Power house is one where electric power is produced using fuel. The fuels used are coal and bagasse. Fuel is fired in a closed vessel called as boiler & stem is produced from water in it. This steam is utilized to run the turbine & electric power is produced from alternator coupled to it. The whole power plant can be divided in to two sections. Boiler Section Turbine Section There are different systems in power plant as- Fuel handling system for coal & bagasse. ater!Steam flow system. "ir flow system. #as flow system. "sh handling system. $ooling system %$ooling tower&. 'ubrication oil system for turbine (ibration indication system in turbine. P'$!)$S!S$")" System.
* . PLANT TRAINING REPORT BOILER +umber of boilers-, -st B.-'/0 $"P"$-T12 *33 tph P0/SS40/2567g!cm, T/8P/0"T40/2596$ 8":/2 Thermodyne T1P/2 Top supported; Bidrum; Balanced draft; +atural circulation with pulsating grate --nd B.-'/0 $"P"$-T12 *<3 tph P0/SS40/2=>7g!cm, T/8P/0"T40/2596$ 8":/2 8itsui Babcoc7 ilco?. T1P/2 Top supported; Bidrum; Balanced draft; +atural circulation with traveling grate. TURBINE -st T40B-+/ $"P"$-T12*68 0P82>3630P8 ST"#/2= T1P/2 Bac7 pressure with bleed steam. 8":/2 Triveni --nd T40B-+/ $"P"$-T12,<8 0P82599=0P8 ST"#/2*<
, . PLANT TRAINING REPORT T1P/2 $ondensate cum -st & --nd /?traction. 8":/2 Sini +ippon CYCLES "T/0!ST/"8 $1$'/
< . PLANT TRAINING REPORT #"S $1$'/
5 . PLANT TRAINING REPORT B"#"SS/ $1$'/
6 . PLANT TRAINING REPORT $."' $1$'/
= . PLANT TRAINING REPORT "-0 $1$'/
> . PLANT TRAINING REPORT BOILER FITTINGS, MOUNTINGS & ACCESSORIES. F-TT-+#S2 These parts form boiler body & cannot be separated. /?2 Steam drum; 8ud drum; Ban7 zone; )own comer tubes; Front header; 0are header; Side header; Boiler tubes; Top headers; 0oof tubes; Screen tubes; 0iser tubes.
8.4+T-+#S2 These parts are mounted on boiler body & can separated from it. /?2 Safety valves; #auge glass; Pressure gauges; Temperature gauges; Pressure transmitters; Temperature transmitters; Soot blowers; Blow off coc7; Stem stop valve; non return valve; "ttemperator control valve.
"$$/SS.0-/S2 These parts are used for the proper functioning of the boiler. These are the parts apart from boiler body. /?2 Transfer pump; Feed tan7; Feed pump; )eairator tan7; /conomizer; Super heater; "ir pre-heater; /SP; F) fan; S" fan; -) fan.
9 . PLANT TRAINING REPORT (.'(/S & 8.4+T-+#S SL. NO. ITEM DISCRIPTION TYPE/MODE OF OPERATION * ,- )rum safety valve Spring loaded , Superheater safety valve Spring loaded < Feed water control valve Pneumatic operated 5 Feed water isolating valve 8otorized 6 Feed water chec7 valve +0( = ,-+os of drum safety valve Bi-color > /lectronic level indicator $onductive type 9 Start up vent valve 8otorized @ 8ain steam valve with integrated by-pass 8otorized *3 "ttemperator control valve Pneumatic operated ** "ttemperator isolating & by-pass 8anual *, "ll necessary vent; drain & isolated valve 8anual
*5 . PLANT TRAINING REPORT PRDS (Pressure Reu!"#$ Desu%er&e'("#$ s(e')* Se!("+#. From this valve steam pressure & temperature can be maintained at desired value. +umber of P0)S- 5 -st2- =>7g!cm, to 567g!cm,%For *6 8 turbine& --nd2- 567g!cm, to >7g!cm,%For distillary& ---rd2- 567g!cm, to *.67g!cm,%For process& -(th2- 567g!cm, to >7g!cm,%For distillary&
*6 . PLANT TRAINING REPORT BOILER OPERATION ST"0T-+# .F B.-'/0 -.pen all the vent valves. -8aintain steam drum level 63E -8aintain feed tan7 level @3E. -Start the sto7er firing. -Start -); F); S" Fan. -Slowly increase the firing. -"fter reaching the design pressure close all the vent valves.
ST.PP-+# .F B.-'/0
*= . PLANT TRAINING REPORT -Stop the firing. -Stop S" fan. -Stop F) fan. -Stop -) fan. -8aintain 63E water level in steam drum. -.pen airvent slowly.
B"$: -+ B.-'/0 0easons- -Feeding of wet bagas; Faming of superheater coil. --) draft less. -F) draft more. --mproper damper opening. -+T/08")-"T/ & $.+T-+4.4S B'. ).+. -ntermediate blow down. -t is given to mud drum. -f T)S hardness of mud drum increases or the water level in steam drum increases then it is opened & blow down. $ontinuous blow down. -t is given to steam drum. " continuous crac7 remains open at 63E level of steam drum. Sludge; oil content in water is removed from this crac7 continuously. These lines are ne?t connected to silencer drum.
*> . PLANT TRAINING REPORT RO PLANT Plant capacityG63m<!hr
*9 . PLANT TRAINING REPORT
B.-'/0 "T/0 P"0"8/T/0S T. B/ 8"+T"-+/) PARTICULARS FEED BOILER CONDENSATE
*@ . PLANT TRAINING REPORT (PPM* WATER WATER WATER PH 9.6-@.6 @.6-*3.6 @-@.6 T+(', &'r#ess 3 3 3.3, TDS ,.6 ,63 - C ',-',"#"(. - >3 - P ',-',"#"(. - ,3 - C+,+ur $lear $lear $lear Ir+# 3.3, - 3.3,-3.36 O", C+#(e#( 3 3 3 C&,+r"e 3 3.6 3.3, P&+s%&'(e - <3-53 *6
PROCESS/BOILING HOUSE
,3 . PLANT TRAINING REPORT Fuice from the mill house is pumped to boiling section where the sucrose contains is e?tracted by different processes on it. There are two processes carried out here -. /?traction of sugar from Cuice. --. /?traction of sugar from raw sugar. %0efinery Section& The whole boiling house can be divided as2- $larification /vaporation Pan boiling $entrifugal Sugar drying #odown PurityG Pole!Bri? CLARIFICATION/
,* . PLANT TRAINING REPORT E0APORATION/
,, . PLANT TRAINING REPORT $lear Cuice from clarifier is pumped to Falling Film /vaporator %FF/& bodies. The Cuice is pumped to the top of a body by circulation pump & it is made to circulate in FF/ bodies. Aere the heat e?change ta7es place between Cuice & steam. The Cuice is brought in indirect contact with steam. The Cuice flows in tube side & steam flows in shell side. "fter getting heated the syrup formed is pump to the pan section by syrup pump. +umber of FF/ bodies2 *3 %9 remains online during process& Aeating surface area2 <633m, -nlet bri? of Cuice2 *6 .utput syrup bri?2 =9.> The vapors condensate is collected in cigar & this water is used in ne?t process and mill for spraying as hot water. PAN BOILING/
,< . PLANT TRAINING REPORT Syrup from evaporation section is boiled in pan section. The syrup is made to flow through the pipes & steam is supplied from the shell side. Sugar powder is added as seed. (acuum is created in pan by condensing the vapor formed in condenser. There are two types of pans. Batch pan $ontinuous pan.
,5 . PLANT TRAINING REPORT .(/0(-/ .F 8"T/0-"' F'.2
,6 . PLANT TRAINING REPORT
CENTRIFUGALS/
,= . PLANT TRAINING REPORT This is the section where sugar is cured%0ecovered& from the mother liIuor%masecute&. The masecute is charged in centrifugal & sugar is separated from heavy & light molasses due to centrifugal action. The sugar is separated in bas7et having two meshes. or7ing screen Supporting screen. $/+T0-F4#"'S 4S/) F.0 )-FF/0/+T 8"SS/$4T/S. " centrifugal- = +os. B centrifugal- 6 +os. Thyssen :rupp made $ centrifugal- , +os. 0* centrifugal- < +os. 0, centrifugal- , +os. Five$ail-:$P made 0< centrifugal- , +os. $apacity2 *>63:g!cycle +umber of cycles2 *9-,3 0P82 **33
,9 . PLANT TRAINING REPORT SUGAR DRYING AND GODOWN. Sugar from the centrifugal section is brought to dryer through screw conveyor. )01/02 +o of )ryers2 < Fluidized Bed )ryer2 , 0otary dryer2 * Sugar from the dryer is send to grader through buc7et elevator. #0")/02 $apacity2 <6 tons!hr %5 +os.& From grader the different size sugar is stored in different silo. The sugar is collected through chute in to bags. The bags are carried through the belt conveyor in to the godown for storage.
,@ . PLANT TRAINING REPORT
<3 . PLANT TRAINING REPORT REFINARY PROCESS.
<* . PLANT TRAINING REPORT SUGAR LAB A!("1"("es (&'( 're %er2+r)e $hec7ing of Sugar & 0aw sugar 8oisture $olor So, content $hec7ing of 8i?ed Cuice & Pure Cuice. Purity Bri? Sucrose ater content from sugar cane to final sugar. $hec7ing of Bagasse Pole 8oisture I#s(ru)e#(s use Bri?ometer - Bri? $hec7ing PA meter J PA chec7ing /.$.; T.).S. analyzer. Photo sucrose scan2 Transferancy $onical flas7s; Burettes; pipettes etc.
<, . PLANT TRAINING REPORT MILLING 8illing is the section where cane is crushed & made in ruptured form for the ma?imum e?traction of Cuice. The bagasse formed send to boilers & Cuice e?tracted send to boiling house. The eIuipments used here are $rane; Feeder table; $ane carrier; $hopper; 'eveler; Fibreriser; Belt conveyor; 8ill; -nter ra7e carrier; Bagasse elevator through which cane handling ta7es place & operation on cane is carried out. )ifferent capacity motors of different power & rpm; #ear bo? with reIuired gear reduction ratio are used. $ompound imbibition; Aot water spray system; 'ubrication oil supply for bearings; Aydraulic system to maintain the gap between the rollers; ater circulation system to identify bearing temperature is used. By pass pumps to pump the Cuice; 0otary screen to filter the Cuice & to put the bagasse again in to inter ra7e carrier are used. Finally the Cuice is collected in to 0aw Cuice tan7 and it is pumped to boiling house.
<< . PLANT TRAINING REPORT
<5 . PLANT TRAINING REPORT TECHNICAL SPECIFICATION OF MILL E3UIPMENTS/ o $0"+/ $"P"$-12 *, tons %=+os.& F4+$T-.+2 To lift the cane bundles of 6-9 ton & to put in feeder table. 8.T.0 0"T-+# o F//)/0 T"B'/ "0/"2 5,m, %5 +os.& 8.T.0 0"T-+#2 ,3AP F4+$T-.+2 To feed cane in to cane carrier at an uniform rate by the action of drag chain which is driven by sproc7et running at <rpm driven by motor through gear bo?. -t is manually operated. o $"+/ $"00-/0 '/+#TA2 >3m 8.T.0 0"T-+#2 *,6AP F4+$T-.+2 To carry cane at reIuired speed. -t is driven by plane chain. -t is automatically operated. o $A.PP/0 %, +os.& )-"8/T/02 *=33mm +48B/0 .F B'")/S2 *6B 5G=3 8.T.0 0"T-+#2 <33AP F4+$T-.+'2 Sugar canes are chopped in to pieces here. -t is driven at ,63rpm.
<6 . PLANT TRAINING REPORT o '/(/'/0 )-"8/T/02 *933mm +48B/0 .F B'")/S2 9B *3G93 8.T.0 0"T-+#2 633AP F4+$T-.+2 Aere sugar cane is formed in still small pieces & leveled. o F-B0/0-S/0 %,+os.& S-+# )-"8/T/02 ,333mm +48B/0 .F B'")/S2 *> B 9G*<= 8.T.0 0"T-+#2 ,533AP "+(-' P'"T/2 -t covers the hammer of fibreriser. The clearance between the tip of hammer & anvil plate can be varied by bolting arrangement. The varies from **3mm to =6mm at centre to *3mm at end. F4+$T-.+2 $hopped pieces of sugar cane are ruptured in small pieces here. -t is run at >63rpm. The preparative inde? is maintained between 95-99. o B/'T $.+(/1.0 8.T.0 0"T-+#2 *,3AP F4+$T-.+2 To carry cane from fibreriser to first mill. o ).++/' $A4T/2 F4+$T-.+2 To hold the bagasse under pressure on the top of a mill.
<= . PLANT TRAINING REPORT o P0/SS40/ $A4T/2 F4+$T-.+2 To carry bagasse under pressure between top roller. The pressure is maintained by adCusting the trashplate provided with bolting arrangement. o 8/SA$A"0T :+-F/2 F4+$T-.+2 To clear bagasse from the groves of the roller. o -+T/0 0":/ $"00-/0 +48B/0 .F 0":/S2 5, 8.T.0 0"T-+#2 =3AP "+#'/ .F /'/("T-.+2 56 $/+T0/ T. $/+T0/ )-ST"+$/ .F T.P 0.''/02 *5m
<> . PLANT TRAINING REPORT 4UICE FLOW SYSTEM/ $ompound imbibition system is used. The actual flow of Cuice is as shown in F"$ #+. Aot water %93$& spray is made before the last mill. Primary Cuice is collected in first mill tan7 & secondary Cuice is collected in second mill tan7. -t is pumped to rotary screen to filter it. Finally the mi?ed Cuice is collected in raw Cuice tan7. P48PS 4S/)2 T1P/2 $/+T0-F4#"' %,+os - Bypass& $"P"$-T12 5,6m<!hr; 53AP motor %.n - st ; -- nd & --- rd mill& ,,6m<!hr;=3AP motor %.n -( th & ( th mill& 0.T"01 S$0//+2 SP//)2 <60P8 %, +os.& 8.T.0 0"T-+#2 *3AP F4+)T-.+2 T. filter the Cuice & put the bagasse in to conveyor. -t is given "ngular draft.