Table of Contents

CHAPTER 1..............................................................................................................................1
INTRODUCTION.................................................................................................................1
1.1 INTRODUCTION...........................................................................................................1
1.2 COMPANY PROFILE.....................................................................................................2
1.3 LEADERSHIP TEAM.....................................................................................................3
1.4 ORGANIZATION DETAILS..........................................................................................3
1.5 DEPARTMENT STRUCTURE.......................................................................................4
1.5.1 DEPARTMENTAL FUNCTION...............................................................................5
CHAPTER 2..............................................................................................................................7
PROCESS PLANT....................................................................................................................7
2.1 PROCESS PLANT DETAILS.........................................................................................7
2.2 PROCESS PLANT MACHINERY..................................................................................8
2.3 SUGAR MAKING PROCESS........................................................................................8
2.4 COGEN PLANT DETAILS...........................................................................................13
2.5 COMPONENTS OF PLANT.........................................................................................13
2.5.1 STEAM GENERATOR...........................................................................................14
2.5.2 TURBINE................................................................................................................19
2.5.3 SURFACE CONDENSER......................................................................................21
2.5.4 CONDENSATE EXTRACTION PUMP................................................................21
2.5.5 DEAERATOR.......................................................................................................23
2.5.6 BOILER FEED PUMP............................................................................................24
2.5.7 HIGH PRESSURE FW HEATERS.........................................................................24
2.5.8 COOLING TOWER................................................................................................26
2.5.9 WATER TREATMENT PLANT.............................................................................28
CHAPTER 3............................................................................................................................29
TASKS PERFORMED........................................................................................................29
3.1 STEAM GENERATOR EFFICIENCY......................................................................29
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3.2 OVERALL EFFICIENCY OF THE PLANT.............................................................30

3.3 HEAT RATE...............................................................................................................31
3.4 EFFECTIVENESS OF H P HEATERS.....................................................................32
3.5 TECHNICAL DETAILS OF STEAM GENERATOR...............................................34
3.5.1 TEMPERATURE PLOT.............................................................................................35
TEMPERATURE PLOT OF FLUE GAS........................................................................35
TEMPERATURE PLOT OF FEED WATER...................................................................36
3.6 EXPERIMENTAL ANALYSIS.....................................................................................37
3.6.1 ANALYSIS OF FUEL.............................................................................................37
3.6.2 ASH CONTENT......................................................................................................40
3.6.3 FEED WATER QUALITY....................................................................................41
CHAPTER 4............................................................................................................................42
REFLECTION NOTES.......................................................................................................42
4.1 TECHNICAL DEVELOPMENTS................................................................................42
4.2 NON - TECHNICAL OUTCOMES..............................................................................44
4.3 BEST EXPERIENCES..................................................................................................45

LIST OF FIGURES
Figure 1: Department Structure.................................................................................................4
Figure 2: Steam Turbine..........................................................................................................19
Figure 3: Surface condenser...................................................................................................21
Figure 4: Deaerator.................................................................................................................23
Figure 5: Schematic of High Pressure Feed water Heater 1....................................................25
Figure 6: Schematic of Feed Water Heater 2...........................................................................26
Figure 7: Flow diagram of Water Treatment Plant..................................................................28
Figure 8: Flow diagram for flue gas path................................................................................35
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Figure 9: Flow diagram of the feed water path........................................................................36

LIST OF TABLES
Table 1: Organization Details...............................................................................3
Table 2: Details of Process Plant...........................................................................7
Table 3: Machines of Process Plant.......................................................................8
Table 4: Details of Cogeneration Plant.................................................................13
Table 5: Details of Steam Generator....................................................................15
Table 6: Operating Parameters of Turbine.............................................................20
Table 7: Parameters of Surface Condenser.............................................................21
Table 8: Technical Specification of CEP...............................................................22
Table 9: Technical Parameters of Deaerator...........................................................24
Table 10: Details of Feed water heaters................................................................24
Table 11: Operating parameters of H P -1........................................................................25
Table 12: Operating parameters of H P -2........................................................................26
Table 13: Design Data of Cooling Tower.........................................................................27
Table 14: Technical Specification of the cooling Tower.......................................................27
Table 15: Fuel Specification of the Steam Generator..........................................................34
Table 16: Fuel Consumption rate...................................................................................34
Table 17: LOI Percentage............................................................................................ 34
Table 18: Data of ash collection.................................................................................... 35
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Table 19: Readings for calorific value of Coal..................................................................39

Table 20: Readings for calorific value of bagasse..............................................................40
Table 21: Reading for calculation of ash content of coal......................................................40
Table 22: PH and EC readings....................................................................................... 41

CHAPTER 1
INTRODUCTION
1.1 INTRODUCTION
Indian sugar industry, second largest agro-based processing industry after the cotton
textiles industry in country, has a lions share in accelerating industrialization process and
bringing socio-economic changes in under developed rural areas. Sugar industry covers
around 7.5% of total rural population and provides employment to 5 lakh rural people. About
4.5 crore farmers are engaged in sugarcane cultivation in India. Sugar mills (co-operative,
private, and public) have been instrumental in initiating a number of entrepreneurial activities
in rural India, understand its problems and challenges in context of ongoing liberalization
process. Indian sugar industry can be a global leader provided it comes out of the vicious
cycle of shortage and surplus of sugarcane, lower sugarcane yield, lower sugar recovery, ever
increasing production costs and mounting losses. It needs quality management at all levels of
activity to enhance productivity and production. Attention is required on cost minimization
and undertaking by product processing activities.
Sugar is produced in 121 countries and global production now exceeds 120 million
tons a year. Approximately 70% is produced from sugar cane which is largely grown in
tropical countries and the remaining 30% is produced from sugar beet grown mostly in the
temperate zones of the north.
Sugar cane is a genus of tropical grasses which requires strong sunlight and abundant
water for satisfactory growth. As with most commercial crops, there are many cultivars
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available to the cane farmer, usually hybrids of several species. Some varieties grow up to 5
meters tail.
The cane itself looks rather like bamboo cane and it is here that the sucrose is stored.
In the right climate the cane will grow in 12 months and when cut, will re-grow in another 12
months provided the roots are undisturbed.
A typical sugar content for mature cane would be 10% by weight but the figure
depends on the variety and from season to season and location to location. Equally, the yield
of cane from the field varies considerably but a rough and ready overall value to use in
estimating sugar production 100 tons of cane per hectare or 10 tons of sugar per hectare.

1.2 COMPANY PROFILE

Sri Chamundeswari Sugars Limited (SCSL), incorporated in December 1970, is
promoted by Dr.N.Mahalingam of the Sakthi Group Coimbatore, Tamil Nadu. The
Company's Board comprises of One Non-Executive chairman, one Managing director, one
Executive director, and seven non-executive directors
SCSL started its operation to manufacture sugar with an installed capacity of 1250
TCD in 1974 at K.M.Doddi, Maddur Taluk, Mandya District in Karnataka. It undertook
expansion of its sugar manufacturing capacity from 1250 TCD to 2400 TCD in 1986 and
further to 4000 TCD in 2006
In the year 2002-03, the company set up a distillery unit to manufacture rectified
spirit, denatured sprit and extra alcohol from molasses with an installed capacity of 50 kilo
liters per day (KLPD). Along with the Distillery Plant, biogas and bio-compost units has been
setup to treat and add value to the effluent form the distillery. The bio-compost unit was put
up to produce Bio-fertilizer by biologically assimilating wastewater effluent into Press-mud
organically without causing any damage to environmental factors. It is one of the model units
in India, which are treating effluents.

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In March 2004, the Company put up a Unique Plant for Extracting Methane forcibly
form Wastewater of Distillery Plant. This plant is in conformity to the norms of UNFCCC as
a Project of Clean Development Mechanism. The project eliminates incidental emission of
Methane Gas to the atmosphere while in storage. The project is eligible for carbon credits
under CMD.
The Co-generation plant of 26 MW has been started operations with effective from
02.04.2008. During the year 2007-08 the Company has taken on Lease 1250 TCD capacity
Hemavathy Sakkare Kharkhane Niyamit situated at Srinivasapura, Channarayapatna Taluk,
Hassan District of Karnataka for a period of 30 years commencing form 26/10/2007 . The
company has Commenced Operations in the leased facility form Dec.2007.

1.3 LEADERSHIP TEAM

At the helm of the leadership team stands honorable Chairman, Dr. N. Mahalingam,
who continues to be Chamundeshwaris torch bearer leading it into a prosperous future. His
son, M. Srinivaasan, took over as the Managing Director of the company in 1993-94 and as
an experienced entrepreneur ensures the smoothing running of all daily operations.
The Company's Board comprises of One Non-Executive chairman, one Managing
director, one Executive director, and seven non-executive directors.

1.4 ORGANIZATION DETAILS

S.

SUGAR PROCESS PLANT

DETAILS

N.
1

COGENERATION

DETAILS

PLANT
Capacity of the plant

Sugar grade

4000 TCD

S 30

Capacity of the plant

26 MW

Export

17.5 MW

Home
Type of fuel used

7.5 MW
Bagasse, coal,
biogas

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Sugar production quantity

375 Tons/day

Total number of employees

680 including
Cogen

Table 1: Organization Details

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1.5 DEPARTMENT STRUCTURE

Sri Chamundeswari Sugars Pvt. Ltd.

Biogas plant

Process Plant
Accounts Dept.

Distillery

Cogen Plant

Electrical Dept.

Administration
H R Department
Mechanical Dept.

Sugar unloading

Engineering Dept.
Process Dept.

Laboratory
Control Room

Engineering Dept.
Mechanical Workshop

Water Treatment Plant

Tool and Spares

Marketing Dept.

Scaffolding

Test Laboratory

Packing and Storage

Figure 1: Department Structure

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1.5.1 DEPARTMENTAL FUNCTION

Sri Chamundeswari Sugars Pvt. Ltd. has 3 important units which includes Sugar
Process Plant, Cogeneration plant and Distillery.
The sugar process plant has various departments which performs different functions
in order to run the plant in a coordinated and effective way.
The sugar process plant consists of following departments with its functions.

Administration It includes the office of vice president, accounts handling

department and H R department. The accounts of plant of Doddi region is handled by
this department. Every important meeting with employees, guests, higher officials and
various delegates is carried out here itself. All the financial transactions related to
plant is accounted here. The recruitment of the new employees and training facility is

managed by H R Department.
Sugar unloading There is a separate unit for sugar cane unloading that is brought
through tractors. The sugar is unloaded mechanically through three hoists which is
controlled manually. The sugar cane of amount 4000 Tones is unloaded daily in order
to run the plant to its full capacity. The main function of this department is to decide
on which feeder among 3 feeders to unload the sugar cane to balance flow of sugar

cane in the cane carrier.

Process Department The sugar making process starting from raw sugar cane to
final sugar includes various steps which is done through the help of various machines.
The whole sugar making process is handled by process department. The head of this
department is the Deputy General Manager under which several process engineers
and employees works. It also consist one laboratory .The laboratory functions to take
sample of sugar juice tapped from various points to evaluate its physical and chemical
properties and compared with the standards so that the sugar quality analyzed.

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Engineering Department This department consist of one senior engineer and other
junior engineers. Their function is to keep all the machines of the process plant in the
workable condition. The maintenance and the fabrication work is the main job of this

department.
Mechanical Workshop All the mechanical maintenance and the fabrication work is
carried out here. It consists of tools and spares department which takes care of the
tools to increase its availability. The scaffolding department keeps all the scaffoldings
needed for construction and maintenance of machines and equipment. Casting of

some spare parts is also done in this department for temporary purpose.
Packaging and storage The final sugar coming from the process plant has to be
packaged and supplied in the market. The main function of this department is to
maintain the ware house available for the new packed sugar and to load the final
sugar pack into vehicles.

The Cogeneration plant consists of various departments in order to run the plant
effectively. It actually runs with manufacturer supplied instructions so that all the machines
run in the safest mode and prevent the unwanted tripping of any system.
The accounts, engineering and laboratory perform the same function as in the process plant.

Control Room The control room consists of four computers from where engineers
will be monitoring the whole plant every time. All the machines parameters can be
controlled from the control room itself. The engineers in the control room monitor the
plant as a whole and take any action if some parameters offset the set point of the
system.

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CHAPTER 2
PROCESS PLANT
2.1 PROCESS PLANT DETAILS
S. NO.

Particulars

Value

Sugar Cane crushing capacity

4000 TCD
8.5 -10.5 %

Sugar produced

9 tons average for every

Molasses for distillery

100 tons
4 -5 %

Bagasse

25 -30 %

Imbibition water flow

30 -35 %
Avg. 48 TPH

Raw juice

65 -70%

Table 2: Details of Process Plant

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2.2 PROCESS PLANT MACHINERY

S. NO.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

MACHINES
Crushing mills
Juice Buffer collection tank
Primary Heater
Reaction vessel
Secondary heater
Clarifier
Vacuum filter
Clear Juice heater
Multiple effect evaporators
Vacuum Pan Crystallizer
Crystallizer
Centrifugals
Raw sugar melter
Hopper
Sizer

NUMBER
6
1
4
1
4
1
1
1
10
9
13
15
1
2
6

Table 3: Machines of Process Plant

2.3 SUGAR MAKING PROCESS

The industrial process for sugar manufacturing involves the application of several
processes to transform sugarcane juice into crystals and clean them naturally from impurities
that can harm the organism.
The manufacturing process consists of the following sub-processes:

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a. Entrance

b. Milling

f. Separation g. Refining

c. Clarification

d. Evaporation

h. Drying

i. Packing

e. Crystallization

2.3.1 ENTRANCE
Starts by weighing the units on a scale that transports sugar cane in the mill and that
are at the entrance of the industrial area. Also, this is where the quality of raw material is
determined, taking samples that are analyzed continuously in the quality control lab.
The sugarcane that arrives at the manufacturer is discharged on the feeding tables
through sugarcane rotators with a capacity of 50 MT. To have a cleaner process, in the
sugarcane tables water is applied between 40 and 50C for washing, removing solids or
foreign matter like soil, salts, minerals, stones and others that are adhered to the same in the
soil when lifted to the cages that transport the same to the manufacturer.
Then, the sugarcane undergoes a preparation process that consists of braking and
removing fiber from the stem cells through chippers, oscillating mincers and fiber removers
to proceed with the juice extraction process.

2.3.2 MILLING
This is a continuous process that is currently carried out in six mill tandems. The
prepared sugar cane is fed into these tandems, which undergoes a series of extractions using
roll mills or mallets, and all the mills have four V-type striped mallets. To make the mill
process more efficient, the poor juices of the subsequent millings are reprocessed
(compounded imbibition process) and hot water is applied in the last milling at a temperature
between 70 C and 80 C to increase the extraction.
The bagasse is an industrial product that is transported toward the boiler system to use
it in its biomass state as fuel. The remaining is used for the hydrolyzation and reserve to
cover emergency stops.

2.3.3 CLARIFICATION
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The juice derived from the mills goes through heaters that reach temperatures
between 60C and 70 C. Then, it goes through a tank where, milk of lime is added,
decreasing the pH to produce only white sugar.
In this phase, milk of lime is used as a bleaching agent; and the juice is neutralized
and the limed juice enters a gravitational settling tank; a clarifier. The juice travels through
the clarifier at a very low superficial velocity so that solids settle out and clear juice exits.
The mud from the clarifier still contains valuable sugar so it is filtered on rotary
vacuum filters where, the residual juice is extracted and the mud can be washed before
discharge, producing sweet water. The juice and the sweet water are returned to process.
The clear juice has probably only 15% sugar content but saturated sugar liquor,
required before crystallization can occur, is close to 80% sugar content. Evaporation in a
steam heated multiple effect evaporator is the best way of approaching the saturated
condition because low pressure water vapours can be produced for heating duties elsewhere
in the factory.
The evaporator sets the steam consumption of the factory and is designed to match
the energy balance of the entire site; the manager wants to avoid burning auxiliary fuel and
equally wants to avoid paying to dispose of surplus bagasse. The greater number of effects,
the less steam is required to drive the first effect. Each subsequent effect is heated by the
vapour from the previous effect so has to be operated at a lower temperature and therefore
lower pressure.

2.3.4 CRYSTALISATION
Physical chemistry assists with sugar purification during the crystalisation process
because there is a natural tendency for the sugar crystals to form as pure sucrose, rejecting
the non-sugars. Thus, when the sugar crystals are grown in the mother liquor, they tend to be
pure and the mother liquor becomes more impure. Most remaining non-sugar in the product
is contained in the coating of mother liquor left on the crystals.

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The mother liquor still contains valuable sugar of course so the crystallization is
repeated several times. However non-sugars inhibit the crystallization. This is particularly
true of other sugars such as glucose and fructose which are the breakdown products of
sucrose. Each subsequent step therefore becomes more difficult until one reaches a point
where it is no longer viable to continue.
The crystallization itself a boiling, takes place in a vacuum pan; a large closed kettle
with steam heated pipes. In practice, the heating is done with a low pressure water vapour
from the evaporator. Some modern pans are continuous flow devices but most are batch
devices which go through a discrete cycle and are then emptied for a new boiling. A typical
cycle might be 4 hours long. The mixture of crystals and mother liquor from a boiling, called
the massecuite, is dropped into a receiving tank called a crystallizer where it is cooled
down and the crystals continue to grow. This also releases the pan for a new boiling. From
the crystallizer the massecuite is fed to the centrifuges.
Syrup is taken to pan floor for making sugar crystal. Three massecuites boiling
systems is normally adopted, in which, A, B and C massecuites are boiled. A-massecuites is
formed boing syrup, sugar melt, A light molasses and on B single cured sugar as seed.
This A- massecuite is boiled till it attains the required size of sugar crystal and it is dropped
into crystallizers and cooled. After exhaustion of sugar in solution, the A massecuite is
passed on to the centrifugal for separating sugar crystals from the massecuite. The separated
A sugar is bagged after drying, A-Light and A-Heavy molasses are pumped to pan floor
and are used for making A and B-massecuite respectively.
B-massecuite boiled in B pans is dropped into B-crystallizers and then it is cured
in B-centrifugal machines. B-heavy molasses and B-single cured sugar are obtained
separately. B-single cured sugar is used as seed for massecuite. B-heavy molasses is used for
making C-massecuite in C-pans. C-massecuite is dropped into C-crystallizers where it is
cooled. C-massecuite is then taken to C-fore worker centrifugal machines for curing. Final
molasses and C-single cured sugar are obtained. C single cured sugar are again cured in
another centrifugal machine in which C-double cured sugar and C-light molasses are
obtained. C-light molasses are taken to pan floor and is used in making C-massecuite. CDept. of Thermal power Engineering VTU PG Studies, Mysuru

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double cured sugar is melted and is used in making A-massecuite. Sugar discharged from Amachine is dropped on to grass hopper conveyors.

2.3.5 REFINEMENT
Regarding the production of refined white sugar, there is an additional process that
uses standard white sugar or raw sugar as raw material.
In this process, sugar at 60 brix degrees is dissolved. Then, activated charcoal and
diatomaceous earth is added. This solution undergoes a first and second filtration in vertical
filters until obtaining clear liquor. The liquor is evaporated and the crystallization of crystals
is started

2.3.6 DRYING
In the centrifuge process, condensate water is used to wash sugar, which results in a
humidity between 0.3% and 0.6%; therefore, it is necessary to pass it through the drying
process to reach levels between 0.2% for raw sugar and 0.03% for white sugar.

2.3.7 PACKING
Export raw sugar goes directly from the dryer to the storage warehouses. In the
warehouses, it is loaded in trucks that transport the same to the shipping port. Standard white
and refined sugars are packed in sacks of 50 and 46 kg and jumbos of 1400 kg to be
commercialized locally and internationally.

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2.4 COGEN PLANT DETAILS

S.NO.

Particulars

Details

Plant Capacity

26 MW

Process heat

55 MW

Plant Utilization

7.5 MW

Export to Grid

17.5 MW

Steam Generator

Babcock and Wilcox

Fuel Used

(Thermax)
Bagasse, Biogas, Coal

Turbine Type

Extraction type Impulse

turbine

Table 4: Details of Cogeneration Plant

2.5 COMPONENTS OF PLANT

The power plant comprises of the following listed components.
1. Steam Generator
2. Steam Turbine
3. Surface Condenser
4. Condensate extraction pump
5. Gland steam condenser
6. Deaerator
7. Boiler Feed pump
8. High pressure feed water Heater -1
9. High pressure feed water Heater -2
10. Cooling Tower
11. Water Treatment Plant
The components are described in detail below
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2.5.1 STEAM GENERATOR

A steam generator generates steam at the desired rate at the desired temperature and
pressure by burning fuel in its furnace. A steam generator is a complex integration of furnace,
superheater, reheater, boiler or evaporator, economizer, and air preheater along with various
auxiliaries such as pulverizers, burners, fans, stokers, dust collectors and precipitators, ash
handling equipment, and chimney or stack. The boiler (or evaporator) is that part of the steam
generator where phase change (or boiling) occurs from liquid (water) to vapor (steam),
essentially at constant temperature and pressure.
The steam generator installed in the plant is Babcock and Wilcox type manufactured
by Thermax Limited, Pune, India. It incorporates travelling grate furnace and three types of
fuel namely bagasse, coal and biogas produced from the effluent of the process plant. The
technical specification is given in the following table.

S.No.

Particulars

Details

Pressure

110 kg/cm2 A

Steam outlet Temperature

540 0C

Evaporation capacity

135 TPH

Main fuel

Bagasse, coal and Biogas

Feed water inlet temperature

2100C

Heat Transfer Surface area

Boiler( Furnace panels and convective banks)

3090 m2

Economizer

3142 m2

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Heating surface area for superheating steam

Primary Superheater 1
Primary Superheater 2
Secondary superheater 1
Efficiency of the steam generator
On Bagasse firing
On coal firing

1515 m2
1515 m2
609 m2
71 %
85 %

Table 5: Details of Steam Generator

Boiler pressure part description is as follow
This boiler is a single drum, natural circulation, top supported, and membrane wall
construction. Various pressure parts are grouped as follows:
a.
b.
c.
d.
e.
f.
g.
h.

Steam Drum
Downcomer tubes
Furnace membrane water walls
Riser tubes
Saturated steam supply tubes
Super heater
Convection Bank
Economizer

The short description of each of the part is given below.

a. STEAM DRUM
Steam Drum is welded cylindrical vessel made of SA 517 Gr. 70 material. It is
provided with manholes for maintenance purpose. It is fitted with several components to
perform important functions like water level gauge, level transmitters, drum safety valves,
continuous blow down outlet, HP dosing connection to dose phosphate in to the steam drum
to maintain the boiler water quality, two air vent with isolation valves, local pressure gauge.
Steam drum internals are provided to supply moisture free steam to S.H. coils. Steam
drum receives water/steam mixture from the water wall panels through the riser tubes in the
baffles of the boiler drum. From the drum internal pocket, water steam mixture flows
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tangentially through the Cyclone steam separators. In this tangential flow, water which is
heavier is separated from steam and trickle down to mix with the water in the drum. Steam
rises upward to flow through the two rows of scrubbers, Primary scrubbers (21) and
secondary scrubbers (16) and finally through perforated sheets to steam outlet of the drum.
b. FURNACE
Furnace is the part of the boiler where the chemical energy in the fuel is converted
into thermal energy by absorbing the heat produced through combustion of fuel. The furnace
is designed for efficient and complete combustion, with due consideration to the factors that
effect, combustion efficiency like fuel residence time inside the furnace, temperature and the
turbulence required for complete mixing of the air and fuel.
Furnace is constructed with membrane (water wall) construction. It comprises of
front panel, rear panel, L.H panel and R.H panel.
c. RISER TUBES
The purpose of these tubes is to carry the saturated steam from side wall panels, front
wall and rear wall to steam drum. The total numbers of riser tubes from all four sides that are
connected to steam drum are 50, each of 101.6 mm OD and 5.6 mm thick.
d. SUPER HEATER
From the drum, steam flows to primary super heater -1 inlet header ( 250 NB *160
SCH) through 7 nos. 101.6 OD* 5.6 thick supply tubes. From the primary superheater inlet
header steam flows to primary superheater -1 outlet header through 50.8 OD * 5.6 thick coils.
Primary SH-1 outlet header is connected to attemperator -1 header. Attemperator-1 is
provided to control the temperature after P SH-2 by water spray from feed water system. One
spray nozzle is provided in attemperator-1. From attemperator, steam is passed through
primary SH-2 inlet header and from the PSH-2 steam flows to PSH-2 outlet header through
50.6 OD* 4.5 thick coils.
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Form PSH-2 outlet header, steam passes through attemperator-2. Attemperator-2 is

provided to control the final superheater temperature. Spray nozzle is provided in the
attermperator-2. From attemperator-2, steam is passed through secondary SH -2 inlet header.
Steam then, flows to SSH-2 outlet header through 50.8 OD* 4.5 thick coils.
The main function of attemperator is to limit the temperature within the set point of
each superheater.
e. CONVECTION BANK
The name itself indicates that heat transfer in this area is by convection mode. This is
a single drum boiler and the convection bank is in the form of modules between two headers.
Water is supplied to the convection bank by 101.6 OD *5.6 thick Downcomer. Convection
bank are connected to steam drum through 12 nos. 101.6 O.D*5.6 thick riser tubes.
Convection bank modules are constructed with 50.8 OD *4.06 thick tubes. Both ends of the
tubes are welded to the convection bank top and bottom header.
f. ECONOMIZER
The function of the economizer in a steam generating unit is to absorb heat from the
flue gases and add this as a sensible heat to the feed water, before the water enters to the
steam drum.
Provision of this additional heating surface, increases the efficiency of the steam
generating unit and saving in fuel consumption is achieved. Economizer is located in
between boiler bank outlet and air pre-heater.
Economizer assembly is constructed with 62 rows of 38.1 OD * 4.06 thick tubes, in
four banks and two headers. Both the ends of the coil were terminated to the top and bottom
header by welding.
Feed water flows from the bottom header to the top header through these coils.
Heated water flows out from the top header to steam drum through the convecting pipe.
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Economizer is provided with 6 nos. motorized soot blowers to clean the external
deposits.

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g. SOOT BLOWERS
Soot blowers are the devices in steam generator that functions to remove soot
deposited on the heat transfer surfaces on various zones like furnace wall, super heater, and
economizer. There are 18 soot blowers in the steam generator.
There are two types of soot blowers installed in the steam generator
1. Rotary Soot Blower
2. Long Retractable soot blower
Rotary Soot blowers
It is also called wall blower. The lance extends a short distance around 200 mm from
the furnace wall. The nozzle direction is such that the steam impinges on the walls cleaning
the surface. During operation, the lance rotates cleaning the radial area covered by the steam
form the nozzle. There are 14 rotary soot blowers .Among them, 4 are in water walls, 4 in
convection bank tubes and remaining 6 are in economizer tubes.

Long Retractable soot blowers

The function of the long retractable soot blowers is to remove the soot deposited on

coil/tubes in high temperature zone.( eg. Superheater coils). To avoid sagging of lance
element from high temperature of flue gas, LRSB is parked outside the boiler. Venturi
nozzles fitted on lancing element achieve high cleaning efficiency.
The operation of the soot blower is explained below
The soot blower consists of lance tube with a nozzle at the end. When it is operated,
the lance tube is extended into the boiler and steam is admitted through the lance. The steam
comes out at a high velocity jet through the nozzle which cleans the ash deposited on the
surface. When the lance moves into the boiler, it is also rotating so that it cleans the sweeping
area covered by the circular travel of the nozzle. The lance is then retracted back.
There are 4 LRSB installed on the superheater coils zone.
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Technical Parameters are given as:

Temperature range

320 340 0C

Steam consumption (for 18) =

2 2.25 tons /shift

Blowing pressure

15 -40 kg/cm2

Blowers operating time

1 min 42 sec

2.5.2 TURBINE
A steam turbine is a prime mover which continuously converts the energy of high
pressure, high temperature steam supplied by a steam generator into shaft work with the low
temperature steam exhausted to a condenser.
The turbine used in this plant is of Extraction turbine type, in which a controlled
extraction from a particular stage is sent for the process heating and remaining steam is
completely expanded in turbine to produce a power of 26 MW.

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Figure 2: Steam Turbine

The Technical specifications of the turbine are as below:

Type
Rated output

Horizontal, impulse, multi stage, axial flow,

condensing, extraction, axial exhaust
26 MW

Operating parameters of Turbine :

Turbine Speed

4897 rpm

Generator Speed

1500 rpm

Inlet steam pressure

105

kg/cm2

Inlet steam temperature

540

37.57 oC

Exhaust steam temperature

Max. Exhaust steam pressure

0.1

kg/cm2

Max. 1st Extraction pressure

21.3

Max. 2nd Extraction pressure

10.59 kg/cm2 (Un-controlled extraction)

Max. 3rd Extraction pressure

Max. inlet flow

3.0

kg/cm2 (Un-controlled extraction)

kg/cm2 (Controlled extraction)

132

TPH

1st Ext. flow

2.0 to 9.35 TPH

2nd Ext. flow

3.9 to 19.73 TPH

3rd Ext. flow

9.0 to 82.89 TPH

Max exhaust steam flow

68.55

TPH

Table 6: Operating Parameters of Turbine

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2.5.3 SURFACE CONDENSER

Figure 3: Surface condenser

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 above 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. The details of
shell and tube heat exchangers are tabulated below.
Particulars

SHELL SIDE

TUBE SIDE

Design pressure (kg/cm )

-0.9 & F.V

5.0

Design temperature (oC)

120

80

No. of passes

02

No. of tubes

5760

Tube size

19.05 18BWG 7475 mm

Table 7: Parameters of Surface Condenser

2.5.4 CONDENSATE EXTRACTION PUMP

The condensate extraction pump (CEP) of vertical centrifugal type pumps the feed
water from the condensate hot well to the Deaerator. Three number (each 50% capacity) in
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parallel supplies the feed water to the deaerator. (1 working and 2 stand by).The discharge
from each CEP connects to a header and is supplied to deaerator.
The technical specification of the CEP is tabulated below.
S.No.

Parameters

Value

Pump Type

Centrifugal, vertical

Number

3 (1W +2 S)

Liquid Temperature

45.450C

Liquid specific gravity

Capacity (max)

50 m3/hr

Discharge pressure

7.7 kg/cm2a

Suction pressure

0.1 kg/cm2

Number of stage

Pump speed

Approx 2950

10

Gland packing

Mechanical seal

11

MOC of impeller

Stainless steel

Table 8: Technical Specification of CEP

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2.5.5 DEAERATOR

Turbine 3rd Ext

9 ATA Header

HP-1 Vent
HP-2 Vent
HP-1
condensate
HP-2

CEP discharge

condensate

Flash steam from

CBD tank

Pegging steam

Figure 4: Deaerator
Generally, power stations use a deaerator to provide for the removal of air and other
dissolved gases from the boiler feed water. A deaerator typically includes a vertical, domed
deaeration section mounted on top of a horizontal cylindrical vessel which serves as the
deaerated boiler feed water storage tank.
Pressure maintained (kg/cm2)

1.2

Pressure of F.W inlet (kg/cm2)

3.5 to 4

Temperature of F.W inlet (oC)

55

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Temperature of F.W outlet (oC)

120

Temperature of steam inlet (oC)

127to130

Flow rate of F.W inlet (TPH)

24.5

Flow rate of steam inlet (TPH)

4.7

Flow rate of F.W inlet (TPH)

24.5

Water level maintained in Deaerator

50%

Table 9: Technical Parameters of Deaerator

2.5.6 BOILER FEED PUMP
The boiler feed pump feeds the water from the deaerator with a suction pressure of
2.5 kg/cm2 to a discharge pressure of 115 kg /cm2. There are 3 boiler feed pumps among
which 2 are working and 1 is standby. Each boiler feed pump motor rating is 450 kW
2.5.7 HIGH PRESSURE FW HEATERS
The feed water heating equipment then raises the temperature of the water by
utilizing extraction steam from various stages of the turbine. Preheating the feed water
reduces the irreversibilities 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.
The plant uses two High pressure feed water heaters and the details of these feed
water heaters are as below
Details of feed water heaters
Raise in Feed water Temperature(HP1/HP-2)

40 / 30 (oC)

No. of passes for tubes

02

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122.04 m2

Heating surface area

Table 10: Details of Feed water heaters

Turbine 2nd Extr

F.W to HP-2

Cond. from HP-2

HP-1
Deaerator
T = 40 oC
Flash tank

BFP discharge

Figure 5: Schematic of High Pressure Feed water Heater 1

Operating parameters of High Pressure heater -1
Steam inlet Temperature (oC)

254.6

Steam inlet Pressure (kg/cm2)

Steam inlet Flow rate (TPH)

10.2

F.W inlet Temperature (oC)

120.1

F.W outlet Temperature (oC)

160

F.W Pressure (kg/cm2)

120-123

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F.W flow rate (TPH)

128-135

Table 11: Operating parameters of H P -1

Turbine 1st Extr

steam

Boiler

HP-2
Deaerator

T = 30 oC

HP-1

F.W from HP-1

Flash tank

Figure 6: Schematic of Feed Water Heater 2

Operating parameters of High Pressure Heater-2

Steam inlet Temperature (oC)

325.9

Steam inlet Pressure (kg/cm2)

20

Steam inlet Flow rate (TPH)

7.5

F.W inlet Temperature (oC)

160-165

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F.W outlet Temperature (oC)

190-195

F.W Pressure (kg/cm2)

120-123

F.W flow rate (TPH)

128-135

Table 12: Operating parameters of H P -2

2.5.8 COOLING TOWER

A Cooling Tower is an enclosed device, designed for the evaporative cooling of the
water by the direct contact with air, which must be maintained with reasonable care if it is to
be given peak performance. The cooling tower consists of a RCC structure, fill and fill
supports, water distribution system, fans, gear boxes, drive shafts and motors. The sizing of
the tower is done depending on the amount of the water to be cooled and the degree to which
the water is to be cooled.
The cooling tower in the plant is Induced mechanical draft type with two cells each
including Induced draft fan.
OPERATING PRINCIPLE
Cooling tower operates on the principle of evaporative cooling of water. Hot water
from the plant is distributed and allowed to flow over packing. Air is induced through the
packing and brought in contact with water by means of fans. The intimated contact of water
and air causes evaporation of the water. The water that is evaporated carries away the latent
heat of vaporization from the bulk of the water, thus cooling it. In order to provide heat
transfer (bulk of heat by latent heat and smaller proportion of sensible heat), fills are used.
DESIGN DATA:
Water flow rate

5200 m3/hr

Hot water temperature

42 0C

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Cold water temperature

32 0C

Design inlet WBT

27.5 0C

Number of Cells

Table 13: Design Data of Cooling Tower

TECHNICAL SPECIFICATION:
Fan Type

Axial Flow

Fan Diameter

9150 mm

Number of Blades

Motor Type

3 phase AC squirrel cage induction motor

Rated motor power

55 kW

Fill pack MOC

PVC and Type: Film flow

Drift eliminator MOC

PVC

Table 14: Technical Specification of the cooling Tower

COOLING TOWER WORKING PARAMETERS
Loss of water due to evaporation: 45 m3/hr
Make- up water Needed: 45 m3/hr

(Excluding other losses)

2.5.9 WATER TREATMENT PLANT

The raw water is first pre-treated and demineralized prior to feeding it to the boiler. The
main advantages of feed water treatment are

Prevention of hard scale formation on the heating surfaces

Elimination of corrosion
Control of carry over to eliminate deposition on superheater tubes and
Prevents of silica deposition and corrosion damage to turbine blades

Raw water contains varieties of impurity such as suspended solids and turbidity, organics,
hardness (salts of calcium and magnesium), alkalinity (carbonates, bicarbonates and
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hydrates), other dissolved ions (sodium, sulphate, chlorides), silica, dissolved gas(O 2,
CO2).The extent of pre-treatment depends on source of raw water.The water treatment plant
consists of following flow diagram.
Raw water Tank

Clarifier (Fecl3,
Polymer, NaHcl3)

D M Plant

Clear water Tank

Degasser Plant

Raw water Tank

Multi Grade Filter

Ultra filtration Unit

Strong acid cation

Strong base anion

Storage tank
Mixed bed
DM Storage tank

R O Plant

Figure 7: Flow diagram of Water Treatment Plant

CHAPTER 3
TASKS PERFORMED
3.1 STEAM GENERATOR EFFICIENCY
The boiler (steam generator) efficiency is defined as
rate of energy absorption by water

boiler = form steam

rate of energy release by combustionof fuel

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boiler =

w s (h1h 11 )
wf CV

Where ws is the steam generation rate and wf is the fuel consumption rate and CV is
the calorific value of the fuel
Heat input rate (Qin) = wf * C V
Of the total fuel energy input (coal, bagasse and biogas)
Qin = wc * GCVcoal + wb * GCVbagasse + wb* GCVbiogas
Qin = 0.833*20580 + 11.94 * 9240 + 0.2778 *16000 = 131913.54 kW
The value of the variables are tabulated below
S.NO
.
1
2

PARAMETERS

VALUE

Qin (kW)

131913.54

h1 (kJ/kg)

3420

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h11 (kJ/kg)

875

ws (kg/s)

35.28

Calculating with the above values

boiler =68.065 %
The efficiency of the steam generator came to be 68.065 % which implies that only
68.065 % of the energy on the fuel is taken by the feed water. The ideal efficiency of the
steam generator on bagasse is 71 % which shows that the boiler is running in 3 % lower
efficiency as provided by the manufacturer.

3.2 OVERALL EFFICIENCY OF THE PLANT

The overall efficiency of the plant is defined as

o =

Electrical Power+ Thermal Power

wf CV

Electrical power output =

25.1 MW = 25100 kW

Power taken by auxiliaries, BFP and CEP = 2450 kW

Process steam parameters are as below,

Extraction pressure = 1.15 kg/cm2 , Temperature = 128.3 0C ( Superheated condition)
Mass flow rate (m) = 73.8 TPH = 20.5 kg/s

At P = 1.15 kg/cm2 ,the steam parameters are,

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Tsat = 103.6 0C, cp = 2.135 kJ/kg

, hfg = 2241.1 kJ/kg

h(extracted steam) = 2727.417 kJ/kg

Qin
h = 2727.417
kJ/kg

Sugar Process
heat

M=20.5 kg/s

T sat
h f = 434.2 kJ/kg
m = 20.5 kg/s

Thermal Power ( Qin) = m ( h hf) = 20.5 (2727.417 434.2) = 47469.5919 kW

Q in = 47469.5919 kW
Net power Output = 22650 kW
o =

Electrical Power+ Thermal Power

wf CV

o =

22650+ 47469.5919
131913.54

o =53.155
The overall efficiency of the plant is 53.155 %. The overall efficiency of
the Cogeneration plant is fairly in the higher end than that of the thermal power plant alone
running on the same fuel because the majority of the heat which is otherwise(thermal power
plant alone) dumped in the condenser is used as thermal power in the process industry in case
of Cogeneration plant.
3.3 HEAT RATE
Net heat used

Heat rate= produce power

Net power produced

Heat rate=

131913.5420.52727.417
22650

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Heat rate=

3.35 kJ /s
= 12079 kJ/kw hour
kW
= 2876.1207 kCal/kW hr

Heat rate = 2877 kcal/kW hr

It indicates that the heat supply of 2877 kcal is required to produce 1 kW hr of power.

3.4 EFFECTIVENESS OF H P HEATERS

For High Pressure heater-1

Turbine 2nd Extr

HP-1 cond.
213.6 oC

250.6 oC
10.2TPH
9.9 kg/cm2

5.05TPH

HP-1
HP-2

BFP
o

121.1 C

T = 40 C

160.9 oC

124 kg/cm2
121.6TPH
Deaerator

250.6
steam
180.0
160.9
F.W

Temp

120.1 VTU PG Studies, Mysuru

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actual heat transfer

maximum heat transfer

Effectiveness of heat exchanger =

Q act
Q max

33.78 4.2 40.8

2.2 2.83 ( 250.6180 ) +2.83 2013.6+ 2.83 4.2 (180120.1)

5788.5
6850.015

0.85

For High pressure heater -2

Turbine 1st Extr.
325.9 oC
20.52 kg/cm2
7.5TPH

F.W out

200.8 oC

HP-2

F.W in
170.9 oC
124.2 kg/cm2
121.6 TPH

T = 30 C

Condensate to HP-1

325.9
213.6

steam

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200.8
F.W
Temp (oC)
170.9
length

Effectiveness of heat exchanger =

actual heat transfer

maximum heat transfer
Q act
Q max

33.78 4.2 30
2.08 2.27 ( 325.9213.6 )+ 2.08 1883..6+ 2.08 4.2 (213.6170.9)

3890.14
4823.005

= 0.80

3.5 TECHNICAL DETAILS OF STEAM GENERATOR

FUEL SPECIFICATION
S. N.

Fuel

Gross calorific value (kJ/kg)

Imported Coal (Sub bituminous)

20,580

Bagasse

9240

Biogas

16000

Table 15: Fuel Specification of the Steam Generator

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AVERAGE FUEL CONSUMPTION RATE

S. N.

Fuel

Consumption rate (TPH)

Imported Coal (Sub bituminous)

Bagasse

43

Biogas

Table 16: Fuel Consumption rate

LOSS OF IGNITION (LOI) % ANALYSIS

S. N.

ASH

LOI %

Bottom ash

8.43

APH ash

20.60

ESP ash

13.82

Table 17: LOI Percentage

ASH COLLECTION DATA

S. N.

ASH

COLLECTION RATE

Bottom ash ( kg/hour)

416 (approx..)

Fly ash (kg/hour )

564(approx.)

Table 18: Data of ash collection

3.5.1 TEMPERATURE PLOT

TEMPERATURE PLOT OF FLUE GAS
Air from Atmosphere

Furnace

379.1 0C

30 0C

FD Fan

207.8 0C
Economizer

722.1 C
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128 0C
183.3 0 C

Stack to atmosphere

I D Fan

128 0C

ESP

Figure 8: Flow diagram for flue gas path

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TEMPERATURE PLOT OF FEED WATER

44.5 oC

condenser

CEP

45.3 oC

Deaerator

115 oC
207.1 oC

Economiser

HP-2

170.9 oC

HP-1

282.5 oC
317.6 oC

Steam

PSH-1

419 oC

Attemperator-1

344.2 oC
425.4 oC

SSH

Attemperator-2

455 oC

PSH-2

525.6 oC
Turbine

Figure 9: Flow diagram of the feed water path

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3.6 EXPERIMENTAL ANALYSIS

Three experiments were carried out of which it includes on analysis of fuel and P H
and Electrical conductivity of feed water.
3.6.1 ANALYSIS OF FUEL
The most important characteristic of the fuel is its calorific value. i.e. energy content.
The fuel used in the plant is coal, bagasse and biogas. Among three fuels, the calorific value
of the fuel is determined in each shift of the plant in order to know the efficiency on which
the plant is running. The determination of the calorific value helps to know the rate of energy
input on the plant.
The plant consists of Bomb calorimeter with a microprocessor to find the calorific
value of the fuel. Several procedures need to be followed and the result will be shown in the
monitor
Bomb calorimeter consists of following main components.

Thermocouple
Stirrer
Water container
Oxygen port
Insulated cover
Sample tray made of SS
Electrodes - To supply current
Magnesium wire for ignition
Microprocessor connection
Monitor

The following procedures are to be carried out in order to determine the calorific value of the
fuel.

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The sample is to be dried for at least 5 -6 hours before it is taken for the experiment.
The sample is taken in a sample tray
If the experiment is carried on as received basis, the moisture should not be removed.
The moisture has to be removed if the experiment is conducted on dry basis and it is

done with the help of the furnace whose temperature is maintained at 102 -103 0C.
The initial weight of the tray is to be noted. And the sample along with the tray is
weighed. The difference in the initial and final weight gives the mass of the sample.

In the plant, the provision of taking sample is 1 gm to the maximum.

Magnesium wire is used for ignition of the fuel which is connected to the two
electrodes where electric supply is given. The thread is also placed in the magnesium

wire for easy combustion.

The oxygen is supplied to the calorimeter to a pressure of 30 kg/cm 2 which will be

recorded by the local pressure gauge.

Now the calorimeter is kept inside the container which is surrounded by

demineralized water.
The stiller is placed in order to maintain the uniform temperature of the water
The thermocouple is placed to measure the temperature of the water which is
connected to the microprocessor so the temperature reading is displayed in the

monitor.
The electric current is supplied and the ignition starts. The record of the gradual

increment in the temperature of the water is shown in the monitor.

The mass of the water taken is also recorded.
The calorific value is shown in the monitor directly.

The following table illustrates the reading to find the calorific value of the coal.
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S. NO.

EXPERIMENTAL DETAILS

VALUE

Initial mass of the tray

19.3866 gm

Final mass with sample

20.3589 gm

Mass of the sample

0.9723 gm

Mass of the Magnesium wire

0.0182 gm

Mass of the thread

0.0165 gm

Ignition temperature of coal

450 0C

Initial temperature of the water

27.87 0C

Final Temperature of water

30.02 0C

Water equivalent mass

2152 .33 gm

10

Oxygen pressure in the calorimeter

30 kg/cm2

11

Calorific value of the coal

4780 kcal/kg

Table 19: Readings for calorific value of Coal

Similarly, the experiment is conducted to find the calorific value of the bagasse on a
dry basis. The sample is kept in the furnace at a temperature of 102 0C so that the moisture is
removed off.
S. NO.

EXPERIMENTAL DETAILS

VALUE

Initial mass of the tray

19.3866 gm

Final mass with sample

20.366 gm

Mass of the sample

0.98 gm

Mass of the Magnesium wire

0.0182 gm

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Mass of the thread

0.0165 gm

Ignition temperature of bagasse

285 0C

Initial temperature of the water

27.87 0C

Final Temperature of water

28.97 0C

Water equivalent mass

2152 .33 gm

10

Oxygen pressure in the calorimeter

30 kg/cm2

11

Calorific value of the bagasse

2200 kcal/kg

Table 20: Readings for calorific value of bagasse

3.6.2 ASH CONTENT
The ash content of the fuel is found with the help of the muffle furnace. The fuel
sample is taken in a crucible and kept in the muffle furnace. As the ash content of the bagasse
is very low in the range of 1 %, this analysis is not done for the same.
The ash content of the coal is found. The coal sample is taken in a crucible with a
known mass of about 1 gm. And it is kept in a muffle furnace along with the sample for about
2 hours at temperature of about 815 0 C. The mass of the ash of the sample is taken and ash
content is determined.
S.NO.

EXPERIMENTAL DETAILS

VALUES

Mass of the sample

5 gm

Muffle furnace temperature

8150C

Mass of the ash

0.1225 gm

Percentage of ash

2.45 %

Table 21: Reading for calculation of ash content of coal

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3.6.3 FEED WATER QUALITY

The quality of the feed water is to be maintained in the feed water system so that
there is no corrosion and erosion of the components of feed water line. The main parameters
to be controlled are PH and electrical conductivity (EC) of the feed water. The P H value should
always be above 7 i.e. basic. Lesser the EC, higher will be the purity of the water. The ions
present in the feed water indicate more EC as it takes part in the conductivity of the current.
Hardness in the feed water should be nil.
The water quality is determined at Water Treatment Lab at each shift of 8 hours.
The P H and EC at different points of feed water system are determined with the help
of laboratory equipment.
PH

Tapping points

Electrical Conductivity

Standard

Result

Standard

Result

Feed water

8.5-9.2

8.7

(s/cm)
10

7.8

Boiler water

9.3 -9.8

9.58

120- 0

48

Main Steam

8.5-9.2

8.68

10

7.42

T G condensate

8.5-9.2

8.72

10

8.00

Sugar Condensate

8.5-9.2

8.66

10

8.7

Cooling Tower

7.6 -8.0

8.00

5000

3560

Recirculation Water

Table 22: PH and EC readings

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CHAPTER 4
REFLECTION NOTES
Sri Chamundeswari Sugars Pvt. Ltd. is the process plant which produces power and
process heat combined. The industrial training of duration four months in this plant has not
only increased my exposure to live problems technically but also increased the level of
communication skills, time management, resource utilization and many other uncountable
personal developments.

4.1 TECHNICAL DEVELOPMENTS

After four months of industrial training and the step by step learning process in this plant,
I am much more sound and confident in the field work and technical analysis of the problem.
No matter how much I explain in this report, it will be still less than I learnt. The following
listed technical achievements are very few among them which I can remember.

The thermal power plant consists of various components starting from steam
generator to steam turbine. The training gave more insight on the components, design
criteria of various systems like steam generator, heat exchanger, cooling tower, ash

handling equipment and steam turbine.

The steam parameters like pressure, temperature, specific volume, and enthalpy are
very much important in the power plant. The effect of variation of steam parameters
greatly affects the system efficiency. By this training, I feel very much comfortable on

using these parameters in the application level.

The technical analysis of the various graphs like Temperature vs. enthalpy, load vs.
turbine efficiency gave me more confidence on analyzing the graph and interpreting
the result.

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During the maintenance of various machines and components, I got to know how
various elements functions in a relationship and it boosted my theoretical knowledge

in the next level.

The type of maintenance ,technical procedure to be followed during maintenance,
changing of lubricant oil of various parts , changing of seals like mechanical seal,

gaskets, oil ring etc were the best and enjoyable aspects of this training.
Various technical training, insight to design drawing , seminars on the live problems ,
interactions with the experienced employees and workers gave me the real interest in

the engineering
During the training I was assigned to conduct experiment on finding the calorific
value of coal and bagasse I found it with the help of bomb calorimeter. It was very
good to see the apparatus which I read in the book and conduct the experiment. I
learned the procedures to be followed while conducting experiment and the patience
to wait for the result of the experiment. The experiments on finding P H, Electrical
conductivity and calorific value also taught me that work and fun can be carried out

simultaneously
Several technical analysis like efficiency of steam generator, overall efficiency of the
plant, heat rate , effectiveness of High pressure feed water heaters were calculated.
During the period, I had referred several research papers and through website, which

strengthened my theoretical knowledge on the application level.

I was once given the chance in control room to see whole power plant in the monitor.
Various pressure, temperature and flow transmitters will be connected to the
equipment which shows each parameters value in the monitor of the control room.
One can inspect whole plant from control room. Each component like CEP, BFP,
SAF, PAF, CRF, turbine load, governer of turbine, extraction valve for process heat
can be controlled (on /off/dampers) from the control room itself. Equipments are
operated manually or automatically depending upon their criticality of the

components on the plant.

In the instrumentation part, several pressure gauges, level meter, thickness gauge,
torque meter, temperature gun , mechanical tools were used in the field.

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Interrelationship between engineering department, mechanical workshop, tools and

spares, scaffolding department is very crucial and it should be in punctual manner.

4.2 NON - TECHNICAL OUTCOMES

Some of the personal developments which boosted my confidence level and made be
suitable to work in any company are listed below.

The most important is the time utilization and proper management of time. Starting

from 10 am to 4 pm in the plant and working with the time limit was worthy indeed.
Safety precautions to be used when inside the plant like helmet, apron, and ear muff
in the noisy area, taught me more about safety factors. Using of oxygen supply,
scaffolding, body supports when going very deep in the pump suction line were

important one.
To be careful in accidental area and near the working pump, turbine, compressors and

electrical circuit zone.

Importance of both technical and non-technical team in any job is very crucial. Every
employee has their own importance in the plant and job is succeeded by their

synergetic effort.
Health checking scheme
Resource Utilization
Improvement in the communication skills
Team Work benefits
Confidence in work
Maintaining confidentiality of the important documents
Management of tools and work. A Place for everything and everything in Place is

how they keep the mechanical tools and equipment.

To respect the job and work.

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4.3 BEST EXPERIENCES

The microphone communication for speedy communication among the employees

was great.
The process plant needs thermal energy (process heat) in order to operate and
produce the final product. According to the demand of the process plant, they will
be demanding to the Cogen, the control persons will operate the valve through
control room and supply the required process heat by maintaining flow rate of the
steam and extraction pressure.
If any parameters get offset from the set point value, say if load fluctuation
occurred in the steam generator, it greatly affects the turbine output. In any worst
condition, if the Cogeneration plant cannot supply process steam to the process
plant, they will not be giving clearance in operating the process plant. So, the
process plant will stop the mills and important machines. Once the Cogen starts to
operate in a normal condition, the control room gives the clearance to run the

process plant.
If any maintenance is to be carried out for some equipment, say pump, there is a
sequence of process to be followed. First, the concerned department has to take
permission from the control room and it will assign the suitable date of
maintenance. The pump section has to get tools and spares from mechanical
department and scaffoldings from scaffolding department. On the concerned day
of maintenance, all the flow lines will be isolated from control room itself. Then,
only the maintenance starts.

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REFERENCES
1. Power Plant engineering by P.K.Nag
2. Heat Transfer by Cingel and Ghajar
3. Sugar manufacturing process.pdf

Dept. of Thermal power Engineering VTU PG Studies, Mysuru

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