SUMMER INTERNSHIP (2022)

AN INTERNSHIP REPORT

Submitted by

Vansia Bhargavkumar Pravinsinh

Enrolment Number:- 190990119012

In Partial Fulfilment for The Award of Degree Of

BACHLOR OF ENGINEERING

In

Department of Mechanical Engineering

Shroff S. R. Rotary Institute of Chemical Technology, Vataria

Gujarat Technological University, Ahmedabad

July, 2022

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 Shroff S R Rotary Institute of Chemical Technology

Block Number 402, Ankleshwar-Valia Road, Ta: Valia, Dist: Bharuch

CERTIFICATE
This is to certify that the Internship report submitted along with the Summer
Internship has been carried out by Vansia Bhargavkumar Pravinsinh under
my guidance in partial fulfillment for the Degree of Bachelor of Engineering
in Mechanical Engineering, 7thSemester of Gujarat Technological University,
and Ahmedabad during the academic year 2021-2022.

Sign: ______________ Sign: ____________

Dr. Hiren Mahida Dr. Hemant Gupta

Internal Guide Head of the Department

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 Shroff S R Rotary Institute of Chemical Technology

Block Number 402, Ankleshwar-Valia Road, Ta: Valia, Dist: Bharuch

DECLARATION

I hereby declare that the Internship report submitted along with the Internship
entitle Summer Internship 2022 submitted in partial fulfilment for the degree
of Bachelor of Engineering in Mechanical Engineering to Gujarat
Technological University, Ahmedabad, is a bonafide record of original project
work carried out by me at under the supervision of and that no part of this
report has been directly copied from any students’ reports or taken from any
other source, without providing due reference.

Name of Student Sign of Student

Vansia Bhargav ______________

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 Shroff S R Rotary Institute of Chemical Technology

Block Number 402, Ankleshwar-Valia Road, Ta: Valia, Dist: Bharuch

ACKNOWLEDGMENT

First, I would like to thank Mr. Manish Kishore, Vice President of Human Resource
Management at Birla Cellulosic Kharach, for giving me the opportunity to do an internship
within the organization.

I would also like to extend my thanks to Mr. Hitendra Singh Parmar, General Manager
and Head of Energy Centre at Birla Cellulosic, Kharach, and Mr. Bhagwan Patil,
Manager and Section Head at Power Plant (Operation) at Birla Cellulosic, Kharach for
their guidance and motivations during the entire tenure of the internship.

I would like to thank Dr. Hiren Mahida department internship coordinator of Mechanical
engineering Department for their support and advices to get and complete internship in
above said organization.

I would like to thank my Head of the Department, Dr. Hemant Kumar Gupta for his
constructive life lessons and support throughout my internship.

I am extremely grateful to my department staff members and friends who helped me in

successful completion of this internship.

~ Vansia Bhargav

(190990119012) 6
 Shroff S R Rotary Institute of Chemical Technology

Block Number 402, Ankleshwar-Valia Road, Ta: Valia, Dist: Bharuch

ABSTRACT

A thermal power station is a power plant in which the prime mover is steam driven. Firstly,
the water is heated in a boiler using a fuel and it turns into steam which is made to pass
through a steam turbine at a high pressure. This steam spins the steam turbine which drives
an electrical generator. Normally, after it passes through the turbine, the steam is condensed
in a condenser and recycled to where it was heated. This is known as a Rankine cycle. The
greatest variation in the design of thermal power stations is due to the different fuel sources.
Some prefer to use the term energy centre because such facilities convert forms of heat
energy into electricity. Some thermal power plants also deliver heat energy for industrial
purposes, for district heating, or for desalination of water as well as delivering electrical
power. A large part of human CO2 emissions comes from fossil fuelled thermal power
plants. But efforts to reduce these outputs are various and widespread. Major production of
electricity is achieved through coal a thermal power plant which is around 75% of the total
power generation. India's total power generation in Dec 2020 stood at 103.66 billion units,
according to data realised by the Central Electricity Authority. A coal based thermal power
plant converts the chemical energy of the coal into electrical energy. This is achieved by
raising the steam in the boilers, expanding it through the turbine and coupling the turbines
to the generators which converts mechanical energy into electrical energy.

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 List of Figures

Figure 2.1 The General Layout of Powerplant ............................................ 17

Figure 3.1 PLC control panel of CHP ......................................................... 18

Figure 3.2 Sieve ......................................................................................... 18

Figure 4.1 Boiler-1 overview ...................................................................... 23

Figure 4.2 Boiler-3 overview ...................................................................... 23

Figure 4.3 Air flow line diagram ................................................................. 24

Figure 4.4 Water flow line diagram............................................................. 25

Figure 5.1 Turbine ...................................................................................... 30

Figure 6.1 Cooling Tower ........................................................................... 34

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 List Of Tables

Table 2.1 Specification of Boiler and Turbine .............................. 15

Table 3.1 Yard Specification ........................................................ 19

Table 3.2 Shed Specification ........................................................ 19

Table 3.3 Specification of Indian & imported coal ....................... 20

Table 6.1 Chemical composition of Indian fly ash ........................ 33

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 Table of Contents

CERTIFICATE........................................................................................... 2

DECLARATION ........................................................................................ 5

ACKNOWLEDGMENT............................................................................. 6

ABSTRACT ................................................................................................ 7

Chapter 1 : Safety Induction .................................................................... 12

Chapter 2 Introduction ............................................................................. 13

2.1 About the Aditya Birla Group ............................................................ 13

2.2 Vision and Mission of Birla Cellulosic ............................................... 13

2.3 Unit’s Awards & Accolades ............................................................... 14

2.4 Certifications ..................................................................................... 14

2.5 Departments in Birla Cellulose .......................................................... 14

2.6 Department overview ......................................................................... 16

2.7 General Layout of Thermal Powerplant ............................................. 17

Chapter 3 Coal Handling Plant ................................................................ 18

3.1 YARDS & SHEDS: ............................................................................. 19

Chapter 4 Boiler ........................................................................................ 22

4.1 BOILER USED IN BIRLA CELLULOSIC POWER PLANT ............... 22

4.2 Boiler Construction ............................................................................ 26

4.3 Boiler Mounting ................................................................................. 27

4.4 Boiler Accessories .............................................................................. 27

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Chapter 5 Turbine .................................................................................... 30

5.1 Turbine Specification ......................................................................... 31

5.2 Generator........................................................................................... 32

5.3 Surface Condenser ............................................................................. 32

Chapter 6 Ash Handling Plant ................................................................. 33

6.1 ID Fans .............................................................................................. 33

6.2 Chimneys ........................................................................................... 34

6.3 Cooling Tower ................................................................................... 34

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 Chapter 1 : Safety Induction

There are various norms to be followed by each and every organisation and each
organisation have their own way to implement it. The rules and guidelines that need to be
followed for working may vary from one organisation to another, the true motive behind
all the safety rules and guidelines across the globe still remains the same; i.e., to ensure that
the work is done with zero risks and zero harm to each and every employee, labours and all
the humans that are required to be associated to the process directly or indirectly.

So, to ensure the safety of every person inside the company premises, Birla Cellulosic takes
all the measures prior to allowing anyone inside the campus by teaching all the safety
guidelines to every intern, visitor, worker, employee with the help of the video lessons they
have prepared for the same purpose. This is carried out in the Employee Relation
Department (ERD) which is located in the immediate right to the entrance gate. Every
person that wants to admit inside the company requires the have understood all the safety
guidelines. After the video tutorials are over, there is a 12-mark Multiple Choice Questions
bases test taken to assess the grasping of the visitor/intern/new employee/worker/labour.

Once the following person passes the test, they are required to go to fire and safety
department where they are given the required PPEs as per the job they need to do. Each job
requires different safety precautions to be taken care of. Hence, the PPEs also differ
accordingly. PPE stands for Personal Protection Equipment. The employer requires to have
assessed and understood the job before filing the work permit since according to the work
permit only the PPEs are issued. The standard PPE that even a visitor is supposed to equip
before entering the company premises is as followed: -

1. Safety Helmet
2. Reflective Jacket
3. Face Mask (For protection from COVID-19)
4. Safety Shoes

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 Chapter 2 Introduction

A Thermal Power Station is a power station in which heat energy is converted

to electricity. Typically, fuel is used to boil water in a large pressure vessel to produce high-
pressure steam, which drives a steam turbine connected to an electrical generator. The low-
pressure exhaust from the turbine passes through a steam condenser and is recycled to
where it was heated. This is known as a Rankine cycle. Natural gas can also be burnt
directly in a gas turbine similarly connected to a generator.

2.1 About the Aditya Birla Group:

ADITYA BIRLA GROUP (ABG) is a model group in India built on the philosophy laid by
its founder chairman Late Shri Aditya Vikram Birla. It was his vision and belief that led to
the growth of the group through turbulent times by revolutionary strategic initiatives and
main emphasis on teamwork and people building management. ADITYA BIRLA GROUP
is operating in INDIA since 1947 and is India’s second largest business house. Committed
to being a global benchmark group the Aditya Birla Group reaches out to the core sectors
in India. Aditya Birla Group has distinction of being World’s:

 Largest producer of viscose staple fibre.

 Largest producer of carbon black.
 Largest single location refiner of palm oil.
 Fourth largest producer of insulators.
 The fifth largest producer of acrylic fibre.
 The seventh largest cement producer globally.

2.2 Vision and Mission of Birla Cellulosic:-

We aim to create Superior and Sustainable Value for all our stakeholders through-
Innovation in Product and Process, Excellence in Quality, Service and People
Development. Cost effective Operations and Environment Friendliness & Safety
Consciousness in all activities.

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2.3 Unit’s Awards & Accolades:-

 Obtained world class manufacturing (WCM) silver award by chairman.

 Rajiv Gandhi National Quality Award.
 M.S University Baroda Awarded with corporate citizen of the year.
 Obtained the golden WCM award.
 Ramakrishna Balaji National Quality Award.
 CII Exim bank highest level certification for business excellence.
 Deming Award.

2.4 Certifications:

 ISO 9001
 ISO 14001

2.5 DEPARTMENTS IN BIRLA CELLULOSE:-

 ENERGY CENTRE
 VISCOSE
 LABORATORY
 SPINNING
 Excel
 AUXILARY
 CS2/ACID
 WTP/ETP
 WORKSHOP
 FIRE & SAFETY
 HR & ER
 ADMIN
 ELECTRICAL
 ISTRUMENTATION
 STORES
 PURCHASE
 SALES

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  About Energy Centre, Birla Cellulosic:-

 Birla Cellulosic has Coal Based Thermal Powerplant of Installed Capacity 2×15
MW And 1×10 MW. There are Two Extraction cum back pressure turbine
(15+15) MW And One Extraction cum condensing turbine (10MW) And Two
Boilers of 100 TPH each and One Boiler of 120 TPH.

Table 2.1 Specification of Boiler and Turbine

Sr. no. Instrument Type Capacity Manufacturer

1. Boiler - 1 AFBC 100 TPH BHEL
2. Boiler - 2 AFBC 110* TPH BHEL
3. Boiler - 3 AFBC 120 TPH ENMAS
4. Turbine - 1 Extraction cum 15 MW Shin Nippon,
Backpressure Japan
5. Turbine - 2 Extraction cum 15 MW Shin Nippon,
Backpressure Japan
6. Turbine - 3 Double Extraction 11.8 MW Shin Nippon,
cum Condensation Japan
7. Generator - 1 Synchronous 18750 kVA Toyo Denki
Seizo K.K.
Japan
8. Generator - 2 Synchronous 18750 kVA Toyo Denki
Seizo K.K.
Japan
9. Generator - 3 Synchronous 18750 kVA Toyo Denki
Seizo K.K.
Japan

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2.6 Department overview :-

The Energy centre of Birla Cellulosic has 4 departments which work simultaneously in
corresponding to their respective section Heads in order to run the Powerplant. These
Departments are as followed:-

1. Coal Handling Plant (CHP)

2. Boiler and Turbine
3. Ash Handling Plant (AHP)
4. Mechanical Maintenance Department

 AVAILABILITY OF COAL:-

Coal for the power station is supplied from nearby western coal fields; imported coal from
Indonesia and South Africa, which contain vast reserve of power grade coal for this unit,
coal transportation from western coal fields is affected by trucks. The daily coal
requirement is nearly 800 tons.

 AVAILABILITY OF WATER:-

The circulating and consumptive water requirement for this unit is met from ‘KIM’ river.
The reserve quantity of water is adequate to meet the balance water requirement. Besides,
it also recycles the ash water, thereby reducing the water requirement.

 COST OF CO-GENERATION:-

Cost of H.P steam generation : Rs. 1078/ ton

Cost of L.P steam generation : Rs. 1012/ ton

Cost of Power generation : Rs. 3.52/ ton

 SPECIFICATION OF POWER PLANT:-

Installed Capacity: 2 x 15 MW + 1 x 10 MW (=40 MW)

Type : Coal based thermal power plant

Turbine : Steam turbine (Extraction cum back pressure)

Boiler Type : Atmospheric Fluidized Bed Combustion (AFBC)

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2.7 GENERAL LAYOUT OF THERMAL POWER PLANT:-

The general layout of the thermal power plant using steam as working fluid works on the
Rankin Cycle. Steam is generated in boiler, expanded in the prime mover and condensed
in condenser and fed in to the boiler again.

COAL HANDLING PLANT

ASH HANDLING PLANT

ELECTROSTATIC ELECTROSTATIC ELECTROSTATIC

PRECIPITATOR PRECIPITATOR PRECIPITATOR

UNIT #1 UNIT #2 UNIT #3

BOILER #1 BOILER #2 BOILER #3

MAIN BUILDING
#Ground floor (0 m) : TMQ room, Maintenance Section, Air Compressor
Unit, Boiler Feed Pump, Air Drying Unit.
#1st floor (4.5 m) : Electrical, Distribution Lines.

#2nd floor (9 m) : Control Room, Conference Room, Turbine- Generator Set.

ENTRY

Figure 2.1 The General Layout of Powerplant

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Chapter 3 Coal Handling Plant

Figure 3.1 PLC control panel of CHP

Figure 3.2 Sieve

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3.1 YARDS & SHEDS:

The Birla Cellulosic houses 7 yards and 4 sheds to store the supplied coal.

Density of the coal supplied is .85Kg/cm2

 YARD SPECIFICATION:

Table 3.1 Yard Specification

YARD NO. LENGTH HEIGHT WIDTH (m) CAPACITY

(m) (m) (tons)
1 35 2.5 18 1148
2 19 2.5 16 646
3 37 2.5 25 2250
4 A&B 40 2.5 30 1393
5 A&B 28.5 2.5 18.5 2359
6 A,B&C 90 2.5 13.5 2582
7 A&B 47 2.5 19.5 1865

 SHED SPECIFICATION :

Table 3.2 Shed Specification

SHED NO. LENGTH HEIGHT (m) WIDTH (m) CAPACITY

(m) (tons)
1,2,3&4 60 2.5 20 2550

BIRLA CELLULOSE gets the coal from 4 main suppliers :

 SECL(South East Coal Limited) & WCL(West Coal Limited) are the INDIAN
coal.
 SURIYA & ADANI are the imported coal.
POWER PLANT utilizes a mixture of INDIAN (70%) & IMPORTED (30%) coal for the
improved efficiency.

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 Specification of INDIAN & IMPORTED coal :

Table 3.3 Specification of Indian & imported coal

CHARACTERISTICS INDIAN COAL IMPORTED COAL

Inherent Moisture 8% 13 %
Volatile material 25-32 % 33.63%
Ash ARB <30% 6.2%
Fixed carbon ARB 30-40% 47.17%
GCV ARB 4833 Kcal/Kg 5167 Kcal/Kg
GCV ARB 8733 Kcal/Kg 9300 Kcal/Kg

 Start up Procedure:-

1) Ensure manpower and equipment availability.

2) Ensure manpower availability,1 no at BC 6,1 no at coal bunker
3) Start PLC control supply from PLC
4) Select auto or remote switch from PLC and proper required cycle
5) Check ready to start indication on PLC
6) Start belt conveyor 7A or 7B from local manually
7) Blow hooter and press auto start from PLC
8) Sequential starting of different systems of CHP in following order from Control
panel.
9) Start coal feeding after checking all equipments drawing current normal.
10) Ensure coal size below 8 mm at belt conveyor BC 6 and take continuous
observation.

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 PROCEDURE :-

Initially coal is fed to the ground hopper through trucks coal falls on the vibrating feeder
through the Rack & Pinion gate on to the belt conveyer which carries the coal to the surge
hopper, the surge hopper consists of a similar RPG & VF arrangement as seen in GH. The
coal then falls into the primary crusher where in the coal size will be reduced to 25mm the
coal then falls on the BC-3 which carries the coal to SH-2.

Coal from the primary crushing house enters the secondary crushing house where the
further reduction in size of the coal takes place. As the coal passes through the secondary
crusher ,size of the coal reduces to 6mm.the powdered coal is then send to bunker through
BC-6 which stores and supplies the coal to the furnace.

Coal whose size is greater than 6mm is separated & is sent back to primary crusher through
BC-5 for further crushing of the coal.

 DO's :-
 Check oil level of screen before Starting of plant
 Take bunker level before starting plant
 Coal stock should be party wise
 Ensure manpower positioning on BC 6 and bunker before starting plant
 Water flow continue during hot work

 DON'Ts :-
 Don’t start feeding before ensuring all equipments are running normally
 Don't stop plant before ensuring bunker position
 Don't maintain coal stock height more than 6 to 7 feet
 Don't feed high moisture coal
 Don't stop plant before complete removal of coal dust from equipments and
conveyors.

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 Chapter 4 Boiler
A boiler is a device used for generating :-

 Steam for power generation, process use or heating purpose, and

 Hot water for heating purpose.

4.1 BOILER USED IN BIRLA CELLULOSIC POWER PLANT:-

The boiler used in Birla Cellulosic power plant is Atmospheric Fluidized Bed
Combustion (AFBC) boiler. It contains standard operating principle of AFBC
boiler and technique for maintaining basic objective of smooth operation for supply
of uninterruptedsteam. Three boilers are used in power plant two having a capacity
of 100 TPH and one has a capacity of 120 TPH. Boiler is used coal.
 Boiler Input:-

 Dematerialized Water
 Air
 Coal
 Bed Material

 Specification of Boiler:-

Make : BHEL (Bharat Heavy Electricals

Limited)Type : AFBC Box type, Single drum

Flow : 100 TPH

Pressure at O/L : 65 Kg/Sq. cm

Main Steam Temperature : 485 Deg C

Water Temperature : 196 Deg C DESIGN

Efficiency : 82.6 %

Furnace Width : 9906 mm

Furnace Depth : 5461 mm

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Figure 4.1 Boiler-1 overview

Figure 4.2 Boiler-3 overview

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Figure 4.3 Air flow line diagram

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Figure 4.4 Water flow line diagram

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 Boiler Start Up:-

The lighting up of the boiler is to be done with the help of oil fired start up system.
After lighting up the oil fired start up system the bed end is gradually heated by
introducing the hot air and once the bed temperature reaches the ignition temperature
of the fuel to be fired, fuel can be introduced. Subsequently other compartments can
be activated one afteranother.

4.2 Boiler Construction:-

The complete furnace section is fusion welded finned wall type, arrange in a gas and
pressure tight envelop. This eliminates the refractory materials from the entire wall
section, besides providing structural rigidity for the unit. Above the expanded bed, are
studded withpins made of carbon steel.

The steel drum has been conservatively sized and internals resulting in high steam
quality. Part of the evaporating heating system will be located in the fluidized bed proper.
The superheated steam system is in two sections and the super heaters are located at
furnace outlet in a semi radiant, convective area, to ensure rated superheat temperature
an inter storage De- super heater is provided in between the two stages of super heaters,
to controlthe final steam temperature from the unit.

The location, selection and arrangement of the super heater section are so chosen, that
the rated steam temperature at the super heater outlet is achieved between 50 to 100%
MCR. The boiler is also provided with a tubular air heater as the last stage for heat
recovery.

 Working of AFBC Boiler:-

AFBC boiler has four compartments for bed firing. Coal is fed to eight different points
in each compartment through four coal feeders using hot air from primary air fan
discharge. Fluidizing air to the bed is supplied by forced draft fan. Two nos. of FD fans
are provided in each boiler, which supply hot air heater for fluidizing the bed as well as
supply hot air totwo PA fans.
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4.3 Boiler Mounting:-
There are fitting primarily intended for the safety of the boiler and control of the
steam generation process completely.
According to the Indian Boiler Act, 1923 they are,
1. Pressure gauge
2. Safety valves
3. Water level indicator
4. Feed check valve
5. Steam stop valve
6. Man hole and Mud holes

4.4 Boiler Accessories:-

These are the devices incorporated in the boiler circuits to boost- up the efficiency
and performance of the steam generation plant and assist in the systematic and
adequate operation of the boiler unit for prolonged periods.
Usually, a boiler is fitted with the following accessories,
1. Air Preheater
2. Economiser
3. Superheater
4. Feed Pump

 Water Used for Boilers:-

When water is used for high pressure boiler, the boiler feed water should be free from
anydissolved or undissolved impurities. For high pressure boiler demineralized water
isrequired with caution i.e. Ca, Mg, & K anions i.e. Cl, SO4, CO2 & SiO2 are removed.

Dissolved gases present in water are removed by deaeration, which is done in

deaerator. The deaerator can not remove oxygen completely so after deaeration traces
of oxygen are removed by scavenging agents like hydrazine.

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Feed Water Limits:-

pH at 25 0C : 8.8- 9.2

Hardness : NIL

Total copper (max) : 0.01

ppm Total silica (max): 0.02

 Air and Flue gas circuits:-

Air is supplied to the combustion chamber of the boiler through FD or ID fans or by

using both. The dust from the air is removed before supplying to the combustion
chamber. The exhaust gases are first introduced to the air and then it is passed through
the dust collectorswhere most of the dust is removed before exhausting the gases to
the atmosphere through chimney.

 Air Circuit:-

FD fan 1 & 2 suck the air from the atmosphere which is filtered before the suction of
the FD fan, and is preliminary heated to 200 0C in the air pre heater. This air pre
heater is supplied to the boiler at four compartments at require temperature (900 0C
in the boiler chamber). Partial air is used to force the coal in to the boiler by means
of PA fans 1 & 2.

 Flue Gas Circuit:-

The gas generated by the combustion of the air and coal is termed as FLUE GAS.
Flue gases are used to produce steam in boiler by giving its heat. Flue gases first
travel throughthe secondary super heater (759 0C), primary super heater (580 0C),
economizer (384 0C), giving its heat and leave the boiler at 290 0C. After this flue gas
is forced to travel throughthe air pre heater where it is used to pre heat the atmosphere
air, further losing its temperature to 123 0C and finally exhaust in atmosphere through
chimney by ID fan 1 & 2.

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 Feed Water Circuit:-

Demineralized water from the DM tank is feed in to the Deaerator in which it is

preliminaryheated to about 140 0C. In deaerator the oxygen of the water is minimized
in order to prevent corrosion and scaling of the boiler’s component. Hydrazine is
also added for the oxygen removal in the water. This water is then feed to the high
pressure heater through the boiler feed pump, where it is further heated to the 190 0C.
This water is then feed to theboiler for further heating. This whole cycle of heating the
water is required so as to increasethe boiler efficiency and reduce the time required in
conversion of water to steam at required temperature and also for getting high
temperature of steam.

 Steam Circuit:-

The preliminary heated water in the feed water circuit is feed to the boiler where it first
enters in the Economizer where it is partly converted in the steam and then to the steam
drum where only the converted steam is allowed to go further restricting the water in the
drum. This steam then travels to the stage-1 super heater where it gains the temperature of
380 0C and then to the de- super heater which controls the temperature of the steam coming
out from the stage-1 super heater.

29
 Chapter 5 Turbine
Three Turbines are installed for power generation in BC power plant.

 Turbine #1&2 are of Extraction cum Back Pressure.

 Type and turbine #3 is of Extraction cum Condenser Type.

At a time any two turbines work simultaneously and one turbine remains at standby
condition. The contents written below provide an overview of Back Pressure turbine
and its components with flow diagram. It contains standard operating principle of Back
Pressure turbine and technique for maintaining basic conditions with objective of
smooth operation.

Figure 5.1 Turbine

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5.1 Turbine Specification:-

Make : Shin Nippon, Japan.

Type : Extraction cum Back Pressure, Horizontal,

Impulse, Multi Stage, Axial Flow, Geared.

Power Generation : 15 MW

Speed(Turbine/Generator):(6038/1500)RPM

 A steam turbine is a prime mover that derives its energy of rotation due to
conversion of the heat energy of steam into kinetic energy, as it expands
through a series of nozzles mounted on the casing or produced by fixed blades.
 If high velocity steam is allowed to blow on to a curved blade, the steam will
suffer a change in direction as it passes across the blades & leaves.
 As a result of its change in direction across the blade, the steam will impart a
force to the blade.
 If the blade were free, it would move in the direction of force. If, therefore a
number of blades were fixed on a circumference of a disc, which is free to
rotate on a shaft, then steam blown across the blades, would cause the disc to
rotate.

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5.2 Generator:-
 Generator type : Sync generator
 Generator output : 18750KVA
 Rating / RPM : Continuous /1500 rpm
 No.of poles and Phase: 04 and 03
 Make : Toyo denki seizo K.K., Japan
 Voltage & current : 6600Volts and 1804amperes.
 Field current : 450amperes
 Installed quantity : 2 (one set for each turbine)

 Turbine and Feed Water System:-

The turbine is of single casing, single extraction cum back pressure type. The
mainparameters are as follows:

Temperature : 480C

Flow : 123 TPH

Speed: 6038 RPM

Power Produced: 15 MW

The turbine is coupled with the generator to produced rated output of 15 MW

continuously. The TG set is capable of frequent start-up & shut down operation.

5.3 Surface Condenser:-

Surface condenser is use for condensing steam extracted from turbine #3. In this
water fromcooling tower is pass through tube and steam is passed through cell of
the condenser. It is

counter type of heat exchanger. Steam after condensing is collected in the hot well,
from which with the help of pump it is directly feed to the deaerator

32
 Chapter 6 Ash Handling Plant

Ash is the material produced from the combustion of coal or we can say that non
combustion part of the coal is called as ash.

Fly ash is produced by 82 % coal based thermal plants and number of captive power
stationscattered all over the country. Most power stations in India dispose ash using
the wet slurrydisposal system. Due to this system required more than 1 acre of land
for ash pond area perMV power production.

Chemical Composition of Indian Fly Ash:-

Table 6.1 Chemical composition of Indian fly ash

Sr. No. Constitutes Percentage Range (%)

1 Silica (SiO2) 49 – 67

2 Aluminium Oxide (Al2O3) 16 – 29

3 Iron Oxide (Fe2O3) 4 – 10

4 Calcium Oxide (CaO) 1–4

5 Magnesium Oxide (MgO) 0.2 – 2

6 Sulphur (SO3) 0.1 – 2

7 Loss of Ignition 0.5 – 3

6.1 ID Fans:-

I.D fans sucks the gases out of the furnace and throw them into the stack by creating
sufficient negative pressure in the furnace in the balanced draft units. It is located in
between the ESP and Chimney in the flue gas path. It handles large volume hot
dust/ash laden flue gas from furnace and all leakages occurring in the system till the
inlet of the fan. It overcomes the pressure drop inside the furnace, super heater,
economizer, gas ducting & ESP.

33
6.2 Chimneys:-

Exhaust gasses that are sucked from ESP through I.D fan is passed on to chimney.
Chimney is a long erect structure whose function is to let the flue gasses enter
atmosphere at greater heights. The height of the chimney at BIRLA CELULOSE is
76meters. The temperature of flue gasses coming out of chimney is 135 degree
Celsius. The amount of SOX &NOX in the flue gasses should be less than 100 & 50
mg/m3 respectively.

6.3 Cooling Tower:-

The condensate (water) formed in the condenser after condensation is initially at high
temperature. This hot water is passed to cooling towers. It is a tower- or building-like
device in which atmospheric air (the heat receiver) circulates in direct or indirect
contact with warmer water (the heat source) and the water is thereby cooled. A cooling
tower may serveas the heat sink in a conventional thermodynamic process, such as
refrigeration or steam power generation, and when it is convenient or desirable to
make final heat rejection to atmospheric air. Water, acting as the heat-transfer fluid,
gives up heat to atmospheric air, and thus cooled, is re-circulated through the system,
affording economical operation of theprocess.

Figure 6.1 Cooling Tower

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