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Internship Report
Intern Syed Arsalan Ahmed BE Mechatronics Engineering NUST
Foreword
This internship report is written to share my experience of working in a professional setup and to give a formal report of the knowledge gained during the six weeks. Getting an internship at AGL was no doubt an honour for me as I had the opportunity to witness the running of one of the most technically advanced Combined Cycle Power Plant in the country. The experience was great because during the study period one hardly gets a chance to witness application of theoretical knowledge but an internship after graduation has provided me with a chance to get a steady knowledge about the implementing of engineering concepts to practical systems and robust designing. The internship although providing a good knowledge of all the processes of a power plant helped me focus mainly on the Instrumentation and Automation as I was assigned in E&I Department. I must add that being a mechatronics engineer and working on a power plant was a dream come true as I felt at home at the all the sections of power plant. I must also add that I am highly impressed with the level of professionalism and technical expertise of the AGL staff. Their dedication to the work and the sense of responsibility has helped AGL to be a reliable power provider to the country.
Acknowledgements
First I would like to thank the AGL HR department for providing me with an opportunity to intern here. I would also like to acknowledge the fact that government of Pakistan has showed its utmost negligence in solving the energy crisis of the country thus giving chance to many private companies to establish power plants providing young engineers such as myself with great learning opportunities. I would like to acknowledge the support provided by the AGL technical team in helping me adjust in the new environment and helping me in every possible way to learn. Especially Deputy Manager E&I Mr. Iftikhar has trained the Management Trainees very well and developed a competent learning environment which helped me as an intern.
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Table of Contents
Foreword ................................................................................................................................................. i Acknowledgements ................................................................................................................................. ii Table of Contents ................................................................................................................................... iii 1. Introduction .................................................................................................................................... 1 Attock Group of Companies: ................................................................................................................ 1 Attock Gen Limited: ............................................................................................................................. 1 2. 1. 2. 3. 3. 1. 2. 3. 3. 4. 5. 4. 1. 2. 3. 4. 5. Plant Overview ................................................................................................................................ 2 Engine:......................................................................................................................................... 2 Turbine: ....................................................................................................................................... 3 Alternator: ................................................................................................................................... 3 AGL Systems .................................................................................................................................... 4 Fuel Oil System: ........................................................................................................................... 4 Lube Oil System: .......................................................................................................................... 5 Compressed Air System: .............................................................................................................. 6 Cooling Water System: ................................................................................................................. 7 Charge Air & Cooling System: ....................................................................................................... 8 HRSG System: .............................................................................................................................. 8 Electricity Generation System .......................................................................................................... 9 Generators:.................................................................................................................................. 9 Switch Gear Room: .................................................................................................................... 10 Black Start Unit: ......................................................................................................................... 10 Switch Yard: ............................................................................................................................... 10 Operation and Maintenance: ......................................................................................................... 11 Control Room: ................................................................................................................................... 11 Engine Safety: .................................................................................................................................... 11 24K Engine Maintenance: .................................................................................................................. 11
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1. Introduction
2. Plant Overview
A crisp overview of the plant is given in the coming lines. The AGL power plant is a combined cycle power plant with the gross production capacity of 165 MW. The plant can run on both heavy and light furnace oil. The main constituents of the plant are:
1. Engine:
The Engines installed at the plant are of the latest cutting edge technology made and installed by Wrtsil, a Finnish company with expertise in IC Engines. There are a total of nine 18V46 engines each with a rated power of 17550 KW. The engines can run on both HFO and LFO providing flexibility on operation but mostly it is run of HFO thus producing low cost electricity. The engine is equipped with a turbocharger and a charge air cooler which boost up the engine efficiency. A few engine specifications are given below.
Manufacturer Number of engines Engine Type Numbers of cylinders Cylinder bore Stroke Speed Rated Output Main Bearing Connected rod bearing Camshaft bearing Exhaust valve type Rotation direction Weight MEP Compression ratio Compression Rings Oil Scrapper Ring Swept volume per cylinder
Wrtsil
9 W18V46 18 460mm 580mm 500 rpm 17.5 MW Metal Metal Tri Metal Nimonic Clockwise 237,000 Kg 24 bar 14 : 1 2 1 96 L
The engine operating parameters (load, rpm etc) are controlled by the Governor. The Governor control on the engines has been provided by Woodward 723 and Woodward 502. These are the brain of the engine and monitor the engine parameters in real time. The governor can also automatically trip the engine if any anomalies are observed.
2. Turbine:
In order to improve the overall plant efficiency the plant is designed to recover the heat produced by the combustion inside the engines, which would otherwise be a waste, and produce super heated steam which runs the turbine; thus making the power plant a combined cycle power plant. The steam turbine installed is an impulse type steam turbine. The main features of the turbine are given below.
Manufacturer Inlet Pressure Inlet Temperature Exhaust Pressure Power Rating Turbine Speed Alternator Speed Turbine Trip Speed Turbine Critical Speed Band Turbine Rotation Staging Steam Flow
Peter Brotherhood Ltd 15.0 Bar 357C 0.14 Bar 15300 KW 6048 rpm 1500 rpm 6652-6955 rpm 1500-3000 rpm Anti Clockwise 9 Rateau 18.3 Kg/s
3. Alternator:
The alternators or generators installed on each engine are Synchronous type with brushless exciter circuits. The generators have a feedback control provided by the Automatic Voltage Regulators. The AVR controls the field excitation current by monitoring the output voltage and current thus providing real time voltage and current regulations. The main alternator specifications are as follow.
Generator Type Poles Windings Output Power factor Voltage Current Frequency AVR Excitation Voltage Excitation Current Speed Cooling method
ABB AMG 1600SS12 DSE 12 Star(+ a neutral connection) 20,588 KVA 0.80 15kV 792 A 50 Hz ABB EA63-5 109V DC 10.3 A 500 rpm Air cooled
3. AGL Systems
In this chapter the different systems operating within the plant are described in detail.
The LFO from the LFO tank is directly sent to the engine hall but HFO from the buffer tanks first go to the fuel treatment room. Fuel Treatment Room HFO Separator Unit: The fuel treatment room houses five centrifugal separators which remove the solid particles from the fuel and also regulate the remove and monitor the water content in the fuel. Each separator has the 4
capacity to filter 10,600 litres of fuel per hour. The waste is collected in the sludge tank. The separator is PLC controlled and monitors certain parameters with the help of sensors. The respective commands are then issued to pneumatically controlled actuators. The separator unit comprises of the following items. 1. 2. 3. 4. 5. 6. Separator (Alfa Laval) Feeding pump Analogue and digital pressure sensors Temperature sensor (PT100) 3-wayPneumatic Valve Water transducer
HFO & LFO Feeder Unit: In order to pump the fuel from the day tanks a feeder unit is unit is used. The feeder unit has two pumps for feeding HFO and one pump for LFO, a total of three such stations for intermitted operation. The HFO line also has filters for purifying the fuel. The feeder unit monitors the quality and amount of fuel in real time. The pump motors have VFD control for adjusting the amount of fuel being fed to the engine hall. The following parameters of the fuel are measured with the help of sensors. 1. 2. 3. 4. 5. Viscosity Density Flow rate Temperature All the control of the FT Room is automated and only supervised from the Control Room.
Booster Unit: The main purpose of the booster unit is to increase the pressure of the fuel, but it also maintains the fuel at optimum temperature by heating it in the heat exchangers, re-filtering it and cooling the unused fuel sent back from the engine (amount of fuel used is decided by the governor). The Feeder and Booster pumps have a capacity of 14,100 l/hr.
Lube Oil Pumping Unit Present in the Fuel treatment room and it pumps the lube oil to engine hall. Lube Oil Tanks: There are three lube oil tanks in the tank yard. A clean lube oil tank(55 m 3), 2 Service Tanks (16 m3) and 1 Used Lube Oil Tank(16 m3). Lube Oil Separator Units: Centrifugal separators are installed behind each engine to remove water and solid impurities from the lube oil. These separator units are just like the HFO separator units. Lube Oil Cooler: The LO Cooler regulates the LO temperature for optimum working. Pre Lube Oil Pump A pre lube oil pump is present to pump the lube oil at engine starting. Oil Mist Detector: An oil mist detector detects the mist in lube oil and then it is purified by oil mist separator. The lube oil system has the following main instrumentation: 1. 2. 3. 4. 5. 6. Level Switches Level Sensors Analogue Flow meter Analogue and digital temperature sensors Analogue and digital pressure sensors PLC controlled 3-way AMOT Valve
5. HRSG System:
The Heat Recovery and Stem Generation System forms a very important part of the combined cycle power plant. The Waste Heat of AGL HFO Engines is utilized by installing 9 No.s Vertical Water Tube Boilers from Aalborg Industries. Each Boiler has a capacity of almost 8 Tonnes/Hour Steam Production. They produce Saturated and Super-Heated Steam. Saturated Steam is used for plants own consumption while Super-heated Steam is used to run the Steam Turbine.
1. Generators:
Each engine and the steam turbine has an alternator coupled to its shaft as a load. The generators are synchronous type with exciter circuits mounted on the rotor. The Alternators are Brushless Excited Synchronous Generators with the field current controlling the amount of output power and phase angle. The AVR controls these parameters and works on the feedback principle monitoring the output voltage and currents by first steeping them down to a suitable level using Current Transformers and Potential Transformers. It then decides how much excitation current needs to be supplied to the exciter circuit. The following diagram will give an idea of such a generator.
NGR Panel: The purpose of a neutral grounding resistor is to limit the ground fault current to a safe level so that all the electrical equipment in the power system is protected. The resistor should be the only current path between the neutral of power transformers or power generators and ground.
4. Switch Yard: The MV busbar is fed to switch yard. Here it is stepped up to 132 kV from 15 kV by power transformers. Switch yard consists of the following equipments: 1. 3 Power Transformers 2. A bus bars tie breaker 3. 2 outgoing feeders 4. Sf6 Circuit-breakers with common operating mechanism 5. Current Transformers for measuring and protection(mounted on Power Transformers) 6. Voltage Transformers 7. Lightning arrestors with counter(mounted on the Power Transformers) 8. Three pole rotary type dis-connector with manual operating mechanism
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Control Room:
The main and most important portion of the plant is the Control Room. All the plant activity, parameters and systems are monitored through the control room. The automation of the plant is done with the help of MODICON Quantum PLCs from Schneider Electric. The communication protocol used is HART. All the parameters are displayed on computer screens and appropriate decisions are taken by the maintenance staff according to any situation. The engine parameters can be adjusted by altering the governor controls and power distribution can also be monitored.
Engine Safety:
The plant has state of the art safety features embedded in the control systems. There are numerous engine trips and alarms. To mention a few: 1. 2. 3. 4. 5. 6. 7. 8. 9. Oil Mist Detector Liner Temperatures Head Temperatures Big end bearing Temperatures Exhaust Gas Temperatures Turbocharger Over speed trip Engine RPM Trip Turbine Over speed Trip Boiler Pressure Trip
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