This document provides a summary of training activities completed by Talha Abdul Rehman during his internship at WHRPP BCL-CHK from August 2022 to present. It outlines several maintenance and improvement projects he assisted with, including turbine bearing replacement, desuperheater header replacement, vibration sensor replacement, cable replacement, and solar panel installation. It also provides an overview of the WHRPP plant specifications and concludes with a description of a DCS HMI design project to create a backup system for power generation monitoring.

2. Talha Abdul Rehman
Trainee Engineer
WHRPP BCL-CHK
Date of Joining: 02 Aug, 2022
Electrical Engineer
GraduationYear: 2022

3. Activities DuringTraining
• Turbine Bearing Replacement
• Replacement of Desuperheater
header at CFB-II
• Vibration Sensor of Bearing 1 is
changed
• CCCT Line Replacement
• Solar Project Activities
• MV and LV cables testing and laying
• Inverters and Solar Panels inspection
and installation
• Transformer and relay testing
• DCS HMI Designing Project
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4. WHRPP Overview
• Tubine: Rated Power 16 MW, Rated Steam Admission 77.1 t/h
Steam Temperature 324°C Working Pressure 1.53 Mpa (15 bar)
• Generator: Rated Power 18 MW Rated RPM 3000
2 Pole 50Hz
• Generator Protection Device: DSA2382
Protections : 87G, 64V, 59, 51, 49, 57, 51V, 40, 95U/O, Io >, 32
• AQC WHE : Capacity 14.5 t/h Steam temp 323°C
• PH WHE: Capacity 24.1 t/h Steam temp 296°C
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OVERALL MAINTENANCE ACTIVITIES &
LEARNING OUTCOMES
• WHRPP & CFB
• Boiler’s preservation.
• TG building Compressors maintenance.
• AQC WHE tube replacement.
• AQC bypass damper’s actuator replacement.
• Pre.duster baffle plates replacement and repair.
• Patch work in ducts.
• CFB Superheater header maintenance.

6. Turbine Bearing Replacement
• As the temperature of the turbine bearing increase
to 92⁰C which is alarming.
• To overcome this issue, the decision is made to
replace the journal bearing of the turbine.
• Front pedestal casing and bearing housing is first
removed
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7. Turbine Bearing Replacement
• Journal bearing was removed which is
compose of upper and lower half.
• The rotor is polished by Brasso Polish to
remove scaling and debris.
• New bearing is placed in the housing and
bearing housing is placed.
• Pedestal is placed and activity is finished.
• After replacement, the bearing temperature
fall back to 85⁰C which is acceptable.
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8. CFB Header Replacement
• There were leakage at jointing of tubes with the header and cracks at the
body of the header.
• Due to this steam loss occur and also trip boiler sometimes which is costly
for running plant.
• The header is replaced at 07 June 2023 by Lyallpur Company Faisalabad.
• The material used in header is ASTM-192.
Major Activities
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9. CFB-II Desuperheater Header Replacement
Working at the header
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10. Turbine Bearing 1Vibration Sensor
Replacement
• Due to vibration, sudden increase in vibration
at load changing is observed.
• To rectify of this issue the replacement of the
Shinkawa CV-861 vibration sensor is
suggested.
• After changing the sensor the vibration of the
bearing is in limit and the issue is sloved.
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11. CCCT Line Partial Replacement
• CCCT ( Closed circuit cooling tower) line is
corroded from different places due to which
the demin water composition deteriorate.
• To overcome this issue the MS (Mild Steel) line
is used to replace the most effective areas of
the line.
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12. Solar Extension Project Description
• Already installed solar plant is 15.2MW and now extension is made about
4.543MW.
• New installed panels are 8259 with each panel of power 550W.
• One LV panel is installed at canteen are and one at New Area.The MV panel is
added in Solar CCR for power transmission.
• TheTransformer of 3.5MVA is installed at New area.
• 2 inverters are installed at existed area, 8 inverters are installed at new area and 8
inverters are installed at canteen area.
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13. Solar Project Activites
• First the unloading of the solar pallets are done
with extra care.
• The civil work is done by using coordinates and
with proper manpower and tools.
• The excavation work and other cable laying is
done by the contractor under the supervision
of the BCL employees.
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14. Solar Project Activities
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15. MV and LV Cable InsulationTesting
• MV cable 3x240mm2 is used for transmission
of cable from 76D transformer to cement mill
substation.
• Same cable is used from New areaTransformer
5 to Solar CCR and from CCR to Grid.
• The insulation of cable is test from Megger
MT1025 insulation tester.
• The MV joint is also made there.
• Similarly, the insulation of the LV cables is
checked.
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16. Earth ResistanceTest and Equipment
Grounding
• There are special instruction from Sungrow
that the grounding of the equipment must be
proper.
• For that purpose, the earth pits are made by
excavation and mesh is made to low the earth
resistance below 1 Ohm.
• Bear conductor with conductor rod is used.
Bentonite Earthing Powder is used to reduced
the earth resistance.
• The earth resistance is measured by using the
earth resistance tester.
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17. Transformer and LV, MV Panels inspection
• The transformer of rating 3.5MVA is installed
which is step up transformer of 800/6300V.
• First the supply is given from the grid to on the
transformer and then the voltages at HT and
LT winding of transformer is measured.
• The LV and MV panels are also checked same
way to check the voltages.
• The relay P122 at MV panel is inspected by
using Megger Sverker 750.
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18. Visit to Mainwali Plant and Inverters Operation
• The sungrow team visit the plant and measure
each string voltages and grounding conditions.
• Then the inverters are operated under the
supervision of the concerned personnel.
• Then the data logger is communicated there
and can be access by authorized personnel at
any location using the wifi.
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19. DCS Project
Designing of HMI for Power Generation
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• As, the hard disk of main CCR corrupted. Due to this, the backup is required.
• Using KepServer Ex andWinCC the new design of HMI is generated.
• In KepServer Ex, the devices are created to show the required power
generation. After making data in KepServer Ex, the WinCC is used as the
graphic designing.
• InWinCC, the tag management is opened and tags are added from the
KepServer Ex.
• Graphic designing is made inWinCC then for report generation new layout is
created and save as report.pdl

20. DCS Project Activities
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