INTERNSHIP REPORT

ATTOCK GEN LIMITED (AGL)

(July 3, 2017 – July 31, 2017)

INTERN

Tashfeen Ali Ahmed

(500092)
BE MECHANICAL ENGINEERING

|NUST SCHOOL OF MECHANICAL AND MANUFACTURING ENGINEERING|

(NUST-SMME)

Dated: July 28, 2017

 A report submitted to

Attock Gen Limited (AGL) as intern record

And

National University of Science and Technology (NUST) School of Mechanical and

Manufacturing Engineering (SMME) in conformity with the requirements for the
degree of Bachelors in Mechanical Engineering

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 Acknowledgement

First I would like to thank the AGL HR department for providing me with an opportunity
to intern here. The internship opportunity I had with ATTOCK GEN LIMITED was a great
chance for learning and professional development.

I thank Sir Muhammad Khalid for his supervision. I thank Sir Aizaz (Senior Officer) for
his cooperative attitude and help without which our internship objective could not have
been achieved.

I thank Wartsila Staff for their hospitality and care. I thank Sir Fahad (Senior Electrical
Engineer) and Sir Bani Ameen (Assistant Mechanical Engineer) for their devotion to teach
me. I lastly thank Sir Faizan Rasul (Trainee Mechanical Engineer) and Hafiz Hamza
(Trainee Mechanical Engineer) for their guidance and brotherly stance towards me. I am
grateful to them for answering my queries and helping me with their technical knowledge.

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 Preface

The following internship report documents the work done at Attock Gen Limited (AGL)
thermal power plant during the four week summer internship program starting from July
3rd to July 31st, 2017.

The report shall give an overview of the plant with technical details and the tasks carried
out during the period of internship. It has been divided into two sections accordingly.

I have tried my best to keep report simple yet technically correct.

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Contents
Acknowledgement ........................................................................................................................... II
Preface ........................................................................................................................................... III
SECTION I: PLANT OVERVIEW .......................................................................................... 1
1.1 Introduction ........................................................................................................................... 2
1.2 Diesel Generators (DG) ......................................................................................................... 2
1.2.1 Specifications ................................................................................................................. 3
1.2.2 Heads .............................................................................................................................. 3
1.2.3 Liner ............................................................................................................................... 3
1.2.4 Cams ............................................................................................................................... 4
1.2.5 Governor ......................................................................................................................... 4
1.2.6 Sump ............................................................................................................................... 4
1.2.7 Firing Order .................................................................................................................... 4
1.3 Turbochargers ........................................................................................................................ 4
1.4 Heat Recovery Steam Generators (HRSG) ........................................................................... 5
1.5 Steam turbine Generators (STG) ........................................................................................... 5
1.5.1 Specifications ................................................................................................................. 5
1.6 Alternator............................................................................................................................... 5
1.6.1 Specifications ................................................................................................................. 6
1.7 control room .......................................................................................................................... 6
SECTION II: TASKS PERFORMED ....................................................................................... 7
2.1 HFO Fuel line TRACING ..................................................................................................... 8
2.1.1 Statement ........................................................................................................................ 8
2.1.2 HFO Fuel Line................................................................................................................ 8
2.1.3 Buffer Tank .................................................................................................................... 9
2.1.4 Day Tank ........................................................................................................................ 9
2.1.5 Fuel Treatment Room ..................................................................................................... 9
2.1.6 Booster Unit.................................................................................................................... 9
2.1.7 Fuel Pump....................................................................................................................... 9
2.1.8 Fuel Injector.................................................................................................................... 9
2.2 Rankine cycle ...................................................................................................................... 10

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 2.2.1 Statement ...................................................................................................................... 10
2.2.2 Theory .......................................................................................................................... 10
2.2.3 Steam Cycle .................................................................................................................. 11
2.2.4 Feed Water Tank .......................................................................................................... 11
2.2.5 Heat Recovery Steam Generator .................................................................................. 11
2.2.6 Cyclone Separator ........................................................................................................ 12
2.2.7 STG .............................................................................................................................. 12
2.2.8 Condenser ..................................................................................................................... 12
2.2.9 T-s Diagram .................................................................................................................. 12
2.2.10 Determination of Power Output ................................................................................. 14
2.2.11 Conclusion .................................................................................................................. 14
2.3 Inspection ............................................................................................................................ 15
2.3.1 Vibrations ..................................................................................................................... 15
2.3.2 Fuel Injector Test .......................................................................................................... 15
2.3.3 3K Maintenance............................................................................................................ 15
2.3.4 Head Box Up ................................................................................................................ 16
2.3.4 Starting Air Compressor Inspection ............................................................................. 16
2.3.5 Lube Oil Purifier Unit Inspection ................................................................................. 16

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SECTION I: PLANT OVERVIEW

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1.1 INTRODUCTION
Attock Gen Limited (AGL) is the first power sector venture of the Attock Group of Companies and
is the first Independent Power Producer (IPP) commissioned under Government of Pakistan's
Policy for Power Generation Projects of 2002. Prime Minister of Islamic Republic of Pakistan
inaugurated Attock Gen Limited's power plant in an impressive ceremony at Morgah, Rawalpindi
on April 07, 2009.

AGL plant with a gross capacity of 165 MW has been designed to achieve maximum efficiency.
The Plant configuration consists of 9 reciprocating 16.5 MW furnace oil fired engine generator sets
and 9 heat recovery steam generators (HRSG) to provide steam for one 11.6 MW condensing steam
turbine. The concept of 9 engines plus one steam turbine in a combined cycle mode, improves the
reliability as well as the efficiency. The project is sponsored by The Attock Oil Company and
Attock Refinery Limited.

The unique feature of AGL's power plant is its fuel which is environment friendly RFO which is
extracted from the indigenous crude oil processed at the Attock Refinery in Rawalpindi. The major
fuel used is Heavy Furnace Oil (HFO) while Light Furnace Oil (LFO) is also used.

The AGL Power Plant is a combined cycle power plant, the main constituents of which are:

1. Diesel Generators (DG)

2. Turbochargers
3. Heat Recovery Steam Generators (HRSG)
4. Steam Turbine Generator (STG)
5. Alternators
6. Control Room

1.2 DIESEL GENERATORS (DG)

The Engines installed at the plant are of the latest cutting edge technology made and installed by
Wärtsilä, a Finnish company with expertise in IC Engines. There are a total of nine 18V46 engines
named as DG1 to DG9 each with a rated power of 17550 KW. The engines can run on both HFO
and LFO providing flexibility on operation but mostly it is run of HFO thus producing low cost
electricity. The engine is equipped with a turbocharger and a charge air cooler which boost up the
engine efficiency.

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1.2.1 Specifications
A few engine specifications are given below.

Manufacturer Wartsila
Number of Engines 9
Engine Type W18V46
Configuration V type
Number of Cylinders per Engine 18
Cylinder Bore 460 mm
Stroke 580 mm
Speed 500 rpm
Rated Output 17.5 MW
Rotation Direction Clockwise
Swept Volume per Cylinder 96 L
MEP 22.3 bars
1.2.2 Heads
There are a total of 18 heads, 9 on each bank of the engine. Heads consists of

1. Air Inlet Channel provides compressed air from turbocharger to the head. The diameter for
inlet is greater than that of exhaust.
2. Exhaust Outlet Channel takes exhaust gases from the liner (piston cylinder) through
exhaust valves and discharges it from the head. The diameter for exhaust is less than that
of inlet.
3. Opening Valves – There are 4 valves, 2 each for inlet and outlet from the liner. For inlet
valve the seat angle is 20 degrees while for outlet, it is 30 degrees. The opening and closing
of these valves is controlled by cams attached to roller, pushrod assembly which is
connected to rocker arm. The rocker arm lies above head and is attached to the opening
valves. When the cam pushes the pushrod, the rocker arm moves down opening the inlet
or outlet valve respectively.
4. Fuel Injector in the center of head sprays fuel inside the liner.
5. Starting Air Valve inside the head is used during the starting of engine.
6. Safety Valve operates when the pressure inside the liner exceeds a certain limit.
7. Water Cooling System – The head is water cooled from HT water. Outlet temperature of
HT water is about 85-90°C while the inlet temperature differential is 10-12°C. The
temperature of head is maintained to prevent overheating and forced forging.

1.2.3 Liner
The piston inside the liner consists of three rings, 2 compression rings and 1 scraper ring. The liner
is lubricated using lube oil. The lube oil performs following functions:

1. Lubrication – reduces friction

2. Cleaning – the exhaust gases consists of carbon particles that may attach on the inside of
the liner. Lube oil cleans the carbon particles. When the piston moves down, the scraper
ring scraps away lube oil into the sump tank below.
3. Cooling – maintains temperature.

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1.2.4 Cams
Two cams control the opening and closing of inlet and exhaust valve of the heads and 1 cam
controls the plunger and barrel mechanism present inside the fuel pumps. The 3 of these cams per
cylinder are timed in a specific configuration as mentioned by the manufacturer.

1.2.5 Governor
The engine operating parameters (load, rpm etc.) are controlled by the Governor. These are the
brain of the engine and monitor the engine parameters in real time. The governor can also
automatically trip the engine if any anomalies are observed. It controls the amount of fuel for input.

1.2.6 Sump
It is filled with lube oil for lubrication and cooling of the engine.

1.2.7 Firing Order

The firing order for 18V46 engine is as mentioned:

A bank: 1 7 4 2 8 6 3 9 5

B bank: 8 6 3 9 5 1 7 4 2

Figure 1: Terminology and Cylinder Designations

(image obtained from wartsila manual)

1.3 TURBOCHARGERS
A turbocharger, or colloquially turbo, is a turbine-driven forced induction device that increases an
internal combustion engine's efficiency and power output by forcing extra air into the combustion
chamber. Turbochargers increase the volumetric efficiency. This improvement over a naturally
aspirated engine's power output is due to the fact that the compressor can force more air—and
proportionately more fuel—into the combustion chamber than atmospheric pressure.

The exhaust runs turbines (type axial) on each bank of the engine. These turbines are connected by
a common shaft. The compressor increases the mass of intake air entering the combustion chamber.

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1.4 HEAT RECOVERY STEAM GENERATORS (HRSG)
A heat recovery steam generator (HRSG) is an energy recovery heat exchanger that recovers heat
from a hot gas stream. The HRSG in AGL are water tube boilers where water flows through pipe
and exhaust gases surrounding it heats the water in tubes. HRSGs consist of four major
components: the economizer, evaporator, super heater and water preheater. The different
components are put together to meet the operating requirements of the unit. There are a total of 9
HRSGs, one each connected to a DG.

The exhaust gases after passing through turbocharger enters the HRSG from superheater and goes
all the way down through HP evaporator, economizer to LP evaporator from where the exhaust
gases move to the stack and are discharged.

In addition to HRSG, an additional auxiliary boiler (type fire tube) lies beneath the feed water tank.

HRSG is discussed in detail in section 2.2.5.

1.5 STEAM TURBINE GENERATORS (STG)

In order to improve the overall plant efficiency the plant is designed to recover the heat produced
by the combustion inside the engines, which would otherwise be a waste, and produce superheated
steam which runs the turbine; thus making the power plant a combined cycle power plant. The
steam turbine installed is an impulse type steam turbine.

1.5.1 Specifications
The main features of the turbine are given below.

Manufacturer Peter Brotherhood Ltd.

Inlet Pressure 14.5 – 15 bars
Inlet Temperature 357°C
Exhaust Pressure 0.14 – 0.2 bar
Exhaust Temperature 65°C
Power Rating 15.3 MW
Turbine Speed 6048 rpm
Alternator Speed 1500 rpm
Turbine Trip Speed 6652 – 6955 rpm
Steam Flow 18.3 kg/s

1.6 ALTERNATOR
The alternators or generators installed on each engine are Synchronous type with brushless exciter
circuits. The generators have a feedback control provided by the Automatic Voltage Regulators.
The AVR controls the field excitation current by monitoring the output voltage and current thus
providing real time voltage and current regulations.

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1.6.1 Specifications
The main alternator specifications are as follow.

Generator Type ABB AMG 1600SS12 DSE

Voltage Output 15 kV
Frequency 50 Hz
Cooling Method Air Cooled

1.7 CONTROL ROOM

The control room has all the parameters of the plant on display. It serves as a central space where
all the operations of the plant can be controlled and monitored.

The plant is under constant observation from the control room. The stopping and starting of an
engine can be done from control room. In case of any change in parameters, it can be observed on
display.

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SECTION II: TASKS PERFORMED

PAGE | 7
2.1 HFO FUEL LINE TRACING
2.1.1 Statement
Determine and observe the HFO fuel line and understand the principles of the installed components.

2.1.2 HFO Fuel Line

The engines need a constant supply of fuel at a specific temperature and pressure. So in order for
the smooth operation of the plant a reliable system of providing fuel has been established. The fuel
comes from ARL and goes through following steps.

ARL
Fuel treatment (FT) Room

Buffer Tank HFO Separator Unit

Day Tank

Feeder Unit

Booster Unit

Clean/Dirty Leak
Tank

Heater Unit Mixing Tank

Duplex Filter

LP Pipe

Fuel Pump HP Pipe Telescopic Pipe Fuel Injector

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2.1.3 Buffer Tank
The buffer tanks are used to store the HFO which is being supplied from the Attock Refinery. There
are two HFO buffer tanks each with a capacity of 250,000 liters.

2.1.4 Day Tank

The day tanks serve the purpose of supplying fuel to the engines. The HFO day tanks and the LFO
day tank have a capacity of 250,000 and 100,000 liters respectively.

2.1.5 Fuel Treatment Room

1. HFO Separator Unit - The fuel treatment room houses five centrifugal separators which
remove the solid particles from the fuel and also regulate the remove and monitor the water
content in the fuel. The separator is PLC controlled and monitors certain parameters with
the help of sensors.
2. Feeder Unit - In order to pump the fuel from the day tanks a feeder unit is unit is used. The
feeder unit has two pumps for feeding HFO and one pump for LFO, a total of three such
stations for intermitted operation.

2.1.6 Booster Unit

The main purpose of the booster unit is to increase the pressure of the fuel, but it also maintains the
fuel at optimum temperature by heating it in the heat exchangers, re-filtering it and cooling the
unused fuel sent back from the engine. The duplex filter is a multi-caged filter with fine pores such
that it filters out any unwanted particle in the fuel.

From booster unit, the fuel travels through LP line to the fuel pump.

2.1.7 Fuel Pump

Fuel pump increases the pressure of the fuel. It works on plunger and barrel mechanism. This
mechanism is performed by the cams which push the roller/pushrod assembly to perform piston
movement of plunger and barrel.

The position of fuel rack of fuel pump controls the amount of fuel. This position is directly governed
by the governor. In order to stop the engine, starting air is connected to the fuel pump which is
operated in a way that it pushes the fuel rack outwards and stops the fuel flow.

From fuel pump, the fuel flows through HP pipe and telescopic pipe into the fuel injector
present inside head.

2.1.8 Fuel Injector

The fuel Injector sprays the fuel inside the liner at a high pressure. The opening pressure for nozzles
is 450 bar.

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2.2 RANKINE CYCLE
2.2.1 Statement
Observe the Rankine cycle of the combined cycle. Draw T-s diagram and determine the output
power of STG.

2.2.2 Theory
The Rankine cycle is a model that is used to predict the performance of steam turbine systems. The
Rankine cycle is an idealized thermodynamic cycle of a heat engine that converts heat into
mechanical work while undergoing phase change. The heat is supplied externally to a closed loop,
which usually uses water as the working fluid. The Rankine cycle closely describes the process by
which steam-operated heat engines commonly found in thermal power generation plants generate
power.

There are four processes in the Rankine cycle.

 Process 1-2: The working fluid is pumped from low to high pressure. As the fluid is a
liquid at this stage, the pump requires little input energy.
 Process 2-3: The high pressure liquid enters a boiler where it is heated at constant pressure
by an external heat source into superheated region.
 Process 3-4: The superheated water expands through a turbine, generating power. This
decreases the temperature and pressure of the vapour, and some condensation may occur.
The output in this process can be easily calculated using the chart or tables noted above.
 Process 4-1: The wet vapour then enters a condenser where it is condensed at a constant
pressure to become a saturated liquid.

The general description for such a cycle is as follows

Figure 2: Rankine Cycle Figure 3: T-s Graph

(image obtained from wikipedia) (image obtained from wikipedia)

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2.2.3 Steam Cycle
The steam cycle observed in the AGL plant is as follows:

Figure 4: Steam Line AGL

2.2.4 Feed Water Tank

It is a water storage tank. The temperature of water is maintained to 130°C. A pipe from the feed
water enters the LP Evaporator for maintaining the temperature.

Another pipe from the feed water tank is pumped into the economizer.

2.2.5 Heat Recovery Steam Generator

1. Economizer – Water in the economizer is heated to a high temperature. It does not converts
the water into steam yet.

PAGE | 11
 2. HP evaporator – Water from steam drum is heated to a higher temperature to form steam
in the HP evaporator which has two stages. The steam formed enters the steam drum from
above. Water at this stage now settles in the steam drum while steam remains over it.
3. Super Heater – Steam from steam drum now goes through the super heater where it is
heated to a temperature of about 350°C. This superheated steam now goes to main header
line named ‘902 Header’.
4. Steam Drum – Present above the super heater. The steam flow is described in the fig

2.2.6 Cyclone Separator

Before allowing superheated steam into the turbine, cyclone separator removes any mist/water
droplets which may damage the turbine blades.

2.2.7 STG
The superheated steam goes through turbine rotating the crank at 6000 rpm which is then gear down
to 1500 rpm for the alternator. Many parameters are being observed on turbine through sensors
from the control room.

2.2.8 Condenser
The steam from the turbine is then condensed to water and is pumped to the feed water tank. Steam
enters the air-cooled condenser at the top (blue pipe) of the heat exchangers, flows downward
through the heat exchanger tubes, and it condenses.

2.2.9 T-s Diagram

A simplified T-s graph for the above described cycle was determined by only considering the boiler
inlet and outlet parameters, turbine outlet parameters and condenser outlet parameters. The
complexity of the cycle was simplified by ignoring the number of components present in the cycle
such as cyclone separator.

Parameters obtained from the control room at that moment were as follows: (Enthalpy and entropy
were determined from steam tables).

Stage 1: Condenser Output

Temperature (T1) 62°C

Pressure (P1) 0.2 bar (20 kPa)
Entropy (s1) 0.8320 kJ/kg.K
Enthalpy (h1) 251.420 kJ/kg
Region Saturated water
Stage 2: Boiler Input

Temperature (T2) 130°C

Pressure (P2) 13.8 bar (1.38 MPa)
Entropy (s2) 1.6346 kJ/kg.K
Enthalpy (h2) 326.790 kJ/kg
Region Compressed

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 Stage 3: Boiler Output

Temperature (T3) 354°C

Pressure (P3) 13.8 bar (1.38 MPa)
Entropy (s3) 7.1379 kJ/kg.K
Enthalpy (h3) 3150.10 kJ/kg
Region Superheated
Stage 4: Turbine Output

Temperature (T4) 65°C

Pressure (P4) 0.25 bar (25 kPa)
Entropy (s4) 7.8302 kJ/kg.K
Enthalpy (h4) 2617.5 kJ/kg
Region Wet region
From the following data, t-s graph is as follows

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2.2.10 Determination of Power Output
To determine the power output, mass flow rate of steam is to be determined first. We know that:

Steam produced per boiler = 7.9 tons/hr

Steam needed for HFO heating = 3 tons/hr

Steam needed for Feed Water heating = 2.6 ton/hr

So mass flow rate for steam is calculated as

𝑚̇ = (7.9 × 9) – 3 – 2.6 = 65.5 tons/hr = 18.2 kg/s

Power output is

𝑊̇𝑇,𝑐𝑎𝑙𝑐 = 𝑚̇(ℎ3 − ℎ4)

𝑊̇𝑇,𝑐𝑎𝑙𝑐 = 18.2 (3150.1 − 2617.5) = 9.7 𝑀𝑊

The power output for STG as informed by the control room was 11 MW

𝑊̇𝑇,𝑎𝑐𝑡𝑢𝑎𝑙 = 11 𝑀𝑊

2.2.11 Conclusion
The percentage difference is found to be 11%. This difference occurred due to our assumptions and
simplification of the plant but was found close to the actual production.

REMARKS: Due to unavailability of data for the liner parameters, the diesel cycle could not be
drawn. Hence the graph for the combined cycle could not determined.

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2.3 INSPECTION
During my internship period in AGL, I actively took part in the daily activities happening in the
plant. These activities were related to preplanned maintenance of certain plant components (engines
etc.) or inspection of a certain component (e.g. compressor) due to undesirable result produced (e.g.
pressure build up is not as much as required).

The details of such activities is as follows.

2.3.1 Vibrations
Vibrations in any mechanical setup in operation is of vital importance. The vibrations of Diesel
Generators (DGs) are taken on monthly basis using vibrations scanner. The criteria for taking
vibrations is pre-described by the manufacturer Wartsila.

There are a total of 8 points on each bank of the engine where vibrations are taken. Hence making
a total of 16 points for vibration inspection of the engine. At all these points the vibrations are to
be taken along longitudinal, transverse and vertical directions (xyz axes).

 Longitudinal - along axis of crank shaft

 Transverse - across the axis of crank shaft
 Vertical - vertically up/down

According to the manual, the frequency of the vibration scanner is to be set at 7.3 Hz. The vibration
readings should not exceed 28mm. In case of high vibration readings, the vibration dampers are
inspected for cracks or loosening of bolts.

2.3.2 Fuel Injector Test

Fuel injectors spray the HFO inside the cylinder liner. The opening pressure for fuel injectors is
determined. If it is not in the limit, the injectors cannot spray fuel in the form of fine mist and
combustion process does not occur efficiently.

The opening pressure for fuel injectors is 450 bars. If the opening pressure is found to be different
then following steps are taken.

Opening Pressure Adjustments

400-450 bars No readjustments
350-400 bars Adjust to 400 bars
<350 bars Change nozzle to new one
The opening pressure is adjusted by tightening or loosening the adjustment screw on top of fuel
injectors.

2.3.3 3K Maintenance
The engines are inspected on their running hour basis. After every set time interval certain elements
of the engines are inspected. These inspection schedule has been provided by the Wartsila.

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During my internship, I participated in a 3K maintenance. This maintenance is carried out when
the engine has completed its 3000 running hours.

3K maintenance included:

1. Inspection of fuel injectors: The cylinder head covers are removed and fuel injectors are
sent for fuel injector test. The faulty injectors are repaired or either replaced.
2. Cam inspection: The cams are inspected for any scratches or ambiguity. This is a visual
inspection.
3. Change of governor oil

The clearances in the valves are set before starting the engine. It is 1 mm for inlet valve and 1.5
mm for outlet valve.

2.3.4 Head Box Up

Spare heads were assembled after cleaning. This included

1. Washing the head in cylinder head washing machine. Then cleaning it with diesel and
removal of carbon attached in the outlet valves.
2. Inspection of seat and replace of seat with a new one. The seat is removes using a hydraulic
jack.
3. Cleaning of inlet and exhaust valve in sand blasting machine.
4. Maintaining the required angles for valves. For inlet 20 degrees, for outlet 30 degrees.
5. Cleaning of springs.
6. Inspection of rotocaps.
7. Assembling the valve spring and rotocap in head using the hydraulic jack.

2.3.4 Starting Air Compressor Inspection

The starting air compressor is a 2 stage compressor with intercooling driven by an electric motor.
Intercooling improves the efficiency of compressor by reducing the amount of work done by the
second staged compressor.

During my internship period, one of the 5 starting air compressors was found to be malfunctioning
as it didn’t produce the required pressure of 30 bars. On inspection, there was a leakage in the
suction valve which was replaced..

2.3.5 Lube Oil Purifier Unit Inspection

The purifier unit works on centrifuge principle. Its inspection includes:

 Dismantling the purifier unit.

 Cleaning of each component
 Replace of seal rings

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