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CERTIFICATE
Thi s is t o certi fy that the project entitl ed
i s a bonafi de record of work carri ed out by Mr. Kuldeep of B. Tech. six th semest er NGF Coll ege of Engineeri ng and Technol ogy, Pal wal , under my guidance in partial f ulfil ment of t he requi rements f or the t rai ni ng programme at Vedanta Al uminium Ltd. (CPP)
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ACKNOWLEDGEMENT
I take immense pleasure in thanking Mr. GattuRambhav (VP Power) CPP( 9x135MW ), Mr. Koustav R. Kundu (AVP HR) and Mr. Sunil Srivastava ( Head L & D) and for having permitted me to carry out this project work. I would also like to extend my special thanks to Mr. G.S. Rao (GM CPP), and Mr. ManasTyagi (Head - Operations), who had been a source of inspiration and for their timely guidance in the conduct of our project work. I wish to express my deep sense of gratitude to my coordinator, Mr. SumeetVerma (AM Operations) for his able guidance and useful suggestions, which helped me in completing the project work, in time. Words are inadequate in offering my thanks to the complete staff at CPP for their encouragement, cooperation and contribution in carrying out the project work.
Kuldeep
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PLANT OVERVIEW
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Contents :
1. Introduction to CPP 2. Boiler introduction 3. Water and steam circuit 4. Turbine introduction 5. Air and flue gas system 6. Pulverized coal system 7. SH and RH system 8. Boiler drains 9. Deareator feed water system 10. Main and reheat system 11. HP LP by - pass system 12. Condensate water system 13. Circulation water system 14. Turbine lube oil system 15. Gland sealing system 16. Generator water cooling system 17. Protection philosophy 18. Boiler protections 19. Turbine protections 20. Electrical protections
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INTRODUCTION :
The CPP(Captive Power Plant) of Vedanta Aluminium Limited,Jharsuguda has a total installed capacity of 1215 MW. (9x135MW) consisting five units in phase#1 and four units in phase#2, with a central control room for each phase. CPP is meant to supply power to the smelter plant#1 which concludes two potlines,The power requirement for each pot line is 425MWand 125 mw is required to run the auxiliaries of both the pot lines. The 8%i.e. 97.2 MW of the total installed capacity (1215 MW) is consumed in the operation of the auxiliaries of the nine units. The balance and available power is exported to the grid, i.e. 142.8 MW, which is connected to the Budhipadar substation of OPTCL. CPP gets the coal supply from MCL through rack and truck supply mode. The daily consumption for coal is 2421 Tonnes (GCV 3300Kcal/Kg) for each unit per day, for nine units it is total 21789 tonnes of coal per day. Coal is supplied to the bunkers through conveyors after crushing up to a size of 20mm in crushers. The ash generated is taken to the ash dye through the HCSD system. And the hot flue gases are discharged to atmosphere through a common stack for five units in phase#1 and for four units in phase#2 of height 275 meters, After collection in ESP (Electrostatic Precipitators)
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Raw water is supplied from Hirakud Dam which is supported by a pumping station at Pitapally village, and is stored in a reservoir at CPP. Condenser water is cooled by cooling towers been supplied by Paharpur Cooling Towers Ltd. which consists of five CT fans per unit of induced draft type. Total water flow in condenser is 21596 m per hour per condenser at a pressure of 0.20Mpa, supported by two CW pumps, through a sump of depth 6.9 meters. For steam production the DM water is produced by DM plant having three streams having a capacity of 250 tonnes per hour. Two storage tanks of 1500m capacity. It is supplied to plant through three DM pumps maintaining a pressure of 0.35Mpa. The power flow is handled by a 220KV switchyard with double bus bar system containing nine generator transformers, four station transformers, two grid feeders, four smelter feeders and it is also connected to IPP (4x600MW) through two feeders. Switchyard have a common control room for both the phases. Plant local operation and maintenance facility is provided by the Korea Electric Power Corporation (KEPCO).
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INTRODUCTION TO BOILER :
The boilers installed in CPP are super high pressure, balance draft, once reheat, natural circulation,pulverised fuel fired boiler, with single furnace, corner tangential firing, all-steel overhung construction and with dry-ash furnace. The boilers are manufactured by SHANGHAI ELECTRIC CO. LIMITED. Boilers are super high pressure boilers with boiler drum pressure 15.66MPa. The boilers are balance draft boilers. Two primary air fans, two secondary air fans and two induced draft fans are installed to balance the system. The coal for combustion is supplied from the coal handling plants by the help of conveyor belts. The coal comes into the bunkers and to the mill coal through coal feeders. The pulverisers or the mills pulverise the coal up to 70 micron size for a proper combustion. Four mills are installed for one boiler. Three mills operate in normal conditions and fourth mill is in standby mode, and is for guaranteed performance in any odd situation. The primary air carries the coal from the mill to the boiler furnace. The boiler furnace is kept under negative pressure as it increases the time for the coal to burn completely andno combustible particle should not go out unburnt. Boiler generates 440 tonnes of steam per hour at a pressure of 14.28 Mpaat a rated condition, coming out of boiler through two pipes installed with stop valves. Boiler consists of pressure parts such as DSH (Divisional Superheater), LTSH (Low Temperature Superheater), PSH (Platen superheater), FSH (Final Superheater), Wall reheater, PRH (Platen Reheater), FRH ( FinalReheater).
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Feed water piping Economizer Steam drumDowncomers Water-cooled wall tubesteam and water mixture outlet riser pipes Steam drum Furnace roof C header second pass front, left and right walls (Making a bottom ring header) I header Butterfly header Second pass roof header (Interconnection with c header) second pass rear wall and connecting to bottom ring header of second pass Low temperaturesuperheater1stStage spraytype attemperator Divisional superheater nd Platensuperheater2 Stage spray type attemperator Last stage or final superheater Main steam pipe High-pressure cylinder Exhaust connecting pipeReheater Emergency spray type attemperator Wall reheater Platen reheater Last stage or final reheater Reheated steam piping outlet Medium pressure turbine Low pressure turbine Condenser Water formation Condensate extraction pump Gland steam condenserLP heater #7LP heater #6LP heater #5 LP heater#4Deaerator Boiler feed pumpHP heater #2HP heater#1 Feed water pipingEconomiser Drum.
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ii. iii.
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Turbine Introduction :
The steam turbine installed is a super-high pressure, reheat and double exhaust, tandem compound reaction condensing unit, whose features are combined HP cylinder and IP cylinder, inverted flow path arrangement. The LP cylinder is a radial diffusing type with double exhausts for purpose of reducing axial length of turbine and lowering resistance by the greatest extent. The turbine is supported on three points. The connection between HP-IP rotor and LP rotor is provided by rigid a coupling which is machined integrally with the turbine rotor. This construction guarantees the stability of bearings during operation. The LP rotor and generator rotor are connected by a semi-flexible coupling so that the turbine rotor can expand and contract taking thrust bearing of middle bearing pedestal as dead point. Whereas, HP-IP cylinder expands and contracts to the front taking the cross point of longitudinal key and transverse key on middle bearing pedestal as dead point. The LP outer cylinder expands backward taking its front end as dead point. The overall unit length is 13.5 m and located on the operating floor at an elevation of 9m. Both sides of the forepart are provided with the combination of HP main stop valve and HP governing valve, which are located on the supporting frame of main stop valve. Four governing valves are connected with steam inlets on the HP cylinder via four flexible HP admission pipes. The governing valve is controlled by servomotor.
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The HP nozzle block is composed of four nozzles segment. Each governing valve regulates the inlet flow for its corresponding nozzle segment. The rated output (135MW) is reached when three valves opens fully. The fourth nozzle segment is reserved for guaranteed performance in summer or low parameter. The HP-IP cylinder is a single-shell casing, with a single-row control stage and 13 pressure stages in the HP section of reaction type and one governing stage of impulse type There is an extraction after the 10th stage for supplying steam to HP heater#1. The exhaust steam from HP section enters the reheater after passing through two outlets on the lower cylinder and HP exhaust check valve, and then the steam is partially sent back to the HP heater#2 as regenerative extraction steam. The reheated steam enters the combined reheat valve which is controlled by 2 servomotors in left-right arrangement via two pipes, and then goes into IP section via two rigid admission crossover pipes. The IP section has 13 pressure stages, with a third extraction point after 7th stage leading to the deaerator and 4th extraction point after 10th stage directed to the LP heater #4. The 5th extraction point is equipped on the lower half of IP exhaust section from which steam is directed to LP heater #5. The LP cylinder is double flow and double exhaust type, and equipped with the 3rd stage and 5th stage extraction points, respectively leading to LP heater #6 which is connected with the condenser via pipes and LP heater#7 inside the condenser (built-in type).
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The LP cylinder is equipped with a low-load water spray device with atomizing nozzle appearance. The water will be automatically injected when the exhaust steam temperature is over 80 degree Celsius, assuring the normal operation of the unit. The normal barring gear speed is 7-9 rpm, however it is also possible to turn it at a speed of 60rpm. The turbines rotor is turned by electromotor after speed drop by using this barring gear.
Turbine Overview :
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i.
MAKE
SANGHAI
TURBINE CO.LTD
TYPE
Tandem Compound, Regenerative,Reheat,Cylinder having single flow HP Turbine, Single flow IP Turbine , Double flow double Cylinder LP Turbine HPT - 13+1( Governing stage ), IPT - 13, LPT - 6x2. HPT - Reaction, Barrel Type, single Flow IPT - Reaction, Barrel Type, single Flow LPT- Reaction, Barrel Type, Double Flow 135MW 145.117MW 3000 RPM 0.1 Clockwise as seen from Turbine to Generator
iv. TYPE
v. Nominal Rating vi. Peak Loading vii. Rated Spead Over Speed Set viii. value Direction of ix. rotation
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The milling system is to support the supply of pulverised coal fuel to the boiler with the help of PA fans. The total air is devided into two parts i.e. hot PA is meant for carrying and drying the coal. And cold PA is for maintaining mill outlet temperature. Passing through classifier going to boiler furnace. Circuit : Bunker Feeder Mills Boiler furnace(Along with hot PA)
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Superheater/Reheatersystem :
The saturated steam is coming out of the boiler, in order to enhance its enthalpy content, we are giving a superheat to this steam with the help of superheaters. Then entering to HP turbine and again for reheating going to the reheater. There are various stages for SH i.e. LTSH, DSH, PSH and FSH. Similarly for RH i.e. FWRH, PRH and FRH. This system ensures the desired superheat in the steam supply. Circuit : Drum LTSH DSH PSH FSH HPT HPT Exhaust FWRH PRH FRH IPT LPT
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Boiler drains :
Boiler drains includes PBD, CBD, EBD. They are used for different purposes : PBD and CBD : For maintaining the SiO level in the SH steam. CBD is continuous while the PBD is periodic blow down. EBD : This blow down is for protection purpose. If drum level goes to 100MM then it will get open and when level is coming down to 50MM, it is closed in auto mode. Circuit :
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This system is a vital for unit start up and as well for protection also. The by pass system is designed for handling 70% of the steam generated at BMCR i.e. 440 tonnes per hour. During start up, it helps in getting the parameter matching for turbine rolling. And for protection purpose, it helps to open when turbine inlet pressure reaches to 13.93Mpa. Circuit : MS line HP by-pass valve CRH RH LP by-pass valve IPT LPT Condenser
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Circuit : Injector MOP Governing system Septrum valve Injector MOP Lube oil cooler Lube oil filter turbine bearings Return to MOT Injector ACLOP or DCLOP or MOP Lube oil cooler Lube oil filter JOP Turbine bearings Return to MOT
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Circuit : GCW tank GCW pump Cooler Filter Stator and rotor cooling pipes Generator stator and rotor coils Return headers GCW tank
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Protection philosophy :
While running an equipment, it's safe and reliable operation is required to achieve the strategic goals. But there are certain situations, which are coming in the way along that our machine could get damage. In those unwanted situations, we have to safeguard our system from those damages as well to minimise the possible threats which can harm the system.
So we have already recognised some of the reasons for possible damages and a procedure is coming into picture called as protection, which is acting to safeguard our system from possible harmful effects.
So widely the protections are classified for Boiler, Turbine and Generator. Here is a brief description for each one.
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Boiler protections :
A no. of threats are recognised in boiler area under which its need to shut down the boiler to avoid from possible damages, they are :
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MFT on loss of all FD fans : It acts when both the FD fans trip together because there is no air available for combustion and also the furnace implosion may occur, so MFT necessary. MFT on loss of all ID fans : It acts when both the ID fans trip together because there is no power available for taking out the combustion products and still there is fire in boiler, so furnace explosion may happen. So MFT necessary. MFT on APH trip : It acts when both the APH trips together because already combustion process going on and the hot flue gases coming out of boiler and if APH stops rotating, then the baskets in APH will melt due to high temperature. So MFT necessary. MFT on furnace pressure overlimited : We are keeping furnace pressure at negative side but if It goes too high or too low, then furnace explosion or implosion can come in to picture. So MFT mandatory. Its tripping values are 1700Pa. If it acts in negative side that too LL, then ID fan will also trip. And if it acts in positive side that too HH, then FD fan will also trip. MFT on steam drum level over limited : This protection acts when the drum level goes too high or too low, why because if it goes high then moisture carryover can take place and if too low then starvation can occur in boiler water tubes. So MFT is necessary, its tripping values are +400MM and -350MM. MFT on loss of all fuel : It acts when there is no fuel supply to boiler i.e. no oil along with no coal. Because if no supply of fuel then there is no steam production.
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MFT on loss of fire : This protection acts when there is no fire in boiler. There are four sensors, each corner, if three out of four sense no flame then its a loss fire trip for that corner. And if it happens for all corners then its a MFT to boiler. MFT on loss of flame scanner cooling air : It acts when the cooling air supply to the scanner is disrupted why because it that air is absent then the flame scanner will get damage and there will be no one to sense the flame in the boiler. It have a delay of five minutes, if still no air then its MFT. MFT on air flow less than 25% : It acts when then total air flow in the boiler is less than 25% of rated air flow i.e. 600 tonnes per hour, because in that case the flame stability is poor and also the combustion process is affected. MFT on igning defeat more than 5 times: It happens during start up of the boiler, if the igning is not successful even after trying for five times, then its MFT. Because it means the fuel system is not ready for use. MFT on BFP trip : We have two pumps for feed water supply to boiler, one running and one standby. If one trips somehow then another take start but no boiler feed pump running, then there is no water supply to the boiler and is a scarcity in boiler and it leads to starvation and also tube failures. So MFT necessary. MFT on Turbine trip : If turbine trips somehow then the load of the boiler i.e. super high pressure steam, where it will get adjust. In certain situations we can handle that amount of steam but ideally its MFT to boiler.
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MFT on no fire in 60 minutes without MFT : This protection is also for start up time, if purging of the boiler done and there is no flame in boiler within 60 minutes from the purg finish time, leads to MFT because it senses that the purging of the boiler expired and its not reliable to give fire in the boiler. MFT on PA fan trip : It acts when both the PA fans trip together because there is no air flow to carry the pulverised coal to the boiler and no further combustion process possible, leads to MFT. MFT on Reheater loss protection : This is a very important protection for RH, why because if it doesnt acts then there may be RH meltdown. It acts when three conditions occurs : 1. Boiler load more than 30%. 2. HP LP by pass not open. 3. Turbine trip. These three conditions ensures that there is no steam in RH but still a heat available to get transfer to RH, resulting in RH tubes overheating and melting. So MFT is a must. MFT on oil fuel trip : This protection acts when there is no oil supply to boiler and coal elevation senses no fire in the boiler. Its a same case of no fuel and no steam production, leads to MFT. MFT on PB trip : This is the last situation to save the boiler from damage, if the operator is not able to handle anyhow and its going to be a damage then the push button on the DCS desk leads to a MFT trip.
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Electrical protections :
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induces current in rotor body, wedges and retaining rings at twice of the line frequency. Heating occurs in these areas resulting temperature depending upon the level and direction of unbalanced currents. Under these conditions, it is possible to reach temperatures at which rotor material no longer contain centrifugal forces imposed on these resulting in serious damage to TG-set.
the statorat
apotentialclose to ground. If a faulty phase winding connected to ground, the normal low voltage can rise to as far as line neutral voltage. Usual method for detection of fault is by measuring the voltage across the secondary winding temperature.
Generally it is electrically
isolated from ground. So one ground fault creates no problem but presence of two or more ground faults will cause magnetic and thermal imbalance and localised heating &damage to rotor metallic parts.
power protection. Motoring of TG when Turbine o/p is reduced less than no load losses of Generator while it is still on line. No damage to generator due to its motoring action but turbine blades may get overheated.
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CONCLUSION I completed my summer training at Vedanta Aluminium Limited,Jharsugura,Odisha. I got the full industrial exposure at the VALJ. I learnt about the safe and optimal operation of the boiler, turbine and other vital equipments. I learnt about boiler and turbine protections and interlocks. I worked as a Graduate Engineer Trainee in the captive power plant
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