Bullehshah Packages Power House Internship Report

Biomass Power Plant 41MW

Internship Report
Submitted by
Salman Qaiser
Submitted to
Sir Ehsan-ul-Haq
Sir Muhammad Ali
Date of Submission
1st August, 2019

In fulfilling the requirements of my Internship at

Bullehshah Packages Limited

University
Riphah International University

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Bullehshah Packages Power House Internship Report

Contents

Biomass Power Plant 41MW...................................................................................................................... 3

 What is Biomass Power Plant? ...................................................................................................... 3

 Block Diagram of Power Plant ...................................................................................................... 4

Electrical System in Biomass Power Plant ............................................................................................... 5

DCS (Distributed Control System) ........................................................................................................ 5

 Block Diagram of DCS ............................................................................................................... 5

VFD (Variable Frequency Drive) .......................................................................................................... 6

Distribution of Power ............................................................................................................................. 6

 Block Diagram of distribution ................................................................................................... 6

 SLD (Single Line Diagram) ........................................................................................................ 7

Project on Baler, safety and PLC wiring .............................................................................................. 8

 Safety Parameters on Baler ........................................................................................................ 8

 Panel Wiring .............................................................................................................................. 11

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Bullehshah Packages Power House Internship Report

Biomass Power Plant 41MW

 What is Biomass Power Plant?
Biomass is the process of generating electricity from the fuels like corn straw and wheat
straw. The mixture of both the fuels is added to the furnace where there is a burner and in
this furnace, steam will be carried out and then this steam starts the turbine and turbine
helps the generator to start and generates electricity. Power House has 3 boilers that are
listed as follows
o 200 TPH
o 150 TPH
o 65 TPH
First raw water is added to demineralized water plant then from here demineralized water
goes to demineralized water tanks and from here feed water goes to derator and then to
feed water pumps. From here the feed water goes to the HP heaters and from here hot
water goes to the economizer and then travels to the steam drum. And then from steam
drums the steam travels through the super heaters. There are three passes of boiler that
are 1st pass, 2nd pass and 3rd pass. First steam goes to SH1 and SH2 that are in the 3rd pass
of boiler then the steam travels to SH3 that is in the 1st pass of boiler and at the end steam
goes to SH4 that is 2nd pass of boiler. Then from here steam goes to main stream line and
from here steam is given to turbine of 6770 rpm to make the generator on and generates
electricity of 41MW.

 Main areas of Power House

The main areas of biomass power plant are listed as follows
o Biomass Plant
o 200 TPH Boiler
o 150 TPH Boiler
o 65 TPH Boiler
o Fuel Yard
o Compressor
o Control room
o Water chest
o Turbine hall

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 Bullehshah Packages Power House Internship Report

 Block Diagram of Power Plant

Demineralize Demineralize
Raw Water Demine water Feed water Deaerator
water plant water tanks
water

Water
Bypass

Feed Water
Economizer Feed Water HP Heaters Feed Water Pumps
Feed water

Steam Drum Steam SH 1 SH 2 SH 4 SH 3

Return Boiler 3rd Pass Boiler 2nd Boiler 1st

Condensate Tank Pass Pass
Condensed

Condenser Water Turbine Steam Main Stream Line

13 bar

5 bar

PM6 PM7

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Electrical System in Biomass Power Plant

When generator produce 41 MW of electricity then this electricity is distributed to all the
machines of Bullehshah Packaging i.e. PM-6, PM-7, Corrugator department, finishing
department, recycling department etc. There are control rooms of all these departments where
whole the system is controlled automatically or manually. DCS (Distributed Control System) is
used to control the machines logically by server or computer.

DCS (Distributed Control System)

 Block Diagram of DCS

Server

Operation Operation
Controller
Station 1 Station 2

Input/output
Cards

DCS is the online system for controlling the machines of Bullehshah Packaging. The system is
controlled by the controller attached to the server. DCS is based on four important subsystems
that are as follows
o Analogue Input
Analogue input is used to control all the temperatures, pressures, flow and levels
of the tanks in all the instruments that are used in machines. This input will be
received to the instruments of the machines from the controller of DCS.
o Analogue Output
Analogue output is the output of machines like actuators, motors, valves and
pumps etc. we will give output to program controller and the machines will
receive the input according to that output.
o Digital input
Digital input is the input in the form of digital binary values i.e. 0 and 1. This
input is for switches in the machines. It is used to tell us the status (on and off) of
instruments attached to machines.

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o Digital Output
Digital output is the output and commands of valves, SOV’s etc. We will give
digital output to program controllers and in the field they will receive input
according to that output.

VFD (Variable Frequency Drive)

A variable frequency drive is the machine that is used to derive the motor and to vary the
frequency of the motor. A full machine VFD consists of an inverter and a converter. Below is the
internal block diagram of a variable frequency drive.

Figure 1: internal block diagram of VFD

Distribution of Power
 Block Diagram of distribution
Below is the symbolic diagram of distribution of power to the mill.

GRID STATION FUTURE STEAM TURBINE

132 KV D.G. SET 2.5 MW 41MW, 11 KV

,,,,

11KV SWITCH GEAR LEVEL 1 POWER DISTRIBUTION ROOM

SWITCHGEAR +J1 SWITCHGEAR +J2 SWITCHGEAR +J3

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Bullehshah Packages Power House Internship Report

Then afterwards this supplies power to all the departments of Bullehshah Packaging. This was the
main symbolic diagram of power Distribution.

 SLD (Single Line Diagram)

The power distribution of Mill is based on single line diagram. Power is distributed
according to the single line diagram. The basic components of SLD are
o 11KV Circuit Breaker
o Motorized 11KV Circuit Breaker
o Motorized 11KV Circuit Breaker with synchronizing provision
o L.V Circuit Breaker
o PT(Potential Transformer) ,
o Cable A of 15 KV, 3C * 240
o Cable B of 15 KV, 3C * 120
o Cable A of LT, 1C * 300
Below is the hand made single line diagram of power distribution of Bullehshah
Packages,

Figure 2: SLD of Power Distribution

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Bullehshah Packages Power House Internship Report

Project on Baler, safety and PLC wiring

 Safety Parameters on Baler
There are number of safety parameters required on the baler such as follows
o Conduit Pipes
A conduit pipe is broken that is of the size 13 mm as shown in diagram below

Figure 3: Broken Conduit Pipe

The conduit pipe should not be broken or damaged because it can be harmful for
the operators and workers.

Number of conduit pipes is incomplete and also there are some pipes which are
not in use or they are empty. There is no wire inside the pipe. Figure is shown
below

Figure 4: Incomplete Pipe

The solution of this problem is that we should use conduit pipes according to our
requirements. Excess pipes should not be used. The conduit pipes should be
properly fitted from one conduit to other conduit.

A conduit pipe of 37mm is connected improperly to conduit or the pipe is h the

help of insulation tape.

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Figure 5: oversized conduit

The solution to this problem is that the above pipe is of 37mm and the conduit if
of 40mm. So the conduit pipe should also be of size 40mm. By this we shall not
require an insulation tape for connecting the pipes.

A conduit pipe of 27mm is not fitted to T shape connector properly. The conduit
pipe is damaged from all the three sides of connector as shown in figure

Figure 6: Different widths of pipe

The conduit pipe should be properly fitted inside the T shape connector. The T
shape connector is of diameter 1.25 inches and a conduit pipe which is of 20 mm
size is connected there. The pipe is small as compared to the T. all the three pipes
should be of 27mm to be connected properly in all the three sides of T shape
connecter.
Two different conduit pipes are connected to each other. One is of 28mm and the
second pone is of 20mm and they are connected by insulation tape. There are two
solutions of this problem
 One is that we should connect two sided connector
 Second one is that the size of pipe should be same.
o Panel Gland
A conduit pipe of the size of 27mm is improperly connected to the panel gland
and also the heat resistive insulation is not properly on the conduit pipe. The pipe

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is also damaged. So as there is high voltage on the panel so it can be harmful for
workers. Figure is shown below

Figure 7: Panel gland

The size of the gland and the size of the panel should be same so that it can be
fitted easily and heat resistive insulation should be of greater length so that it can
be fitted on both the gland and the pipe.

o Solenoid Valves
There are solenoid valves or indicators on the balers and they are severe damaged
as shown in figure

Figure 8: Solenoid Valves or Indicators

These valves should be changed for the proper working of the Baler.

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 Panel Wiring
o X2 Terminal Block (Motor Signals)
S.no Wire Number Point coming Point going to Component
from
1 5 02-6 17-2 Starter Key
21-10 S
2 4 02-5 17-3 Starter Key
21-11 R
3 1 02-2 17-6 Starter Key
21-11 B
4 3 02-5 17-6 Power View
21-12 Terminal A(1)
5 16 02-16 17-9 No wire
21-13
6 14 02-14 17-9 Power View
21-11 Terminal A(2)
7 15 02-15 17-10 Power View
21-14 Terminal A(3)
8 2 02-3 17-10 Power View
21-15 Terminal A(5,6)
9 7 02-8 17-13 Switch KA070
21-16 (Diesel Motor
Stop Relay)
10 11 02-11 17-14 Switch Terminal
21-16 11
11 6 02-7 17-15 Switch KAS73
21-17 (Motor
Emergency Stop
Relay)
12 3 02-4 17-16 Switch Terminal
21-18 3
13 8 02-9 17-17 Switch KA071
21-18 (Max Min RPM
Commutation
Relay)
14 10 02-11 17-18 Switch Terminal
21-19 10
15 -24 02-12 21-12 35-12 SB62
(Bedplate
Emergency Stop
Push Button-1)

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Bullehshah Packages Power House Internship Report

o Other Important Components in Panel

 Shear Forward Detector (B02)

It is an inductive primary sensor and it is cylindrical in E2A Series. It is
10V to 32V connector. It has a sensing range of 15mm. Its thread size is
M30 and haves a DC min voltage of 10V and maximum voltage of 32V.
 Torsion Encoder (B35)
A torsion encoder provides a specific number of pulses for each
revolution. Basically these pulses will be in the form of square waves. Its
external diameter is 40mm and has a resolution up to 2000 ppr. Its input
voltage is 5V to 24V and it gives us NPN output. It has a current
consumption of 80mA maximum. And has a maximum frequency
response of 100 KHz.
 COMPOBUS Input Units (D09-D12)
Compo buses are used for communication purposes. These are used for
high speed communication of 750 kbps and 500m. It operates on input
current of 6mA and takes an input voltage of 15V DC and gives us output
current of 0.3A and voltage of 0.6V.

 Voltage Stabilizer (GS04)

Voltage Stabilizer is used to make the output voltage that feeds the
equipment connected to it. It takes input of 19-72V DC and input current
of 24.8A and provides us output of 24V and output current of 21A.
 Analogue Signal Converter
It converts voltage and current of measurands and integrate them with
SCADA and RTU.

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