ACKNOWLEDGEMENT

At this very outset I acknowledge with gratitude the guidance and support
rendered to me by training centre “BOILER & CO-GENERATION” of
HINDALCO, without which this training would not have materialised.
I would like to thank Mr. S K Das (GM Training and Development Centre)
for providing an opportunity to interact and take guidance from engineers of
“BOILER & CO-GENERATION DEPARTMENT”.
I would like to thank Mr. S K Gupta, Mr. P K Singh, Mr. Ankit Kumar
Singh, Mr. Rajesh Pandey and all engineers and staff of the department for
their encouragement during the training period.
I also want to thank the management of the company to provide me such a
material which is helpful to make such a report.

Kamal Kishor Yadav

Mechanical Engneering
UCER, Allahabad
 PREFACE

In this era of globalization and liberalization of economy, the technology is

changing at a swift rate and in this process of revolution one needs to keep
up with the world to strive for excellence and to meet the global standards.
Giving this due consideration practical training schedule have been inducted
in the curriculum of technology studies as they give a practical exposure to
the actual conditions, irrelevant of the field.

In this context I got opportunity to undergo practical training of 30

days at Hindalco Industries Limited, Renukoot Sonebhadra (U.P.)
During the training I was asked to study about “Boiler & Co-Generation”
in detail and it was a great experiences for me working on this project under
of the professionals.
 CONTENTS

 HINDALCO - AN OVERVIEW

 INTRODUCTION OF BOILER

 BOILER & CO – GENERATION

(1) Main boiler components

(2) Ash handling plant
(3) DM plant
(4) Coal handling plant (CHP)
(5) Cooling tower

 5.6 MW TURBINE

 CAPACITOR

 EMERGENCY OIL PUMP

 GENERAL SALIENT FEATURE OF PLANT

 HINDALCO - AN OVERVIEW

 Organization at a glance

I-HISTORY-

“Hindalco” was set up in collaboration with Kaiser Aluminium and

Chemicals Corporation, U.S.A., in a record time of 18 months. The plant
started its commercial production in the year 1962 with a capacity of 20,000
tons per annum.

The company has grown manifold and is managed by Board of

Directors, with Shri. Kumar Mangalam Birla as the Chairman of the Board
of Directors. Day to day affairs of the Company are managed by a team of
Professional Executives headed by Shri. A. K. Agarwala as the Director
(Whole Time).

II-HINDALCO TODAY

Aluminium has turned out to be the wonder metal of the industrialized

world.

Aluminium’s growth rate is the highest amongst the major basic

metal today. Hindalco ranks as the largest Aluminium producer in India
and contributes about 40% share in total production of the country. The
Company's fully integrated aluminum operations consist of the mining of
bauxite, conversion of bauxite into alumina, production of primary
Aluminium from alumina by electrolysis and production of properzi redraw
rods, rolled products, extrusions and values added products like foil and
wheel at Silvassa. Hindalco's integrated operations and operational
efficiency have enabled the company to be one of the world’s lowest cast
producers of Aluminium. The company's cost efficiency has helped it to
record and outstanding performance in the face of adverse market
conditions.

Hindalco also owns a large Captive Thermal Power Plant at

Renusagar that meets the power requirement of the company very
effectively. Hindalco currently has primary aluminum capacity of
242,000MTPA the capacity is being increased further by 100,000 MTPA,
and is expected to be achieved by 2010-11

The production performance of the company during the year 2000-01 is

given below

PARTICULARS PRODUCTION
Power Generation (Renusagar) 769MW
Alumna 660000MTPA
Aluminium metal 342000MTPA
Rolled Products 80000MTPA
Extrusions 16250MTPA
Wire Rods 52203MTPA
Foils 17207MPTA
Co-generation 78MW

III-LOCATION-

 Lying in the foothills of the Vindhya Range, Renukoot is about 160 kms
from Varanasi and 154 kms from Mirzapur. It is well connected to both
these cities by beautiful metalled roads passing through green forests.
 There is direct daily train named Tata-Hatia –Amritsar Express also
famous as, Moori Express between Amritsar to Tatanagar and Ranchi via
Renukoot. Besides this, there is a direct train Swarnajayanti Express
 between Ranchi to New Delhi via Renukoot commuting both ways twice
a week.
 Apart from above, Renukoot is also connected with Kolkata through
direct train named Shaktipunj Express commuting between Jabalpur to
Kolkata via Renukoot.
 The nearest Airport is at Babatpur, Varanasi, which is about 180 Kms by
road from Renukoot.
 For any further information regarding reservation facilities etc., one can
contact transport department of Hindalco.

HINDALCO’S VISION

“To strengthen our position as a premium Aluminium Company,

sustaining domestic leadership and a global competitiveness through
innovation, quality and value added growth.”

HINDALCO’S MISSION

“To pursue the creation of value for our customers, shareholders,

employees and society at large.”

INTEGRATED OPERATION OF THE COMPANY

The company has its own mine of bauxite. Bauxite is mixed by open
lohardanga & Richuguts mines of bauxite are then transported by means
of ropeways to the nearest railway head. From there is transported to
Renukoot in railway wagons.

POWER-GENERATION-

Renusagar Power company is a captive power plant of company. It is

situated at the pinhead of Asia’s biggest open mines. Renusagar power
plant is the best performing power plant in India. It operates at a plant
load factor of above 92%. All the ten turbines of the company operate
to generate 765 MW electricity for plant townships.

ALUMINA PLANT-

From bauxite alumina is extracted in the alumina plant. This plant has
the capacity to produce 350000MTPA of alumina. The capacity this
plant will shortly be increased to 3,70000MTPA.

REDUCTION PLANT

This plant has two units-

(1) Potroom –In the potrooms, aluminum is extracted

By reducing the alumina.
(2) Carbon plant - The carbon anodes used for the
Extraction of aluminum is manufactured here.

FABRICATION PLANT-

In this fabrication plant the primary metal is extracted in the potroom is

remitted and recast into billetsand slabs and then again remitted to draw
roads, sheets etc.
 AN INTRODUCTION TO ADITYA BIRLA
GROUP

The Aditya Birla group is India’s second largest business house, With
turnover of over Rs.280 billion, asset base valued at over Rs.265 billion and
nearly 72,000 employees in 18 countries the world over.
Over 65Units in India and overseas as well (in Thailand, Indonesia,
Malaysia, Philippines, Egypt and Canada) and international trading
operation spanning several countries including Singapore, Dubai, Russia,
Vietnam, Myanmar and China make it India’s first truly multinational
conglomerate.

Committed to being a global benchmark Group, the Aditya Birla Group

reaches out to the core sector in India – in industries integral to the nation’s
growth- Cement, Aluminum, Fertilizers, Power, software, Viscose Staple
Fiber, Textiles, Petroleum Refining, Telecommunications, Industrial
Chemicals & Financial Services.

The Aditya Birla Group is the worlds:

 Largest producer of Viscose Staple Fiber with 20% global market

share.
 Third largest manufacturer of Insulators.
 Fifth largest producer of Carbon Black.

In India, it has a leadership position in:

 Aluminum – India’s largest integrated Aluminum producer and

among the world’s lowest cost producers.
 Viscose Filament Yarn- No.1
  White Cement- No.1
 Rayon Grade Pulp- No.1
 Grey cement- No.3
 Apparel / Garments: India’s premium branded apparel brand include
Louis Phillipe, Van Heusan, Byford, Peter England, and San Frisco.

The group also has a significant presence in the Financial Sector, Power and
Telecommunications Sectors in tie-ups with giants like Sun Life Insurance
(Canada), Powergen Pic. (U.K.) and AT & T (U.S.A.) and Tata respectively.

On the social front: a value based, caring corporate citizen, the Aditya Birla
Group inherently believes in trusteeship concept of management. Part of the
group’s profit is ploughed back into meaningful welfare driven initiatives
that make a qualitative difference to the lives of a marginalised people.
 A-GPOUP COMPANIES-AT A GLANCE IN INDIA

COMPANY KEY PRODUCTS/SERVICES

Hindalco Aluminium
Indal Aluminium
Grasim Viscose Staple Fiber, Cement,
Sponge Iron, Textiles, (Fabrics and
Apparels), Chemical, International
Business
Indian Rayon Viscose Filament Yarn, Textiles,
Insulators, Carbon Black, Ready to
wear Apparels, Software,
International Business
Indo Gulf Fertilizers, Cooper
Birla Global Finance Financial Services
HGI Industries Casting, Gases
Essel Mining Iron and Manganese ore mining,
Ferro alloys, HDPE woven sacks
Shree Digvijay Cement (Subsidiary Cement
of Grasim)
Dharani Cement (Subsidiary of Cement
Grasim)
Birla Technologies Limited Financial Services, telecom,
IDEA CELULER Insurance and e-learning
 INTRODUCTION

BOILER

Any closed vessel exceeding 22.75 liters in capacity, which is used exclusively for
generating steam under pressure and included any mounting or other fitting
attached to such vessel, which wholly or partly under pressure when is shut off.

CO-GENERATION

A co-generation facility is defined as one, which simultaneously produces two, or

more forms of useful energy such as electric power and steam, electric power and
shaft (mechanical) power etc. co-generation facilities, due to their available to
utilize the available energy in more than one form use significantly less fuel input
to produce electricity, steam shaft power or other forms of energy than would be
needed to produce them separately.
Thus by achieving higher efficiency , co-generation facilities can make a
significant contribution to energy conservation.
Qualifying requirement of topping cycle would be required that at least 20% of
the total energy output is in the form of useful thermal energy.
The some of useful power output and half the useful thermal output be greater
than 45% of the facility's energy consumption.
 PARAMETER DETAIL

1. BOILER # 1

CAPACITY = 80 TPH
PRESSURE = 52.5 Kg/sqcm
TEMPERATURE = 450ºC
MAKE = Walchandnagar, Pune
TYPE = Pulverized fuel Boiler
YEAR OF
COMMISSIONING =1986

2. BOILER # 2
CAPACITY = 80TPH
PRESSURE = 52.5 Kg/sqcm
TEMPERATURE = 450ºC
MAKE = BHEL, Trichi
TYPE = fluidized Bed Combustion Boiler
YEAR OF
COMMISSIONING =1989

3. BOILER # 3
CAPACITY = 140 TPH
PRESSURE = 111 Kg/sqcm
TEMPERATURE = 535ºC
 MAKE = BHEL, Trichi
TYPE = Pulverized fuel Boiler
YEAR OF
COMMISSIONING =1996

4. BOILER # 4

CAPACITY = 150 TPH

PRESSURE = 111 Kg/sqcm
TEMPERATURE = 535ºC
MAKE = BHEL, Trichi
TYPE = Pulverized fuel Boiler
YEAR OF
COMMISSIONING =2004

BOTTOMING TURBINE

CAPACITY = 31.4 MW & 35 MW

INLET STEAM
PRESSURE = 49 Kg/ cm2
TEMPERATURE = 440ºC
MAKE = BHEL

TOPPING TURBINE

CAPACITY = 5.6 MW & 6 MW

INLET STEAM
PRESSURE = 111 Kg/cm2
TEMPERATURE = 535ºC
MAKE = BHEL
 CO-GENERATION PLANT IN HINDALCO

The expansion of Alumina plant necessitated additional requirement of

power and steam. In order to cater this requirement a co-generation plant
was envisaged considering its higher cycle efficiency & low cost of
power generation. As such a co-generation plant consisting of a Boiler
with the capacity 140 TPH, Pressure 112 kg per cm2 and temperature
535º C and two TG sets-one back pressure turbine and other condensing
cum extraction turbine with total power generating capacity of 78 MW
have been installed.
The main co-generation plant contract was awarded to M/s. BHEL,
India for supply of steam generator and TG sets. Various other
manufacturers as detailed below coal handling with coal crushers:
 Mechanical coal handling plant
 Ash handling plant
 Milling system
 D M Water Plant
 Cooling tower
 Diesel generator set
 Boiler feed pump
 Circulating water pumps
 Auxiliaries cooling water pumps
 Chlorination plant

BOILER AND CO-GENERATION PLANT

It is divided into different units

 Main boiler components

 Ash handling plant
 DM plant
  Coal handling plant(CHP)
 MAIN BOILER COMPONENTS

The major accessories of a steam generation unit are listed below:

1. Furnace.
2. Economizer.
3. Boiler drum.
4. Down comers.
5. Water walls.
6. Riser tubes.
7. Super heater.
8. Desuper heater.

(1) FURNACE:

A Boiler furnace is the first pass of the boiler in which fuel is burned and
from which the combustion products pass to the super heater and second
pass of boiler.
The combustion process is the continuous process, which
takes place in first pass of the boiler and controlled by fuel input through
coal feeders. In HINDALCO there has two type of firing method use in
Boiler.
1. Front firing methods
2. Corner firing with tangential arrangement

It is water-cooled furnace and enclosure is made up of water wall.

The furnes is open at the bottom to allow ash/clinkers to fall freely into
the furnace bottom ash hopper, and the top of its rear wall, above the arch,
to allow hot gases to enter the rear gas pass.

(2) ECONOMISER:

The purpose of the economizer is to preheated the boiler feed water

before it is introduced into the boiler or steam drum by recovering heat
from the flue gases leaving the boiler.
(3) BOILER DRUM:

The boiler drum is a cylindrical pressure vessel with hemispherical ends.

It contents two rows of cyclone separators, four rows of drier boxes, a
perforated feed water distribution pipe, and a chemical dosing pipe.
The boiler drum is located upper front of the boiler. It is suspended from
roof steelwork by two u-shaped slings. It forms a part of the water
circulation system of the boiler. The drum serves mainly two functions:

 The first and primary one is that it separates steam from the
mixture of water and steam discharged into it and to reduce the
dissolved solid contents of the steam to below the prescribed
limit of 1ppm.

 Secondly, the drum houses all equipment's used for purification

of steam after being separated from water. These equipment are
known as Drum internals.

DRUM INTERNELS

These are the equipment, which are the used to separate water from
steam and to direct to the flow of water and steam to obtain an
optimum distribution of drum metal temperature in boiler operation.
The drum internals consists of baffle arrangement, devise which
change the direction of flow of steam and water mixture, separators
employing spinning action for removing water from steam or steam
purifiers as washer and screen dryers.

(4)DOWNCOMERS
Downcomers provide a passage for water from the water drum to
bottom ring header. From bottom ring header the water goes to water
 walls for heat absorption and conversion into steam heating. To
achieve the circulation of water into water wall Boiler circulation
pumps are provided in down comers.

(5) WATER WALLS:

Water walls are the necessary element of the boiler. They serve as the
means of heating and evaporating the feed water supplied to the
boiler from the economizers via boiler drum and Downcomers. These
tubes receive water from the boiler drum by means of douncomers
connected between drum and water walls lower header.
Water walls absorb 50% of the heat released by the combustion of
fuel in the furnace, which is utilized for evaporation of feed water.
The mixture of the water and steam is discharged from top of the
water walls in to the upper wall header and then passes through riser
tubes to the steam drum.

(6) RISER TUBES

A riser is a tube through which the mixture of water and steam pass
from an upper water wall header to the steam drum.

(7) SUPER HEATER

The steam generated by the boiler is usually wet or at the most dry
saturated because it is in direct contact with water. So, in order to get
superheated steam, a device known, as superheater has to be
incorporated in the boiler.
 The dry saturated steam from the boiler drum flow inside
the superheater tubes and the hot flue gases flows over the tubes ands
in this way its temperature is increased at the same pressure.

(8) DESUPERHEATER

The desuperheater is only brought into use when the reheated outlet
temperature rises above the normal temperature. The desuperheater
comprises a spray nozzle shell and associated spray assembly
projecting into a section of the superheater steam line. Spray water
for desuperheater is taken from the boiler feed water pump discharge.
 BOILER AUXILIARIES

1. FANS

A fan is a device by which the air is made to flow at required velocity

and pressure in a defined path imparting K.E. of its impellers to
air/flue gases. This pressure boost is used to create a draught in the air
and flue gas system.

(a) P.A. FAN

The primary air fan supplied heated air to the coal mill to give dry and
pulverized coal to the furnace for efficient combustion. There are two P.A.
fans per boiler, each fan having pneumatically operated radial
Guide vanes at the fan inlet to control the fan output.

(b) F.D.FAN

The forced draught fan is provided to supply air required for pulverized
coal combustion in the furnace, air for fuel oil combustion and over fire
air to minimize NOX production. The F.D. fan system comprises of two
single stage axial flow, constant speed, and auto variable pitch fans per
boiler.

(c) I.D. FAN

The induced draught system comprises of two centrifugal double inlet

fans per boiler. The I.D. fan serves the purpose of evacuation the products
of combustion or the flue gases in the atmosphere via chimney.
(d) SCANNER AIR FAN

Scanner fans are installed in the boiler for supplying continuously cooling
air to the flame scanner provided for the flame supervision. It takes
suction from F.D. fan outlet and boosts the pressure further to provide
cooling air to the scanners.

(e) SEAL AIR FAN

Seal air fan supply sealing air at a pressure higher than

That inside the mill, to a brush sealing around the steam of the coal mill
yoke casting to prevent coal dust escaping to atmosphere.

SOOT BLOWERS

Soot / Ash deposited in various region of boiler is removed with the help
of soot blowers, which utilize steam as the main working medium. This
part is mainly concerned with the existing soot blowing system and the
problems arising in the system during operation.
 ELECTROSTATIC PRECIPITATORS (ESP)

FUNCTION:

Function of ESP is to clean the flue gas coming out from boiler by utilizing
electrostatic forces. Ash particles are collected in hoppers. It works on the
principle of CORONA EFFECT.

WORKING:

A high voltage DC current is connected between the emitting and

collecting electrodes and ground. The electrical field becomes strongest
near the surface of the wires. So strong that an electrical discharge, the
corona discharge develops along the wires.
The gas is ionized due to the corona discharge and large quantities of +ve
& -ve ions formed. The positive ions are immediately attracted towards the
negatively charged wires.
The -ve ions however has to transverse the entire space between the
electrodes.
The deposited ash particles are removed by emitting & collecting rappers.
These rappers hammer strikes on the common support of emitting &
collecting electrodes.
Ash is collected in the hoppers and deashed by dry or wet ash handling
system.
 415V,1PHASE
50Hz, AC

ELECTRONIC TRANSFORMER
CONTROLLER RECTIFIER

DC POWER
Voltage: 40-70KV
Current: 1200mA

POSITIVELY CHARGED
COLLECTING PLATE

DEPOSITED
ASH

FLUE GAS INLET +

NEGATIVELY CHARGED
EMMITING ELECTRODE
TOTAL ASH FROM BOTH BOILER = 21.32TPH
ASH COLLECTION PER SHIFT = 172.32 T
CAPACITY OF ASH REMOVAL = 28TPH
TOTAL ASH REMOVAL TIME = 6.8HRS
ASH CONDITIONER CAPACITY = 60TPH
MECHANICAL EXHAUSTER
CAPACITY = 1550 M3/HR
PRESSURE = 500MMHg
BLOWER CAPACITY = 2800M3/HR
PRESSURE = 1.0 Kg/cm2

ASH COMPOSITION

SiO2 = 61.2%
Al2O3 = 21.48%
Fe2O3 = 10.38%
TiO2 = 1.7%
P2O5 = 0.19%
SO3 = 0.1%
CaO = 2.1%
MgO = 0.54%
Na2O = 0.3%
K2O = 1.26%
MnO = 0.05%
 DE-MINERALISED WATER PLAN

To operate high pressure boiler there is need to have high quality water,
which should be free from minerals and should have low conductivity and
low silica content. Thus water is produced from the De-mineralised (DM)
water plant where clear water is converted into distilled water by ion-
exchange process and is usually termed as De-mineralised (DM) water.
The DM water is feed into the boiler with the help of boiler feed pump.
In HINDALCO the main source of water is River water. In pump house
collect raw water and treated with LIME & ALUM, after then the clear
water is comes in DM plant.

There have 7 DM units in HINDALCO.

2*35 m3/hr = 70 m3/hr.

} For B # 1 & 2
3*40 m3/hr = 120 m3/hr.

2*60 m3/hr = 120 m3/hr. } For B # 3 & 4

 B # 1 & 2 DM PLANT

CLEAR DYNASAND FILTER WATER

WATER FILTER STORAGE TANK

STRONG ACID ACTIVATED MULTIGRADE

CATION (SAC) CARBON FILTER FILTER (MGF)
(ACF)

DEGASSER DEGASSED STONG BASE

TOWER (DG) WATER ANION (SBA)
TANK (DGWT)

COLD MIX BED COLD DM

POLISHING UNIT TANK
TANK

HOT DM B#1&2
PLATE HEAT TANK DEARATOR
EXCHANGER

Dyanasand filter &MGF = For turbidity removal.

ACF = To remove the residual chlorine and organic matters.

SAC = To remove the hardness of water.

Type = H+
Group = carbonic acid
Resin = INDION-225
 NaCl + R.H = R.Na + H Cl

CaCl + R.H = R.Cl + HCl

DG = To remove CO2.

SBA = Type = OH-

Resin = INDION-NIP

HCl + OH = RCl +H2O

DM Water

MIX BED UNIT = If any left out ions then remove in mix
Bed.

DM WATER

ph = 7.0 – 8.5
SiO2 = < 0.02 PPM
Conductivity = < 5 micro mhosh

FEED WATER

pH = 8.8 - 9.2
SiO2 = < 0.02 PPM
Conductivity = < 5 micro mhos
 COAL HANDLING PLANT (CHP)

In HINDALCO coal is proceeded ifrom coal mines Binna &

Duthichuava. It comes by Railway wagons then its unloaded in
Wagon tippler area, then from the coal is conveyed through Belt
conveyor in coal yard area.
For the storage of coal yard is established its capacity is about
50,000MT.

QALITY OF COAL

Moisture = 3% to 30%
Volatile matter = 3% to 50%
Ash = 2% to 30%
Fixed carbon = 16%to 92%
Calorific value = 2950 to 3500 KCal/Kg

ANALYSIS OF COAL

There are two types of analysis of coal are:

(1) Proximate analysis
(2) Ultimate analysis

But in the laboratory proximate analysis of coal is done and ultimate

analysis of coal is not done.

The proximate analysis of the coal gives the composition of coal in

respect of moisture, volatile matter, ash and carbon.

Total moister = 8.2%

Ash = 37.2%
Volatile matter = 24.8%
Fixed carbon = 100 – 70.2
 = 29.8%
Calorific value (CV) = 3825 K Cal / Kg.

Grade of coal is decided according to the useful heat value or

calorific value of coal:

:GRADE:
 A : Exceeding 6200
 B : Exceeding 5600 but not exceeding 6200
 C : Exceeding 4940 but not exceeding 5600
 D : Exceeding 4200 but not exceeding 4940
 E : Exceeding 3360 but not exceeding 4200
 F : Exceeding 2400 but not exceeding 3360
 G : Exceeding 1300 but not exceeding 2400

EQUPMENT FUNCTION

(1) CONVEYOR BELT : It is used for conveying the material one

place to another place.

(2) COAL IMPACTOR : It is used for sizing the coal and crushing
the coal of required size ( - 6 mm to – 20 mm) which is fed into
coal bunker.

(3) BUCKET ELEVATOR : It consists buckets fixed to a chain. The

chain moves over two wheels. This is carried by the bucket from
the bottom and discharge at the top.
 BOILER ROTARY PARTS

Rotary parts of boiler are :

(1) Ball mill ( B # 1)

(2) Bowl mill ( B # 3&4)

BALL MILL

Ball mill consist of a slow rotating drum which is

partly fitted with steel balls. Raw coal from feeder is supplied to the
classifier from where it moves to the drum by means of screw
conveyor. As the drum rotates the coal gets pulverized due to the
combined impact between the coal and steel ball.Hot air is introduced
into the drum. The powdered coal it picked by the air and coal air
mixture enter the classifier where sharp changes in the direction of
the mixture throw out over sized coal particles. The over sized
particles are returned to the drum.

BOWL MILL

Crushed raw coal mill to pulverized at the rate of to

suit the boiler steam demand. The pulverizer consist of the stationary
rollers and power driven bowl in which the pulverization takes place
as the coal passes between the sides of the bowl and rollers the
induced draft fan a steam.
  Coal fed to PF Boiler bunker i.e. ( Boiler # 1, Boiler # 3 &
Boiler # 4) of -20 mm size through tripper conveyor into
the PF Boiler bunker of required size.
 Coal fed to FBC Boiler bunker i.e. ( Boiler # 2) of -6 mm size
through tripper conveyor in the FBC Boiler bunker of required
size.

COAL CONVEYOR BELT SPECIFICATION

(1) Belting (belt material) = Nylon

(2) Grade = M – 24

(3) Type = 500/3

(4) No. of plies =3

(5) Top cover rubber thickness

= 5/3
Bottom cover rubber thickness

(6) Carrying capacity = 175 Mt / hr

(7) Belt joining = Vulcanised

(hot/cold)

(8) Material to be conveyed = Coal.

 COOLING TOWER

The purpose of cooling tower is to cool the warmed cooled water

back to condenser. By the way, the cooling water requirement get
reduced to make up water supply only. The tower may be WET or
DRY type.
In HINDALCO wet type cooling tower is used.

WET COOLING TOWER

Wet cooling tower cool the hot water by dissipating

Heat to the environment through the mechanism of (1)Addition of
sensible heat to the air.
(2) Evaporation of a portion of the recalculation water itself.
When operated in the open mode there is the third mechanism.
(3) Addition of sensible heat to the natural body of water as a result of
terminal temperature
Difference. Wet cooling tower are classified as either
(1)Mechanical draught
(2)Natural draught
 5.6MW TURBINE
(OVERHAULING REPORT MAY-07)

COMMISSIONING OF TURBINE: -

At 8.30 hrs ESV of turbine opened for chest warm up

At 9:00 hrs turbine rolling started to 500 rpm and turbine tripped manually
as turbine damping device valve found leaking, damping device replaced.
At 9:25 turbine rolling once again started
At 10:00 hrs turbine speed raised up to 2000 rpm
At 11:00 hrs turbine speed raised up to 4000 rpm
At 11:50 turbine speed raised up to 8000 rpm

Over speed testing by oil injection was checked but machine did not tripped
up to max pressure of 5.2 kg/cm2

Machine synchronized at 12:20hr

Control valve setting:

Following is adjustment / setting of valves w. r. t. secondary oil pressure
14/05/2007

SL NO HPSO HPCV
(Kg/cm2) (mm)

1 1.5 0
2 2.0 8
3 2.5 12.5
4 3.0 17
5 3.5 20
6 4.0 27
7 4.5 34
Note: -
While control valve adjustment control oil pressure - 8 Kg/cm2
Oil temperature 42° C

OBSERVATIONS: -

Turbine centering was out at turbine front side

Turbine blades were in chocked condition by more the 30%
Turbine ESV diffuser was in loose condition
BP gland upper half was in seized condition with casing upper half.
Steam chamber Nozzle assembly, many nozzles are in damaged condition.
Turbine front pedestal holding down conical washer 5nos were in broken
condition
Turning gear coupling pads was in damaged condition.

MAJOR JOB / CHANGES CARRIED OUT: -

0.05 shim was placed below turbine both turbine bearing for final alignment
of turbine and gear box
0.05 shim placed both the side of pedestal axial key
5nos spherical washer replaced in front bearing bottom pedestal as they
found broken ( three nos in front left side and two nos on right side)
Turbine BP gland top half was cut removed from top casing as it was seized
in casing. Gland replaced with old spare gland.
ESV diffuser was found lose and strainer in 100% OK condition.
Rear turbine oil gland fins replaced.
GOP drain line modified with expansion bellow arrangement.
Trip level clearance 1.0 and 1.1 axial and 0.85 radial
Generator both bearing upper half holes were modified to suit the shaft
vibration pick up location.
SPARES CONSUMED:-

5.6MW turbine

1) Parting Plane bolts along with nut - 19nos

2) BP gland - 1Set (old repaired one)
3) Turbine Rear Brg Oil Gland fins - 1set
4) Holding down bolt conical washer - 5nos
5) Expansion bellow 2” - 1no
6) Turning gear coupling pad - 1no
(locally fabricated)
7) Ceramic washer - 1set complete
8) Damping Device (3/4”) - 1No

BLADE SCALE REPORT:

Please find here with the test report of scale sample, collected from 5.6 MW
turbine rotor blade, sent by you on dated 04.05.2007. Tests are carried out on
XRF - IQ method which is not calibrated for such type of samples hence
values are only indicative.

Na2O = 9.1%
Al2O3 = 16.4%
SiO2 = 19.4%
Fe2O3 = 4.5%
MoO3 = 4.4%
TiO2 = 0.9%
SO3 = 0.9%
Cao = 0.9%
Bao = 0.2%
MgO = 0.1%
Cr2O3 = 0.1%
CuO = 0.1%

The major constituents are Na2O, Al2O3, SiO2, Fe2O3 and MoO3.

In future we request you to please send these type of samples with proper
transmittals mentioning purpose of analysis as the same is requirement of
our ISO system and for our record also

Regards,

M P Sharma
Laboratory

3- CAPACITOR

Capacitance of a conductor:- The ability of a conductor to store the charge is

known as capacitance.

When a conductor is charged more and more its potential keep on

increasing.

Qwhere, “q” is the charge, “V” is the potential difference and “C” is a
conatant called capacitance of a conductor.

Thus , the capacitance of a conductor is defined as the change required to

raiseits potential through one volt.
Capacitance of a conductor dose not depend on their Q or V. So , ifVis
changed Q will also changed in such a way that Q / Vremains constant.

The proportionality between Q and V is true only until V becomes so large

that dielectric breakdown occurs. The propwerty of a capacitor changes ,
so ,it is important to keep V below the breakdownpotential for a capacitor.
CAPACITOR:

It is an electric device which is a combination of two conducting bodies

separateld by an insulating medium. It is used to store electric charge.

PRINCIPAL OF A CAPACITOR
The action of a capacitor can be explaned by assuming first that an isolated
metal plate is given a positive charge “Q” or so that its potential is raised
by V volt (say) and then capacitance ; “C “ of the isolated metal sphere is
given by :-
C=+Q/V

Suppose that another insulated plate is broght near the first one. By
induction , negative charge will appear on the side of insulated plate and
positive charge will appear on first plate. The negative charge on the plate
tends to lower the potential of the first plate . So the result is the potential of
first plate is lowered slightly and is given by:--

C=Q/V
Now let the second plate be connected to the earth . Electons from the earth
flow to neutralize the positive charge on the second plate. Now the plate has
only negative charge on the surface facing the first plate. Hence , the
potential of the first plate is further reduced to V and thus its capacitance
increases. This type arrangement is called capacitor.

UNITS OF CAPACITANCE
In cgs electrostatic system the capacitance of a conductor is said to be one
statfarad if one stat coulomb of charge is sufficient to raise its potential
through one statvolt.

1 statefarad = 1 stat coulomb/ statvolt.

In SI unit, the capacity is measured in farad (F) . The capacitance of a

conductor is said to be one farad if one coulomb of charge is sufficient to
raise its potential through one volt.
1 farad = 1 coulomb / 1 volt

One farad is very large capacitance .so capacitance is generally measured in

microfarad ( 10 F ) or micro microfarad i.e. picofarod ( 10 F ). Relation
between farad and stat farad is –

1 farad = 9 x 10 statfarad.
 DIFFERENT TYPE OF VARIABLE CAPACITOR

1-PAPER CONDENSOR :--

The capacitor consists of a strip of wax paper placed between two strip of
iron or aluminium foil which are about an inch wide and 8 to 12 feet in
lenth. The strip of the foil and waxes paper are then rolled up and encased in
a small cardboard or metalcylinder. This arrangement results in small
physical size but with large plate area and comparatively large capacitance.
Oft en the plates of aluminium or thin are separated by a thin filmof paper
treated with oil or a film of plastic material

2:--MICA AND CERAMIC CONDENSORS :--

These condensers are formed by combined mica or ceramic which are

dielectric material between the two plates.

3- GLOSS CAPACITOR S:--

It was the first electric medium used in capacitor. It was invented by Pieter
Van Musschen Brook in 1746.

4- OIL FILLED CAPACITORS :-

Application which involve high current at power line frequencies , high to

extremely high voltage , D. C. filtering and high energy discharge cycles
use capacitors having in common an oil impregnate , relatively large in size ,
steel cases and apaper or combination of paper and polyester dieletric.

5- FLIR DIELECTRIC CAPACITORS :--

 Fixed value air –dielectric capacitors are printcipally used as laboratory
standards for calibration and measurement purposes. With precision
construction and appropriate materials , a capacitance stability of 0.01 % can
be obtained ovwer period of years.

6- VACCUM AND GASS FILLED CAPACITORS :-

these are used as high voltage capacitors in are borne transmitting

equipment. Gas filled type are used for high voltages on the circuits of 250,
000 volt.

7-VARIABLE AIR CAPACITORS :-

These are widly used in the tuning of radio receivers. Aaaaaaaaathese

capacitors have relatively small capacitance as compared to other capacitors.
These capacitors are constructed of a number of fixed parallel metal plates
connected together and constituting are plate of CAPACITOR . The second
set of movable plates also connected together ferms the other plates. By
rotating a shaft on which the movable plates are mounted. The effective area
of the capacitor is that of the interuaved portion of the plates only.

8-ELECTROLYTIC CAPACITOR :-

These are wade by poming a direct current between two sheets of aluminium
foil with a suitable electrolyte of liquid conductor between them. An
extremely thin film of aluminium oxide is then formed on the anod plate.
The anode plates on the positive of the D.C. supply. This film is an insulator
and fermes the dielectric between the two plates. The electrolyte is god
conductor. Since the dielectric thickness d is very small and c 1/d therefore
the capacitance is very large In order to maintain the oxide –film , the anode
terminal is marked in red or by a+ sign. It is very important to connect this
terminal to the positive side of the circuit in which the capacitor is used. If
this is not done , the oxide film will be break down.
USE OF CAPACITOR

Capacitors find many applications in electric circuits.

1-acapacitor is used to eleminate sparking when a circuit
containinginductance is suddenly opened. The ignition system every
automobile engine contains a capacitor for this purpose.
2-Capacitors are used in radio circuits for tuning and for smmothing the
rectified current delivered by power supply.
3-We also increase the efficiency of alternating current power transmission
by increasing the use of large capacitor.

CHARGING AND DISCHARGING OF CAPACITORS

CHARGING:- When a capacitor is connected to a battery , positivel charge

appears on plate and negative charge on other. The potential difference
between the plates ultimately becomes equal to the emf of battery. The
whole process takes some time and during this there is no electric current
through the wires and the battery. The resistance of the connecting wire and
the internal resistance of thye battery is ’R’. The capacitor has the
capacitance ‘C’.

Charge deposited is given by :-

Q = C ( I – I / e ) = 0.63 C

Thus , 63% of the maximum charge is deposited in one time constant (CR ).
DISCHARGING:--
If the plates of a charged capacitor are connected through a conducting
wire , the capacitor gets discharged. Again there is flow of charge through
the wires and hence there is current. Suppose a capacitor of capacitance C is
has charge Q . At t = 0 , the plates are connected through the resistance R .
Let the charge on the capacitor be q and current in the circuit be I at time t
Charge (q) is given by ;-

Q = qe – t / Cr

AT t = CR , the remaining charge is q = Q = 0.37 Q.

Thus 37 % of the discharging is e complete in one time constant.
When we connect a capacitor to a battery, electrons flow from the negative
terminal of the battery to the plate A of the capacitor, connected to it, and at
the same rate, electrons flow from the other plate B of the capacitor towards
the positive terminal of battery. Positive and negative charges thus appear on
the plates , and oppose the flow of electrons which cause them . As the
charges accumulate, the potential difference between the plates increase, and
the charging current falls to zero when the potential difference becomes
equal to the battery voltage.

When the battery is disconnected and the plates are joind together by a wire,
electrons flow back from plate A to plate B until the positive charge on B is
completed neutralized . A current thus flow for a while in the wire and
charge on the plates become zero.

MORE ABOUT CAPACITORS

The capacitance of a capacitor varies directly with area of facing plates and
the directly constant of the insulating material. Capacitance also varies
inversely with with separation of plates i. E. with the thickness of the
dielectric. Alternating current ( A. C. ) also cannot flow , but electrons move
to and from the capacitor and gives the appearance of a continuous current
loop as with D . C . flow , a blocking or couple capacitor can separate A . C .
component of a signal circuit .

EMERGENCY OIL PUMP

5.6 MW TURBINE
Pump type KPDS 50/16
Pump No. 1671195005
D/A No. 107250243/02
Total head 25.19 M
 Rate of flow 11.11 L/S
Pump input 5.240 Kw
Size 100MM
Speed 2900 RPM
Material Code SPL
Recom’d Prime Mover 7.5 Kw
Rating

Oil Vapour Extraction Fan (OVEF)

MAKE-DOCTAIRE
TYPE-SWSI
CAPACITY-0.11M3/SEC
S.P.-100 MMWG
BHP- 0.263
SIZE-1000HPR
RPM-2830
SR NO. 1713
MFG.INDUSTRIAL MACHINARY MANUFACTURERS PVT LTD.
DISTRIBUTED BY.
C.DOCTAIRE & COMPANY PVT.LTD.,DELHI

NAME - 5.6 MW TURBINE

TYPE – HG40/25/0-3
APPLICATION – GENERATOR DRIVE
CAPACITY – 5600 Kw
SPEED – 8000 RPM
TRIP SPEED – 8800 RPM
GENERATOR TYPE – TAII 830-HP-15
OUTPUT VOLTAGE – 11.5 KV
FREQUENCY – 50 Htz.
CURRENT – 351.4 Amp.
POWER FACTOR – 0.8
TYPE OF EXCITER – IFU3167-6TV91
TYPE OF LUBRICANT - EP46
FREQUENCY OF LUBRICATION - CONTINUOUS
AUXILIARY COOLING WATER PUMP

MAKE- FLOWMORE PRIVATE LIMITED

S.No. 49502092 K3B(EAST)/ 49501092 K3B(WEST)
FIG-7000
SIZE-30M
STAGE-1
CAPACITY-2000M3/HR
TDH-43.4MTR
PUMP INPUT-262.6KW
SPEED-987 RPM
MOTOR – 315 kW
MOTOR ERS No.- 422-C-21(EAST)
MOTOR ERS No.- 422-C-20(WEST)
MOTOR FULL LOAD CURRENT- 75 Amps.
LUBRICANT USED IN PUMP- SERVOSYSTEM 32
LUBRICATION FREQUENCY- WEEKLY

AUXILIARY OIL PUMP (AOP)

5.6 MW TURBINE
Pump type KPDS 65/26L
Pump No. 1671895022
D/A No. 107250243/01
Total head 89.46 M
Rate of flow 29.17 L/S
Pump input 39.490 Kw
Size 125MM
Speed 2950 RPM
Material Code 10R
Recom’d Prime Mover 55 Kw
Rating
COOLING WATER PUMP

MAKE- WPIL LIMITED

PATENT No. 2029333
SL.No. – IAZ-3438(EAST)/ IAZ-3437(WEST)
TYPE-VERTICAL
SIZE-CM48TC

SPEED-594 RPM
DISCHARGE-7500M3/HR

HEAD-33.35 MTR
PUMP INPUT-757.94KW
LUBRICANT USED IN PUMP- SERVOSYSTEM 32
LUBRICATION FREQUENCY- WEEKLY
MOTOR ERS No.- 1200-E-02(EAST)
- 1200-E-01(WEST)

CT BOOSTER PUMP

Make- Sam Turbo

SL. No.-11251
Type-TCH+ N25/230
Size- 50X25
Capacity- 30M3/Hr
Head- 60 Mtrs.
Speed- 2900 RPM
Input Power- 15 kW
Motor Full Load Current- 28 Amps.
Lubricant Used in Pump- Servosystem-57/68
Frequency of Lubrication- Weekly

COOLING TOWER
Make- Paharpur RCC Cooling Tower
Type-DF-ID Counter Flow
Model-83636-14V-06
Total flow-10000M3/hr
No. of Cells-6(5 Op + 1 Spare)
Flow per cell –2000M3/hr
HWT-45*C
CWT-35*C
Range-10*C
WBT-27.8*C

Evaporation loss-144.6M3/hr
Drift loss-0.05%

Fan Speed-132 RPM

Gear Box- Series 32.2 (Spiral Bevel cum helical)
Lubricant Used in Gear Box- Servosystem-121
Lubrication Frequency- Weekly
Motor-50 HP
Motor RPM-1500
 KNOW YOUR EQUIPMENT

CONDENSATE EXTRACTION PUMP

MAKE- KSB PUMPS, PUNE
SL. NO.- 0319010(NORTH)/0319009 (SOUTH)
TYPE- WKT 125-4
CAPACITY- 138.6 M3/Hr.
TOTAL HEAD- 100 Mts.
SPEED- 1480 RPM
LUBRICANT USED IN PUMP-
SERVOPRIME- 46T
LUBRICATION FREQUENCY- WEEKLY
MOTOR kW (HP)- 75(100)
MOTOR ERS No.-
…………… (NORTH)
…………… (SOUTH)
MOTOR FULL LOAD CURRENT- 123 AMP.

MGF BACK WASH PUMP

MAKE- SAM TURBO

SL. NO.- 11219(SOUTH)/11220(NORTH)
TYPE- CPC 150/320
CAPACITY- 350 M3/Hr.
TOTAL HEAD- 30 Mts.
SPEED- 1450 RPM
DRIVE HP- 45 kW
TEST PRESSURE- 4.5 KG/SQ.CM
LUBRICANT USED IN PUMP-
SERVOSYSTEM- 57/68
LUBRICATION FREQUENCY- WEEKLY
MOTOR ERS No.- 60.B.144 (SOUTH)
60.B.145 (NORTH)
MOTOR FULL LOAD CURRENT- 80 AMP.
MGF CIRCULATING WATER PUMP

Make- Sam Turbo

SL. No./Year -11737/04
Type- CPC 125/320
Size- 150X125
Capacity- 150M3/Hr
Head- 30 Mtrs.
Speed- 1450 RPM
Test Pressure- 6 Kg/cm2
Brg. No.- TAG 2157 2008/A
Input Power- 22 kW
Motor Full Load Current- 41 Amps.
Lubricant Used in Pump- Servosystem-57/68
Frequency of Lubrication- Weekly

OIL VAPOUR EXTRACTION FAN (OVEF)

MAKE-DOCTAIRE

TYPE-SWSI

CAPACITY-0.11M3/SEC
S.P.-100 MMWG
BHP- 0.263
SIZE-1000HPR
RPM-2830
SR NO. 1713
MFG.INDUSTRIAL MACHINARY MANUFACTURERS PVT LTD.
DISTRIBUTED BY.
C.DOCTAIRE & COMPANY PVT.LTD.,DELHI

GENERAL SALIENT FEATURES OF PLANT

 HIGH SYSTEM EFFICIENCY:52-55%

 LOW STEAM TO POWER RATIO: 2.3-2.4MT/MW

 LOW COST OF STEAM GENERATION:75-86

Paise/KWH
 LOW UNBURNT CARBON:
BOILER#1 = 0.95%
BOILER#2 = 4.46%
BOILER#3 = 1.8%

 LOW WATER CONSUMPTION:7-8 LACS

GALLON/DAY
 LOW CAUSTIC CONSUMPTION:0.119 - 0.123
KG/CUB.M
 LOW SPECIFIC OIL CONSUMPTION:0.142
LTR/MT OF STEAM
 LOW SPECIFIC COAL CONSUMPTION:0.22
MT/MT OF STEAM
 HIGH LOAD FACTOR: 87%
 STEAM BALANCE

STEAM GENERATION

B#1 = 80TPH
B#2 = 80TPH
B#3 = 140TPH
B#4 = 140TPH
HI-TECH
CARBON = 25TPH

STEM DISTRIBUTION

ALUMINA PLANT = 220TPH

PASTE PLANT = 6-8TPH
AUXILIARY STEAM = 15TPH
REMAINING STEAM FOR
POWER GENERATION = 92-96TPH
STEAM DISTRIBUTION TO PROCESS PLANT

PLANTS FLOW PRESSURE

1. OLD DIGESTION- 25 TO 28 TPH 44 KG/SQCM

2. NEW DIGESTION- 60 TO 75 TPH 44 KG/SQCM

3. REYNOLD DIGESTION-22 TO 25 TPH 44 KG/SQCM

4. EVAPORATION-I 9 TO 10 TPH 8 KG/SQCM

5. EVAPORATION-II- 26 TO 28 TPH 8 KG/SQCM

6. EVAPORATION-III- 28 TO 30 TPH 8 KG/SQCM

FOR PASTE PLANT – 6 TO 8 TPH

 Sc hemat ic Diagr ame of Bal l Mil l (Boil er #1)
Automatic Nitrogen TL Furnace TR
Charging System

Temperature BL BR
Transmitter PA
Cold Air
FAN

Nitrogen Cylinder Vol. Coal Fdr-N Vol. Coal Fdr-S

Lift & lube Oil

Auxi. Air
P
Damper
A
H
BSD BSD

HAD

CAD

BALL MILL
SASOD
Classifier
SACD

MGB Grease Spray System Mill Seal Air

PASO

PA Control Damper

1 All Shut Off Dampers - Red for open

and Green for close.
Gear Box Oil Pump 2 Motors- Green for running, Red for stop
 Water Circuit

A- COND. TO
FROM ALUMINA
ALUMINA. PLANT
PLANT

TO
BOILER TO
NO.1 BOILER 1
&3
B#3 DRY ASH HANDLING SYSTEM

BAG
FILTER

VACUUM
BREAKER

B#1&2 DRY ASH HANDLING SYSTEM

BAG
FILTER

VACUUM
BREAKER
 CONCLUSIONS

I have done my practical training from Hindalco Industries Limited. A time

of 30 working days. I collected information and knowledge about whole of
company. I also gained knowledge about the basis material principal, design
and construction of different Mechanical equipment used in Boiler & Co-
generation Plant.
It is very sad fact that the practical training period was only of 30 days. So I
wasn’t able to know about various part of Boiler and Turbine equipment in
detail. So it would be much helpful that the Training period should be of two
month.