kg/hr
 Power generated is 3.76KW
 Design pressure is 10.54 kg/cm^2
 Connection load is 36.7 KW
 Water pump - Power- 4KW, flowrate- 5.8 m^3/hr, temp- 120°c, pressure- 25 bar, Hmax- 177.4 m, Hact -
133 m.
 Water:conductivity - 10 micro siemens/cm, pH - 8.5 - 9.5

DESIGN PARAMETERS:

 Back pressure regulating valve is provided.

 Eccentric reducer is provided so that NPSH is created.

 40 mm insulation is provided.

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4.9 AQUAMATIC ( Hotel Ashiyana, FC road, pune)

KEY POINTS:

 Study of P & I diagram

 It is a coil type hot water generator
 Fuel used is HSD
 Calorifier is used
 Monobloc burner is used

Operating Conditions:
 Heat output is 200000 kcal/hr
 Power generated is 0.232 MW
 Connection load is 2.67 KW
 Flame temp - 1200-1300°C
 Soft water in boiler - 500l
 Calorifier capacity - 1000 - 1200 l of water

DESIGN PARAMETERS:

 Initially water in calorimeter is at 40°C

 Outlet temperature of water from boiler is 90°C

 This water is used to heat up the water in the calorimeter to 50°C by circulation through coil in
calorimeter which is then sent for general use in hotel.

 The water in calorimeter coil is again sent to the boiler as it temperature reduces with the help of
circulating pump.

 Set point of circulation pump at inlet and outlet are maintained at 57 and 70°c respectively.

17
Enviro division product specifications and learning

5.1 BAG FILTER 8000m3/hr (PIX Transmission Pvt. Ltd., Nagpur)

KEY POINTS:
 Capacity of bag filter is 8000 m3/hr
 Working and operating controls of bag filter
 Setting of purging pressure and purging frequency according to load on bags
 Setting rpm of Air Lock Rotary Valve
 Inspection of bag fabric material and its handling conditions.

OPERATING CONDITIONS:

 Purging pressure for purging the air bags is set at 7 kg/cm2.

 The rpm of Air Lock Rotary valve is maintained between 5-20
 Air flow to the atmosphere is done by blower which is set at 5.7 kg/cm2 and is being powered by
motor of 20 hp
 Suction pressure for sucking the air containing carbon particles from the process is set at 0.5
kg/cm2

DESIGN PARAMETERS:

 Total bags used were 72 in a matrix of 12*6 with size of bag as 3000 mm length and diameter of
149 mm.
 High Level sensor is provided near hopper to indicate the load variation near hopper walls and
inside the hopper.
 Automatic Pressure switch is there if the purging pressure falls below 3 kg/cm2, which cut offs
the circuit and stops the bag filter operation.

APPLICATION:

 Bag filter is used to avoid flow of minute carbon black particles to atmosphere, from the
incoming air from the factory’s process.

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Chemical Dosing

Boiler water chemical dosing:

 The boiler water dosing is done by testing the water at blowdown

 The blowdown is checked per shift

 The storage tank is of 8 KL. The dosing is done as 500 l/hr.

 The chemicals used are:-

Maxtreat : 3100 - oxygen scavenger

3004 - pH booster

3221 - Antiscalant

 After chemical dosing the water parameters at blowdown are as follows:-

pH - 10.5 - 12.5

p- Alkalinity - 300 ppm

m- Alkalinity - 700 ppm

chloride - App. 1000 ppm

TDS - <3500 ppm

Phosphate - 15-30

Sulphite - 40-50

Cooling water chemical dosing :

 The cooling water chemical dosing is done based on the bio-organic growth

 The chemicals used are:-

Maxtreat:611 biocycle - dosing is done weakly (40-50 ppm)

608 biocycle - Alternate day ( 40-50 ppm)

25210 antiscalant - daily dosing (40 - 60 ppm)

 After dosing of chemicals the water parameters are :-

Hard or soft - nil <200 ppm

TDS - <2000 ppm

pH - 8.5

Phosphate - 5 ppm

Chloride - <50 ppm

p- Alkalinity , m-Alkalinity - 200-250 ppm

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