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INDUSTRIAL TRAINING REPORT L&DC
INDUSTRIAL TRAINING REPORT L&DC
INDUSTRIAL TRAINING REPORT L&DC
SUBMITTED BY:
NAME: CHIMALAKONDA SUBRAHMANYA KRISHNA TEJA
B. TECH 3rd YEAR , MECHANICAL ENGINEERING
TRAINEE NO: 100033487
CERTIFICATION
T. SATYA DATTU
DEPUTY GENERAL MANAGER
CAPTIVE POWER PLANT
VISAKHAPATNAM STEEL PLANT
DECLARATION
I’m also thankful to Das sir, Sunil sir & Shubham sir for
clarifying my doubts and for giving valuable advices for
doing this project.
OVERVIEW OF RINL
THERMAL POWER PLANT
RANKINE – CYCLE
CONCLUSION
OVERVIEW OF RINL
The various departments available in the VSP
include:
1) Raw Material Handling Plant (RMHP)
2) Coke ovens & Coal Chemical Plant (CO&CCP)
3) Sinter Plant (SP)
4) Blast Furnace (BF)
5) Steel Melt Shop (SMS)
6) Continuous casting Department
7) Rolling Mills RS & RS (Roll Shop & Repair Shop)
8) Light & Medium Merchant Mill (LMMM)
9) Wire Rod Mill (WRM)
10) Medium Merchant & Structural Mill (MMSM)
11) Thermal Power Plant (TPP)
RMHP :
VSP annually requires quality raw materials viz. Iron Ore, fluxes (Lime
stone, Dolomite), coking and non coking coals etc. to the tune of 12-13
Million Tonnes for producing 3 Million Tonnes of Liquid Steel. To handle
such a large volume of incoming raw materials received from different
sources and to ensure timely supply of consistent quality of feed
materials to different VSP consumers, Raw Material Handling Plant
serves a vital function. This unit is provided with elaborate unloading,
blending, stacking & reclaiming facilities viz. Wagon Tipplers, Ground &
Track Hoppers, Stock yards Crushing plants, Vibrating screens, Single /
twin boom stackers, wheel on boom and Blender reclaimers, Stacker –
cum – Reclaimer (SCR). In VSP peripheral unloading has been adopted
for the first time in the country. Coking coals are received through
conveyors directly from M/s Gangavaram Port Limited to Coal Stock
Yard.
CO & CCP :
Blast Furnaces, the mother units of any Steel plant require huge
quantities of strong, hard and porous solid fuel in the form of hard
metallurgical coke for supplying necessary heat for carrying out the
reduction and refining reactions besides acting as a reducing agent. At
VSP there are Five Coke Oven Batteries, 7 Metre tall and having 67
Ovens each. Each oven is having a volume of 41.6 cu. metre & can hold
upto 31.6 Tonnes of dry coal charge. There are 5 Coke Dry Cooling
Plants (CDCP) each having 4 cooling chambers. Nitrogen gas is used as
the Cooling medium. The heat recovery from nitrogen is done by
generating steam and expanding in two back pressure turbines to
produce 7.5 MW each.
SINTER PLANT :
Sinter is a hard & porous ferrous material obtained by agglomeration of
iron ore fines, coke breeze, Lime stone fines, Metallurgical wastes, etc.
Sinter is a better feed material to the blast furnace in comparison to the
iron ore lumps and its usage in BF help in increasing productivity,
decreasing the coke rate & improving the quality of the hot metal
produced.
BLAST FURNACE :
Hot metal is produced in the Blast furnaces which are tall vertical
furnaces and it runs with blast at high pressures & temperatures. Raw
materials are charged from top and the hot blast at 1373 K to 1573 K
2nd 5.75 g/cm2 is blown from bottom. VSP has two 3200 cu meter BF's
with conveyor charging and named as "GODAVARI" & "KRISHNA".
STEEL MELT SHOP :
Steel generated has lot number of impurities in it which makes it unfit for
engineering practices. So in order to remove those impurities from the
steel, oxygen is blown to enter in to the convertor so that the impurities
gets oxidized and form slag with basic fluxes as that of lime. By
controlling the oxygen flow the different grades of the3 steel of superior
quality can be obtained.
Components of TPP:
1. Boiler
2. Turbine Generators
3. Chemical Water Treatment Plant
4. Chilled Water Treatment Plant
BOILER
A boiler is a closed vessel in which water is converted into
steam with the help of burning of fuel in presence of air under
desired pressure, temperature and mass flow rate. The steam
produced by boiler can be used for various purposes including
heating, for generation of power with the help of turbine by
rotating it. Boilers are commonly used in residential,
commercial and industrial settings.
In this boiler the hot flue gases The water is present inside the
is present inside the tubes and tubes and hot flue gases
water surrounds them surrounds them
They are low pressure boilers. They are high pressure boilers
The operating pressure is and the operating pressure is
about 25 bar 165 bar
The steam generation rate in The steam generation rate in
fire tube boiler is low, i.e. water tube boiler is high, i.e
9tonne per hour 450 tonne per hour
The overall efficiency of this The overall efficiency is upto
boiler is upto75% 90% boiler with the
economiser
It can works on fluctuating It works on fluctuating loads
loads for shorter period all the time
Operating cost is low Operating cost is high
It is suitable for small power It is suitable for large power
plants plants
Let’s discuss about some of the boilers briefly:
3. Cooling Towers:
As the chilled water absorbs heat from the indoor spaces, its
temperature increases. This warmer chilled water is then sent
to cooling towers.
5. Heat Dissipation:
The heat that was initially absorbed from the building is
carried away by the air as water evaporates. This cooled
water, now referred to as "cooled return water," is then sent
back to the chiller plant to be reused in the cooling cycle.
6. Condenser Water Loop:
In addition to the chilled water loop, there's a separate
loop called the condenser water loop. This loop collects hot
water from the chiller's condenser, where the heat absorbed
from the building's air is released. The hot condenser water is
sent to the cooling towers.
1) Safety valve:
When the pressure inside the boilers increase , then
these safety valves lifts up from the seat automatically
and allow the steam to enter into the atmosphere until
the pressure inside the boiler becomes normal.
l
2)Water level indicator: These indicate the amount of water
in the boiler shell so that to operate the boiler safely and
smoothly.
4) Feed pump: This sends water into the boiler and sends
only required amount of water to maintain proper
functioning of boiler.
Mountings Accessories
Devices mounted on boiler Devices fitted in boiler to
surface for safe operation of increase efficiency and proper
boiler and control of steam working of boiler
generation
CONDENSATION:
Condensation is the process which involves the
transformation of a substance from a gaseous state to a liquid
state as it loses heat. This occurs when a gas cools down and
its molecules lose energy, causing them to come closer
together and form a liquid.
BF Gas Properties:
1. Ignition Temperature: 600-650C
2. Explosive range: 45-70 %
3. Density: 1.2 kg/nm3
4. Calorific value: 840 kcal/nm3
5. Nature: Poisonous, colourless, explosive and burns with
yellow flame.
CO GAS PROPERTIES:
1. Ignition Temperature: 550-600C
2. Explosive range: 7-30 %
3. Density: 0.42-0.45 kg/nm3
4. Calorific value: 4300-4500 kcal/nm3
5. Nature: Poisonous, typical smell of H2S, burns with yellow
flame.
PULVERIZED COAL
Pulverized coal refers to coal that has been crushed into a fine
powder and then combusted in a boiler to generate heat. This
fine powder form allows for efficient and complete
combustion, maximizing the energy extraction from the coal.
Pulverized coal is commonly used as a fuel in power plants for
electricity generation and in industrial processes that require
heat.
Here's how the process of using pulverized coal as a fuel
works:
BOILING OF WATER
SUPERHEATING
Superheating is a process in which a substance, typically a
gas or a vapor, is heated to a temperature above its boiling
point while still remaining in its gaseous state. This results in a
substance with higher thermal energy than is typically
associated with its state at that temperature and pressure.
Superheating is commonly encountered in the context of
steam, especially in power generation and industrial
processes.
Here's how superheating works:
✓ Heat Exchange Area: The area where the hot and cold
fluids come into contact to facilitate heat transfer.
In summary, heat exchange is a fundamental
process involved in the movement of thermal energy between
substances or mediums. It plays a vital role in maintaining
temperatures, energy efficiency, and various technological
processes. In the boiler we use several heat exchangers:
1.Economizer
2. Air Pre Heaters (APH)
3. Super Heaters (SH)
4. Low Pressure Heaters (LPH-1, LPH-2)
5. High Pressure Heaters (HPH-1, HPH-2)
RANKINE CYCLE
The Boiler-Turbine system basically runs of the principle of
Rankine cycle. The Rankine cycle is a thermodynamic cycle
used in steam power plants and other heat engines to convert
thermal energy into mechanical work. It's the fundamental
operating principle behind many power generation systems,
including steam turbines commonly used in electricity
generation.
Here's how the Boiler Feed Pump works and its significance:
BFP pumps water to the HP heaters and further into the boiler
at a very high pressure of around 100-110kg/cm2.
DEAERATOR
A deaerator is a device used in power plants, industrial boilers,
and other facilities to remove dissolved gases, primarily
oxygen and carbon dioxide, from water. These gases can be
detrimental to various processes and equipment, Causing
corrosion and reducing the efficiency of heat transfer.
Deaeration is important in systems where the presence of
these gases can lead to problems such as:
ECONOMISER
An economiser in a boiler is a heat exchanger that is designed
to recover heat from the flue gases leaving the boiler and
transferring it to the incoming feed water. Its primary purpose
is to improve the overall efficiency of the boiler system by
preheating the water before it enters the boiler. This reduces
the energy required to heat the water to the desired operating
temperatures, thus saving fuel and reducing operating costs.
Here’s how an economiser works and it’s benefits :
BOILER
A water tube boiler is a type of boiler that uses a network of
tubes to circulate water and heat it. In contrast to a fire tube
boiler, where hot gases pass through tubes immersed in
water, water tube boilers have the water inside the tubes and
the hot gases surrounding them. This design allows for higher
heat transfer efficiency and the ability to generate high-
pressure steam.
Types of Superheaters
STEAM HAMMERING
Steam hammering, also known as water hammer, is a
phenomenon that occurs in steam systems when a sudden
change in the flow of steam causes a pressure wave to travel
through the pipes. This pressure wave creates a loud
hammering noise and can potentially cause significant
damage to the system.
Causes:
Consequences:
AIR PREHEATER
An air preheater is a type of boiler accessory used to improve
the efficiency of a boiler system by preheating the combustion
air before it enters the combustion chamber. The primary
function of an air preheater is to recover the heat from the flue
gases leaving the boiler and transfer that heat to the incoming
combustion air. This process reduces the energy required to
heat the air, which in turn improves the overall efficiency of the
combustion process. Here's how an air preheater works:
BOILER DRAFT
The difference between atmospheric pressure and the
pressure existing in the furnace or flue gas passage of a boiler
is termed as Draft. Draft can also be referred to as the
difference in pressure in the combustion chamber area which
results in the motion of the flue gases and the air flow.
Types Of Drafts :
Drafts are produced by the rising combustion gases in the
stack, flue, or by mechanical means. For example, a boiler can
be put into four categories: natural, induced, balanced, and
forced.
•Induced draft: When air or flue gases flow under the effect of
a gradually decreasing pressure below atmospheric pressure.
In this case, the system is said to operate under induced draft.
The stacks (or chimneys) provide sufficient natural draft to
meet the low draft loss needs. In order to meet higher
pressure differentials, the stacks must simultaneously
operate with draft fans.
CHIMNEY
A chimney is a vertical structure or conduit that is designed to
carry away smoke, gases, and other byproducts of
combustion from a building, industrial facility, or any type of
heating or combustion system. Chimneys provide a means for
these emissions to safely exit the structure or system and be
released into the atmosphere.
Chimneys play a crucial role in industrial processes,
residential heating systems, and power generation facilities by
providing a safe and efficient means to exhaust combustion
byproducts. They contribute to both operational efficiency and
environmental protection by ensuring that harmful emission
are properly dispersed and minimized.
➢ Why are chimneys designed with a very high length?
POWER GENERATION IN
TURBINE
A steam turbine is a mechanical device that converts the
energy stored in steam into mechanical work, which is then
used to generate electricity or perform other types of
mechanical tasks. It's a critical component in many power
generation systems, including steam power plants and certain
types of industrial processes. Here's what happens inside a
steam turbine:
1.STEAM PATH
2.WATER PATH
3.FLUE GAS PATH
1.WATER PATH:
2.STEAM PATH: