TATA STEEL LIMITED

JAMSHEDPUR DIVISION

VACATIONAL TRAINING IN (G) BLAST FURNACE

Training guide: Trainee’s Name:

Mr. Ashish Sharma Suraj Kumar
Vishwakarma

MECHANICAL ENGINERRING DEPARTMENT

DIT UNIVERSITY, DEHRADUN

1
 G Blast Furnace,

TATA Steel,

Jamshedpur-831 001

CERTIFICATE

This is to certify that the project report entitled “Blast furnace ”, being submitted
by Suraj Kumar Vishwakarma of DIT University to Tata Steel, as a part of summer
training course of B.Tech curriculum is a bona-fide record of work carried out by
him under my supervision and guidance. The sincerity and sense of dedication
shown by him during the project is commendable. The project was completed
during the period from 17.5.2016 to 27.6.2016.

Mr. Ashish Sharma

Chief/Head: Raw materials planning group

Arigino division

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 ACKNOWLEDGEMENT
First I would like to thank TATASTEEL for giving me an opportunity as a vocational trainee
in their esteemed, a state-of-art steel plant. I was encouraged practical learning, which is
impossible to achieve through books. I have learnt a lot from here.

I take this opportunity to express my deep sense of gratitude to Mr. PAWAN AND OMJEE
ANAND (Senior Manager, Mechanical maintenance (G Blast Furnace)), project guide, for his
immense support and guidance. I would also like to thank (Manager), Mr. PRADHUL
(Fore-man, G Blast Furnace), for helping me throughout and giving useful suggestions and
views on my project. I would also like to thank Mr. RAHUL KUMAR AND BABULAL (Sr.
office associate) for his constant support and guidance during my training in TATA STEEL.

I would also like to thank all my friends and all employees of G Blast Furnace who helped
me throughout the project by giving their valuable time and guidelines to complete the
project and so many other countless people of TATA STEEL, Jamshedpur for helping me in
my project.

SURAJ KUMAR VISHWAKARMA

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 SUMMARY
The city of Jamshedpur was built by the skill, passion and intelligence for building a new
city by Jamshedji. TATA Steel formerly known as TISCO and Tata Iron and Steel
Company Limited is the world's sixth largest steel company, with an annual crude steel
capacity of 31 million tons. It is the largest private sector steel company in India in terms of
domestic production. Ranked 258th on Fortune Global 500, it is based in Jamshedpur,
Jharkhand, India. It is part of Tata Group of companies. Tata Steel is also India's second-
largest and second-most profitable company in private sector with consolidated revenues
of ₨ 1,32,110 crore and net profit of over ₨ 12,350 crores during the year ended March
31, 2013.

Its main plant is located in Jamshedpur, Jharkhand, with its recent acquisitions; the
company has become a multinational with operations in various countries. The registered
office of Tata Steel is in Mumbai.

Established in 1907, Tata Steel is the world's 6th largest steel company with an existing
annual crude steel capacity of 28 million tones. Asia's first integrated steel plant and India's
largest integrated private sector steel company is now the world's second most
geographically diversified steel producer, with operations in 24 countries and commercial
presence in over 50 countries.

Tata Steel has set an ambitious target to add 50 million tons per annum capacity by
2015.Overseas acquisitions have already added up to 21.4 million tones, which include
Corus production at 18.2 million tone, NatSteel production at two million tone and
Millennium Steel production at 1.2 million tones. Tata is looking to add another 29 million
tones through the acquisition route.

 Tata Steel has lined up a series of Greenfield projects in India and outside which
includes

1. 6 million tones plant in Orissa (India)

2. 12 million tone in Jharkhand (India)
3. 5 million tones in Chhattisgarh (India)
4. 3-million tones plant in Iran
5. 2.4-million tones plant in Bangladesh
6. 5 million tones capacity expansion at Jamshedpur (India)
7. 4.5 million tones plant in Vietnam (feasibility studies underway)

The company is facing increasing criticism that the drive for growth and profits is
completely overshadowing its once famed philanthropy and causing lasting social and
environmental damage at various locations. In response, Tata cites its programs for
environment and resource conservation, including a reduction in greenhouse erosion, raw

4
materials and water consumption. The company has increased waste re-use and re-cycling,
and reclaims land at its captive mines and collieries through forestation. Mr. R. P. Sharma,
Tata Steel's chief, environment and occupational health, says, "Our capital investment in
pollution-abatement solutions was in the vicinity of Rs 400 crore in 2003-04." It has also
set the target of achieving reduction in CO production per ton of steel.

Tata Steel's vision is to be the global steel industry benchmark for Value Creation and
Corporate Citizenship.

Tata Steel is one of the few steel companies in the world that is Economic Value Added
(EVA) positive. It was ranked the "World's Best Steel Maker", for the third time by World
Steel Dynamics in its annual listing in February, 2006. Tata Steel has been conferred the
Prime Minister of India's Trophy for the Best Integrated Steel Plant five times.

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 CONTENTS

1.0 CHAPTER ONE

1.1 About Tata steel limited
1.2 About G blast furnace
1.3 Process description
2.0 CHAPTER TWO- PRIMARY UNIT
2.1 Blast furnace
2.2 Parts of blast furnace
2.3 Input – Output Model
2.4 The main chemical reaction producing the molten iron
2.5 Design features and furnace parameter
2.6 Basic Oxygen Furnace
2.7 Working of blast furnace

3.0 CHAPTER THREE-SCONDARY UNIT TRT

3.1 Feature of TRT (TOP PRESURE RECOVERY TURBINE)

3.2 Selection of TRT based on BF volume

3.3 General description of TRT

3.4 TRT base farm

3.4.1 Starter

3.4.2 Rotor

3.4.3 Bearing

3.4.4 TRT

3.4.5 Factor on which the output of TRT depend

3.4.6 Computation of power output of TRT (GBF)

3.5 The performance charterstics of turbine ( GBF)

3.5.1BF top pressure control

3.5.2 Parameters for each system, configuration and working principle

3.5.2.a. MPS9.6-220/61 Turbine machine

3.5.2.b.High/Low voltage power generation/distribution system

3.5.2.c. Water spray & drainage system

3.5.2.d. Nitrogen seal system

3.5.2.e. Lube oil system

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 3.5.2.f. Hydraulic servo control system

3.5.2.g. Large valve system

3.5.2.h Automatic control system

3.6 GBF TRT start up process

3.6.1 Run Procedures for TRT

3.6.2 TRT Machine train start up, normal operation and shut down process

3.6.3 Shut down process of TRT

3.7 GBF TRT Normal Shut Down Process Steps

3.8 Conclusion

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1.0 CHAPTER ONE

1.1 About TATA Steel Ltd.

FOUNDER: JAMSHETJI NUSSERWANGJI TATA

(1893-1904)

Jamshetji Nusserwanji Tata ranks among the greatest visionaries of industrial enterprise of
all time. Gifted with the most extraordinary imagination and prescience, he laid the
foundations of Indian industry, contributed to its consolidation, and became a key figure in
India’s industrial renaissance. The first stake for the steel plant was driven on a forest-
covered plateau in Sakchi on 27th February 1908. The dream had come alive, but the
dreamer himself was no more for. Jamshetji had died at Nauheim in Germany in 1904 after
his successors to preserve the family name. His spirit continued to inspire his sons to carry
their father’s dreams to fruition well after his death. Jamshetji Tata won himself an
enduring place in India’s history with his unique courage, commitment and vision.

8
 JEHANGIR RATANJI DADABHAI TATA

(1904-1993)

JRD Tata has been one of the greatest builders and personalities of modern India in the
twentieth century. He assumed Chairmanship of Tata Sons Limited at the young age of 34;
but his charismatic, disciplined and forward-looking leadership over the next 50 years and
more, led the Tata Group to new heights of achievement, expansion and modernization.
Under his stewardship, the number of Tata ventures grew from 13 to around 80,
encompassing steel, power generation, engineering, hotels, consultancy services,
information technology, art and culture, consumer goods, industrial products, etc.
Numerous national and international honors were bestowed on JRD Tata. These included
Knight Commander’s cross of the Order of Merit of the Federal Republic of Germany,
Bessemer Medal of the Institute of Metals, London, and the United Nations Population
Award. Government of India conferred the highest civilian award of the land, Bharat Ratna
to JRD Tata in 1992, For all his colossal achievements, JRD Tata was a modest, sensitive
man, forever espousing the cause of his employees. His natural love for people endeared
him to all... across the entire spectrum of society.

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 CHAIRMAN: RATAN N TATA

The Tata Group since 1991, Ratan N Tata is the Chairman of Tata Sons, holding company
of the Tata Group, and major Group companies including, Tata Motors, Tata Steel, Tata
Consultancy Services, Tata Power, Tata Tea, Tata Chemicals, Indian Hotels, Tata
Teleservices and Tata AutoComp. He is also Chairman of two of the largest private sector
promoted philanthropic trusts in India. During his tenure, the Group has further expanded
its global reach, with its revenues growing over sixfold to Rs 97,000 crore ($21.9 billion).

Mr Tata joined the Tata Group in December 1962. After serving in various companies, he
was appointed the Director-in-Charge of The National Radio & Electronics Company
Limited (Nelco) in 1971. In 1981, he was named Chairman of Tata Industries, the Group's
other holding company, where he was responsible for transforming it into the Group's
strategy think-tank and a promoter of new ventures in high-technology businesses. The
government of India honoured Mr Tata with one of its highest civilian awards, the Padma
Bhushan, on Republic Day, January 26, 2000. He has also been conferred an honorary
doctorate in business administration by the Ohio State University, an honorary doctorate in
technology by the Asian Institute of Technology, Bangkok, and an honorary doctorate in
science by the University of Warwick .Now in the days the Tata family of enterprises
comprises 98 companies in seven business sectors. This section lists all these companies
under the sectors in which they operate, besides the two promoter companies of the group.

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1.2 About G Blast Furnace

The purpose of a Blast furnace to chemically reduce and physically convert solid iron oxide
(Fe2O3) into liquid iron called “Pig Iron” or “Hot Metal” (Fe-94%approx.).

G-blast furnace of Italimpianti design was commissioned at Tata Steel in November, 1992.
The furnace had produced 14.08 million ton of hot metal during its first campaign of 4391
days & was blown out on 22nd December, 2004. The furnace held the distinction of highest
achieved first campaign productivity of 7818 t/m3 not only in the country but surpassed
many first campaign productivity figures in some of the leading blast furnaces in the world.
The furnace was upgraded & blown on 6th April, 2005. Furnace inner volume was
increased to 2643 m3. Many new design features were introduced in the new furnace
including stave cooling system & super micro-pore carbon hearth for longer campaign life.
The furnace remained equipped with Bell less top Paul Wurth charging system with belt
conveyor charging for the raw materials from the stock house. The furnace was also
equipped with Under Burden probe, Vertical probe, Profilometer & Tuyere probe for better
process control measures along with sophisticated instrumentation & distributed control
system furnace automation. The furnace is designed to produce 1.8 MTPA of hot metal at
an average daily production rate of 5200tpd.

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1.3 Process description
• The Blast furnace is a huge, steel stack lined with refractory brick,(modern furnace use
bricks in hearth only) where iron ore, sinter, pellets, coke and fluxes(lime stone, pyroximite
and quartzite) are dumped into the top, and preheated air is blown into the furnace
through tuyeres.

• The raw materials require 4 to 4.5 hours to descend to the bottom of the furnace where
they become the final product of liquid slag and liquid iron.

• These liquid products are drained from the furnace at regular interval.

• The hot air that was blown into the bottom of the furnace ascends to the top in 3 to 3.5
seconds after going through numerous chemical reactions.

• Once a blast furnace is started it will continuously run for 10 to 20 years with only short
stops to perform planned maintenance.

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2.0 CHAPTER TWO- PRIMARY UNIT
2.1 Blast Furnace
Blast Furnace is the most important part of an integrated steel plant. It is considered as the
heart of an ISP. The objective of Blast Furnace is to take the raw material from RMHP, coke
from Coke Ovens and Sinter from Sinter Plant and convert it into pig iron or ”Hot Metal”.
Coke serves as the heat source and reducing agent while Limestone and Dolomite are used
as flux, which combines with gangue to produce slag. A Blast Furnace is so called because it
uses air blast as oxygen source for the process.
HOT AIR BLAST

BURDEN CHARGE

Blast furnace is a counter current reactor.

Process in blast furnace is called counter current reaction.

BF is a counter current heat and mass exchanger, in which solid raw materials are charged
from the top of the furnace and hot blast, is sent through the bottom via tuyeres.The heat
and is transferred from the gas to the burden and oxygen from the burden to the gas. Gas
ascends up the furnace while burden and coke descend down through the furnace. The
counter current nature of the reactions makes the overall process an extremely efficient
one in reducing atmosphere. The real growth of blast furnace technology came with the
production of high strength coke which enabled the construction of large size blast
furnaces.

2.2 Parts of Blast Furnace

1. Hot blast from Cowper stoves
2. Melting zone
3. Reduction zone of ferrous oxide
4. Reduction zone of ferric oxide
5. Pre-heating zone
6. Feed of ore, limestone and coke
7. Exhaust gases
8. Column of ore, coke and limestone
9. Removal of slag
10. Tapping of molten pig iron
11. Collection of waste gases

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2.3 Input – Output Model
BF is a counter current heat and mass exchanger, in which solid raw materials are charged
from the top of the furnace and hot blast, is sent through the bottom via tuyeres. The heat
and is transferred from the gas to the burden and oxygen from the burden to the gas. Gas
ascends up the furnace while burden and coke descend down through the furnace. The
counter current nature of the reactions makes the overall process an extremely efficient
one in reducing atmosphere. The real growth of blast furnace technology came with the
production of high strength coke which enabled the construction of large size blast
furnaces.

Sinter Iron ore lump

Coke

Blast
Hot Blast Hot Blas BF Gas Clean BF
Furnace GCP
Gas

Hot metal

Slag

PCM

SSM

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2.4 The main chemical reaction producing the molten iron
Fe2O3 + 3CO → 2Fe + 3CO2[33]
C + O2 → CO2[33]
CO2 + C → 2CO[33]
CaCO3 → CaO + CO2[29]
SiO2 + CaO → CaSiO3[34]
Preheated blast air blown into the furnace reacts with the carbon in the form of coke to
produce carbon monoxide and heat. The carbon monoxide then reacts with the iron
oxideto produce molten iron and carbon dioxide. Hot carbon dioxide, unreacted carbon
monoxide, and nitrogen from the air pass up through the furnace as fresh feed material
travels down into the reaction zone. As the material travels downward, the counter-current
gases both preheat the feed charge, decompose the limestone to calcium oxide and carbon
dioxide, and begin to reduce the iron oxides in the solid state. The main reaction controlling
the gas atmosphere in the furnace is called the Boudouard reaction:
The decomposition of limestone in the middle zones of the furnace proceeds according to
the following reaction:

The calcium oxide formed by decomposition reacts with various acidic impurities in the
iron (notably silica), to form a fayalitic slag which is essentially calcium silicate, CaSiO3:[33]

The "pig iron" produced by the blast furnace has a relatively high carbon content of around
4–5%, making it very brittle, and of limited immediate commercial use. Some pig iron is
used to make cast iron. The majority of pig iron produced by blast furnaces undergoes
further processing to reduce the carbon content and produce various grades of steel used
for tools and construction materials.

Although the efficiency of blast furnaces is constantly evolving, the chemical process inside
the blast furnace remains the same. According to the American Iron and Steel Institute:
"Blast furnaces will survive into the next millennium because the larger, efficient furnaces
can produce hot metal at costs competitive with other iron making technologies."[29] One of
the biggest drawbacks of the blast furnaces is the inevitable carbon dioxide production as
iron is reduced from iron oxides by carbon and there is no economical substitute –
steelmaking is one of the unavoidable industrial contributors of the CO2 emissions in the
world.
2.5 Design Features and Furnace Parameters
 Design production: 1.8 MTPA
 Design productivity: 2.27 t/ m3/ day (on working volume)
 Hearth diameter: 11.05 meter
 Working volume: 2308 m3
 Inner volume: 2648 m3
 Tuyeres : 30 No. (Double chamber)
 Charging system: belt conveyor & PW Bell less top

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  Furnace top pressure: 1.50 bar
 Rated daily hot metal production: 5200 ton
 Hot blast temperature: 1175°C
 Max blast pressure: 3.5 bar
 High top pressure: 1.5 bar
2.6 Basic Oxygen Furnace

Hot Metal coming out of the Blast Furnace is collected in ladles and poured into mixers. The
mixers (2) serve the purpose of storing as well as homogenization of temperature and
composition. Coke oven gas is used here to maintain the temperature at 1260o C. the quantity
of raw materials for producing one ton of steel are as follows:

Hot Metal 1073 kg

Scrap 65.9 kg

Iron Ore 15.6 kg

Briquetted lime 10.6 kg

Calcined Lime 81.3 kg

Dolomite 31.3 kg

Fe- Mn 1.11 kg

Fe- Si 1.32 kg

Al 0.15 kg

Coke Breeze 3.27 kg

The shop has three converters each having a capacity of 110-130T per heat. The converters
were commissioned by Mannesmann Damage of Germany. Each converter has its own lance
system for blowing oxygen at high pressure so as to form an emulsion on the surface of metal
which increases the surface area to such an extent that separation of impurities takes place
very fast.

2.7 Working of Blast Furnace

A Blast Furnace is a type of metallurgical furnace used for smelting to produce industrial
metals, generally iron.

In a blast furnace, fuel and ore are continuously supplied through the top of the furnace,
whileair (sometimes with oxygen enrichment) is blown into the bottom of the chamber, so
that thechemical reactions take place throughout the furnace as the material moves
downward. The end products are usually molten metal and slag phases tapped from the
bottom, and flue gases exiting from the top of the furnace.

16
Blast furnaces are to be contrasted with air furnaces (such as reverberatory furnaces),
which were naturally aspirated, usually by the convection of hot gases in a chimney flue.
According to this broad definition, bloomeries for iron, blowing houses for tin, and smelt
mills for lead, would be classified as blast furnaces. However, the term has usually been
limited to those used for smelting iron ore to produce pig iron, an intermediate material
used in the production of commercial iron and steel.
3.0 CHAPTER THREE-secondary unit TRT

3.1 Features of TRT (TOP PRESURE RECOVERY TURBINE)

1. Energy saving equipment for the blast furnace of a steel plant.

2. Power generating equipment furnished with a function to control the top
pressure of the blast furnace.
3. Power is generated by driving a turbine using blast furnace gas.
4. No fuel is needed for power generation.
5. No fuel is burned and hence there is no generation of CO2 or other green
house gases.
6. Contributes to CO2 reductions in accordance with power generation volume.
7. Generates less noise in comparison to a conventional septum valve.
8. No sophisticated technology is needed for its operation and maintenance.
9. Only small amount of water, nitrogen etc are needed for its operation.
3.2 Selection of TRT based on BF(blast furnace gas) volume

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A top-pressure recovery turbine plant is installed in the downstream of gas-cleaning
equipment for a blast furnace. There are two types of gas-cleaning equipment: a wet type
that uses water and a dry type that does not use water. After dust is collected by either of
them, blast furnace gas is led to the turbine and drives it while expanding from around the
furnace top pressure to atmospheric pressure. The power generated by the turbine is
transferred to the generator and converted to electric power. In conventional practice, the
energy of blast furnace gas was wasted by pressure reduction at a septum valve. It is now
recovered as electric power, realizing significant energy saving.

The top pressure is controlled by opening or closing the 1st stage stator blades of the
turbine in accordance with the increase or decrease of the blast furnace gas volume. With a
conventional turbine, a governor valve was also used in combination for controlling the top
pressure. A governor valve, however, induces a larger pressure loss in comparison with
stator blades and thus was disadvantageous in view of power recovery and noise
prevention. Hence, in the system widely used now, the governor valve is eliminated and the
top pressure is controlled only by the 1st stage stator blades.

3.3 General description of TRT

BF top pressure recovery turbine is featured in low gas pressure, low temperature, high
flow rate and harsh operation condition (medium contains solid particle after several time
dust-removal). This turbine unit is designed with two stage stator blades adjustable.

18
This unit is of double support with two stages, which mainly consists of stator, rotor and
base frame. The turbine unit connects with the power generator via coupling directly. The
radial bearing is of four-lobes sliding bearing, whereas the thrust bearing is Michel bearing,
both of them are forced lubrication.

The geometric shapes of outlet/inlet of turbine unit are of rectangle (vertically

downwards): radial suction (upwards) and radial discharge (downwards).

3.4 TRT base farm

The machine package is installed and supported on the base frame. The base frame is of
welded structure, there have a lateral guide key on the top of bracket of right base frame,
which refers to the fixed point of machine train. Vertical guide key seat is placed in the
middle position between right bracket and left bracket so as to guarantee that the center of
machine train is in the vertical plane in hot state.

3.4.1 Stater
The stator mainly contains following items: casing, left bearing housing, right bearing
housing, low pressure water spray, blade carrier, control mechanism, turning, shaft end
seal.

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Whole machine train is supported by the four supports that locate on the bracket of base
plate for left and right. Both the supports for discharge side are fixed support and both of
the supports for suction side are sliding support.

The casing is horizontal split. Support bearing, speeding measuring device, vibration
measuring device, and safety governor are installed inside the left bearing housing, while
support bearing, thrust bearing, turning, couplings are installed inside the right bearing
housing.

3.4.2 Rotor

Rotor consists of main shaft, one/two stage rotor blades, emergency governor of main shaft
and turning gear etc.

Main shaft is forged with high alloy forging steel, “Fork-type” blade root is designed and
adopted, rotor blades are to be fitted and fixed on the main shaft by conical pins, the
location of admission seal socket corresponding to the first stage blade is manufactured
into spherical raised face, that is a special design to keep the clearance value between blade
tip and admission seal socket during the operation.

3.4.3 Bearing

Radial bearing is placed in the left bearing housing. Whereas radial bearing and thrust
bearing are placed in the right bearing housing. Radial bearing is made of forged steel,
inner surface of which is coated with Babbit metal. The radial bearing is of four-lobes
sliding bearing, whereas the thrust bearing is Michel bearing

3.4.4 TRT

Blast furnace top pressure recovery turbine unit is an energy recovery machine train, and
its function is to guide gas into turbine by residual pressure of blast furnace top gas, then
gas works due to expanding and the generator is driven to generate power.

20
This unit can recover 25-30% energy of all the blast furnace requires. At the same time,
when it is running normally, it can take the place of pressure reducing valve unit and adjust
and steady the pressure of blast furnace top and purify gas. The unit can control blast
furnace top pressure sensitively and the scope of fluctuation is small .So it plays an active
role that can make blast furnace running normally and increasing production.

(Values under working conditions)

3.4.5 Factors on which the output of TRT depend

1. Pressure of blast furnace at the blast furnace top.

2. Pressure drop across the GCP.
3. Pressure of BFG at the inlet and outlet of BFG.
4. Temperature of BFG at the inlet of turbine.
5. Quality of BFG at the BF top.
6. Efficiency of TRT.
7. Efficiency of generator coupled with TRT.

3.4.6 Computation of power output of TRT (GBF)

TRT output = Q × d × Cp × Ta × {1-(𝑃2/𝑃1)^[(𝐾 − 1)/𝐾]} ×ῃg × ῃt

Where,

Q (discharge) = 340000 Nm^3/hr = 94.44 Nm^3/s

d (density of BFG) =1.25 kg/Nm^3 ( at STP)

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Cp = 1.009 KJ/Kg K

Ta (temp of gas at inlet of turbine) = 61ᵒ C =334 ᵒK

ῃg (efficiency of the generator)= 97%

ῃt( efficiency of turbine) = 89%

P1= pressure of BFG at the inlet of turbine = 2.2 bar (Abs )

P2= pressure of BFG at the outlet of turbine = 1.12 bar (Abs)

K (coefficient of adiabatic expansion)= 1.385

Therefore,

TRT power output = 94.44 × 1.25 × 1.009 × 334 × (1-0.5^0.2779) × 0.89 × 0.97 KW

= 118.05 x1.009 x 334 x ( 1- 0.824) x 0.89 x 0.97

= 119.11 x 334 x 0.176 x 0.89 x0.97

= 6044 KW

= 6 MW

From the above equation it can be seen that the:

Power output is directly proportional to the gas flow rate and exponentially proportional
to the ratio of the pressures at the inlet & outlet of turbine which is why if there is a large
fluctuation in the top pressure of the BF the turbine electronics trip the whole system and
is resumed again when the pressure becomes normal.

IMPORTANT: To generate electricity is the secondary purpose of the machine , the

primary objective of it is to control the BF top pressure by using its first stage stator blades.

3.5 The performance charterstatics of turbine (GBF)

22
@340000 Nm^3/hr

3.5.1 BF top pressure control

The unit consists of following items:

1. MPS9.6-220/61turbine machine.

2. High and low power supply and distribution system.

3. Water supply and drainage system.

4. Nitrogen seal system.

5. Lube oil system.

6. Hydraulic pressure servo control system.

7. Gas piping and large-size valve system.

8. Automatic control system.

3.5.2 Parameters for each system, configuration and working principle

3.5.2.a. MPS9.6-220/61 Turbine machine

Design Parameters of Turbine:

Inlet pressure: 120 kPa

Inlet flow rate: 420,000 Nm3/hr

Inlet temperature: 61oC

Outlet pressure: 10-12 kPa(G)

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Size

Model: Wet axial reaction type

Casing: Horizontal split type

Output power for turbine: 8600 kW

Output power for maximum point: 9250 kW

Rpm: 3000 r/min

Over speed protection: over 10% speed

Electrical system: Open the quick- opening valve in the team of pressure reducing valve
quickly, and close the rapid cut-off valve and the stator blades quickly at the same time.

Machine system: The safety governor works. Close the rapid cut-off valve.

Hydraulic system: Open the by-pass quick-opening hydraulic valve quickly, and close the
rapid cut-off valve and stator blades quickly at the same time.

3.5.2.b.High/Low voltage power generation/distribution system

Composing:

The system consists of high voltage power distribution system, low voltage power
distribution system, hydraulic pressure oil system, auxiliary lube oil system, generator and
excitation cubicle etc.

24
Principle

 Brushless excitation synchronous generator: 10000 kW

Brushless excitation type generator is applied and it is provided with excitation
control cubicle that could meet the requirements of automatic and manual
excitation adjusting, magnetism extinguishing, and enhancing excitation. The
function to control automatically according to the voltage, reactive power factor is
set.

 High voltage power distribution system

The function of this system contains high voltage switch board, generator
synchronization, and disconnecting alarm etc.

 Low voltage control system

Setting the function of the spare power supply is used automatically.

 Hydraulic pressure oil system

Both the oil pumps are spare for each other. When the pressure of the system
is less than 11 Pa (110kgf/cm2) the spare pump is used automatically, and it
is stopped manually after eliminating the failure.

When the temperature of oil is less than 20oC, the oil pumps can’t start
automatically. At this time, the temperature must be risen, and when the
temperature reaches 25oC, the heater is cut off, and then the oil pump can be
started.

 Lube oil system

Control of the heater: Temperature rise is controlled manually. When the
temperature reaches 25oC, the heater breaks off automatically, and it stops
running. One of the oil pumps is running and another is spare. Uninterrupted
switch can be realized.

When the oil pressure at the farthest distance of lube oil pipe is below 0.09
MPa, the auxiliary oil pump begins to run automatically.

 Turning
Electric turning can be operated manually in the field, and start and stop of
motor of turning can be realized. During start, the turning is lifted and when
the speed is over 30rpm, the limit switch works, and the motor is stopped
automatically.

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3.5.2.c. Water spray & drainage system

Soft water spray device is equipped to prevent the turbine from accumulating dust,
clogging. The spot of spray water is before the stator blades of the turbine first stage.
Continuous or discontinuous can be chosen according to the dust content at the inlet of the
turbine and the condition of the dust accumulated.

In order to drain the machine water and condensate water in the pipes before the main
machine of turbine and in the main machine safely, two drain pots are set.

Water supply:

Spray water for turbine – using fresh industrial water Cleaning of rapid cut off valve, oil
cooler, and cooler of generator- is done by using fresh industrial water.

3.5.2.d. Nitrogen seal system

The medium for turbine is blast furnace gas that belongs to combustible toxic gas, so it is
forbidden to leak the gas. The medium for seal is nitrogen.

Shaft-end seal for turbine:

The pressure of nitrogen source is reduced to 0.3-0.4 MPa by the customer, and after
control of pressure by the pneumatic film adjusting valve, the pressure of nitrogen to seal is
higher by 0.02-0.03 MPa than that of the sealing gas, so leakage of gas is avoided. If the

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pressure of nitrogen source is under the monitor valve or used out, ejector will run
automatically to avoid the leakage of gas.

3.5.2.e. Lube oil system

This system consists of lube oil system, overhead tank, instruments and various valves etc.

Lube oil station

Nominal flow rate: 648 l/min

Pressure of oil supply: 0.2 MPa

It consists of oil pump, adjusting valve, oil cooler and oil filter etc.

The function is to supply some diluted oil used for force feed circulation lubrication.

Overhead oil tank

It is the welding parts of horizontal cylindrical type, and it is installed at the position above
5m from centre position of the main shaft of the main machine. The function is to supply oil
by natural position difference during coasting running of the turbine caused by the failure
of power and machine.

The overhead oil tank consists of oil tank, drain valve, drain pipes, throttle orifice
and air hood.

Check and test instrument

Instrument is divided into two types which are local instrument and remote transmitting
instrument. Local instrument is set on oil system, which is provided with display for
measuring point of pressure and temperature.

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3.5.2.f. Hydraulic servo control system

 Performance data of the system

Oil supply pressure: 12.5 MPa

Oil supply temperature: 30-60ºC

Oil filtering accuracy: 5 μm

 Composition of the system and its working principle

This system consists of servo valve, servo oil cylinder and oil source (power oil
system) which provides oil source for quick shut off valve.

 Servo oil cylinder

Double servo oil cylinder is specially designed for stator blades of the turbine,
whose construction are double piston rods with small friction and better sealing
performance.

 Power oil system

Power oil system consists of oil tank, variable oil pump, oil filter, heater,
accumulator, valve, connecting pipe and local check and test elements, which
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 can change oil supply flow according to flow required by the system, maintain
stable oil supply pressure.

Power oil system can send emergency shutdown signal at time when oil
couldn’t be supplied by the oil pump due to power out or other failure and
supply enough pressure oil from accumulator to servo oil cylinder (under
emergency power cut condition) so that the main machine of the turbine can
stop operation safely.

Variable oil pump and oil filter are parallel installation and standby for each
other. When one pump is in trouble, the oil pressure will be reduced and the
spare pump can automatically start up.

3.5.2.g. Large valve system

Quick shut off valve (FV103)

 Application
Quick shut off valve is an emergency shut-off equipment of gas pipelines, which
can shut off in 0.5~1s (also can regulate the open/close velocity). It is one of the
key equipments of TRT. It can shut-off the medium quickly when the main engine
is abnormal, thus main engine and normal production get protected.

 Working principle
Valve stem is connected directly with the output shaft of control device. When
switch on power supply and press the open button, the control device will drive

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 valve stem and disc to rotate from 0o to 90o, and make the valve open. Press the
close button, the valve will close under the function of spring.

Inlet and outlet Enclosed Type Hydraulic Goggle Valve (FV101 & FV102)

 Application
The enclosed type hydraulic goggle valve is a reliable shut off equipment of gas
pipelines. It can realize local control and remote control. It runs smoothly and
steadily, seals reliably. The valve has the function of nitrogen purging and there is
manual control device to control by hand at emergency.

 Specification technical parameters

Nominal Diameter 1800mm 2400mm

Nominal Pressure 0.25MPa 0.1MPa

Suitable temperature ≤150˚ C

Suitable medium Gas, exhaust gas, etc.

Leakage Zero

Drive mode Hydraulic driven ( with manual

control)
Work pressure of hydraulic system 10 MPa

Direction of installation Horizontal pipelines

 Operation
Before operation, check whether the hydraulic oil route is smooth, whether there
is oil leak out or whether the output pressure of hydraulic units meets the work
demand. If there is problem, solve it in time.

Check whether the connection of oil pipelines, nitrogen system and electric system
is correct. Make sure they are all correct before run the valve. Check the nitrogen
purging. The working pressure of nitrogen is more than 1.1times of medium work
pressure. For inlet goggle valve, the pressure should be lower than 0.275MPa; for
outlet goggle valve, the pressure should be lower than 0.11MPa or it may destroy
the bonnet. Check whether there is leak or block periodically to ensure the course
of gas exchanging can go on successfully.

The order of operating step is: unclamp- switch (transverse move) - clamp.

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  Electrical operation
Before electric control, disconnect the clutch between hand wheel and chain wheel,
or the hand wheel will rotate with motor and cause accident. Check the bypass
valve at motor’s oil ports and ball valve at oil cylinder’s ports: bypass valve must
be closed, and ball valve must be opened absolutely.

 Remote control
Move the Change switches to remote position. Control system will transmit remote
control signal to remote control system first.

Then, control the valve open or close according to demands from remote control
system. Meanwhile, feedback signals to remote control system.

 Vent valve control

When the goggle valve is closed, vent valve open automatically, and lamp light.
When the vent valve is closed lamp is light.

Pressure equalizing valve (FV104)

 Application
This valve is a kind of triple eccentric metal-to-metal seal valve, which is widely
used in metallurgical, chemical, cement and generating electricity industries to cut
off gas pipelines. In TRT system, it takes the action of equalizing pressure.

 Specification technical parameter

Nominal diameter 250 mm Drive modes Electric (explosion proof)

Nominal pressure 0.25MPa Operating time 15s (from full close to full
open)
Suitable 250˚ C Voltage of power 415V
temperature supply

 Structure and principle

Working principle: The valve stem is joined with the output shaft of electric
actuator. Switch on the power supply, the electric actuator will drive the valve
stem and disc to rotate between 0o to 90o, thus make the valve open or close. The
valve adopts triple eccentric metal-to-metal seal structure, which makes the valve
close more tightly. So, it can compensate the abrasion of seal surface in certain

31
 degree. The valve is composed of valve body, disc, seal ring, valve stem, support
and gland.

 Operation
Can be electric controlled and hand wheel controlled. Stand at the actuator side,
see along the valve stem direction, clockwise move makes the valve close and
anticlockwise makes the valve open. Press the “open” or “close” button, the valve
will realize open or close and the corresponding indicating lamp will give signals.
The actuator is stopped under the function of travel switch and moment switch. If
there is anything abnormal during electric operation, press the “stop” button in
time and the valve stops.

3.5.2.h Automatic control system

 Composition of the system

The System consists of forward feedback control system, speed regulating
protection system, power control system, control system for top pressure of blast
furnace, supervision and protection system for shaft vibration, shaft displacement
and speed, control system for differential pressure of nitrogen seal, supervision
and protection system for bearing temperature of the machine train, start-up
interlock control and serious failure emergency shutdown interlock control
system, lube oil pump, power oil pump interlock control system.

Start-up operation and check and test for TRT machine train will be controlled by
above mentioned system which can complete each operation and control (start up,
speed up, interconnect, output per litre, top pressure control, normal shut down,
emergency shutdown, electric operation and normal operation) for TRT unit
smoothly under precondition of assuring normal operation for blast furnace and
top pressure fluctuation within limit.

List of Critical Equipment

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Details of critical equipment:-

1. FV 401, FV402 & FV403:- It is hydraulic operated pressure control valve. (Servo
control) It is used to control the furnace top pressure when TRT is to be shut down or
during any abnormality in turbine.

2. FV 103 (TRT gas inlet quick shut off valve) :- Quick shut-off valve is an emergency
shut-off equipment of gas pipelines and it is hydraulic driven, which can shut off in 0.5~1s
(also can regulate the open/close velocity). It is one of the key equipments of TRT. It can
shut off the medium quickly when main engine is abnormal, thus main engine and normal
production get protected.

3. FV 104 (TRT gas inlet control valve – Balance valve):- It is a motorized ball valve
used to equalize the TRT side pressure. It can have control action

4. FV 101 (TRT gas inlet goggle valve):- It is hydraulic operated shut off valve. It is used
for TRT maintenance.

5. FV 102 (TRT gas outlet goggle valve):- It is hydraulic operated shut off valve. It is used
to isolate the TRT from gas network for maintenance work.

6. Nitrogen sealing system: - The medium for turbine is blast furnace gas that belongs to
combustible toxic gas, so it is forbidden to leak out. The medium for seal is nitrogen.

7. Shaft-end seal for turbine: - The pressure of nitrogen source is reduced to 0.4-0.5 MPa
in N2 PRS and after control of pressure by the pneumatic film adjusting valve, the pressure
of nitrogen to the seal is higher by 0.02-0.03MPa than that of the sealed gas, so leakage of
gas is avoided. When the pressure of nitrogen source is under the monitor value or used
out, ejector will run automatically to avoid the leakage of gas. In case nitrogen is not
available, steam is being used for sealing purpose.

 Nitrogen - Pressure 0.4~0.5MPa, and the generator is driven to

generate power. The unit can
 Flow: - 60Nm3/hr (normal control blast furnace top pressure
valve). sensitively and the scope of
 Steam - Pressure: - 1.0～1.2 Mpa, fluctuation is small.

 Temperature: - 280～315ºC,
Design Parameter of turbine:-
Flow:-100kg/h.
 Inlet Pr. - 120 kPa,
 Inlet flow rate: 420, 000 Nm3/hr,
8. Turbine: - Blast furnace pressure
 Inlet temperature: 61º C.,
top gas pressure recovery turbine
 Outlet Pressure: 10-12 kPa (G)
unit is an energy recovery machine
train, and its function is to guide
gas into turbine by residual
pressure of blast furnace top gas,
then gas works due to expanding

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3.6 GBF TRT start up process

34
3.6.1 Run Procedures for TRT

• Start nitrogen seal, check water level of water seal and record data.

• Put through gas.

Start Process:

Start the train, judge starting condition of it (refer to 900663.40.1003). If it doesn’t meet
the requirements please go on judging till satisfaction. Start TRT after it meets starting
condition, its process is as follows:

• Get permission to start TRT from control room

• Decide to start BF with TRT

• Open outlet goggle valve (FV101)

• Open balance valve ( FV104)

• Open quick shut off valve ( FV103)

• Close balance valve (FV104)

• Open inlet goggle valve (FV102)

• Close bypass valve slowly( FV401, FV402,FV403)

• Control speed rise of turbine

• Adjust speed rise of turbine

• Grid incorporation of generator

• Control power up of turbine

• Control blast furnace top pressure of turbine

• Start is over, turbine run into normal operating condition

Starting of TRT

• After the BF is under normal condition, start electric barring gear:

• Fully close stator blade of turbine.

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• Open inlet valve

• Start stator blade of turbine, speed up slowly (manually or automatically).

• Speed up to 500 r/min for 20-30 minutes. Continue to speed up after check.

• Pass critical speed area of generator quickly, speed up to 2000 r/min for 20-30 minutes.
Continue to speed up after check.

• Speed up to 2850 r/min, stabilize speed and put into excitation.

• Speed up to 3000 r/min, stabilize speed and interconnected by hand. Open quick shut off
liter power slowly after interconnection.

• Operation for a period after interconnection, fully check operation condition of turbine
generator and each auxiliary, record data.

• Make a summary after check.

• Put into automatic speed up, interconnect, liter power and release shut down according
to above mentioned procedure.

3.6.2 TRT Machine train start up, normal operation and shut down process

Start auxiliary machine

• Start hydraulic oil system, control oil pressure and record data (12 MPa)

• Start lub oil pump, adjust and record data, oil pressure at farthest point is 0.12-0.15 MPa.

• Start electric barring gear (start barring gear during gas treatment, shut down after
closing exhalant in turbine).

• Start adjustable stator blade for 2-3 times. Fully close after confirmation.

• Check gas pipe and concentration of CO near machine by protection station in order to
assure safety.

• Organize some person to make fully check for N2 seal and each auxiliary system, inform
them to prepare start TRT for BF after it is under normal condition.

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Control requirement of start up interlocking system

The main function of control system is to guarantee the normal start-up of TRT machine
train. The operation of forced start-up couldn’t be done in any way when the machine train
meets the normal conditions of start-up. Normal start-up conditions are listed as below:

• Pressure of lube oil is normal

• Pressure of power oil is normal

• Turning gear of machine train

• Pressure of N2 is higher than specified value

• BF accepts the start-up requirements

• Electric system is normal

• Pressure and temperature of cooling water system is normal

• Stator blade angles close properly

• Large scale valves are in auto control mode

When the following above conditions are fulfilled:

• Open outlet goggle valve (FV101)

• Open balance valve (FV104)

• Open quick shut off valve (FV103)

• Close balance valve (FV104)

• Open inlet goggle valve (FV102)

• Turbine stator blades closed completely

Then the TRT will give the start-up signal to the blast furnace, when, the request is allowed,
the stator blades will be turned on after accepting the PLC control signal, and the gas
through the turbine will increase gradually, the rotation speed will be increasing
accordingly. The bypass valve should be closed when the control signal is accepted, inlet
37
pressure of the turbine will go up continuously, and then the rotation speed will go up to
3000 rpm. In the speed up process, the top pressure is controlled by the blast furnace. After
the successful signal of electric combination, the stator blades start-up steadily and slowly
while accepting the PLC control system, the generator power increases. Bypass valve closes
completely. During the power increasing, the top pressure is controlled by both blast
furnace and TRT. When the power increase is finished, the top pressure is controlled by the
TRT stator blade.

3.6.3 Shut down process of TRT

When heavy failure occurs on the machine train, both of quick cut-off valve and stator
blade closes quickly, bypass valve control the top pressure, then the stop signal from TRT
goes towards the blast furnace and second stage ventury flap gradually starts controlling
the top pressure. After that, the bypass quick open valve opens completely and the top
pressure control of the blast furnace is done by second stage ventury.

TRT Normal Stop

Stator blades closes gradually, the generator power closes gradually, when the power
comes to “0”, close the quick cut off valve, and open the bypass valve SBV001 or SBV002
quickly, when the bypass valve control the top pressure then, the stop signal from the TRT
goes towards the blast furnace, then the top pressure controlled the equipment start-up.
After that, the bypass quick open valve opened completely, the top pressure control of the
blast furnace launched by it.

3.7 GBF TRT Normal Shut Down Process Steps

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Shut down under normal and non-accident condition, its normal shut down process
is as follows:

• Press normal shut down button (in HMI)

• Top pressure control change over to low power control

• Close stator blade gradually, power of generator drops to “0”

• Enter into interlock shut down control

• Close quick shut off valve, send shut down signal to blast furnace, open bypass valve
quickly

• Dive into top pressure control of bypass valve

• Prepare to change over top pressure control of blast furnace

• Blast furnace control top pressure

• End of normal shut down

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 CONCLUSION

Concluding the project, I would like to say that I got a good overview of the TOP
PRESSURE RECOVERY TURBINE AT GBF .Thus gaining immense knowledge and valuable
experience of the real time working of the power generation through BF gas as well as the
communication system. The hands on experience with these systems gave me an insight
into the actual working of an industry, I also got know that how actually the process takes
place not only at GBF but in entire TATA Steel. Apart from our area of project I also got an
idea of the various other components of G Blast Furnace which also enhanced my
knowledge and experience and made my stay at Tata Steel for the period of training a
memorable and enlightening experience.

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