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 are
mostly meant by in-house power generation for industry and not selling the power to grid of electricity
boards.

CONTENTS
FRONT PAGE

ACKNOWLEDGEMENT

PREFACE

OVERVIEW

SAFETY MEASURES

SYNOPSIS

CIRCUIT DIAGRAM

TYPES & PARTS

DM PLANT

10-11

COOLING TOWER

12-13

STEAM TURBINE

14-15

DEARAETOR

16-17

AFBC

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

ACKNOWLEDGEMENT

I would like to thanks whole heartedly to Miss Farha Sultan who is my training in
charge, mentor and guide during the whole training period at the workshop training at
Adhunik Alloy & Power Limited Kandra, 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.

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

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.

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.

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.

CIRCUIT DIAGRAM OF POWER PLANT

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

10

DE-MINERALIZATION 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

11

12

COOLING 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 airconditioning, 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 towers are 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 towers rely 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

13

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.

14

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.

15

16

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.

17

Tray-type deaerator

Spray-type deaerator

18

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.

19

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.

20

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.

21

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.

22

23

DISTRIBUTED 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

24

25

11KV H.T. INCOMER & DISTRIBUTION PANEL

BOILER FEED PUMP-1
BOILER FEED PUMP-2
PELLET PLANT
SMS FEEDER
EARTHING TRANSFORMER
FEEDER
AUXILLIARY FEEDER
TRANFORMER-3
DRI FEEDER
AUXILLIARY FEEDER
TRANFORMER-2
BUS P.T.(POTENTIAL
TRANSFORMER)
SPARE FEEDER MOTOR
AUXILLIARY FEEDER
TRANFORMER-1
GRID INCOMER
GENERATOR INCOMER

350KW
350KW
1000AMP
1000AMP
50AMP
175AMP
1000AMP
175AMP
1000VA
350KW
175AMP
250AMP
2500AMP

26

415V L.T. INCOMER & DISTRIBUTION PANEL

DG INCOMER-1
BOILER FEED PUMP-1
BOILER FEED PUMP-2
CW PUMP-1
AUXILLIARY TRANSFORMER
INCOMER-1
AFBC
FIRE WATER
DG WATER PUMP
BOP INCOMER-1
ASH & CAOL HANDLING
INCOMER-1
ESP INCOMER
ID FAN-1
FD FAN-1
BUS COUPLER-1
AUXILLIARY TRANSFORMER
INCOMER-2
BUS COUPLER-2
AFBC BOILER INCOMER-2
FIRE WATER
AUXILLIARY TRANSFORMER
INCOMER-3
DG INCOMER-2
BOILER FEED PUMP-3
CW PUMP-2
CW PUMP-3

2500AMP
800AMP
800AMP
800AMP
4000AMP

1250AMP
800AMP
800AMP
800AMP
800AMP
4000AMP
4000AMP
4000AMP
400AMP
4000AMP

800AMP
800AMP
800AMP

27

28

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.

29

30

CIRCUIT BREAKER

A circuit breaker is an automatically operated electrical switch designed to

protect 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, threepole circuit-breakers fitted with reliable and well-proven vacuum
interrupters 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.

31

Typical users
Automobile industry
Cement industry
Chemical industry
Iron and steel works
Mining industry
Petroleum industry
Pipeline installations
Power supply utilities
Rolling mills

32

UNINTERRUPTED POWER SUPPLY (UPS)

Uninterruptible Power Systems (UPS) have become an indispensable element

of 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.