AMMAR FASIH HANIF

MECHANICAL ENGINEERING (3RD YEAR)

NED UNIVERSITY OF ENGINEERING AND
TECHNOLOGY ( 2018 )
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FFBL POWER COMPANY LIMITED (FPCL)

CONTESTS
Contents
PREFACE .................................................................................................................................................. 3

ACKNOWLEDGEMENT ............................................................................................................................. 4

COMPANY INTRODUCTION ...................................................................................................................... 5

BACK END SECTION ................................................................................................................................. 6

COAL CYCLE ............................................................................................................................................. 6

COAL UNLOAD SHED ............................................................................................................................... 6

STACKER .................................................................................................................................................. 7

COAL SHED .............................................................................................................................................. 8

RECLAIMER ............................................................................................................................................. 8

CRUSHER HOUSE ..................................................................................................................................... 9

COAL BUNKERS........................................................................................................................................ 9

FLY ASH HANDLING SYSTEM .................................................................................................................. 10

BOTTOM ASH HANDLING SYSTEM ......................................................................................................... 11

SORBENT HANDLING SYSTEM ................................................................................................................ 11

FRONT END SECTION ............................................................................................................................ 12

BOILER .................................................................................................................................................. 12

THEORITICAL BACKGROUND .................................................................................................................. 13

WATER CIRCULATION IN BOILER ............................................................................................................ 14

MAIN COMPONENTS OF BOILER ............................................................................................................ 14

STEAM TURBINE GENERATOR ................................................................................................................ 15

BALANCE OF PLANT (BOP) .................................................................................................................... 19

AMMAR FASIH HANIF

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FFBL POWER COMPANY LIMITED (FPCL)

PREFACE
This report is prepared to fulfill the requirement of the FPCL 04 weeks intership
program. The prime focus of this report is to highlight the main features of FPCL
that I studied during the period of my internship. The report is divided into three
main sections including the indtroduction of company, back end section and
front end section.

This report is aim to provied the introduction of the company’s history and its
working environment.

AMMAR FASIH HANIF

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FFBL POWER COMPANY LIMITED (FPCL)

ACKNOWLEDGEMENT
The internship opputunity I had with FFBL Power Company Limited (FPCL), was a
great chance for me to enchance my theoritical and practical knowledge in
the world of mechanical engineering. I consider myself blessed to avail such
oppurtunity in a prestigious organization.

However I like to place on record my best regards and deepest sense of

gratitude to all the eningeers and technical staff for their valuable and precious
guidance which were extremely helpful to me. I really appreciate the fact the
that despite of the hectic routine of the engineers they entertained and guided
us in all the best manner.

AMMAR FASIH HANIF

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FFBL POWER COMPANY LIMITED (FPCL)

COMPANY INTRODUCTION
FFBL Power Company Limited (FPCL) owns state of the art 118 MW Coal Power
Plant on approximately 50 acres of land within the existing FFBL Complex on the
south side.
FPCL was initiated to meet the increasing power requirement of Fauji Fertilizer Bin
Qasim Limited (FFBL), which was initially producing it’s own power via burning of
natural gas in gas turbines. Because of the increasing demand of power and
limited and unreliable supply of natural gas for gas turbines it was a threat to
company’s reliable future.
Incorporated in June 2014 for setting up a coal power plant (CPP). Capable of
generating 500 TPH steam via 02 CFB steam boilers and power of 02 different
frequencies (50Hz & 60Hz) via 04 steam turbines.
Among the total of 04 turbines 03 ( 60MW & 2 x 24MW ) are condensing type while
the remaining 01 is extraction type.
Power produced is also distributed among FFBL and K-Electric,

118MW

60MW (50Hz) 58MW (60Hz)

K-Electric FFBL

For the smooth and uninterrupted operation, project is divided into two main
sections

FRONT END BACK END

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FFBL POWER COMPANY LIMITED (FPCL)

BACK END SECTION

The back end of the plant mainly handles the supply,
loading, unloading, storage, processing and feeding of Sorbent
coal fuel to the boilers for the purpose of power
generation.
Ash
This massive coal handling involves dozens of loaded
dumpers, hoppers, vibrating feeders, vibrating screens,
Coal
flap gates, metal detectors, magnetic separators, dust
suppressing system, unloading shed, transfer towers, coal sampling
unit, coal shed, conveyer belts, stacker, reclaimer and a lot other
piece of machinery.

COAL CYCLE

UNLOAD
BUNKERS SHED

TRIPPER STACKER
CARS

CRUSHER COAL
HOUSE SHED

RECLAIMER

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FFBL POWER COMPANY LIMITED (FPCL)

COAL UNLOAD SHED

At the very first the imported coal from South Africa
deposits to Port Qasim from where it is loaded into
trucks each weighting around 20-40 tons. These truck
enters the plant site and passing through the weight
bridge arrives at the coal unload shed.
Coal Unload Shed is built up of hoppers, rack and
pinion gates and vibrating feeders. Two sump pumps are
also installed to tackle conditions emerging from heavy
rain or flood.

This coal now heads up to the Coal shed passing through pent house and to TT-
01 via CT-01.

STACKER
A ‘Stacker’ is a large machine used in bulk material
handling. Its function is to pile bulk material and particular
for this case to pile up the coal.
FPCL owns the luffing and slewing type stacker, having
capacity of 500 MTPH. It is designed with the ±11° luffing
angle and 135° slewing angle (80° west and 55° east). It is
operated on 480V power voltage and 50Hz with installed
power of 210KW. The three basic movements of the stacker
involves luffing, slewing and travelling along the rail track. It is
equipped with specialized sensors use to measure the stock
quantity and height of stockpile. The coal is carried to stacker from TT-01 via CT-
02.
In case of shutdown of stacker ‘Emergency Reclaimer Hopper’ is used. Coal is fed
to the system manually by the front loader. This finally arrives at TT-05 after passing
through TT-03 and TT-04.

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FFBL POWER COMPANY LIMITED (FPCL)

COAL SHED
The largest coal shed of Pakistan, with a storage capacity of
60,000 MT. The shed is of Lattice Grid Space Frame design
having dimensions of Length 240m x Width 90m x Height 35m.
Stock piles dust suppression system is also installed in the shed with
aim to minimize to suspended dust in the air and to avoid self-
ignition of tiny coal particles.

RECLAIMER
The piled up coal is now ready to move forward for further
process. This bulky coal is extracted from the pile by another
heavy machinery known as ‘reclaimer’.
Basically reclaimer is a large machine used in bulk material
handling applications, to recover the material from the
stockpile.
Here a portal reclaimer is installed with two basic movements,
travelling along the track and vertical motion of scrappers with the help
of pulley.

Main and assistant scrappers are installed on the reclaimer. These scrappers travel
through chain drive mechanism which is driven by the combination of 2 vertical
motors and reducer gearbox.

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FFBL POWER COMPANY LIMITED (FPCL)

CRUSHER HOUSE
As per standard practice the coal fed into the CFB Boilers
is of particular size. Here the required coal size is 8mm
or less. This reduction in size of coal is achieved through
crushing performed in the ‘Crusher House’.
TT-05 consists of two flap gates (FG-03 and FG-04) and
two magnetic separator.
Coal from TT-05 moves to Crusher House via CT-07A or
CT-07B (passing through magnetic detector). In the
crusher house the coal first arrives at Flap Gates (FG-4 or
FG-5) and then moves to coal vibrating screen (CVS). CVS
distributes the coal into two categories, coal with size above 8mm and below
8mm. Coal above 8mm size are thrown to crushers (CR-1 or CR-2), here we
achieve our required size and then it is sent to CT-08A or CT-08B. The coal which is
already less than 8mm in size simply bypass the crusher and sent to CT-08.
Crusher generally consists of a shaft on which arms and hammers are mounted
on it. Walls of the crusher are adjustable so as to vary the size of crushed coal.
Crusher House has two crushers each with its own Dust extraction system.

COAL BUNKERS
Now the crushed coal is moved forward to TT-06 via CT-08A/ CT-08B in which coal
is inspected in Coal Sampling Unit (CSU). Finally the coal moves to the last TT, i.e.
TT-07 via CT-09A/CT-09B, here any metal piece present in the coal are separated
by Metallic Separator.
Last station is the Tripper Cars (Travelling Trippers + Dust Extractor). Two tripper cars
units are installed which feed the coal to bunkers via CT-10A/CT-10B. Now the
coal is ready to burn.
Burning of coal does not only provides the vast amount of energy to make steam
but it also produces a massive quantity of ash. Here in FPCL adequate steps has
been taken to deal with this ash. This includes all the way from collecting, storing
and disposing of ash content.

AMMAR FASIH HANIF

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FFBL POWER COMPANY LIMITED (FPCL)

FLY ASH HANDLING SYSTEM

Fly ash refers to the coal combustion product composing of fine particles that
after burning escape along with the flue gases in the coal fired
boilers. These fly ash contents can pollute the environment if
released directly out of the stack.
However FPCL ensures that such particles do not emit in
the atmosphere and so it has developed a complete fly
ash collection system.
Fly ash is transported through dense ash conveying
system (DAC). Once in the hopper fly ash is pushed to the
silo by means of pressurized air. Series of dome are installed
consisting of a master and slave dome valves, which
operates sequentially by means of pressurized air coming from
the rotary screw air compressor and eventually fly ash set in the fly ash silo.
Fly ash silo has diameter of 12m with a total volume of 1150 m3 and 100t/h and 50
t/h dry ash and wet ash unloading rate respectively. The silo itself contains number
of additional components like level indicator, high level alert, fluidization air
system, electric heater etc.
Dry fly ash is mainly sold to the cement factories while the left over bulk of fly ash
is turned to wet fly ash and deposited in landfills.

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FFBL POWER COMPANY LIMITED (FPCL)

BOTTOM ASH HANDLING SYSTEM

Bottom ash is the coal non-combustible product that is left at
the bottom of coal fired boiler. However unlike fly ash it has
no commercial importance and hence it simply disposed.
This system simply starting from the link conveyor to bucket
elevator drops the bottom ash into the silo. Same as the
previous one bottom silo also consists of bag filter, air guns,
high level indicator etc. However unlike fly ash, bottom ash
has no use and simply deposited in the landfills. Silo has a
volumetric capacity of 210 m3 with unloading rate of 100t/h and
50 t/h for dry ash and wet ash respectively.

SORBENT HANDLING SYSTEM

Power generation involve burning of coal which results in high amount of SOx
emission due to the presence of sulfur content in the coal. This emission of SOx is
dangerous to human health. However FPCL ensures that no such gases let loose
in the atmosphere and for this reason Limestone (Na2CO3) is added with coal.
The process is known as ‘Desulfurization ‘. In which limestone reacts with SOx to
produce less harmful products.

The limestone journey begins from the loaded limestone dumper in the limestone
storage shed from here it is transported in limestone materials silo so to be further
forwarded to the crusher mill. The required size of limestone to be fed in boiler is
1mm. This crushed limestone is then forwarded to system containing PL classifier,
double cyclone separator and circulation blower, this system ensures the
availability of the required size sent to boiler. Now coal is sent to the main
limestone storage silo, and then fed into the boiler through means of pneumatic
conveyor system.

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FFBL POWER COMPANY LIMITED (FPCL)

FRONT END SECTION

After the deposit of coal in the boiler coal bunkers, the whole of the process
including coal burning, steam generation in boiler and distribution, power
generation in turbines and its distribution is all now in the hands of Front End
management.
Front end is basically divided into three main portions.

FRONT
END

BOILER STG BOP

BOILER
A boiler is simply a closed vessel in which fluid is heated. In our
case fluid is water which is heated to turn it into steam.
FPCL owns the modern environmental friendly 02 x 250 MTPH,
Circulating Fluidized Bed (CFB) Boilers from Hyundai Heavy
Industries. This CFB boilers has certain remarkable advantages
which include,
• Low NOx and SOx emissions.
• Combustion of wide range of fuel ( low to high quality
coal)
• High thermal efficiency
• Low combustion temperatures, which helps in reducing
thermal stresses.
• Simple bottom ash removal system

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FFBL POWER COMPANY LIMITED (FPCL)

02 identical boilers are installed on the plant site with specifications including
capacity of 250 MTPH, 92 bar and 515°C. This is a water tube boiler, in which water
is in the tubes while the flue gases travels in the shell. Further units of the boiler
include economizer, primary and secondary air heaters and 3 sets of super
heaters.

THEORITICAL BACKGROUND
The process of power generation through steam follows the ‘Rankine Cycle ‘

Schematic of Rankine Cycle T-s diagram of Rankine Cycle

Water first enters in boiler gains heat and changes into superheated steam. This
high pressurized steam then rotate the turbine generating power and leaves as
low pressure steam. This low pressure steam is then cooled to liquefy by means of
condenser and sent back to the boiler by means of a pump.

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FFBL POWER COMPANY LIMITED (FPCL)

WATER CIRCULATION IN BOILER

Increasing temperature and pressure

Economizer steam drum downcomer header superheater

MAIN COMPONENTS OF BOILER

ECONOMIZER
It is simply a heat exchanger which pre heats the Boiler Feed Water (BFW). The
waste heat of the flue gases still contains a lot of energy with it. Such energy if
blown out of the stack without proper utilization can lower the plant efficiency as
per the loss of energy. Therefore BFW is allowed to come into thermal contact with
these flue gases numerous times so to extract the maximum energy from the flue
gases.
Economizer uses the waste heat energy of flue gases and pre heat the BFW.

STEAM DRUM
Steam drum serves the following functions.
• Store water and steam sufficiently to meet varying requirement.
• Provides place from which heavy impurities can be removed via
blowdown.
• Provides place for distribution of feed water into boiler circuits.
• Provides place for installation of water and steam separation equipment.

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FFBL POWER COMPANY LIMITED (FPCL)

DEAERATOR
Is a device use to separate oxygen or other dissolved gases from BFW. If these
gases are not removed prior to the entrance to the boiler, they make cause
serious corrosion problems.

SUPERHEATER
It is used to further heat the steam to make it superheated. Like economizer, super-
heater also uses the waste flue gas heat to warm the steam. Installation of super-
heater ensures the high quality moisture free steam which thus increases the plant
efficiency and protects the turbine blades from erosion.

AIR PREHEATER
It preheats the upcoming air for combustion using the waste heat of flue gases.

Other boiler equipment includes,

• Safety valves
• Water level indicator
• Steam stop valve
• Feed check valve
• Blow off valve

STEAM TURBINE GENERATOR

FPCL owns the following 04 turbines,
• 02 x 24 MW condensing type turbines to supply power to FFBL.

• 01 x 10 MW extraction turbine to supply power and process steam to FFBL.

• 01 x 60 MW condensing type turbine to supply power to K-Electric.

THEORY
A steam turbine utilizes the thermal energy of pressurized steam and converts it
into mechanical work.

Pressurized steam from the boiler ejects into the turbine via nozzle, hitting the
blade/bucket mounted on the shaft, thus rotating the shaft due to the applied

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FFBL POWER COMPANY LIMITED (FPCL)

torque. The shaft is coupled with the generator rotor which in turns rotates the
generator rotors resulting in power generation.

TYPES OF TURBINE
A) I) Condensing Turbine:

This type of turbine completely utilizes the steam thermal energy to drive the
turbine to achieve the maximum electric output from generator. The exhaust
steam is at relatively lower pressure and then condenses to feed back in boiler.

A) II) Back Pressure Turbine:

It uses the steam supply to drive turbine and to provide process steam. This type
of turbine uses extraction system, a part of steam at certain required pressure and
temperature is bleed out of the turbine and supplied for process heating, while
the remaining drives the turbine.

B) I) Impulse Turbine:

In this type of turbine the steam expands in stationary nozzle where it attain high
velocity. The velocity of steam remains constant while passing through the blades
and the pressure on both sides of blades is same.

B) II) Reaction Turbine:

The steam partially expands in the nozzle and partially in the rotor blades. Velocity
of steam increases as expansion takes place while passing over the blades.
Pressure difference exists on two sides of the plates.

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FFBL POWER COMPANY LIMITED (FPCL)

TURBINE BEARING
Bearing are machine element that reduces the friction
between the moving parts. Rotary bearings hold
rotating components such as shafts or axles within
mechanical systems, and transfer axial and radial loads
from the source of the load to the structure supporting
it. Two main types of bearing include,
Radial Bearing:
Radial ball bearings are designed to withstand forces
that are perpendicular to the direction of the shaft,
or radial loads. Some ball bearings are able to withstand a radial and axial load
applied on the shaft, these combined axial/radial load bearings are achieved
by axial angular contact.
Axial Bearing:
Axial bearings, or thrust bearings, are designed to withstand force in the same
direction as the shaft. This is called an axial load, or thrust load. In some
applications, ceramic bearings, a type of radial bearing, are used to withstand
high rotational speeds.

Turbine Sealing
Mechanical seal is device that helps prevent the
leakage in machine part, mainly at their join. Like
the bearing in the rotors of turbine ensures to restrict
the fluid from sliding to the other end.
Labyrinth Seal
The most common type of seal used in turbine is
labyrinth seal. The portion of the seal that is in contact with the shaft is made of
soft material, so to avoid shaft wear. Labyrinth seal consists of teeth, which
creates the whirlpool when fluid flows through it causing pressure drop and
hence preventing leakage.

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FFBL POWER COMPANY LIMITED (FPCL)

Oil System
Oil
System

Jacking Oil HP Oil

Lube Oil Use at startup of turbine
Use for lubrication to life up the shaft and
purpose for bearing and rotor so to reduce friction
gears and produce initial oil
film.
Use to operate mainly
the gorvernor valve at
the turbine and
sometimes the shutoff
valve

Brief description of 60 MW Lube Oil System

Lube system has following main components,

1. Oil reservoir
2. Oil cooler
3. Oil filter (10 micron size)
4. Oil moisture remover

FLOW DIAGRAM

Lube oil machine

Oil Cooler Oil filter
system

Oil moisture Oil reservoir

remover

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FFBL POWER COMPANY LIMITED (FPCL)

BALANCE OF PLANT (BOP)

Balance of Plant is a term that includes all the supporting components and
auxiliary systems of a power plant needed to deliver energy. FPCL includes the
following components/ departments in BOP,
• Instrument and Service air compressor
• Cooling Tower
• Diesel Storage Unit
• Water Treatment Unit

Cooling Tower:
A cooling tower is heat removal device.
Cooling towers reject heat from water-cooled
systems to the atmosphere. Hot water from the
system enters the cooling tower and is
distributed over the fill. Air is induced or forced
through the fill, causing a small portion of the water to evaporate. This
evaporation removes heat from the remaining water, which is collected in the
cold water basin and returned to the system to absorb more heat. Each cooling
tower line, although operating under the same basic principle of operation, is
arranged a little differently.
Water Treatment Unit:
Water passing through the open environment, long pipes and different
machinery picks variety of contaminants with it. If these contaminants in water
are not removed can cause serious damage to the system. For the sake of
removing such contaminants plant own a water treatment unit which performs
the following chemical additions,
• Addition of H2SO4 to control PH of water
• Addition of Bio dispersant to avoid algae formation
• Addition of Sodium Hydro Chloride to kill bacteria

--------------------THE END-----------------

AMMAR FASIH HANIF