FPCL Power Plant (MECHANICAL)

FFBL Power Company Limited-FPCL
FPCL Internship Report
Name: Syed Umer Asif

University: DHA Suffa University
Email: syedumerasif@gmail.com
Internship Report Page 1

Table of Contents
PREFACE ................................................................................................................................................ 4
Acknowledgement ................................................................................................................................ 5
INTRODUCTION ..................................................................................................................................... 6
Safety .................................................................................................................................................... 9
Description of Front End ........................................................................................... 11

1)STEAM TURBINE GENERATOR ........................................................................................... 11
Turbine Rotors .................................................................................................................................... 12
Pressure Reducing Desuperheating Valve (PRDS): ............................................................................. 14
GEAR BOX ............................................................................................................................................ 14
Turbine Bearings ................................................................................................................................. 15
Turbine Seals ....................................................................................................................................... 17
Turbine Couplings ............................................................................................................................... 18
Lubrication System .............................................................................................................................. 19
Pumps ................................................................................................................................................. 20
2)Boiler ............................................................................................................................................. 21
CFB Technology ................................................................................................................................... 21
Economizer ......................................................................................................................................... 22
Steam Drum ........................................................................................................................................ 23
Superheaters ....................................................................................................................................... 23
Baghouse ............................................................................................................................................. 24
Stack of Steam Boiler .......................................................................................................................... 24
3)Balance of Plant ....................................................................................................................... 26
Description of Back End............................................................................................. 28

1)Coal Handling Process ........................................................................................................... 28
Flow Diagram of CHP .......................................................................................................................... 28
CONVEYOR BELTS ................................................................................................................................ 30
Stacker................................................................................................................................................. 32
Reclaimer ............................................................................................................................................ 33
Crusher ................................................................................................................................................ 35

Tripper Cars ......................................................................................................................................... 37
2)Flow Diagram of Sorbent handling plant ..................................................................... 38
3.1)Flow Diagram of Fly Ash handling plant .................................................................... 41
3.2)Flow Diagram of Bottom Ash handling plant .......................................................... 43

PREFACE
This report is based on the training and knowledge that I got from my internship at
FFBL Power Company Limited. It includes all the knowledge that has been passed
to me at this industry either theoretical or practical means. The aim to write this
report is to share a meaningful material and concepts about the field of Mechanical
Maintenance.

Acknowledgement
I am grateful to Allah Almighty for the successful completion of my 4 weeks

internship at FPCL. During my internship I have learnt about the power plant and
its environment. I learnt about the FPCL as an organization, job handling
procedures, maintenance and repairing procedures and job environment in FPCL.
I would like to thank all of the staff, engineers and management members of FPCL
for making this internship happen. I am thankful to all engineers and staff members
who took out time for internees from their busy schedule and gave us knowledge
about the Plant and mechanical maintenance.

INTRODUCTION
FFBL Power Company Limited (FPCL) is an unlisted public limited company

incorporated by the Sponsor as a special purpose vehicle in June 2014. FPCL is
first of its kind power plant in Pakistan’s power industry that has been completed
through Non-EPC basis. The complete project management and execution has
been carried out successfully by FPCL own team of engineers and professionals.
FPCL has another distinct feature in the sense that it is generating power at two
different frequencies i.e. 50 Hz and 60 Hz, to meet its clients power and
operational requirements as under:
 K‐Electric ‐ 50 Hz
 Fauji Fertilizer Bin Qasim Limited (FFBL) ‐ 60 Hz
The power plant is located at Eastern Industrial Zone of Port Qasim, Karachi in the
province of Sindh, on approximately 100 acres of land adjacent to Fauji Fertilizer
Bin Qasim (FFBL) Fertilizer Complex. The Installed capacity of the Power plant is
118 MW, out of which up to 60 MW of power is exported to K‐Electric and
remaining is supplied to FFBL Fertilizer complex.
FPCL holds Generation License No. (SGC/111/2015) from NEPRA and has
commenced its Commercial Operation since 19th May 2017.
FPCL plant is based on state of the art components including 02 x 250 Metric Tons
Per Hour (MTPH), Circulating Fluidized Bed (CFB) boilers from Hyundai Heavy
Industries (HHI) – South Korea. CFB Technology has following prominent features:
1. Environment friendly with low NOx and Sox emissions.

2. High thermal efficiency.
3. Fuel flexibility i.e. can burn wide range of coal qualities from imported to
local.

4. FPCL Power Block has the capability to generate power on both 50 & 60 HZ
and is based on Steam Turbine Generators (STG) supplied by General
Electric (GE) – Europe. Plant operation is controlled thru latest Distributed
Control System (DCS) and Safety systems.
Seamless power supply to K-Electric network is ensured thru 132 KV Grid station
based on latest technology of Alston – Europe.

GENERAL REVIEW
As per requirements under the NEPRA Act, FPCL is approaching the National
Electric Power Regulatory Authority (“NEPRA”) for award of generation license for
the Project. The Plant configuration consists of 2 x 250 TPH, 92 bar and 515°C
high pressure/temperature Circulating Fluidized Bed (CFB) boilers that are being
procured from Hyundai Heavy Industries (HHI) – Korea following a recently
executed contract. CFB Technology for boilers is being employed due to its ability
to provide improved thermal efficiency and its excellent ability to burn a wide
range of coals from international to local as well as bituminous to sub‐ bituminous
coal through the same boiler.
 Low Elimination of separate De Sox system requirement as

desulphurization take place within boiler
 NOx generation due to boiler operation at low temperature i.e. 850 – 900
°C
 Low Furnace Temperature
 Good Turn Down Factor (40 to 100 % Operation)
 No Ash Slagging
 Simple Bottom Ash Removal System
The Company has shortlisted world renowned companies like Siemens, Alstom,
Elliott and General Electric as the potential suppliers for supply of two (02 x 24
MW) condensing steam turbine generators (STGs) and one (01 x 10 MW) back
pressure STG for captive power use at 60 Hz as well as one (01 x 60 MW)
condensing STG for power export to KElectric / Bulk Power Consumers at 50 Hz.
Currently, bids evaluation is in progress and the contract is expected to be
awarded in October 2014

Safety
Safety is the first priority in the FPCL. Safety is a measure of success in any work.
It means constant evaluation of thing, we do and how we go about doing them so
that we won`t get harm, they our equipment’s condition will not contribute to an
accident. In FPCL safety is considered equal to production.
Safety priorities of FPCL are:
 Employs
 Company assets
 Environmental
PERSONEL PROTECTIVE EQUIPMENTS:

Following equipment are available for personal protection.
 Safety helmets and shoes should be worn at plant site during working and
any other activity.
 Goggles for protection against liquids and gases
 Gloves for protection against dirt and heat
 Respiration Mask with filters
 Ear plugs for protection of ears against loud noises

WORK PERMIT PROCEDURE

The FPCL is controlled by Operation Department and no work can be carried out
by an unauthorized person or Department. Any work which is related to concern
Department is carried by its permission.
The permission is sought on a prescribed format known as work permit.
Types of Work Permits:
 COLD WORK PERMIT

This is required when urgent or routine repairs/inspection is to be carried out and
job doesn’t involve a flame or spark.
 HOT WORK PERMIT
It is require for jobs as lighting all naked flames, fires, exposed material including
electric aces and sparks, electronic and gas welding/cutting, blow lamps and tar
heating.
 VESSEL ENTRY PERMIT

This is required when one or more persons to enter in to any confined space such
as tower/vessel/storage tank, excavation more than 1.5 deep, column, reactor,
piping will 1m, sewers etc.
 EXCAVATION WORK PERMIT

This permit is issued to cover all excavation work inside the plant.
 VEHICLE ENTRY PERMIT

This permit is required before any vehicle can enter the work area.
 RADIOGRAPHY WORK PERMIT

This permit is required to do any sort of radiographic testing anywhere in the plant.

Description of Front End

FPCL complex includes the following process units in the front end site.
PROCESS UNITS:
The process Units are:
1. Steam Turbine Generator (STG)
2. Boiler
3. Balance of Plant (BOP)
1)STEAM TURBINE GENERATOR

Steam turbines use high-pressure steam to turn electricity generators at incredibly
high speeds, so they rotate much faster than either wind or water turbines. For
example, a typical power plant steam turbine rotates at 4000 to 6000 repetitions per
minute (RPM); about 100–200 times faster than the blades spin on a typical wind
turbine, which needs to use a gearbox to drive a generator quickly enough to make
electricity

The basic parts of stream turbines are blades and rotors. A set of blades is known
as a stage. They also have steam inlets (usually a set of nozzles) and outlets. Two
independent mechanisms, known as governors, are used to ensure safe operation of
the turbine.
Turbine Rotors
The steam turbine rotors must be designed with the most care as it is mostly the
highly stressed component in the turbine. The design of a turbine rotor depends on
the operating principle of the turbine.
Working principle of Turbine
High pressure steam is fed through a set of fixed nozzles in the turbine stator to
the turbine rotor (runner) and passes along the machine axis through multiple
rows of alternately fixed and moving blades. From the steam inlet port of the
turbine towards the exhaust point, the blades and the turbine cavity are
progressively larger to allow for the expansion of the steam.
The stator blades in each stage act as nozzles in which the steam expands and
emerges at an increased speed but lower pressure. As the high velocity steam
impacts on the moving blades it imparts some of its kinetic energy to the
moving blades.
There are two basic steam turbine types, impulse turbines and reaction turbines,
whose blades are designed control the speed, direction and pressure of the
steam as is passes through the turbine.
Two basic types of steam turbines are
• Impulse Turbine: The rotating blades are like deep buckets. High-velocity
jets of incoming steam from carefully shaped nozzles kick into the blades, pushing
them around with a series of impulses, and bouncing off to the other side with a
similar pressure but much-reduced velocity.
• Reaction Turbine: In a reaction turbine, there is a second set of stationary

blades attached to the inside of the turbine case. These help to speed up and direct

the steam onto the rotating blades at just the right angle, before the steam dissipates
with reduced temperature and pressure.
FPCL is installed with 4 turbines altogether consisting of:
 2 * 24 MW which generates electricity at 60Hz and is a condensing turbine

 1 * 10 MW which generates electricity at 60Hz and is a back pressure
turbine
 1 * 60 MW which generates electricity at 50Hz and is a condensing turbine
Dedicated back pressure steam turbine generator of 10MW is considered to supply

steam to FFBL process through letdown of pressure and temperature. The function
is to supply steam however we will get 10MW also.

Pressure Reducing Desuperheating Valve (PRDS):
Standby dedicated pressure reducing desuperheating station is attached to the

10MW back pressure steam turbine generator which reduces the pressure of the
steam and is also an emergency valve to send steam to FFBL plant to continue the
process.
GEAR BOX
Gear boxes are used to increase or decrease the rpm as per your driven machine. A
typical medium back pressure turbine rpm is generally is in range of 4000-5000 so
if you want to drive a fan whose rpm is 2000 then you need a gearbox. So typically
providing a gearbox in a turbine won't impact the construction of turbine.
The efficient rotational speed of a turbine is higher than that required by useful
loads, such as propellers on aircraft and ships. So the output is geared down to a
more reasonable speed.
Driver Gear: Driver gear is one which is connected to the power source i.e Incase
of Gear pumps the power source may be motors. Likewise power source varies
with type of applications.

Driven Gear: Driven Gear is one which is meshed with the driver gear. Driven gear
rotates with the help of power source connected to the driver gear. Driven gear
should be of same module with the driver gear irrespective of number of teeth.
Turbine Bearings
One of the steam turbine basic part is bearing. They are two types of bearings used
based on the type of load act on them
 Radial Bearing
 Thrust Bearing
Radial Bearings
For small turbines mostly equipped with anti-friction type bearings. Widely used
anti-friction bearings are the self-aligning spherical ball or roller bearing with
flooded type lubrication is used.
For larger turbines, the radial bearing will be a tilting pad type. The number of pad
per bearing will be selected based on the weight of the rotor. For these types of
bearing forced lubrication is used.
Thrust Bearings
The main two purposes of the thrust bearing are:

 To keep the rotor in an exact position in the casing.

 To absorb axial thrust on the rotor due to steam flow.
The thrust bearing is located on the free end of the rotor. The axial thrust force is
very small for impulse turbines. This is due to the presence of pressure equalizing
holes in the rotor discs to balance the thrust force generated across the disc. A
simple thrust bearing such as a ball bearing for small turbines are commonly used
in small and medium-size turbines. Tilling pad type thrust bearings are used in the
large steam turbines.
In the case of reaction turbine, the pressure drop across the moving blades creates a
heavy axial thrust force in the direction of steam flow through the turbine. Due to
greater thrust force, the heavy duty thrust bearing such as tilting pad type thrust
bearings are used. The axial thrust in reaction turbines can be nearly reduced by the
using off balance or dummy pistons.

Turbine Seals
Seals are used to reduce the leakage of steam between the rotary and stationary
parts of the steam turbine. Depend upon the location of seal, the seals are classified
as two types, they are
 Shaft Seal
 Blade Seal
Shaft Seals
Shaft seals are used to prevent the steam leakage where the shafts extend through
the casing. In the case of a small turbine carbon rings are used as shaft seal up to
the surface speed of the shaft is 50m/s. The carbon ring is made up of three
segments butting together tightly under the pressure of a garter spring. The carbon
rings are free floating in the housing and an anti-rotating pin is used to prevent the
rotation of carbon ring seal.
Due to the self-lubrication properties of the carbon rings, they maintain a close
clearance with the shaft. Refer below figure.
For larger steam turbines labyrinth seal are used as shaft seals. In the case of
condensing steam turbine to prevent the air ingression at the shaft seal by Gland
condenser and ejector arrangements

Blade Seals
Blade seals are used to prevent the steam leakage between the diaphragm and the
shaft. The efficiency of the turbine depends largely on the blade seals. Labyrinth seals
are used as blade seals in the small and large turbines. In the case of large steam
turbine spring loaded labyrinth seals are used. The seals are made up of brass or
stainless steel.
Turbine Couplings
The purpose of couplings is to transmit power from the prime mover to the driven
piece of machinery. Flexible type couplings are used in turbines. The coupling
hubs are taper bore and key way to fit the tapered end of the shaft.
Hydraulic Governor
The governor has adjustable speed drop and load limit controls. A split field,
electric motor-operated speeder gear to facilitate remote alteration of engine speed
setting from the switchboard is incorporated. This alters the spring pressure usually
through a screwed rod.

Lubrication System
Oil flood lubrication is used for small turbines and pressurized lubrication is used
for larger turbines. The pressurized lubrication system consists of lube oil tank, oil
pump, filter, cooler, pressure regulating valve etc.
Lube Oil System

At first from the oil reservoir tank the oil goes into oil clarifier skid in which
moisture is removed from the oil. Then it goes back into the reservoir tank and
pump to main lube oil cooler, after cooling it, it goes to oil filter and then the
filtered oil is forwarded to the machineries part.
Jacking Oil
When a turbine-generator shaft is rotating very slowly, the normal lubricating oil
supply cannot ensure that a hydrodynamic oil wedge will be maintained. Also,
additional lubrication measures are required to prevent bearing damage and to
minimize breakaway torque when starting a turbine-generator from standstill. In
both circumstances the jacking oil system provides high pressure oil to the base of
the bearing and floats the rotors on a film of oil.
Condensing turbines
Turn the steam at least partly to water using condensers and giant concrete cooling
towers. This allows the steam to expand more and helps the turbine extract the
maximum energy from it, making the electricity generating process much more
efficient. A large supply of cold water is needed to condense the steam.

Pumps
The condense stream is stored in a large storage which is then pumped to de-
aerator. Centrifugal pumps are used in this for this purpose as we need a constant
flow rate in deaerator.
Centrifugal pumps:
Like most pumps, a centrifugal pump converts rotational energy, often from a
motor, to energy in a moving fluid. A portion of the energy goes into kinetic
energy of the fluid. Fluid enters axially through eye of the casing, is caught up in
the impeller blades, and is whirled tangentially and radially outward until it leaves
through all circumferential parts of the impeller into the diffuser part of the casing.
The fluid gains both velocity and pressure while passing through the impeller. The
doughnut-shaped diffuser, or scroll, section of the casing decelerates the flow and
further increases the pressure.
Mechanical seal is used in centrifugal pump. It prevent liquid under pressure from
leaking out of the pump and maintain pressure.

2)Boiler
Boiler has the function to convert water into steam. The process of change of water
to vapor done by heating the water in the pipes with heat from burning fuel.
Combustion processes carried out continuously in the combustion chamber with
fuel and air flow from the outside.
The resulting steam is superheat steam which have high temperature and high
pressure. Steam production quantities dependent on the surface area of heat
transfer, flow rate, and the heat of combustion is given. Boiler construction
consisting of water-filled pipes called a water tube boiler
CFB Technology
Circulating fluidized bed is a relatively new technology with the ability to achieve
lower emission of pollutants. Extensive research has been conducted on this
technology for the past 10 years because pollution in the world is getting more

serious by the day and clean practice will be very crucial for the sustainability of
the earth. The importance of this technology has grown recently because of
tightened environmental regulations for pollutant emission
FPCL plant is based on state of the art components including 02 x 250 Metric Tons
per Hour (MTPH), Circulating Fluidized Bed (CFB) boilers from Hyundai Heavy
Industries (HHI) – South Korea. CFB Technology has following prominent features:
 Environment friendly with low NOx and Sox emissions.

 High thermal efficiency.
 Fuel flexibility i.e. can burn wide range of coal qualities from imported to
local.
The CFB Boilers in FPCL plant has a total steam generation of 500Met/hr. Steam
temperature and steam pressure is approximately 515 degree centigrade and 92
bar.
The boiler efficiency is 88% and coal consumption is 51.6 T/H.
Major Components of Boilers

A boiler, also referred to as a steam generator, is a major component in the plant
cycle. It is a closed vessel that efficiently uses heat produced from the combustion
of fuel to convert water to steam. Efficiency is the most important characteristic of
a boiler since it has a direct bearing on electricity production. Boilers are classified
as either drum-type or once-through. Major components of boilers include an
economizer, superheaters and reheaters..
Economizer
An economizer is a mechanical device which is used as a heat exchanger by
preheating a fluid to reduce energy consumption. In a steam boiler, it is a heat ex-
changer device that heats up fluids or recovers residual heat from the combustion
product i.e. flue gases in thermal power plant before being released through the

chimney. Flue gases are the combustion exhaust gases produced at power plants
consist of mostly nitrogen, carbon dioxide, water vapor, soot carbon monoxide etc.
Steam Drum
A steam drum is a standard feature of a water-tube boiler. It is a reservoir of
water/steam at the top end of the water tubes. The drum stores the steam generated
in the water tubes and acts as a phase-separator for the steam/water mixture. The
steam drum separates steam from the steam/water mixture and keeps the separated
steam dry.
Superheaters
Superheaters are bundles of boiler tubing located in the blow path of the hot gases
that are created by the combustion of fuel in the boiler furnace. Heat is transferred
from the combustion gases to the steam in the superheater tubes. Superheaters are
classified as primary and secondary. Steam passes first through the primary
superheater (located in a relatively cool section of the boiler) after leaving the
steam drum. There the steam receives a fraction of its final superheat and then
passes through the secondary superheater for the remainder.

Reheaters
Reheaters are bundles of boiler tubes that are exposed to the combustion gases in
the same manner as superheaters.
Baghouse
A baghouse is a large-scale air pollution control device. It functions by filtering
particulates such as dust, ash, soot, and other impurities out of the exhaust from the
boiler. As the name implies a baghouse is literally a large enclosure that houses
“bags,” which in this case act as filters that remove the pollutants. Industrial
baghouses may be entered from time to time by personnel for cleaning,
maintenance, and bag replacement.
Stack of Steam Boiler

Stack is a equipment to take out the product of combustion at a sufficiently high
elevation to prevent disturbance caused by ash, low flying smoke, and soot and to
disperse the combustion gases. To perform flue gas flow through steam boiler
room such as furnace, superheater, steam boiler bank, economizer, air heater, dust
collector until be discharged to atmosphere, requires a certain amount of draft.
Amount of draft can be generated by fan either force draft fan or induced draft fan
to overcome the pressure drop (draft loss) that are developed in the steam boiler.
Beside that, height and difference between the outside air and inside flue gas
temperature of the stack can produce the draft.

3)Balance of Plant
Apart from the turbine, generator, and generator step-up transformer, the balance
of plant system controls the entire of plant. It is a complex system designed to
manage regulate the rest of the plant to ensure reliable and efficient power. The
BoP system controls and monitors complimentary devices, values, gauges, fuel
levels and pumps, electronically using a number of different systems. It works by
measuring current running condition (e.g. rate of fuel injection into the combustion
cans), comparing the values with pre-set reference values and altering the system
in charge (e.g. fuel valve and pump system) to ensure it matches the reference
exactly (or within pre-set tolerance levels). There are two parts of balance of plant
system, the Electrical Balance of Plant (EBoP) and Mechanical Balance of Plant
(MBoP).
Components of the MBoP system are:
1. COOLING WATER SYSTEM: cools condensed spent steam from the steam
turbine so it can be fed back to the Heat recovery steam generator (HRSG). It is
also used the cool the lube oil systems, flame detectors, turbine supports, liquid
fuel shaft pump and atomizing air systems.
2. DRAINAGE SYSTEM: used to remove unwanted water from the different

systems.
3. HEATING, VENTILATION, AIR CONDITIONING SYSTEMS: These

systems are used to remove hot air and heat the enclosures during downtime. The
system also protects potentially dangerous systems (e.g. gas turbine, gas valves,
load gear, etc.) from gas leaks as they cause to fires or explosions.
4. OIL TREATMENT SYSTEM: ensures clean oil is supplied where it is needed.

In use oil is flushed out of components, like gas-insulated transformers, as fresh oil
is pumped in. The difference in density between the used oil (as a result of dirt and
other impurities) and new oil makes it easy to flush used oil out the bottom of each
unit, and pump new oil in through the top. Used oil is then sent through the oil

treatment system to recover as much oil as possible, to reduce wastage, and the dirt
from the spent oil is discarded.
5. RAW, POTABLE, AND DEMINERALIZED WATER SYSTEMS: are

responsible for providing water for the power plant. Raw water is pumped, usually
from a natural source (e.g. a river) into reservoirs. This water is then converted to
portable water for consumption and demineralized water. Demineralized (or de-
ionized) water is water with most mineral ions removed. Water has to be
demineralized to ensure water fed to the HRSG for boiling, is free from impurities
and boils as close to 100o as possible, this reduces heat used during boiling.
6.BACK UP POWER: there are occasions where the plant losses power. To avoid
serious damage being caused to the plant equipment, there are a few power loss
prevention and control system employed.
7.GAS CONDITIONING SKID: is used to treat gas before it enters the gas
turbine. This treatment process removes liquid droplets and solid particles from the
gas ensuring only gas is injected into the gas turbine. The skid also adjusts gas
temperature and pressure to injection requirements.
8.OIL-WATER SEPARATOR: is used to separate oil and other solids from

water. The system uses gravity to perform the separation, wastewater (including oil
and particles) is pumped into a large tank, since oil is denser than water, it floats
and the solid particles, which are denser than water, sink. Oil is skimmed off the
top of the water, via an oil skimmer, while the water is drained, and the solid
particles settle at the bottom of the tank. See figure below.
9.STORAGE TANKS & VESSELS: are metal units of varying strengths and
sizes used as reservoirs for water, oil and fuel (e.g. diesel). Gas is usually not
stored in large volumes, rather it is supplied directly from the source, the gas
storage facility is used to hold gas before it enters the gas conditioning skid.
10.COMPRESSED AIR SYSTEM: is used to provide valves, pumps and other

equipment high-pressureair for operation.

Description of Back End

FPCL complex includes the following process units in the back end site.
PROCESS UNITS:
The process Systems are:
1- Coal Handling Process
2- Sorbent Handling Process
3- Ash Handling Process
1) Coal Handling Process

Coal is imported from South Africa because that coal has high calorific value.Then
Coal is unloaded from trucks then shifted into hopper where hopper gives
direction that coal towards conveyor belt. Vibrating feeder feed that coal on
conveyor belt by its vibration then coal goes into transfer tower where right flap
gate is opened then stacker stack that coal.
Flow Diagram of CHP
This is the entire process of the coal

handling process from the weigh bridge
to the tripper car section. The Process
starts with the trucks that carry coal
fro
m
the port and are then weighed in the weighing
bridge near the unloading shed. The coal is

dropped into a huge mesh of about 20*20 meters, which separated the undesired
coal size. Coal goes through to 4 underground separate hoppers and from there
vertically bellow to the vibrating feeders which transfers coal to a Conveyer Belt
named CT01. In between the hoppers and the feeders there is a Rack & Pinion
Gate which enables the operator to decide when the coal is to be dropped or
stopped in hazardous or unsafe cases.
Coal then travels on the CT01 which has a maximum capacity of transferring
500 tons/hour of coal, is self-aligning / self-adjusting, 1200mm wide and 13mm
thick. It has three rollers in a single row to support the belt at an approximate 2
meters. The belt is continuously tightened with the use of weights known as the
“take-up unit”, this is done so that the belt would not slack during the process. The
take-up unit is basically weights that hang relying on the tension of the conveyer
belt.
The coal is then transferred to the “Transfer Tower 1” where the coal is divided
into two separate paths through the “Flap Gate”. The flap gate has two outlets and

it covers the undesired path outlet to transfer coal to the desired one. CT02 and
CT03 are the outlets of the flap gate 1.
CT02 is the primary belt with a carrying capacity of 200 tons/hour and its
purpose is to transfer coal to the “Stacker”. CT03 is the backup or alternative belt
which is a precautionary belt which is used to transfer coal to “TT-3” (Transfer
Tower 3). There is a third way to get coal onto CT03, which is through a hopper
which is a bypass through all of the earlier process. This is done as a further
precaution, in cases of flooding inside the unloading bay.
CONVEYOR BELTS
There are three types of Conveyor belts installed at the coal handling plant. These
are distributed according to their different sizes or widths. A total of 14 belt
conveyors are present at CHP.
The belts are available in the following width:
1200mm – CT-01 , CT-02 , Boom Conveyor of Stacker
800 mm – CT-05
650 mm – CT-03 , CT-04 , CT-06, CT-07 A/B , CT-08 A/B, CT-09A/B CT-10
A/B
Components of Belt Conveyors:
1. Pulleys
The different types of pulleys installed on the conveyor belts are:
A. Drive Pulleys – Drive Pulleys are those which are connected to the drive unit
and are responsible for moving the belt. Drive pulleys are large in size. The

surface has a rubber coating with diamond shaped grooves which aid the
pulley in gripping the belt.
B. Snub Pulley –They are used to increase the surface contact area of the belt
around the drive pulley for better friction. They also absorb the load as the
belt returns from the drive pulley so that the idlers are protected from
damage.
C. Take Up Pulley – Located at the take up unit. Attached to the tensioning
weight
D. Tail Pulley –
E. Bend Pulley – To change the direction of the belt. Usually before take up
pulleys
2. Belt
Synthetic Carcass type belt- 3 ply EP 600/3 . Top cover 6mm bottom cover
= 3 mm.
The conveyor belts are made of rubber. There are 3 layers of ply in between
two rubber layers. The ply is made of polyester plus Nylon (fiber? Or
nylon)...the ply adds strength and rigidity to the belt. The upper rubber layer is
thicker than the bottom. The layers can be removed by pliers if required.
3. Tensioning Unit
Types of Tensioning Devices
A. Vertical Gravity Takeup

The Vertical Gravity Take up unit consists of bend pulleys which redirect
the returning side of the belt downwards where it wraps around another
pulley to which a large weight is attached. This weight provides tension to
tighten the belt. The vertical gravity takeup is situated close to the drive
pulley to prevent slipping when the conveyor is started
B. Horizontal Gravity Takeup

Similar working principle to Vertical Gravity Takeup. Used in places where
there isn’t enough space for vertical gravity takeup units.

C. Screw Take Up
The tail pulley bearings are mounted on rails and can be adjusted
individually using long bolts. These type of take up pulleys are used for
short belts.
OTHER
V-type belt Cleaners – These are present on the inside of the belt, near tail pulleys
and take up pulleys (on the return side of belt) . In case any material spills from the
side of the belt and lands on the inner part of the belt, the cleaner prevents it from
reaching the pulleys and damaging its surface or the belt.
Belt Sway Switch – If the belt deviates too much from the center, it will touch the
switch and the belt will get shut down.
Stacker
The stacker is a very
important equipment in
which there are multiple
operations happening
simultaneously and it has the
capability of stacking 500
MTPH. CT02 now follows
an inclined path on to the
static part of the stacker
which is connected to a
motor-run baseplate. It takes around 8 motors to move the stacker and has
hydraulic rail clamps acting as brakes. The belt drops the coal into a feeding tripper
(this can be thought of as a universal joint which stays connected even if its

moved) which feeds coal to the Boom Belt Conveyer. This belt now is used to do
the actual stacking process, its height can be adjusted by the Luffing mechanism
which 11 degrees above and below the Horizontal axis. Its boom can be slewed to
80 degrees to its west side and 55 degrees to the opposing side. This is useful in
many ways, one of being to position the piles of the coal accordingly. Next this
slewing and luffing mechanism enables the stacker and reclaimer to pass one
another with ease. It’s equipped with a lot of sensors that help with the stacking
process. There is a Piezoelectric Transducer hanging from the bottom of the top
most part of the stacker. This is where the coal is dropped and the sensor basically
senses that what is the current level of the Coal pile and can more coal be added to
it. Secondly there is a laser sensor that measures the relative position and coal
distance from the belt as well.
Reclaimer
Moving on from the
stacker, to reclaim the coal
we make use of a Portal type
of Reclaimer, which transfers
coal to CT05 at 200 MTPH.
The reclaimer has small
compartments called
scrapersthat scoop up coal
and drop the coals onto the
conveyer belt. There are two scrapers, one being the primary and the other
auxiliary. The scrapers can be lowered using a motor pulley system that can extend
the scrapers to touch as low as the ground. The scraper belt is run by the driving
end near the control unit. Two separate motors with reduction gearboxes constitute
the driving end which drive the scraper belt through sprocket. There are bearings
that have auto lube used as supports for the shafts. This entire structure runs on
rails just like the stacker and has two braking systems. One is called the rail clamps
that grip the rails to brake. The other is attached to the motors that stop the motor
to stop the movement and operation.
There is a Dust Suspension system that keeps the coal shed from getting very dusty
through the dry fog system. The dry frog is a mixture of pressurized air and water
droplets that is sprinkled on the coal.
The CT05 travels to the TT-4 where it is again passed through the DS system as
the coal changes the direction and conveyer belt. In TT-4, CT05 and CT04 meet
and keep traveling onwards to TT-5.
TT-5 has 2 flap-gates for each of the conveyer belts to control the flow of the coal
and to ensure the constant flow of coal is maintained in situations in which one of
the belts is under maintenance or needs to be switched. The coal is dropped down
to CT07 A/B on which there are DS systems on both the belts and also consist of a
metal detector to separate the metal from the coal as this will disrupt the entire
process.
CT07
A/B
transfer the
coal to the
Crusher
House
where it
goes

through flapgates present on each belt to divert the coal whenever necessary. The
belts are weighed to check the amount of coal present, then is fed through a Circle
Vibrating Screen. The fine coal smaller than 8mm is transferred to the next
conveyer belt namely CT08 A/B.
Crusher
The coarse coal makes its way through the coal crusher which is also linked to a
heater which keeps the crusher warm in cold weather conditions. The crusher has
hammers attached to the shaft that rotates through a motor and a gearbox. There
are multiple hammers that hit the coal against the wall of the casing and the
distance between the hammer and the wall determines the coal size. This is
adjusted by knobs that are present outside the gate. Crusher has a door which is
hydraulically opened using a dedicated pump. The grate lets the crushed coal pass

through only if it is small enough to pass through the grate. Otherwise it’s
reprocessed through the hammers until it’s able to pass.
Coming out of the

crusher house there is a
dust collector that
takes up any dust
remains that is
suspended in the air
due to the coal
dropping from a
height. These dust
collectors are called
bag filters, since they
use long bags made out
of Nano material that retains the coal dust. The bags are cleaned using pressurized
air which takes the dust and collects below. Then the dust is dropped down back to
the coal conveyer CT08 A/B since these are important in the combustion process in
the boilers.
CT08 A/B both have the capacity of 200 ton/hour, and transfer coal from the
crusher house to TT-6. Using the flapgates the belts are controlled, in case of
switching either “CT09 A or B” is turned off or the other “CT09 A or B” one keeps
running. At the initial stage “DS” systems also called the dry fog systems are used
to suppress the coal & dust particles by sprinkling pressurized air and water on the
coal piles. Coal samples are taken further down the belt for testing purposes.
Multiple gages are reading the RPM of the motor and weight of the belt as data.

Then CT09 A/B transports the coal toTT-7 where a magnetic separator
separates any metallic parts if there are present. There is another Dust Suppression
unit in this TT which has the same function as the earlier ones. As a precaution and
safety check there is another metal detector to detect any last stage metals before it
enters the final stage of tripper cars.
The CT10 A/B then connects to a big contraption called the tripper cars on each
belt. Before going to the tripper cars the belt is weighed one last time and then it
enters the tripper cars.
Tripper Cars
Tripper cars take up the belt through rollers and drops the coal into the coal bins

which have a capacity of 450 tons. There are a total of 4 bins below the 2 tripper
cars. As the coal is dropped into the bins below there is a lot of dust that lifts up in
the air, to maximize the efficiency of coal transfer a “Dust Extraction” setup is
introduced on the belt which scavenges for any outlying coal/dust particle and
shoots it down to the bin directly through a pump. The tripper cars have hydraulic
rail grippers which act as the brakes.
There is another backup at the end of the CT10 A/B where the remaining
particles are shun off into a detachable dust bin, which can be manually emptied
into the funnel that leads down to the coal silos.
2)Flow Diagram of Sorbent handling plant

The next diagram was of the Sorbent handling Plant. The first stage was the drop
off of the Limestone/Sorbent at the Limestone storage shed after being weighed at
the weigh bridge. Then the crane drops the limestone onto two hoppers which
through a Rod Gate transfers the Sorbent unto a Belt conveyer BC11. The belt is
equipped with a weight machine that measures the sorbent mass and is also
detected of any metal substance.
BC11 transfers the Sorbent into a silo of a capacitance of 100 T/H, which has two
indicators “radar charge level indicator” & “capacitance charge level indicator”.
These indicators tell us about the height of the silo and the amount that is stored
through which we can measure the levels and requirement of more sorbent.
Through a rack and pinion gate the sorbent is transferred onto two weighing belt
conveyers with separate inputs, which can either be used in need of maintenance.
Here the metal, if any, is separated before going to the column mill

Column Mill
The column mill is basically similar to the crusher in CHP, with the difference of
crushing process. This has a single shaft with 4 rollers that are attached to the shaft.
The crushing process is done by pressing the sorbent against the walls of the mill,
until they are of the correct size which is desired of 1mm. since the size is very
trivial there is the need of ensuring that this size is double checked,this is done
after the column mill. The mill is operated through a big motor which reduces the
RPM through a pulley system attached with 5 re-enforced V belts. The belts
transfer power to a bevel gear that changes the horizontal rotation to a vertical
rotation. This not only changes the direction but also acts as a reduction gear
mechanism because of the change of size. The bevel gear finally transmits power
to the shaft which has rollers attached to it. The walls of the mills are adjustable
which enables us to adjust the size of the sorbent particles. The current settings
were kept such that the rollers were 39 mm apart from the wall. These rollers are
tapered to enable us to get different sizes of particles if we adjust the height of the
wall.

The mills transfer the material to a sealed belt conveyer which transfers the sorbent
to a Bucket Elevator. This bucket elevator transfers the sorbent to the PL
Classifier, this sorts the uncrushed and crushed sorbent. This has multiple screens
that let the crushed and powder like sorbent blow through the chamber and into the
double cyclone separator. Whereas the uncrushed limestone is transferred to the
sealed belt conveyer that transfers the material to the electric three way valve
transferring it to the column mill.
Cyclone Separator
The cyclone separator mainly separates the extremely fine grains and undesirable
large grains of limestone. The desirable grains are passed down to the chain
conveyer through a double heavy hammer valve.

The undesirable heavy grains are recycled and thrown back into the PL classifier
which checks for its size again. This is done through a negative pressure pump.
Ensuring the size of the sorbent to be desirable and keeping the process efficient. A
dust collector intakes the dust emerging in the chain conveyor and filters it through
a bag house and gets the air to the atmosphere, whereas dropping the sorbent
particles to the chain conveyor. All of this is to ensure that maximum possible
sorbent particles are utilized.
Finally the desirable grains are transferred to another chain conveyor through a
bucket elevator and into a main limestone silo capable of storing 450 tons.
The silo has multiple sensors and valves, namely a pressure relief vacuum valve
(releases pressure in cases of excess pressure), a bag filter, a continuous elevation
indicator (noting the amount filled in the silo), a low level and a high level
indication (both are for extreme cases if the silo is nearly empty or nearly filled).
This will automatically give information to the operator and he opens or closes the
operations of the plant. The silo is also fitted with a fluidizing mechanism that
blows air from the walls keeping the limestone from sticking to the sides.
Finally there is a pumping system similar to the Fly ash system discussed in the
next section. This pumping system basically transfers the limestone to the smaller
silo near the boilers and is transferred according to the need.
3.1)Flow Diagram of Fly Ash handling plant

The fly ash handling process controlled the transfer of ash from the boiler to the
silo and then finally to the trucks. The main purpose of the fly ash to be transferred

is to get it out in an organized fashion by two means. It’s either transferred to be

disposed into a landfill or exported to companies that use it to make cement.
The fly ash is taken from the boiler output and is stored passed through multiple
bag filters. This separates the ash and passes it through the master pump for the
bag filters. Each boiler has 2 rows of 5 bag filters and each bag filter lets ash pass
through their inlet dome valve. The master pump is on the start of every row and is
followed by 4 slave pumps.
A Rotary Screw Compressor sends pressurized air to a combination dryer through

a filter which then passes the air onto an air receiver. There are two types of air
receivers, Service and Instrument air receivers, both having their dedicated
compressors, filters and combination dryers.
The services type uses the air to transport the ash along the pipe channels and the
instrument type is used for purging the bags inside the bag house. The purging is
an important task since the ash attached to the microfiber bag and the requirement
of purging is large since 1 pump controls 10 bag filters, hence 2 pumps controlling
the bag filters purging process.
The services air enters the piping through a ball type valve and directly into a filter
which further decontaminates the air. Then the air is preheated to make the flow of
ash smoother, this is called fluidization, it is done since the ash tends to solidify
and clog the pipes. After every ball valve is a NRV (no return valve) and at the end
of a row of pumps there is a pneumatic panel to offer as another check before
transporting the ash through a resisting elbow (simple bending of a pipe) to the
piping delivering it to the main silo.

The pipe transferring the ash to the main silo is pretty long and needs the ash to be
in check, hence there are multiple density stabilizers which ultimately end in the
main silo.
There are two types of ash outputs, dry and wet, the dry ash is mainly fed to the
companies to make cement which have sealed containers to carry the dry ash.
Whereas the wet ash is to be disposed into a wasteland and it uses the truck with an
open end. The ash is wet to prevent the ash from flying out and keeping it
contained. The silo is fitted with the same sensors as discussed earlier in the
Sorbent silos, in addition to those instruments there are heaters for the air that is
used in the fluidization process. Furthermore there are two shoots for dry and wet
ashes. The ash comes down a manually operated flashboard valve, passing through
a dome valve and then a flow control valve. The wet ash is a bit different where it
is sprayed with water and passed through Electro motion rotating feeder and then
to the wet ash unloader.
3.2)Flow Diagram Bottom Ash handling plant

Bottom ash has a less complicated transfer process than the fly ash since it is more
dense and easier to handle. Bottom ash passes through hoppers unto a link
conveyer, which then transports the bottom ash to a silo through a bucket
conveyer. The operations of the silo and the extraction process are similar to the
process of the fly ash silo. It constitutes of the dry ash and wet ash just like the fly
ash process. A milestone in the company can be seen by the amount of bottom ash
received in the silo. The amount is very trivial, since the coal crushing is so
efficient that the coal that reaches the boiler is of very fine quality producing only
fly ash.

FPCL Power Plant (MECHANICAL)

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FFBL Power Company Limited-FPCL

FPCL Internship Report

Name: Syed Umer Asif

Internship Report Page 1

Description of Front End ........................................................................................... 11

3)Balance of Plant ....................................................................................................................... 26

Description of Back End............................................................................................. 28

Internship Report Page 2

Tripper Cars ......................................................................................................................................... 37

2)Flow Diagram of Sorbent handling plant ..................................................................... 38

3.1)Flow Diagram of Fly Ash handling plant .................................................................... 41

3.2)Flow Diagram of Bottom Ash handling plant .......................................................... 43

Internship Report Page 3

Internship Report Page 4

I am grateful to Allah Almighty for the successful completion of my 4 weeks

Internship Report Page 5

FFBL Power Company Limited (FPCL) is an unlisted public limited company

1. Environment friendly with low NOx and Sox emissions.

Internship Report Page 6

Internship Report Page 7

 Low Elimination of separate De Sox system requirement as

 Low Furnace Temperature

 Good Turn Down Factor (40 to 100 % Operation)

 Simple Bottom Ash Removal System

Internship Report Page 8

PERSONEL PROTECTIVE EQUIPMENTS:

Internship Report Page 9

WORK PERMIT PROCEDURE

Types of Work Permits:

 COLD WORK PERMIT

 HOT WORK PERMIT

 VESSEL ENTRY PERMIT

 EXCAVATION WORK PERMIT

 VEHICLE ENTRY PERMIT

 RADIOGRAPHY WORK PERMIT

Internship Report Page 10

Description of Front End

1)STEAM TURBINE GENERATOR

Internship Report Page 11

Working principle of Turbine

Two basic types of steam turbines are

• Reaction Turbine: In a reaction turbine, there is a second set of stationary

Internship Report Page 12

FPCL is installed with 4 turbines altogether consisting of:

 2 * 24 MW which generates electricity at 60Hz and is a condensing turbine

Dedicated back pressure steam turbine generator of 10MW is considered to supply

Internship Report Page 13

Pressure Reducing Desuperheating Valve (PRDS):

Standby dedicated pressure reducing desuperheating station is attached to the

Internship Report Page 14

Internship Report Page 15

 To keep the rotor in an exact position in the casing.

Internship Report Page 16

Internship Report Page 17

Internship Report Page 18

Lube Oil System

Internship Report Page 19

Internship Report Page 20

Internship Report Page 21

 Environment friendly with low NOx and Sox emissions.

The boiler efficiency is 88% and coal consumption is 51.6 T/H.

Major Components of Boilers

Internship Report Page 22