You are on page 1of 26

A

SEMINAR
ON
BOILER MANUFACTURING

BY:- SHAILESH PATEL

Contents

CNC Plasma plate cutting


Plate rolling or bending
Dye penetration test
Welding
NDT Test
Corrugation
Assembly
Stress relieving process
Hydraulic Testing
Shot blasting
Painting
Insulation
Handing over to customer

CNC Plasma cutting machine

CNC Plasma Plate Marking


It is the most earliest process in mfg. of boiler in which

plate of iron, mild steel etc is cut by the CNC plasma


cutting machine.
The design of job is inserted into plasma CNC machine.
First of all the dimension and the position of cutting lines,
holes, ellipse etc is marked on the plate of material by
pre-programmed design in CNC machine.
Marking is done by the electric arc and at pressure 8 kg
is produced by the hydrogen gas.
Then the plate is checked by the quality control manager
and then it is sent for cutting.
Marking is done at the arc 15 voltage for 12 mm plate.

Cutting Specifications
Cutting voltage depends on the thickness of the

plate.
If the thickness of plate is 45 to 50 mm then it is cut
by plasma cutting and if thickness is 60 to 100 mm
then it is cut by gas cutting.
The nozzle of torch is of 2 mm so there is always
defect of + or - 2 mm in size.
The laser cutting is most accurate method for cutting
but its can cut the metal of only 22 mm.
There are two types of cutting straight and bevel
cutting.

Plate Rolling Machine

Plate Rolling
It is the process of rolling or bending the plate of mild

steel into specified circumference as per drawing.


There are 3 rollers, two moving in same direction and
one in opposite direction.
The pre punching of ends of the plate is done before
starting actual rolling to give desire radius or
circumference to rolled plate.
The plate to be bend is passed through three rollers
and circumference is set by moving the roller up and
down.

Dye Penetration test


DP test is done to check the defects form during the primary

welding process like holes, porosity, surface defects etc.


First of all the welded surface is cleaned with cleaner and
surface is made neat.
Then dye is applied on surface and again it is cleaned with
cleaner.
Now developer spray is applied on surface so it will show
the defects with red color and the defects is then removed
and job is sent for welding.
It is due to fact that dye is remain in defected area and so it
is not cleaned by cleaner and so developer catches the
defects and develops it.

Welding
It is the most important process because most of the

parts of boiler are to be welded by this method.


There are mainly two types of welding used to joint
the two end of rolled plate.
L seam and c seam welding.
There are certain types of welding like SAW, GTAW,
FCAW etc. which are widely used for welding.
The welding process is selected as per drawing or
strength required for joint.

C seam and L seam joint

C seam welding

L seam welding

NDT
Non destructive test is done to check the accuracy of

welding and joints.


The test can be done by x-ray, ultrasonic rays, dye
penetration test etc.
In this the x-ray of job is tested and if there is any
defects it is removed.
It is very important test because there must not be
any space or gape between welded joints as this
shell will be subjected to high pressure.
It is approved by quality department and is handed
over to assembly shop.

Corrugation
It is the process of grooving on furnace shell.
It is the hot working process in which temperature is

achieved to 900c and then by roller the grooving is


done.
The temperature is achieved by burning of LPG gas
and air.
The mixture of air and gas is maintained by valves.
The soaking process is done as per thickness.
The job is rotated by motor arrangement.

Corrugated Shell

Assembly
In assembly shop the furnace shell is fitted in

main shell of boiler.


It also includes welding of nozzles, pipes,
man hole, upper and lower bottom in the
main shell and the entire structure of boiler is
build up.
It also include the surface finishing of the
surface of boiler body.

Assembled job

Stress Relieving Furnace

Stress relieving furnace


It is the heat treatment process in which job is heated to specified

temperature, maintain at that temperature for certain period of time and


it is then cooled to lower temperature.
The principle of stress relieving process is to remove the internal
stresses which is induced during the welding or heat treatment process .
The job of thickness more than 18 mm is stress relieved .
Free heating 0 to 300c
Heating
300 to 600c
Soaking
at 600c
Cooling
600 to 300
The temperature in furnace is created by burning of Propane gas or
high speed diesel.
The rate of cooling and heating depends on thickness of material or job.
Usually burners for gas inlet and exhaust for flue gas out is provided to
continue the combustion.
The total control of temperature and cooling is done by control panel.

Hydro testing
In hydro test water is fed into boiler and pressure is

applied for testing for its capacity to bear pressure


more than working pressure.
The job is tested for pressure 1.5 times more than
working pressure.
It is very important test in which job is tested for
leakage, pressure bearing capacity, alongation due
to pressure etc
Two gauges are used to test the hydro test in case of
alternation.

Shot blasting & Painting


Shot blasting is the process of bombarding sand or

metal shots at jobs on its outer surface equally


distributed to remove the scale and other impurities
from surface and to make it clean for painting.
It makes surface smooth and parallel so that painting
can easily be done.
Then the job is painted by spraying colour on it.

Painted job

Insulation
Insulation is provided to keep the door safe from

heating due to boiler temperature by insulating the


shell by glass or mill wool or coated sheet of SS of
0.55 mm or by woolen cover of 5 to 10 cm.
The thickness of insulation depends on the drawing
or temperature created in boiler.
Usually ceramic fiber blanket is used as insulation
material of grade S as it can bear the temperature up
to 1200c.
The door is also insulated with cement concrete in
special case where higher temperature is to be
maintained.

Insulated job

Blanket Insulation

Final job

Thank You !!!

You might also like