Ruma Akter

Welcome To My
Presentation
1
Presented By
Ruma Akter
ID # 14307029
Department of Mechanical Engineering
IUBAT – International University of Business Agriculture and Technology

Spring - 2018
2
A Study on Operation and Maintenance of Gas Engine
at Akij Cement Company Limited (Power Plant).
3
Contents
 Introduction  Operation of the engine
 Objectives  Maintenance of the engine
 Limitations  Problems Findings & Solution
 Company Overview  Recommendations
 Engines of the power plant  Conclusion
4
Introduction
 Power plays a great role wherever man lives and works-in industry, agriculture
transportation etc. Power provides our homes with light and heat. The living standard
and prosperity of a nation vary directly with increase in use of power.
 A power plant is an industrial facility used to generate electric power with the help of
one or more engine which converts different energy sources into electric power.
5
Objectives
 To know about the power plant engineering.
 To study about the gas engine.
 To study about operation of gas engine.
 To study about maintenance of gas engine.
 To know about the various parts of engine.
 To know about power distribution system of the power plant.
 To study about engine efficiency of the power plant.
6
Limitations
 Due to shortage of practicum period the whole thing could not be covered.
 Engineers could not provide enough time due to the business of their job.
 Some important data could not be provided due to the confidentiality of the power plant.
 Taking photograph for some places were prohibited.
7
Company Overview
8
Company Overview (Cont.)
Name Of the Company :
AKIJ CEMENT COMPANY LIMITED
9
 Background
Akij Cement Company Ltd. is the Leading cement company in Bangladesh. In the year of
1995 factory started its journey and the factory produces their product till today. Akij Cement
Company Ltd. has no compromise with quality and bestowed upon client's satisfaction and
premium services towards client.
10
 Power Plant at a Glance

 Established year : 2008
 Land area : 1 acre.
 Manpower Status
 Engineer : 10 persons
 Worker : 03 Persons
 Staff : 07 persons
Total Man-power : 20 persons.
11
 Installed Capacity (Power generation)
 In the year of 2008 : 6.7 MW
 Attainable Capacity
 Present capacity : 12.03 MW
(In the year of 2012, Company increased the capacity of power generation.)
12
 Mission
The mission of the Akij Power Generation Ltd is that, Generate adequate Power for running
the factory and reduce the Load of Rural Electrification Board (R.E.B).
 Vision
To provide quality & uninterrupted electricity to the vast majority of Akij factory for
continuous Production and economic development.
13
Organogram
14
Engines of the Power Plant
15
Gas Engine
 A gas engine is an internal combustion engine which runs on a gas fuel, such as coal gas,
producer gas, biogas, landfill gas or natural gas.
 Merits of Gas Engine
 Gas engines are less expensive to maintain.
 Gasoline has a weaker odor, and creates less black smoke and soot.
 Gasoline engines hold up better in extreme weather conditions, especially cold weather.
 Gasoline are also free from solid and liquid impurities.
 They undergo complete combustion with minimum air supply.
16
Engines of the Plant & Engine Specification
Model - Rolls-Royce (B35:40V16AG )
Manufacturing country - Norway
Capacity - 6.7 MW
Engine Type - V-engine
Number of Cylinder - 16
Speed - 750 RPM
Starting system - Air Starting System
Type of Fuel - Natural Gas
Cooling System - Radiator Type
Generation Voltage - 11 KV
17
Engines of the Plant & Engine Specification (cont.)
Model - MWM ( CG260-16 )

Manufacturing Country - Germany
Capacity - 4.3 MW
Engine Type - V-engine
Speed - 1000 RPM
Starting System - Air starting system
Type of Fuel - Natural gas
Cooling System - River water cooling system
18
Engines of the Plant & Engine Specification (cont.)
Model - Caterpillar (CG260-16)

Manufacturing Country - America
Capacity - 1.03 MW
Engine type - V-engine
Speed - 1500 RPM
Starting System - Self Starter
Type of fuel - Natural gas
Cooling System - River water cooling system
Generation Voltage - 11 KV
19
Engine Operation
20
Engine Operation
 Power Plant Control Room  Cooling System

 Roll-Royce Engine Control Unit  Exhaust System
 Function of Roll-Royce Engine Control  Log Sheet
Cabinet  Checklist
 Rolls-Royce Operator Interface System  Power Distribution System
 Engine Starting System  Engine Efficiency
 Lubrication System  Efficiency Improvement
21
Power Plant Control Room
 The whole operation of the engine is

observed from a control room adjacent to
the engine room.
 The Shift engineer is responsible for

activities in the control room.
 In case of any emergency the engineers

can shut down any engine even the whole
plant, if they want from the control room.
Figure: Control Room

22
Power Plant Control Room (cont.)
In the control room there are various types

of panel or cabinet. Such as :
 Motor Control Cabinet 1 & 2
 Alarm Control Cabinet
 Synchronizing Cabinet
 Control Cabinet Generator
G1, G2 & G3
 Gas Detection Cabinet
 LT and HT Control Cabinet
 Fire Alarm Panel
Figure : Control Cabinets

23
Rolls-Royce Engine Control Unit
 The RRECU (Rolls-Royce Engine Control Unit)

is a distributed engine control system for
monitoring and control of all engine functions.
 Each engine contains ECC (Engine Control

Cabinet) and Neutral Grounding Resistor ( NGR)
Panel.
 Neutral Grounding Resistor systems protect

power transformers and engine from damaging
fault currents. Figure : ECC & NGR
24
Function of Rolls-Royce Engine Control Cabinet
Functions are important to ensure optimal engine performance. The functions are given
below:
o Air & Fuel ratio control o Main gas injection control
o Cylinder balancing control o Gas pressure control
o Ignition control o Safety system control
o Knock control o Speed control
o Engine Load control o Emergency On/Off control
25
Rolls-Royce Operator Interface System
Auxiliary Systems for engine
 LT-System (Low Temperature System)
 HT-System (High Temperature System)
 LUB System
 Charge Air
 Interlocks
 Start / Ctrl Air
 Gas System
 Power Dist.
 Alarms
Figure: Rolls-Royce Operator Interface System
 Reports 26
Engine Starting System
 Starting system for both Roll-Royce and MWM is air

starting system. And for Caterpillar self-starting system.
 For starting the engine, the initial air pressure for

Roll-Royce is 25 bar, For MWM air pressure is 10 bar.
Figure: Engine Starting System
27
Procedure to Start the Engine
 After checking all parameters by the operation engineer from computer monitor (SCADA)
engine recommend to start the engine from control panel.
 When the engine rpm is 750 for Rolls-Royce, 1000 for MWM & 1500 for Caterpillar it is
ready for synchronize with other engines.
28
Start Sequence of Rolls-Royce
The sequences are given below:
INT Start
INTEIRL. O.K.
RUN
START AIR ON
ING. ON
EXITATE
PRECH. GAS
ON
MAIN GAS
ON
ING
COMFIR
29
Starting Pre-checklist (Interlocks) For Rolls-Royce
 RPM > 40 Before start  LT Flow Low
 Main Control Start Interlock  SSV Remote Indication

 LO Press Priming Pump Low  Shutdown
 Turning Gear Activated  Dwell Time After Stop
 Key Switch ECC Panel  Sensor Failure
 Starting Air Pressure Low  Gas Supply Pressure
 Emergency Stop Activated  Control Air Pressure Low
30
Stop Sequence of Rolls-Royce
Like Start Sequence Rolls-Royce also has stop sequence. The sequences are given below:
LOAD GEN-BR COOL

INT. STOP STOPED
DOWN OUT DOWN
31
Fuel System
 Rolls-Royce, MWM and Caterpillar engine is designed to operate on natural gas.
 Gas pressure for Rolls-Royce 50-52 bar, MWM 6-18 bar and Caterpillar 12-15 bar.
 Gas inlet temperature 30°C for three engines.
Figure: Fuel System

32
Lube Oil System
Advantages of Using Lube oil system
 Lube oil is used for internal combustion engine
 Main function to reduce friction & wear on moving parts
 Clean the engine from sludge and varnish
 Acts as a coolant , carrying heat away from the bearings, cylinders and pistons.
Lubrication point/sector:
1. Oil pressure control valve
2. Pipe to lube oil nozzle
3. Big end bearing
4. Camshaft brackets
5. Chain lubrication
33
Lube Oil System (Cont.)
Figure: Lube Oil System
34
Cooling System
The engine system is cooled by two closed cooling water system. They are:
 A high temperature water cooling system (HT)
 A low temperature water cooling system (LT)
 HT parameters:
 HT water pressure inlet is 2.4 bar
 Temperature after radiator is 72° C
 Outlet temperature (from engine) of water is 80° C
 Emergency shutdown temperature is 95° C

35
High Temperature Water Cooling System (HT)
Figure: High Temperature Water System (HT)
36
Low Temperature Water cooling System (LT)
 Contains 12 radiator fans
 LT water temperature before cooler is

35°~ 50° C.
 Normal engine stop temperature is 55° C.
 Two pump are installed for circulate the LT

water system
Figure: Low Temperature Water System (LT)
37
River water cooling system
 In this system 5 submersible pump (SP) are set up besides the river this pump pull up water
and fill the reserve tank .
 From the tank with the help of pump water goes into the Heat Exchanger & after exchanging
heat cooling water goes to the engine body.
38
Exhaust System
 The exhaust gas system leads the exhaust gases to turbocharger and after that out of
the power house, thus ensuring that emissions and noise are kept on an acceptable
level.
39
Log Sheet
 It is the official record of instrument reading & operating details entered up by the shift in
charge. Every day after 1 hour of interval, from operator interface data has to take for Rolls-
Royce, MWM & Caterpillar.
Figure: Log Sheet 40

Checklist
 There is also a checklist for all the three engines. Every day shift wise shift in charge has to
check the lists requirements and has to take the records on the checklist. This is a vital
responsibility for all shift in charge.
Figure: Checklist 41
Power Distribution System of Akij Power plant
Figure: Power Distribution System at ACCL

42
Efficiency at ACCL Power Plant
 Thermal Efficiency
 Efficiency was 43.4 %
 Efficiency Improvement
 They have used their exhaust gas for co-generation/regeneration.
 By using this heat loss, they improve the efficiency of engine. So, after improvement of
engine efficiency it becomes (63-66%) now.
43
Maintenance of Engine
44
Maintenance of Engine
 Purpose of Maintenance
 Working Principle of four stroke engine
 Main components of Engine
 Daily maintenance
 Weekly maintenance
 Hours basis maintenance
45
Purpose of Maintenance
 To optimize the reliability of equipments and different parts of engine;
 To ensure that equipments and engines are always in good condition;
 To get higher efficiency from engine;
 To enhance, through modifications, extensions, or new low-cost items, the productivity of
existing equipment or production capacity.
46
Working Principle of Four Stroke Engine
 A four-stroke (also four-cycle) engine is an internal combustion (IC) engine in which the piston
completes four separate strokes while turning the crankshaft and comprise a single thermodynamic
cycle. The four separate strokes are termed:
1. Intake 2. Compression 3. Combustion 4. Exhaust
47
Main Components of Engine
 Engine block  Crankshaft
 Cylinder head  Connecting rod
 Piston & piston rings  Turbocharger
 Flywheel & bearing  Charge air cooler
48
Main Components of Engines ( Cont.)
 Engine Block: Engine Block (sometimes called Cylinder Block) is the large casing that
contain the cylinder and its internal components, intake and exhaust passages, coolant
passages, crankcases, and other internal components.
Figure: Engine Block 49

 Cylinder Head: In an internal combustion engine the cylinder head (often informally abbreviated to
just head) sits above the cylinders on top of the cylinder block.
Figure: Cylinder Head 50

 Piston: In an engine, its purpose is to transfer force from

expanding gas in the cylinder to the crankshaft via a piston rod
and/or connecting rod.
Figure: Piston
 Piston Rings: Piston rings are split rings that fits into a groove
on the outer diameter of a piston in a reciprocating engine such
as an internal combustion engine or steam engine.
Figure: Piston Rings

51
 Flywheel & Bearing
 A flywheel is a wheel mounted on the crankshaft which stores excess energy.
 This is a single row cylindrical roller bearing which has high load carrying capacity, high stiffness,
low friction, separable and interchangeable.
Figure: Flywheel & Bearing 52

 Crankshaft: The crankshaft, sometimes

casually called the crank, is the part of an engine
which changes the up and down motion of the
piston into rotation.
Figure: Crankshaft
 Connecting Rod: Connecting rod make

connection between the piston and crankshaft. The
end connecting the piston is known as small end
and the other end is known as big end.
Figure: Connecting Rod
53
 Turbocharger : A turbocharger, or turbo,

is a gas compressor. It is used to force air
into an internal combustion engine.
 The purpose of a turbocharger is to

increase the density of air entering the
engine to create more power
 A turbocharger has the compressor

powered by a turbine. The turbine is
driven by the exhaust gas from the
engine.
Figure: Turbocharger
54
 Charge Air Cooler: A charge air cooler is used to cool engine air after it has
passed through a turbocharger, but before it enters into the engine.
Figure: Charge Air Cooler
55
Schedules for Maintenance
 Maintenance activities are divided into three categories. They are:
 Daily basis
 Weekly basis
 Hours basis
 Daily basis maintenance:
Every day plant engineers check the following terms or sector to know about the status of
the plant. These are:
 Gas module
Any Leakage
Main gas supply unit
Gas pressure regulating unit 56
Schedules for Maintenance (Cont.)
 Air module & dryer  Generator 4 &5 Battery Condition

Inlet, Outlet  Visual condition
Air Leakage
Working condition  Charge air filter
Valve position  Manual rotation of filter
 Parameters
Visual condition
Oil level (50% +)
Oil pressure
Oil temperature
57
 Weekly Basis Maintenance
 Air Starting System

 Lube Oil System
 Ventilation Air System
 HT & LT System
 Gas System
 Lube Oil cooler
 Switch Gear Room (SWGR)
 Lighting System
 Overhead crane & exhaust fan
58
 Hour Basis Maintenance
 Every 50 Operating Hour’s Maintenance

 Every 10,000 Operating Hour’s Maintenance
59
 Every 50 Operating Hour’s Maintenance
 Charge air cooler:
 Check any leakage
 Check draining of aircoolers
 Turbocharger
 Clean the compressor by injecting water (Normal load)
 Clean the compressor by injecting water when load is 70%
60
 Pre-chamber valve change
 Replace all used pre-chamber valve
 Spark plug clean
 Clean spark plug carefully

 Ignition system
 New spark plug need to be installed
 Filter needed to replace after 1000 operating hours interval
61
 Centrifugal filter
Clean centrifugal filter

If necessary, replace new filter paper
Remember : close lube oil valves before cleaning
 Lube oil system
Check the quantity of oil

Refill oil if necessary
 Bearing greasing
D-end bearing greasing (1500 Hours)

62
 Every 10,000 Operating Hour’s Maintenance
 Cylinder liner
 Piston rings
 Measure linear bore  Renewed piston rings
 Renewed anti-polishing ring
 Turbocharger
 Overhaul or change if necessary
 Check missing parts
 Piston  Check running performance
 Inspect and measure mating surface
 Remove and clean carbon deposits
 Replace if necessary
`
63
64
Problem Findings and Solution
65
Problem Findings and Solution
 Problem 01: Engine starting problem.
 Analysis: Engine starting problem may happen due to battery damage, low compression and
insufficient fuel pressure, etc. For battery damage, starter motor was not able to rotate with
sufficient rpm to start the engine.
 Solution: Replaced the battery by a new one and then problem was solved.

 Problem 02: Engine Vibration.

 Analysis: Engine vibrations may happen due to vibration chokes failure, combustion problems,
vibration damper problems, ball bearings failure etc. Due to failure of enough lubricant oil in the ball
bearing it couldn't move properly.
 Solution: The problem was solved by poured Lubricant oil into bearing house and other places.
66
Problem Findings and Solution (Cont.)
 Problem 03: Engine shut down.
 Analysis: Due to the short circuit the Neutral Ground Resistor (NGR) was burned and engine
suddenly stopped.
 Solution: NGR was replaced and the problem was solved.
 Problem 04: Rotating rectifier damaged.
 Analysis: Rotating rectifier is an auxiliary excitation system which produce AC current by using gas
engine & then rotating rectifier convert the AC current to DC current. Due to the unbalanced AC
current the rotating rectifier was damaged.
 Solution: Replaced the rotating rectifier.

67
Recommendations
 Safety sign or “caution” sign is very less, should increase safety sign.
 Fire protection system is not good enough.
 Helmet should be used for safety during work in engine hall.
 Should take necessary steps to increase thermal efficiency.
68
Conclusion
 Power Generation in a company like Akij Cement Company Ltd is too much important not
only for its own production but also it has a great impact in the economy of the whole
country. Like other fast-growing industry, it has a good demand of power generation.
The local electricity supply system is not capable to run the factory itself. Even though it has
interruptions regularly. So, it must to be self-dependent energy source like concept has its
own. The practice should be done for the rest other companies of Bangladesh. I hope this
report and practical knowledge will be helpful and definitely it will be effective for my
bright future in mechanical engineering sectors.
69
ANY
QUESTION?
70
71

Ruma Akter

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Ruma Akter

Загружено:

Авторское право:

Доступные форматы

Welcome To My

IUBAT – International University of Business Agriculture and Technology

 Introduction  Operation of the engine

 Objectives  Maintenance of the engine

 Limitations  Problems Findings & Solution

 Company Overview  Recommendations

 Engines of the power plant  Conclusion

 To know about the power plant engineering.

 To study about the gas engine.

 To study about operation of gas engine.

 To study about maintenance of gas engine.

 To know about the various parts of engine.

 To know about power distribution system of the power plant.

 To study about engine efficiency of the power plant.

 Taking photograph for some places were prohibited.

AKIJ CEMENT COMPANY LIMITED

premium services towards client.

 Power Plant at a Glance

 Land area : 1 acre.

Total Man-power : 20 persons.

 Installed Capacity (Power generation)

 In the year of 2008 : 6.7 MW

 Present capacity : 12.03 MW

continuous Production and economic development.

producer gas, biogas, landfill gas or natural gas.

 Merits of Gas Engine

 Gas engines are less expensive to maintain.

 Gasoline are also free from solid and liquid impurities.

 They undergo complete combustion with minimum air supply.

Model - MWM ( CG260-16 )

Model - Caterpillar (CG260-16)

 Power Plant Control Room  Cooling System

 The whole operation of the engine is

 The Shift engineer is responsible for

 In case of any emergency the engineers

Figure: Control Room

In the control room there are various types

Figure : Control Cabinets

 The RRECU (Rolls-Royce Engine Control Unit)

 Each engine contains ECC (Engine Control

 Neutral Grounding Resistor systems protect

o Air & Fuel ratio control o Main gas injection control

o Cylinder balancing control o Gas pressure control

o Ignition control o Safety system control

o Knock control o Speed control

o Engine Load control o Emergency On/Off control

 Starting system for both Roll-Royce and MWM is air

 For starting the engine, the initial air pressure for

Figure: Engine Starting System

engine recommend to start the engine from control panel.

ready for synchronize with other engines.

 RPM > 40 Before start  LT Flow Low

 Main Control Start Interlock  SSV Remote Indication

LOAD GEN-BR COOL

 Gas inlet temperature 30°C for three engines.

Figure: Fuel System

 Main function to reduce friction & wear on moving parts

 Clean the engine from sludge and varnish

Figure: Lube Oil System

 A high temperature water cooling system (HT)

 A low temperature water cooling system (LT)

 HT water pressure inlet is 2.4 bar

 Temperature after radiator is 72° C