Main Cpp Project

8/10/2019 Main Cpp Project

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2011

Adhunik Alloys & Power Ltd.

Saurabh Kumar

[CAPTIVE POWER PLANT]Captive power plants are those power plants which operate independent of wheeling to grid! They aremostly meant by in-house power generation for industry and not selling the power to grid of electricityboards.


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CONTENTS

FRONT PAGE 1

ACKNOWLEDGEMENT 3

PREFACE 4

OVERVIEW 5

SAFETY MEASURES 6

SYNOPSIS 7

CIRCUIT DIAGRAM 8

TYPES & PARTS 9

DM PLANT 10-11

COOLING TOWER 12-13

STEAM TURBINE 14-15

DEARAETOR 16-17AFBC 18

WHRB 19

STEAM CONDENSING 20-21

DCS 22-23

11KV H.T. INCOMER & DISTRIBUTOR 24

415V L.T. INCOMER & DISTRIBUTOR 25-26

SWITCH YARD 27-28

CIRCUIT BREAKER 29-30

UPS 31


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ACKNOWLEDGEMENT

I would like to thanks whole heartedly to Miss Farha Sultanwho is my training in

charge, mentor and guide during the whole training period at the workshop training at

Adhunik Alloy & Power LimitedKandra, Jamshedpur (Jharkhand) and without whom I

would not be able to do this project. She is constant source of inspiration for me and is

always available to me for constant guide and support.

My heartiest thanks to my family members who have given their full support in

everything from emotional to monetary support.

I would also like to thanks my friends who have arranged different resources and creative

ideas from different sources.

My heartfelt thanks to the employees of Adhunik Alloy & Power Limited who have

helped in their way by explaining every doubt of me.


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PREFACE

The use of practical knowledge and talent techniques gives finer prospect to Engineers

who effort in during their course.

In this regard and to develop their own ideas and make themselves a component in the

global market engineering students from different streams do vocational trainings in

different steamed industries.

In this project I have tried to do a thorough study of Captive power plant used in many

industries for internal power generations. Industries use Captive power plant for the

power used in the different parts of industry thus reducing its dependence on external

power sources and also do a environmental friendly work.

Project by

Name-Saurabh Kumar

College-CEB

Reg no-0801219415

Branch-EEE


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AN OVERVIEW

ADHUNIK ALLOYS & POWER LIMITED (AAPL) is a part of Adhunik group of

companies. This plant is located at Kandra situated in the state of Jharkhand near

Jamshedpur. It is an integrated steel plant based on sponge iron technology. AAPL has

2*350 TPD DRI plant, a coal washer of 1000 TPD, a 30 MW Captive power plant, 2*30 ton

induction furnaces, a 2 strand continuous caster and rolling mill of 147,700 TPA. The

steel plant is based on green technology where waste heat recovery of DRI and washer

rejects are used to generate power.

The company has also been allotted the northern Dhandu Coal block in latehar district,

Jhanrkhand. Allotment of iron ore mines is in advanced stage of necessary approvals and

development. These resources are to be used in a captive basis for the production of

steel. AAPL has acquired land adequate for setting up full-fledged steel manufacturing

facilities.

AAPL is also ISO certified company and has deep concern about the environment and

around the plant area.


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SAFETY MEASURES

Everyone in the workplace has a legal responsibility for workplace health and

safety, and one of the way to improve health and safety at work is by working

together.

Working in the processing factories involve working near heavy machinery that

either moves or has moving parts. That entails some very specific safety hazards.

So it is important that employee, supeerviser and other people are informed about

safety hazards so that they can have their safety measures to minimize the safety

problems.

A risk assessment is simple but thorough way of identifying the safety problems

that exist in your workplace or in the task you do and controlling them. Safe work

and procedures everyone is doing their job safely and is commited to improving

health and safety in the workplace.


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SYNOPSIS

In todays world one of the major concern for the scientist and

every other human being on this earth is new and cost effective means

of energy. Everyone is concerned about finding the ways for fulfilling

his need of energy. Captive power plant is also a stepping stone in this

regard.

Captive power plants are those power plants which operate

independent of wheeling to grid! They are mostly meant by in-house

power generation for industry and not selling the power to grid of

electricity boards. A captive power plant ensures internal power

generation and thus less dependence on external power sources. So it

saves both power and cost of industries.

Captive Power Plant will be to ensure availability of adequate electrical

energy in a cost effective manner utilizing primarily off gases and waste

by-products of various modules. Adhunik further plans to expand its

captive power plant capacity to 79 MW by setting up an additional 45

MW captive power plant.


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CIRCUIT DIAGRAM OF POWER PLANT


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Types of Captive power plant:-

There are two types of captive power plant

DRI type of captive power plant

DM plant

Parts of a captive power plant

DM Plant

Cooling tower

Steam turbine

Dearator

Atmospheric fluidized bed combustion boiler(AFBC)

Waste heat recovery boiler (WHRB)

Steam condensing


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DE-M INERALI ZATION PLANT

Demineralization is the process of removing mineral salts from water by

using the ion exchange process. With most natural water sources it is

possible to use Demineralisation and produce water of a higher quality than

conventional distillation.

FLOW DIAGRAM OF DE-MINERALIZED WATER TREATMENT PLANT


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COOLI NG TOWER

A cooling tower is a heat rejection device, which extracts waste heat to the

atmosphere through the cooling of a water stream to a lower temperature.

Common applications for cooling towers are providing cooled water for air-

conditioning, manufacturing and electric power generation. The generic

term cooling tower is used to describe both direct (open circuit) and

indirect (closed circuit) heat rejection equipment. A direct, or open circuit

cooling tower is an enclosed structure with internal means to distribute the

warm water fed to it over a labyrinth-like packing or fill. The fill may

consist of multiple mainly vertical, wetted surfaces upon which a thin film of

water spreads. In a across-flow cooling tower air moves downwards.

Cooling towersare heat removal devices used to transfer process waste heat

to the atmosphere. Cooling towers may either use the element of water to

remove process heat and cool the working fluid to near the wet-bulb air

temperature or in the case of closed circuit dry cooling towersrely solely on

air to cool the working fluid to near the dry-bulb air temperature. Common

applications include cooling the circulating water used in oil refineries,

chemical plants, power stations and building cooling. The towers vary in size

from small roof-top units to very large hyperboloid structures (as in Image 1)

that can be up to 200 metres tall and 100 metres in diameter, or rectangular


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structures (as in Image 2) that can be over 40 metres tall and 80 metres long.

Smaller towers are normally factory-built, while larger ones are constructed

on site. They are often associated with nuclear power plants in popular

culture, although cooling towers are constructed on many types of buildings.


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STEAM TURBINE

A steam turbine is a mechanical device that extracts thermal energy from

pressurized steam, and converts it into rotary motion. Its modern manifestation was

invented by Sir Charles Parsons in 1884.

It has almost completely replaced the reciprocating piston steam engine primarily

because of its greater thermal efficiency and higher power-to-weight ratio. Because

the turbine generates rotary motion, it is particularly suited to be used to drive an

electrical generator

about 80% of all electricity generation in the world is by use

of steam turbines. The steam turbine is a form of heat engine that derives much of

its improvement in thermodynamic efficiency through the use of multiple stages in

the expansion of the steam, which results in a closer approach to the ideal

reversible process.


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DEARATOR

A deaerator is a device that is widely used for the removal of air and other

dissolved gases from the feed water to steam-generating boilers. In particular,

dissolved oxygen in boiler feed waters will cause serious corrosion damage in

steam systems by attaching to the walls of metal piping and other metallic

equipment and forming oxides (rust). Water also combines with any dissolved

carbon dioxide to form carbonic acid that causes further corrosion.

There are two basic types of deaerators, the tray-type and the spray- type:

The tray-type (also called the cascade-type) includes a vertical domed

deaeration section mounted on top of a horizontal cylindrical vessel which

serves as the deaerated boiler feed water storage tank.

The spray-type consists only of a horizontal (or vertical) cylindrical vessel

which serves as both the deaeration section and the boiler feed water storage

tank.


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Tray-type deaerator

Spray-type deaerator


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ATMOSPHERIC FLUIDIZED BED COMBUSTION

BOILER (AFBC)

Fluidized bed combustion (FBC) is a combustion technology used in power

plants. Fluidized beds suspend solid fuels on upward-blowing jets of air

during the combustion process. The result is a turbulent mixing of gas and

solids. The tumbling action, much like a bubbling fluid, provides more

effective chemical reactions and heat transfer. FBC plants are more flexible

than conventional plants in that they can be fired on coal and biomass, among

other fuels.


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WASTE HEAT RECOVERY BOILER (WHRB)

Waste heat recovery is a process that captures excess heat that would

normally be discharged at manufacturing facilities and converts it into

electricity and steam. A "waste heat recovery boiler" contains a series of

water-filled tubes placed throughout the area where heat is released.

When high-temperature heat meets the boiler, steam is produced,

which in turn powers a turbine that creates electricity. This process is

similar to that of other fired boilers, but in this case, waste heat

replaces a traditional flame. No fossil fuels are used in this process.


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Metals, glass, pulp and paper, silicon and other production plants are

typical locations where waste heat recovery can be effective

STEAM CONDENSING

The condenser condenses the steam from the exhaust of the turbine into

liquid to allow it to be pumped. If the condenser can be made cooler, the

pressure of the exhaust steam is reduced and efficiency of the cycle increases.


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The surface condenser is a shell and tube heat exchanger in which cooling

water is circulated through the tubes. The exhaust steam from the low

pressure turbine enters the shell where it is cooled and converted to

condensate (water) by flowing over the tubes as shown in the adjacent

diagram.
http://en.wikipedia.org/wiki/File:Surface_Condenser.png


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DI STRIBUTED CONTROL SYSTEM

A distributed control system (DCS) refers to a control system usually of

a manufacturing system, process or any kind of dynamic system, in which the

controller elements are not central in location (like the brain) but are

distributed throughout the system with each component sub-system

controlled by one or more controllers. The entire system of controllers is

connected by networks for communication and monitoring.

DCS is a very broad term used in a variety of industries, to monitor and

control distributed equipment.

Electrical power grids and electrical generation plants

Environmental control systems

Traffic signals

radio signals

Water management systems

Oil refining plants

Chemical plants

Sensor networks


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11KV H.T. INCOMER & DISTRIBUTION PANEL

BOILER FEED PUMP-1 350KW

BOILER FEED PUMP-2 350KWPELLET PLANT 1000AMP

SMS FEEDER 1000AMP

EARTHING TRANSFORMER

FEEDER

50AMP

AUXILLIARY FEEDER

TRANFORMER-3

175AMP

DRI FEEDER 1000AMP

AUXILLIARY FEEDER

TRANFORMER-2

175AMP

BUS P.T.(POTENTIALTRANSFORMER)

1000VA

SPARE FEEDER MOTOR 350KW

AUXILLIARY FEEDER

TRANFORMER-1

175AMP

GRID INCOMER 250AMP

GENERATOR INCOMER 2500AMP


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415V L .T. INCOMER & DISTRIBUTION PANEL

DG INCOMER-1 2500AMPBOILER FEED PUMP-1 800AMP

BOILER FEED PUMP-2 800AMP

CW PUMP-1 800AMP

AUXILLIARY TRANSFORMER

INCOMER-1

4000AMP

AFBC

FIRE WATER

DG WATER PUMP

BOP INCOMER-1 1250AMPASH & CAOL HANDLING

INCOMER-1

800AMP

ESP INCOMER 800AMP

ID FAN-1 800AMP

FD FAN-1 800AMP

BUS COUPLER-1 4000AMP

AUXILLIARY TRANSFORMERINCOMER-2

4000AMP

BUS COUPLER-2 4000AMP

AFBC BOILER INCOMER-2 400AMP

FIRE WATER

AUXILLIARY TRANSFORMER

INCOMER-3

4000AMP

DG INCOMER-2

BOILER FEED PUMP-3 800AMP

CW PUMP-2 800AMP

CW PUMP-3 800AMP


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SWITCHYARD

Switchyard forms an integral part of any power plant i.e. Industrial CPP,Thermal Power Utilities, Gas Turbines based power plants or Hydel power

plants. These power plants have their main plant equipment integral controls

(Boiler / Turbine / Gas Turbine / Hydro Turbine) as well as plant DCS System

(BoP / Station C & I). While the entire power plant is integrated at the DCS

level, true unification is achieved by incorporating / integrating switchyard

controls (SCADA) also in the plant DCS.

Features:

Monitoring of status of switchyard equipment like isolators,

breakers, ground switches.

Issue of close/open commands to isolators, breakers.

Monitoring of system parameters like voltage, current, frequency,MW, MVAR, energy.

Time stamping of alarms, events, protective relay operations.

Presentation of information useful to operator in different forms

Report generation.

Historical storage and retrieval.

Remote control and monitoring from Load dispatch centre

through fibre optic.


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CIRCUIT BREAKER

A circuit breakeris an automatically operated electrical switch designed toprotect an electrical circuit from damage caused by overload or short circuit.

Its basic function is to detect a fault condition and, by interrupting

continuity, to immediately discontinue electrical flow. Unlike a fuse, which

operates once and then has to be replaced, a circuit breaker can be reset

(either manually or automatically) to resume normal operation. Circuit

breakers are made in varying sizes, from small devices that protect an

individual household appliance up to large switchgear designed to protect

high voltage circuits feeding an entire city.

Outdoor Vacuum circuit breaker

The Siemens outdoor vacuum circuit breaker type are structure-mounted,

easy-to-install for use in 12/36 kV systems. They are porcelain-clad, three-

pole circuit-breakers fitted with reliable and well-proven vacuuminterrupters from Siemens. Adequate phase clearances and heights have been

provided to meet standard safety requirements. They are suitable for direct

connection to overhead line and cables.


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Typical users

Automobile industry

Cement industry

Chemical industry

Iron and steel works

Mining industry

Petroleum industry

Pipeline installations Power supply utilities

Rolling mills


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UNINTERRUPTED POWER SUPPLY (UPS)

Uninterruptible Power Systems (UPS) have become an indispensable elementof many data processing installations (EDP), from desktop PC's to mainframe

computer systems. UPS systems provide a measure of insurance and security

for the user who is concerned about data loss and hardware failures caused

by power disturbances. The measure of insurance needed is proportional to

the financial impact of the downtime caused by such an incident.

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