A Study On

Operation and Control of Thermal Power Plant at APSCL

(Ashuganj Power Station Company LTD)

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 A Study On
Operation and Control of Thermal Power Plant

Prepared as a Part of the Fulfillment of the Requirements of Degree of Bachelor of Science in

Mechanical Engineering at IUBAT.

Prepared By

Md. Sarowar Hossain

ID: 11107096

Program: BSME

IUBAT-International University of Business Agriculture & Technology

15th December, 2014

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 Request for the Report

15th December, 2014

Coordinator
Department of Mechanical Engineering
IUBAT—International University of Business Agriculture and Technology
4 Embankment Drive Road, Uttara Model Town, Sector 10,
Dhaka- 1230, Bangladesh
Subject: Request for the report.

Dear Sir,

With due respect, I‘d like to submit this report as partial fulfillment of the BSME program, on
the topic of “A Study on Operation and Control of Thermal Power Plant”. It
was a great opportunity for me to work on this topic to actualize my theoretical knowledge in
the practical area and to have an enormous experience. Now I am looking forward for your
kind assessment regarding this report.

It would be very kind of you, if you please take the trouble of going through the report and
evaluate my performance regarding this report.

Sincerely Yours,

………………………………..

Md. Sarowar Hossain

ID# 11107096
Department of Mechanical Engineering

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 Letter of Transmittal

15th December, 2014

Engr. Abdul Wadud

Faculty
Department of Mechanical Engineering
IUBAT- International University of Business Agriculture and Technology
4, Embankment Drive Road, Uttara Model Town
Sector#10, Dhaka-1230, Bangladesh

Sub: Letter of Transmittal of the Practicum Report.

Dear Sir,

With due respect, I want to draw your kind attention that I am a student of Bachelor of
Science in Mechanical Engineering (BSME). For completion of my graduation I have done
my practicum in Ashuganj Power Station Company Ltd.(APSCL) and have prepared this
report titled as “A Study on Operation and Control of Thermal Power Plant ”. It was very
helpful for me to work there, because I learned and gained knowledge. I think it was a great
opportunity for me to learn about the production and maintenance system of an industry.
Having worked in that particular place it makes me satisfied about my graduation.

Under the above circumstances I would like to submit my internship report for official
purpose. I tried my level best to achieve my goal to make a realistic and informative research
paper.

Sincerely Yours,

_________________
Md. Sarowar Hossain
ID# 11107096
Department of Mechanical Engineering

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 Student Declaration

I hereby declare that I have uniquely prepared this report which is entitled as ―A
Study on Operation and Control of Thermal Power Plant‖ after completion
of twelve weeks practical work in Ashuganj Power Station Company Ltd.
(APSCL) Ashuganj,Brahmanbaria.

I also confirm that the report is only prepared to fulfill the academic
requirement and not for any other purpose. It will not be used with the interest
of any other competitor.

Faithfully Yours,

-----------------------------
Md. Sarowar Hossain
ID# 11107096
Department of Mechanical Engineering

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Forwarding Letter

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APSCL Permission

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 Acknowledgement

In the process of doing and preparing practicum Report, I would like to pay my gratitude and
respect to some persons for their immense help and enormous co-operation.

I want to thank the Managing Director of Ashuganj Power Station Company Limited
(APSCL), Mr. Md. Nurul Alam (P.Engg.) to give me chance to complete my practicum at
APSCL. I would also like to thank Mr. Md. Luthfar Rahman, Manager (HRD) for his kind
cooperation during practicum period. I thank my mentor Assist. Engr. Md.Yasir Amin (Boiler
Saetion) and Assist. Engr. Md. Ashikur Rahman ( Turbine Section) of Thermal Power
Plant, Ashuganj Power Station. They provided me the practical knowledge of the power
plant, without their guidance and help I could not completed my practicum. I also like to
thank other Engineers and staff of APSCL for their cooperation with me.

I would also like to pay my gratitude to our respected Course Coordinator Engr. Abdul
Wadud who gave the opportunity to do the report on ―A Study on Operation and Control of
Thermal Power Plant‖

Finally I would like to thanks again to the respected Vice Chancellor of IUBAT ―Prof. Dr. M
Alimullah Miyan” because he gave the opportunity to study in such a beautiful university to
acquire knowledge on BSME that will be very helpful for our prospective career.

-----------------------------
Md. Sarowar Hossain
ID# 11107096
Department of Mechanical Engineering

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 Executive Summary

Practicum provides students the opportunity to test their interest in a particular zone and
also provides students high level of practical knowledge. IUBAT has added this
Practicum program for the graduating students to introduce them to the professional life.

In order to thoroughly understand the role of power sector in Bangladesh, the general
electricity production, distribution and transmission system in the country must also be
taken into account. The purpose of this report is to give a brief description about what I
have learned and visited in the power station. In this regard I ventured into history and
have followed some significant data collected from APSCL. APSCL has 9 units with
installed capacity of 777 MW. APSCL fulfills about 15% of power requirements of the
country. Unit 1 and 5 are for steam power plant, unit 6 and 7 are gas tubine-1 (GT-1) and
gas turbine-2 (GT-2), unit 8 is gas engine and unit 9 is combined cycle plant. Unit 1 and
2 produce 64 MW each, unit 3, 4 and 5 produce 150 MW each, unit 6 and 7 produce 56
MW each, unit 8 produces 50 MW and unit 9 produces 34 MW. Sub-station of APSCL
plays a vital role for power distribution.

During this Practicum my theoretical knowledge was verified to the practical field of power
system. My mentor has helped as a lot by giving me the proper introduction about the plant
and I have observed different systems and devices under his observation. The systems or
the devices that were observed during the internship include generator, boiler, water
treatment plant, steam turbine, gas turbine, compressor and other essential equipments of
the APSCL. In this report the main emphasis is on the explanation about Thermal power
plant along with the knowledge about power generation and maintenance system at
APSCL. It is expected that in the future this practical knowledge will enhance my potential
to grow up in power industries.

Table of contents
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page no

Preparatory part

A. TitleFly………………………………………………………………… i

B. Title Page……………………………………………………………….. ii

C. Request for …………………………………………………………. iii

D. Letter of Transmittal …………………………………………………….iv

E. Student's Declaration…………………………………… v

F. Forwarding Letter ……………………………………………………….vi

G. BITAC permission …………………………………………………vii

H. Acknowledgement……………………………………………………….ix

I. J. Executive Summery ……………………………………………..x

J. Table of contents …………………………………………………….xi-xx

L. List of figures …………………………………………………..xxi-xxv

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 TABLE OF CONTENT
PAGE
CHAPTER 1....................................................................................................1-2
INTRODUCTION
1.1 Origin of the report1
1.2 Objectives 1
1.3 Scope 1
1.4 Methodology1
1.5 Limitations 2
1.6 Report Organization2

CHAPTER 2
ABOUT APSCL
2.1 Background of Ashuganj Power Station
2.2 Location
2.3 Formation of the Company
2.3.1 Shareholding Information
2.3.2 Organization Structure
2.3.3 APSCL Board of Directors
2.4 Company profile
2.5 Vision
2.6 Mission
2.7 The Objective
2.8 Present Situation of Generation
2.9 Generation Plan of APSCL-2016 to 2020

CHAPTER 3
THERMAL POWER PLANT (ST)
3.1 Main parts of a steam power plant………………………………………………………4
3.2 Working Cycle..................................................................................................................5
3.2.1 Rankine Cycle..............................................................................................................16
3.2.2 Rankine cycle with superheat
3.2.3 Rankine cycle with reheat
3.2.4 Regenerative Rankine cycle
3.2.5 Efficiency of a Rankine cycle
3.3 Working principle

CHAPTER 4
BOILER
4.1 Layout of APSCL ST-5 Boiler
4.2 Classification

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4.3 Purpose of boiler
4.4 Fire tube boilers
4.5 Water tube boilers
4.6 Babcock and Wilcox boiler
4.7 UNIT NO: 3,4,5
4.8 Basic Requirement for Producing Power
4.8.1 Air
4.8.2 Gas
4.8.3 Working principle

CHAPTER 5
BOILER PARTS
5.1 Major Components
5.1.1 Boiler Drum
5.1.1.1 Steam separator
5.1.2 Header
5.1.3 Down Comer
5.1.4 Water-wall Tube
5.1.5 Burner
5.2 Boier Mountings
5.2.1 Safety valves
5.2.2 Water level indicators
5.2.3 Stop valve
5.2.4 Pressure gauge
5.2.5 Blow off cock
5.2.6 Feed check valve
5.2.7 Fusible plug
5.3 Boiler Aaccessories
5.3.1 Economizer
5.3.2 Super heater
5.3.3 Feed pump
5.3.3.1 Feed pump specification:
5.3.4 Steam trap
5.3.5 Air pre-heater
5.3.6 Pressure reducing valve
5.3.7 Spray Attemperator
5.3.8 Forced draft fan
5.3.9 Draught
5.3.10 Reheater
5.4 Boiler Auxilary
5.4.1 HP heater
5.4.2 LP heater
5.4.3 Condenser

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5.4.4 Feed Tank
5.4.5 Dearator
5.4.6 Make up water tank

CHAPTER 6
BOILER STARTUP SHUTDOWN AND CONTROL
6.1 Startup Procedure
6.1.1 Pre-Startup walkthrough
6.1.2 Filling the boiler drum
6.1.3 Establishing Flow Through the Boiler
6.1.4 Preparation for Light-off
6.1.5 Lighting of the boiler
6.1.6 Warming up the Boiler
6.2 Basic Shutdown Procedure
6.2.1 Reducing Firing rate
6.2.2 Reducing Steam Flow
6.2.3 Reducing Air and Gas Flow
6.3 Control of boiler
6.3.1 Ratio control
6.3.2 Furnace pressure control
6.3.3 Drum level feed water control
6.3.4 Single element level control
6.3.5 Two element level control
6.3.6 Three element level control
6.3.7 Burner management system
6.3.8 Purge control
6.3.9 Flame detection
6.3.10 Flame tripping validation

CHAPTER 7
TURBINE
7.1 Types of turbine
7.1.1 Impulse turbines
7.1.2 Reaction turbines
7.2 Types of turbine in use
7.3 Steam turbine
7.3.1 Main parts of steam turbine
7.3.2 Rotor assembly
7.3.3 Turbine blades
7.3.4 Fixed blade

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7.3.5 Moving blade
7.3.6 High Pressure Turbine (HPT)
7.3.7 Intermediate Pressure Turbine (IPT)
7.3.8 Low Pressure Turbine (LPT)
7.3.9 Blading stages
7.4 Valves
7.4.1 Main stop valves
7.4.2 Control valves
7.5 Bearing
7.5.1 Journal bearing
7.5.2 Thrust bearing
7.6 Lubrication
7.6.1 Lubricating Equipments
7.6.2 Lube Oil tank
7.6.3 Centrifuge pump
7.6.4 Lube oil cooler
7.6.5 Lube oil
7.7 Generator
7.7.1 Generator Specification
7.8 Steam Turbine Control and Protection
7.8.1 Steam turbine control system
7.8.2 Steam turbine control valves
7.8.3 Mechanical governance
7.8.4 Speed changer
7.9 Turbine temperature and pressure control
7.9.1 Steam temperature
7.9.2 Bearing temperature
7.9.3 Pressures control
7.10 Steam turbine protection
7.10.1 Steam turbine trip
7.10.2 Lubricating oil protection
7.10.3 Bearing protection
7.10.4 High vibration protection

CHAPTER 8
WATER MANAGEMENT
8.1 Pump station
8.1.1 The specifications of CW pump
8.2 River water screening System
8.2.1 Heavy-duty Bar
8.2.2 Rotating Bar
8.2.3 Band Screening Bar

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8.3 Distribution of River Water
8.3.1 Supply to Condenser
8.3.2 Supply to Water Treatment Plant
8.4 Water Treatment Plant
8.4.1 Clarification and Sedimentation
8.4.2 Filtration
8.4.3 Over head tank
8.4.4 Demineralization
8.4.5 Make up water tank
8.4.6 Discharge canal
8.5 Chemical Test

CHAPTER 9
9.1 Discussion
9.2 Conclusion
9.3 Bibliography
9.4 Appendix

List of Figures
Page
CHAPTER 2
Figure 2.2-1: Location of APSCL
Figure 2.2-2: Ashuganj Power Station Complex
Table 2.3.1: Shareholding Information
Figure 2.3.2: Organization Structure
Figure 2.4-1: Unit-1 & 2 (2×64 MW)
Figure 2.4-2: Unit-3, 4 & 5 (3×150MW)
Figure 2.4-3: GT-1, GT-2 & ST (146 MW CCPP)
Figure 2.4-4: 50 MW GEPP
Figure 2.9-1: Unit-1&2 (2×64=128MW)
Figure 2.9-2: 2×150=300MW GT Power Plant Site
Figure 2.9-3: 4×850 MW CCPP Project Site
Figure 2.9-4: The company total generation graph from 2016 to 2020

CHAPTER 3
Figure 3: APSCL Thermal Power Plant (ST-5)
Figure 3.1: Overall water and steam cycle of steam turbine units.
Figure 3.2.1: Symple Rankine Cycle
Figure 3.2.1-1: Rankine Cycle
Figure 3.2.2: Rankine cycle with superheat
Figure 3.2.3: Rankine cycle with reheat
Figure 3.2.4: Regenerative Rankine cycle
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CHAPTER 4
Figure 4.1: Layout of APSCL ST-5 Boiler
Figure 4.1.1: Layout of APSCL ST-5 Boiler
Figure 4.5: Overall water and steam cycle of steam turbine units.
Figure 4.8.2: Gas Supply

CHAPTER 5
Figure 5.1.1: Boiler Drum
Figure 5.1.1-2: Boiler Drum
Figure 5.1.1.1: Steam separator
Figure 5.1.2: Header
Figure 5.1.3: Down comer
Figure 5.1.4: Water wall tube
Figure 5.1.5: Sectional and practical view of Burner
Figure 5.2.1: Safety valves
Figure 5.2.2: Water level indicators
Figure 5.2.3: Stop valve
Figure 5.3.8: Forced draft fan
Figure 5.3.9: Draught
Figure 5.3.10: Reheater
Figure 5.4.1: HP heater
Figure 5.4.2: LP heater
Figure 5.4.3: Diagram of a typical water-cooled surface condenser.
Figure 5.4.4: Feed Tank
Figure 5.4.5: Dearator
Figure 5.4.6: Make up water tank

CHAPTER 6
Figure 6.3.2: Block diagram of boiler control- furnace control
Figure 6.3.3: Boiler drums/level measurement
Figure 6.3.4: Storage tank of a boiler
Figure 6.3.7: One burner of a boiler of APSCL
Figure 6.3.9: Flame detection
Figure 6.3: Control System of water & steam cycle
Figure 6.3: Control system of Feedwater and Boiler Feed Pumps
Figure 6.3: Control system of Condenser
Figure 6.3: Control system of Boiler Air & Flue Gas system
Figure 6.3: Burner control
Figure 6.3: Control System of Fuel Gas system
Figure 6.3: Burner control
Figure 6.3: Control of Lube oil System

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Figure 6.3: C0ntrol of Bearing temperatures

CHAPTER 7
Figure 7: Steam turbine of unit-5 of APSCL.
Figure 7-1: Steam turbine section of unit-5 of APSCL
Figure 7.3: Steam Turbine with casing
Figure 7.3.1: Sectional view of steam turbines
Figure 7.3.8: Fixed blade
Figure 7.3.5: Moving blade
Figure 7.3.8: HP, IP and LP turbine at a glance
Figure 7.3.9: Velocity and pressure diagram of fluid
Figure 7.4.1: Main stop valves
Figure 7.5.1: Journel bearing
Figure 7.5.2: Thrust bearing
Figure 7.6: Lubrication system
Figure 7.6.2: Lube oil Tank
Figure 7.6.3: Centrifuse pump
Figure 7.6.4: Lube oil cooler
Figure 7.7: Generator of unit-2
Figure 7.7.1: Internal view of Generator During Overhauling
Figure 7.8.2: Live steam valve and main stop valve
Figure 7.10.1.1: Operator activating a manual trip
Figure 7.10.1.2: Operator activating a reset mechanism
Figure 7.10.1.3: Simplified diagram of a basic reset mechanism
Figure 7.10.1.4: Solenoid trip mechanism
Figure 7.10.3: A thrust bearing wear detector

CHAPTER 8
Figure 8.1: Pump station
Figure 8.1.1: CW pump
Figure 8.2.1: Heavy-duty Bar
Figure 8.2.2: Rotating Bar
Figure 8.2.3: Band Screening Bar
Figure 8.3.1: Condenser
Figure 8.3.2: Water circulation system
Figure 8.4: Water Treatment Plant
Figure 8.4.1: Sedimentation
Figure 8.4.2: Gravel filter
Figure 8.4.3: Over head tank
Figure 8.4.4: Demineralizationsection
Figure 8.4.5: Makeup water tank
Figure 8.4.6: Discharge Canal
Figure 8.5: Chemical lab

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 List of Tables

CHAPTER 2
Table 2.3.1: Shareholding Information
Table 2.8: Present Situation of Generation

CHAPTER 7
Table 7.6.5: Lube oil specification
Table: 7.7.1 Generator Specification

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CHAPTER 1

1.1 Origin of the report

This report had been prepared as an integral part of the Practicum program for the Bachelor
of Science in Mechanical Engineering (BSME) at the Department of Mechanical Engineering
(ME) in IUBAT—International University of Business Agriculture and Technology. As a
partial fulfillment of the BSME program this practicum report had been accomplished on
―Operation and Control of Thermal Power Plant at APSCL‖ under the instruction of
‗Md. Luthfar Rahman, Manager‖ Executive Engineer(HRD) at APSCL. This was nominated
as the organization for the practicum while honorable faculty Engr. Abdul Wadud;
Coordinator, Department of Mechanical Engineering, rendered his kind consent to
academically supervise the practicum period.

1.2 Objectives

The objective of this practicum is to gather practical knowledge and experience and
implementation of theoretical study in real world. To this regard this report is contemplating
the knowledge and experience accumulated from the internship program. With the set
guidelines by the BSME Department of IUBAT and my Practicum Supervisor, this report
comprises of an organization part and a project part. The prime objective of the organization
part is to present a background and introduction of APSCL. And the project part deals with
the operation of Thermal Power Plant of APSCL

1.3 Scope

This organization is directly controlled by the ministry of Power and electricity of

Bangladesh. So the scope is huge for learning because there is a huge limitation on in private
industries.

1.4 Methodology

For prepare this report mostly primary information is used. However, secondary sources are
also used in some places.

 Primary Information: The primary source of information is hand on experience that

we achieved in APSCL. Notes, lectures, sketches, diagrams, templates that are found
in APSCL are the primary source of information.
 Secondary Information: The secondary source of information is based on Internet
Searching, Reference Books etc.

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1.5 Limitations

Although it was a very good working experience, there were some problems and limitations
as well. The problems and limitations were:
 I was not allowed to go to everywhere inside the plant and sub-station due to risk of
high voltage.

 Sometimes I could not collect my necessary data or information due to confidentiality

reasons.

1.6 Report Organization

In this practicum report I have mainly discussed about APSCL‟s Thermal power Plant . I have
also discussed other sections. Chapter 2 is about organaization. Chapter 3 is about basic idea
of thermal power plant (CCPP). Here I have discussed about working cycle,and working
principle of Thermal Power Plant . Chapter 4 consists of Boilers. Here I have mentioned
working principle of a Boiler. Chapter 5 is Boiler components. Here I have mentioned
different components of a boiler. In Chapter 6 I have discussed about operation and
controlling system of boiler. Chapter 7 is Turbine.Here I have discussed about different types
of turbine,bearings and valves. In Chapter 8 I have discussed about water treatment plant.
Here I have discussed about the total water treatment process done at APSCL. Chapter 9 is
conclusion. From the experience having from my internship, I have mentioned some
recommendations of my own in this chapter.

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Chapter 2: Introduction of APSCL
Power generation sector is one of the most important sectors for any nation because the
growth of the economy is vastly dependent on this sector. It is a great opportunity to
accomplish the internship at Ashuganj Power Station Company Limited (APSCL). It is the
second largest power station in capacity in our country . There are three types of power plants
at APSCL such as, thermal power plant, gas turbine power plant and combine cycle power
plant. So there is a lot of opportunity to learn about various types of power plants. During my
practicum I closely observed boiler section, turbine section, generation section and operation
section. In this chapter I have discussed the overall idea about APSCL, including the
background, present capabilities and future plan

2.1 Background of Ashuganj Power Station

For a thermal power plant, infrastructure facility like river, transportation of heavy
equipments either in highway, railway or waterway, and fuel sourcing (gas networks) are
mandatory. Considering the above mentioned facilities of Ashuganj an agreement was signed
in 1966 with a foreign construction company to establish a thermal power plant at Ashuganj.
Ashuganj which is situated near the Titas Gas field and on the bank of river Meghna was
selected as the suitable place for establishing the largest power plant of the country at that
time. With the acquiring of 311 acres of land on the north-east side of the Meghna Railway
Bridge the construction work of Ashuganj thermal power plant was started in 1966. With the
financial assistance of the German Government two units of 128 MW capacities were
established. In 1968 the erection of main equipments was started and by July 1970 the two
units were commissioned. At that time to establish another three units in future some facility
was preserved. After the post liberation period Ashuganj power plant has played an important
role in the reconstruction and economic development of the war stricken country,
Bangladesh.

While plan was taken to increase the capacity of Ashuganj power plant to meet the increasing
demand of electricity, M/S Lahmyer International from Germany investigated the possibility
of expanding the power plant and recommended to establish three units (unit 3, 4 and 5)
having a capacity of 150 MW each.

These three units were commissioned on December, 1986 and May, 1987 respectively. As the
plan of establishing unit 3 and 4 was going on, at the same time another decision was taken to
establish a combined cycle plant in Ashuganj by British financial support. The total capacity
of this combined cycle plant is 146 MW, where two gas turbine units have 56 MW capacity
each and one steam turbine unit have a capacity of 34 MW. The main equipments of this unit
are made and established by GEC from England (at present ALSTOM, UK). As of the
combined cycle plant GT-1, ST, and GT-2 units were commissioned in 1982, 1984 and 1986
respectively.

Main fuel used for this power plant is natural gas (coming from Titas Gas). For steam
generation and cooling, the required water is taken from Meghna River. Huge amount of

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water used for cooling is discharged into river through discharge canal of power plant. It
should be mentioned that in dry season the water coming from the discharge canal is used for
irrigation of a large area on Ashuganj with the help of a sluice gate. With this water 36,000
acres of land is irrigated.

As a part of the Power Sector Development and Reform Program of the Government of
Bangladesh, APSCL has been incorporated under the Companies Act 1994 on 28 June, 2000.
Ashuganj Power Station Complex had been transferred to the APSCL through a Provisional
Vendor's Agreement signed between BPDB and APSCL on 22 May, 2003. All the activities
of the company started formally on 01 June, 2003. From that day the overall activities of the
Company along with the operation, maintenance and development of the power station are
vested upon a Management Team consisting of the Managing Director, the Director
(Technical) and the Director (Finance).

According to the Articles of Association of the Company, 51% of total shares are held by
BPDB and the rest 49% are distributed among Ministry of Finance, Ministry of Planning, and
Power Division, Bangladesh Ministry of Power, Energy, and Mineral Resources.

To solve the huge deficiency of electricity of the country, the government has planned to
establish new plants on quick basis. According to the direction of the government APSCL has
taken a project of establishing a 50 MW plant with self finance. Accordingly for the
completion of this project an agreement was signed with TSK, Spain (EPC) on 25 July,
2010. This unit is commercially generating 53 MW of electricity from 30 April, 2011.

2.2 Location

Figure 2.2-1: Location of APSCL

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 Figure 2.2-2: Ashuganj Power Station Complex

2.3 Formation of the Company

As a part of the Power Sector Development & Reform Program of Government of
Bangladesh (GOB), APSCL has been incorporated under the Companies Act
1994. APSCL has been registered in the office of the Register of the Joint Stock Companies
& Firms of Bangladesh on 28 June 2000. Through a Provisional Vendor’s Agreement
APSCL Management has taken over a asset s & abillities of APS Complex consisting of
the following assets and liabilities:

Total Assets : Tk. 1605,76,00,000

Total Liabilities : Tk. 1486,10,00,000

Equity of BPDB : Tk. 119,66,00,000

The Registration No. of APSCL is 40630 (2328)/2000 dated 28.06.2000. According to the
Articles of Association of the company, 51% of total shares is held by BPDB and the rest
49% is distributed among Ministry of Finance, Ministry of Planning, Power Division,
MOPEMR & Energy Division, MOPEMR of GOB.

Authorized Capital : Tk. 1500,00,00,000

Paid up Capital : Tk. 10,00,000

The Overall activities of the Company along with Operation, Maintenance and development
of the Power Station are vested upon a Management Team consisting of 3 Members:

Managing Director

Director (Technical)

Director (Finance)
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2.3.1 Shareholding Information

TAble for Shareholding Information of APSCL only.

Table 2.3.1: Shareholding Information

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2.3.2 Organization Structure

Figure 2.3.2: Organization Structure

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2.3.3 APSCL Board of Directors
1. Mr. Foiz Ahamed, Additional Secretary (Admin), Power Division, Ministry of
Power, Energy & Mineral Res. & Chairman, APSCL.
2. Mr. Shafat Ahmed Choudhuri, Additional Secretary (Admin/Operation),
Ministry of Power, Energy & Mineral Res. & Director, APSCL.
3. Mr. Md. Anwar Hossain, Joint Secretary (Development) , Power Division,
Ministry of Power, Energy & Mineral Res. & Director, APSCL.
4. Mr. Md. Harunur Rashid, Joint Secretary, Prime Minister‘s Office & Director,
APSCL.
5. Dr. Md. Quamrul Ahsan, Professor, Dept. of Electrical & Electronic Engg.,
BUET & Director, APSCL.
6. Mr. Tamal Chakraborty, Member(Generation), BPDB & Director, APSCL.
7. Mr. Md. Abul Quasem, Member (Company affairs), BPDB & Director,
APSCL.
8. Mr. Mamtaz Uddin Ahmed, President, ICMAB & Director, APSCL.
9. Mr. Md. Abduhu Ruhullah, Member (P&D), BPDB & Director, APSCL.
10. Mr. Md. Shamsul Haque, Director, FBCCI & Director, APSCL
11. Mr. Md. Nurul Alam, Managing Director, APSCL.

2.4 Company profile

As a part of the power sector development and reform program of the Government of
Bangladesh (GOB), Ashuganj Power Station Company Limited (APSCL) has been included
under the Companies Act 1994 on 28th June, 2000. Ashuganj Power Station (APS) complex
had been transferred to the APSCL through a provisional vendor‘s agreement. The agreement
had been signed between BPDB and APSCL on 22nd May, 2003. All the activities of the
company started on 1st June, 2003. From that day, the overall activities of the company are
vested upon a management team. The team consists of the managing director, the director
(Technical) and the director (Finance). According to the articles of association of the
company, 51% of total shares are held by BPDB and the rest 49% shares are distributed
among ministry of planning, power division, MOPEMR & energy division, MOPEMR of
GOB .

 Name : Ashuganj Power Station Company Limited (APSCL),

 Location: 90 km North-East of Dhaka on the left bank of the river Meghna.
 Corporate Office : Ashuganj, Brahmanbaria-3402,
 Registration Date : 28 June 2000,
 Registration No: C-40630 (2328)/2000 date. 28.06.2000.
 Company Status : Public Limited Company,
 Main Work : Power Generation,
 Land : 311.22 Acres
 Number of Generation Units : 9 (6 Steam Turbines + 2 Gas Turbines + 1 Gas Engine),

Page | 26
  Installed Capacity : 777 MW,
 Present de-rated capacity: 731 MW,
 Dependable Capacity: 573 MW,
 Area of Land : 263.55 Acres,
 Manpower: 517 (Regular employee) [2].

There are three plants in APSCl-

Plant 1: Thermal Power Plant (TPP)

Two Steam Units of 64MW- Unit # 1 & 2 each-commissioned in 1970.

Plant 2: Combined Cycle Power Plant (CCPP)

Gas Turbine Units-GT1 and GT2 of capacity 56MW each-commissioned in 1982 and 1986
respectively.One Steam Turbine (ST) of capacity 34MW with waste heat recovery Boiler
commissioned in 1984.

Plant 3: Thermal Power Plant (TPP)

Unit # 3 of 150MW capacity was commissioned in 1986.

Unit # 4 of 150MW capacity was commissioned in 1987.

Unit # 5 of 150MW capacity was commissioned in 1988.

Plant 4: 50 MW Gas Engine Power Plant (GEP)

To meet the extra demand of electricity of the country the Government of Bangladesh planed
to establish more power generation units as early as possible. As guided by the Government
of Bangladesh (GOB) Ashuganj Power Station Company Ltd. took a project in 2010 to
establish a power generation unit having a generation capacity of 50MW, financing with its
own fund. To fulfill this project an agreement was signed with the M/S TSK, Spain (EPC) on
25th July of 2010. The new generation unit has started its commercial operation at 53MW
load from 30th April of 2011.

Figure 2.4-1: Unit-1 & 2 (2×64 MW)

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 Figure 2.4-2: Unit-3, 4 & 5 (3×150MW)

Figure 2.4-3: GT-1, GT-2 & ST (146 MW CCPP)

Figure 2.4-4: 50 MW GEPP

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 2.5 Vision
To become the leading power generation company in Bangladesh.

2.6 Mission
To increase Ashuganj Power Station‟s Generation Capacity to 1500 MW by 2015.

2.7 The Objective

Enhance the station‟s dependable capacity in order to comply with the government‟s
target to provide electricity for all by 2021 and increase overall thermal efficiency of the
station by installing new plant in order to generate more power consuming the same amount
of gas .

2.8 Present Situation of Generation

SL
GT- 1 GT- 2 ST(cc) UNIT - 1 UNIT - 2 UNIT - 3 UNIT - 4 UNIT -5
No. Particulars
Model & GEC BBC BBC BBC BBC ABB
GEC GEC
Capacity of 69.6 Germany Germany Germany Germany Germany
1 69.6Mva 43 Mva
Turbo- Mva 80 Mva 80 Mva 190 Mva 190 Mva 190 Mva
13.8 Kv 13.8 kv
Generator 13.8 Kv 11.0 kv 11.0 kv 15.75 kv 15.75 kv 15.75 kv
Installed
2 Capacity 56 56 34 64 64 150 150 150
(Mw)
Present
De-rated
3 40 40 18 64 64 105 140 140
Capacity,
MW
Date of
4 Commiss- 15/11/82 23/03/86 28/03/84 17/08/70 8/7/1970 17/12/86 4/5/1987 21/03/88
ioning
Total
Energy
10,575. 22,328. 21,306. 29,767.
5 Generation 5,936.68 6607.73 1,734.07 9,744.33
44 50 43 39
to date ,
Gwh
Cost of fuel
6 perunit 1.30 1.30 0.00 0.93 0.87 0.90 0.90 0.79
Gen.(TK)
Station
Thermal
7 20 20 28 30 31 31 36 36
Efficiency
%
Table 2.8: Present Situation of Generation
Page | 29
2.9 Generation Plan of APSCL-2016 to 2020
Atlanta Enterprise Ltd. in association with the Prokousal Upadesta Ltd. and Institute of Water
Modeling has prepared a master plan for Ashugonj Power Station Company Ltd. According
to that master plan the following projects has been considered for the year of 2016 to 2020.

 Retirement of unit 1 & 2 (2×64=128 MW) and establishment of future 450MW CCPP
Plant.
 Retirement of 146 MW CCPP (GT-1, GT-2 & ST) (2017) and Establishment of
2×150=300 MW Gas turbine power plant (Picking plant) (2020).
 As per the Master plan of APSCL, establishment of 2×850 MW CCPP Plant (new-1
& new-2) in fully new site (site-1).

1. Retirement of unit 1 & 2 (2×64=128 MW) and establishment of future 450MW

CCPP Plant:

Unit-1 and unit-2 will be removed from its site by 2016 and this sitewill be prepared
for future 450MW CCPP. The work for clearing thesite of existing 128MW ST will
be started in due time

Figure 2.9-1: Unit-1&2 (2×64=128MW)

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2. Retirement of 146MW CCPP (GT-1, GT-2 &ST) plant andestablishment of
2×150=300MW GT (peaking plant) as thereplacement of 146 MW CCPP.

Figure 2.9-2: 2×150=300MW GT Power Plant Site

3. 2×850 MW CCPP (New-1 & New-2) will be constructed in new site within 2020.

Currently 39% of total generated gas is used for power generation. To meet up the
demand for power of the country more gas based power plant projects are in progress.
Due to that demand and use of gas is increasing day by day. Alternate fuel is
considered for these two new projects (2×850 MW CCPP) to reduce dependency on
gas .100 acres of land is going to be acquired for these projects.

Figure 2.9-3: 4×850 MW CCPP Project Site

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From 2016 to 2020 the total established generation of the company will be 3828 MW and by
this time the company‘s generation figure will be as below:

Figure 2.9-4: The company total generation graph from 2016 to 2020

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CHAPTER 3

THERMAL POWER PLANT (ST):

Steam is an important medium of producing mechanical energy. Steam has the advantages
that it can be raised from water which is available in abundance it does not react much with
the materials of the equipment of the power plant and is suitable at the temperature required
in the plant. Steam is used to drive steam engines, steam turbine etc. Thermal electrical
power generation is one of the major methods. For a thermal power plant the range of
pressure may vary from 10 kg/cm2 critical pressure and the. range of temperature may be
from 2500C to 6500C.

Figure 3: APSCL Thermal Power Plant (ST-5)

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3.1 Main parts of a steam power plant

1. Boiler (Babcock and Wilcox)

2. Steam turbines (LPT, IPT and HPT)
3. Super heater
4. Heaters (LPH and HPH)
5. Condenser
6. Air Compressor
7. Pumps
8. Economizer
9. Generator

Figure 3.1: Overall water and steam cycle of steam turbine units.

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3.2 Working Cycle
Vapor and gas power systems develop electrical or mechanical power from energy sources of
chemical, solar, or nuclear origin. In vapor power systems the working fluid, normally water,
undergoes a phase change from liquid to vapor, and conversely. In gas power systems, the
working fluid remains a gas throughout, although the composition normally varies owing to
the introduction of a fuel and subsequent combustion.

In thermo dynamic point of view Steam Turbine Power Plant works under Rankin cycle.
In case of Steam Turbine heat of combustion is carried out through water vapor and
transferred in to mechanical power or work out put through Turbo-generator.
There are four processes in the Rankine cycle, each changing the state of the working fluid.
These states are identified by number in the diagram.

3.2.1 Rankine Cycle:

Figure 3.2.1: Symple Rankine Cycle

In an ideal Rankine cycle the pump and turbine would be isentropic, i.e., the pump and
turbine would generate no entropy and hence maximize the net work output. Processes 1-2
and 3-4 would be represented by vertical lines on the Ts diagram and more closely resemble
that of the Carnot cycle. The Rankine cycle shown here prevents the vapor ending up in the
superheat region after the expansion in the turbine, which reduces the energy removed by the
condensers.

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 Figure 3.2.1-1: Rankine Cycle

 Process 1-2: The working fluid is pumped from low to high pressure, as the fluid is a
liquid at this stage the pump requires little input energy.
 Process 2-3: The high pressure liquid enters a boiler where it is heated at constant
pressure by an external heat source to become a dry saturated vapor.
 Process 3-4: The dry saturated vapor expands through a turbine, generating power.
This decreases the temperature and pressure of the vapor, and some condensation may
occur.
 Process 4-1: The wet vapor then enters a condenser where it is condensed at a
constant pressure and temperature to become a saturated liquid. The pressure and
temperature of the condenser is fixed by the temperature of the cooling coils as the
fluid is undergoing a phase-change.

In an ideal Rankine cycle the pump and turbine would be isentropic, i.e., the pump and
turbine would generate no entropy and hence maximize the net work output. Processes 1-2
and 3-4 would be represented by vertical lines on the Ts diagram and more closely resemble
that of the Carnot cycle. The Rankine cycle shown here prevents the vapor ending up in the
superheat region after the expansion in the turbine, which reduces the energy removed by the
condensers.

Page | 36
3.2.2 Rankine cycle with superheat:

Figure 3.2.2: Rankine cycle with superheat

In a real Rankine cycle, the compression by the pump and the expansion in the turbine are not
isentropic. In other words, these processes are non-reversible and entropy is increased during
the two processes. This somewhat increases the power required by the pump and decreases
the power generated by the turbine. In particular the efficiency of the steam turbine will be
limited by water droplet formation. As the water condenses, water droplets hit the turbine
blades at high speed causing pitting and erosion, gradually decreasing the life of turbine
blades and efficiency of the turbine. The easiest way to overcome this problem is by
superheating the steam. On the Ts diagram above, state 3 is above a two phase region of
steam and water so after expansion the steam will be very wet. By superheating, state 3 will
move to the right of the diagram and hence produce a dryer steam after

3.2.3 Rankine cycle with reheat:

In this variation, two turbines work in series. The first accepts vapor from the boiler at high
pressure. After the vapor has passed through the first turbine, it re-enters the boiler and is
reheated before passing through a second, lower pressure turbine. Among other advantages,
this prevents the vapor from condensing during its expansion which can seriously damage the
turbine blades, and improves the efficiency of the cycle

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 Figure 3.2.3: Rankine cycle with reheat

3.2.4 Regenerative Rankine cycle:

The regenerative Rankine cycle is so named because after emerging from the condenser
(possibly as a sub-cooled liquid) the working fluid is heated by steam tapped from the hot
portion of the cycle. On the diagram shown, the fluid at 2 is mixed with the fluid at 4 (both at
the same pressure) to end up with the saturated liquid at 7. The Regenerative Rankine cycle
(with minor variants) is commonly used in real power station.

Figure 3.2.4: Regenerative Rankine cycle

3.2.5 Efficiency of a Rankine cycle:

The efficiency of a Rankine cycle is usually limited by the working fluid. Without the
pressure going super critical the temperature range the cycle can operate over is quite small,
turbine entry temperatures are typically 565°C (the creep limit of stainless steel) and
condenser temperatures are around 30°C. This gives a theoretical Carnot efficiency of around

Page | 38
63% compared with an actual efficiency of 42% for a modern coal-fired power station. This
low turbine entry temperature (compared with a gas turbine) is why the Rankine cycle is
often used as a bottoming cycle in combined cycle gas turbine power stations.

3.3 Working principle

1. At first water is feed into the boiler and heated by the furnace heat. A boiler contains
9 furnace where each furnace having about 12000C.
2. In boiler the separation line separates the steam from water. Water evaporates
through natural circulation with down comer.
3. Then steam is super heated and passed through the high pressure turbine
(HPT).
4. After discharging from HPT the temperature and pressure decreases and again
reheated to get proper temperature.
5. Then it passes through the intermediate and low pressure turbine. It rotates the turbine
at a high speed.
6. The shaft of the turbines is coupled with the shaft of generator. Since the turbine
rotates, the generator shaft also rotates and produces electricity.
7. Then the steam is condensed at condenser by river water. After condensing the steam
turns into water. Then the water is pumped to the low pressure
8. Then the water is pumped into deareator and removed oxide particle and Oxygen gas.
9. Then the water is pumped into Feed Water Tank (FWT) and passes through the High
Pressure Heater (HPT).
10. Finally the water is feed into boiler drum and the process circulated in cyclic order
11. All the units are controlled by manually except the unit-5. It follows DCS (Digital
Control System).

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CHAPTER 4

BOILER
A boiler is a closed vessel in which water or other fluid is heated under pressure. The steam
or hot fluid is then circulated out of the boiler for use in various process or heating
applications.

4.1 Layout of APSCL ST-5 Boiler

Figure 4.1: Layout of APSCL ST-5 Boiler

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Figure 4.1.1: Layout of APSCL ST-5 Boiler

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4.2 Classification
The main classifications of boilers are
 According to tube contents the boilers are classified into two types.
1. Water tube boiler
2. Fire tube boiler
 According to the position of the furnace-
1. Internally fired
2. Externally fired
 According to the axis of the shell
1. Vertical
2. Horizontal
 According to the number of tubes
1. Single number
2. Mmultimember
 According to the method of circulation of water and steam circulation
1. Natural circulation
2. Forced circulation
 According to the pressure in the boiler
1. High pressure
2. Low pressure

4.3 Purpose of boiler

 For power generation as in case of steam engine or turbine.
 For processing as in case of industrial purpose like sizing, bleaching etc. In a textile
industry or other industrial purposes.
 For heating as in case of heating installation for buildings.

4.4 Fire tube boilers

In fire tube steam boilers, the flames and hot gases, produced by the combustion of fuel, pass
through the tubes which are surrounded by water. The heat is conducted through the walls of the
tubes from the hot gases to the surrounding water. For example: Simple vertical boiler, Cochran
boiler, Cornish boiler, Locomotive boiler etc.

4.5 Water tube boilers

A watertube boiler is a type of boiler in which water circulates in tubes heated
externally by the fire. Water tube boilers are used for high-pressure boilers. Fuel is
burned inside the furnace, creating hot gas which heats water in the steam-generating
tubes. In smaller boilers, additional generating tubes are separate in the furnace, while
larger utility boilers rely on the water-filled tubes that make up the walls of the
furnace to generate steam. For example: Babcock and Wilcox boiler, Benson boiler,
La-Mont boiler etc.

Page | 42
 Figure 4.5: Overall water and steam cycle of steam turbine units.

4.6 Babcock and Wilcox boiler

It is a stationary type water tube boiler. It consists of a steam and water drum. It is
connected by a short tube with uptake header or riser at the back end. The water tubes are
inclined to the horizontal and connect the uptake header to the down take header. Each row
of the tubes is connected with two headers and there are plenty of such rows. The headers
are provided with hand Ther is a slow moving automatic boiler chain gate. A fire brick
baffle causes hot gases to move upwards and downwards and again upwards before
leaving the chimney. There is a fire chamber inside of the boiler and it consists of 9 furnaces.
In APSCL each furnace produces about 12000C temperature. It has a steam super heater
consists of large numbers of steel tubes and two boxes. One is saturated steam box and
another is super heated steam box.

4.7 UNIT NO: 3,4,5

Boiler type- Forced draught natural circulation.

Manufacture- IHI, Japan (Ishikaw heavy Industries)
There are three types of draught-
1) Forced draught
Page | 43
2) Natural draught
3)Induced draught
It is called natural circulation. Because the water is in the upper portion of boiler. The
characteristics of water are to flow down. The steam is produced after burning. The
characteristics of steam are to move upward. So circulation occurs naturally.

4.8 Basic Requirement for Producing Power

- Gas (most costly)
- Water (less cost)
- Air (full free)
Electricity has been produced by processing these three elements . Gas is most costly.
So the cost decreased by saving gas .

4.8.1 Air:
For gas consumption, air preheating system is used. The main purpose of air preheater is to
develop efficiency. Air-preheater is used in 1,2,3,4,5 NO UNIT. The air preheater used in
Ashuganj is recuperative type air pre-heater. There are 850 tube in air pre-heater. The air
passes through the tubes.

4.8.2 Gas:
Gas is supplied by Titas gas initial temperature of gas is about 8-90C. The heating of gas is
done by heat exchanger. Two type of tubes in heat exchanger. One for gas flow and other for
steam flow. By this way, the gas is heated.

The existing Titas gas RMS situated in Ashuganj Power Station Complex is receiving gas
supply at a pressure of 1000psi (present pressure is 700 – 800psi) through a 10″ dia pipe from
the valve station. In the Titas RMS the gas pressure is regulated and three different pipe lines
are in use to supply gas to the power station complex. The 450MW (3×150) receives gas at a
pressure of 500psi (present pressure 470psi) through a 10″ dia pipe, the 128MW (2×64)
receives gas at a pressure of 65psi through a 16″ dia pipe and the 90MW CCPP (56MW GT1
+ 34MW ST) and the 2nd unit of GT 56MW receives gas at a pressure of 500psi (present
pressure 330psi) through an 8″ dia pipe.

Figure 4.8.2: Gas Supply

Page | 44
4.8.3 Working principle:
Air is supplied from air register. Gas is supplied from gas station. The mixture of air and gas
is done by mixing plate. The ratio of air: fuel is about 10:1. The fire is produced by ignition
phenomena.

As a result of burning, the steam is produced. The steam is gathered on boiler

drum. The upper portion is steam and lower portion is water. The water goes to
the boiler drum through economizer from feed pump. There are four down comer.
The water falls down through the down comer. Initial temperature of steam is
about 330 0C and final temperature of super-heated steam is 5250C. There are
three super -heater. The live steam goes to the turbine from super heater . There
is no water particles in live steam.
The temperature and pressure of steam decreases after using. Then the steam is
again send to the boiler. Then the steam is reheated. When it comes, is called cold
re-heated and when is leaves, called hot re-heated.

Page | 45
CHAPTER 5

BOILER PARTS
It can be described at four parts

- Major Components
- Boiler Mountings
- Boiler Accessories
- Boiler Auxilary

5.1 Major Components

5.1.1 Boiler Drum:

The steam and water mixture enters the steam drum through riser tubes, drum internals
consisting of demister separate the water droplets from the steam producing dry steam. The
saturated water at the bottom of the steam drum flows down through the downcomer pipe,

Figure 5.1.1: Boiler Drum

normally unheated, to headers and water drum. Its accessories include a safety valve, water-
level indicator and level controller. Feed-water of boiler is also fed to the steam drum
through a feed pipe extending inside the drum, along the length of the steam drum.

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 Figure 5.1.1-2: Boiler Drum
5.1.1.1 Steam separator:
It is a device used for separating suspended water particles carried by the steam on its way
from the boiler to the engine. Stationary boilers and nuclear reactors may have more
complex devices which impart a "spin" to the steam so that water droplets are thrown
outwards by centrifugal force and collected.

Figure 5.1.1.1: Steam separator

It is important to remove water droplets from steam because:

 In all engines, wet steam reduces the thermal efficiency

 In piston engines, water can accumulate in the cylinders and cause a hydraulic
lock which will damage the engine

Page | 47
  In thermal power stations, water droplets in high velocity steam coming from
nozzles (or vanes) in a steam turbine can impinge on and erode turbine internals
such as turbine blades.
5.1.2 Header:
Two types of header
a)Inlet header
b)Outlet header

Figure 5.1.2: Header

5.1.3 Down Comer:
From boiler drum water pass through the down comer to Inlet header.

Figure 5.1.3: Down comer

5.1.4 Water-wall Tube:
In this tubes water absorve heat and become steam
Outside Diameter 63.5 mm
Page | 48
Thickness- 5.1 mm Material- SA 210 C

Figure 5.1.4: Water wall tube

5.1.5 Burner:
• Electric Ignition system
• Fuel-Natural gas
• Air Temperature 88-130C
• Fuel Temperature 25-30C
• Fuel pressure 5.2bar

Figure 5.1.5: Sectional and practical view of Burner

Page | 49
5.2 Boier Mountings

These are the fittings which are mounted on the boiler for its proper functioning. They are
described in below:

5.2.1 Safety valves:

The function of safety valves is to prevent the steam pressure in the boiler
exceeding a predetermined maximum pressure. Various kinds of safet y valves are
used such as spring loaded safety valve, dead weight safety valve, lever safety valve,
high steam and low water safety valve etc. Among them dead weight safety valve is
used for Lancashire boiler and lever safety valve for stationary boiler.

Figure 5.2.1: Safety valves

5.2.2 Water level indicators: Water level indicator indicates the exact level of water at
any time in the boiler.

Figure 5.2.2: Water level indicators

Page | 50
5.2.3 Stop valve:
Stop valve is also called junction valve. The function of stop valve is to shut off steam or
control the flow of steam from boiler to main steam pipe to requirements.

Figure 5.2.3: Stop valve

5.2.4 Pressure gauge:

Pressure gauge show the pressure of steam formed at any time.

Figure 5.2.4: Pressure gauge

5.2.5 Blow off cock: It is used to remove mud, scale or sediments collected at the bottom
of the boiler. It is also used to empty the boiler when required.

Page | 51
5.2.6 Feed check valve:
It is used to control the supply of water into the boiler. It does not allow any water to flow
back from the boiler.

Figure 5.2.6: Feed check valve

5.2.7 Fusible plug: It is used to put off the fire in the furnace of the boiler when the level
of water falls to an unsafe limit.

5.3 Boiler Aaccessories

These are the devices, which form an integral part of a boiler and help in running the boiler
efficiently. They are described in below:

5.3.1 Economizer:
It is a device used for heating feed water which is supplied to the boiler by utilizing the heat
in the exhaust flue gases before leaving through the chimney. Economizers, are mechanical
devices intended to reduce energy consumption, or to perform useful function such as
preheating a fluid. The term economizer is used for other purposes as well. Boiler, power
plant, heating, ventilating, and air conditioning (HVAC) uses are discussed in this article. In
simple terms, an economizer is a heat exchanger In boilers, economizers are heat exchange
devices that heat fluids, usually water, up to but not normally beyond the boiling point of that
fluid. Economizers are so named because they can make use of the enthalpy in fluid streams
that are hot, but not hot enough to be used in a boiler, thereby recovering more useful
enthalpy and improving the boiler's efficiency. They are a device fitted to a boiler which
saves energy by using the exhaust gases from the boiler to preheat the cold water used to fill
it (the feed water).

Page | 52
 Figure 5.3.1: Economizer

5.3.2 Super heater:

It is a device used for drying wet steam and then increase the temperature of dry steam
without increasing its pressure by utilizing the heat of combustion products. Fossil fuel power
plants often have a superheater section in the steam generating furnace. The steam passes
through drying equipment inside the steam drum on to the superheater, a set of tubes in the
furnace. Here the steam picks up more energy from hot flue gases outside the tubing and its
temperature is now superheated above the saturation temperature. The superheated steam is
then piped through the main steam lines to the valves before the high pressure turbine.

Figure 5.3.2: Super heater

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5.3.3 Feed pump:
It is used for pumping water to the boiler. A boiler feedwater pump is a specific type of
pump used to pump feedwater into a steam boiler. The water may be freshly supplied or
returning condensate produced as a result of the condensation of the steam produced by the
boiler. These pumps are normally high pressure units that take suction from a condensate
return system and can be of the centrifugal pump type or positive displacement type.

5.3.3.1 Feed pump specification:

This pump is used to supply feed water in to the boiler. It also keeps the water curculation on
boiler. It‘s required power is 4640kw, suction pressure is 18bar boost pressure is 160bar,
capacuty is 629T/h and rpm is 5712.

Figure 5.3.3: Feed pump

5.3.4 Steam trap: It is used to drain of water resulting from the partial
condensation of steam from steam pipes.

5.3.5 Air pre-heater:

It is a device used to heat the air before it flows into the furnace for combustion by utilizing
the heat in the exhaust flue gas. An air preheater (APH) is a general term used to describe any
device designed to heat air before another process (for example, combustion in a boiler) with
the primary objective of increasing the thermal efficiency of the process. They may be used
alone or to replace a recuperative heat system or to replace a steam coil.

Page | 54
In particular, this article describes the combustion air preheaters used in large boilers found in
thermal power stations producing electric power from e.g. fossil fuels, biomass or waste.
The purpose of the air preheater is to recover the heat from the boiler flue gas which
increases the thermal efficiency of the boiler by reducing the useful heat lost in the flue gas.
As a consequence, the flue gases are also conveyed to the flue gas stack (or chimney) at a
lower

Figure 5.3.5: Air pre-heater

temperature, allowing simplified design of the conveyance system and the flue gas stack. It
also allows control over the temperature of gases leaving the stack.

5.3.6 Pressure reducing valve: It is used for maintaining constant pressure in the steam
supply pipe line.

5.3.7 Spray Attemperator: Spray attemperator is used to control the temperature of

superheated steam.

Figure 5.3.7: Spray Attemperator

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5.3.8 Forced draft fan:
It is a device used for creating positive preesure in the boiler. It’s required power is
960kw,working pressure is 93mbar and rpm is 1480.

Figure 5.3.8: Forced draft fan

5.3.9 Draught:
A fuel-heated boiler must provide air to oxidize its fuel. Early boilers provided this stream of
air, or draught, through the natural action of convection in a chimney connected to the
exhaust of the combustion chamber. Since the heated flue gas is less dense than the ambient
air surrounding the boiler, the flue gas rises in the chimney, pulling denser, fresh air into the
combustion chamber.
Most modern boilers depend on mechanical draught rather than natural draught. This is
because natural draught is subject to outside air conditions and temperature of flue gases
leaving the furnace, as well as the chimney height. All these factors make proper draught
hard to attain and therefore make mechanical draught equipment much more reliable and
economical.

Figure 5.3.9: Draught

Page | 56
5.3.10 Reheater:
Power plant furnaces may have a reheater section containing tubes heated by hot flue gases
outside the tubes. Exhaust steam from the high pressure turbine is passed through these
heated tubes to collect more energy before driving the intermediate and then low pressure
turbines.

Figure 5.3.10: Reheater

5.4 Boiler Auxilary

5.4.1 HP heater:
HP heater means High Pressure heater.It is a closed type heater These heaters are used to pre-
heat water delivered to a steam generating boiler. Preheating the feed water reduces the
irreversibility‘s involved in steam generation and therefore improves the thermodynamic
efficiency of the system. This reduces plant operating costs and also helps to avoid thermal
shock to the boiler metal when the feed water is introduced back into the steam cycle.
Here feed water is heated by using super heated steam which coming from High Pressure
turbine’s extraction line. There are two HP heaters in every ST unit in APSCL. This heater
heated the water before it goes to the Economizer.

Figure 5.4.1: HP heater

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5.4.2 LP heater:
LP heater means LowPressure heater.It is a closed type heater. Here feed water is heated by
using super heated steam which coming from Low Pressure turbine’s extraction line. This
heater heated the water before it goes to the Feed water Tank.

Figure 5.4.2: LP heater

5.4.3 Condenser:
It is used to condense the steam. The condenser condenses the steam from the exhaust of the
turbine into liquid to allow it to be pumped. If the condenser can be made cooler, the pressure
of the exhaust steam is reduced and efficiency of the cycle increases.
The surface condenser is a shell and tube heat exchanger in which cooling water is circulated
through the tubes. The exhaust steam from the low pressure turbine enters the shell where it
is cooled and converted to condensate (water) by flowing over the tubes as shown in the
adjacent diagram. Such condensers use steam ejectors or rotary motor-driven exhausters for
continuous removal of air and gases from the steam side to maintain vacuum.
For best efficiency, the temperature in the condenser must be kept as low as practical in order
to achieve the lowest possible pressure in the condensing steam. Since the condenser
temperature can almost always be kept significantly below 100 °C where the vapor pressure
of water is much less than atmospheric pressure, the condenser generally works under
vacuum. Thus leaks of non-condensible air into the closed loop must be prevented.

Figure 5.4.3: Diagram of a typical water-cooled surface condenser.

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4.4.4 Feed Tank:
From condenser water stored in feed tank.Its capacity is 172ton

Figure 5.4.4: Feed Tank

5.4.5 Dearator:
A deaerator is a device that is widely used for the removal of oxygen and other dissolved
gases from the feedwater to steam-generating boilers. In particular, dissolved oxygen in
boiler feedwaters will cause serious corrosion damage in steam systems by attaching to the
walls of metal piping and other metallic equipment and forming oxides (rust). Dissolved
carbon dioxide combines with water to form carbonic acid that causes further corrosion.

Figure 5.4.5: Dearator

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5.4.6 Make up water tank:
This is a storage tank of Feed water.
Capacity-231 ton
Max allowable temp-120˚C
Max allowable working pressure -1/1bar

Figure 5.4.6: Make up water tank

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CHAPTER 6
BOILER STARTUP SHUTDOWN AND CONTROL

6.1 Startup Procedure

6.1.1 Pre-Startup walkthrough:

Before starting up a boiler an operator should to make an walk through of the boiler to make
sure that everything needed for startup is available and operating properly.

6.1.2 Filling the boiler drum:

Filling the steam drum and other boiler components accomplshes two things:

 It forces air out of the waterwall tubes.

 IT brings the drum water level to an acceptable firing level.
The firing level and the normal operating water level in a steam drum may be
different.Typically, a steam drum is between 1/3 and ½ full during normal operation.

6.1.3 Establishing Flow Through the Boiler:

When the steam drum is filled to the established firing level, the operator’s next job is to
provide the proper conditions for starting flow through the boiler. The continuous fliw of
water, which later becomes steam, Is important to keep the boiler and its components cool.

6.1.4 Preparation for Light-off:

Usually, the first step in this procedure is to start the air preheater.With the air preheater
started, the operator next has to establish aflow of air through the boiler by forced draft fan.

6.1.5 Lighting of the boiler:

The procedures for light off usually begin with sparking the ignitors. In most cases, a large
spark plug is used to produce the spark that lights off the boiler flame.

6.1.6 Warming up the Boiler:

When the ignitor flame is stable, The operator inserts a warm up burner in to the boiler. The
warmup burner is then connected to the boiler and the fuel and air atomization lines for the
warmup burner are opened.

6.2 Basic Shutdown Procedure

6.2.1 Reducing Firing rate:

The first step in shutting down a boiler is to reduce firing rate in accordance with plant’s
operating procedure.As with startup, temperature and pressure must be reduced gradually to
protect the boiler components.
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6.2.2 Reducing Steam Flow:
As steam floe decreases, Feedwater flow to the boiler must be reduced. The reduction in
feedwater flow is matched with the decrease in steam flow so that the water level in the boiler
remains constant.

6.2.3 Reducing Air and Gas Flow:

The forceddraft fan is the last component to be shut down.This fan is used to purge the boiler
of combustibles and to aid in the cooling of the boiler and its components

6.3 Control of boiler

One of the controls of power plant is boiler control which is an important part of a power
plant. APSCL uses different types of control for different parts and purposes of the boiler.
Most of the controls are auto control which are controlled from the control room. There is
also manual control for each auto control. If any auto control fails, then it is controlled
manually. Some of the control parts of boiler at APSCL are discussed.

6.3.1 Ratio control:

At APSCL, ratio control is used to ratio the quantity of air required for different fuels. The
ratio of fuel and air requirement is set initially at 1:15. The set point of the controlled
variables changes in direct proportion to change in the uncontrolled variable.

6.3.2 Furnace pressure control:

Furnace pressure control is required to maintain a constant pressure in the boiler furnace. At
APSCL, furnace pressure is controlled by FD and ID fans. For the pushing air of FD fans in
to the furnace, flame tries to exert outside which may cause external fire to the boiler. Block
diagram of furnace control is shown in figure 6.3.2

Figure 6.3.2: Block diagram of boiler control- furnace control .

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6.3.3 Drum level feed water control:
The drum level must be controlled at specific limits which are specified by the boiler
controller. If the level exceeds the limits, boiler water carry over into the super-heater or
turbine may cause damage. This type of fault increases the maintenance costs or outages of
either the turbine or the boiler. If the level is low, overheating of water wall tubes may cause
damage and serious accident.

Figure 6.3.3: Boiler drums/level measurement

The boiler of the APSCL uses differential pressure transmitter which represents the level
control measurement and probe type sensor which gives level alarms and low and high
shutdown. A boiler drums level measurement system is shown in figure 3.8 which contains a
differential transmitter and a sensor.

6.3.4 Single element level control:

Single element level control gets input from only one process variable. This type of control is
used to control the feed water storage system of a boiler. In single element level control
system, the level transmitter sends a signal to the level controller and then the signal is
compared to the set point. APSCL uses this type of control for storage tank where water level
is the single process variable input. A storage tank of APSCL is shown in figure 3.9.

Figure 6.3.4: Storage tank of a boiler .

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6.3.5 Two element level control:
In this control system, there are two elements available where steam flow is controlled in
addition to drum level. This control system has a secondary variable which has a predictable
relationship with the manipulated variable. This control system is used in the boiler where
feed water is controlled at a constant pressure. At APSCL, this control system is used for feed
water control in unit 1 and 2, where feed water is controlled at a constant pressure (93 bar).
The steam flow adjusts the feed water control valve based on steam flow signal and the drum
level controller signal. As steam flow increases or decreases, the steam flow adjusts the
output of the feed water tank and directly sets the feed water final element.

6.3.6 Three element level control:

In this control system, there are three elements available where steam flow and feed water
flow is controlled in addition to drum level. This control system is used in the boiler where
feed water is controlled at variable pressure. APSCL also uses this type of control system for
feed water control in unit 3, 4 and 5, where feed water is controlled at variable pressure (at
super-heater 135 bar and at re-heater 36 bar). The steam flow adjusts the feed water control
valve based on steam flow signal and the drum level controller signal. As the steam flow
increases or decreases, the steam flow adjusts the output of the feed water tank and directly
sets the feed water controller at set point. Control is improved by adding mass flow
compensation to drum level, steam flow, and water flow. In this control system, feed water
flow is measured equal to steam flow to maintain the drum level.

6.3.7 Burner management system:

Burner is an important part of a boiler which burns the fuel to provide heat for producing
steam. At APSCL, there are nine burners in each boiler. These burners burn the natural gas
and produce heat. APSCL uses a control system for the burners so that it can control and save
the heat.

Figure 6.3.7: One burner of a boiler of APSCL

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Burning management system is an on/off control system. The system monitors the fuel
burning equipments during startup, shutdown and operation of the boiler. When the system is
in safe mode, burning will start at any load. If any unsafe condition occurs, the system
automatically shuts off fuel flow. One burner of APSCL is shown in figure 3.10.

6.3.8 Purge control:

Purging is required before ignition of the first burner to clear any combustibles from the
boiler. This is the critical time before the lighting of the first burner. Purge air flow must not
be less than 70 percent of the maximum air flow required for a unit. APSCL purges the
furnace for four minutes to fully clear the boiler gas passages. During the purge, the air
damper is driven to the full open position.

6.3.9 Flame detection:

Flame detection is very important for a burner of a boiler. Without flame detection, burner
will not get proper heat at proper position.

Figure 6.3.9: Flame detection .

At APSCL, visible light, infrared (IR) and ultraviolet (UV) technologies are used for flame
detection. Flame configuration is shown in figure 3.11 where infrared (IR) and visible light is
90% of the flame and ultraviolet is between 1to 10 percent of the flame.

6.3.10 Flame tripping validation:

APSCL uses flame tripping concept. If there is any loss in burner flame, the burner safety
shut off valve is automatically closed. The burner is also closed, if its flame interferes with
the air/fuel ratio supplied to any other individual burner flame.

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 Figure 6.3: Control System of water & steam cycle

Figure 6.3: Control system of Feedwater and Boiler Feed Pumps

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 Figure 6.3: Control system of Condenser

Figure 6.3: Control system of Boiler Air & Flue Gas system

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 Figure 6.3: Burner control

Figure 6.3: Control SyStem of Fuel Gas system

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 Figure 6.3: Burner control

Figure 6.3: Control of Lube oil System

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Figure 6.3: C0ntrol of Bearing temperatures

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CHAPTER 7
TURBINE

A turbine is a rotary engine that extracts energy from a fluid flow and converts it into useful
work. The simplest turbines have one moving part, a rotor assembly, which is a shaft or drum
with blades attached. Moving fluid acts on the blades, or the blades react to the flow, so that
they move and impart rotational energy to the rotor

Figure 7: Steam turbine of unit-5 of APSCL.

Figure 7-1: Steam turbine section of unit-5 of APSCL.

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7.1 Types of turbine
On the basis of principle of operation

 Impulse turbine
 Reaction turbine

7.1.1 Impulse turbines:

These turbines change the direction of flow of a high velocity fluid or gas jet. The resulting
impulse spins the turbine and leaves the fluid flow with diminished kinetic energy. There is
no pressure change of the fluid or gas in the turbine rotor blades as in the case of a steam or
gas turbine, all the pressure drop takes place in the stationary blades.

Before reaching the turbine, the fluid's pressure head is changed to velocity head by
accelerating the fluid with a nozzle. Impulse turbines do not require a pressure casement
around the rotor since the fluid jet is created by the nozzle prior to reaching the blading on the
rotor. Newton's second law describes the transfer of energy for impulse turbines.

7.1.2 Reaction turbines:

These turbines develop torque by reacting to the gas or fluid's pressure or mass. The pressure
of the gas or fluid changes as it passes through the turbine rotor blades. A pressure casement
is needed to contain the working fluid as it acts on the turbine stages or the turbine must be
fully immersed in the fluid flow. The casing contains and directs the working fluid and, for
water turbines, maintains the suction imparted by the draft tube. Francis turbines and most
steam turbines use this concept. For compressible working fluids, multiple turbine stages are
usually used to harness the expanding gas efficiently. Newton's third law describes the
transfer of energy for reaction turbines.

7.2 Types of turbine in use

 Steam turbine
 Gas turbine
 Water turbine
 Wind turbine
 Transonic turbine
 Ceramic turbine

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7.3 Steam turbine
Steam turbine is such type of turbine where steam is used as working fluid. When steam is
injected over the blades it rotates at a certain speed. Since steam is used for rotation it is
called steam turbine. Generally it is used at steam turbine power station.

Figure 7.3: Steam Turbine with casing.

In Ashuganj power station, steam turbines are used for steam turbine units. All the turbines
are manufactured by BBC (Germany).

7.3.1 Main parts of steam turbine:

 Rotor
 Blades (fixed and moving)
 Bearings (thrust and journal)
 Turbine casing
 Valves (main stop valve, control valve etc).

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 Figure 7.3.1: Sectional view of steam turbines

7.3.2 Rotor assembly:

The turbine rotor assembly consists of the turbine shaft and the attached moving blade. The
rotor assembly absorbs energy from working fluid (steam, gas, water etc) and converts that
energy into mechanical energy.

7.3.3 Turbine blades:

The energy conversion takes place through the turbine blades. A turbine consists of alternate
rows of blades. This blades convert the chemical or thermal energy of working fluid into
kinetic energy and then from kinetic energy to mechanical energy as rotation of the shaft.

There are two types of blade, fixed and moving blade. Moving blade is also two types. One is
impulse blade and another reaction blade.

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7.3.4 Fixed blade:
A fixed blade assembly is very important for turbine blading. It is also known as diaphragm.
The shape of the blade is the key to the energy conversion process. Since the fixed blades
have a conversing nozzle shape, it is also called nozzles. When steam is passed over the fixed
blades, they increase the velocity of steam as an operation of nozzles. Here blades are
converted the thermal energy of steam into kinetic energy by causing the steam to speed up
and gain velocity.

Figure 7.3.4: Fixed blade

7.3.5 Moving blade:

Moving blade can be shaped in either of two ways: reaction shaped or impulse shaped. The
shape of the blade determines how the energy is actually converted. Either type of moving
blades or a combination of both can be attached to the shaft of the rotor on dices, called
wheels as shown in the figure. Along the outer rim of the blades is a metal band, called
shrouding which ties the blades together. The moving blades convert the kinetic energy in the
moving speed into the mechanical energy as rotor rotation.

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 Figure 7.3.5: Moving blade

Depending on pressure steam turbines are three types.

7.3.6 High Pressure Turbine (HPT):

The high pressure (HP) turbine is the first main engine turbine to receive steam from the
super heater. It is designed to efficiently extract work out of high pressure steam. As steam
impacts the moving blades, it pushes the blades forward. This impact causes the steam to lose
velocity without losing pressure.

7.3.7 Intermediate Pressure Turbine (IPT):

From the boiler re-heater, the steam enters into the intermediate pressure turbine. IPT blades
are larger than HPT blades and blades are fixed with the shaft. Thus, steam hits the blades to
rotate the shaft.

7.3.8 Low Pressure Turbine (LPT):

The LPT is located next to the IPT. Steam comes from IP turbine to LP turbine. In low
pressure the steam expands and creates pressure on the turbine blades. LPT blades are
comparatively larger than others. So the steam entering LP chamber is at a lower pressure
than others
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 Figure 7.3.8: HP,IP and LP turbine at a glance.

7.3.9 Blading stages:

Two successive fixed and moving blades are collectively known as blading stage. The effects
of pressure and velocity of working fluids depend upon the stage conditions. In Ashuganj
power station, the turbines which are used have 23 stages at HP turbine and 21 stages at IP &
LP turbine. Now the effects of pressure and velocity on various blading stages are described
in below:

Figure 7.3.9: Velocity and pressure diagram of fluid.

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For impulse blading velocity increases and pressure decreases across each row as the steam
passes through the fixed blading. Again when steam passes through the impulse type moving
blade, its velocity decreases, but its pressure remains constant as shown in the figure.

For reaction blading velocity increases and the pressure decreases across each row as the
steam passes through the fixed blading. When steam passes through the reaction type moving
blade, its pressure and velocity both decreases as shown.

7.4 Valves
Steam from the boiler is routed to the turbine through a steam line that contains the main stop
valves and the control valves.

7.4.1 Main stop valves:

It is such a valve through which steam passes to the turbine blades. By controlling this valve
steam flow can be controlled. Each main stop valve consists of a valve disk, a valve stem and
a hydraulic actuator.

The hydraulic actuator contains a piston and a compression spring. Since the valve disk and
stems are connected to the piston, movement of the piston causes movement of the valve
disc. During normal turbine operation, hydraulic oil is directed into or out of the hydraulic
actuator. Directing oil into the actuator opens the valve and compress the spring, as shown in
figure (1).

As long as the amount of oil in actuator is held constant, the valve will remain in the same
position. Bleeding oil from the actuator allows the spring to push on the piston, closing the
valve. Tripping the turbine causes hydraulic oil to be bled quickly from beneath the piston,
allowing the spring to quickly shut the valve. Steam pressure also helps to close the valve by
forcing the disc back toward the seat. When the valve is closed as shown in figure (2), the
flow of steam toward the HP turbine is shut off.

Figure 7.4.1: Main stop valves

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7.4.2 Control valves:
When the main stop valves are fully opened, the flow of steam into the HP turbine is usually
regulated by four or more control valves. The control valves regulate the turbine speed or its
power output. Steam from the main stop valve flows to the control valves through a steam
line. The steam is sent to different sections of the turbines nozzle block through the four
steam lines below the control valves. Each control valve feeds only one section of the nozzle
block.

The control valves are operated by hydraulic actuators. The control valves regulate steam
flow into the turbine by opening and closing in sequence. As each valve is opened, more
steam is admitted to the turbine. During normal operation, the control valves are
automatically positioned to compensate for changes in load. For example, if load increases,
the control valves are opened more which increase the flow of steam into the turbine. If load
decreases, the control valves are closed more which decrease the flow of steam into the
turbine. At full condition, all the control valves are completely opened as shown in the figure.

7.5 Bearing
There are two types of bearings used in turbine section

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7.5.1 Journal bearing:
Journal bearings consist of a shaft or journal which rotates freely in a supporting metal sleeve
or shell. There are no rolling elements in these bearings. Their design and construction may
be relatively simple, but the theory and operation of these bearings can be complex. This
article concentrates on oil- and grease-lubricated full fluid film journal bearings; but first a
brief discussion of pins and bushings, dry and semi lubricated journal bearings, and tilting-
pad bearings.

Figure 7.5.1: Journel bearing.

7.5.2 Thrust bearing:

A thrust bearing is a particular type of rotary rolling-element bearing. Like other bearings
they permit rotation between parts, but they are designed to support a predominately axial
load.

Figure 7.5.2: Thrust bearing

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7.6 Lubrication

Figure 7.6: Lubrication system

7.6.1 Lubricating Equipments:

7.6.2 Lube Oil tank:

It is a central lube oil storage from where the oil is supplied according to neccessary.
Capcity: It’s capacity is 50*205kg

Figure 7.6.2: Lube oil Tank

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7.6.3 Centrifuge pump:
It is used as a water separator.

rpm-9850,required power6.6kw

Figure 7.6.3: Centrifuse pump

7.6.4 Lube oil cooler:

It is used to cooled the lube oil.

Figure 7.6.4: Lube oil cooler

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Figure shows the lubrication system used in a Steam turbine plant. Sufficient oil is stored in
an external tank to replace that, which may be lost during the normal duration of run. Oil is
drawn from the tank by a gear or rotor type lubrication pump. A relief valve is fitted to return
the excess oil to the pump inlet than that required for lubrication. The oil flows through a
paper or metal screen filter of 10 to 40 micron filtration capacity. In the case of clogged filter,
the oil pressure drop across the filter increases which causes a by-pass valve to open and
unfiltered oil to reach the bearings. This is undesirable. For such malfunctions, various;
warnings, safety and indicating devices such as oil temperature indicator bulb, oil over
temperature switch, low oil pressure switch and so on are installed in the filtered oil line.

7.6.5 Lubeoil:
The ISO grade number indicated is the preferred grade for speed and temperature range. ISO
68- and 100-grade oils are commonly used in indoor, heated applications, with 32-grade oils
being used for high-speed (10,000 RPM) units and some outdoor low-temperature
applications. Note in the table that the higher the bearing speed, the lower the oil viscosity
required; and that the higher the operating temperature of the unit, the higher the oil viscosity
that is required. If vibration or minor shock loading is possible, a higher grade of oil than the
one indicated in Table should be considered.

Bearing Speed Bearing / Oil Temperature (°C)

(rpm) 0 to 50 60 75 90

300 to 1,500 - 68 100 to 150 -

~1,800 32 32 to 46 68 to 100 100

~3,600 32 32 46 to 68 68 to 100

~10,000 32 32 32 32 to 46

Table 7.6.5: Lube oil specification

32 grade Lubrication oil used In feed pump and 46 grade Lubrication oil used in turbine .

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7.7 Generator
Synchronous generators, also called alternators or AC generators are the principle sources of
electrical power throughout the world. Generators basically follow Faraday‟s law of
electromagnetic induction which states that, when magnetic flux changes through a circuit, an
emf is induced in it and it remains only as long as the change in the magnetic flux remains
through the circuit. At APSCL electric power is generated by steam turbines and gas engine.
Steam of steam turbine is produced by using natural gas. In figure we have shown an AC
generator of APSCL

Figure 7.7: Generator of unit-2

7.7.1 Generator Specification:

Rated speed 3000 rpm

Voltage 15750 V

Armature current 6965 A

Excitation voltage 323 V( at full load), 210 V (at no load)

Over speed 3600 rpm

Power factor 0.8

Output 190000 KVA

Table: 7.7.1 Generator Specification

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 Figure 7.7.1: Internal view of Generator During Overhouling.

7.8 Steam Turbine Control and Protection

7.8.1 Steam turbine control system:

Steam turbine control systems are composed of a number of components that work together
to regulate the flow of steam through turbine. Our supervisor of APSCL discussed and
showed about these components of the control system. Some of these components are
discussed.

7.8.2 Steam turbine control valves:

During the turbine operation, the speed of a steam turbine must be controlled by a desired
valve at all times. Turbine speed is determined by the amount of steam flowing through the
turbine and turbine control valves are opened by determining the pressure and temperature of
the steam. Live steam valve and main stop valve of turbine section of APSCL are shown in
figure 6.8.2

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 Figure 7.8.2: Live steam valve and main stop valve.

APSCL mainly uses live steam valve and main stop valve for turbine section. The live steam
valve is open at around 520° C temperature and 135 bar pressure of the steam and the main
stop valve will operate at any fault of turbine.

7.8.3 Mechanical governance:

At steam turbine section of APSCL, mechanical governance is used to maintain the speed of
the turbine at desired value when the generator is disconnected from the power system.
Mechanical governor consists of a set of pivoting arms, a bracket, and a spring.

7.8.4 Speed changer:

The steam turbine section of APSCL uses speed changer which performs two functions.

1. Adjust the turbine speed when the turbine is off line,

2. Allow the generator to increase its load without changing turbine speed when the turbine is
on line.

7.9 Turbine temperature and pressure control

During the turbine operation, the turbine metal will expand or contract when the temperature
changes. So, the different temperatures of turbine section are measured and displayed in the
control room of APSCL, where the operator can take steps to avoid these problems.

7.9.1 Steam temperature:

At the steam turbine section of APSCL, temperature sensors are located at the main steam
path, re-heat line, turbine extraction lines and on LP turbine exhaust to control the steam
temperature. Thermocouples are used in the steam line to determine the steam temperature in

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a turbine. The thermocouples generate electrical signals that are proportional to the actual
steam temperature at each point.

7.9.2 Bearing temperature:

Bearings are usually made of metals that have low melting points. So, bearing can fail or
damage if operated at very high temperature. At APSCL, two types of temperature
measurement system are used to monitor turbine bearing, one is bearing oil temperature and
other one is bearing temperature. During normal operation, heat is generally removed by oil
that is used to lubricate the bearings. Thermocouples are placed in the oil leaving path of each
bearing, which provide the accurate temperature of the bearing oil. From oil temperature,
operators get the bearing temperature condition.

7.9.3 Pressures control:

Turbines are operated at certain pressure and specified pressure is dropped at each stage of
steam turbine section. To operate the steam turbines efficiently, the pressure within the
turbine must be maintained. At the steam turbine section of APSCL, steam pressures are
typically measured at the main steam line and the crossover line. At APSCL, two types of
pressures are monitored in turbine. These are above atmospheric pressure and below
atmospheric pressure (vacuum). Steam turbines are operated more efficiently at greater
vacuum and operated less efficiently at lower vacuum.

7.10 Steam turbine protection

During emergency conditions, steam turbine protection systems are designed to protect the
turbines automatically. Steam turbine protection system is the subsystem of turbine control
system. Operators of the control system of APSCL continually monitor the turbine operation
and trip the turbine if any emergency occurs. Some of the steam turbine protection systems
are discussed below.

7.10.1 Steam turbine trip:

Turbine trip shuts down the turbine by closing the turbine steam valves. In a turbine trip, the
main stop valves, the control valves, the re-heat stop valves, and the live steam valves are
closed. Two cases of steam turbine trip of APSCL are discussed below.

Over speed mechanism In normal operation, the steam turbines of APSCL rotate at 3300 rpm.
Due to some fault, the generator may be disconnected from the power system, and then the
turbine can go over speed. For this, the turbine governor reaches in excessive speed and
immediately begins to close control valves and live steam valves to decrease the flow of
steam to turbine.

Manual trip The turbine can be tripped manually at any time. Usually, manual trip is done if
other trip methods fail during fault occurred or for overpowering the turbine. Manual trip
unblocks the drain lines to the hydraulic oil reservoir. So, oil pressure is released from the
hydraulic actuator piston. As a result, the turbine valve closes
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 Figure 7.10.1.1: Operator activating a manual trip

Figure 6.10.1.1 shows an operator initiating a manual trip by pulling a manual trip handle at
the front of the turbine. After a turbine trip has occurred, the faults must be corrected before
the turbine can be used. The first step in returning the turbine to service is by resetting the trip
mechanism. This is typically done by pulling a reset handle like the one shown in figure
6.10.1.2

Figure 7.10.1.2: Operator activating a reset mechanism

Pulling the reset handle clears the trip through reset linkage, as shown in figure 6.10.1.3

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 Figure 7.10.1.3: Simplified diagram of a basic reset mechanism.

Solenoid trip When fault occurs, the solenoid trip can be operated by an electrical input from
any of the several systems. This mechanism is located inside an electrical coil. The electrical
coil gets energized when fault occurs and then it moves the plunger. The movement of the
plunger drives out the trip finger to trip the turbine. The control room operator can also
operate this.

Figure 7.10.1.4: Solenoid trip mechanism.

Figure 6.10.1.4 is a simplified diagram of a typical solenoid trip mechanism. Here, this
mechanism includes lube oil, thrust bearing, low vacuum and a high vibration protection
system. Generally, there is another power source called station battery. Usually, this
arrangement is to ensure emergency power available to the solenoid.

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7.10.2 Lubricating oil protection:
Steam turbine bearings are designed to operate within an oil pressure range of 20-30 psig
(pound-force per square inch gauge). If the oil pressure drops below the preset range, then an
insufficient quantity of oil will be delivered to the bearings. As such, there remains
insufficient quantity of oil to support the shaft and an insufficient supply of oil to cool the
bearings. If the lube oil pressure is not set to normal, serious damage could happen to the

bearings. Lubricating oil protection system starts action when low lubricating oil pressure
condition occurs. If the turbine lubricating oil pressure decreases to a rated value, then the
contacts become closed by a pressure switch that located in the lubricating oil supply line to
the bearings. Closing of the contacts causes two separate actions.

1. Backup pumps are started to restore the pressure to within normal range,

2. Alarm is energized to alert the operator about the low pressure condition.

The alarm is to alert the operator about the situation and allows time to take proper action. If
the pressure continues to decrease without being affected by the remedial action, then the
second pressure switch becomes closed and then energizes a solenoid trip, which removes the
turbine from service.

7.10.3 Bearing protection:

Excessive thrust can damage the thrust bearingThrust bearing protection system protects the
turbine from excessive thrust and temperature.When the temperature of bearing become very
high, the bearing is cooled by lube oil.Lube oil is the part of the thurst bearing protection
system.Another purpose of using lube oil to avoid friction.With this protection system, power
loss by mechanical friction decreases.

Figure 7.10.3: A thrust bearing wear detector.

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Figure 6.10.3 is simplified diagram of a thrust bearing detector. The thrust bearing wear
detector is usually located on the lowest part of Turbine bearing.The main portion of this
system are pressure switch, oil supply, bearing wear detector probe, and a runner. The runner
is actually part of the shaft. Excessive thrust can be detected by this.

7.10.4 High vibration protection:

Extra vibration is harmful for turbine. Generally, maximum allowable vibration limit is 7-
10 mils the turbine must be removed from service when the vibration exceeds specified
limits. Vibration recorders are set to drive an alarm in the control room when excess
vibration occurs in the turbine . This alarm alerts the control room operator to take proper
action during high vibration condition.There are several vibration protection systems that are
provided with contacts.During exessive vibration condition, a solenoid trip is activated by
these contacts.

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CHAPTER 8
WATER MANAGEMENT

8.1 Pump station

Boiler is used to produce steam. The steam is further re-used after using. This is done to
make up losses. The water is taken from the river. There is a lack of sufficient water to run
the 5-units continuously. So re-use is needed. The water required for producing steam is more
than ten times expensive than normal drinking water. The temperature of the steam is about
5000C. So the steam is condensed to re-use. The water requires for condensing is collected
from river. After condensing the water is thrown into the river. The diameter of the condenser
tube is about 19mm. The dirt particles are introduced, if the river is directly collected. As a
result efficiency gets lower. So the water is refined to keep the system better.

There are 8 CW pumps is Ashuganj Power Station. Three are for 120MW, 3 are for 300 &
the rests are for 150MW. Five CW pumps are in operation while the three others remain
stand by. The water is also used for cooling of the pump. 90% of water is used for producing
steam & the rest 10% is used for cooling. The capacity of CW pump is about 10500 litre/sec.

Figure 8.1: Pump station

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8.1.1 The specifications of CW pump:
Name- Circulating cooling water pump

Ampere- 220

Thrust Bearing Temp – 670C (Alarm- 750C)

Manufacturer- Ebara, Japan

Weight- 127 tonnes

Type- Mixed Flow Vertical Type

Motor Capacity- 2.5MW

Revolution- 297 r.p.m

Discharge- 10500 litre/sec

Valve- Butterfly type ( hydraulic system )

Figure 8.1.1: CW pump

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8.2 River water screening System:
Water is the most important thing in a steam power plant. Water supplies generally are
divided into two major categories: surface water and ground water. Surface water is available
from rivers lakes and other impoundments as well as the sea. Ground water is present is
below the earth‟s surface.

In Ashuganj Power plant, water is collected from the river Meghna. This water comes
through 3 channels. One channel is for CCPP, ST-1 & ST-2 and one channel is for ST-3, ST-
4 & ST-5 and other channel is for demi water.

This water is used mainly for generation of steam, for condenser, cooling of overall system,
cooling of lubricating oil, for chillers etc. So to use the water efficiently
water screening system is essential. There are three steps of water screening system. They are
described in below:

8.2.1 Heavy-duty Bar:

It‘s the first stage of screening system. In this stage water is screened by trust rack. Heavy
wastes like wooden piece, dead animals, water hyacinth etc. are removed in this stage.

Figure 8.2.1: Heavy-duty Bar

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8.2.2 Rotating Bar:
In this stage water is screened by scrapers. Smaller waste than heavy-duty bar waste are
removed in this stage.

Figure 8.2.2: Rotating Bar

8.2.3 Band Screening Bar:

It is a process where 57 baskets are arranged in such a way that screens the water by passing
water through net to remove very small wastes like small pieces of stones, sand etc. It is the
most effective and modern screening process. A tray is placed below the baskets (net) that
takes the waste which is separated from nets by spraying water.

Figure 8.2.3: Band Screening Bar

8.3 Distribution of River Water

The filtered water comes into transmission line through water pumps. Next, water goes into
condenser and water treatment plant through pipes.
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8.3.1 Supply to Condenser :
A large portion of water goes to the condenser. About 90,000 tons of water per hour is used
for condensation purpose for all thermal power plants. The steam temperature is about 48˚ C
when steam comes into condenser. The water takes the heat energy from the steam. From the
condenser end the water comes out with higher temperature. Outgoing Water temperature is
almost 44˚ C. Water then goes back to the river through the drains.

Figure 8.3.1: Condenser

8.3.2 Supply to Water Treatment Plant:

A portion of water is supplied to the water treatment plant. The water treatment plant has a
significant role in thermal power plant. Natural water contains minerals and these mineral
particles are harmful for the steam turbine. A water treatment plant removes these unwanted
minerals from water. Figure 5.2 shows the water treatment plant of APSCL. The process by
which the dissolved gas is removed is known as water de-mineralization. The de-mineralized
water is used for steam generation purpose.

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 Figure 8.3.2: Water circulation system

8.4 Water Treatment Plant

A portion of water is supplied to the water treatment plant. The water treatment plant has a
significant role in thermal power plant. Natural water contains minerals and these mineral
particles are harmful for the steam turbine. A water treatment plant removes these unwanted
minerals from water. The process by which the dissolved gas is removed is known as water
de-mineralization. The de-mineralized water is used for steam generation purpose.

Figure 8.4: Water Treatment Plant

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8.4.1 Clarification and Sedimentation :
After the screening process water is used for clarification. In clarification process the raw
water is blended with Al2(SO4)3 and polyelectrolyte to remove sludge. In sediment basin the
sludge‟s are deposited below the basin. Then the clean water is collected in other basin and
the sludge is removed from basin by a pump.

Figure 8.4.1: Sedimentation

8.4.2 Filtration :
After the clarification water is used for filtration. In this process the clean water is pumped to
the gravel filter. The ―Anthracite coal‖ of the filter removes any solid particles like sand, silt
etc.

Figure 8.4.2: Gravel filter

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8.4.3 Over head tank:
Distill water is stored in over head tank ,and send to de-mineralization section as per as
required.

Figure 8.4.3: Over head tank

8.4.4 Demineralization:
In demineralization ions are removed from the water. In this process the water passes through
the scavenger, cation, anion and mixed bed filter.

Figure 8.4.4: Demineralizationsection

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8.4.5 Make up water tank:
Capacity-231 ton

Max allowable temp-120˚C

Max allowable working pressure -1/1bar

Figure 8.4.5: Makeup water tank

8.4.6 Discharge canal:

Figure 8.4.6: Discharge Canal

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8.5 Chemical Test
For testing the quality of demi water in APSCL there is a chemical lab facility.

Figure 8.5: Chemical lab.

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CHAPTER 9
9.1 Discussion

After starting my practicum seen there many project is started, there are different kinds of
Challenges . Then the Engineers and Technicians are working for the maximum production.
Even here many problems are found on generation systems, motor problem, gear problem,
boiler problem and mechanism system problem. I have done more works to learn operation
systems, I always was present with engineer and tried to understand the problem if I did not
understand I ask him. I tried a lot even used internet for learning how the power plant works.

I think that knowledge make my engineering knowledge very strong. And the improvement
will help me for future engineering work for my future carrier.

9.2 Conclusion
After passing 12 weeks in APSCL. I gain some knowledge on Thermal Power Plant .That
how those Boilers are working what to be the process. I also achieved some knowledge how
the GasTurbine working. That is very different experience for me. I also have seen how the
power is supplied to the grid. I also have seen some repairing process at workshop. But GT-
2 did not have work to do. That‘s why I messed their working Systems .How the engineer
works I have seen there .How the Operator operate a plant that I also have seen there .In my
practicum report I included those things what I have seen there .Overall this is a huge
opportunity for me to see a Power Plant during my student life.

9.3 Bibliography
[1] Vision, Mission of APSCL. [Online]. Available: http://www.apscl.com/Profile.asp.

[2] Background of APSCL. [Online]. Available: http://www.apscl.com/Profile.asp.

[3] Production report of APSCL. [Online]. Available: http://www.apscl.com/Profile.asp.

[4] Future plan of APSCL. [Online]. Available: http://www.apscl.com/Profile.asp.

[5] Collected information during the internship period at Ashugonj Power Station Company
Limited.

[6] NUS Training Corporation ―Power principle: Power plant practices series,
Instrumentation and control‖, A Halliburton company. December 23, 1983.

[7] G.F. (Jerry) Gilman, ―Boiler Control Systems Engineering‖, 1st edition, ISA- The
Instrumentation, System, and Automation Society, 2005.

[8] NUS Training Corporation ―Power principle: Power plant basic series, Plant Cycle‖, A
Halliburton company. April 30, 1982.

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[9] NUS Training Corporation ―Power principle: Power plant practices series, Turbines‖, A
Halliburton company. 1983.

9.4 Appendix

APSCL - Ashuganj Power Station Company Ltd

BPDB - Bangladesh Power Development Board
CCPP - Combined Cycle Power Plant
GEP- Gas Engine Power Plant
GT- Gas Turbine
ST- Steam Turbine
CW- Condensate Water
BFP- Boiler Feed Pump
FD- Foced Draught
MOPEMR- Ministry Of Power Energy and Mineral Resource
GOB- Government Of Bangladesh

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