INTERNSHIP REPORT

Nishat Mills limited

Submitted to :

Mr. Zawwar Iqbal Rao

( General manager )

Supervision of :

Mr. Naveed-ul-qamar
AM (Q.C)

Submitted by :

Zeeshan Arshad

Centre of Coal Technology

Faculty of Engineering & Technology Punjab University
Lahore

Nishat Mills Limited

Combined heat and power plant
Unit # 42

Turbine
A turbine is a rotary mechanical device that extracts energy from
a fluid flow and converts it into useful work. A turbine is a turbo machine with
at least one moving part called a rotor assembly, which is a shaft or drum
with blades attached. Moving fluid acts on the blades so that they move and
impart rotational energy to the rotor. There are two types of turbine.
1-Impulse turbine
2-Reaction turbine

Difference between reaction and impulse turbine

The term impulse and reaction denote the basic type of turbine. The basic
and main difference between impulse and reaction turbine is that there is
pressure change in the fluid as it passes through runner of reaction turbine
while in impulse turbine there is no pressure change in the runner. In the
impulse turbine first all pressure energy of water convert into the kinetic
energy through a nozzle and generate a high speed jet of water. This water
jet strikes the blade of turbine and rotates it. In the reaction turbine there is
pressure change of water when it passes through the rotor of turbine. So it
uses kinetic energy as well as pressure energy to rotate the turbine. Due to
this it is known as reaction turbine.

construction
Main parts of steam turbine:
Rotor
Blades (fixed and moving)
Bearings (thrust and journal)
Turbine casing
Valves (main stop valve, control valve, governor valve etc).
Rotor

assembly

The turbine rotor assembly consists of the turbine shaft and the attached
moving blade. The blades are usually made separately and then mounted on
the wheel. On some rotors, a hot wheel is placed on the shaft and allowed to
cool. Cooling causes the wheel to shrink and fit tightly on the shaft. The rotor
assembly absorbs energy from working fluid (steam, gas, water etc ) and
converts that energy into mechanical energy.

Rotor
Turbine

blades

The energy conversion takes place through the turbine blades. A

turbine consists of alternate rows of blades. This blades convert the chemical
or thermal energy of working fluid into kinetic energy and then from kinetic
energy to mechanical energy as rotation of the shaft.
There are two types of blade, fixed and moving blade. Moving blade is also
two types.One is impulse blade and another reaction blade.
Fixed blade:
A fixed blade assembly is very important for turbine blading. It is also known
as diaphragm. The diaphragm is the stationary part mounted to the
casing. It is made of hard metal. It separates the two stages and holds the
nozzles. The diaphragm could be made to surround the shaft closely, but if
the shaft rubs on the diaphragm and damages it, the whole diaphragm has
to replace. The shape of the blade is the key to the energy conversion
process. Since the fixed blades have a conversing nozzle shape, it is also
called nozzles. When steam is passed over the fixed blades, they increase
the velocity of steam as an operation of nozzles. Here blades are converted
the thermal energy of steam into kinetic energy by causing the steam to
speed up and gain velocity.
Moving blade:
Moving blade can be shaped in either of two ways: reaction shaped or
impulse shaped. The shape of the blade determines how the energy is
actually converted. Either type of moving blades or a combination of both
can be attached to the shaft of the rotor on dices, called wheels as shown in
the figure. Along the outer rim of the blades is a metal band, called
shrouding which ties the blades together. The moving blades convert the
kinetic energy in the moving speed into the mechanical energy as rotor
rotation.
Blading stages:
Two successive fixed and moving blades are collectively known as blading
stage. The effects of pressure and velocity of working fluids depend upon the
stage conditions.

For impulse blading velocity increases and pressure decreases across each
row as the steam passes through the fixed blading. Again when steam
passes through the impulse type moving blade, its velocity decreases, but its
pressure remains constant.
For reaction blading velocity increases and the pressure decreases across
each row as the steam passes through the moving nozzles mounted on the
rotor. When steam passes through the reaction type moving blade, its
pressure and velocity both decreases.
Blading deposits
If steam entering a turbine contains solids carried over from the boiler,
material may collect on the buckets and form deposits. If enough deposit
builds up on the bucket, the shape of the bucket changes. The path of the
steam through the buckets ( is reduced in size) when the deposits forms. The
reduction in flow causes steam pressure to build up on one side of the wheel.
This change in steam flow acting on the bucket causes the rotor to push
forward. This pushing increases the load on the thrust bearing.
If some of the deposits break off from the buckets, the distribution of the
weight becomes uneven and the vibration of rotor increases.
Main stop valves:
It is such a valve through which steam passes to the turbine blades.
By controlling this valve steam flow can be controlled. Each main stop valve
consists of a valve disk, a valve stem and a hydraulic actuator. The hydraulic
actuator contains a piston and a compression spring. Since the valve disk
and stems are connected to the piston, movement of the piston causes
movement of the valve disc. During normal turbine operation, hydraulic oil is
directed into or out of the hydraulic actuator. Directing oil into the actuator
opens the valve and compress the spring.
As long as the amount of oil in actuator is held constant, the valve will
remain in the same position. Bleeding oil from the actuator allows the spring
to push on the piston, closing the valve. Tripping the turbine causes hydraulic
oil to be bled quickly from beneath the piston, allowing the spring to quickly
shut the valve. Steam pressure also helps to close the valve by forcing the
disc back toward the seat. When the valve is closed), the flow of steam
toward the HP turbine is shut off.
Control valves:
When the main stop valves are fully opened, the flow of steam into the HP
turbine is usually regulated by four or more control valves. The control valves
regulate the turbine speed or its power output. Steam from the main stop

valve flows to the control valves through a steam line. The steam is sent to
different sections of the turbines nozzle block through the four steam lines
below the control valves. Each control valve feeds only one section of the
nozzle block.
The control valves are operated by hydraulic actuators. The control valves
regulate steam flow into the turbine by opening and closing in sequence. As
each valve is opened, more steam is admitted to the turbine. During normal
operation, the control valves are automatically positioned to compensate for
changes in load. For example, if load increases, the control valves are
opened more which increase the flow of steam into the turbine. If load
decreases, the control valves are closed more which decrease the flow of
steam into the turbine. At full condition, all the control valves are completely
opened.
Governors
The governor is the mechanism which opens and close the governor valve.
The governor valve regulates the amount of steam allowed into the turbine
and the amount of mechanical work produced. The governor valve is used to
control turbine speed. The speed of the driven equipment must be controlled
to perform its operating function. When a heavier load is placed on the
turbine more power is needed than when the turbine is partially loaded.
When the turbine shafts rotates, the force of spring prevents the fly balls
from moving apart. As the shafts approaches the operating speed, spring
tension is overcome by force of spinning force, and the balls move away
each other. As the fly balls separate, the governor valve is closed. Then the
turbine reaches operating speed, governor valve allows less steam in than at
start up and turbine stops accelerating. When an increased load on the
turbine slows the turbine down, the fly balls are pulled in toward each other.
With no difference between the speed at full and no load, regulation would
be zero. But if the governor design permits some increase in speed as the
turbine load is decreased, the turbine regulation is not zero.
Bearings
Two types of bearings are used to support and locate the rotors of steam
turbines:
Bearings support the shaft and allow it to rotate with the minimum friction.
Bearings also control radial and axial movement of the shaft. The lubricant to
the bearing provides a film between the rotating shaft and the stationary

parts which support and center the shaft. The combination of bearings is
used on many turbines which drive pumps.
The shaft is supported by a sleeve bearing. The sleeve bearing mounted at
the end of the shaft prevents radial movement .Journal bearings are used to
support the weight of the turbine rotors. A journal bearing consists of two
half-cylinders that enclose the shaft and are internally lined with Babbitt, a
metal alloy usually consisting of tin, copper and antimony; and Thrust
bearings axially locate the turbine rotors. The journal bearings in which the
shaft rests control radial movement
A thrust bearing is made up of a series of Babbitt lined pads that run against
a locating disk attached to the turbine rotor. High-pressure oil is injected into
the bearings to provide lubrication. The oil is carefully filtered to remove solid
particles. Specially designed centrifuges remove any water from the oil. The
thrust bearings limit movement of the shaft towards the end of the turbine.
The thrust bearings limit the amount of axial movement.

Casing
The inner casing carries guide blades and is kinematic ally supported. The
spaces between inner and outer casings are filled by sealing rings. The inner
casing is fixed in the horizontal and vertical planes in the outer casings so
that it can freely expand radial in all directions and axially from a fixed point.
The connection with the piping is made through breach nuts. This
arrangement provides ease of opening the joint during maintenance.
The turbine operates because there is difference in pressure between steam
in the chest and steam in casing. Steam pressure is higher in the steam
chest than in the casing. Without this pressure difference, steam would not
flow through the nozzle. If the pressure in the casing were allowed to go up
as high as the inlet pressure, then casing would be damaged. For this reason
turbines must never be started with the exhaust valve closed.
Some turbines have a safety valve installed on the exhaust line to relieve the
excessive pressure. The valve prevents the excessive pressure from
damaging the casing. On some turbines a sentinel valve whistle if the
pressure in the turbine too high. Under correct start up and operating
conditions, sentinel valve should never open to sound a warning. If the
sentinel valve ever starts to open , operator must take the immediate action
to reduce the pressure.

Working of Steam Turbine

Steam turbines are heart of power plant, they are the devices which
transform thermal energy in fluid to mechanical energy.

Energy Absorption from fluid - Role of Rotor Blades

When high energy fluid (high pressure and high temperature) passes through
series of rotor blades, it absorbs energy from fluid and starts rotating, thus it
transforms thermal energy in fluid to mechanical energy.

Rotating blades of turbine helps in transforming thermal in fluid to

mechanical energy

If you take a close look at one of the blade, it would be clear that a blade is a
collection of airfoil cross sections from bottom to top. When flow passes
through such airfoils it induces a low pressure on bottom surface and high
pressure on top surface of airfoil as shown in figure below.

Fluid flow around airfoil cross sectioned blade induces a high

pressure (P) and low pressure(P) on blade surfaces

This pressure difference will induce a resultant force in upward direction, thus
making the blade rotate. So some part of fluid energy will get transformed to
mechanical energy of blade. Before analyzing energy transfer from fluid to
blade, we will have a close look at energy associated with a fluid.

Energy Transfer to Rotors

When fluid passes through rotor blades it loses some amount of energy to the rotor blades.
Due to this both kinetic and enthalpy energy of fluid come down for a typical rotor. As kinetic
energy comes down velocity of flow decreases. If we directly pass this stream to next stage of
rotor blades it will not transfer much energy because of low velocity of flow stream. So before
passing the stream to next rotor stage we have to increase the velocity first. This is achieved
with use of a set of stationary nozzle blades, also known as stator. When fluid passes through
stator blades velocity of fluid increase due to its special shape thus one part of enthalpy
energy will get converted into kinetic energy. Thus enthalpy of stream reduces and kinetic
energy of stream increase. It is to be noted that here there is no energy addition or removal
from flow, what happens here is conversion of enthaply energy into kinetic energy. Now this
steam of fluid can be passed to next rotor blades and process can be repeated. Velocity and
enthalpy variation of flow is shown in following figure.

Velocity and enthalpy variations across rotor and stator stages of a typical steam
turbine

Degree of Energy Transfer

Total energy transfer to the rotor blade is sum of decrease in kinetic energy
and decrease in enthalpy. Degree of contribution of each term is an
important parameter in axial flow machines. This is represented by a term
called of degree of reaction, which is defined as

Where both enthalpy change and kinetic energy changes are defined across
the rotor blade.

0 % Reaction - Impulse Turbines

When D.O.R = 0 there will not be any enthalpy change across the rotor, such
a turbine is known as impulse turbine. Blades of such a turbine would like as
shown below.

A typical impulse turbine rotor cross section and flow pattern

Here incoming flow stream hits the blade and produces and impulse force on
it. Since enthalpy across the blade does not change temperature will also
remain same. There will be minor pressure drop across the rotor, but this is
almost negligible. Here energy transfer to the blade is purely due to
decrease in kinetic energy of fluid.

100 % Reaction Turbines

When D.O.R = 1 kinetic energy change across the rotor will be zero, energy
transfer will be purely due to decrease in enthalpy. Since kinetic energy is
same across the rotor absolute value of velocities remain same. This is
shown in figure below.

Fig.6 A typical reaction turbine rotor cross section and flow pattern
Usually people use compromise of above two discussed cases,that is 50%
D.O.R . Such turbines are known as Parson turbines, where both kinetic and
enthalpy energy transfer contribute equally to power transfer to rotor.lu

Lubrication
A turbine equipped with an oil relay governor must have an ample supply of
clean oil available under pressure for bearing lubrication and for the
governor hydraulic system. The oil circulating system keeps a good supply of
clean oil flowing to the governor and bearings. An oil is pumped, it passes an
oil filter to be cleaned of any impurities. As the oil passes through the
bearings, it removes heat that builds up in them. The oil is pumped through
cooler on its way to the bearings. Oil that becomes too hot loses its ability to
maintain an oil film in the bearing. Oil must be kept at proper temperature.
Oil becomes too hot is not good lubricant.
Severe damage to the turbine may result if the oil circulation system fails to
deliver oil to the bearings. The bearings melt out. Some turbines may be
stopped when the lubricating oil pressure becomes too low. An automatic
dump valve releases oil from trip cylinder when oil pressure is too low.
Unless dual or standby equipment has been provided, the turbine may have
to e shut down if a filter or cooler begins to clog or oil pump shows wear.
Standby equipment permits the flow of oil to be maintained if trouble occurs
with the operating filter, cooler or oil pump.
Extraction and induction
Removing steam at an intermediate stage is extraction. Some steam may be
removed from or added to a stage before it reaches the exhaust. Stem
removed from a stage can be used for the processes that need steam
pressures and temperatures above the pressure and temperature of the
exhaust.
Steam may also be fed or induced into the turbine at an intermediate stage.
Sometimes excess steam is available at the plant, at the pressures of a
turbines intermediate stage. This steam can be induced into the turbine at
that stage.
Over speed trip

The governor regulates the turbine under normal conditions, but sometimes
abnormal conditions occur. If all load is removed from a fully loaded turbine,
the turbine may over speed. If the steam is not shut off promptly, the turbine
over speeds until it flies apart. A trip pin in the turbine shaft is used to shut
off the steam flow in an emergency. At n0rmal speed trip pin inside the shaft.
The pin consist of unbalanced weight held in the shaft by a spring.
If the turbine over speeds, the pin is ejected from the shaft by centrifugal
force. When the turbine over speeds, the extended pin strikes the over speed
latch. The trigger releases the latch holding the trip lever, which is then
pulled down by a spring. The force of the spring closes the trip valve. The
Trip valve closes and cuts off the steam flow to the steam chest. The turbine
stops.
Large trip valves use oil under pressure to open them and hold them open.
The spring loaded valve is held open by the pressure of the oil. Overs peed
pin are set to act at speed 10 to 15% over maximum turbine speed. On one
type of small turbines, the rotor is equipped with a brake rim that is
activated when the turbine over speeds. The brake act like the brake of the
car, centrifugal force stretches or expands its rim rubs on the wall of the
casing and slows down the rotor. If brake rim does overspeed, some damage
occur to the wheel.

9MW TURBINE SYSTEM

1 st extraction (intermediate stage

Main steam Turbin

steam)
process
e
465

C 53 bar

Condense

250 0C 10 bar
1 stejector

Second extraction
extraction

Hp
heate
Intermediate stage steam
r
Gland steam
heater

Condensate

Common
point

Steam
De-aerator

Goes to
De-aerator

6MW TURBINE SYSTEM

Vent

Steam

Main Steam
Turbine
Super Saturated Steam

Low temperature
Turbo
wate
r
pum
p
Exhaust steam

Exhausts steam
to Gland steam

1.5 MW
Deaerator

TURBINE

Exhaust to
Deaerator

Contents
o Section
o Section
o Section
o Section
Turbine

1
2
3
4

Coal
water
Boiler

Here I will discuss the types of coal that is imported from Indonesia and South
Africa.

Indonesians Coal

These are the specifications of coal that is imported for power production.
Coal type

sub-bituminous

Calorific value

6400-6800 Kcal/kg

Moisture Content

2%-5%

C Content

30-50%

S content

1-1.1%

Ash

12%-15%

Volatile matters
HGI
Ash fusion temperature

35%-45%
less than 50
< 1600 0C

South African Coal

These are the specifications of coal that is imported for power production.
Coal type
Calorific value
Moisture Content

sub-bituminous
6400-6800 Kcal/kg
2%-5%

C Content

30-50%

S content

1-1.1%

Ash

12%-15%

Volatile matters
HGI
Ash fusion temperature

22%-29%
> 50
< 1600 0C

Ash test of fly ash

Total Moisture Content
Ash
Volatile matters
Fixed carbon

Loss on ignition

04-0.95%
80%-89%
2%-2.5%
2.5-8%

LOI is the amount of unburned hydrocarbons present in ash. Sometimes LOI

is very high in especially in South African coal. High the LOI means the high
the loss of unburned carbon. High the LOI reduce the quality of ash that have
bad impact on ash quality. Low LOI is preferred for usage in cement industry.

Use of fly ash

The use of fly ash provides three critical benefits to cement manufacturing
and the environment. First, being rich in silica, alumina, and iron, the fly ash
can essentially replace raw materials in cement raw feed, such as shale and
clay, which are otherwise mined or purchased. Second, the carbon content in
fly ash can provide a fuel supplement for the energy-intensive cement
manufacturing process. Finally, high-volume consumption of fly ash will
reduce the annual volume of waste and improve the overall environment.
This concept has been repeatedly demonstrated at commercial scale in
which several hundred tons of dry fly ash with up to 20 % unburned carbon
was used as a raw mix component in several cement plants in the Midwest.
Prior to the demonstrations, the fly ash was evaluated for compatibility and
fuel value to optimize its use (at rates up to 6 % of the raw mix). The
demonstrations realized several material, operational, energy, and
environmental benefits. The plant operations were efficient, stable, and
predictable. The cement plants realized an approximate fuel savings of 4 %
and a nearly 10 % increase in cement production. Cements produced from
the demonstrations showed properties comparable to those of the normally
produced cements. The demonstrations prove that using fly ash in this
regard is beneficial to both cement plants and power plants, and the
environment.

Provision of free flow of air through oven:

Dry air
Desiccators
Coal sample
Balance

Coal sample pulverizes to 60 meshes.

Three pre tarred uncovered crucibles were weighed.

Then weighed again with 1.0000 gm of sample in each.

The crucibles were placed in the standard coal ash determination

muffle furnace (preheated up to 750 C

The heating operation was continued for about two hours after which
these were removed from the furnace cooled in a desiccator and
weighed. The crucibles were again placed in the furnace for 1hour,
cooled in a desiccator and reweighed. The experiment was repeated
till constant weight of crucible plus ash was obtained. The ash
content was then determined using relationship given below :
%age ash = (c-a)/ (b-a) x 100
Where:
a = wt. of empty pretared crucible
b = wt. of crucible with sample
c = wt. of crucible after heating.

Plant method
At plant ash is determined by heating the coal in a furnace at 8500C
for 1 hour and for biomass for 40 minutes and apply for same ash
calculation.

Fixed Carbon
It is obtained by subtracting volatile matter, moisture and ash.
Fixed Carbon = 100 (V.M+ Moisture + Ash)

Cost estimation of water treatment

plant
R/O PLANT POWER COST
1-Feed Pumps =7.5Kw*3=22.5KW*24hrs*18.3Rs/kw/hrs = 9882
2-High Pressure Pumps=18.5*3=55.5Kw*24hrs*18.3Rs/Kwhrs= 24375.6Rs
3-Turbine Motor= 22.8Kw=22.8Kw*24hrs*18.3/Kwhrs=

9829.29Rs

4- Compressor Motor =4Kw=4Kw*12hrs*18.3/Lwhrs = 878.3 Rs

CHEMICAL AT RO PLANT
RO TREAT 5000= 27 kg/day * 400 =10800Rs
HCL = 120kg/day *6Rs/kg =720 Rs
BIOCIDE = 15Kg/day * 230Rs/kg =3450Rs

Labor cost = 3600/day

Lab analysis cost= 1100/day
Assume maintenance cost=2000/day
TOTAL COST =66634
Cost per hour =66634/24=2776.4
Capacity of plant = 63 ton/hour
Cost operation =2776.4/63=44.7Rs/ton

Demin Plant Cost

Feed pumps =5.5Kw *2 =11Kw* 24hrs *18,3 Rs/ Kwhrs =

4831.2 Rs

Dilution pump =2.2kw= 2.2Kw *****1.2 hrs *18.3Rs/Kwhrs= 48.31Rs

Acid Dosing Pump =0.75Kw= 0.75Kw *0.5 hrs *18.3Rs/Kwhrs = 13.72 Rs

Compressor Motor = 7.5 Kw = 7.5 Kw * 0.3hrs *18.3 Rs /KWhrs = 41.754 Rs

Chemical used at Demin plant

HCL =345Kg/ day*6 Rs/day = 2070 Rs
NaOH =420 kg/day * 24.5 Rs/day =10290 Rs

Lab analysis cost= 1100/day

Assume maintenance cost=2000/day
Total cost = 20395
Cost per hour = 20395/24= 850 Rs
Capacity of plant = 60 ton/hour
Cost operation = 850/60=14.166Rs/ton

Cost of mixed bed polisher plant

Feed pumps =7.5Kw =7.5Kw* 24hrs *18,3 Rs/ Kwhrs = 3294 Rs
Dilution pump =2.2kw= 2.2Kw *1.5 hrs *18.3Rs/Kwhrs=60.39Rs
Acid dosing pump =0.75Kw= 0.75Kw *0.5 hrs *18.3Rs/Kwhrs = 10.86Rs

Chemicals at MBP plant

HCL = 320 kg/day * 6Rs/kg = 1920 Rs
NaOH =370kg/day * 24.5 Rs/kg= 9065 Rs
Assume Maintenance Cost =2200/day
Total cost = 16550 Rs
Cost per hour =16550 /24= 690 Rs
Capacity of plant = 90 ton/hour
Cost operation = 690/90=7.66Rs/ton