Tech Technology

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INDUSTRIAL TRAINING REPORT
ON
POWER PLANT
Submitted on completion of vocational training at JAYASWAL NECO INDUSTRIES LTD. Siltara
Degree of Bachelor of Technology in M M College of Technology Raipur
Submitted By
Name: 1.Ramshankar sahu
2. Janendra sahu
3. Navin manikpuri
SUBMITTED TO:
JAYASWAL NECO INDUSTRIES LTD. SILTARA, RAIPUR (C.G.)

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Certificate
This is to certify that the project report entitled RamShankar
Sahu (BE in Mechanical Engineering) as POWER PLANT
PROCESS has been done during his vocational training period
from 02/06/18 to 30/06/18 at "JAYASWAL NECO
INDUSTRIES LTD." is a record of studies, site experience and
keen interest to the subject and analysis carried out by him
under my supervision and guidance. This is a part of partial
fulfillment of their vocational training programme.
Sign
GM/AM/Incharge
(Power plant)
Sign
Mr. Girijashankar Sahu
(H.R.Incharge)

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Declaration
I hereby declare that the Industrial Training Report entitled
("Power Plant") is an authentic record of my own work as
requirements of Industrial Training during the period from
02/06/18 to 30/06/18 for the award of degree of B.E. (M. M.
COLLEGE OF TECHNOLOGY RAIPUR, CSVTU BHILAI,
under the guidance of Mr. Govind Chandrawanshi, AM (Power
plant) .
(Name of Student) (Signature of student)
1. Ramshanarsahu
2. Janendrasahu
3. Navin manikpuri
Date: ___________
Place: Jaiswal Neco Industries ltd. Raipur (C.G)

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Acknowledgement
It was memorable experience for me to visit the Sinter. I don't
have adequate word to express my profound gratitude to project
report in charge Mr. Govind Chandrawanshi, GM (Power plant) for
providing me such valuable opportunity training in Jayaswal
Neco Industries Ltd. Siltara, Raipur. I would like to thank Mr.
Girjashankar Sahu, our training in- charge. I would like to convey
a few words of thanks to my college MMCT Raipur, Dr. Samita
chakraborty the director of the college for their support in
preparing of my project report. I would like to thank my academic
head Mr. Revendra Verma and all the staff member of my college
for their promote response at the time when I needed.
Date:-
Place:-

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Preface
Practical studies are the part of a study. During this practical
training students learn and get practical knowledge, which is not
given in classroom. The aim of this program is to develop not
only theoretical knowledge but also to give and improve practical
skill, in every student, which is helpful to them in every field of
life in their future. In short, students can get full practical
knowledge of personnel, marketing, and finance department.
Being student of second year B.E. program, I have the honor of
having a practical training in the Jayaswal Neco Industries Ltd.
located at Siltara, Raipur. Such training promotes a student to
boost his potentialities and the inner qualities, and there by
students come to know about their reality that how the theoretical
knowledge work in actual sense in any unit, and this has indeed
proved to be very useful to me. All information furnished here in
are correct and true according to me and sincerely apologize if
any incorrect data.

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CONTENS
TOPIC PAGE NO.
Intoroduction of JNIL 07
History 09
Production/Application 11
Power Plant Introduction 12
Power Plant Layout 14
DM Plant 15
Dearator 17
Economizer 17
Evaporator 18
Water Wall Tube 19
Steam Drum(WHRB) 19
Boiler Mounting 20
Water Circulation 23
Steam Circulation 24
Turbine 25
Condensate Water 26
Re-Circulation 27
Accessories 28
Flue Gas Circulation 29
Saftey 30
Conclusions 31

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CHAPTER 1.
Introduction of JNIL
Industries Limited, as it stands today, started in 1976 as a small
scale Iron Foundry unit at Nagpur. Today Jayaswal Neco
Industries Limited (Foundry Division) has grown to be India’s
largest producer of Iron & Steel castings with an installed
capacity of 140,000 MTPA. Its foundries are located across the
states of Maharashtra & Chhattisgarh.
In 1996, JNIL established a 1 Million MTPA Steel plant at Siltara
Growth Centre (Raipur). The Steel Plant Division produces Iron
& Steel products catering to the need of Automotives,
Engineering, Power, Railways, Bearings, Structural and Fasteners
Industries in India. JNIL-Steel Plant Division has an installed
production capacity of 700,000 MTPA through the Blast furnace
route and another 300,000 MTPA through the Direct Reduced
Iron (DRI) route. Its products include speciality Steels: Hot
Rolled Bars in Rounds & Squares, Wire rods in coils and high
strength Leaf springs in Flats. The plant also boasts of 5 captive
power plants based on waste heat recovery which produces about
60 MW/day. The Steel plant is under expansion that will see its
capacity to be enhanced to about 2 Million MTPA by 2015.

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The Neco Group has also been granted Coal and Iron Ore mines
in the State of Chhattisgarh and Jharkhand and has undertaken
setting up of Thermal Power Stations of 3240 MW in the State of
Chhattisgarh and 500 MW in Jharkhand in the next few years.

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HISTORY
Basant Lal Shaw migrated to Kolkata (erstwhile Calcutta) and
started a trading business in Metal Scrap. Although the initial
days were filled with many hardships, Mr. J.R Shaw’s enterprise
and dedication saw him set up a thriving business which
expanded manifold. He soon started wholesale trading business in
Steel imported from Birmingham, England. In 1912, when
TISCO started manufacturing steel in India for the very first time,
Mr. J.R.Shaw became one of the very first and prominent dealers
for their product. His firm,eponymous Jagbandhanram-
Dwarkaprasad, played an important role in promoting the product
among consumers who doubted the quality of the Indian steel.
Mr. B.L.Shaw also played an active role in promoting the
business even as he completed his graduation. At that time, he
was one of the very few formally educated persons from the
community.
After completing his graduation (B.Com) from Calcutta
University, Shri B.L.Shaw started his first foundry in 1963 in
Hooghly district under the registered name of Jayaswal Udyog
Pvt Ltd. The foundry manufactured sanitary castings catering to
Middle East markets. The factory, under the stewardship of Shri
B.L.Shaw, saw tremendous growth in 1960s & early 1970s.
However, the Naxalite movement in Bengal in 1970s, that saw
wide ranging violence and disturbance in carrying out any kind of
business activities, forced Mr. B.L. Shaw to scale down the Unit.
In 1976, he shifted base to Nagpur owing to favourable business
climate and re-started operations from the present headquarters at
MIDC (Hingna Road) under the name
of Nagpur Engineering Company Limited. This factory made
construction castings and later diversified into making castings
for Indian railways as well.
Over the period of time, this company established 9 other
foundries which were clubbed together to form what is today
known as Jayaswal Neco Industries Limited (JNIL). In 1996,

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JNIL also established an Integrated Steel Plant of 1 Million
MTPA capacity through Blast Furnace route that included Sinter
Plant, Oxygen Plant, Coke Oven and Captive power generation
facility with one of the finest infrastructural facilities at its Siltara,
Raipur Plant. This plant, established in collaboration with China
Shougang International Trade & Engineering Corporation,
produces alloy steel bars & rods from 5 mm in coils to 60 mm
bars and narrow width HR Coils. This Integrated Steel Plant, the
cherished dream of Shri B.L.Shaw, today stands tall among its
peers in India and is the pride of Jayaswal Neco Industries
Limited.

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Production – Steel Products
Steel Bilets Steel Rectangular Bloom
Steel Round bar Steel Wire
Application :- Automobile Sector, Other Industries etc.

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Power Plant
Definition
A power plant is an industrial facility used to generate electric
power with the help of one or more generators which converts
different energy sources into electric power.
Electricity is a secondary energy source, which means
that electricity is obtained from the conversion of other primary
sources of energy, such as coal, natural gas, nuclear, solar,
or wind energy. The energy sources used to make electricity can
be renewable or non-renewable, but electricity itself is either
renewable or non-renewable. The power plant is the location in
which the energy conversions take place.
Traditionally, large power plants have been located in sub-urban
regions away from cities, as they need a vast area of land and
sometimes water. All electricity produced in a power plant is
alternating current (AC). The type of electric current found in
your home is direct current (DC)
In general, power plants can be divided into two categories -
conventional and non-conventional power plants.
Conventional power plants are
 Fossil fuel power plants: Generates electric power by
burning fossil fuels like coal, natural gas or diesel.
 Nuclear power plants: Controlled nuclear reaction is
maintained to generate electricity.
 Hydroelectric power plants: Electricity is produced by
building dams on suitable rivers.
Non-conventional power plants are:
 Wind power plants: The kinetic energy of wind is used to
create power.
 Solar power plants: Generates power by
collecting solar radiation.

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 Geothermal power plants: Uses the natural heat found
in the deep levels of the earth to generate electricity.
 Biomass power plants: Natural organic matter is burnt to
produce electricity
.
Context
Each power plant technology has advantages and
disadvantages. For example, nuclearpower plants provide large
quantities of reliable power with low levels of greenhouse gas
emissions. Fossil fuel power plants deliver on-demand, consistent
and reliable energy when the resources
are available. Hydro, solar and wind power plants
generate renewable electricity, thereby delivering emissions-
free electricity.[3]
To find out more about the advantages of
disadvantages of each power plant type, visit the respective
generation source topic page.

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Power plant layout (Coke Oven)

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DM Plant (Demineralization)
Deffinition: - Demineralized water also known as Deionized water,
water that has had its mineral ions removed. Mineral ions such as
cations of sodium, calcium, iron, copper, etc and anions such as
chloride, sulphate, nitrate, etc are common ions present in water.
Deionization is a physical process which uses specially-manufactured
ion exchange resins which provides ion exchange site for the
replacement of the mineral salts in water with water forming H+ and
OH- ions. Because the majority of water impurities are dissolved salts,
deionization produces a high purity water that is generally similar to
distilled water, and this process is quick and without scale buildup.
Process: - D. M. Plant this is a plant in which water is treated. Which
is PH value 8 of treated water? Which is called D. mineralized water?
This water goes to the boiler section of the 10 m3 / hr ls power plant
from the DM plant. There are two storage tanks with a volume of 50
meters cubes. If ordinary water is pumped directly into the boiler, many
types of incompatibilities present in the water and temporal and
permanent hardness such as calcium magnesium etc. are present in the
water. Which reduces the capacity of the boiler, and it looks like crust
and war etc. at the bottom of the boiler. For this reason, use this DM
Plant.

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Process Steps of D. M. Plant
1. Pressure filtration
There is a tank in it. In which there are three to four floats of sand.
Those who work for filtering water. In this, water flow with water
ranging from 5 to 3 kg per area.
2. Filtering of Activated Carbon
● Removes particles of carbon in water in it.
Prabal acid cation
● Removes the digestive resins from the water, and removes them.
4. Strong Acid Growth
● Remove the corrosion resins from the water in it.
5. Coordinated layer
● in this, those disorders are found which cannot be exerted by strong
acid cation, strong alkali growth.

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Deaerator
Process: - A deaerator is a device that is widely used for the removal of
oxygen and other dissolved gases from the feedwater to steam-
generating boilers most deaerators are designed to remove oxygen down
to or less as well as essentially eliminating carbon dioxide.DM water
comes from DM plant and goes in the Dearator with the normal
temperature, at that time the temperature of the dearator remains 125
degrees C. Dearator's work removes the oxygen present in the
condensate water so that the corrosion do not come in the
boiler.Condensate water feed comes through check valve and goes
inside the economizer with 125 degrees Celsius
Deffinition: - A deaerator is a device that is widely used for the removal of oxygen
and other dissolved gases from the feedwater to steam-generating boilers.
Low Pressure Heater
Deaerator
Economizer
Deffinition: - common application of economizers in steam power plants is to
capture the waste heat from boiler stack gases (flue gas) and transfer it to the boiler
feedwater. This raises the temperature of the boiler feedwater, lowering the needed
energy input, in turn reducing the firing rates needed for the rated boiler output.

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Process:- Instead of discharging flue gases/vapour from
a boiler directly, efficiency can be improved by passing the gases
through a heat exchanger, called an economiser. The gases can then be
used to heat feedwater prior to being pumped to the boiler, saving fuel
to raise steam and improving thermal efficiency of the boiler.The
condensate water steam form changes through the heating source in the
economizer, and the temperature of the steam becomes 200 degrees
Celsius and the flue gas comes from the coke oven plant, which comes
from flue gas tubes, whose temperature ranges from 950 to 1000
degrees Celsius and water Entering from the water wall enters the
economizer and the condensate water plus steam whose temperature is
200 degrees celsius, from the economizer. Becomes economizer made up
of 32 pipes, with a heating surface of 3200 meters squire
Evaporator
Deffinition: - Evaporator the fuel us used as a heating sources is may be the
boiling water or a steam but for boilers fire flame is used as coal or a gas. ...
A boiler adds energy in the form of heat to cause the liquid to evaporate,
an evaporator allows a liquid to evaporate and take energy from its
surroundings

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Process:- Steam Plus Water goes into the evaporator 1,2 and 3, whose
function is similar to an economizer, in which the heating source is
from a flu-gas, it has several banch in which the water plus steam flows.
Process: - Steam plus Water goes into the Water wall tube, whose
function is similar to an Evaporater, in which the heating source is
from a flu-gas, it has several banch in which the water plus steam
flows.and the water pluse steam is goes to the boiler drum.
Water Wall Tube
Definition: - A high pressure water tube boiler (also spelled water-tube and water
tube) is a type of boiler in which water circulates in tubes heated externally by the
fire. Fuel is burned inside the furnace, creating hot gas which heats water in
the steam-generating tubes. ... The heated water then rises into the steam drum.
Definition: - Boiler drum is used for separation of steam and water mixture
coming from the water wall tubes. It ensures that only steam goes with no part of
water to turbine...
Steam Drum (WHRB)

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P
Process: - With saturated temperature of 350 ° C, steam plus water
boiler transmits in a drum with a filter splitter, where the water is down
and the steam is located towards the top. The name of this boiler is the
waste heat recovery boiler, which is 5 meters long and the steam
Working pressure is 70 kg /centimeters square (68.67 bar) at and
maximum pressure is 77 kg/centimeter square (75.53 bar) and maintain
the steam pressure 65 kg/Centimeter square (63.76 bat) the temperauter
of the steam 272/283*C (Degree Celsius) and maximaum temp. Of the
steam 292*C the steam generation 21.800/hours and maximum steam
generation 27/hours
The steam drum is in the two man hole and water wall
Tube to economizer fitted is in the 9 man hole
Mainully sens the pressure of the steam
Boiler Mounting
Deffinition: - Various valves and fittings are required for the safe and proper
working of a boiler. Those attached directly to the pressure parts of the boiler are
referred to as the boiler mountings.
Man Hole
Pressure Gauge

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The water level indicator is mainully which is
40-50% level in the steam drum
The air released from the steam drum to the
Atmosphere and comes to the water is in the steam drum
Spring loaded shefty valve maximum pressure
76/77 kg/centimeter sqare
The working of the stop valve steam is transferred to the
Main steam line and super heater
The temperature sensing is below to the 650*C
The resistance temperature detector is a high sensing
Element is above the 650*C
Water Level Indicator
Air Vend
Spring Loaded
Stop Valve
RTD
Thermocouple

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The working of the soot blowers is clean the dust
Dust partical in the flue gas tube
When boiler of shut down the steam is converts to the
Water form in tube which clean the water form by the
Steam pressure
The steam and water back to the steam drum and
Dearator
The working of the feed check valve transferred to
The boiler of condensate water
The working of the air fails to open and air fail to
C close is trip of the equipment and use in the
Turbine to hotwell
The working of the intermediate blow down and
Continuous blow down is total dissolved solid in
Present in the water
Drain Valve
Soot Blowers
Non Return Valve
Feed Check Valve
AFO & AFC
IBD & CBD

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This valve is used for water tested in boiler
Process: - The hot water down of the steam drum transfers into a pipe
like a down comer header, and then the transfered in the bottom ring
and the hot water is transformed into the economizer, so that the hot
water steam plus water changes and then goes to the water plus steam
evaporator.the steam plus water is transfered to the top ring header. The
steam plus water final transferring is made from steam drum in which
steam drum is filtered. Water goes down to the cause of gravity and like
steam is uper side in the boiler drum, the water is recirculate and the
Water Sampling Valve
Water Circulation
Steam Drum Down comer Header Bottom Ring Header
Economizer
EvaporatorTop Ring Header

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steam remains on top then the steam goes super heater to be a super
heater.
Process: - The steam of the pressure 65kg/centimeter sqare and temp.
350*C is transferred to the primary super heater by the steam stop
valve.The working of the primary super heater remove moisture contain
from the steam and temp. Of the steam 275*C/283*Cby the flue
gas.The steam is transferd to the De-super heater and maintan the temp.
at below the 500*C by the water cooling sprey.the steam is finally
transfered to the super heater and steam is super heater at a high
temp.490/485*C.The high super heat steam is transfered to the comman
header by the main steam line.the high super heat steam is transfered to
the two turbine
Steam Circulation
Steam Drum Primary Super Heater De-Super Heater
Super HeaterCommon HeaderTurbine

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Process: - The high super heat steam is transferred to the two turbines.
The name of the turbine is known as impules and reaction turbine.made
in the chaina (Qingdao Jieneng) and model 6.28.The steam is enter to
the turbine blade at a high temp. And high pressure 490*C and 64
kg/centimeter sqare respectively expand in blade at high velocity and
low pressure. The steam is passing the 14 stage and 11 blade in the
turbine and revolution of the turbine blade at 3000 RPM.The steam is
exit the turbine blade at low temp. And low pressure 49*C and 0.0098
MP (0.098 bar) respectively.The electricity generate in the two turbine
2*6 = 12 MW there is 1 MW = 4 ton steam pressure the steam pressure
and velocity is low in the end of the turbine blade
Impulse turbine: - high pressure and low velocity
Reaction turbine: - high velocity and low Pressure
Turbine (Impulse & Reaction Turbine)
Condenser Generator
Cross Section Blade Graph

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Process:-The exhuat steam is transfered to the surface condenser at a
low pressure and temp.The exhust steam entire the condenser and heat
exchange in the water tube at a critical temp. and made the condensate
water the water tube is known as cooling tower the soft water is coming
from the softing plant is a capacity 2*75 ton and the soft water is
transfered to the cooling tower the soft water is dump the upper to lower
position at various process and heat exchange in the steel blade and the
cool water at 30*C inlet the condenser by the recycle cooling water
pump.The heat water exchange by the steam in the soft water at 40*C
outlet the condenser at 40*C by the recycle pump. The soft water is
recirculate in the cooling tower to condenser and condenser to cooling
tower.The axulary cooling water pump is used for soft water is
transfered to the softening plant and coming to the cooling tower in the
upper side.It is used for heat exchanged for the soft water the cooling
Condensate Water
Softening Plant
Cooling Tower Reservoir
Condenser (Surface)
Inlet Outlet

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tower fan is outlet the hot gas released in the atmosphere in the soft
water.
Process: - The condensate water is transferred to the connected hot
well as a contain in the container at a temp. 50*C.The condensate water
is transferred to the injector.The working of the injector the steam is
suck from the turbine and the heat exchange in the flowing condensate
water and then increase the temp. of the condensate water.the vaccume
create in injector (-0.40 kg/centimeter square).the condensate water is
transferred to the glade vend condenser the working of the glade vend
condenser lekage steam is sucke from the turbine and the heat
exchange in the tube in the flowing condensate water and then increase
the temp. Of the condensate water.
Process: - The condensate water is transferred to the low pressure
heater and the low pressure heater is connected to the turbine and
increases the temp. Of the condensate water.the condensate water is
finally transferred to the dearator at a temp. 125*C and the condensate
Hot Well Ejector Condenser Gland Vend Condenser
Low Pressure Heater Deaerator
Re-Circulation

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water is transferred to the feed water without oxygen the process is
recirculatin
Accessories
Deffination: - Boiler accessories are those components which are. Installed either
inside or outside the boiler to increase the. Efficiency of the plant and to help in the
proper working. Of the plant.
 Deaerator
 Economizer
 Evaporator (1,2 & 3)
 Primary Super Heater
 De-Super Heater
 Super Heater
 Ejector Condenser
 Gland Vend Condenser
 Low Pressure Heater
 Feed Water Pump
 Separator Steam

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Process: - The flue gas is coming from the coke oven at a high temp.
950to 1000*C in the flue gas tube by the force draft fan (FD fan).The
flue gas is transferred to the super heater at a temp. 490*C is released
and remains flue gas is transferred to the De-super heater and flue gas
is goes to the primary super heater and flue gas is goes to the evaporator
1,2&3 the remains flue gas is goes to the water wall tube and
econominzer at a temp. of 200*C and remains flue gas at a temp. Of
150*C released atmosphere from chimney by the induced draft fan.
Flue Gas Circulation
Coke Oven Plant Water Wall Tube
Super Heater
De-Super HeaterPrimary Super HeaterEvaporator
Economizer Induced Draft Fan Chimney

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Power plants are much safer than they once were; however, plant
employees still encounter hazards. Training, along with proper
Operation and maintenance procedures are key to reducing accidents
and mitigating their effects.
Safety

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Conclusions
At present, thermal power generation accounts for approximately
70 % of the total amount of electricity produced around the
world. However, thermal power generation, which uses fossil
fuels, causes more CO2 emissions than other power generation
methods. In order to reduce CO2emissions per unit power
produced, Toshiba Group is developing next-generation thermal
power technologies aimed at improving plant efficiency and
commercializing the CO2 capture and storage system. To
improve the efficiency of thermal power generation, it is of vital
importance that the temperature of the steam or gas used to rotate
the turbines is raised. Toshiba Groupis working on the
development of ultra-high-temperature materials and cooling
technologies in order to commercialize an A-USC system
(Advanced Ultra-Super Critical steam turbine system) more
efficient than previous models, which is designed to increase
steam temperature from 600°C to above the 700°C mark.