TOPIC : COMPRESSED AIR SYSTEM NETWORK STUDY & DOCUMENTATION

Under the guidance of: Mr. Pravin Kumar Submitted by: Abhimanyu Barik 202915 Aman K Bharthwal 203000 Biraj Mohapatra 202957 Monica Pawar - 202972 Vishal Bhor - 202992
Description Introduction Deliverables Expected and Achievements Analysis and Understanding- Work Details Outcome of the project Personal Learning Page No. 2 6 6 8 9

Ind ex
S.No 1. 2. 3. 4. 5.

CHAPTER 1: INTRODUCTION
The coal handling plant (CHP) in a thermal power station covers unloading of coal, its crushing, storage and filling of boiler bunkers. The coal handling plant can be divided into various sections which are as follows: 1. Coal unloading system: As mentioned above, the coal received at power station may be unloaded by means of wagon tippler or track hopper or by combination of both depending on the type of coal rakes to be used for transportation of coal to the station. Generally coal rake consists of 59 wagons, each wagon carrying payload of 60 tons.
2. Coal crushing: Coal unloaded in the wagon tippler hoppers/track hoppers is conveyed to

crusher house by belt conveyors via junction towers. Suspended magnets are provided on conveyors at junction towers for removal of tramp Iron pieces. In case the sized coal is received, then the coal is sent directly to stockyard and the crusher is by-passed. In line magnetic separators are also provided at discharge end of conveyors for removal of remaining metallic ferrous tramp from the coal before it reaches the crushers. The received coal is sized in primary crushers (rotary crushers) from (-) 600 mm to (-) 125 mm. After that the coal is passed to secondary crushers(ring granulators) the coal is crushed to (-)20mm. The crushed coal is either fed to coal bunkers of the boilers or discharged on to conveyors for storage in coal stockyard.

3. Coal Stacking & Reclaiming at Stockyard: Crushed coal is sent to stockyard when coal

bunkers are full. Stacking/ reclaiming of coal is done by bucket wheel type stacker-cumreclaimer moving on rails. Reclaim hoppers are provided to reclaim coal by dozers when stacker cum- reclaimer is not in operation.
4. Dust Control System and Ventilation system: The dust control system is required for control

of fugitive dust emissions from dust generation points such as transfer points, feeders, crushers etc. Dust control is achieved by dust suppression and extraction system. Manpower planning is very much important in coal handling plant. The manpower planning is very necessary for observing the proper running of conveyors and the various components present in coal handling plant. CHP O&M procceses cannot run smoother without the following: a) LOCO Operation and Maintenance b) Track Maintenance and Signaling c) Bulldozer and Hydra O&M Manpower deployment for the above mentioned areas is very important for smooth running of the various processes going in coal handling plant. The manpower deployment in CHP can be divided into following areas: a. CHP Operation & Maintainance b. LOCO Operation and Maintenance c. Track Maintenance and Signaling d. Bulldozer and Hydra Operation and Maintainance

CHAPTER 2: DELIVERABLES EXPECTED & ACHIEVEMENTS

During the beginning of the project I expected: a. To know and study all the technical processes going in various areas of coal handling plant. b. To study the currently planned manpower deployment in coal handling plant. b. To plan the effective deployment of manpower in the various areas of coal handling plant. c. To know all the responsibility of the workers working in these areas of coal handling plant. In response to the assigned project we achieved the following things: Came to know and studied all the technical details of all the process undergoing in coal handling plant right from the source to the consumer end. Completely studied the manpower deployment in these areas. Successfully planned the utilization of manpower in all areas of coal handling plant.

CHAPTER 3: ANALYSIS AND UNDERSTANDING :WORK DETAILS

For achieving the aim of the given project I prepared a step wise method which step included the following s: 1) 2) 3) 4) Planning Execution of the project Analysis Documentation

1. Planning: To start with our project, in the first week we got a brief idea about compressed air network from our guide and head of mechanical maintenance department. They clarified our objective i.e. what we have to do. We planned to: a) Collect all compressors and motors specification, lube oil data and cooling water requirement. b) Study the different components of compressed air systems. c) Trace all the pipe lines of compressed air from suction chamber to the various components of power plant. d) Find the interconnections of the compressed air lines of all the units. e) Draw the detail network diagrams of service and instrument air for each unit separately in boiler, ESP and silo area. f) Finally combine the instrument air lines of all units in one layout and service air lines of all units in another layout.

2. Execution of the project: It was really a challenging task to trace each and every line of instrument and service air and interconnections of air networks. We divided our team into two groups. In the first week one group collected all the specification of compressor, motor, lube oil and cooling water of all units and the other group collected the same data for ash plant of unit# 2 and 3. In further weeks we followed the compressed air lines from the compressor house to the turbine generator building part and traced the interconnections. Then we traced the service air line from the unit# 2 and 3 ash plant which goes to the silo, unit#2 service air receiver tank near the ESP and unit#3 service air receiver tank near ESP. After that we traced the service air network and the instrument air network in the boiler section of all the units and finally traced the interconnection in the boiler part. We took 3 days for each unit to trace the instrument air and service air lines in the boiler section. After tracing the entire network with the help of AUTOCAD, we drew the layout of each unit and the complete layout of service air and instrument air. 3. Analysis: By working on this project we came to know the various application of instrument and service air in the power plant. By studying the complete network we knew that service air is used for cleaning purposes, fluidization of ash slurry to avoid settling of slurry in the slurry sump, fluidization of ash in silo, ash conveying in ESP transmitter and chimney transmitter, for operating hydraulic cylinders to open and close the feed gate pass in the bottom ash plant and atomization of oil in oil gun. The instrument air is used for opening and closing of secondary air dampers, controlling corner nozzle valves, burner tilting, reheater spray control valve and isolating valve, platen superheater spray control valve and isolating valve, final superheater spray control valve and isolating valve, controlling LORTV, LOTV and LOFCV, opening and closing of PA fan dampers, FD fan blade pitch control, APH hopper valve control, water flow control valve in bottom ash handling plant, controlling of soot blower pressure regulating valve, soot blower steam drain temperature control, ID fan damper control, controlling flow of ash from ESP and chimney transmitter and to IP converter control valves. During tracing the air networks we observed following lines where there was wastage of instrument and service air. a) In unit#1, at ESP, service air line divides into two lines. One line goes to ESP transmitter which is shown in yellow circle while another line is open to atmosphere shown in red circle which leads to wastage of service air.

Figure 8: Wastage of Service Air

b) In unit#3, near the FD fan there is wastage of service air because the valve is not functioning properly.

c) In unit#1, in boiler section one of the instrument air line goes to water flow control valves in the bottom ash handling plant and another line in connection with this line goes to feeder floor of unit#2 and it is open to atmosphere and is not in use. This leads to wastage of instrument air. In the following figures, the yellow circle shows interconnection of above mentioned lines and the red circle shows line open to atmosphere. . .

Figure 9: Wastage of Instrument Air

4. Documentation: Refer following detail drawings attached along with this report: DRAWING NO.1: U#1 COMPRESSOR LINE DIAGRAM DRAWING NO.2: U# 2&3 COMPRESSOR LINE DIAGRAM DRAWING NO.3: U #4&5 COMPRESSOR LINE DIAGRAM DRAWING NO.4: SERVICE AIR NETWORK, TATA POWER, JOJOBERA DRAWING NO.5: INSTRUMENT AIR NETWORK, TATA POWER, JOJOBERA

CHAPTER 4: OUTCOME OF THE PROJECT:

This project will really help the mechanical maintenance department at Jojobera power plant for various purposes. We have submitted the copies of updated layout of service air and instrument air which will help the department to trace the air lines for any maintenance work in the future or for any further modification.

While tracing the service and instrument air networks we observed some pipe lines from where there is wastage of air and informed the concerned department to take necessary action in this regard. As a result of which auxiliary power consumption can be reduced.

CHAPTER 5: PERSONAL LEARNING:

Abhimanyu Barik: This group project really gave me a different type of learning experience. This project helped me a lot to sharpen my technical skills. As our project is on compressed air network and air is required in various location of a power plant for plant operation I got a chance to move to each and every area of the plant .While tracing the air network I got the opportunity to practically observe the accessories of a power plant and their location in the plant which I have studied in theory. Initially it was difficult to trace the network, but after tracing the network of one unit it became easier for tracing the air network of other units. During tracing the compressed air network I learned the application of service air and instrument air in various locations for pneumatic operation in the power plant. Before doing this project I had a little knowledge about silo operation, role of service air in ash slurry sump and pressure sand filter in water treatment plant. But after carrying out this project I got in depth knowledge about these things. Apart from technical skills I got an opportunity to learn how to work in a team and how to execute a project work. This experience will help me in my future. I am very much thankful to our guide for clearing our doubts and for his proper guidance throughout the project .I am also thankful to all of them who directly or indirectly helped us during our project work. Aman K Bharthwal: From this project I got in depth knowledge about compressor working principles and got knowledge regarding the practical requirements of compressed air in a power plant. During tracing the lines of instrument air and service air I got a chance to know the exact locations of the equipments to which the compressed air goes for pneumatic operation. Actually this project not only helped me to know about compressed air system but also in gaining in depth knowledge of various areas like boiler section, ash handling, ESP and silo and how it works. In practice it was very difficult for tracing the air lines and I find that a power plant is critical. At last, I am very thankful to my project guide and those who helped me directly or indirectly in making this project successful. Biraj Mohapatra: With the onset of our group project, I got to know the basics of power plant. As a mechanical engineer, I had a very little knowledge about the detail usage of compressors in power plant and our project was related to compressor air networks. So initially I found this project little bit difficult but after few days with the help of our project guide and group mates I really came to know a lot about the use of instrument and service air in power plant. Tracing the service and instrument air network was difficult but it really gave a lot of practical knowledge about how the compress air is really transferred from the source to the point of application. While tracing, we also found some of the excess lines which can be eliminated without hampering the air network. This was a great project which gave me a lot of experience and I hope it would help me in my future works. I am really very thankful to our guide for delivering such a theoretical and practical knowledge on our project which really helped us a lot in completing our project and am also thankful to our group mates who helped me a lot in understanding and completing our project.

Vishal Bhor:

Group project at Jojobera was real start for my life in TATA POWER. We were allotted such a project that we got the chance to see each & every part of power plant. It taught me a lot of things about power plant. First time, I got the chance to see air preheater, non-return valve, butterfly valve in open condition during their maintenance work. I practically understood the boiler during the project work. During the project, I came to know that air is the basic need of power plant like oxygen for human life, as whole working of power plant is done with the help of pneumatic instruments. Service air & instrument air have wide applications in different elevations of boiler, air preheater, electrostatic precipitator, chimney, PA fan, FD fan, ID fan, silo, turbine section and few other parts of the power plant.

I am really thankful to head of MMD Dept, our guide Mr. Pravin Kumar & other staff in power plant for their help during our project work. Monica Pawar: At first, I am thanking to TATA Power for giving us such a useful training program including NPTI training and group project rather than directly imposing to on-job training. Initially, I found it challenging to trace the complete network of compressed air system but we divided ourselves in groups and divided our work and later shared it with each other. Here, I learned how to work in a group and how to proceed for a project and to execute it in industry. While tracing out the compressed air network, we reached almost each part of power plant as compressed air has applications everywhere in the plant. While working on this project, I got a chance to learn practically about different components of power plant. I was not much aware of the use of compressed air in power plant. But while proceeding for a project, I came to know that pneumatic valves are used everywhere in power plant. For their proper operation, moisture free instrument air is required. And where some amount of moisture is tolerated in air, service air is used i.e. for atomization of oil in oil guns, ash conveying, etc. Apart from project, in free time, we curiously went to see different systems like coal handling, ash handling, etc. When U#5 of Jojobera was in shut down condition for maintenance work, we got an opportunity to study some auxiliaries in open condition. We followed the feed cycle practically and learned it actually reaching auxiliaries of power plant which we had learned only in theories. After working on this group project, my gain in knowledge is not only limited to the project topic but I got to know a lot of things related to thermal power plant. At the end I would like to say thanks to our project guide Mr. Pravin Kumar and HOD of MMD Mr. Chaterjee for guiding us at every step and am also thankful to my group mates.

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