ZPC Bulawayo Power Station ITA Report

NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY
FACULTY OF INDUSTRIAL TECHNOLOGY
DEPARTMENT OF INDUSTRIAL AND MANUFACTURING

ENGINEERING
INDUSTRIAL TRAINING ATTACHMENT REPORT
BY
STUDENT NAME: PREVALENCE MAPHOSA
STUDENT NUMBER: P0111490E
ORGANISATION: ZPC BULAWAYO
INDUSTRIAL SUPERVISOR: MR T. CHUMA
ACADEMIC SUPERVISOR: ENG. T. CHIKOWORE
ACADEMIC YEAR: 2014-15
Submitted for the partial fulfilment for the requirements of a Bachelor of engineering (Honours)
degree in Industrial and Manufacturing Engineering
ITA Report – ZPC BULAWAYO POWER STATION
DEDICATIONS
The author dedicates this report to the almighty God the creator of all and the entire ZPC
Bulawayo Power Station family.
P. MAPHOSA IME 2014/15 i

ACKNOWLEDGEMENTS
I greatly appreciate the effort of all the people who helped me in coming up with this report. To
begin with, I would like to extend my gratitude to the entire ZPC BPS staff for selflessly
dedicating their time and effort to help me learn the systems and processes at the plant.
I would also like to utter my greatest acknowledgements to my academic and industrial

supervisors, Engineer T Chikowore and Mr. T Chuma for giving me the support and guidance
during my industrial attachment period. My acknowledgment goes also to my workmate
Simbarashe Mutsengerere for his support during my attachment period.
P. MAPHOSA IME 2014/15 ii

ABSTRACT
This report reflects on the industrial knowledge and practical skill acquired by the author towards
the attainment of a Bachelor of Engineering (Honours) Degree in Industrial and Manufacturing
Engineering during the period from January 2015 to July 2015. The report covers broad aspects
from the nature of the organisation, operations, systems and projects done by the author during
his attachment to the Zimbabwe Power Company‟s Bulawayo Power Station. An outline of the
plant‟s polices in line with EMS ISO 14001(2004), QMS ISO 9001(2008) and SHE (Safety
Health and Environment) is also given. Chapter one is the introductory chapter and the author
looks at the general organogram, history and set up of ZPC Bulawayo Power Station. Respective
departments and their core duties are briefly discussed in this chapter. Chapter two contains
detailed information on the processes and systems at the station‟s Coal Plant. This includes
information on handling, conveying of coal from the stock site to the bunkers and ash disposal.
Chapter three discusses the processes and systems at the water treatment and effluent plant.
Chapter four contains information on the boiler section and the performance department. Here
the author summarises the energy conversion process from coal combustion to the point where
steam is sent to the turbine. The turbine section and control room is discussed in chapter five,
where the author focuses of the final energy conversions in the steam power plant. Chapter six
looks at engineering and maintenance management issues at the plant. The seventh chapter
discusses the health, safety, environment and quality issues for the company. The eighth chapter
contains recommendations in the form of projects, done by the author during his attachment
period. References on sources from which the author obtained some information and formulae
are also given under references column. This information is of great value and it is sincerely
appreciated. Although great care has been taken to avoid mistakes in this edition, it is difficult to
claim perfection. Constructive criticism and suggestions will be warmly welcome for the further
improvement of this document.
P. MAPHOSA IME 2014/15 iii

Contents
DEDICATIONS ............................................................................................................................... i
ACKNOWLEDGEMENTS ............................................................................................................ ii
ABSTRACT ................................................................................................................................... iii
CHAPTER 1. INTRODUCTORY CHAPTER ........................................................................ 1
1.0 Introduction ........................................................................................................................... 1
1.1 Company background ........................................................................................................... 1
1.2 Company location ................................................................................................................. 2
1.3 Company mission and vision ................................................................................................ 2
1.3.1 Vision ............................................................................................................................. 2
1.3.2 Mission Statement .......................................................................................................... 2
1.3.3 Core Values .................................................................................................................... 3
1.4 Bulawayo Power Station Structure ....................................................................................... 4
1.5 Products and markets ............................................................................................................ 6
1.6 Company‟s core business ...................................................................................................... 6
1.7 Training Program .................................................................................................................. 6
1.8 Summary ............................................................................................................................... 8
CHAPTER 2. COAL AND ASH PLANT ................................................................................ 9
2.0 Introduction ........................................................................................................................... 9
2.1 Department structure and objectives ..................................................................................... 9
2.1.1 Coal and ash plant objectives ....................................................................................... 10
2.2 Coal analysis ....................................................................................................................... 10
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2.2.1 Coal visual inspection .................................................................................................. 11
2.2.2 Coal grading ................................................................................................................. 11
2.3 Coal handling ...................................................................................................................... 11
2.3.1 Wagon tippler ............................................................................................................... 11
2.3.2 Overhead crane ............................................................................................................. 11
2.3.3 Fire prevention ............................................................................................................. 12
2.4 Conveyor systems ............................................................................................................... 12
2.4.1 Conveyor belts.............................................................................................................. 12
2.4.2 Redlers .......................................................................................................................... 14
2.5 Ash handling and disposal................................................................................................... 17
2.5.1 Soaking and conveying of ash ...................................................................................... 17
2.5.2 Beneficial uses of coal ash ........................................................................................... 18
2.6 Coal data capture and records ............................................................................................. 19
2.6.1 Coal supply records ...................................................................................................... 19
2.6.2 Periodic coal records summary .................................................................................... 20
2.7 Summary ............................................................................................................................. 22
CHAPTER 3. WATER TREATMENT PLANT ................................................................. 23
3.0 Introduction ......................................................................................................................... 23
3.1 Structure 0f the department and its importance .................................................................. 23
3.1.1 Overview of power generation water properties .......................................................... 23
3.1.2 Uses of soft and demineralised water ........................................................................... 25
3.2 Ion exchange resins ............................................................................................................. 25
3.2.1 Anion exchange resins ................................................................................................. 25
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3.2.2 Cat ion exchange resins ................................................................................................ 26
3.3 Water softeners .................................................................................................................... 27
3.3.1 Regeneration of softeners ............................................................................................. 28
3.4 Demineralisation of water ................................................................................................... 29
3.4.1 Regeneration of demineraliser ..................................................................................... 30
3.5 Common problems in ion exchange systems at BPS .......................................................... 30
3.6 Effluent plant ....................................................................................................................... 31
3.6.1 Effluent plant process flow .......................................................................................... 31
3.7 Summary ............................................................................................................................. 33
CHAPTER 4. BOILER HOUSE ........................................................................................... 34
4.0 Introduction ......................................................................................................................... 34
4.1 Section overview and organisational structure .................................................................... 34
4.2 Literature Review ................................................................................................................ 35
4.2.1 Water tube boilers ........................................................................................................ 35
4.2.2: Fire tube boilers........................................................................................................... 36
4.3 Structure and components of boilers at BPS ....................................................................... 37
4.4 Boiler light up and combustion process .............................................................................. 38
4.4.1 Combustion Process ..................................................................................................... 39
4.5 Heat Exchange and steam generation process ..................................................................... 41
4.5.1 Convection ................................................................................................................... 42
4.5.2 Conduction ................................................................................................................... 42
4.5.3 Radiation ...................................................................................................................... 43
4.6 Boiler Pressure Raising ....................................................................................................... 43
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4.7 Super Heating of Steam....................................................................................................... 44
4.8 Essential Boiler mountings............................................................................................ 45
4.8.1 Automatic Feed water regulators ................................................................................. 45
4.8.2 Boiler water level gauge glass ...................................................................................... 46
4.8.3 Alarms .......................................................................................................................... 46
4.8.4 Grit arrestors ................................................................................................................. 46
4.8.5 Boiler safety valves ...................................................................................................... 46
4.8.6 Soot blowers ................................................................................................................. 47
4.9 Boiler Efficiency ................................................................................................................. 48
4.9.1 Factors affecting Boiler efficiency ............................................................................... 49
4.10 Boiler storage and water quality.................................................................................... 50
4.10.1 Chemical dosing ......................................................................................................... 50
4.10.2 Boiler blow down .................................................................................................... 50
4.11 Summary ........................................................................................................................... 50
CHAPTER 5. TURBINE HOUSE & CONTROL ROOM ................................................... 51
5.0Introduction .......................................................................................................................... 51
5.1 Process overview (Turbine-Alternator) ............................................................................... 53
5.2 BPS Essential turbine auxiliaries ........................................................................................ 55
5.2.1 Air ejector and Quick start nozzle ................................................................................ 55
5.2.2 Turbine gland sealing ................................................................................................... 56
5.2.3 Feed water heaters ........................................................................................................ 56
5.2.4 Evaporators................................................................................................................... 56
5.3 Cooling water system at BPS .............................................................................................. 57
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5.3.1 Condenser ..................................................................................................................... 57
5.3.2 Cooling towers ............................................................................................................. 58
5.3.3 Oil and alternator fan air coolers .................................................................................. 59
5.4 Turbine lubrication oil system............................................................................................. 60
5.4.1 Main oil pump .............................................................................................................. 60
5.4.2 Auxilliary oil pump ...................................................................................................... 60
5.4.3 High pressure jacking oil pump ................................................................................... 62
5.4.4 Barring / Turning gear oil pump. ................................................................................. 62
5.4.5 Steam Governors .......................................................................................................... 62
5.5 Alternator and Generation process ...................................................................................... 62
5.5.1 Generator synchronisation............................................................................................ 63
5.5.2 Power from a generator ................................................................................................ 63
5.6 Summary ............................................................................................................................. 64
CHAPTER 6. ENGINEERNG AND MAINTENANCE MANAGEMENT .......................... 65
6.0Introduction .......................................................................................................................... 65
6.1 Bulawayo Power Station Planning Procedure ..................................................................... 65
6.1.1Scope ............................................................................................................................. 65
6.1.2Responsibility ................................................................................................................ 65
6.1.3 G87 Form: .................................................................................................................... 65
6.1.4 Work Order Cards (WOCs).......................................................................................... 66
6.1.5 Working Instructions .................................................................................................... 66
6.1.6 Maintenance Records ................................................................................................... 66
6.2 Maintenance work ............................................................................................................... 66
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6.2.1 MMD (Mechanical Maintenance Department) ............................................................ 66
6.2.2 CMD (Civils Maintenance Department) ...................................................................... 67
6.2.3 Control and Instrumentation and EMD (Electrical Maintenance Department) ........... 67
6.3 Conclusion ........................................................................................................................... 67
CHAPTER 7. HEALTH, SAVETY, ENVIRONMENTAL AND QULITY MANAGEMEN . 68
7.0 Introduction ......................................................................................................................... 68
7.1 Health and Safety ................................................................................................................ 68
7.1.1 BPS Safety Policy ........................................................................................................ 69
7.2 Environmental Management ............................................................................................... 70
7.2.1 Environmental Policy ................................................................................................... 70
7.3 Quality Management ........................................................................................................... 71
7.3.1 BPS Quality Policy....................................................................................................... 71
7.4 Summary ............................................................................................................................. 72
CHAPTER 8. PROJECTS............................................................................................................ 73
8.0 Introduction ......................................................................................................................... 73
8.1 Project one: Implementation of six sigma (DMAIC) on boiler plant defects ..................... 73
8.1.2 Literature review .......................................................................................................... 77
8.1.3 Methodology ................................................................................................................ 78
8.1.4 Project solution ............................................................................................................. 78
8.1.5 Results, Conclusion and recommendations .................................................................. 85
8.2. Project 2: Condenser extraction pump steam turbine drive design ................................... 86
8.2.1 Project Proposal............................................................................................................ 86
8.2.2 Literature review .......................................................................................................... 88
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8.2.3 Design Process ............................................................................................................. 94
8.2.4 Results .......................................................................................................................... 99
8.2.5 Project summary, recommendations and lessons learnt. ............................................ 102
8.3 Project three: Boiler performance optimisation by simulating an ARENA software based
operating program ................................................................................................................... 102
8.3.1 Project proposal .......................................................................................................... 102
8.3.2 Literature review ........................................................................................................ 104
8.3.3 Methodology .............................................................................................................. 108
8.3.4 Results presentation and analysis ............................................................................... 110
8.3.5 Conclusions and recommendations ............................................................................ 112
8.4. Other work done ............................................................................................................... 112
8.4.1 Boiler 9 Temperature fall trend and report (16-18 June 2015) .................................. 112
REFERENCES ........................................................................................................................... 115
APPENDICES ............................................................................................................................. 116
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List of Figures
Figure 1. 1: Position of ZPC in the ZESA structure and Government ............................................ 3
Figure 1.2: Organogram of the Bulawayo Power Station ............................................................... 4
Figure 2. 1: Coal/ Ash plant organisational structure...................................................................... 9
Figure 2. 2: Rubber Conveyor Belt System (Harbajan, 2010) ..................................................... 13
Figure 2. 3: Structure and operation of redlers (AutoCAD drawing) ........................................... 16
Figure 2. 4: Ash handling at BPS (AutoCAD drawing) ............................................................... 18
Figure2. 5: Ash disposal at BPS (AutoCAD drawing).................................................................. 19
Figure 2. 6:Daily coal record sheets for 22/02/2015 ..................................................................... 21
Figure 3.1:Brine softener and Demineraliser layout at BPS ......................................................... 24
Figure 3.2: Water softening process ( (Alchin, 2009) ................................................................... 27
Figure 3.3: Softener regeneration steps (Alchin, 2009) ................................................................ 28
Figure 3. 4: Chemical reactions in the demineraliser (Alchin, 2009) ........................................... 29
Figure 3. 5: BPS Effluent Plant schematic diagram ...................................................................... 32
Figure 4. 1: Organisational structure of the boiler house section .................................................. 34
Figure 4. 2: Boiler Input and Output diagram (Rolland, 2005)..................................................... 35
Figure 4. 3: Water tube boiler (Roland, 2005) .............................................................................. 36
Figure 4. 4: Fire tube boiler (Hilton, 2010) ................................................................................... 36
Figure 4. 5: Coal ignition in a chain grate furnace (AutoCAD drawing) ...................................... 40
Figure 4. 6 Heat exchange and steam generation process (AutoCAD drawing) ........................... 41
Figure 4. 7: Thermostatic feed water regulator (AutoCAD drawing) ........................................... 45
Figure 4. 8: Spring loaded safety valve (AutoCAD drawing)....................................................... 47
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Figure 4. 9: Retractable soot blower nozzle (Rosella, 1995) ........................................................ 48
Figure 5. 1: Organisational structure of the turbine/alternator section ......................................... 51
Figure 5. 2: Thermal plant Turbo-alternator components (PennWell, 1997)................................ 52
Figure 5.3: Temperature - entropy diagram for BPS Rankine cycle ............................................. 54
Figure 5.4: Air ejectors (Leyzerovich, 2008) ................................................................................ 55
Figure 5. 5 Shell and tube surface condenser ................................................................................ 58
Figure 5. 6: Hyperbolic Cooling tower (photo)............................................................................. 59
Figure 5. 7 BPS 30MW turbine alternator oil circuit .................................................................... 61
Figure 5. 8: Generator excitation and three phase connection (AutoCAD drawing) .................... 63
Figure 5. 9: Single phase circuit (AutoCAD drawing).................................................................. 64
Figure 8. 1: Power units sent out against target for Jan-June 2015 ............................................... 74
Figure 8. 2: Boiler plant uptime against target for Jan to Jun 2015 ............................................. 80
Figure 8. 3: Scatter plot for generated power against refractory failure ....................................... 81
Figure 8. 4 Pareto graph for the forced outage contributing defects ............................................. 82
Figure 8. 5: Ishikawa diagram for refractory failure root causes at BPS ...................................... 83
Figure 8. 6: Ishikawa diagram for tube burst root causes at BPS ................................................. 83
Figure 8. 7: User interface for Microsoft Access database for Maintenance plan database user .. 84
Figure 8. 8: Impulse turbine against reaction turbine performance (Molling, 2006) .................... 89
Figure 8. 9: Steam inlet and outlet vector triangle for turbine blade ............................................ 91
Figure 8. 10: Combined vector triangle for turbine blade ............................................................. 92
Figure 8. 11: Torsional shear stress (Gupta, 2005) ....................................................................... 94
Figure 8.12: Graphical solution for turbine triangle of vectors..................................................... 97
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Figure 8. 13: Final turbine assembly drawing ............................................................................. 100
Figure 8. 14: Parallel arrangement of steam powered pumps and electric pumps ...................... 102
Figure 8. 15: Boiler efficiency results ......................................................................................... 111
Figure 8. 16: Boiler efficiency against design target for BPS boilers ......................................... 111
Figure 8. 17: Boiler 9 S/heater temperature trend for 16-18June 2015....................................... 113
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List of Tables
Table 1. 1: Training used by trainee during attachment period ...................................................... 7
Table 5. 1: Turbine specifications at BPS ..................................................................................... 52
Table 5. 2Generator Specifications at BPS ................................................................................... 52
Table 8. 1Boiler outage and power generation summary for Jan-Jun 2015 ................................. 79
Table 8. 2: Calculation results summary ....................................................................................... 99
Table 8. 3: Detailed parts list for steam turbine components ...................................................... 101
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CHAPTER ONE: INTRODUCTORY CHAPTER

1.0 Introduction
This chapter covers the company‟s background as well as its vision and mission statement. The
chapter includes as well a brief background of the company, its location and its organisational
structure. The author will briefly outline as well as the industrial training program used during
the period of attachment.
1.1 Company background
Zimbabwe Power Company (ZPC) is a subsidiary of ZESA Holdings group of companies. It was
incorporated in 1996 as an investment vehicle in the generation of electricity and became
operational in 1999. The organization has been authorized to construct, own, operate
and maintain power generation stations for the supply of electricity. ZPC currently operates four
coal fired power stations, Hwange, Bulawayo, Munyati and Harare thermal station, and one
hydro power station, Kariba South Power Station. The five power stations have a total of 1960
MW as installed capacity and each power station holds a generation license from the Zimbabwe
Electricity Regulatory Authority (ZERA). Plans are currently being put in place for the
repowering the small power stations by replacing the current boiler plants with new circulating
fluidized bed (CFB) technology which is expected to enhance the small thermal stations'
generating capacity to 340MW. The company's mandate is to generate electricity for the
domestic market. The Small Thermal Power Stations are operating as embedded generators (i.e.
power stations that are directly connected to the distribution network) but will be dispatched only
to meet supply shortfalls as follows:
 For strategic system security

 To cover constraints on the national grid
 To provide an alternative to imports to reduce demand on foreign currency.
 To sell electricity to the domestic market through PPA's with the Zimbabwe Electricity
Transmission and Distribution Company (ZETDC)
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Bulawayo Power Station is a coal-fired thermal power station generating plant which was
commissioned between 1948 to 1958 being the first small thermal power station in Zimbabwe
with a total installed capacity of 120 MW .It is located at the heart of Bulawayo the country‟s
second largest city. It was designed with a common range of 10 boilers feeding into common
steam receivers from where the turbines are run. From the time it was commissioned up to 1960,
the plant was connected to a local network within Bulawayo area, the average load factor was
about 50% of the total capacity of the plant. In 1961 the plant was connected to the main grid and
thereafter used as a peak load station. Currently (as at 30 July 2015) the plant is working at rated
capacity 60MW as the small 15MW and one 30MW turbo-alternators are de-commissioned.
1.2 Company location
Bulawayo power station is located in the heart of the city of Bulawayo at the corner junction of
Khami road and Lobengula Street.
1.3 Company mission and vision
The company is guided by its mission and vision in its day to day operations and strategic
planning.
1.3.1 Vision
To be the leading supplier of energy and related services in the region
1.3.2 Mission Statement
To generate electricity and supply of energy related products, we are committed to delivering
reliable energy and services to exceed stakeholder expectation through:
 Use of environmentally friendly technologies.

 Development and retention of highly skilled, effective and motivated staff.
 Positive returns for our shareholders

1.3.3 Core Values
In pursuit of the vision and mission, the ZPC will be guided and upheld by the following
principles/core values:
 Teamwork: Bound and powered together as one, we shall maximize on the skills base of
team members.
 Environment: Towards clean and sustainable energy generation
 The customer: Powering the economy and homes into the future
 Creativity: Creating energy solutions with the courage to implement
 Professionalism: Fearless, diligent and accountable application of skills without favour
 Social Responsibility: Uplifting the welfare of our communities
Figure 1. 1: Position of ZPC in the ZESA structure and Government

1.4 Bulawayo Power Station Structure
The management team at BPS consists of the Power Plant Manager on top of the hierarchy and
just below the manager are the managers of the Maintenance, Human Resources and Operations
department. The station‟s accountant is the head of the finance department while the senior loss
control officer is the head of the loss control department. The station‟s engineer is the leader of
the maintenance department followed by the maintenance engineer. Sectional forepersons of the
various maintenance sections are the immediate supervisors and lastly they are artisans and
assistants. The Operations department is composed of Shift charge Engineers, boiler and turbine
operators and lastly the auxiliary plant attendants.
Figure 1.2: Organogram of the Bulawayo Power Station

 Maintenance Department - This is the department responsible for the engineering

maintenance jobs in the power plant. The section head is the Plant Engineer and works with
the help of the foremen of the subsections. The subsections of this department are the
Electrical maintenance (EMD), Mechanical maintenance MMD, Civils (CMD) and
Information technology (IT). The EMD works on electrical maintenance while the MMD
works on mechanical faults. IT focuses on the Information and technology, which looks
mainly at the plant‟s computer networks and operations. The CMD work involves boiler
construction, cleaning and also on carpentry related jobs.
 Loss Control department- The loss control department is the security services provider for
the station.
 Human resources department- This department focuses on welfare of the workers through
addressing work related problems. The plant‟s clinic is also under this department and is
there to give medical care to workers at work. The administration of the station is under the
human resources department and looks at jobs related to contract signing, termination,
disciplinary issues and employee promotion among other jobs.
 Operations department- This is the department which looks at the plant operations through
the chemical services, water treatment, coal plant, boiler and turbine house. The operations
manager is the section head and is backed by the shift charge superintendents in his duties.
Operations related jobs involve boiler and turbine operations, water treatment, coal
bunkering and ash monitoring.
 Finance department- The finance department focuses on the monitory related issues of the
power station. This is done through integrated performance of the accounting, procurement
and the stores sub departments. The accounting jobs involve monitoring day to day business
transactions while the procurement involves purchasing and ordering of goods which involve
spare parts, other raw materials and protective clothing and equipment, among other things.
The store is there to issue out the purchased goods to their respective departments.

1.5 Products and markets
The main product from ZPC is electricity. Bulawayo Power Station operates and trades with
ZETDC, the only customer under a Power Purchase Agreement (PPA). ZETDC is the
transmission business subsidiary of ZESA Holdings. ZETDC has both local and regional
customers. The local customers include households and industrial companies in Zimbabwe while
some of the regional customers are Namibia (Nampower), Zambia and South Africa (Eskom).
ZPC produces 920MW at full capacity for both local consumption and export market.
1.6 Company’s core business
The core business at Bulawayo Power Station (BPS) is to generate electricity for consumption in
Zimbabwe and regionally. Electricity is produced using raw materials which are coal, water, air
and chemicals used for water treatment and other auxiliary purposes. Coal is supplied by Hwange
Colliery Company and Makomo (Pvt) Ltd Company. Water is obtained from the city council
water works, and some from the station‟s boreholes. Chemical energy from Coal is converted
into heat energy and used to heat water in a pressurised vessel (boiler) into high pressure
superheated dry steam. The thermal energy from steam is converted to rotational mechanical
energy by an impulse turbine at 3000r.p.m. The turbine is coupled to a rotor which possesses a
strong magnetic field, whose magnetic flux cuts stationary three phase armature windings on the
alternator to produce electrical energy. The generated electrical power is fed into the national
grid and from this point ZETDC the immediate customer takes over the responsibility of
transmitting and distribution the electrical power to its customers.
1.7 Training Program
The trainee was attached under the Operations department for the weeks covered so far. He took
timely visits to the Planning department. However he will be officially shifting to the Planning
and Mechanical department up to December 2015. The training program is flexible and efficient
for the attachee as the courses covered in theory have been applied in many areas.

Table 1. 1: Training used by trainee during attachment period
DEPARTMENT LEARNING AREAS DURATION MENTOR
COAL PLANT  Coal receiving, 2 weeks Coal plant

bunkering systems, foreman
records, ash disposal
WATER  Ion exchange systems 3 weeks Shift charge

TREATMENT  Effluent plant Engineer
TURBINE  Rankine cycle, 8 weeks Shift charge

HOUSE  operation of systems, Engineer
 oil, air, water, steam
circuits, generators,
BOILER HOUSE  Rankine cycle 6 weeks Shift charge

 Operation of systems Engineer
 Air, gas, water circuits
PERFOMANCE  Performance 5 weeks Performance

DEPRTMENT measurements Engineer
 Technical reports
CONTROL  Synchronisation, 2 weeks Control room

ROOM  Generation statistics technician
 Transformers

1.8 Summary
In this chapter the author gave a brief description of the company‟s background, location, vision,
mission statement and also the core values. The company‟s organisational structure was also
looked at, siting briefly the core duties of the different departments. The author also gave an
outline of the training program followed on the industrial attachment period. The full training
program for the year is found on the appendix section of the report.

CHAPTER TWO: COAL AND ASH PLANT

2.0 Introduction
Coal is one of the major raw materials at Bulawayo Power Station as it is the source of heat
energy used in the generation of steam. This chapter will focus on the coal and ash plant
department at BPS. Coal handling, conveyor systems and ash disposal will be discussed in detail.
The author will also outline the coal data capturing and recording processes.
2.1 Department structure and objectives
Bulawayo Power Station‟s main coal suppliers are Makomo and Hwange Colliery Company. The
coal is transported on rail wagons and road trucks from the coal mines to the power station.
Available at the power station is a department dedicated for the stocking, handling, conveying
and keeping of coal records at the plant. This department is named as the “Coal and Ash Plant
Department”. The Coal and Ash Plant staff comprises the foreman, plant operators, and
assistants. For the structure of the coal yard reader may refer to a provided A1 size drawing
provided.
Figure 2. 1: Coal/ Ash plant organisational structure

2.1.1 Coal and ash plant objectives
Like other departments at ZPC Bulawayo, the coal and ash plant processes are governed
according to ISO 9001(2008) and ISO 14001 (2004) and hence it has its QMS and EMS
objectives. The QMS and EMS objectives are given as:
2.1.1.1 QMS Objectives
To ensure that all wagons are offloaded within 48 hours of receipt to avoid demurrage charges.
 To ensure the boiler coal bunkers are filled up at knock off time during generation periods so
as to guarantee a continuous and consistent supply of coal to the boiler plant.
 To ensure that ash hoppers are emptied before 1600 hours daily during generation periods so
as to accommodate overnight ash bunkering.
 To adhere to set Safety, Health and Environment (SHE) standards in order to foster zero
tolerance on accidents and work based injuries per month.
2.1.1.2 EMS Objectives

 To continuously minimise dust levels so as to reduce effects on the environment.
 To always dispose of ash per the city council by-laws and intended usage by the general
public
2.2 Coal analysis
Coal is a non-renewable solid fossil fuel formed by a series of natural geochemical processes
from the plants that remain accumulated together with other sediments for a long time. Due to
these geochemical processes, coal composes some chemical components which have an effect on
its energy content and combustion characteristics. These components include sulphur, moisture,
ash, volatile matter and fixed carbon among other elements. Coal analysis is mostly done to
determine whether the coal is fit for the supplier‟s price or not. Poor quality coal attracts a
discount from the actual price paid for the coal.

The coal from different suppliers is separated and the samples are tested for conformance to the
required specifications. One of the critical components tested is the carbon content of the coal.
This analysis of coal is done at the stations laboratory.
2.2.1 Coal visual inspection
Experience is also applied in analysis of coal as visual inspection can be used for simple analysis.
Visual inspection involves the use of one‟s sight to estimate the condition of the coal by looking
at the amount of alien objects in the coal and its physical qualities.
2.2.2 Coal grading
After conduction of experiments and other surveying techniques, the results are used to classify
the coal into different commercial grades. Decisions are taken whether to appeal for discounts or
compensations on not. Optimum conditions may also be determined on how the coal will be used
to achieve the best possible results.
2.3 Coal handling
Coal handling involves the process of caring for coal from arrival, offloading, stocking up to the
bunkering process. Fire prevention is one of the critical aspects in coal handling.
2.3.1 Wagon tippler
The wagon tippler is a gear driven device used to offload wagons. A pinion is coupled to a
motor and drives a larger gear. Angular motion forces the wagon upside down to offload the
contents. The wagon is supported by bars on the tippler to prevent it from toppling. The wagon
tippler is driven by a 400V/ 66A three phase motor.
2.3.2 Overhead crane
The overhead crane is used for carrying coal from the stock yard to the hoppers which supply the
submerged belts. Its other purpose is to estimate the amount during survey of coal at the stock
yard. This is done by lowering a gauge to estimate the height of the stocked coal and this height
is used to approximate the volume of coal present.

2.3.3 Fire prevention
Coal is a black fuel and thus absorbs great amounts of heat energy during hot days. Due to its
absorption of heat and its chemical properties it has a tendency of igniting naturally due to
excessive heating. This ignition will cause the coal at stock site to burn rapidly and such issues
are common at Bulawayo power plant during hot seasons. Structures such as water sprinklers are
essential components of the coal plant as they reduce this natural combustion.
Water sprinklers comprise of water pipes and a pump which gives the water pressure so that it
reaches all the parts of the pile. Sprinklers are also used to minimise coal dust in the atmosphere
as required by Environmental Management System ISO 14001 (2004).
This is also a good safety measure as workers are at less risk of infection by pneumoconiosis and
other and cancers respiratory diseases.
2.4 Conveyor systems
Conveyor systems are available in different types, and are mainly chosen depending on the job at
stake which is determined by the nature, shape, mass and quantity of conveyed products. There
are two types of conveyor systems used at ZPC Bulawayo for carrying coal. These types of
conveyor systems are the redlers and conveyor belts.
2.4.1 Conveyor belts
This is a conveyor system which uses rotational power from an electric motor to run the rubber
belt hence transporting the load over a distance. In construction the rubber belt is wrapped
around two drums, the drum on the drive end being connected to a motor, usually through a fluid
coupling which regulates the motion between the motor and drums for safety. The rubber belts
have a high thermal strength to prevent them from burning if they carry coal which is under
natural combustion. They also have a large tensile strength as the coal can be conveyed at an
average flow rate of 120tonnes per hour on the inclined belt.

Figure 2.2 shows a rubber conveyor belt. ZPC Bulawayo has six rubber conveyor belts for
conveying coal as indicated on the site drawing.
These belts are as follows:
 Two submerged belts which are the North and South submerged belts. These belts supply the
North and South redlers. These submerged belts are individually driven by electric motors of
rating (400V/ 38A)
 One main stocking belt which collects coal from the redlers and stocks through a distributor
 Two cross over belts which are the East and West crossover belts which supply the main
inclined bunkering belt through hoppers. The cross over belt motors are rated (400V/ 14.4 A
at 975 rpm.
 One main inclined bunkering belt which collects coal from the two cross over belts through a
hopper and sends it to the bunkers, where it is further transferred to the boilers. The motor
for the inclined belt is rated (380V-400V/ 41.4A)
Figure 2. 2: Rubber Conveyor Belt System (Harbajan, 2010)

2.4.1.1 Machine Operational Principle
The rubber conveyor belt operational principle is such that the belt is wrapped around two rollers
(the idler and the drive rollers) using an adhesive lap join, Harbajan (2011). The drive roller
being attached to the geared motor while the idler roller is provided with slots for tensioning the
belt furthermore the conveyor system is provided with several equally spaced side to side contact
rollers to support and to guide the load being transported.
2.4.1.2 Design Features and Materials
The features of the conveyor belts at BPS consist of two mild steel rollers which are rubberised
to achieve the drive frictional contact of the belt system. The side to side contact rollers are made
of mild steel material. Depending on the applications, components such as bearings and seals are
determined by where the conveyor will utilized, in area with water, bearings with covered
bearing cage are used and seals are used to seal off areas which do not need to come into contact
with water on the machine components.
2.4.1.3 Maintenance Procedures for conveyor belts
Rubber belts are prone to breaking due to heavy loading which exceeds their tensile strength.
Maintenance procedures of belts mainly involve joining the loose ends through a process called
splicing. Splicing can either be cold or hot splicing. Hot splicing involves the use of special glue
to join the loose ends and applying constant heat to strengthen the bond.
Cold splicing involves using a knitted wire which is pressurised on the loose ends of the belt after
stretching them together using a tool called a tick-to. Constant supply of oil on rollers and gears
which drive the belts is done to ensure good lubrication on these parts.
2.4.2 Redlers
Redlers are one of the most sophisticated conveyor systems. There are two pairs of redlers used
at Bulawayo power station.

These are:
 The North and South redlers which are supplied by the submerged belts and they carry coal
to the crossover belts for bunkering and also the main stocking belt for stocking purposes.
The North and South redlers are individually driven by motors which have a rating
(400V/48A at 1465 rpm).
 The emergency pair of redlers which are used to carry coal straight to the boilers in case of
an emergency on the main bunkering line. They collect coal from a hopper which is supplied
by a Front-End loader.
2.4.2.1 Operational Principle of Redlers
A scaled drawing of a Redler is shown in Figure 2.3. The redlers need a continuous supply of
coal to continue carrying the products to the next level. The North and South redlers collect coal
from the submerged belts and carry it upwards to the crossover belts and the stocking belt. The
confined space between the walls of the redlers and the links allows for successive compressions
as the links move up the wall. Coal is forced to move upwards in the confined space and the flow
continues with constant supply from the belts. The links of the Redler (Refer to internal view of
Redler in Figure 2.3) are driven by a sprocket which is coupled to a motor though a gear box and
a fluid coupling. The continuous upward motion of the links prevents the coal from sliding down
due to gravity. The magnetic selector (M.S on coal plant structure drawing) is a screen which
uses magnetic force to remove metal pieces from the coal. This magnetic force attracts the metal
pieces and they become embedded on it. The elements are later removed to clear the screen.
2.4.2.2 Maintenance Procedures for redlers
Redler links are prone to being worn out and also they can be misaligned with the sprocket after
long time use. This can also be due to inadequate tension between the links. Worn out Redler
links are changed for new ones and those off line can be re aligned.

The walls of the redlers are also warn out due to corrosion and the pressure exerted on the by
compressed coal as it moves up wards. These walls can also be replaced but they are usually
patched due to financial problems. This patching is done by welding plates on the worn out parts
of the walls. The drive systems of the redlers which comprises of gears, shafts and sprockets also
need to be continuously lubricated to ensure that they work in good condition.
The lubrication minimises wearing of parts and also ensures smooth movement of parts.
Predictive maintenance procedures are also done to check the condition of the lubricants and they
are changed if they are no longer in good conditions. Lubricants used on redlers include special
types of oils and grease.
Figure 2. 3 Structure and operation of redlers (AutoCAD drawing)

2.5 Ash handling and disposal
Coal ash from the furnace is hazardous, considering it temperatures and is a threat to
environment when not handled properly.
2.5.1 Soaking and conveying of ash
The ash which exits the boilers is at very high temperatures which exceed the thermal capacity of
the rubber material used for conveyor belts. The ash belt is partly submerged in a water seal
which prevents air from being sucked into the furnace through the ash chutes and cools the ash at
the same time.
Under normal operating conditions, the water from ash yard is drained to effluent plant and
recycled back to the plant. Currently the effluent plant is not working and thus the water is lost to
the Bulawayo City Council drainage system. After releasing its heat energy to the water, the ash
is conveyed to the ash hoppers through the main ash conveyor belt. Along the belt is a series of
water sprinklers which keep the ash wet. Dry ash has a tendency to stick together on conveyor
rollers disturbing their angular motion. This can cause misaligning of the belt, leading to
spillages on the floor due to irregular distribution of ash on the belt. It is also difficult to release
the ash through the opening of hoppers if it is dry. Dancing rollers are provided on the way to
hold the belt in position.
The ash is then sent to the hoppers where tipper trucks are used to carry it to dump site. Figure2.5
shows a pictorial summary of the processes in handling and disposal of coal ash at Bulawayo
Power Station.

Figure 2. 4: Ash handling at BPS (AutoCAD drawing)

2.5.2 Beneficial uses of coal ash
ZPC is registered with ISO 14001 (2004), which is the Environmental Management Systems.
Regulations and guidelines on handling and disposal of environmentally unfriendly products of
power generation are given and coal ash has not been spared due to its negative impacts on the
land. However coal ash can be used for other domestic and industrial purposes, which helps in
minimising the levels of coal at the disposal sites and also reduces costs at economic levels. Due
to its non-biodegradable status, coal ash is used in the construction industry for filling roads,
building foundations and construction of furnaces. The ash is also used for filling mine dumps,
which prevents further erosion and formation of gullies.

Figure2. 5: Ash disposal at BPS (AutoCAD drawing)

However the filling of mine dumps is to be done where there is no interaction with animals and
humans as the ash can cause water contamination in swampy places and also during rainy
seasons, as water flows directly to the rivers. Boiler slag is silica free and is used as a substitution
for sand in other industrial processes, which makes working conditions healthier as workers are
at less risk of silicosis.
2.6 Coal data capture and records
Upon the delivery of coal at the station, it is the duty of the coal plant supervisor to capture data
and record it for accounts use. The records at the coal plant are also used for trending generation
statistics.
2.6.1 Coal supply records
Coal supply records include invoices and receipts which are used for referencing purposes. The
information is essential in keeping the business track between ZPC and the coal supplier for
current and future accounting purposes.

The receipts contain the following data:
 Name of coal supplier (Makomo or Hwange Colliery Company)

 Type and name of transport service provider (Road truck or Rail wagon)
 Date of loading of truck or wagon.
 Supplier‟s weight of coal supplied.
 Date at which wagon or truck arrives at station.
 Wagon or truck registration number.
2.6.2 Periodic coal records summary
Daily coal records are compiled at the end of each working day. Two copies are printed out,
signed by the coal plant supervisor and one is filed for use at the coal plant and the other one is
sent to the control room where the statistics is used for performance evaluation and for
accounting purposes. Figure 2.5 shows a Microsoft Excel daily coal record sheet.
The daily coal record includes information on:
 Total coal offloaded from both rail wagons and truck

 Total coal bunkered on the da
 The name of transport provider and registration number of truck or wagon use
 Name of coal supplier
 Supplier‟s coal tonnage
 The station‟s coal tonnage for each rail wagon or truck
 Dates of loading, offloading and date at which coal arrives at the station
 Type of coal supplied
At the end of the day the document is sent to the station control room where generation statistics
are prepared.

Figure 2. 6 Daily coal record sheets for 22/02/2015

2.7 Summary
In this chapter the author looked at the coal and ash plant department, its structure and the core
business of the department, its key QMS and EMS objectives. Coal surveying and grading
processes are briefly discussed. Conveyor systems and the coal handling processes are described
in detail as well. The chapter also focuses on the very critical aspect of ash handling and disposal
according to ISO 14001 Environmental Management Systems. Beneficial uses of coal ash have
been outlined as a means of reducing the negative impact of the ash on the environment.

CHAPTER THREE: WATER TREATMENT PLANT
3.0 Introduction
The chapter will look at the water treatment section of Bulawayo Power Station. The author
discusses the water treatment processes, the ion exchange systems and the operation of these
systems. The author will look also at the water recycling process at the effluent plant.
3.1 Structure 0f the department and its importance
The Water treatment plant is the section under the Operations department. The plant is dedicated
for the treatment of water which used for the power plant operations. Effluent water processing is
also done under the section. The treatment process involves reduction of hardness in raw water
(softening) and deionisation or demineralisation of the raw water. Bulawayo Power Station
receives water in raw form from Bulawayo City Council (BCC) through city mains at 11th and
13th avenues. The plant is monitored by auxiliary plant attendants under the supervision of the
shift charge engineer.
3.1.1 Overview of power generation water properties
All natural waters contain, in various concentrations, dissolved salts which dissociate in water to
form charged ions. Ionic impurities can seriously affect the reliability and operating efficiency of
a boiler. Overheating caused by the build-up of scale or deposits formed by these impurities can
lead to catastrophic tube failures, costly production losses, and unscheduled downtime. For high-
pressure boiler feed water systems and many process systems, nearly complete removal of all
ions, including carbon dioxide and silica, is required. Scale build up in the condenser pipes
hinders heat exchange and hence causing poor performance of the cooling systems. Ionic
impurities also have corrosive effects in the pipes work which carry cooling water to machine
components.

Figure 3. 1:Brine softener and Demineraliser layout at BPS

3.1.2 Uses of soft and demineralised water
Softeners are used to supply evaporator tanks through the evaporator sump and stock pumps.
Evaporator tanks supply evaporators which are used to top up water in the generation feed water
circuit. Soft water is also used in the cooling systems, through the water duct. The water is used
for cooling in the condenser and auxiliary components oil coolers. Currently softener 2 supplies
the evaporator tanks while softener 1 supplies the cooling water duct. Demineralised water also
tops up water in the generation circuit through the feed tanks.
3.2 Ion exchange resins
Ion exchange resins are organic polymers that are capable of exchanging particular ions within
the polymer and with ions in a solution that is passed through them. Ion exchange resins are used
in the water softening and demineralising processes. The ion exchange resins are insoluble
substances which have loose ions which have loose ions which are able to be exchanged ions in a
solution which comes into contact with them. The ion exchange takes place with no physical
alteration to the ion exchange material.
Suppose a resin has greater affinity for ion Y than for ion X. If the resin contains ion X and ion Y
is in the solution which passes through the resin, the ion exchange equation is:
where R is the resin.
When the resin exchange capacity nears exhaustion, the resin will be in the form YR.
There are basically two types of ion exchange resins, the positive ion (cat ion) exchange resins
and the negative ion (anion) exchange resins.
3.2.1 Anion exchange resins
Let resin be
Regeneration:

from solution bonds with positively charged resin in a reversible reaction
Softening: (removal of , etc. anions)
( )
i.e. the remains in the solution and remains attached to the resin. The ( ) anion
bonds with ( ) anion from the acid to give out pure water which is sent to the station.
The softening process continues until softener is exhausted, and the regeneration is done. The
laboratory technicians take samples from the softener at regular intervals, where they test for the
PH of the water and notify the attendants if there is a need to do a regeneration exercise.
3.2.2 Cat ion exchange resins
Let resin be
Regeneration:
I.e. from acid solution bonds with negatively charged resin in a reversible reaction.
Softening: (removal of , etc. cations)
( )
i.e. The cation goes into solution and the ( ) cation remains attached to the resin. ( )
bonds with in solution and water is formed

3.3 Water softeners
At Bulawayo Power Station, two softeners (Number 1 and 2) use cat ion resin in the form of
sodium and the other two (Number 4 and 5) are Hydrogen ion exchange softeners and they use
acid.
The sodium in softeners 1 and 2 is used to remove hardness in the form of magnesium and
calcium ions from the water, along with some traces of iron and manganese. The resin has
greater affinity for and ions. Softeners 4 and 5 have volume of 5375 litres
and have a capacity of discharging water at 52 . Softeners 1 and 2 have a volume of 4700
litres and can deliver softened water at 27 .
Figure 3.2 Water softening process ( (Alchin, 2009)

As the hard water passes through the resin in the softener, the sodium ions are stripped off the
resin and magnesium and calcium ions are attached to the resin. The now soft water is discharged
to the station until the softener resin is exhausted.
3.3.1 Regeneration of softeners
Exhaustion of the resin means that it now has less affinity to magnesium and calcium ions than
sodium ions. The regeneration of these softeners involves addition of a strong solution of sodium
chloride (brine) so that the sodium ions displace magnesium and calcium ions from the resin and
they go into solution. The magnesium and calcium ions are then washed out of the softener
during wash stage of regeneration. This involves passing influent water back up through the resin
to remove suspended solids, passing a regenerant solution down through the resin to replace the
ions that have bound to the resin and then rinsing again with water to remove the regenerant
solution. In water softening the regenerant is a strong solution of sodium chloride.
Figure 3.3: Softener regeneration steps (Alchin, 2009)

3.4 Demineralisation of water
The water from the softener contains some traces of ion impurities, and the demineraliser plant is
used for completely removing these ion impurities. The process is also called deionisation. Water
is passed through an acid resin containing ions which replace cation impurities in water and
through a second resin containing ions which replace the anion impurities. The
ions then bond to form water. The type of demineraliser is called the twin or mixed
bed and is the type used at Bulawayo Power Station.
The ions are from a strong acid and base respectively. At Bulawayo Power Station,
sulphuric acid and sodium hydroxide are used for the deionising plant. Cat ions in the water are
taken and ions are released and thus first effluent consists of a very weak mixture of acids.
The water is then passed through a second vessel of anion exchange resin and sodium hydroxide
is used as a regenerant. Anions are exchanged for ions which then react with ions to
form water. Twin bed units reduce the total solids content by approximately 1 to 2mg/l.
Figure 3. 4 Chemical reactions in the demineraliser (Alchin, 2009)

3.4.1 Regeneration of demineraliser
BPS uses a mixed bed resin type demineraliser, which is a vessel containing anion and cat ion
exchange resins in the form of sulphuric acid and caustic lye at the same time. As the water flows
through the pressured resin bed ion exchange is repeated many times, polishing the water to high
purity.
Exhaustion of the resin is when the ions in the resin have mostly been replaced by the impurity
ions being removed from the solution. An electricity conductivity (DC Meter) is used to
determine the purity of the water at the discharge of the demineralising plant. A regeneration
process is started when the meter indicates an ionic breakthrough. The optimum operating
conductivity of the BPS demineralising plant is 0≤C≤2 µS/cm. The regeneration process involves
addition of strong acid (anion resin) and caustic lye (cat ion resin) and using air and water to mix
and form the pressurised mixed bed resin. First the resin is separated by backwashing, with the
anion resin settling on top of the cat ion resin. Regenerant acid is introduced through the bottom
distributor and caustic lye is introduced through the distributor above the resin bed. Following
regenerant introduction, air and water are used to mix the two resins. The last stage is the rinsing
stage and the plant is ready for use.
3.5 Common problems in ion exchange systems at BPS

 Improper regeneration caused by failure of systems due to long term use. Example is the
softener final rinse stage which may be set to be 5minutes but in practice, the attendant must
wait until clear water is discharged, indicating a complete rinse.
 Leaking valves and pipe joints (flanges) causing loss of acid, water, brine and caustic
 Instrumentation problems which involve failure of demineralising plant pneumatic valves,
gauge glasses and DC meter. The instrumentation problem may cause complete cancelation
of the regeneration process especially the failure of valves and DC meter.
 Acid pipeline failure. This is a safety concern as attendants have to carry acid and caustic lye
on open containers, risking skin contamination and inhaling the dangerous acid fumes.

3.6 Effluent plant
The effluent plant is installed as a strategy of reducing the plant‟s costs and maintaining a
good environment as well. This is achieved by recycling the water from the station‟s drains.
3.6.1 Effluent plant process flow
The station‟s drains cascade and deliver to a raw water sump, which serves as a reservoir for
the primary mixture of water and mud. Centrifugal closed blade (primary sump pumps)
pumps are used to carry the water and sludge mixture to the distribution box, which further
delivers to the settling tanks. The settling tanks are large and have low water velocities,
allowing the sludge to settle at the base due to its high density, whereas the water stays at the
top. Clearer water from the settling tank is allowed to flow to the main effluent tank and the
muddy water flows to the clarifloculator, also known as a clarifier, where further separation
of mud and water takes place. Settling tanks are disludged after a period of time to allow
continuous recycling of water. The clarifier is a sedimentation basin. Turbulence is provided
by means of rotating beams, making the separation process faster. Organic polymers are
added to the muddy water in the clarifier. The high molecular weight compounds absorb into
particle surfaces and through interparticle bridging, co-a lease with the particles to form
floccule. Clear water exits the clarifier to the final effluent. A mixture of water and mud
from the clarifier is sent to a sludge sump. From the effluent tank, water is pumped through
filters to the water reservoirs and softeners. The sludge from the sludge sump is pumped
through sludge pumps to the ash hoppers, where it is disposed. However the settling tanks at
BPS is not being used due to shortage of raw effluent or primary pumps.

Figure 3. 5: BPS Effluent Plant schematic diagram

3.7 Summary
The chapter looked at the water treatment plant flow of processes and duties conducted. The
author discussed the importance of the plant in a power plant set up, alluding to the dangers of
using raw water in power generation. The ion exchange system and their operation are discussed
in detail as well. Lastly the author gave a brief outline of effluent plant processes.

CHAPTER FOUR: BOILER HOUSE
4.0 Introduction
The chapter discusses the boiler section of the plant. The author will give a brief literature review
of the boiler and discussing the design and operation of the types of boilers. the heat exchange
and steam generation process will be outlined as well, alluding to the boilers at the Bulawayo
Power Station.
4.1 Section overview and organisational structure
The boiler house is a section under the Operations departments. The soul responsibility of the sub
department is the operation of the boilers which provide the turbine with steam and monitoring
the ash and flue gas disposal systems. The boiler plant is under control of boiler operators, under
the supervision of the shift charge engineer.
Figure 4. 1: Organisational structure of the boiler house section

4.2 Literature Review
A boiler‟s main components are the furnace and the steam generating vessels. The furnace is
where the combustion of the fuel takes place and the steam generating vessel is where the steam
is produced. The type of a boiler is determined by the structure and means of heat transfer
between the fire and the fluid (water at BPS). There are two types of boilers which are the Water
tube and Fire tube boilers.
4.2.1 Water tube boilers
Water tube boilers have steam generating vessels where the water flows through tubes and fire is
outside the tubes. These boilers can be of single- or multiple-drum type. These boilers can be
built to any steam capacities and pressures, and have higher efficiencies than fire tube boilers.
This property makes them to be more useful in thermal power plants as compared to fire tube
boilers.
Figure 4. 2: Boiler Input and Output diagram (Rolland, 2005)

Figure 4. 3: Water tube boiler (Roland, 2005)

4.2.2: Fire tube boilers
Fire tube boilers comprise of steel tubes, through which hot gasses from a furnace flow. The fire
carrying tubes are submerged in the water which is to be converted to steam. Fire tube boilers,
typically have a lower initial cost, are more fuel efficient and easier to operate, but they are
limited generally to capacities of25 tons/hr and pressures of 17,5 bars.
Figure 4. 4: Fire tube boiler (Hilton, 2010)

4.3 Structure and components of boilers at BPS
BPS has the Yarrow model stocker chain grate water tube boilers. There are six water tube
boilers, each with a rated steam generation capacity of 15MW. The furnaces are designed to use
the washed pea (18mm) sized type of coal.
 Combustion chamber: The combustion chamber is where the coal is burnt to produce heat
which is used for the steam generation process. Major components of the combustion
chamber include the stocker chain grate and the ignition arch.
 Main steam drum: - The main steam drum serves as a link between other components and
is fixed on strong steel pillars at the apex of the combustion chamber. Feed water from the
economizer comes to the main steam drum before distribution to other steam generating
components. Generated steam from the boiler exits the main steam drum through vortex
tubes and flows to the super heater.
 Water/ Mud drums: - The boilers have three water drum which are the front, center and
rear water drums. The mud drums are suspended on the main steam drum through steam
generation tubes. The drums are suspended to allow for expansions and contractions which
take place during the operation process. During the evaporation of water, scam collects at the
bottom of the water drum and is washed out of the system through blow down processes.
 Bailey/ Water wall: -The water wall provides cooling in the furnace and hence takes part
also in the generation of steam. The wall is made of a series of tubes which carry water
during recirculation, cooling the refractory walls of the furnace. The wall is linked to the
main steam drum through the bottom and top boiler headers.
 Super heater: - Saturated steam from the MSD is super-heated to dry steam in the super
heater. The super heater comprises of a top and bottom mild steel drums) and a series of
rows of super heater tubes (mild steel and carbon molybdenum). Hot flue gasses exiting the
furnace conduct energy to the exposed super heater tubes, thus facilitating the superheating
process. By design steam should exit the super heater at a temperature 442-464 and 42-
43.8 Bars pressure.

 Economizers: – A cross flow heat exchanger which uses flue gasses to pre-heat boiler feed
water. The economizer serves to improve thermal efficiency of the system and at the same
time serves as a measure to reduce energy loses to the atmosphere.
 Fans – Types of fans at the boiler plant are the FD, ID, Secondary and Booster fans. FD fans
blow primary combustion air into the furnace while ID fans suck out flue gasses out of the
furnace to the atmosphere. The secondary air fans blow air across the furnace to produce
turbulence, aiding combustion while the booster fans aid the separation of grit from flue
gasses before discharge to the atmosphere.
 Air Heater: – A counter flow heat exchanger using flue gasses to pre-heat primary air and
cools the flue gasses before discharge to the atmosphere. The temperature of the primary air
is to be maintained at 250°F for efficient cooling of the stocker grate and to reduce
corrosion.
4.4 Boiler light up and combustion process
The pre-start activities at the boiler plant include clearing of safety documents, clearing of
scaffolding and a pre-start check of the plant‟s components. The operator must also make sure
that the boiler is filled with adequate amount of water and chemicals.
 Set the fire (radial) doors to about 3 inches to drop a fuel 2 feet long on the grate
 Start ID fans with regulating (suction) dampers in shut position and then open the
dampers a little to provide a slight draught into the furnace.
 Raise the radial doors and throw red hot fuel to ignite the coal already on the bed
 Pocking may be done to establish a good bed of red hot fuel
 When the ignition has taken place evenly, add more coal on to the grate and run it slowly
 Adjust the furnace draft, if necessary by starting FD fans to provide a little force drought for
ignition.
 Watch the fire through the peeping holes and maintain the ignition between 3 inches and 2
feet along the grate, making sure that the fire doors are not heated

 When the rate of ignition exceeds the lowest grate speed, the grate can be run continuously
and the air supply, grate speed and fire thickness can be increased to raise steam at the
desired rate to suit the boiler and super heater and to control the ignition point.
 Under grate dampers should be opened successively as the fuel bed reaches them, but the
first damper is to be kept shut to prevent cooling the ignition arch.
 Start secondary air fans and adjust the droughts to suit the combustion
 By the time the boiler commences to deliver steam to the range, the fire thickness, grate
speed, air supply and drought should be adjusted to the values normally used for routine
steaming.
4.4.1 Combustion Process
The combustion process comprises the mixing of air and coal, ignition, the chemical reactions
and the disposal of combustion products.
The first stage is the mixing excess of primary air from the air heater air and coal. Air is at air
heater inlet is at 57°C and discharged to wind box at 118°C. Cold air causes cooling of the
combustion chamber. The ignition process is facilitated through the use of reflective ignition
arch. The bricks absorb heat energy from the fire through radiation to reach a temperature
exceeding the ignition point of coal (460°C for bituminous coal, 600°C anthracite and 700°C for
coke). The heat energy is then reflected to the coal, causing it to ignite.
The chemical reaction stage involves the exothermic reaction of the components of coal to
produce heat and oxides. The last stage is the disposal of combustion products like carbon and
sulphur oxides. Secondary air fans provide turbulence to facilitate the burning of small
suspended particles of coal before being sucked out if the furnace by ID fans as grit.
The factors which affect the efficiency of coal combustion are:

 Fuel to air ratio- Air must be available in excess for complete combustion. However it must
not be too much as it will absorb heat from flue gasses as they exit the furnace
 Coal moisture content- evaporation on the coal surface localized turbulence and porosity on
fire bed aiding the combustion process
 Volatile content: too much volatile matter delays the ignition of coal, thus disturbing the
efficiency of the combustion process
 Ash in the fuel
 Calorific value (gross CV should be at least 24MJ/kg)
 Coal swelling index (should not exceed 2.5 to prevent incomplete combustion). Coal with a
greater swelling index tends to absorb more heat before ignition as it expands in volume
Figure 4. 5: Coal ignition in a chain grate furnace (AutoCAD drawing)

4.4.1.1 Chemical Reactions in coal combustion

 ( )

 ( )

 ( / mole)
The partial combustion of carbon produces carbon monoxide which lowers the efficiency of the
combustion process. Sulphur trioxide has a significant corrosive effect on the colder parts of the
furnace and should not condense.
4.5 Heat Exchange and steam generation process
Figure 4. 6 Heat exchange and steam generation process (AutoCAD drawing)

4.5.1 Convection
Heat exchange takes place between fluids and is thus limited to liquids and gasses. The heated
fluid becomes less dense, goes to the top and the natural circulation continues as heat is
exchanged. In the boilers, convection occurs at the following places:
 During the isothermal recirculation and raising pressure between the water drums and steam
drums. Less dense steam moves to the top in the MSD while the denser water flows down
the generating tubes to the water drums.
 Super heater steam and water in the conduction tubes
 The rear water drum bank is a purely convective surface
 The heat transfer to the second bank (center water drum) tubes is partially convective and
radiation, shielding the super heater from direct fire
Heat exchange is mathematically given as:
( ) …………………………………….. Equation 4.1
Where n=1, h is convective heat transfer coefficient in (W/ ) and A is the convective surface
area.
4.5.2 Conduction
Heat exchange takes place through vibration of one molecule to the next. In fluids it results on
transfer of kinetic energy between colliding particles.
In the boiler plant heat conduction takes place:
 Cross flow heat exchange between air economizer tubes and flue gasses, counter flow heat
exchange between air heater tubes is partially conductive
 Super heater and generating tubes transfer heat to the steam and water by conduction
Heat exchange is mathematically as:
( ) …………………………………….. Equation 4.2

Where k = thermal conductivity coefficient (W/K) and x is thickness of conductive surface and
n=1 and t is the absolute temperature.
4.5.3 Radiation
Heat exchange takes place due to electromagnetic waves. The waves have great power to move
in space without losing their energy. Radiation takes place between the ignition arch and coal
during ignition process. The heat exchange between the flames, hot flue gasses and tubes is
through radiation. The front water drum tube bank and the bailey walls form a radiant heating
surface. Most loses taking place in boilers are due to radiation and thus lagging must be put in
place to minimize these losses.
Radiation is mathematically given as:
( ) …………………………………….. Equation 4.3
Where n=4 ε is the emissivity of the surface and δ is the Stefan-Boltzmann constant =
(W/m2 K4)
4.6 Boiler Pressure Raising
The pressure raising process involves the gradual adjusting of the furnace drought, grate speed,
fire thickness and air supply to reach the desired steam pressure. The components of the boiler
like water drums, generating tubes, super heater tubes and water walls are made of different
materials of variable thermal strength and hence there is need to reach temperature equilibrium
before pressure-raising. This is done to prevent thermal shock on these components due to
sudden increase in temperature and is achieved through the recirculation processes. As the water
circulates through the tubes its temperature is increased to saturation at which point more heat is
absorbed (latent heat of vaporization) and changes to steam and is subsequently released to the
steam space of the MSD.
Steam is also formed in the Bailey walls. The circulation is from the bottom header up the tubes
to the top header, some water being changed to steam in the process. From the top header the
water flows down the recirculation tubes to make another circuit. The steam formed flows from
the top header up two steam release pipes into the stilling boxes located inside the MSD.

Water flows down two down comers to the bottom header. Whilst steam is formed within the
MSD itself, most of the steam is formed in the tubes.
The pressure raising process involves the following steps, among others:
 Test the water gauge glass, safety valves and alarms operation
 Make sure the crown valve is shut to prevent carryover
 Water drum drains, economizer recirculation valve must be open to achieve recirculation
between the MSD, economizer and water drums. The master blow down valve should be
shut in the process.
 Water level must be monitored as expansions during pressure raising may be a danger of
water when boiler is cut in.
 Super heater header for discharge drum must be kept open to ensure continuous flow of
steam through the tubes. This protects the super heater tubes from overheating.
 Gradually raise the pressure of the steam at 7 bars / hour up to the desired pressure.
 Regulate the super heater temperatures so that it does not exceed the safe operating
temperature (930 °F for mild steal and 1100 °F for alloy super heaters).
 When the pressure has reached the desired range pressure and temperature 43.8 bars and 454
°C the steam can be delivered to the engine room.
4.7 Super Heating of Steam
From the MSD, the saturated steam passes through eight vortex steam separators into the
saturated steam pipe which runs to the top super heater drum. In the super heater, the steam flows
through eight rows of tubes making passes between the top and bottom drum. The passes are
formed by provision of seven internal baffles arranged in increasing refractory and thermal
conductivity. The first five rows of tubes are made of mild steel and the last three are made of
carbon-molybdenum alloy steel. The molybdenum in the alloy forms stable BCC structure
interstitial carbide making the alloy tougher, wear resistant and highly refractory. The thermal
conductivity of the alloy is 43W/m°C with 0.5% molybdenum.

The temperatures in the super heater are controlled through a regulator and baffle, which monitor
the flow of flue gasses to the tubes. During normal operation, the regulator is ¼ to fully open
position. The resulting super-heated steam leaves the top super heater drum and passes through
the crown valve to the steam receiver
4.8 Essential Boiler mountings
Boiler mountings are the devices installed on boilers for mainly efficiency and safety of
operation.
4.8.1 Automatic Feed water regulators
Feed water regulators control the flow of water into the main steam drum and are located in the
feed range between the pump and economizer. The two types used at BPS are the corpse
regulator and the GA pneumatic valve. The GA is a three level control system (drum water level,
pressure and feed flow). The corpse regulator is purely mechanical control and uses thermal
expansion and contraction of a copper rod to open and close the valve while the GA valve uses
pneumatic force to actuate the valve. Copper is preferred for its high thermal expansion index.
The advantage of the corpse regulator is that it is independent of external power, while the GS
valve needs air from an electric compressor. The main advantage of the GA valve over the corpse
is its response as accelerating air is faster compared to expansion of the copper rod.
Figure 4. 7: Thermostatic feed water regulator (AutoCAD drawing)

4.8.2 Boiler water level gauge glass
A gauge glass is a device which indicates the water level in the steam drum. Gauge glasses are
mounted on the boiler as a safety measure as per the statutory laws on pressure vessels. Currently
there gauge glasses at BPS are complemented by analogue water level indicators on the boiler
control panel.
4.8.3 Alarms
High and low water level alarms are installed on the MSD to alert the operators on the water
condition in the boiler. A low water level alarm indicates danger as steam levels will above
normal, increasing explosion chances. A high level alarm alerts the operator to reduce water flow
rate to allow proper steam build up.
4.8.4 Grit arrestors
The grit arrestors are located below the economizer. The sole purpose of grit arrestors is to
reduce the amount of dust and grit entrained in the flue gasses resulting in less wear of ID fan
blades, cleaner air heaters and cleaner flue gasses to the atmosphere. BPS boilers have grit
arrestors built up of 45cells, 14 dust collectors and two booster fans. The flue gasses are forced
through guide vanes (stationary spinners) where a cyclone is made, forcing the heavy grit down
to the dust header. The rest of the gas which is relatively clean passes through an outlet tube to
the ID fan duct work. The booster fan draws the dust through the dust collector which discharges
on to the ash belt.
4.8.5 Boiler safety valves
Statutory laws require a pressure vessel to have safety valves mounted on it. Safety valves are
pressure relief devices and they prevent the boiler from explosion. At BPS there are five spring
loaded type safety valves on each boiler. Three are mounted on the MSD while two are on the
super heater drums. When the pressure in the boiler builds up to exceed normal level, the spring
is compressed and the safety valve lifts to allow steam to the atmosphere. As conditions stabilize,
the spring is set to expand to its normal position, allowing the valve to seat in position.

MSD safety valves are set to lift at 52.3 bars while the sitting pressure is 49.60 bars. The blow
down of the boiler is set not to exceed 5% to prevent water loses.
Figure 4. 8: Spring loaded safety valve (AutoCAD drawing)

4.8.6 Soot blowers
Flue gasses exiting the furnace carry along soot from coal combustion and the suits accumulates
on the outer surface of generating and super heater tubes. The layer of suit on the tube increases
the thermal resistance of tubes, thus reducing heat conduction between the tube and flue gasses.
Soot blowers are thus used to remove the soot from the tube surfaces. Superheated dry steam is
tapped off from the super heater discharge and is used to blow off the soot from the tube surface.
BPS boilers have retractable type soot blowers which move linearly and rotate (2.5rpm), blowing
off soot on the exposed tubes. The soot is sucked out through the ID fans. The soot blowing
process is highly dependent on steam quality and pressure and thus wet steam should not be used.

Wet steam has a tendency to cement soot on tubes, causes corrosion and thermal shock on the
tubes. Other substances blown off from the tubes are low melting point chlorides from alkaline
coal combustion, which condense on tube surfaces.
Figure 4. 9: Retractable soot blower nozzle (Rosella, 1995)

4.9 Boiler Efficiency
According to (Hilton, 2010), the efficiency of a boiler is highly dependent on the efficiency of its
critical components such as the furnace and steam generation parts. These have their individual
measures of efficiency which are described as:
 Combustion Efficiency - indicates a burners ability to burn fuel measured by unburned

fuel and excess air in the exhaust
 Thermal Efficiency - indicates the heat exchangers effectiveness to transfer heat from the
combustion process to the water or steam in the boiler, exclusive radiation and convection
losses
Therefore boiler efficiency can be defined as the fuel to fluid efficiency, indicating the overall
efficiency of the boiler inclusive thermal efficiency of the heat exchanger, radiation and
convection losses. This efficiency is measured as the ratio of energy per generated amount of
steam to the energy used.

Mathematically, the efficiency of the boiler exclusive losses is given as:
̇ ( )
00% ………………… Equation 4.4
̇
Where ̇ is the mass flow rate of steam (kg/hr)
and is the enthalpy of the water before and after generation (kJ/kg)
̇ is the fuel flow rate (kg/hr)
is the gross calorific value of the fuel used (24MJ/kg) for coal
4.9.1 Factors affecting Boiler efficiency
Taking into account the variations in operation, the efficiency of a boiler plant is also affected by:
 Pre-heating of air and feed water

 Air to fuel ratio
 Carbon losses
 Fouling of surfaces
 Fuel composition- moisture, volatile content, ash (minimum 7%), coal size, swelling
index, sulphur and chlorine content etc.
 Heat transfer- losses in flue gasses, radiation to atmosphere etc.
The design of boilers has arrangements to maximize the efficiency of boilers. This has been done
through:
 Pre-heaters
 Secondary air fans
 Grit re-firing
 Soot blowing

4.10 Boiler storage and water quality
The efficiency of a boiler is also affected by the condition of the water used in the generation
process. Boiler storage focuses on the conditions suitable for a boiler to operate well.
4.10.1 Chemical dosing
Chemical dosing is the process of injecting chemicals through the MSD. The water conditioning
is a measure to minimize corrosion, boiler scam, deposits and scale formation.
At BPS chemical dosing is done through the use of a high pressure jacking pump, which injects
the chemicals into the MSD without back pressure. The chemicals used serve different purposes
and are listed below.
 Hardness: Tri-sodium phosphate is added to minimise concentration of calcium and

magnesium ions in the water.
 De-aeration: Sodium sulphite and hydrazine to remove gasses present in feed water so as to
minimise corrosion.
 Alkalinity: Caustic soda, ammonia and amines to increase the alkalinity of water to prevent
acidic corrosion
4.10.2 Boiler blow down
During the vaporisation of water, suspended solids are separated from the water and settle at the
base of the water drums. The process of blow down is done to reduce the concentration of
suspended solids and silica in the boilers. The process is done after the advice from the chemical
services department who carry out tests on the water.
4.11 Summary
In this chapter the author looked at the boiler section of the. More focus was put on energy
conversion process from fuel combustion to the steaming process. The author also summarised
the boiler components and the operating process. Safety devices such as gauge glasses and safety
valves were aslo discussed. Lastly the author looked ant boiler efficiency and storage.

CHAPTER FIVE: TURBINE HOUSE & CONTROL ROOM
5.0Introduction
The thermal power plant cycle of energy conversion cycle ends with the conversion of
mechanical energy from the turbine to electrical energy in the generation. The chapter focuses on
the turbine and alternator section. Circuits of steam, water and oil are discussed and the general
operation of systems at the section. At the turbine house, duties are conducted by the senior
turbine operator, operator and auxiliary plant attendant. The members work under the supervision
of the shift charge engineer, whose immediate supervisor is the operations manager.
Figure 5. 1: Organisational structure of the turbine/alternator section

Table 5. 1: Turbine specifications at BPS
Type Rated Operating Operating Rotation speed

Capacity Temperature Pressure
CA Parson 30MW 442 0C - 460 0C 42-43bars 3000 r.pm
Table 5. 2Generator Specifications at BPS
Rated Voltage Current Excitation Excitation

Output Current Voltage
30MW 11000V 1968Amps 480A 185V
Figure 5. 2: Thermal plant Turbo-alternator components (PennWell, 1997)

5.1 Process overview (Turbine-Alternator)
The generation process at BPS is mainly based on the Rankine cycle. BPS uses the regenerative
Rankine cycle, where bled steam is tapped off from sections of the HP and LP turbine to heat
feed water in the HP and LP heaters. The Superheated steam from the steam receivers reaches the
steam chest at 454°C and 43 Bars pressure. The steam flows through governors to stationary
nozzles, where a pressure drop and an increase in velocity of the steam occur. As the steam exits
the nozzle at high velocity, it strikes the turbine blades as it flows across the turbine. The turbine
blades are made of super alloy material to handle the thermal and mechanical stresses. Steam
expands through the HP turbine before it flows through crossovers to the LP turbine. The
expansion of steam across the turbine is isentropic. A thrust bearing is attached to the turbine
shaft, at the HP turbine end by means of a worm gear. The purpose of the bearing is to hold the
shaft from moving axially as steam expands across the turbine and also due to thermal expansion.
The steam exits the HP turbine at 240°C and 10Bars temperature and pressure. At the end of the
LP turbine, steam is exhausted to the condenser at 37°C and 0.1 bars pressure. In the condenser, a
vacuum is available for the steam to flow efficiently and allows for condensation to take place.
BPS uses the converted machine type generator, where the rotor carries the magnetic field and
the armature windings are stationary. The turbine shaft, rotating at 3000r.p.m is attached to a two
pole magnetic field carrying rotor. The magnetic field is generated in the rotor field windings,
through an exciter. Surrounding the magnetic field in the rotor are three phase stationary
conductor windings. The stationary windings cut the magnetic flux at high frequency, inducing a
voltage in the coil. The power generated is at 11kV and 1968A. The excitation ratings for the
generator are 185V at 480A. The strength of the magnetic flux is controlled through adjusting
excitation current by means of a variable resistor.

Figure 5.3: Temperature - entropy diagram for BPS Rankine cycle

The four processes in the Rankine cycle:
Process 1-2: The water is pumped by six stage centrifugal pump at 43.8 bars from suction range
to the boiler.
Process 2-3: The high pressure water enters a boiler where it is heated at constant pressure by an
external heat source to become a dry vapour. MSD process is isothermal.
Process 3-4: The dry vapour expands isentropically through a turbine, generating power. This
decreases the temperature, pressure and dryness of the vapour
Process 4-1: The wet vapour then enters a condenser where it is condensed at a constant pressure
to become liquid state.

5.2 BPS Essential turbine auxiliaries
The turbine plant auxiliaries are devices which are installed for aiding the turbine operation. The
devices have direct impact on the performance of the turbine and thus
5.2.1 Air ejector and Quick start nozzle
It used to extract air and non-condensable gases from the condenser. The air ejector has a nozzle
at its top portion and a diffuser at its lower portion. Steam from the auxiliary manifold enters the
ejector at the top and expands through the nozzle, attaining a very high speed of the order of 900
to 1200m/s while a pressure drop experienced. The pressure drops induces suction of air through
a pipe connected to the condenser. The air is mixed with the high velocity steam and the mixture
of air, steam and vapour then flows through the diffuser where kinetic energy of the mixture is
converted to pressure energy. The suction of air creates a vacuum in the condenser allows for
efficient expansion of steam in the turbine and cooling in the condenser.
Figure 5.4: Air ejectors (Leyzerovich, 2008)

5.2.2 Turbine gland sealing
The turbine gland sealing is provided to prevent air leakage into the turbine blades and also to
prevent steam from passing through the point where the rotor shaft emerges. Gland sealing is
achieved by the use of dry steam at 13Bars pressure. The penultimate recesses in the shaft and
housing of both HP and LP turbines are connected to a shell and tube heat exchanger known as
the gland steam condenser. The steam is fed back to the system through a drains tank while the
condensate goes back through the condenser.
5.2.3 Feed water heaters
Feed water heaters are the essential components for the regenerative Rankine cycle. The types of
feed water heaters are the counter flow surface heat exchangers which are regarded as the HP
heaters and LP heater. These heaters consist of closed shell in which there are tubes or coils
through which steam is circulated. Usually the water is circulated through the tubes and the
steam and water may flow either in same direction or in opposite direction. The main function of
feed water heaters is to raise the temperature of the feed water by means of turbine steam tap-off
before it reaches the main steam drum. HP heaters use steam tap off from the HP turbine while
the LP heater uses steam tap-off from the LP turbine.
5.2.4 Evaporators
The evaporator is used for water lose compensation in the system. The evaporator collects water
from the highly located evaporator tanks through gravity and heats the water to a vapour state. It
is a surface counter flow heat exchanger. The evaporator uses steam tap-off from the High
Pressure turbine to heat the softened water to its vapour state. The vapour then joins steam from
the LP turbine into the Low Pressure heater. In the Low Pressure heater, the vapour expands and
condenses in the process. The condensate goes to drains cooler then it is discharged to the
condenser. There are two evaporators for each machine and they can be operated in parallel or in
series. When operated in parallel, the vapour from both evaporators is led to the L.P heater and
when operated in series.

Parallel operation gives the more output at less quality vapour while the series operation gives an
output of less quantity at higher efficiency.
5.3 Cooling water system at BPS
The cooling water system includes the condenser plant, alternator fan and oil cooling in the plant.
Softened water is supplied through the suction duct.
5.3.1 Condenser
The condenser is the major component of the power plant cooling system It is a shell and tube
heat cross flow surface heat exchange medium, which allows for heat exchange between turbine
exhaust steam and cooling water. It receives exhaust steam at 37°C from the LP stage of a
turbine and condenses it to 35°C liquid form (condensate).The condenser reduces turbine
backpressure through its vacuum, thereby increasing the output and efficiency of the turbine. The
surface condenser is a closed vessel filled with many tubes of 25mm diameter. As the wet steam
from the turbine gets contact with the cooling water carrying tubes, it condenses and forms a hot
well just at the base of the condenser. 400V/ 52Ampere electric extraction pumps are used to
extract the condensate from the condenser. The size of this hot well (condenser level) is critical
as it also affects condenser vacuum. Cooling water at 19°C enters the condenser at high pressure
from CW pumps and circulates between the tubes, exiting the condenser at 39°C to the cooling
towers through the pressure duct. The velocity, volume and temperature of cooling water are
critical in the efficiency of the condenser. Condenser tube fouling is a major cause of decline in
condenser efficiency as it disturbs fluid flow and heat transfer. The fouling results from
sediments, scaling, corrosion, and biologic growth. Various mechanical and chemical water
treatment procedures are available to minimize fouling during operation.

Figure 5. 5 Shell and tube surface condenser
5.3.2 Cooling towers
BPS has 6 hyperbolic natural cooling towers which are packed with timber material and asbestos
rod shaped material. Currently only three (No. 4, 5 and 6) cooling towers are commissioned. The
principle of operation is the same for all the cooling towers. The tower body is a shallow shell of
circular cross section with a hyperbolic vertical profile. The lower portion of the tower interior is
packed with wooden hurdles and distributing trays for spreading the water and for breaking it to
small particles. The hot water from the condenser is pumped to a height of 9m to 12m above the
ground into troughs and the nozzles at the bottom of the troughs, sprays the water in thin sheets.
These sheets of water are then distributed over the wood work and trays .The hot water then falls
down and the steam vapours which are lighter than air will rise upwards. Increase in velocity at
the nozzle causes a pressure drop at the point, allowing for suction of air into the cooling
medium. Heat exchange takes place by convection.

Figure 5. 6: Hyperbolic Cooling tower (photo)

The hot air along with some vapours will leave the tower at top and the cooled water will fall
down in form of rain into the pond below the tower. From this pond the cooled water again
circulated through the condenser through the suction duct.
5.3.3 Oil and alternator fan air coolers
Air coolers are shell and tube heat exchangers. There are three oil coolers for each turbine.
Cooling water for the oil coolers is and air coolers is taken from the condenser inlet, and the oil
coolers on the Parson machine discharge to the CW pump suction pipe through a pressure
deferential. A cooling water supply for one of the two oil coolers fitted to the generator
transformer is taken from the inlet side of the condenser and after passing through the coil cooler
the water discharges into the suction duct outside the building.

On the combined outlet from the condensers there is a reflex valve (that is a non- return valve)
which prevents water flowing from the pressure duct back through the condenser to the suction
duct. This reflex valve is fitted with a by-pass connection and valve which is normally left open
to ensure that the condenser remains full of water when the machine is off; also it is used for
filling the water space after repairs. Two drain valves are fitted to the bottom of the inlet water
boxes, and four air release cocks to the top of the water boxes.
5.4 Turbine lubrication oil system
Lubricating oil used for steam turbines is a mineral oil containing additives to prevent:
 Oxidation
 Corrosion and properties
 Forming; also other additives are added to improve its lubricating properties
Turbine lubricating oil serves these purposes:
 Lubricates the bearings

 Acts as a hydraulic fluid for the governor system
 Carries way heat from the bearings
5.4.1 Main oil pump
The pump is of gear type and is driven by the main turbine shaft through a worm gear at the
steam end of the HP turbine. The pump is primed by the auxiliary oil pump at the starting of the
turbine. Oil regulators maintain the delivery of the pump at 70psi and the pump stops instantly
when the turbine is tripped.
5.4.2 Auxilliary oil pump
The pump is a gear type and is driven by a mini steam turbine from the auxiliary manifold. The
pump is used to supply oil at the start and stopping of the machine. As the main oil pump is on,
the auxiliary oil pump is shut automatically.

Figure 5. 7 BPS 30MW turbine alternator oil circuit

5.4.3 High pressure jacking oil pump
The jacking oil pump is used for lifting the turbine shaft journals off the bearing during the
starting of the turbine. This makes it easy to rotate the turbine without friction, which may
damage the bearings as well. The pump reduces load for the barring gear oil pump at starting of
the machine. Pump is driven by a 8HP motor at 1440 rpm, delivering pressure up to 138Bars.
5.4.4 Barring / Turning gear oil pump.
The pump supplies oil when the turbine shaft is on barring (rotation speed at 20rpm). This is
done on starting the turbine and also when turbine goes off. Motor drive for pump is rated 4HP
at 1410 rpm. The pump delivers oil at a rate of 636liters/min.
5.4.5 Steam Governors
These are steam regulating valves are operated by turbine (hydraulic) through the fly ball
principle. When the main oil pump pressure reaches 15psi, the first governor starts to operate, up
to turbine economic load (14MW). When load exceeds 14MW the second governor starts to
operate at 43psi oil supply. The pilot valve regulates the supply of oil to governors. Through the
fly ball principle, the governors are set to trip the turbine when its speed exceeds 3000 +12%.
This is a protection system for the turbine and it usually occurs when the magnetic field is
suddenly cut due to system disturbances.
5.5 Alternator and Generation process
BPS uses the 30MW (11kv, 1068A) three phase synchronous generator. The magnetic field is
generated on the field windings on the rotor, through the main and pilot exciters. The pilot
exciter uses a residual magnet to generate a DC voltage that is used by the main exciter, a larger
generator. The pilot excitation system is used so that the generator has no external power
dependence. The main exciter produces a greater current which is connected to the rotor through
carbon brushes where a two pole magnetic field is generated. The rotor rotates at 3000rpm
producing strong magnetic flux lines at 50Hz frequency.

Stationary armature windings on the stator are cut by these magnetic lines, inducing a 11kV
voltage in each phase at 1968Amperes.
Figure 5. 8: Generator excitation and three phase connection (AutoCAD drawing)

5.5.1 Generator synchronisation
The process of synchronisation involves matching the generator to the grid line voltage (average
33kV). These voltages must match through phase, frequency and magnitude. A synchroscope is
an instrument which is used to match the two. Excitation voltage is varied gradually through a
variable resistor and is used to vary the power on the generator. A 11kV/33kV step up generator
transformer connects the generator to the grid, matching the 33kV voltage at 50Hz.
5.5.2 Power from a generator
In the electricity generation process, there are two forms of power, the turbine (mechanical
power) and the reactive power from the generator.

The mechanical power is a product of the turbine‟s torque and angular velocity, while the
reactive power is the sum of power for the three generator phases.
Figure 5. 9: Single phase circuit (AutoCAD drawing)

The circuit on figure 5.8 is reduced to the one on figure 5.9.
Reactive power = where is the power factor. The reactive power is used for
rating a turbine. Thus at full load the BPS turbine power = 30MW.
5.6 Summary
This chapter mainly looked at the turbine house section of the power plant. The turbine house
main components are outlined as well as their operation. Critical specifications for turbine and
alternator are tabulated as well in this chapter. The generator synchronisation process is also
discussed.

CHAPTER SIX: ENGINEERNG AND MAINTENANCE

MANAGEMENT
6.0Introduction
The Engineering and maintenance management is coordinated by the Plant Engineer under the
Planning section. The department is mainly responsible for the planning and execution of
maintenance work in the station. From all departments critical to plant availability are brought
together to facilitate concurrent decision making thereby minimizing the span. The planning
department is also responsible for inventory control.
6.1 Bulawayo Power Station Planning Procedure
The purpose of a procedure is to establish a common approach to the planning and management
of preventive, corrective and planned maintenance activities on a daily basis.
6.1.1Scope
The Planning procedure details the requirements for the co-ordination, execution and
management of daily planning for preventive, corrective and breaks down maintenance activities.
Planning meetings are held at the end of each working day.
6.1.2Responsibility
 The Planning Foreperson and The Principal Planning Technicians are responsible for
implementing this procedure in regard to preventive maintenance works.
 The relevant Maintenance Section Forepersons are responsible for implementing this
procedure with regards to corrective maintenance work.
6.1.3 G87 Form:
A standard form used as a register for work order cards. This form is a very important document
and is kept safely by the foreperson.

6.1.4 Work Order Cards (WOCs)

A W.O.C is used in the station when requesting for assistance from the Engineering Department.
There are different types of job cards i.e. breakdown, maintenance and reliability. Planned
maintenance job cards are generated by the Operations Support Engineer together with planning
foreperson. It is the duty of the Maintenance Engineer to manage the time spent doing the job as
some jobs require more time as others require less time. After completion of the job, the total
time spent doing the job is recorded.
6.1.5 Working Instructions

Planning foreperson issues the form to the respective section who will take it for signature by the
authorized personnel namely:-
 Section Engineer
 OPS Superintendent
 Maintenance Manager
 OPS Manager
6.1.6 Maintenance Records
Planning department is the custodian of all station records. Some of the records kept are:
 Work order registers
 Standby roaster
 Keeping a record of all outgoing files
6.2 Maintenance work
The maintenance department is made up of sections and each section has its responsibility. The
maintenance engineer is the custodian of all the sections and these sections are led by their
respective forepersons.
6.2.1 MMD (Mechanical Maintenance Department)
The section is responsible for all mechanical engineering maintenance. Through the help of
external contractors, the key duties of this section include:

 New mechanical installations

 Maintenance of pumps, conveyor belts etc.
 Welding
 Boiler maintenance
6.2.2 CMD (Civils Maintenance Department)
The section is responsible for jobs which involve:
 Plumbing
 Boiler refractories
 Motor mechanics
6.2.3 Control and Instrumentation and EMD (Electrical Maintenance Department)
The two sections are under the one fore person. C&I duties are related to instrumentation work
which involves overhaul, installation and repair of instruments. Instruments used at the plant
include thermocouples, DC meter, gauge glasses, flow meters and pressure detecting devices
such as Burdon tubes.
The EMD tasks include maintenance of transformers, motors, compressors and installation of
these components.
6.3 Conclusion
The author has not been fully attached to the maintenance section and thus discussed the
department in brief.. In this chapter, the author looked at the maintenance management and
engineering issues at BPS. Issues such as planning procedures, the scope are outlined and lastly
the author discussed in brief, the various maintenance section sand their core duties.

CHAPTER SEVEN: HEALTH, SAVETY, ENVIRONMENTAL

AND QULITY MANAGEMENT
7.0 Introduction
In thermal power station, the processes include fuel combustion, use of toxic chemicals and
dangerous equipment. These aspects need constant monitoring for the health and safety of
workers as well as efficient and environmentally conscious operation of the plant. This
chapter looks at these aspects in relation to the Bulawayo Power Station.
7.1 Health and Safety
The equipment and processes at the station pose a threat to the health and safety of the
workers. The station has set up a risk management officer to cater for the health and safety
awareness towards zero tolerance of accidents. Ergonomics also is a special point of
concentration for the risk officer. Early this year (2015) the risk officer produced a Pre Task
Risk Assessment form. The workers are able to discuss and record potential safety hazards
and environmental aspects in any task to be done. Among other safety and ergonomics
factors are:
 Coal dust: The type of coal being received currently contains too much dust particles
and is a threat to workers health as it causes respiratory problems. The risk and safety
representatives have advised for the continuous use of respirators at the coal plant and
boiler house where high concentration of dust if found. Efforts are also being done to
supress the dust by spraying water. However the use of water is costly. The author
recommends the installation of vacuum dust suppressors.
 Chemical handling: The other threat to safety is at the water treatment plant where
workers have to carry caustic lye with open containers during regeneration process. The
author recommends the repair of the caustic pump for the safety of workers

 Unavailability of lift: The unavailability of a lift at operations is an ergonomic factor as

boiler constructors have to carry heavy materials up the stairs to the roof top.
 Turbine house excessive heat: The heat the turbine house is excessive for healthy
working conditions. Efforts are currently underway to purchase heat reflective overalls,
which will be a good move for the safety of operators.
7.1.1 BPS Safety Policy
Bulawayo Power Station management and staff are committed to operating and maintaining
the power station in a manner that meets the requirements of Occupational Safety and Health
regulations.
To achieve this, the Power Station is committed to:
 Protecting the safety and health of staff by preventing work-related injuries, ill health,
diseases and incidents.
 Maintaining good health among all employees including promotion of HIV/AIDS
programmes.
 Complying with relevant Occupational Safety and Health legislation as stipulated by
local laws and regulations
 Ensuring that workers and their representatives including contractors are consulted and
encouraged to participate in Safety and Health programmes through Safety and Health
committees
 Mobilising the necessary resources to ensure success of Occupational Safety and Health
programmes.
 Put in place continued Safety and Health awareness programmes at all levels of the
workforce.
 Monitor, evaluate and review Occupational Safety and Health performance on a
continuous basis.

7.2 Environmental Management
The boiler house emissions and coal dust are some of the environmental aspects of BPS
thermal power plant. Flue gasses are a threat to environment as they cause global warming.
The station is registered with EMS ISO 14001 (2004) and thus through these standards has
generated an Environmental Management Policy. The policy states clearly what the
company intends to do in an aim of conforming to environmental requirements. The
Laboratory Head Office is in charge of the environmental management issues for the station.
To ensure efficient environmentally conscious operation, the station has preached the 3Rs
(Reduce, Recycle and Re-use) and has set EMS objectives for each section.
7.2.1 Environmental Policy
Bulawayo Power Station is involved in the generation of electricity by combustion of fossil

fuels (coal and oil). The operations result in by-products and waste which interact with the
environment. We are conscious of the potential impacts on the environment. Management
and the entire workforce are committed to operate in a manner which will minimise these
impacts. Our goal is to ensure that we meet all our obligations in the protection of the
environment.
To achieve this goal, BPS will:

 Take appropriate measures to monitor and control our impacts on the environment
 Adhere to set levels for environmental protection as stipulated by local and relevant
international standards, laws and regulations
 Assign responsible, qualified personnel to the management and control of environment
matters
 Put in place continuing education programmes to be conducted on a regular basis for all
levels of workforce
 Ensure the efficient use of resources during the generation of electricity so as to
minimise waste
 Carry out Environmental Impact Assessments for all new project

 Maintain continuous dialogue with interested and affected parties

 Be committed to continuous improvement of our environmental performance
 Management will regularly monitor and review the station‟s policy and performance.
 An environmental report will be published annually and made available to all
stakeholders
7.3 Quality Management
The profitable use of resources which include time, money and raw materials in any
organisations is a result of good planning and quality management objectives. BPS as power
generating organisation is also guided by its quality objectives. The company is registered
QMS ISO 9001(2008), and its quality objectives are in line with the standards. Each section
in the plant has its QMS objectives, which fulfil the company‟s objectives at large. The
quality issues of the station are managed under the Chemical Services Department.
7.3.1 BPS Quality Policy
Bulawayo Power Station is committed to operating, maintaining and continuously improving

the business unit so that it delivers a service that meets its customers‟ needs.
To achieve this goal, Bulawayo Power Station is working with a quality management system
that is based on the International Standard ISO 14001. Through the implementation of this
Quality Management system, management and the entire workforce are committed to the
following:-
 To meet the requirements of our customers, ZETDC, as well as other legislative

authorities.
 To supply reliable electricity at competitive prices
 To generate electricity to maximum capacity and maximize shareholder value
 To achieve operational excellence by operating and maintaining our plant according
to international standards.
 To ensure efficient use of human, financial and material resources.
 To communicate and train staff on all aspects of the Quality Management System.

 To ensure that the station is insurable at all times his policy is supported by objectives
and targets established by all functions at various levels in the Power Station
7.4 Summary
The chapter reviewed the safety, health, environmental and quality management issues for
BPS. The policies of each field were given as well in line with international standards.

CHAPTER EIGHT: PROJECTS
8.0 Introduction
During the attachment period, the author identified some problems in the plant. The author gave
some recommendations in the form of mini projects. In this chapter the author contains the
projects done by the author during the attachment period.
8.1 Project one: Implementation of six sigma (DMAIC) on boiler plant defects
8.1.1.1 Project Proposal
The project aim is improve the boiler plant reliability by implementing six sigma(DMAIC) on
the boiler plant defects at ZPC Bulawayo Power Station. The power station has an available
power generation capacity of 60MW, with two turbo-alternators capable of producing a
maximum 30MW each. The boiler plant has six serviceable Yarrow model chain grate boilers,
each capable of producing 15MW. These boilers use the pea sized (18mm thickness) coal. Coal
is fed into the furnace through chutes from the coal bunkers. A motor driven stocker chain grate
carries the coal across the length of the furnace. Air from forced drought (FD) fans facilitates the
combustion process while secondary air fans blow in air across the furnace, perpendicular to
forced drought air to produce turbulence, aiding the combustion process. Flue gasses from the
combustion process are used to superheat steam in the super heater tubes before pre-heating
boiler feed water in the economizer. Pre heating of air prior to the stocker wind box is done
through the flue gasses before they are exhausted to the atmosphere. Induced drought fans suck
out the flue gasses from the air just at the exit of the air heater. Refractory bricks are used for
insulation of the boilers, which reduces loses of heat energy from the furnace. Downtime for
boilers is mainly caused by defects like refractory failures, tube bursts, stocker grate, fan
problems, clogging and snapping of ash belts.

8.1.1.2 Background
As at 30June 2015, the power station has produced 98 716 MWhrs of electricity, compared to a
target 129 600MWhrs for the first half of the year. The station has not been able to utilize both
30MW turbo-alternators due to low boiler plant uptime, leading to the 44.7% production
variance. An audit on the boiler plant showed that the plant uptime for the boiler plant is at 56%
compared to an acceptable 80%. The biggest concern is on the frequency and length of downtime
due to various defects. Boiler plant reliability plays a critical part in thermal power plant
production as the boilers are the source of energy for turbines; hence there is a need for improved
boiler plant reliability at the power station. Figure 8.1 indicates the variation in power sent out,
compared to the target for the first half of the year.
Monthly Sentout Units versus Target for Jan -Jun 2015
24000
22000
20000
UNITS (MWhr)
18000
16000
14000
12000
10000
JAN FEB MAR APR MAY JUN
MONTHLY SENTOUT
17202 14295 16518 14920 15600 10653
UNITS (MWhr)
MONTHLY TARGET
22320 20880 22320 21600 22320 21600
(MWhr)
Figure 8. 1 Power units sent out against target for Jan-June 2015

8.1.1.3 Aim
To implement six sigma (DMAIC) analysis of the boiler plant defects
8.1.1.4 Objectives
 To identify the vital few defects contributing to forced outage
 To conduct a Root Cause Analysis for the identified defects
 To generate a maintenance plan for the defects
8.1.1.5 Scope
The project is going be based on application of statistical and engineering tools to screen and
analyse root causes the vital few defects which contribute to forced boiler outage at BPS. In the
analysis, the author seeks to identify possible improvements in operation and maintenance. The
researcher seeks to generate a maintenance plan for the few vital boiler defects. The author will
also give recommendations on improvement of operation procedures.
8.1.1.6 Justification
Plant reliability is an important indicator of the health of an industrial unit. It enables

maximization of return on investment through higher throughput and lesser maintenance
expense. DMAIC implementation allows for narrowing down on the major causes of the defects
and possible remedies for minimizing the frequency and effects of these prevailing defects. The
main purpose of improving uptime for boilers is to ensure the boilers provide enough steam so
that the two available turbo-alternators can be put to use. Analysis of the root causes and effects
of boiler defects will help identify possible places of improvement, both in terms of operating
conditions, procedures and maintenance. Planning which is a critical aspect of the plant will be
easy and the “control” phase of DMAIC allows for potential defects to be attended at a tender
age. This will reduce maintenance costs as defects will be attended before maturity. Loses due to
forced downtime, damage of property and injuries to operators in emergencies due to intense
defects will be minimized as well, thus boosting worker confidence.

Continuous generation of power is also a benefit to the customers of the Zimbabwe Power
Company (industry and domestic users) as power cuts are reduced, which promotes reliability of
the company. Reliability to our customers is a key step towards achieving our vision of being the
leading energy supplier in the region.
8.1.1.6.1 Benefits of implementing the project:

 Possible root causes of defects will be identified
 Gives room for improving operating procedures for the plant by increasing operators
awareness, thus reducing maintenance costs
 Every stakeholder in the Operations department gets an opportunity to share ideas on
operation demands for the plant‟s boilers
 DMAIC helps zero in on defects, finding possible solutions and maintaining the new set
standards.
 The project will give room for defect recurrence control
8.1.1.7 Definition of critical terms

 Reliability: The probability that a component part, equipment, or system will satisfactorily
perform its intended function under given circumstances, such as environmental conditions,
limitations as to operating time, and frequency and thoroughness of maintenance for a
specified period of time.
 Throughput: The volume of feed stock charged to a process equipment unit during a
specific time
 Refractory failure: The collapse of brick walls which provide insulation in a combustion
chamber
 Clogging: The accumulation of soot on boiler tubes, hindering the flow of flue gasses out of
the furnaces

8.1.2 Literature review
This section of the project looks at the review of literature, alluding to implementation of the
engineering tools in the project.
8.1.2.1DMAIC (Define, Measure, Analyze, Improve and Control)
According to (Morton, 1999), among the various problem solving methodologies available for
approaching process improvements, DMAIC is one of the most effective and holistic. DMAIC
allows for identification of key points of failure in a system, measurement of impact, analysis and
improvement of a production system. The control stage allows for trending and further
improvement of the new methods.
8.1.2.2 Plant reliability and Reliability Engineering
Reliability engineering deals with the longevity and dependability of parts, products and systems.
Reliability engineering incorporates a wide variety of analytical techniques designed to help

engineers understand the failure modes and patterns of these parts, products and systems. Some
of the mostly used reliability engineering techniques are:
 Reliability-Centered Maintenance (RCM)

 Including failure modes and effects (and criticality) analysis (FMEA,FMECA)
 Root cause analysis (RCA),
 Condition-based maintenance,
 Improved work planning schemes
8.1.2.3 Pareto Analysis
Pareto analysis is a statistical tool used in decision making. Also known as the 80/20 rule, it
allows for identification of the vital few tasks which have greatest effect on the overall
performance of a system. The trivial many tasks that have been separated from the few vital tasks
are not totally ignored but attended as well, however with less priority.

8.1.3 Methodology
The first stage of the project is the “Define” stage. The author conducted an audit on forced
outage at the whole power plant. The results of the audit indicate that more forced downtime was
due to boilers as the primary step in the power generation process. The researcher conducted a
second audit on the boiler plant outage. The researcher then summarized the total forced
downtime against defect frequency as shown on table 8.1. The second stage is the “Measure”
stage. Here the researcher used linear regression to rate the effect of these vital defects on power
generated. The six months were divided into twelve components of half a month long. The
“Analyze” stage involved the use of Pareto analysis to identify the few vital defects to focus on.
The Ishikawa / fish bone tool was then used for conducting a root cause analysis for the defects.
In the “Improve” stage the researcher generated a maintenance plan and made recommendations
on the operation of the boilers. The control stage involves trending, monitoring of the
implemented plan. However this stage will be done after the implementation of the project.
8.1.4 Project solution
This section of the project shows the implementation stages in their order.
8.1.4.1 Defining stage
Audit on the forced down time was done. Information was gathered through plant status records
and oral discussions with senior operators and shift charge engineer.
The graph on figure 8.2 shows the results of the forced outage audit conducted by the researcher
on the boiler plant. The results show the combined outage for the Yarrow 15MW boilers number
6, 7, 8, 9 and 10. Boiler 5 was not included as was on statutory maintenance during the research.

Table 8. 1Boiler outage and power generation summary for Jan-Jun 2015
SECTION FORCED OUTAGE DUE TO CONTRIBUTING DEFECTS (hours)
Tube Refractory Grate Clogging Fan TOTAL UNITS

bursts failure F/OUTAGE MWhrs
JAN 1 264 624 0 0 0 888 9596
JAN 2 0 720 0 0 0 720 9201
FEB 1 120 120 0 0 0 240 8612
FEB 2 552 0 48 0 0 600 7000
MAR 1 336 96 0 0 0 432 10025
MAR 2 264 360 0 0 0 624 8211
APR 1 360 168 0 0 0 528 7543
APR 2 360 192 216 0 0 768 8784
MAY 1 120 0 216 72 120 528 6980
MAY 2 0 0 240 192 0 432 10050
JUN 1 0 552 120 12 0 684 5131
JUN 2 0 384 0 72 0 456 6563
TOTAL 2376 3216 840 348 120 6900
Cum % 34% 81% 93% 98% 100%

Boiler plant actual uptime against target for Jan -Jun 2015
90
80
70
PLANT UPTIME (%)
60
50
40
30
20
10
0
JAN FEB MAR APR MAY JUN
PLANT UPTIME (%) 51 43 48 46 46 30
TARGET (%) 80 80 80 80 80 80
Figure 8. 2 Boiler plant uptime against target for Jan to Jun 2015
8.1.4.2 Measure stage
Results from the “Define” stage were summarized into a table showing the outage time due to
each contributing defect against the total outage for that section of the month. The measure stage
involved testing the correlation between each defect and the power produced at the time. Linear
regression was used to test the relationships. However due to time constraints, only calculations
for refractory failure are shown on this report. Figure 8.3 shows the scatter plot for refractory
failure against power produced in (MWhrs)

scatter plot for generated units against refractory failure

outage
12000
units generated (MWhrs)
10000
8000
6000
4000
2000
0
0 100 200 300 400 500 600 700 800
refractory failure forced outage (hrs)
Figure 8. 3 Scatter plot for generated power against refractory failure

The points marked red are outliers and they were not used in the calculations. Results obtained:
 the intercept a=10061 MWhrs

 the slope b= -9.15
 coefficient of co-relation r= -0.948
 coefficient of determination R2=0.90
 Final relationship: Y= -9.15X+10060 …………………………….. Equation 8.1
The results for the refractory failure versus generated units indicate a 90% linear relationship
between refractories. Therefore a reduction in the recurrence of the defect will have a positive
impact on the units generated. Tube bursts indicated a 46% correlation while the other defects,
due to their rare occurrence did not give a significant correlation, although at some points they
contributed to forced outage.

8.1.4.3 Analyse stage
The first part of analysis was to separate the few vital defects from the trivial many. A Pareto
graph was used and results show that refractory failure and tube bursts were the contributors of
80% of downtime. The trivial defects are grate problems, clogging and fan problems. Figure 8.4
shows the Pareto graph for the screening process.
Figure 8. 4 Pareto graph for the forced outage contributing defects

On projection of the 80% line, the researcher noted that the few vital defects are refractory
failures and tube bursts, hence the defects which contribute most to forced outage for boilers.
The second step in analysis was to find the root causes of these defects. Brainstorming and oral
discussions were used in the information gathering process. The Ishikawa / fishbone diagram was
used in the root cause analysis for the refractory and tube failures. The key points of concern
investigated by the researcher were the operation and maintenance of boilers.

Figure 8. 5 Ishikawa diagram for refractory failure root causes at BPS
Figure 8. 6 Ishikawa diagram for tube burst root causes at BPS

Figure 8. 7 User interface for Microsoft Access database for Maintenance plan database user

Upon determination of some, among many root causes for the boiler refractory failure and tube
bursts, the researcher noted that there were some common root causes for the two defects. Some
of the common root causes identified was:
 delayed reaction
 excessive firing due to malfunctioning instruments
 improper commissioning procedures leading to thermal shock of components
8.1.5 Results, Conclusion and recommendations
The researcher‟s objectives were met and now left is the implementing the proposal. The
maintenance plan was generated on a database system and the user interface was designed
successfully. However given more time, the researcher will implement more software into the
project. I seek to continue working on project and implementing more improvement plans for the
improved performance of the plant. The researcher recommends that the proper warming up
period (72 hours) be allowed for each boiler after repairs. An overhaul of instrumentation, air
dampers and fan servo motors is required at least twice a year as faults in these devices disturb
operation process by making control process difficult.
Among other lessons learnt by the researcher were:
 Practical application of problem identification and solving tools

 Researcher got to more on basic boiler operations and problem identification
 Interaction and discussions improved the researcher‟s team work ability.
Given another chance, the researcher will look into detail on the defects at the boiler plant. This
time the researcher will compensate for variations by analyzing the boilers separately.

8.2. Project 2: Condenser extraction pump steam turbine drive design
8.2.1 Project Proposal
The section of the project covers the proposal.
8.2.1.0 Introduction
The project aims to improve turbine plant protection at ZPC Bulawayo thermal power station,
through the design of a steam powered condenser extraction pump. BPS uses the condensing type
impulse turbine. Superheated dry steam at 454°C and 43 Bars enters the turbine where it expands
and is exhausted to the condenser as saturated steam at 37°C. In the condenser, the steam loses
heat energy and condenses. After condensation, the condensate is extracted through two electric
powered pumps to keep a suitable condenser level. Condensate extraction pumps are very
important as extraction of condensate from the condenser ensures undisturbed flow of steam
across the turbine without building up of back pressure on the turbine blades.
Unavailability of the extraction pumps is also a threat to turbine protection as the filling up of the
condenser causes steam to condense within turbine blades, causing thermal shock and corrosion
of the blades.
8.2.1.1 Background
At full turbine load (30MW), two electric extraction pumps are used to extract condensate at
45t/hr from the condenser, with a single pump able to extract condensate at 18 MW turbine load
without tripping. However during the generation process the available electrical pumps trip on
electrical fault and also during system disturbances like electric surges, causing a rise in
condenser level and significant back pressure on the turbine blades.
8.2.1.2 Aim
To design a steam powered condenser extraction pump with a view of promoting turbine plant
availability and protection during emergencies.

8.2.1.3 Objectives
i. To size a mini turbine blades and shaft drive based on existing electric pump specifications
ii. To do assembly drawing of the mini turbine to drive the pump
iii. To select bearings for the drive system
8.2.1.4 Scope
The project is going to cover mechanical design of a mini steam turbine to drive the pump
impeller. Material selection will be considered in the designs and selection of steam pipe work.
Thrust bearings will also be selected. Assembly drawings for the designed mini-turbine will be
done and patents for selected materials will be given as well. AutoCAD will be used for
mechanical assembly drawings and simulation of other components.
Protection of the turbine plant is very critical, as it minimizes costs incurred is repair and
replacing of turbine blades.
The performance of the turbines at ZPC has been poor, with exhaust temperatures up to 85°C
which could be a result of blade faults associated with the frequent trips of pumps. Reducing
these maintenance costs gives room for expansion of the Zimbabwe Power Company thus giving
an increase in market share in the region.
8.2.1.6.1 Benefits of having a steam powered extraction pump

 Having a steam powered pump will keep the plant available if an electrical pump trips due to
electrical or mechanical fault, hence they is no need to shut the plant to allow maintenance
work on the pump.
 Turbine protection is boosted as the pumps will drain the condenser when the electrical
pumps trip.

 Condenser level will be maintained if electrical pumps trip, thus keeping an optimum
vacuum. This will make it easy to raise load on turbine without vacuum complications in
severe emergencies.
8.2.1.7 Definition of critical terms

 Design - it is the formulation of a plan to satisfy human need (Khepar S.D. and Michael
A.M., 1992).
 Steam turbine- A steam turbine is a mechanical device that extracts thermal energy from
pressurized steam and converts it into useful mechanical work. (Glencore, 1991).
 Electric surge: A disturbance in the electrical circuits which causes isolation of electric
components from their feeding system
The section is on the literature review of the components and systems to be used on the projects.
8.2.2.1 Impulse turbine
According to Maurice (1975), an impulse turbine consists mainly of a fixed nozzle, a series of
moving blades radially mounted on a shaft/rotor and stationary blades mounted on the housing of
the moving blades. The moving and stationary blades intermesh with certain minimum
clearances, with the size and configuration of sets varying to efficiently exploit the expansion of
steam at each stage. The steam or gas possesses thermal energy which is converted to linear
kinetic energy at the exit of the fixed nozzle. The steam then exits the nozzle at a high velocity,
hitting the turbine blade and causing it to rotate at fast angular speed. The rotor or shaft is
connected to the load, which can be an electricity generator or pump. The steam expands as it
flows across the turbine blades up to its point of exhaust. Steam consumption of steam turbine is
depending to required output power and efficiency of the turbine. Efficiency will depend on
turbine size or rotor diameter, blade geometries, material, steam temperature at inlet and also the
losses which occur.

Very high steam temperature will decrease strength of material of turbine blades and cause
limitation of design speed. The impulse turbines fall into two groups which are the condensing
turbine and the back pressure turbine. In the condensing type, steam exhaust is wet while the
back pressure type exhausts steam a dry state.
Figure 8. 8: Impulse turbine against reaction turbine performance (Molling, 2006)

8.2.2.1.1 Impulse turbine blade design derivations
Besides material selection, the performance of turbine blades is also highly dependent on its
geometrical properties. By theoretical analysis steam exits the nozzle at high velocity and
expands in the turbine. The vectors are indicated through steam turbine inlet and outlet vectors as
shown in figure 8.8 and figure 8.9.
8.2.2.1.2.1 Nomenclature and derivations for turbine nozzle and blade.
– Absolute velocity of steam at nozzle exit. Exits nozzle at angle α to plane of rotation

– Steam velocity at inlet, relative to the blade. Approaches the blade at angle θ to the plane of
rotation
- The mean velocity of the blade
– Whirl velocity at inlet. A component of parallel to plane of rotation
– Absolute steam velocity at blade exit. Exits the blade at angle β to plane of rotation
– Exit steam velocity relative to the blade. Exits the blade at angle ϕ to plane of rotation
– Whirl velocity at blade exit. A component of parallel to plane of rotation
– Steam flow velocity at blade inlet. Component of on axis of rotation
– Steam flow velocity at blade exit, a component of on axis of rotation, assumed to be

flow inlet velocity for next row of blades
8.2.2.1.1.3 Nozzle design derivations
Considering a frictionless blade that turns the steam through 180 and exits with zero absolute
velocity. This condition represents the greatest possible conversion of kinetic energy of the
entering jet into blade work.
𝑪𝒂𝒊
𝑪𝒓𝒊
U
𝑪𝒓𝒆 𝑪𝒂𝒆
Since the blade is frictionless
and

Combining equations this means:
…………… Equation 8.1
Actual nozzle angle
Due to geometry restrictions of a real turbine, the blade angle has to be modified to suit the
practical blade. In the derivation, the acute angle between and the tangential direction,
called the nozzle angle, is zero. In an actual turbine, because of physical constraints, the nozzle
angle must be greater than zero but not so great as to cause an appreciable loss in efficiency. Nor
should the angle be so small as to cause an excessively long nozzle that would increase friction
and decrease efficiency.
Equation (8.2), corrected for a finite nozzle angle α, becomes:
Because of disk friction and fanning losses, , is usually increased somewhat, say 10%, over the
theoretical value.
Figure 8. 9: Steam inlet and outlet vector triangle for turbine blade (Joel, 1968)

Work done by the turbine blade:
By Newton second law: Force = Rate of chance of momentum = product of mass and velocity.
Change in velocity (v) which produces the force on the blades in the plane of rotation is the
chance in velocity of whirl. Where the whirl velocities can be graphically determined or
calculated as:
..…………..Equation8.5
√( ) ..…………..Equation 8.6
Figure 8. 10: Combined vector triangle for turbine blade (Joel, 1968)

The change in whirl velocity:
( ) ……………. Equation 8.7
Therefore the force F is given by:
̇( ) ....…………. Equation 8.8
Blade Power (P) = (Work done per second) and is a product of the force and mean velocity of the
blade.
̇( ) ....…………. Equation 8.9
Kinetic energy of steam per unit mass:
(J/kg) ....…………. Equation 8.10
Due to the flow velocity decrease in the flow velocities across the turbine because of friction on
the blades, a thrust exists along the turbine shaft and is also calculated as:
̇( ) ...…………. Equation 8.11
8.2.2.2Shaft design
The twisting equation for a loaded shaft is given as:
Where T =torque (Nm)
J =second moment of area ( )
L =length of the shaft (m)
G =modulus of rigidity (N )

 =angle of twist (rad)
 =shear stress (N )
R =radius of shaft (m)
The second moment of area J is calculated as:
………… Equation 8.13
Where D is the diameter of the shaft
Figure 8. 11: Torsional shear stress (Gupta, 2005)

8.2.3 Design Process
The section covers the design calculations and drawings.
8.2.3.1 Design calculations
Given working conditions for the pump:
Pump rotor diameter and power coefficient at 1500rpm D = 0.48m, k = 0.38
Revolutions per minute 1500 rpm

Maximum blade height 0.35m
Initial steam pressure 42bars
Initial steam temperature 454 C
Steam inlet and outlet angle 20° and 30°
Specific density of condensate at pump discharge 1
Steam speed at nozzle exit 300m/s
8.2.3.1.1 Turbine blade calculations
Given r.p.m for shaft:
Angular velocity
=157.1 rad/s
Mean blade velocity:
From equation (8.1)
Therefore
= 141m/s
Whirl velocity at inlet:
Using equation (8.2)
= 300cos 20
=282m/s

Inlet velocity of steam jet relative to blade:
Using equation (8.6) √( )
√( )
= 175m/s
Using turbine velocity factor according to (E. F. Church, 1950) to determine relative velocity at
blade exit :
Where a factor counting for friction and turbulence
√( )
=√( )
=0.943
Therefore relative velocity at exit =0.944 175
=165.2 m/s
Power is a product of force and velocity of the blade:
Blade Power (P) = (Work done per second) and is a product of the force and mean velocity of the
blade
From equation 8.9 ̇( )
According to (Douglas F J, 2005), the power at impeller discharge is given by:
Where k, 𝛒, ω and D is the power coefficient, density of fluid, angular velocity and impeller
diameter

On the construction of the vector diagram, a scale of 1mm: 1m/s is used.
Figure 8.12: Graphical solution for turbine triangle of vectors
Therefore impeller
= 37.5kW
Therefore turbine design power say 39 kW (to give allowance for losses)
Required steam flow rate ̇ )
=( )
= 0.95kg/s

Using equation 8.8: ̇( )
= ̇ (9+ 282)
= 311
= 295.45
Thrust force on turbine blade:
From equation 8.11 ̇( )
= 0.95(104-69)
= 33.25 N
8.2.3.1.2 Impeller Shaft design
Given conditions:
Shaft of properties: Modulus of rigidity = 80GPa
Maximum angle of twist =0.0174rad/m
Power transmitted at coupling = 39kW at 1500rpm
Length of shaft = 0.7m
Shaft diameter:
Using equation (8.12)
Then
Torque = Power divided by angular velocity. From the turbine calculations, ω =157.1 rad/s
Therefore

=
=248.25Nm
From equation 8.12
= 1.245
Therefore the shaft diameter =√
= 0.106mm (say 11cm).
8.2.4 Results
The section indicates the summary of results obtained from the calculations and design process.
Table 8.2 shows calculation results while table 8.3 shows detailed results from drive turbine
component section.
Table 8. 2: Calculation results summary
QUANTITY MAGNITITUDE
Steam flow for turbine 0.95kg/s
Turbine thrust 33.25 N
Drive shaft 110mm diameter
8.2.4.1.0 Results analysis
The results of the calculations and design process were obtained as planned. Assumptions on the
pump power output were med to compensate for the losses. The assembly drawing and schematic
arrangement of the three pumps were done as planned.

Figure 8. 13: Final turbine assembly drawing

Table 8. 3: Detailed parts list for steam turbine components
PART PART NAME MATERIAL MATERIAL Quantity

No. SPECIFICATION
1 Casing High strength cast iron ASTM-A-278 1
Class 40
2 Turbine blades 12% chromium stainless AISI 403 1

steel
3 Shaft Carbon-molybdenum AISI 4140 1

alloy steel
4 Nozzle Carbon steel ASTM-A-516 1
Grade 60
5 Carbon rings Carbon 5
6 Thrust bearing Steel ASTM-A 216 2

casing WCB
7 Thrust ball race Cold rolled steel AISI 1018 2
8 Steam inlet pipe Carbon-molybdenum AISI 4140 1

alloy steel
10 Rotor disk High strength steel ASTM 517 1
11 Journal bearing Bonded Babbitt SAE 12

Figure 8. 14: Parallel arrangement of steam powered pumps and electric pumps
8.2.5 Project summary, recommendations and lessons learnt.
The projects main objectives were met as planned. The designer had the opportunity to research
on the design processes and material selection for parts. The designer intends to a cost benefit
analysis to compare the two types of drives, electrical and turbine drive. The author also seeks to
do more designs related to the thermal plant mechanical systems.
8.3 Project three: Boiler performance optimisation by simulating an ARENA software

based operating program
8.3.1 Project proposal
The section is on the proposal for the project

8.3.1.0 Introduction
Bulawayo power station is a thermal power station that uses yarrow water tube boilers for steam
generation. At present the station uses six (15 MW) boilers
Of late the boilers have been performing badly as indicated by low steam output and high
recurrence of defects. The dilapidation of the boiler plant is one of the suspected contributions to
this performance drop.
8.3.1.1 Background
The boilers at the plant have a design efficiency target of 85%, and steam output of 72tonnes per
hour. However the boilers are currently underperforming and this is a cost as more costs are
incurred as lots of coal is used for less steam output. Low performance also leads to over firing
which in turn causes defects as tube failure and refractory failure. There is a need to simulate a
software based operation program to counter for the variations in boiler input settings.
8.3.1.2 Aim
To optimise boiler performance by simulating a computer program for boiler operation
8.3.1.3 Objectives
 To estimate the boiler efficiency for boilers 6,7,8,9 and 10
 To simulate an ARENA software program for boiler operation settings
 To give recommendations on possible improvements in boiler operation
 Knowing the boiler efficiency for the boilers will help the operators to come with optimum
fire setting to reduce recurring defects
 By determining boiler efficiency the operations engineer can easily forecast on requirements
for the boiler house.
 Knowing boiler efficiencies will help to compensate for boiler variations during the
simulation process

8.3.1.5 Scope
This project will calculate efficiencies for the boilers that have been running for the past two
months. Boiler 5 will be excluded since it was under statutory maintenance during the period
under review.
8.3.1.6 Project limitations

 Due to the unavailability of the coal meter the researcher will estimate the coal used by a
boiler using the coal bunkered for that particular boiler
 Due to the unavailability of other measuring instruments the researcher will use the direct
method to determine the boiler efficiency.
This section outlines literature of boiler efficiency testing, the calculation procedures, the losses
that may occur during boiler firing.
8.3.2.1 Boiler design
According to Hilton (2010), a boiler must effect a desired change in the thermal conditions of the
process streams within allowable pressure drops and continue to do so for a specified time. Good
combustion and energy efficiency is the ability to mix air and fuel, with little excess air as
possible at high enough temperature to sustain the process and completely burn the fuel with
minimum environmental emissions, and favourable heat transfer.
8.3.2.1.2 Boiler Efficiency
The term “boiler efficiency” is often substituted for thermal efficiency or fuel-to-steam
efficiency. (Hilton, 2010)When the term “boiler efficiency” is used, it is important to know
which type of efficiency is being represented. This is because thermal efficiency, which does not
account for radiation and convection losses, is not an indication of the true boiler efficiency.

Fuel-to-steam efficiency, which does account for radiation and convection losses, is a true
indication of overall boiler efficiency. The term “boiler efficiency” should be defined by the
boiler manufacturer before it is used in any economic evaluation.
8.3.2.1.2.1 Fuel-To-Steam Efficiency
Fuel-to-steam efficiency is a measure of the overall efficiency of the boiler. It accounts for the
effectiveness of the heat exchanger as well as the radiation and convection losses. It is an
indication of the true boiler efficiency and should be the efficiency used in economic evaluations.
As prescribed by the ASME Power Test Code, PTC 4.1, the fuel-to-steam efficiency of a boiler
can be determined by two methods; the Input-Output Method (Direct method) and the Heat Loss
Method (Indirect Method). Minimizing the losses will have a major impact on improving the
boiler efficiency. Some losses are controllable relatively easily, while others are more difficult to
control. One thing is certain, when looking at the efficiency issue and that is you will never get
out what you put into the process, due to physical limitations which define our environment. The
best one can expect is to minimize the impact of the losses, economically.
There are several norms to determine the efficiencies figures and it is practically very difficult to
verify these without costly test procedures. The easiest and most cost effective method is to
review the basic boiler design data and estimate the efficiency value on the five following broad
elements.
 Boiler Stack Temperature

 Heat Content of Fuel
 Fuel Specification
 Excess Air Levels
 Ambient Air temperature and Relative Humidity
8.3.2.2.2 Boiler efficiency calculation methods
There are mainly two methods of calculating boiler efficiency. These are the direct and indirect
methods.

8.3.2.2.2.1 Direct Method
This is also known as „input-output method‟ due to the fact that it needs only the useful output
(steam) and the heat input (i.e. fuel) for evaluating the efficiency. This efficiency can be
evaluated using the formula:
…………………. Equation 8.14
Parameters to be monitored for the calculation of boiler efficiency by direct method are:
 Quantity of steam generated per hour (Q) in t/hr.

 Quantity of fuel used per hour (q) in t/hr.
 The working pressure (in psi) and superheat temperature (°C)
 The temperature of feed water (°C)
 Type of fuel and gross calorific value of the fuel (GCV) in kJ/kg of fuel
8.3.2.2.2.2.1 Merits and Demerits of Direct Method
The merits on the method are:
 Plant people can evaluate quickly the efficiency of boilers

 Requires few parameters for computation
 Needs few instruments for monitoring
However the direct method has de-merits in that it:
 Does not give clues to the operator as to why efficiency of system is lower
 Does not calculate various losses accountable for various efficiency levels
 Evaporation ratio and efficiency may mislead, if the steam is highly wet due to water
carryover

8.3.2.2.2.3 Indirect Method
The efficiency can be measured by measuring all the losses occurring in the boilers using the
principles to be described. The disadvantages of the direct method can be overcome by this
method, which calculates the various heat losses associated with the boiler. The efficiency can be
arrived at, by subtracting the heat loss fractions from 100. An important advantage of this method
is that the errors in measurement do not make significant change in efficiency.
Thus if boiler efficiency is 90%, an error of 0.1% in direct method will result in significant
change in efficiency i.e. .
In indirect method, 1% error in measurement of losses will result in;
( )
There are reference standards for Boiler Testing using indirect method namely British Standard,
BS 845: 1987 and USA Standard is ASME PTC-4-1 Power Test Code Steam Generating Units‟.
Indirect method is also called the heat loss method. The efficiency can be arrived at, by
subtracting the heat loss fractions from 100. The standards do not include blow down loss in the
efficiency determination process.
The principle losses that occur in a boiler are:
 Loss of heat due to dry flue gas

 Loss of heat due to moisture in fuel and combustion air
 Loss of heat due to combustion of hydrogen
 Loss of heat due to radiation
 Loss of heat due to unburnt fuel
In the above, loss due to moisture in fuel and the loss due to combustion of hydrogen are
dependent on the fuel, and cannot be controlled by design.
The data required for calculation of boiler efficiency using indirect method are:

 Proximate and Ultimate analysis of fuel (H2, O2, S, C, moisture content, ash content)
 Percentage of Oxygen or CO2 in the flue gas
 Flue gas temperature in °C
 Ambient temperature in °C and humidity of air in kg/kg of dry air
 GCV of fuel in kJ/kg
 Percentage combustible in ash
 GCV of ash in kJ/kg
8.3.3 Methodology
This section presents structured methods used by the researcher in gathering data, the
experiments involved, interviews conducted at Bulawayo power station and the calculations
involved in order to come up with a detailed investigation on the boiler efficiency. The
researcher collected and compiled data for the months of April, May and June.
The researcher used the case study approach together with experimental research method to come
up with detailed information to study BPS Yarrow chain grate furnace boilers number 6,7,8,9 and
10.
8.3.3.1 Data collection tools
The data collection processes included:
 Interviews- oral interviews with boiler operators were conducted

 Log sheets- log sheets provided information on performance statistics for boilers
 Station daily metering- information about generation information and boiler status
 Daily coal record sheet- coal plant record on bunkering process
 Steam tables- used for the thermodynamic data for calculation process
 The station monthly reports and manuals gave ready processed data of the desired
performance parameters.

8.3.3.2 Boiler efficiency calculation process
The researcher will only show the calculation process for boiler 6 for time saving purposes.
Other results will be tabulated on the next section. The researcher used the direct method for
calculation.
8.3.3.2.1 Boiler 6 efficiency calculation
Feed water pressure : 28 bars
Final steam pressure : 43 bars
Feed water temperature: 230ºC
Final steam temperature: 450ºC
Steam flow rate : t/hr
Fuel flow rate : t/hr
Fuel GVC : 25kJ/kg
From the steam tables,
Feed water enthalpy:
At 28 bars and 230ºC, h = 991 kJ/kg
Final steam enthalpy:
At 43 bars and 450ºC
By interpolation
H (40 bars, 425ºC) = H (400) + (H (450) – H (400))
H (400) = 3214 kJ/kg; H (450) = 3330 kJ/kg
H = 3214 + (3330-3214)
H = 3272kJ/kg

Therefore efficiency is given as

̇ ( )
η= ̇ (
×100
)
Where
Ŋ = efficiency
̇ = fuel mass flow rate
̇ = steam flow rate
GVC = the fuel gross calorific value
Hs = enthalpy of steam
Hw = enthalpy of feed water
Therefore
( )
η= ( )
×100
= 78.49%
8.3.4 Results presentation and analysis
This section presents the key findings pertaining to boiler performance. Tables and other
statistical statements are used to present the information for easier understanding and
interpretation.

BOILER WATER INLET STEAM OUTPUT FUEL USED EFICIENCY %

Temperature ◦C Pressure Bars Enthalpy kJ/kg Temperature ◦C Pressure Bars Enthalpy kJ/kg flow rate t/hr GCV kJ/kg Flow rate t/hr
6 230 28 991 425 40 3272.2 47 25 5.46 78.49
7 230 28 991 416 40 3292.88 43 25 5.8 74.61
8 230 28 991 428 41 3265.04 44 25 6.1 65.56
9 230 28 991 405 39 3318.4 48 25 6.29 71
10 230 28 991 432 41 3255.76 51 25 6.8 67.02
BOILER EFFICIENCY TARGET

6 78.49 85
7 74.61 85
8 65.56 85
9 71 85
10 67.02 85
Figure 8. 15: Boiler efficiency results

The efficiency results obtained indicate that boiler 6 is the most efficient boiler at 78.49% while
boiler 8 is the least efficient with 65.56%. From figure 8.16, it can be seen that there is a very
significant variation in the efficiency of the boilers.
BOILER EFFICIENCY AGAINST DESIGN TARGET

90
85
BOILER EFFICIENCY %
80
75
70
65
60
1 2 3 4 5
EFFICIENCY 78.49 74.61 65.56 71 67.02
TARGET 85 85 85 85 85
Figure 8. 16: Boiler efficiency against design target for BPS boilers

8.3.5 Conclusions and recommendations
The author is yet to finish the performance optimisation part of the project. It is on plan that the
project will be completed on due cause as the author will continue attached to the company up to
the end of the year.
8.4. Other work done
This section of the report shows some of the work carried ou on the attachment period. The
section will mainly cover work done at the performance engineering section.
8.4.1 Boiler 9 Temperature fall trend and report (16-18 June 2015)
ZPC Bulawayo power station uses the PARSONS impulse turbine for electricity generation. The
turbine converts thermal energy from superheated dry steam into rotational mechanical energy.
The efficiency and safety of the turbine rely on the condition of the steam at inlet. The steam is
set t be dry so that turbine blades do not corrode and to prevent thermal shock to the turbine
blades. Thermal shock occurs when there is a sudden change of temperatures on the turbine
blades. However it is noted that as of the past generating week we have been getting out of range
steam temperature from boiler 6 and 9. Figure 1.1 is a line graph showing the fall of super heater
outlet steam temperatures for the period between 16/06/15 at 02:00 am to 17/06/15 at 8:00 pm.
8.4.1.1 Boiler status (as at 18 June)
The sudden drop in temperature is suspected to clogging of the super heater tubes. Clogging is a
process where soot from the combustion chamber accumulates on the boiler generating and super
heater tubes. The soot accumulates on the surface of the tubes forming a thick layer. The heat
transfer rate between the tubes and the flue gasses varies inversely as the thickness of the pipe.
Therefore the suit layer on the surface of the pipe causes an increase in the thermal resistance of
the tubes, hindering the transfer of heat energy between the pipe and flue gasses. Flue gasses
transfer heat energy to the pipes through conduction and the process is the same as well for
exchange between the tubes and the steam. The boiler was last soot blown on the night of 16-17
June at 0010hrs.

However it is the quality of the soot blowing process which is questionable due to the difficulty
in adjusting combustion chamber pressure. The combustion chamber pressure cannot be adjusted
due to the broken air damper hydraulic pump.
BOILER 9 TEMPERATURE DECREASE FROM 16-17 JUNE 2015
460
440
temperature decrease
420
TEMPERATURE °C
400
380 S/H
TEMPERATUR
360 E
340
320
300
5:00:00 PM
2:00:00 PM
8:00:00 PM
2:00:00 PM
5:00:00 PM
8:00:00 PM
2:00:00 AM
5:00:00 AM
8:00:00 AM
2:00:00 AM
5:00:00 AM
8:00:00 AM
11:00:00 AM
11:00:00 AM
11:00:00 PM
Figure 8. 17 Boiler 9 S/heater temperature trend for 16-18June 2015

4.1.2 Other suspected contributors to the temperature fall
 The super heater regulator might be out of full scoop due to mechanical fault
 The tubes might have scales on the inside surfaces
8.4.1.3 Other identified problems on the boiler
 a red hot spot near the west side secondary air duct
 frequent jamming of the grate

8.4.1.3 Recommendations for the temperature fall
I recommend that the secondary air hydraulic dampers to be inspected for possible piston
disturbance. This might be the cause of the problems with the hydraulic oil pump. The damper
flaps have to be inspected as well for misalignment. The boiler needs urgent attention on the
refractory as indicated by red hot spot. An overhaul of primary devices like servo motors and
dampers needs to be done on all boilers.

REFERENCES
Alchin, J., 2009. Explaining the process of ion exchange in water treatment plants. Journal of Ion
Exchange plants, pp.28-36
Budynas, N., 2006. Shigly's Mechanical engineering Design. 8th ed. MacGraw-Hill.
Charlse, R., 1995. Standard Handbook for plant engineering. New York.
Douglas F J, Swaffield, A.J., Jack, .L.B., 2005. Fluid Mechanics. 5th ed. Pearson Education
Limited.
Fernando, S.G., 2011. Wastewater Treatment and Reutilisation. 1st ed. Janeza Trdine: InTech.
Forrest, B., Implementing Six Sigma. Smatter solutions using statistical methods.
Harbajan, K., 2010. Flexible conveyor systems. Journal on conveyor systems , pp.34-38.
Hilton, K., 2010. Boiler efficiency guide. Facts you should kwow about firetube boilers and
boiler efficiency, Cleaver Brooks Inc..
Joel, R., 1968. Applied Thermodynamics. 4th ed.
Khurmi SR, Gupta, J.K., 2005. Machine Design. Uerasia Publishing house.
Morton, T., 1999. Production Operations Management. South West Coledge.
Rajput, R.K., n.d. Engineering thermodynamics. 3rd ed.
White, S., 2011. A phenologycal design tool for Wells turbines.
Shapiro N H, and Mouran, .J.M., 2007. Fundermentals of Engineering thermodynamics.
Thomas, P., 2009. The six sigma handbook.
ZPC BPS Operating and Maintenance instructions for 30MW turboaltaernators.

APPENDICES
Appendix 1: Steam tables

Appendix 2: Boiler component specifications
Item Material Outside diameter Thickness Length No.off
Steam drum Mild steel 4‟ 8” 3” 36‟0” 1
31-35tons
/sq.in.U.T.S
Front and centre Mild steel 2‟ 2 ¼” 1 ⅝” 31‟6” 1 of each

water drums
31-35tons
/sq.in.U.T.S
Rear water drum Mild steel 31- 2‟ 10” 2” 32‟7” 1

35tons /sq.in.U.T.S
Superheater drum Carbon 2‟ 1 ¼” 1 ⅝” 36‟10”(top) 2

molybodenum steel
35‟2”(bottom)
Boiler tubes front Solid drum steel 2” 0.160” 18‟9”(front) 299

& centre 19‟9”(centre) 298
Boiler tubes rear Solid drum mild 2” 0.160” 21‟6” 724

steel
Superheater Mild steel 1 ⅛” 0.128” 25‟0” 668

tubes(1-5 passes)
Superheater Carbon 1 ⅛” 0.128” 25‟0” 404

tubes(6-8 passes) molybodenum steel
Bailey wall header Mild steel 1‟0” 1” 13‟2” 2

top
Bailey wall header Mild steel 1‟0” (square) 1” 19‟6” 2

bottom
Bailey wall tubes Mild steel 2 ¼” 0.212” 17‟0” 20 each side

Appendix 3: Full attachment training program
DEPARTMENT ACTIVITIES TIME SUPERVISOR
COAL PLANT  Receipting of coal received 2 weeks Chemist /Coal

 Conveyor systems-
operation and protection plant supervisor
systems
 Prevention of fires 26/01/15
 Ash and coal handling
To
06/01/15
WATER  Importance of plant 3 weeks Shift charge

 Operation and knowledge
TREATMENT of effluent plant
 Regeneration
 Water supply systems – 09/02/15
raw, soft ,Demine and
cooling To
Taking of water meter
readings 27/02/15

TURBINE  Structure of turbine, 7 weeks Shift charge/STO

generator, condenser,
HOUSE location of bearings and
their importance
 Principle of operation of all 02/03/15
major equipment
 Feed water circuit To
 Cooling water system
 Knowledge and application 17/04/15
of rankine cycle
 Excitation system
 Compressors
 Operating parameters
 Start up and shut down
procedures
 Understand the various
types of turbines, other
cooling systems for
generators
 Lubrication oil circuit
 All oil pumps
 Boiler structure, drum 6 weeks Shift charge/
internals and connections
BOILER HOUSE  Boiler auxiliaries-fans etc. SBO
 Air and gas circuits
 Operation- heat transfers,
combustion theory
 Start up and shut down 20/04/15
procedures
 Emergency responses To
 Operating parameters
 Understand the other types 29/05/15
of boilers and how they
operate
 Protection systems- safety
valves, alarms

CONTROL  Structure of transformers 3 weeks Control room

 Switch gears
ROOM  Isolators technician
 Protection systems for
generators and transformers 01/06/15
 Synchronization
 Protective relays To
 Safety documents
 Recording of generation 19/06/15
statistics
PLANNING  Types of maintenance 4weeks Maintenance

 Raising of job cards
 Gantt charts for projects Engineer/
 Raising defects Planning officer
 Use of SAP 22/06/15
 Project evaluation
To
17/07/15
PERFORMANCE 5 weeks Mechanical

 Calculations of: Engineer
 Boiler efficiency
 Plant availability
20/07/15
 Load factor
 Trending boiler and To
turbine parameters
 Generation statistics 21/08/15
 Plant optimization
 Technical report writing
 Condition monitoring

MMD  Maintenance procedures 12 weeks MMD Foreman

 Be involved in the
maintenance of the
following
 Valves 24/08/15
 Leaks
 Pumps To
 Grates
 Conveyor belts 13/11/15
 Gauge glasses
 Lubrication
 Fans
 Sootblowers- gearboxes
etc.
 Welding and fabrication
EMD  Be involved in the 6 weeks EMD Foreman
maintenance of the
following
 Switch gear- OCB,
 Transformers 16/11/15
 Brush gear
 Measuring instruments- To
flow meter, pressure gauge
etc. 31/12/15
 Motors
INDUSTRIAL SUPERVISOR SIGNATURE ………………………………………
TRAINING OFFICER SIGNATURE ………………………………………
TRAINEE SIGNATURE ……………………………………....

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NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

FACULTY OF INDUSTRIAL TECHNOLOGY

DEPARTMENT OF INDUSTRIAL AND MANUFACTURING

INDUSTRIAL TRAINING ATTACHMENT REPORT

STUDENT NAME: PREVALENCE MAPHOSA

STUDENT NUMBER: P0111490E

ORGANISATION: ZPC BULAWAYO

INDUSTRIAL SUPERVISOR: MR T. CHUMA

ACADEMIC SUPERVISOR: ENG. T. CHIKOWORE

ACADEMIC YEAR: 2014-15

P. MAPHOSA IME 2014/15 i

I would also like to utter my greatest acknowledgements to my academic and industrial

P. MAPHOSA IME 2014/15 ii

P. MAPHOSA IME 2014/15 iii

ABSTRACT ................................................................................................................................... iii

CHAPTER 1. INTRODUCTORY CHAPTER ........................................................................ 1

1.0 Introduction ........................................................................................................................... 1

1.1 Company background ........................................................................................................... 1

1.2 Company location ................................................................................................................. 2

1.3 Company mission and vision ................................................................................................ 2

1.3.1 Vision ............................................................................................................................. 2

1.3.2 Mission Statement .......................................................................................................... 2

1.3.3 Core Values .................................................................................................................... 3

1.4 Bulawayo Power Station Structure ....................................................................................... 4

1.5 Products and markets ............................................................................................................ 6

1.6 Company‟s core business ...................................................................................................... 6

1.7 Training Program .................................................................................................................. 6

1.8 Summary ............................................................................................................................... 8

CHAPTER 2. COAL AND ASH PLANT ................................................................................ 9

2.0 Introduction ........................................................................................................................... 9

2.1 Department structure and objectives ..................................................................................... 9

2.1.1 Coal and ash plant objectives ....................................................................................... 10

2.2 Coal analysis ....................................................................................................................... 10

P. MAPHOSA IME 2014/15 iv

2.2.2 Coal grading ................................................................................................................. 11

2.3 Coal handling ...................................................................................................................... 11

2.3.1 Wagon tippler ............................................................................................................... 11

2.3.2 Overhead crane ............................................................................................................. 11

2.3.3 Fire prevention ............................................................................................................. 12

2.4 Conveyor systems ............................................................................................................... 12

2.4.1 Conveyor belts.............................................................................................................. 12

2.4.2 Redlers .......................................................................................................................... 14

2.5 Ash handling and disposal................................................................................................... 17

2.5.1 Soaking and conveying of ash ...................................................................................... 17

2.5.2 Beneficial uses of coal ash ........................................................................................... 18

2.6 Coal data capture and records ............................................................................................. 19

2.6.1 Coal supply records ...................................................................................................... 19

2.6.2 Periodic coal records summary .................................................................................... 20

2.7 Summary ............................................................................................................................. 22

CHAPTER 3. WATER TREATMENT PLANT ................................................................. 23

3.0 Introduction ......................................................................................................................... 23

3.1 Structure 0f the department and its importance .................................................................. 23

3.1.1 Overview of power generation water properties .......................................................... 23

3.1.2 Uses of soft and demineralised water ........................................................................... 25

3.2 Ion exchange resins ............................................................................................................. 25

3.2.1 Anion exchange resins ................................................................................................. 25

P. MAPHOSA IME 2014/15 v

3.3 Water softeners .................................................................................................................... 27

3.3.1 Regeneration of softeners ............................................................................................. 28

3.4 Demineralisation of water ................................................................................................... 29

3.4.1 Regeneration of demineraliser ..................................................................................... 30

3.5 Common problems in ion exchange systems at BPS .......................................................... 30