Thermopack ppt

APL KHANDALA
1MIS | Site Name | 2017-MM-DD
THERMOPACK TRANNING

THERMOPACK SLD
X
M
M
X
REACTOR
X
X
XHEAT
EXCHANGER
1
2
3
4
5
1. MECHANICAL SAFETY VALVE .
2. DPIT .
3. TCV .
4. PCV .
5. OUT TCV .
6. Deration .
DP
M
250c
285c

THERMOPACK APH
THERMIOPAC
APH
C
H
I
M
E
N
Y
C
H
I
M
E
N
Y
FD
290deg C
140deg C
ATMOSPHARIC
AIR INLET
OUT
150deg C
250c
285c
25 to 30c
APH USED FOR INCREASE THE EFFICENCY OF THERMOPACK , IT
CAN INCREASE ATMOSPHARIC AIR TEMPURATURE FROM 110 TO
102degC .
APH CAN INCREASE 4 TO 5% EFFICENCY OF THERMOPACK.

MAIN PARTS OF THERMOPACK
1. BURNER
2. DIESEL PUMP
3. BIO GAS LINE AND VALVES .
4. THERMIC FUEL PUMPS
5. SAFETY VALVES
6. RTDS , PRESURE SWITCH , DP SWITCH .
7. APH , MODULATION UNIT .
8. IGINATION TRANSFORMER .
9. ELECTRICAL PANEL

ABOUT THERMOPACK
1. TOTAL CAPACITY = 20 LAKH Kcal/HOUR
2. THREE PASS Thermopack .
3. MAINTANING TEMPURATURE = 30 TO 35degC .
4. FUEL TYPE = THERMIA-B
5. INLET PRESSURE SET POINT CUT OFF = 265degC .
6. OUTLET MOD OFF = 287 TO 290degC .
7. FLUE GASES TEMP = 350 degC .
8. COMBUSTION AIR PRESSURE = 200mm Wc .
9. DESIGN PRESURE = 10KG
10. TUBE MATERIAL CARBON STEEL SUITABLE FOR 300degC AND 10Kg PRESSURE .

THREE PASS Thermopack
1. FIRST PASS = AIR + FUEL + IGINATION
AIR USE FOR FIRE .
2. SECOND PASS =COMBUSTION AIR USE
FOR RISE THE TEMPURATURE OF THERMIC FUEL
BETWEEN FIRST AND SECOND COIL .
3. THIRD PASS = COMBUSTION AIR PASS OUTER
SIDE OF SECOND COIL .
4. THERMIC FUEL INCOMING COIL .
5. THERMC FUEL OUTER COIL . 1
5
3
2
4
FIRST COIL
SECOND COIL

CIRCULATING PUMP AND MECHANICAL
SAFETY VALVE
It is used to circulating the Thermic fluid .
It should start before firing .
Differential pressure inlet and outlet not less than 1.5 kg .
Working pressure 4 kg.
Two pumps with common Header ,
one for Running and One for standby .
When Pressure Raise Above 4.5 KG that time
Mechanical Safety Valve Operate then thermic fuel
circulate between pumps header and thermopack .
1
2

MODULATION UNIT
1. Servomotor :- Single Phase , 90Watt motor , it rotate in both directions
It take 27 Sec from lower point to highest position and 14 sec from higher to lower position.
servo motor work on two commands high and low through PLC .
2. Connector:- It used for connection of Modulation unit motor. (high and low )
3. Limit switch:- Five Limit switches, 1 and 2 use for low modulation set point
of air and fuel when thermic fuel temperature is high 3 ,4 use for high modulation
motor set point when thermic fuel temperature is low and 5th limit switch use for
independently adjustment between low and high period .
4. 135 Ohm Resistance :- Its used for resistance feedback to
potentiometer and it converted into analog signal for PLC feedback of
Modulation unit operation .
5. Regulating Drum :- it rotate by servomotor through gear train to reduce
speed of modulation unit and it work through servo motor. For diesel and gas
different drum both rotate through common shaft .
6. Motor connection :- Blue is common and one for high speed and another
for low speed of servomotor and it operate through PLC .
1
2
34
5
6

DIFFRENTIAL PRESSURE
DP
OUTLET
INLET
24 V DC FROM
TB0.1- 35
FEEDBACK TO
PLC TB0.1- 36
IT USED FOR DIFFRENTIAL PRESSURE BETWEEN INLET AND OUTLET , IT SHOULD
NOT LESS THEN 1.5KG .
ONLY ONE AUXILARY CONTACT POINT IS USED FOR FEEDBACK TO PLC .
DIGITAL INPUT FEEDBACK TO PLC .
ITS CONTACT POINT CHANGE NC TO NO WHEN INLET AND OUTLET PRESSURE
DIFFERENCE LESS THEN 1.5KG.

PILOT SOLENOID VALVE G7
1. It used to Establish Positive flame and every startup Thermopack.
2. it avoid large amount gas at starting , it also prevent
Thermopack to back pressure .
3. It connected between two main line gas valves an it also used for small
amount of gas at starting .
4. Only use for burner starting , It always off in burner operation time .
PLC RC2
220 VAC
TB2-17
G7
N
TB2-18

MAIN GAS LINE SOLENOID VALVES (G6 ,G8 )
TWO TYPES OF MAIN SOLENIOD VALVES .
1. QUICKT OPENNING - QUICK CLOSING SOLENOID VALVES.
THIS TYPE OF VALVE INSTALLED FIRST FROM GAS SIDE.
2. SLOW OPENNING – QUICK CLOSING SOLENOID VALVES.
IT ALWAYS INSTALLED NEAR BURNER SIDE.
IT ALWAYS USED FOR SLOW OPENNING .
When the burner trip or supply shut down , the spring is
provided inside both the valves and immediately close
the both valves and stop the gas .
Both the valves are normally close type .

WHAT IS TIGHTNESS OK
MAIN GAS LINE
FIRE
G6 G8
LEAKAGE
DETECTION
UNIT
TWO TESTES FOR LEAKAGE DETECTION .
TEST 1:- THIS TEST FOR VALVE V2 LEAKAGE.
Valve open and close for 2sec . Internal
sensor check the condition of valve 2 . If test
is positive red color indication on .
TEST 2:- THIS TEST FOR VALVE V21
LEAKAGE. Valve open and close for 2sec .
Internal sensor check the condition of valve 2 .
If test is positive red color indication on .
1
1. RED INDICATION FOR MAIN INCOMING
VALVE OK
2. RED INDICATION FOR FIRING SIDE
MAIN VALVE .
3. SHORT LINKES FOR VALVE
LEAKAGE TESTING .
2
3

TIGHTNEES OK FIELD FEEDBACK CKT
12 11 7 6 5 3 1
N L
FROM 220VAC BUS
V
NC GIVE FEEDBACK TO TB2-25
TIGHTNEES OK THERE IS NO
LEAKAGE BETWEEN MAIN LINE
GAS VALVES .
FOR RELAY A HOLDING AND
PLC 24VDC FEEDBACK
TIGHTNEES OK
P.B
FOR
RESET
FOR TRIP
COMMAND
TO RELAY-B
1
2
1. Circuit healthy indication
2. Leakage detection unit on indication .

GAS LEAKAGE DETECTION UNIT
1. THIS SYSTEM IS CHECK LEAK PROOFNESS OF BOTH THE SOLENOID VALVES
EITHER AT EACH BURNER STARTUP OR SHUTDOWN .
2. LED IS PROVIDED FOR INDICATION OF LEAKAGE OR HEALTHY
CONDITION OF THE SYSTEM .
3. IF THE LEAKAGE IS IDENTIFY IN ANY SOLENOID VALVE
BURNER CYCLE INTRUPTED AND IT ELIMINATES THE
DANGER OF UNNOTICE GAS LEAKAGE .
4. IT DETECT ONLY SOLENOID VALVE LEAKAGE , NOT FOR
GAS LINE LEAKAGE .

TIGHTNEES OK PLC FEEDBACK CKT
220 VAC
220 VAC
PLC 24V DC
FROM TBI-21
TO TBI-24
TO TBI-22
PLC 24V DC
FROM TBI-23
FROM TB2-26
N
FROM FIELD
TC-DI
FROM FIELD
TC-DI
A
B
RELAY A FOR TIGHTNESS FEEDBACK OK
RELAY B FOR TIGHTNESS NOT OK.

DIESEL PUMP AND VALVE .
1. It is used for Fuel transfer from Day tank to Thermopack . .
2. Start Through RC1/ 4+ and also Main fuel line valve
open with same command . Diesel pump and its valve
operate through common PLC command .
PLC RL1
220 VAC CONTROL
PHASE
1
2
1
2
33
1. DIESEL PUMP
2. DIESEL VALVE
FUSE .
3. DIESEL MAIN LINE
VALVE.

OIL AND GAS METER CKT
A1
A2
N
OIL METER GAS METER220V
FROM
TBP1
FROM
TB2/15
FROM
N-TB
FROM
TB0-1/13

IGINATION TRANSFORMER
1. TWO TRANSFORMER USED IN THERMOPACK
IGINATION ONE FOR GAS AND SECOND FOR DIESEL .
STEP UP TRANSFORMER INPUT 220V AND
SECONDARY VOLTAGE 14 KV .
IT WORK THROUGH PLC COMMAND .
TWO ELECTRODE USE FOR SPARK AND THE GAP
BETWEEN BOTH ELECTRODES SHOULD NOT BE
MORE THEN 5 TO 6mm .
DRY STEP UP TRANSFORMER .

THERMOPACK RTDS
TOTAL SIX RTDS USED IN SINGLE THERMOPACK .
RTDS WORKS ON THE PRINCIPLE OF POSITIVE COEFFICENCE.
WE MOSTLY USED PT100 RTDS , PLATINUM METAL AND IT
PRODUCES 0degC ON 100OHM’s , so 100.39 OHM’s = 1deg TEMPURATURE .
. IT WORKS TO SENSE THE TEMPURATURE OF THERMIC
FUEL INLET AND OUTLET , APH INLET AND OUTLET AND
FLUE GASES .
RTDS TEMPURATURE DIRECTLY PERPORTIONAL TO RESISITANCE .
RESISTANCE IS INPUT SIGNAL FROM RTDS . THREE WIRE RTDS
USED IN THERMOPACK AND TRANSMITTER IS CONVERTED RESISTANCE
SIGNAL TO ANALOG SIGNAL FOR PLC FEEDBACK . (4 to 20ma )
.

UV CELL
THIS IS CALLED EYE OF THE BURNER . IT USE FOR SENSE THE FLAME IN THE BURNER .
ULTRA VIOLET CELL USE FOR FLAME SENSE SAFETY DEVICE IN COMBUSTION CHAMBER . IT CAN CAPABLE TO DETECT
FIRE AND EXPLOSIONS WITHIN 3-4 MILLISECONDS .IT WORKS THROUGH LFE-10 SEQUANCE CONTROLLER .
IT WORKS SENSING LIGHT AND REDUCTION IN RESISTANCE . FAULT:- SENSING , COMBUSTION FLAME , FIRING .
1 3 7 6
2 10 9E
FLAME OK 24VDC FEEDBACK
TO PLC. (FROM TB0.1-27/28)
220
VAC
UVUV

COMBUSTION BLOWER
IT TAKES AIR FORM ATMOSPHARE , AIR UES FOR
FIRE IN THERMOPACK .
FIRE = AIR + FUEL + IGINATION .
PLC RL1
TO
COMBUSTION
BLOWER DOL
220 VAC
CONTROL
PHASE

MODULATION AIR DAMPER CIRCUIT
FEEDBACK TO PLC
K1/13
K1 K2
24 VDC FROM DC BUS24 VDC FROM DC BUS
FEEDBACK TO PLC
K1/14
N N
FROM MODULATION UNIT
CLOSE AIR DAMPER
FROM MODULATION UNIT
OPEN AIR DAMPER
IT USE FOR COMBUSTION AIR BLOWER DAMPER FEEDBACK TO PLC.
K1 FOR AIR DAMPER CLOSE FEEDBACK TO PLC .
K2 FOR AIR DAMPER OPEN FEEDBACK TO PLC .
1
2
1. Contactor for air
damper open close .
2. combustion blower air
damper .

ALLEN BRADELY PLC UNIT
THE PURPOSE OF PLC WAS TO DIRECTLY REPLACE ELECTROMECHANICAL
RELAY AS LOGIC ELEMENT , SUBSITUTING INSTSED A SOLID STATE DIGITAL
DIGITAL COMPUTER WITH A STORED PROGRAM .
PLC IS ABLE TO AMULATE THE INTERCONNECTION OF MANY RELAY TO
PERFORM CERTAIN LOGICAL TASKES .
PLC USE FOR ONLY LIMITED INPUT AND OUTPUT CIRCUITS .
1. DIGITAL INPUTS MODULE MO,M1 = 30.
2. DIGITAL OUTPUTS THROUGH RC1 , RC2 = 25.
3. ANALOG INPUTS = 9 .

AC TO DC CONVERTER
1. CONVERTER :- IT USED TO CONVERT 220VAC TO 24 VDC
2. 24 V DC BUS : - IT USED TO DISTRIBUTE 24VDC .
1 2

MODULATION UNIT RESISTANCE FEEDBACK
1
2
14 15 2 1 3 8 7
FEEDBACK FROM
FIELD 135OHM
RESISTANCE
ANALOG FEEDBACK
TO PLC TB4-4,5
24
VDC
1. POTENTIOMETER :- IT USED TO CONVERET MODULATION UNIT
RESISTANCE TO ANALOG FOR PLC FEEDBACK .
2. 135 OHM’S RESISTANCE :- IT USED TO PROVIDE VARYING RESISTANCE SIGNAL
OF AR-63 MODULATION UNIT SIGNAL TO POTENTIOMETER AND THAT SIGNAL
IS ALSO PERPORTIONAL TO FUEL AND AIR FOR THERMOPACK FIRING. ITS
ALSO LOCATED IN MODULATION UNIT

Thermopack INTERLOCKING
If Diesel Day tank Level low , Thermopack will trip or not start .
if the pressure difference between inlet and outlet of coil is less then 1.5kg, burner will trip.
stack temp raises above 350 degC , burner will trip .
if pressure inside circulation system exceed 4.5kg then Mechanical safety valve will open .
If flame is not generated in burner / flame is not ok, burner will trip .
if modulation unit feedback not received , Thermopack will not start .
If inlet Temperature is above 260degC and outlet 285degC , Thermopack cut off.
If circulation motor feedback is absent then Thermopack will trip .
if gas pressure is less then 30mbar then Thermopack will trip .

START SEQUENCE
START
PLC CHECK ALL SAFETY
INTERLOCKING OK
CIRCULATING PUMP START. AUTO / MANUAL .
IT SHOULD BE START BEFORE 10 TO 15 MINUTES
BEFORE EVERY OPERATION TO CIRCULATE OIL IN
CLOSE LOOP .
COMBUSTION AIR BLOWER
PRE
PURGE
BURNER START
GAS FIRING DIESEL PUMP
TIGHTNEES OK
GAS LINE PRESSURE
MODULATION FEEDBACK
MAIN VALVE OPEN
DIESEL PUMP
START
COMMAND
DIESEL XV
VALVE OPEN
COMMAND

GAS FIRING DIESEL FIRING
FIRE = AIR + FUEL + IGINATION
PILOT VALVE OPEN
MAIN VALVE OPEN
GAS IGINATION DIESEL IGINATION
PLC FEEDBACK
THERMIC FUEL INLET , OUTLET TEMPURATURE
APH , OUTLET TEMPURATURE
DIFFRENTIAL PRESSURE , PUMPS FEEDBACK
FLAME SENSEOR .
MODULATION UNIT
FIELD ANALOG AND DIGITAL FEEDBACK .
HIGH
LOW
MAINTAIN AIR AND FUEL FOR
TEMPURATURE MAXIMUM SET
POINT .
CLOSE AIR DAMPER AND FUEL
VALVE FOR LOW SET POINT
STOP POST PURGE

THANKS

Thermopack ppt

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