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At this very outset I acknowledge with gratitude the guidance and support
rendered to me by training centre “BOILER & CO-GENERATION” of
HINDALCO, without which this training would not have materialised.
I would like to thank Mr. S K Das (GM Training and Development Centre)
for providing an opportunity to interact and take guidance from engineers of
“BOILER & CO-GENERATION DEPARTMENT”.
I would like to thank Mr. S K Gupta, Mr. P K Singh, Mr. Ankit Kumar
Singh, Mr. Rajesh Pandey and all engineers and staff of the department for
their encouragement during the training period.
I also want to thank the management of the company to provide me such a
material which is helpful to make such a report.
HINDALCO - AN OVERVIEW
INTRODUCTION OF BOILER
5.6 MW TURBINE
CAPACITOR
Organization at a glance
I-HISTORY-
II-HINDALCO TODAY
PARTICULARS PRODUCTION
Power Generation (Renusagar) 769MW
Alumna 660000MTPA
Aluminium metal 342000MTPA
Rolled Products 80000MTPA
Extrusions 16250MTPA
Wire Rods 52203MTPA
Foils 17207MPTA
Co-generation 78MW
III-LOCATION-
Lying in the foothills of the Vindhya Range, Renukoot is about 160 kms
from Varanasi and 154 kms from Mirzapur. It is well connected to both
these cities by beautiful metalled roads passing through green forests.
There is direct daily train named Tata-Hatia –Amritsar Express also
famous as, Moori Express between Amritsar to Tatanagar and Ranchi via
Renukoot. Besides this, there is a direct train Swarnajayanti Express
between Ranchi to New Delhi via Renukoot commuting both ways twice
a week.
Apart from above, Renukoot is also connected with Kolkata through
direct train named Shaktipunj Express commuting between Jabalpur to
Kolkata via Renukoot.
The nearest Airport is at Babatpur, Varanasi, which is about 180 Kms by
road from Renukoot.
For any further information regarding reservation facilities etc., one can
contact transport department of Hindalco.
HINDALCO’S VISION
HINDALCO’S MISSION
The company has its own mine of bauxite. Bauxite is mixed by open
lohardanga & Richuguts mines of bauxite are then transported by means
of ropeways to the nearest railway head. From there is transported to
Renukoot in railway wagons.
POWER-GENERATION-
ALUMINA PLANT-
From bauxite alumina is extracted in the alumina plant. This plant has
the capacity to produce 350000MTPA of alumina. The capacity this
plant will shortly be increased to 3,70000MTPA.
REDUCTION PLANT
FABRICATION PLANT-
The Aditya Birla group is India’s second largest business house, With
turnover of over Rs.280 billion, asset base valued at over Rs.265 billion and
nearly 72,000 employees in 18 countries the world over.
Over 65Units in India and overseas as well (in Thailand, Indonesia,
Malaysia, Philippines, Egypt and Canada) and international trading
operation spanning several countries including Singapore, Dubai, Russia,
Vietnam, Myanmar and China make it India’s first truly multinational
conglomerate.
The group also has a significant presence in the Financial Sector, Power and
Telecommunications Sectors in tie-ups with giants like Sun Life Insurance
(Canada), Powergen Pic. (U.K.) and AT & T (U.S.A.) and Tata respectively.
On the social front: a value based, caring corporate citizen, the Aditya Birla
Group inherently believes in trusteeship concept of management. Part of the
group’s profit is ploughed back into meaningful welfare driven initiatives
that make a qualitative difference to the lives of a marginalised people.
A-GPOUP COMPANIES-AT A GLANCE IN INDIA
BOILER
Any closed vessel exceeding 22.75 liters in capacity, which is used exclusively for
generating steam under pressure and included any mounting or other fitting
attached to such vessel, which wholly or partly under pressure when is shut off.
CO-GENERATION
1. BOILER # 1
CAPACITY = 80 TPH
PRESSURE = 52.5 Kg/sqcm
TEMPERATURE = 450ºC
MAKE = Walchandnagar, Pune
TYPE = Pulverized fuel Boiler
YEAR OF
COMMISSIONING =1986
2. BOILER # 2
CAPACITY = 80TPH
PRESSURE = 52.5 Kg/sqcm
TEMPERATURE = 450ºC
MAKE = BHEL, Trichi
TYPE = fluidized Bed Combustion Boiler
YEAR OF
COMMISSIONING =1989
3. BOILER # 3
CAPACITY = 140 TPH
PRESSURE = 111 Kg/sqcm
TEMPERATURE = 535ºC
MAKE = BHEL, Trichi
TYPE = Pulverized fuel Boiler
YEAR OF
COMMISSIONING =1996
4. BOILER # 4
BOTTOMING TURBINE
TOPPING TURBINE
(1) FURNACE:
A Boiler furnace is the first pass of the boiler in which fuel is burned and
from which the combustion products pass to the super heater and second
pass of boiler.
The combustion process is the continuous process, which
takes place in first pass of the boiler and controlled by fuel input through
coal feeders. In HINDALCO there has two type of firing method use in
Boiler.
1. Front firing methods
2. Corner firing with tangential arrangement
(2) ECONOMISER:
The first and primary one is that it separates steam from the
mixture of water and steam discharged into it and to reduce the
dissolved solid contents of the steam to below the prescribed
limit of 1ppm.
DRUM INTERNELS
These are the equipment, which are the used to separate water from
steam and to direct to the flow of water and steam to obtain an
optimum distribution of drum metal temperature in boiler operation.
The drum internals consists of baffle arrangement, devise which
change the direction of flow of steam and water mixture, separators
employing spinning action for removing water from steam or steam
purifiers as washer and screen dryers.
(4)DOWNCOMERS
Downcomers provide a passage for water from the water drum to
bottom ring header. From bottom ring header the water goes to water
walls for heat absorption and conversion into steam heating. To
achieve the circulation of water into water wall Boiler circulation
pumps are provided in down comers.
Water walls are the necessary element of the boiler. They serve as the
means of heating and evaporating the feed water supplied to the
boiler from the economizers via boiler drum and Downcomers. These
tubes receive water from the boiler drum by means of douncomers
connected between drum and water walls lower header.
Water walls absorb 50% of the heat released by the combustion of
fuel in the furnace, which is utilized for evaporation of feed water.
The mixture of the water and steam is discharged from top of the
water walls in to the upper wall header and then passes through riser
tubes to the steam drum.
A riser is a tube through which the mixture of water and steam pass
from an upper water wall header to the steam drum.
The steam generated by the boiler is usually wet or at the most dry
saturated because it is in direct contact with water. So, in order to get
superheated steam, a device known, as superheater has to be
incorporated in the boiler.
The dry saturated steam from the boiler drum flow inside
the superheater tubes and the hot flue gases flows over the tubes ands
in this way its temperature is increased at the same pressure.
(8) DESUPERHEATER
The desuperheater is only brought into use when the reheated outlet
temperature rises above the normal temperature. The desuperheater
comprises a spray nozzle shell and associated spray assembly
projecting into a section of the superheater steam line. Spray water
for desuperheater is taken from the boiler feed water pump discharge.
BOILER AUXILIARIES
1. FANS
The primary air fan supplied heated air to the coal mill to give dry and
pulverized coal to the furnace for efficient combustion. There are two P.A.
fans per boiler, each fan having pneumatically operated radial
Guide vanes at the fan inlet to control the fan output.
(b) F.D.FAN
The forced draught fan is provided to supply air required for pulverized
coal combustion in the furnace, air for fuel oil combustion and over fire
air to minimize NOX production. The F.D. fan system comprises of two
single stage axial flow, constant speed, and auto variable pitch fans per
boiler.
Scanner fans are installed in the boiler for supplying continuously cooling
air to the flame scanner provided for the flame supervision. It takes
suction from F.D. fan outlet and boosts the pressure further to provide
cooling air to the scanners.
SOOT BLOWERS
Soot / Ash deposited in various region of boiler is removed with the help
of soot blowers, which utilize steam as the main working medium. This
part is mainly concerned with the existing soot blowing system and the
problems arising in the system during operation.
ELECTROSTATIC PRECIPITATORS (ESP)
FUNCTION:
Function of ESP is to clean the flue gas coming out from boiler by utilizing
electrostatic forces. Ash particles are collected in hoppers. It works on the
principle of CORONA EFFECT.
WORKING:
ELECTRONIC TRANSFORMER
CONTROLLER RECTIFIER
DC POWER
Voltage: 40-70KV
Current: 1200mA
POSITIVELY CHARGED
COLLECTING PLATE
DEPOSITED
ASH
NEGATIVELY CHARGED
EMMITING ELECTRODE
TOTAL ASH FROM BOTH BOILER = 21.32TPH
ASH COLLECTION PER SHIFT = 172.32 T
CAPACITY OF ASH REMOVAL = 28TPH
TOTAL ASH REMOVAL TIME = 6.8HRS
ASH CONDITIONER CAPACITY = 60TPH
MECHANICAL EXHAUSTER
CAPACITY = 1550 M3/HR
PRESSURE = 500MMHg
BLOWER CAPACITY = 2800M3/HR
PRESSURE = 1.0 Kg/cm2
ASH COMPOSITION
SiO2 = 61.2%
Al2O3 = 21.48%
Fe2O3 = 10.38%
TiO2 = 1.7%
P2O5 = 0.19%
SO3 = 0.1%
CaO = 2.1%
MgO = 0.54%
Na2O = 0.3%
K2O = 1.26%
MnO = 0.05%
DE-MINERALISED WATER PLAN
To operate high pressure boiler there is need to have high quality water,
which should be free from minerals and should have low conductivity and
low silica content. Thus water is produced from the De-mineralised (DM)
water plant where clear water is converted into distilled water by ion-
exchange process and is usually termed as De-mineralised (DM) water.
The DM water is feed into the boiler with the help of boiler feed pump.
In HINDALCO the main source of water is River water. In pump house
collect raw water and treated with LIME & ALUM, after then the clear
water is comes in DM plant.
HOT DM B#1&2
PLATE HEAT TANK DEARATOR
EXCHANGER
DG = To remove CO2.
DM Water
MIX BED UNIT = If any left out ions then remove in mix
Bed.
DM WATER
ph = 7.0 – 8.5
SiO2 = < 0.02 PPM
Conductivity = < 5 micro mhosh
FEED WATER
pH = 8.8 - 9.2
SiO2 = < 0.02 PPM
Conductivity = < 5 micro mhos
COAL HANDLING PLANT (CHP)
QALITY OF COAL
Moisture = 3% to 30%
Volatile matter = 3% to 50%
Ash = 2% to 30%
Fixed carbon = 16%to 92%
Calorific value = 2950 to 3500 KCal/Kg
ANALYSIS OF COAL
:GRADE:
A : Exceeding 6200
B : Exceeding 5600 but not exceeding 6200
C : Exceeding 4940 but not exceeding 5600
D : Exceeding 4200 but not exceeding 4940
E : Exceeding 3360 but not exceeding 4200
F : Exceeding 2400 but not exceeding 3360
G : Exceeding 1300 but not exceeding 2400
EQUPMENT FUNCTION
(2) COAL IMPACTOR : It is used for sizing the coal and crushing
the coal of required size ( - 6 mm to – 20 mm) which is fed into
coal bunker.
BALL MILL
BOWL MILL
(2) Grade = M – 24
COMMISSIONING OF TURBINE: -
Over speed testing by oil injection was checked but machine did not tripped
up to max pressure of 5.2 kg/cm2
SL NO HPSO HPCV
(Kg/cm2) (mm)
1 1.5 0
2 2.0 8
3 2.5 12.5
4 3.0 17
5 3.5 20
6 4.0 27
7 4.5 34
Note: -
While control valve adjustment control oil pressure - 8 Kg/cm2
Oil temperature 42° C
OBSERVATIONS: -
0.05 shim was placed below turbine both turbine bearing for final alignment
of turbine and gear box
0.05 shim placed both the side of pedestal axial key
5nos spherical washer replaced in front bearing bottom pedestal as they
found broken ( three nos in front left side and two nos on right side)
Turbine BP gland top half was cut removed from top casing as it was seized
in casing. Gland replaced with old spare gland.
ESV diffuser was found lose and strainer in 100% OK condition.
Rear turbine oil gland fins replaced.
GOP drain line modified with expansion bellow arrangement.
Trip level clearance 1.0 and 1.1 axial and 0.85 radial
Generator both bearing upper half holes were modified to suit the shaft
vibration pick up location.
SPARES CONSUMED:-
5.6MW turbine
Please find here with the test report of scale sample, collected from 5.6 MW
turbine rotor blade, sent by you on dated 04.05.2007. Tests are carried out on
XRF - IQ method which is not calibrated for such type of samples hence
values are only indicative.
Na2O = 9.1%
Al2O3 = 16.4%
SiO2 = 19.4%
Fe2O3 = 4.5%
MoO3 = 4.4%
TiO2 = 0.9%
SO3 = 0.9%
Cao = 0.9%
Bao = 0.2%
MgO = 0.1%
Cr2O3 = 0.1%
CuO = 0.1%
The major constituents are Na2O, Al2O3, SiO2, Fe2O3 and MoO3.
In future we request you to please send these type of samples with proper
transmittals mentioning purpose of analysis as the same is requirement of
our ISO system and for our record also
Regards,
M P Sharma
Laboratory
3- CAPACITOR
Qwhere, “q” is the charge, “V” is the potential difference and “C” is a
conatant called capacitance of a conductor.
PRINCIPAL OF A CAPACITOR
The action of a capacitor can be explaned by assuming first that an isolated
metal plate is given a positive charge “Q” or so that its potential is raised
by V volt (say) and then capacitance ; “C “ of the isolated metal sphere is
given by :-
C=+Q/V
Suppose that another insulated plate is broght near the first one. By
induction , negative charge will appear on the side of insulated plate and
positive charge will appear on first plate. The negative charge on the plate
tends to lower the potential of the first plate . So the result is the potential of
first plate is lowered slightly and is given by:--
C=Q/V
Now let the second plate be connected to the earth . Electons from the earth
flow to neutralize the positive charge on the second plate. Now the plate has
only negative charge on the surface facing the first plate. Hence , the
potential of the first plate is further reduced to V and thus its capacitance
increases. This type arrangement is called capacitor.
UNITS OF CAPACITANCE
In cgs electrostatic system the capacitance of a conductor is said to be one
statfarad if one stat coulomb of charge is sufficient to raise its potential
through one statvolt.
1 farad = 9 x 10 statfarad.
DIFFERENT TYPE OF VARIABLE CAPACITOR
The capacitor consists of a strip of wax paper placed between two strip of
iron or aluminium foil which are about an inch wide and 8 to 12 feet in
lenth. The strip of the foil and waxes paper are then rolled up and encased in
a small cardboard or metalcylinder. This arrangement results in small
physical size but with large plate area and comparatively large capacitance.
Oft en the plates of aluminium or thin are separated by a thin filmof paper
treated with oil or a film of plastic material
It was the first electric medium used in capacitor. It was invented by Pieter
Van Musschen Brook in 1746.
8-ELECTROLYTIC CAPACITOR :-
These are wade by poming a direct current between two sheets of aluminium
foil with a suitable electrolyte of liquid conductor between them. An
extremely thin film of aluminium oxide is then formed on the anod plate.
The anode plates on the positive of the D.C. supply. This film is an insulator
and fermes the dielectric between the two plates. The electrolyte is god
conductor. Since the dielectric thickness d is very small and c 1/d therefore
the capacitance is very large In order to maintain the oxide –film , the anode
terminal is marked in red or by a+ sign. It is very important to connect this
terminal to the positive side of the circuit in which the capacitor is used. If
this is not done , the oxide film will be break down.
USE OF CAPACITOR
Thus , 63% of the maximum charge is deposited in one time constant (CR ).
DISCHARGING:--
If the plates of a charged capacitor are connected through a conducting
wire , the capacitor gets discharged. Again there is flow of charge through
the wires and hence there is current. Suppose a capacitor of capacitance C is
has charge Q . At t = 0 , the plates are connected through the resistance R .
Let the charge on the capacitor be q and current in the circuit be I at time t
Charge (q) is given by ;-
Q = qe – t / Cr
When the battery is disconnected and the plates are joind together by a wire,
electrons flow back from plate A to plate B until the positive charge on B is
completed neutralized . A current thus flow for a while in the wire and
charge on the plates become zero.
The capacitance of a capacitor varies directly with area of facing plates and
the directly constant of the insulating material. Capacitance also varies
inversely with with separation of plates i. E. with the thickness of the
dielectric. Alternating current ( A. C. ) also cannot flow , but electrons move
to and from the capacitor and gives the appearance of a continuous current
loop as with D . C . flow , a blocking or couple capacitor can separate A . C .
component of a signal circuit .
SPEED-594 RPM
DISCHARGE-7500M3/HR
HEAD-33.35 MTR
PUMP INPUT-757.94KW
LUBRICANT USED IN PUMP- SERVOSYSTEM 32
LUBRICATION FREQUENCY- WEEKLY
MOTOR ERS No.- 1200-E-02(EAST)
- 1200-E-01(WEST)
CT BOOSTER PUMP
COOLING TOWER
Make- Paharpur RCC Cooling Tower
Type-DF-ID Counter Flow
Model-83636-14V-06
Total flow-10000M3/hr
No. of Cells-6(5 Op + 1 Spare)
Flow per cell –2000M3/hr
HWT-45*C
CWT-35*C
Range-10*C
WBT-27.8*C
Evaporation loss-144.6M3/hr
Drift loss-0.05%
TYPE-SWSI
CAPACITY-0.11M3/SEC
S.P.-100 MMWG
BHP- 0.263
SIZE-1000HPR
RPM-2830
SR NO. 1713
MFG.INDUSTRIAL MACHINARY MANUFACTURERS PVT LTD.
DISTRIBUTED BY.
C.DOCTAIRE & COMPANY PVT.LTD.,DELHI
STEAM GENERATION
B#1 = 80TPH
B#2 = 80TPH
B#3 = 140TPH
B#4 = 140TPH
HI-TECH
CARBON = 25TPH
STEM DISTRIBUTION
Temperature BL BR
Transmitter PA
Cold Air
FAN
HAD
CAD
BALL MILL
SASOD
Classifier
SACD
PA Control Damper
A- COND. TO
FROM ALUMINA
ALUMINA. PLANT
PLANT
TO
BOILER TO
NO.1 BOILER 1
&3
B#3 DRY ASH HANDLING SYSTEM
BAG
FILTER
VACUUM
BREAKER
VACUUM
BREAKER
CONCLUSIONS