MOAAZ KHAN

ENGRO POWERGEN QADIRPUR

INTERNSHIP REPORT MECHANICAL ENGINEERING NUST KARACHI JANUARY 2013

MOAAZ KHAN ENGRO POWERGEN QADIRPUR INTERNSHIP REPORT

TABLE OF CONTENTS

TABLE OF CONTENTS..........................................................................................................................2 ENERGY CRISES........................................................................................................................................3 SAFETY FIRST............................................................................................................................................3 BIRDS EYE VIEW......................................................................................................................................4 COMBINED POWER PLANT CYCLE.......................................................................................................4 GAS TURBINE.............................................................................................................................................6 STEAM TURBINE.......................................................................................................................................9 BRAYTON CYCLE....................................................................................................................................10 RANKINE CYCLE.....................................................................................................................................11 COMBINED CYCLE..................................................................................................................................12 GENERATOR.............................................................................................................................................13 BURNERS...................................................................................................................................................14 CENTRIFUGAL PUMPS...........................................................................................................................15 COOLING TOWERS..................................................................................................................................18 BIBLIOGRAPHY.......................................................................................................................................20

MOAAZ KHAN ENGRO POWERGEN QADIRPUR INTERNSHIP REPORT

ENERGY CRISES & ENGRO POWERGENS CONTRIBUTIONS

Life on Earth is driven by energy. Energy is more than a need. It is a fundamental requirement and energy per sec is crucial to provide for adequate living such as food, water, health care, education, shelter and employment. Electricity is the most convenient form of energy available to Human beings. This energy is fundamental to human well being and prosperity. The strong correlation between the availability of electricity and the level of human social development has been known since at least 1895 with the electrification of Niagara Falls with the then new polyphone alternating current (AC) technology invented by Nikola Tesla. Therefore the energy crisis is a crisis of human development. It is indeed a matter of life and death. According to a survey done by Gilani Research Foundation nearly 53 percent of the Pakistans population remains without electricity far more than 8 hours daily throughout the year. Due to this crisis the daily life has come to a standstill. Even more ominously the shortage is Endangering the future economic and social prospects of the country, putting its very fabric under strain. The multidimensional ongoing energy crisis has been having a knock on the life of every Pakistani. Without sufficient energy the wheel can't run on roads, industry and agriculture can't sustain, hospitals and operation theaters can't function, schools and laboratories can't work and public and private sector businesses can't operate. Electricity, which is the lifeblood of modern societies, provides a wide range of services essential to everyday life, including running hospitals, schools and businesses, heating, cooling and lighting in homes and in work, preserving food commercially and at home, pumping fresh water supplies and sewage, maintaining the flow of traffic, operating communications systems, internet and information portals and providing power for a wide range of appliances.

SAFETY FIRST

The company keeps a strict check and balance on safety issues. It aims at producing electricity with safe and healthy acts.

WHY SAFETY FIRST? Keeps you aware of the Hazards and its consequences To ensure safe working environment and risk free atmosphere at plant site. Ensure compliance with all applicable safety related EEL requirements, statutory requirements, government regulations, and industry standards. Ensure that safety requirements are appropriately applied to all project elements through appropriate interaction between the EEL Team and Contractor. Implement a vital Safety Program which trains, motivates and rewards all employees for compliance and safety performance.

MOAAZ KHAN ENGRO POWERGEN QADIRPUR INTERNSHIP REPORT

A BIRDS EYE VIEW OF THE PLANT

Engro powergen is CCP plant producing a total of 217MW power. The plant comprises of various sections, in order to affectionately workout the plants production, protection, maintenance & distribution. The hierarchy of position distribution makes the system efficient and error free. Plant has got the following important areas and distributions

ADMINISTRATION TECHNICAL BLOCK WAREHOUSE PROCESS ELECTRICAL I&C OPERATIONS MECHANICAL Every section is acting as a wing to support the plants production. The section heads are responsible to keep a strict eye on the performance of their respective sections. Work permits are issued from the concerned responsible persons before any job is performed at the plant site.

STEAM TURBINE PLANTS use the dynamic pressure generated by expanding steam to turn the blades of a turbine. Almost all large non-hydro plants use this system. GAS TURBINE PLANTS use the dynamic pressure from flowing gases (air and combustion products) to directly operate the turbine. Natural-gas fuelled (and oil fueled) combustion turbine plants can start rapidly and so are used to supply "peak" energy during periods of high demand, though at higher cost than base-loaded plants. COMBINED CYCLE PLANTS have both a gas turbine fired by natural gas, and a steam boiler and steam turbine which use the hot exhaust gas from the gas turbine to produce electricity. This greatly increases the overall efficiency of the plant, and many new base load power plants are combined cycle plants fired by natural gas.

COMBINED POWER PLANT CYCLE

OVERVIEW A combined cycle is an assembly of engines that convert heat into mechanical energy, which in turn usually drives electrical generators. By Combining two or more thermodynamic cycles results in improved overall efficiency, reducing fuel costs. In a COMBINED CYCLE POWER PLANT (CCPP), a gas turbine generator generates electricity and

MOAAZ KHAN ENGRO POWERGEN QADIRPUR INTERNSHIP REPORT

the waste heat is used to make steam to generate additional electricity via a steam turbine.

As obvious from the name combined cycle stands for a summation of two cycles. These two cycles are called Thermodynamic cycles; Brayton cycle (Gas Turbine) Rankine cycle (Steam Turbine)

The plant has got two turbines in operation; namely the Gas Turbine & Steam Turbine. Gas turbine

MOAAZ KHAN ENGRO POWERGEN QADIRPUR INTERNSHIP REPORT

consumes Natural gas as a primary fuel for its operation while the exhaust flue gases are used in HRSG (Heat recovery Steam Generation) to give up their heat in making steam, which is further used by the Steam turbine. Both turbines are used to drive generators in order to produce Electricity.

GAS TURBINE
A gas turbine, also called a combustion turbine, is a type of internal combustion engine. It has an upstream rotating compress or coupled to a downstream turbine, and a combustion chamber inbetween. Energy is added to the gas stream in the combustor, where fuel is mixed with air and ignited. In the high pressure environment of the combustor, combustion of the fuel increases the temperature. The products of the combustion are forced into the turbine section. There, the high velocity and volume of the gas flow is directed through a nozzle over the turbine's blades, spinning the turbine which powers the compressor and, for some turbines, drives their mechanical output. The energy given up to the turbine comes from the reduction in the temperature and pressure of the exhaust gas Gas turbines operate on the principle of Brayton cycle. Gas turbines are used for various applications for example; driving a pump, driving a generator etc. Here, in our case GT is used to drive a generator. The gas turbine is comprised of three main components: Compressor Combustor Turbine

GT Components

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The MS 9001 E gas turbine assembly consists of six major section or groups: 1. Air inlet 2. Compressor 3. Combustion system 4. Turbine 5. Exhaust

MOAAZ KHAN ENGRO POWERGEN QADIRPUR INTERNSHIP REPORT

GT SPECS in Engro Powergen

Features & Benefits Fuel flexibility to burn a wide range of alternative fuels for lower operating costs, better efficiency, and lower emissions than other technologies. Operational flexibility with fast start, fast load capability. Advanced technology to extend the life of your equipment and plant, operational hours and/or start space. More rugged parts for increased availability and reliability. Output of 128 MW and capable of achieving more than 52% efficiency in combined-cycle. Reliable, low first-cost machine for peaking service in simple cycle. Compact design provides flexibility in plant layout as well as the easy addition of increments of power when phased capacity expansion is required. Cost effective for 100-130 MW gas turbine range.

MOAAZ KHAN ENGRO POWERGEN QADIRPUR INTERNSHIP REPORT

STEAM TURBINE

Steam turbines uses the energy stored inside the high pressure superheated steam to generate electricity. High pressured super heated steam is entered in to the turbine from one end. The steam hits the blades of the turbines with high pressure and velocity which rotates the blade. As stream progresses hitting the blades turn by turn it loses pressure and temperature as it is giving away its energy to the blades, so it is conventionally said that steam is expanded as it progress through the turbines blades. The turbine blades are mounted on a rotor which rotates along with the blades this rotor attached to the rotor of generator axially and rotates the generator rotor. The generator then produces electricity. The functioning of the generator is giving in the subsequent topics.

STEAM TURBINE IN EPQL is manufactured by HARBIN TURBINE and ELECTRIC CORP.

MOAAZ KHAN ENGRO POWERGEN QADIRPUR INTERNSHIP REPORT

BRAYTON CYCLE

A Brayton cycle is a gas turbine cycle that includes four processes o Isentropic Compression o Isobaric heat addition o Isentropic Expansion o Isobaric heat rejection

Isentropic compression: Air is drawn into the compression chamber, which is 17 stages compressor. It compresses the air isentropically (ideal). The process shown on the T-S diagram is 1-2. In actual the process is practically not 100% efficient. The compressor has a limited efficiency. Isobaric Heat addition: Air after compression enters the combustion chamber. Here, permeate gas is mixed with air and ignited (once), which burns to produce a heated mixture. This combustion process is Isobaric. This is shown 2-3 on the graph. Isentropic Expansion: The combusted mixture is passed through the turbine, where it expands and thus enthalpy loss is converted into velocity which imparts force to drive the turbine. The process is kept isentropic (ideally). Constant pressure heat Rejection: If the system is direct closed system then the exhaust gases are cooled down to initial temperature where again the cycle continues to run. In our case the exhaust gases are fed into HRSG, where steam is produced and introduced in the steam turbine.

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RANKINE CYCLE
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. 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. The dry saturated vapor expands through a turbine, generating power. This decreases the temperature and pressure of the vapor, and some condensation may occur. The wet vapor then enters a condenser where it is condensed at a constant pressure to become a saturated liquid. States 1. 2. 3. 4. Saturated Liquid at Condenser (Low) pressure Compressed Liquid at Boiler pressure Superheated Steam at Boiler Pressure Wet steam at Condenser pressure

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EPQL COMBINED CYCLE POWER PLANT

EPQL combine cycle power plant consist of two cycle .The top cycle has Gas Turbine which uses natural gas in combustion chamber to produce Pressured flue gases which expanded through gas turbine provide power to drive generator which produce electricity. Waste heat is used to make steam to generate additional electricity via a steam turbine. Supplementary firing increases the steam production and steam turbine output. This last step enhances the production of electricity. The plant has different sections such as HRSG, Turbines, Condenser, Transformers, GIS, and Balance of plant. All these are discussed below. EPQL CCPP:

GENERATOR

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ELECTRIC GENERATOR In electricity generation, an electric generator is a device that converts mechanical energy to electrical energy, generally using electromagnetic induction. The source of mechanical energy may be a turbine steam engine, water falling through a turbine or water wheel or any other source of mechanical energy generate by turbine or another source. Two main parts of a generator or motor can be described in either mechanical or electrical terms.

MECHANICAL Rotor: The rotating part of an electrical machine. Stator: The stationary part of an electrical machine. ELECTRICAL Armature: The power-producing component of an electrical machine. In a generator, alternator, or dynamo the armature windings generate the electric current. The armature can be on either the rotor or the stator. Field: The magnetic field component of an electrical machine. The magnetic field of the dynamo or alternator can be provided by either electromagnets or permanent magnets mounted on either the rotor or the stator. WORKING The rotor has electrical windings on it care at the center of the windings through which excitation current is passed and it transformers into a magnet. This magnet has two poles. The stator also has electrical winding on it and is fixed to the outer casing of the generator around the rotor. When the generator rotor is turned axially by the mechanical movement of the turbine rotor thee magnet form over the rotor also turns and its magnetic field is cut by the stator winding, which thus induces an alternating current inside the stator windings.

GENERATORS IN EPQL

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GAS TURBINE GENERATOR is manufactured by NANJING TURBINE and ELECTRIC CORP.

STEAM TURBINE GENERATOR is manufactured by HARBIN TURBINE and ELECTRIC CORP.

BURNERS
One special feature of Engro powergen plant is the usage of secondary burners in HRSG. There are 8 burners at the exhaust of gas turbine, whose firing raises the temperature of flue gases, which are further utilized in HRSG to produce high pressure, high temperature steam. This steam is expanded in steam turbine which is coupled with the generator. Burner arrangement: Burners have a special formation arrangement in HRSG. Four burners are installed on one side while four on other side. The formation on one side is 1-3-5-7 while the other is named as 2-4-6-8. Types of burners used The burners that are installed in HRSG are of two different types. The gas run burner utilizes permeate gas while another burner which is diesel run burner is also there for operation. Gas burner is normally in operating conditions. All makes and types of burners have two things in common:

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 They need to atomize the fuel They need to mix the fuel with the air needed for Combustion Why is it necessary to atomize fuel? Even though fuel oil is classified as a flammable liquid, most fuels will not burn easily in a liquid state. If you were to drop a lit match in a container of fuel oil, it would PROBABLY go out almost immediately (dont try this!). In order for fuel oil to burn, it must first be transformed from a liquid to a vaporized state ~ atomized. Atomization increases the exposure of the fuel to the oxygen in the air; this promotes combustion. A nozzle rated at 0.60 US gallons per hour can generate as many as 50 million droplets of oil in an hour.

IMPORTANT If atomization is incomplete, the droplet sizes are too large for complete combustion. The larger droplets will escape the flame only partially burnt. This can usually be seen as fire flies when looking at the flame. This will not only result in a poor flame, but also soot deposits being formed inside the combustion chamber. In addition the combustion plants efficiency will reduce causing excessive fuel usage for the required energy output.

CENTRIFUGAL PUMPS
Pump: A device that is used to force a liquid from a point of low pressure to a point of high pressure.

Theory:

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There are many types of centrifugal pump systems. Figure shows a typical industrial pump system. There are many variations on this including all kinds of equipment that can be hooked up to these systems that are not shown. A pump after all is only a single component of a process although an important and vital one. The pumps role is to provide sufficient pressure to move the fluid through the system at the desired flow rate

Main Components: A centrifugal pump has two main components: 1. A rotating component comprised of an impeller and a shaft. 2. A stationary component comprised of a casing, casing cover, and bearings. Stationary Components: Casing Casings are generally of two types: volute and circular. The impellers are fitted inside the casings. 1. Volute casings build a higher head; circular casings are used for low head and high capacity. A volute is a curved funnel increasing in area to the discharge port. As the area of the crosssection increases, the volute reduces speed and increases the pressure of the liquid. One of the main purposes of a volute casing is to help balance the hydraulic pressure on the shaft of the pump. 2. Circular casing have stationary diffusion vanes surrounding the impeller periphery that convert velocity energy to pressure energy. Conventionally, the diffusers are applied to multi-stage pumps. The casings can be designed either as solid casings or split casings. Solid casing implies a design in which the entire casing including the discharge nozzle is all contained in one casting or fabricated piece. Split casing implies two or more parts are fastened together. When the casing parts are divided by horizontal plane, the casing is described as horizontally split or axially split casing. When the split is in a vertical plane perpendicular to the rotation axis, the casing is described as vertically split or radically split casing. Casing Wear rings act as the seal between the casing and the impeller.

Suction and Discharge Nozzles The suction and discharge nozzles are part of the casings itself. They commonly have the following

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configurations. 1. End suction/Top discharge 2. Top suction Top discharge nozzle 3. Side suction / Side discharge nozzles

Rotating Components 1. Impeller: Impeller is the main rotating part that provides the centrifugal acceleration to the fluid. They are often classified in many ways. Based on major direction of flow in reference to the axis of rotation o Radial flow o Axial flow o Mixed flow Based on suction type o Single-suction: Liquid inlet on one side. o Double-suction: Liquid inlet to the impeller symmetrically from both sides. 2. Shaft: The basic purpose of a centrifugal pump shaft is to transmit the torques encountered when starting and during operation while supporting the impeller and other rotating parts. It must do this job with a deflection less than the minimum clearance between the rotating and stationary parts. Shaft Sleeve: Pump shafts are usually protected from erosion, corrosion, and wear at the seal chambers, leakage joints, internal bearings, and in the waterways by renewable sleeves. Unless otherwise specified, a shaft sleeve of wear, corrosion, and erosion resistant material shall be provided to protect the shaft. Coupling: Couplings can compensate for axial growth of the shaft and transmit torque to the impeller. Shaft couplings can be broadly classified into two groups: rigid and flexible. Rigid couplings are used in applications where there is absolutely no possibility or room for any misalignment. Flexible shaft couplings are more prone to selection, installation, and maintenance errors. Couplings are of different types; grid coupling, flexible disc coupling & gear coupling.

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COOLING TOWERS
Water-cooling towers are heat removal devices used to transfer waste heat from various sources such as machinery or heated process material to the atmosphere. Common applications include cooling the circulating water used in oil refineries, chemical plants, power plants, and building cooling. Smaller towers are normally factory-built, while larger ones are constructed on site. Cooling towers are able to lower the water temperatures more than devices that use only air to reject heat, like the radiator in a car, and are therefore more Cost-effective and energy efficient. Main Components: The basic components of a cooling tower include: Frame and casing Fill Cold water basin Drift eliminators Air inlet Louvers Nozzles Fans

Frame and casing: Most towers have structural frames that support the exterior enclosures (casings), motors, fans, and other components. With some smaller designs, such as some glass fiber units, the casing may essentially be the frame. Fill: Most towers employ fills (made of plastic or wood) to facilitate heat transfer by maximizing water and air contact Cold-water basin: The cold-water basin is located at or near the bottom of the tower, and it receives the cooled water that flows down through the tower and fills. The basin usually has a sump or low point for the cold-water discharge connection. In many tower designs, the cold-water basin is beneath the entire fill. Drift eliminators: These capture water droplets entrapped in the air stream that otherwise would be lost to the atmosphere. Air inlet: This is the point of entry for the air entering a tower. The inlet may take up an entire side of a tower (cross-flow design) or be located low on the side or the bottom of the tower (counter-flow design). Louvers: Generally, cross-flow towers have inlet louvers. The purpose of louvers is to equalize air flow into the fill and retain the water within the tower. Many counter flow tower designs do not require louvers.

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Nozzles: These spray water to wet the fill. Uniform water distribution at the top of the fill is essential to achieve proper wetting of the entire fill surface. Nozzles can either be fixed and spray in a round or square patterns, or they can be part of a rotating assembly as found in some circular cross-section towers. Fans: Both axial (propeller type) and centrifugal fans are used in towers. Generally, propeller fans are used in induced draft towers and both propeller and centrifugal fans are found in forced draft towers. Types of cooling towers: Forced draft Induced draft cross flow Induced draft counter flow Natural draft Balanced draft

Induced Draft cooling tower: It has fans at the upper portion of the tower that induces the air to come in contact with the water droplets and cools it down. Engro Powergen uses induced draft cooling towers.

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BIBLIOGRAPHY
www.google.com www.en.wikiedia.com www.engro.com http://www.engro.com/our-businesses/engro-power-gen-limited/

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