shyam training report

8/3/2019 Shyam training report

1/51

A Report OnSummer Training Taken at SHREE CEMENT LTD. BEAWAR AJMER,

Submitted

In partial fulfillment

For the award of the Degree of

Bachelor of TechnologyIn Department of Mechanical Engineering

Submitted By: Submitted To:

Mohammad Wasim Prof. Om Khatana

4th

Year, ME H.O.D of ME

(RTU) Department of ME

08EMJME033 MJRP Uni. Jaipur

Department of Mechanical Engineering

MJRP College of Engineering & Technology Jaipur

Rajasthan Technical University


2/51

2

ACKNOWLEDGEMENT

My sincere thanks to Prof. OM KHATANA who hasguided me since from conceptual beginning to the final state of this

practical report he has guided me time to time whenever I needed

for its completion.

We are the student of B.Tech. considers the training

to be challenging job. We feel that excellence in any field can not

be achieved without the help of our learned instructors. At the

completion of our training in Shree Cement Limited. We willprefer to make some acknowledgements, which is indeed a

difficult task.

During this brief period many people have touched my

life in ways which have had a profound effect directly or indirectly

upon me. These words although for their praise are not enough

moreover an exhaustive list of them is impossible still I would liketo Mr. B.S Malik (Senior Engineer of mechanical Department),

Mr. Ajay Pal as well as whole mechanical Department by heart.

Last, but not least final word to thanks goes to all

those people who helped me to gain my practical knowledge in

Shree Cement Ltd.

Mohammad Wasim


3/51

3

PREFACE

Persuant to R.T.U. syllabus & course all the

B.Tech students are required to undergo training in an

industry for 4 to 6 weeks. Accordingly I went to SHREE

CEMENT LTD. for my industrial training. A copy of the

training report dully signed by the factory management is

enclosed herewith.

The report is a summary of what I observed

and learnt there. My humble thanks are going to all the

officer related of my training. I also feel that it is right time

to thank the officers and technicians of the Shree process

for the guidance, co-operation and the knowledge extended

by them time to time.


4/51

4

INDEX

S.NO PARTICULARS

1. Acknowledgement

2. Preface

3. Certificate

4. Cement manufacturing process

An introduction

Mining of limestone

Crusher,Stacker,Reclaimer

Grinding of materials

Kiln systems

Clinker grinding

Packing Plant

Bibliography


5/51

5

INTRODUCTION

Shree Cement Plant is the one of the leading plant

of Bangur Group. It is situated at Andheri deori near about

8 km. from Beawar. Factory has two parts one is the

cement plant and other is residential complex. The Cement

plant is divided in to two units firstly in Shree Plant and

second is Raj Plant. Residential complex consist staff

colony, school, dispensary, extension counter of SBBJ.

Survey was done from 1979 and erection period

was approximate 2 years. The plant is taken under

production from 22nd Feb 1984.


6/51

6

The cost of the plant is approximate 125 crore.

In SCL two types of cement is produced. First is ordinary

Portland cement (O.P.C.) and other one is Pozzolona

Portland cement (P.P.C.).

This plant is designed by F.L. Smith of

Denmark under colobration of L&T. It is second modern

plant in India after L&T cement works. The gear box of

cement mill in this plant is the largest in India make by

ASFA Sweden.


7/51

7

Complete Process

RAW MATERIALS:-

The raw material for the cement making is

lime stone, Litrate, Gypsum


8/51

8

And Pozzolona. There are two grades of lime i.e. high grade

.If the percentage content of CaCO3 is less than 70% it is

known as low grade. Mainly raw material is used for making

of cement is limestone .Literates mixed with raw material as

a catalyst by adding of literate clinker obtain on

low temperature and easily.(for good cooking and for

increasing Fe2O3 in the Lime Stone)Gypsum used with

clinker in cement mill for increasing the cementing time of

cement, these cement is called(O.P.C.)

Pozzolona is mixed for maintain the

quality of the cement and this cement is called Pozzolona

port land cement (P.P.C) Corrective material is marble and

its mixed for increasing average percentage of CaCO3 is raw

materials. Lime stone is provided by mines to SCL, Lime

stone is obtained by blasting from open cast. Mines,

Electrical concepts used for blasting purpose.

MINES:-


9/51

9

The quarry is 2.73km away from the plant. The raw

material is mixed from the quarry and transported to

crusher (inspector).

CRUSHER:-

Crusher is machine by the help of which lime

stone is crushed or broken into Small pieces of stone, the

crushed material size is 1 * 1 cm2. Pieces of lime stones are,

transported at first fed into Hooper by the trucks then

reciprocating feeder stone are feed to another crusher. The

crushed raw material is sending to bunker for the storage by

the help of rubber belt Conveyor. (R.B.C.) Raw material is

carried out to lime stone from the bunker to the stockpiles by

means of rope way.

STOCK PILES:-

This is the storage of raw material in the 16rm of piles.

ROPEWAY:-

Ropeway is an arrangement of buckets on rope, which


10/51

10

are used in material handling from the loading to

unloading station. Loading station is near at mines and

unloading station is placed near to the plant.

LOADING STATION:-

By the means of rope way we carried lime stone

form the loading to unloading station. In the rope way, it

has to buckets. These buckets are continue running one by

one and the capacity of each bucket is 2 tonne speed of

ropeway is 15 km/hr.

The advantage offered by a rope way are due

to its ability to overcome difficult conditions. This method

of transport material is largely independent of the nature

and utilization of the ground over which the system is

rounded. It provides a short way between loading

unloading station; operation of the rope way can be fully,

automatic which power consumption is low. The rope way

can be used for virtually any distance from say 1 km to 100

km

.

STACKER AND RECLAIMER:-


11/51

11

Stacker and Reclaimer are auxiliary devices which are

located in between unloading station and raw mill

feeding.

Stacker:-Stacker is use for pre-mixing the raw material Lime Stones

and store the raw material in form of piles. Three types of

operation can be selected by switch in the control room.

These three modes are such as:

1- Auto Mode

2- Manual Mode

3- Local Mode

Stock piling with stacker:-

[1] Process Description: -The mix bed consists oftwo equalled consequentially arranged material. These

material oils are used both for the storing and pre-

homogenisation of the material to be stacked. The material

pile arranged at the rear can be excavated as the materialpile is stock pile.

[2] Stocking the mix bed unit: - Stockpiling themix bed is carried out is accordance with the called


12/51

12

"CHEVRON METHOD" with the aid of a stacker with a

travelling tripper. The stacker with the travelling tripper

discharges the incoming material in layer on to the ground

during its travel pile. In this way until it has reached its full

capacity. As a result the pile consists of a mix of about 400layers.

Reclaimer:-

Reclaimer is used for transferring raw material to

hopper from the piles

stock through a R.B.C. Reclaimer is noting it is just chain

arrangement.

DIFFERENCE BETWEEN STACKER AND

RECLAIMER:

1 Stacker have only D.C. motor drive while theReclaimer has D.C as well as A.C drive A.C drive

motor is used for transferring from one pile to anotherpile.

2 Stacker has a level control sensor for contracting thepile height where as in the Reclaimer. There is no use

of level sensor.


13/51

13

3 Stacker has a belt arrangement while Reclaimerconsist chain arrangement for transferring the

material.

RAW MILL:-

Raw mill namely ATOX 37.5 is used. It is vertically

specially designed by

F.L.S. Company. In this mill a grinding table is rest on the gear

box and rotated by motor power of this motor 1600 kW on the

grinding table. There are three roller which are rotates in the

opposite of grinding table due to motion of grinding table on the

same place(on the own axis).

Hence special mill safety for the gear box, three high power

lubricant pumps and for grinding table's and roller's and roller's

safety. Hydraulic pumps unit is used which is specially design to

done roller up/down motion by means of solenoid values.

In the raw mill bed thickness is controlled by

hydraulic pressure and to making the bed thickness water

spray is used. By means of bed thickness, grinding table

can be avoid the problem of vibration and friction. The

differential pressure of raw mill is about 600 mm wg (max)


14/51

14

Linear Voltage Differential Transformer (L. V. D. T.) is

used for sensing the position of roller by which we adjust

the bed thickness.

Raw mill is used to convert the small pieces of

1ime stone into fine grinding powder (known as raw meal).

The capacity of Raw Mill is about 280 T/hrs.

ADVANTAGES:-

1. Cheaper, simple in installation.

2. Low power consumption3. Lower time is required for grinding.

Height of GCTG : 20.5 meter

Diameter : 07 meter

Separated flue gases from the top of preheated CO gas is

measured with the help of CO gas analyzer, goes into GCT to suction

of smoke fan(S.G.Fan ) or preheated fan. In the Conditioning tower,

remaining raw material with flue gases from the Preheater is separated

out by the help of water spray methods. In the conditioning tower water

spray is done according to temp of flue gases. There is also heat

exchange property between water and gases used. Separated material


15/51

15

from GCT through screw conveyor and air slide goes into air lift by the

air again go to C.F. silo.

DRAW BACK:-

1. Large Quality of air is required.

2. Higher wears and tear.

3. Higher maintenance cost.

4. More Vibration.

5. More sensitive to vibration in feed.

CYCLONES:

There are two cyclones in raw mill section.Cyclone is nothing but in this material is separating come

zone chamber. Here heavy particles of material are

separated from the raw material. From these cyclones raw

mill is send through air sluice into air slide, blowers are

used to transfer the fine powder i.e. meal.

AIR SLUICE:

It is unidirectional device and used to control the

flow of material by varies which are driven by shaft of

motor. In the Air sluice, material flow only up to down,

cant goes in reverse mean form down to up.


16/51

16

AIR SLIDE:-

It is a media of transportation of the fine powder of

material by means of air flow .We can say air slide is

nothing but it is meal handling or transportation

arrangement. The meal is flow over the air layers by means

of thick cloth.

BLOWERS:-

It generates the layer of air. The flow of material in

the air slide. The meal is carried out from air slide through

air lifters elevator.

\C.F.SILO:-

C.F.Silo is the large cylindrical vessel; it is use to

purpose of blending and storage of meal.

Height : 64.005Meter

Diameter : 16 Meter

Max .Capacity :160000tonn.

PREHEATER AND PRECLACINATOR:-


17/51

17

In the preheated cyclones material is preheated by the

help of waste flue gases coming the kiln hood by the property of

heat exchange .Preheated proposed preheating the raw meal in a

cyclone separator before feeding it to the kiln .In each cyclone too

draft and temperature is measured as well as in bottom.

Material and flue gases flow system is in such a way

that the hoe material is come down in side cyclone and hot

gases goes to the higher side preheated cyclone .in the last

of preheated cyclone stage plant modified means plant

capacity is increased to Performa precalcinar in which

direct coal firing is done except of kiln. In such a way the

plant capacity is just double (3000 T/day)

GAS CONDITION TOWER (G.C.T):

Kiln gas temp. at GCTI/L : 370 0C

GCTO/L temperature : 1700C

KILN:

Speed of Kiln : 3.8 RPM (max)

Length of Kiln : 56m

Dia. of Kiln : 3.945m


18/51

18

O/L shell temp. : 3040C

Internal temp. : 14000 C -15000C

Angle of Kiln : 3.8

Capacity of Kiln : 180T(max)

Kiln motor : DC 225 kw.1000RPM

Main aim of the Kiln is to convert the meal into

clinker. The clinkerisation takes place at about 13500C to

1450 0C. The raw meal enter into kiln section is 700 0C temp.

Therefore to rise the temperature of raw meal up to 1350 0C to

1450 0C pulverized coal is fired from one end to the Kiln

hood and fuel gases come out from the kiln hood. In

preheated cyclone, the waste fuel gases are used to pre heat

the raw meal coming from the kiln feed section.

After pre- calcinator the practically calcinate

or decomposionated raw meal is taken int. the kiln for making

for clinker where the temperature is controlled 00C to 1000

0C


19/51

19

and here also 00C is the analyzed by the 0 0C analyzer

(magnetic ST) .The draught also measured here in the range

of 0 to 200 mmwg (water gauge) where some chemical

reaction are done .Out let temperature of Kiln is 0 0C to 1400

0C & draught will be 0 to 10 mmwg. This O/L is also called

KILNHOOD.The CLINKER from KILN is then fed into

FLOAX COOLER due to rotation of KILN here clinker is

cooled by the help of a no. of primary fans.

FLOAX COOLER:-

Floax cooler is consisting with there grates &

horizontal &vertical plates are fitted in each grate speed of

each is controlled by thyristor controlled the speed of D.C.

motor. Grates are run in reciprocating motion which is also

controlled by thyristor controlled temperature in O/L of

FLOAX COOLER is 0 0C to 200 0C and controlled

temperature in O/L of FLOAX COOLER is 00C to150

0C. In

the end of FLOAX COOLER big parts of CLINKER are

broken in the HAMMER MILL.

HAMMER MILL:-


20/51

20

HAMMER MILL is nothing but a shaft consisting

of grater is that to transfer the CLINKER towards the

HAMMER MILL. Screened CLINKER from the grate 7 actual

CLINKER is discharged in the de bucket conveyor (D.B.C.) by

the help of D.B.C. the CLINKER sent to the CLINKER

STOCK PIPE or directly in the CLINKER HOOPER.

Meanwhile during transportation CLINKER is again cooled by

spray of water.

COAL MILL:-

COAL MILL is also called ATOX-MILL as same

as RAW MILL where raw coal is unloaded by trucks in coal

yard from where raw coal is taken into CRUSHER by R.B.C.

& crushed coal is transported by R.B.C. into RAW COAL

HOOPER which is positioned above the COAL MILL.

COAL MILL changes the coal into fine powder

& makes it perfect to firing at the KILNHOOD &

CALCINATOR. The process is same as RAW MILL

described earlier.


21/51

21

CEMENT MILL:-

It is the heart of whole plant. Its main function is

to convert CLINKER into finished product say to cement.

Main Raw materials of CEMENT MILL are:

1- CLINKER

2- POZZOLONA

3- GYPSUM

4- FLY ASH

5- COAL6- FILLER

For making the cement in this mill Gypsum & the

pozzolona mixed with CLINKER in fixed ratio. Weight

feeders are run with D.C. Motor. Speed of motor iscontrolled by thyristor. Grinding media is different

compartment & these grinding media are helped in ground

to the feed material. Mill knocking is controlled by

FOLLOPHONE.


22/51

22

Now in the CEMENT MILL the O/P is in the

form of cement. The cement is transferred by the help of a

BUCKET ELEVATOR. There are two BUCKET

ELEVATORS. Capacity of each Elevator is 100 tonnes

from the BUCKET ELEVATOR; cement is transferred by

the air slide & pipes by the help of F.K. pump to the

cement Silo for storage & packing purpose. This CEMENT

MILL is horizontal type of mill & designed by F.L.S.

SMIDTH COMPANY at DENMARK & manufactured by

L&T LTD. MUMBAI.

Gear Box at this CEMENT MILL is one of the

biggest Gear Box in INDIA which is manufactured by F.L.

SMIDTH. Its main function is as reduce speed as simple

gear Box. There are 4 HOPPERS, One for Pozzolona, Two

for Clinker and One for Gypsum and four Weight Feeders

also in running.

CEMENT CILO AND PACKING MILL:-


23/51

23

Cement from cement silo is feed into cement silo

for packing and storage purpose. Silo is large cylindrical

vessel. There are two cement silos and each silo height is

60 m and dia is 16 m.

From cement silo, cement is extracted by the help

at gates & carried through air side in bucket elevator,

bucket elevator discharge this cement come into hopper.

From hopper, cement is taken into rotary packer through

pneumatic gate.

ROTARY PACKER:-

In the rotary packer filling sponts monitored side

by side. The sponts on the rotary packer move one by one

in position in front at

the rotator. In this works, operator has to fit the value

tails on the as they successively pass him, there are twelve

sponts in one rotary packer. The speed of rotary packer is 3

RPM and is controlled by thyristor panel.

From the rotary packer bags are transported by

means of laminated conveyor and R.B.C on which deflector


24/51

24

are positioned. By the help of deflector are positioned. By

the help of deflector we can select side at instant time.

From here bags are packed and load the trucks and wagons

and sent to the godowns.

SUBSTATION:-

The sub station of cement plant consists of

following equipment:

1- Transformer

2- Circuit Breaker

3- Isolator

4- Bus bars

5- Lightning ArrestorShree Cement plant get supply from 220 kV GSS

Beawar A 132kv single line is came from beawer GSS.

Plant has also its power plant of 42 MW and DG sets to

meet its requirements.

DG SETS SECTION:-


25/51

25

The DG sets which are liable at Shree Cement plant

are from two companies which are Kirlosker Cummins and

Daihatsu. The DG sets are used to serve two purpose first

one is that it provide power at that instant of power failure

Electricity Board and other one is to improve power factor

improvement .Generator sets are diesel operated and gives

output voltage of 11kV which are converted into 6.6kV

using transformer. The VARS are generated by capacitor

bank of capacity 800 KVAR and 1600A current.

It consist 10 DG sets of Cummins and one DG Set of

Daihatsu. Cummins generator are of 1 MVA where

capacity each and Daihatsus capacity is 5 MVA so that

total generator capacity is 15 MVA where as the present

requirement of plant is about 14MVA. After future

expansion the requirement will become 25 MVA.

Cement industry is a basics industry and its cost of

production assures vital improvement. The cost of

production and reduced by smooth systematic running of

plant at its capacity. Automation and instrument play a very


26/51

26

important part for running the industry smoothly and at

maximum production.

.A thermal power station comprises all of

the equipment and systems required to produce

electricity by using a steam generating boiler fired with

fossil fuels or biofuels to drive an electrical generator.


27/51

27

BOILER

A boiler is a closed vessel in which water or

other fluid is heated under pressure. The heated or

vaporized fluid exits the boiler for use in various processes

or heating applications.

The source of heat for a boiler is combustion of

any of several fuels, such as wood, coal, oil, or natural gas.

Electric boilers use resistance or immersion type heating

elements. Nuclear fission is also used as a heat source for

generating steam. Heat recovery steam generators use the

heat rejected from other processes such as gas turbines.

Boilers can also be classified into:

Fire-tube boilers. Here, the heat source is inside the

tubes and the water to be heated is outside.

Water-tube boilers. Here the heat source is outside the

tubes and the water to be heated is inside.

A fire-tube boiler is a type of boiler in which

hot gases from the fire pass through one or more tubes

within the boiler. It is one of the two major types of boilers,


28/51

28

the other being the water-tube boiler. A fire tube boiler can

be either horizontal or vertical. A fire-tube boiler is

sometimes called a "smoke-tube boiler" or "shell boiler".

This type of boiler was used on virtually all

steam locomotives in the horizontal "locomotive" form. It

is also typical of early marine applications and small

vessels, such as the small riverboat used in the movie The

African Queen. Marine units were often called "donkeyboilers". Today, they find extensive use in the stationary

engineering field, typically for low pressure steam use such

as heating a building.

(Diagram of a fire-tube boiler)

In water-tube boilers the water flows through tubes around

a fire. The tubes frequently have a large number of bends
http://en.wikipedia.org/wiki/Image:Steam_Boiler_2_English_version.png


29/51

29

and sometimes fin to maximize the surface area. This type

of boiler is generally preferred in high pressure applications

since the high pressure water/steam is contained within

narrow pipes which can contain the pressure with a thinner

wall.

(Diagram of a water-tube boiler)

In a cast iron sectional boiler, sometimes called a "pork

chop boiler" the water is contained inside cast iron sections.

These sections are mechanically assembled on site to create

the finished boiler.

BOILER FURNACE AND STEAM DRUM
http://en.wikipedia.org/wiki/Image:Steam_Boiler_3_english.png


30/51

30

The boiler furnace auxiliary equipment

includes coal feed nozzles and igniter guns, soot blowers,

water lancing and observation ports (in the furnace walls)

for observation of the furnace interior. Furnace explosions

due to any accumulation of combustible gases after a trip-

out are avoided by flushing out such gases from the

combustion zone before igniting the coal.

The steam drums have air vents anddrains needed for initial startup. The steam drum has an

internal device that removes moisture from the wet steam

entering the drum from the steam generating tubes. The dry

steam then flows into the superheater coils.

FUEL PREPARATION SYSTEM

In coal-fired power stations, the raw

feed coal from the coal storage area is first crushed

into small pieces and then conveyed to the coal feedhoppers at the boilers. The coal is next pulverized into

a very fine powder. The pulverizers may be ball mills,

rotating drum grinders, or other types of grinders.


31/51

31

Some power stations burn fuel oil

rather than coal. The oil must kept warm (above its

pour point) in the fuel oil storage tanks to prevent the

oil from congealing and becoming unpumpable. The

oil is usually heated to about 100 C before being

pumped through the furnace fuel oil spray nozzles.

Boilers in some power stations use

processed natural gas as their main fuel. Other powerstations may use processed natural gas as auxiliary

fuel in the event that their main fuel supply (coal or oil)

is interrupted. In such cases, separate gas burners

are provided on the boiler furnaces.

FUEL FIRING SYSTEM AND IGNITERSYSTEM

From the pulverized coal bin, coalis blown by hot air through the furnace coal burners at

an angle which imparts a swirling motion to the

powdered coal to enhance mixing of the coal powder


32/51

32

with the incoming preheated combustion air and thus

to enhance the combustion.

To provide sufficient combustion

temperature in the furnace before igniting the

powdered coal, the furnace temperature is raised by

first burning some light fuel oil or processed natural

gas (by using auxiliary burners and igniters provide

for that purpose).

AUXILIARY SYSTEMS

Fly ash collection

Fly ash is captured and

removed from the flue gas by electrostaticprecipitators or fabric bag filters (or sometimes both)

located at the outlet of the furnace and before the

induced draft fan. The fly ash is periodically removed

from the collection hoppers below the precipitators or

bag filters. Generally, the fly ash is pneumaticallytransported to storage silos for subsequent transport

by trucks or railroad cars.


33/51

33

Bottom ash collection and disposal

At the bottom of every boiler, a

hopper has been provided for collection of the bottom

ash from the bottom of the furnace. This hopper is

always filled with water to quench the ash and

clinkers falling down from the furnace. Some

arrangement is included to crush the clinkers and for

conveying the crushed clinkers and bottom ash to a

storage site.

Oil system

An auxiliary oil system pump is

used to supply oil at the start-up of the steam turbine

generator. It supplies the hydraulic oil system required

for steam turbine's main inlet steam stop valve, the

governing control valves, the bearing and seal oil

systems, the relevant hydraulic relays and other

mechanisms. At a preset speed of the turbine during

start-ups, a pump driven by the turbine main shaft

takes over the functions of the auxiliary system.


34/51

34

Generator heat dissipation

The electricity generation coupled to

the turbine shaft requires cooling to dissipate the heat

that it generates. While small units may be cooled by

air drawn through filters at the inlet, larger units

generally require special cooling arrangements.

Hydrogen gas cooling, in an oil-sealed casing, is used

because it has the highest known heat transfer

coefficient of any gas and for its low viscosity which

reduces windage losses. This system requires special

handling during start-up, with air in the chamber first

displaced by carbon dioxide before filling with

hydrogen. This ensures that the highly flammable

hydrogen does not mix with oxygen in the air.

The hydrogen pressure inside the

casing is maintained slightly higher than atmospheric

pressure to avoid outside air ingress. The hydrogen

must be sealed against outward leakage where the

shaft emerges from the casing. Mechanical seals

around the shaft are installed with a very small

annular gap to avoid rubbing between the shaft and


35/51

35

the mechanical seals. To avoid gas leakage from the

annular gap, seal oil provided in a way such that part

of the oil flows to inside and part to outside of the

casing to prevent the hydrogen gas leakage to

atmosphere.

The generator also contains water

ducts for further cooling. Since the generator coils are

at a potential of about 22

kV and water is conductive,an insulating barrier such as Teflon is used to

interconnect the water line and the generator HV

windings. Demineralized water of low conductivity and

without impurities is used.

Generator high voltage system

The generator voltage is normally 11

kV in smaller units and in bigger units it would be

about 22 kV. Probably this is limited by the insulation

media available and the construction methodology

limitations available today. The generator HV leads

are normally of large section aluminum channels

because of very high current as against cables used

in smaller machines. They are enclosed in aluminum


36/51

36

bus ducts (with good grounding), live channels being

supported on suitable insulators inside. Further the

generator HV channels (leads) are directly connected

to suitably designed step-up transformers for

connecting to a transmission yard high voltage

substation, of the order of 110 kV or 220 kV for further

transmission by grid. The HV generator channels

generally being of long run and also subjected to heat

and cold, necessary suitable expansion joints are also

provided.

The necessary protection and

metering devices are incorporated on the HV leads of

generator. Thus the steam turbine generator and thetransformer form one unit. In smaller units, generating

normally at 11 kV, a breaker is provided to connect it

to a common 11 kV bus system in a cubicle normally

located indoors.

CONDENSER

The surface condenser is a shell

and tube heat exchanger in which cooling water is


37/51

37

circulated through the tubes. The exhaust steam from

the low pressure turbine enters the shell where it is

cooled and converted to condensate (water) by

flowing over the tubes as shown in the adjacent

diagram.

Such condensers use steam

ejectors or rotary motor-driven exhausters for

continuous removal of air and gases from the steamside to maintain vacuum. The condenser generally

uses either circulating cooling water from a cooling

tower or once-through water from a river, lake or

ocean.
http://en.wikipedia.org/wiki/Image:Surface_Condenser.png


38/51

38

DEAERATOR

A steam generating boiler requires thatthe boiler feed water should be devoid of air and other

dissolved gases, particularly corrosive ones, in order

to avoid corrosion of the metal.

Generally, power stations use a

Deaerator to provide for the removal of air and other

dissolved gases from the boiler feed water. A

deaerator typically includes a vertical, domed

deaeration section mounted on top of a horizontal

cylindrical vessel which serves as the deaerated

boiler feed water storage tank.
http://en.wikipedia.org/wiki/Image:Deaerator.png


39/51

39

There are many different designs for a

deaerator and the designs will vary from one

manufacturer to another. The adjacent diagram

depicts a typical conventional trayed deaerator. If

operated properly, most deaerator manufacturers will

guarantee that oxygen in the deaerated water will not

exceed 7 ppb by weight (0.005 cm/L).

OTHER SYSTEMSMonitoring and alarm system

All of the major plant components and

systems require pre-checking for start-up during the

first start or after a shut-down for any reason

whatsoever. The safety aspects and the normal

procedures have to be looked into at all stages of

operation. Manual intervention is also unavoidable;

however, much the system is made automatic. In view

of this necessary protection, monitoring with alarms

for out of limit parameters, and auto and manual

control equipment are provided on the operator

consoles, both on the mechanical and electrical

equipment.


40/51

40

Battery supplied emergency lighting andcommunication

Central battery system consisting of lead

acid cell units to make up 240 V DC, sometimes in

two individual stacks with its own battery charging

unit, inverter to get 230 V AC, and auto-step less

changeover in case station supply of 230 V AC fails.

The batteries are installed in separate rooms (battery

rooms) with exhaust fans and all round coated with

acid-proof paint (Battery room design issues).

The essential equipment supplied by this

battery system are: control and relay equipment,

communication and emergency lighting, and turbine lubeoil pumps. This control equipment is installed in separate

rooms with monitoring on the operators console. This is

essential for smooth and damageless shutdown of the units.

Transport of coal fuel to site and tostorage

Most thermal stations use coal as the

main fuel. Raw coal is transported from collieries to a

power station site by railway wagons only. Generally


41/51

41

coal wagons are sent as a full railway rake. The coal

received at site by wagons may be of different sizes.

They are unloaded at site by rotary

dumpers or side tilt dumpers to tip over conveyor

belts below. They are generally carried direct to the

crusher house for crushing the coal to about inch (6

mm) size and then by belt conveyors to storage yard.

Normally this crushed coal is stored with compaction

by bulldozers, as compacting of highly volatile coal

avoids spontaneous ignition. Hence this arrangement

is generally adopted.

The crushed coal from storage or after

crushing direct is conveyed to top of boilers by meansof belt conveyor system. At the top of boilers a

horizontal conveyor with distributing arrangement for

feeding to any boiler bunker will feed the coal to the

required boiler bunkers generally which ever boiler is

in operation. This is to avoid long hours of storage inboiler bunkers to avoid spontaneous ignition at that

point.


42/51

42

COOLING TOWER

Cooling towers are evaporative coolers used

for cooling water or other working medium to near the

ambient wet-bulb air temperature. Cooling towers use

evaporation of water to reject heat from processes

such as cooling the circulating water used in oil

refineries, chemical plants, power plants and building

cooling, for example. The towers vary in size from

small roof-top units to very large hyperboloid

structures (as in Image 1) that can be up to 200

metres tall and 100 metres in diameter, or rectangular

structures (as in Image 2) that can be over 40 metres

tall and 80 metres long. Smaller towers are normally

factory-built, while larger ones are constructed on

site.

(A mechanical induced

draft cooling tower)
http://en.wikipedia.org/wiki/Image:A_Marley_industrial_cooling_tower.jpg


43/51

43

STEAM TURBINE

A steam turbine is a mechanical device

that extracts thermal energy from pressurized steam,

and converts it into useful mechanical work. It has

almost completely replaced the reciprocating piston

steam engine, invented by Thomas Newcomen and

greatly improved by James Watt, primarily because ofits greater thermal efficiency and higher power-to-

weight ratio. Also, because the turbine generates

rotary motion, rather than requiring a linkage

mechanism to convert reciprocating to rotary motion,

it is particularly suited for use driving an electricalgenerator about 86% of all electric generation in

the world is by use of steam turbines. The steam

turbine is a form of heat engine that derives much of

its improvement in thermodynamic efficiency from the

use of multiple stages in the expansion of the steam,as opposed to the one stage in the Watt engine,

which results in a closer approach to the ideal

reversible process.


44/51

44

Types

There are turbines generally classified in to twocategories

1. Impulse Turbine

2. Reaction Turbine


45/51

45

IMPULSE TURBINES

An impulse turbine has fixed nozzles that

orient the steam flow into high speed jets. These jets

contain significant kinetic energy, which the rotorblades, shaped like buckets, convert into shaft

rotation as the steam jet changes direction. A

pressure drop occurs in the nozzle. The pressure is

the same when the steam enters the blade as it

leaves the blade. As the steam flows through the

nozzle, its pressure falls from steam chest pressure to

condenser pressure (or atmosphere pressure). Due to

this relatively higher ratio of expansion of steam in the
http://en.wikipedia.org/wiki/Image:Turbines_impulse_v_reaction.png


46/51

46

nozzle, the steam leaves the nozzle with a very high

velocity. At a specific temperature and pressure

steam has certain physical properties. The certain

amount of heat or thermal energy contained within the

steam with an increase of temperature or pressure

the contained energy also increases or vice versa.

The flow of steam through a channel such as a nozzle

reduces its thermal energy; however this decrease in

thermal energy is equivalent to gain of kinetic energy.

The thermal energy is converted from thermal to

kinetic causing the steam to flow from high pressure,

i.e. the steam chest, nozzle block, etc.. to an area of

low pressure, i.e. the turbine casing. The steam

leaving the moving blades still retains a large portion

of the velocity it had after leaving the nozzle. The loss

of energy due to this higher exit velocity is commonly

called the "carry over velocity" or "leaving loss." In

impulse turbines, steam expansion only happens at

nozzles.


47/51

47

Reaction turbines

In a reaction turbine the rotor blades

themselves are arranged to form convergent nozzles.

This type of turbine makes use of the reaction force

produced as the steam accelerates through the

nozzles formed by the rotor. Steam is directed onto

the rotor by the fixed vanes of the stator. It leaves the

stator as a jet that fills the entire circumference of the

rotor. The steam then changes direction and

increases its speed relative to the speed of the

blades. A pressure drop occurs across both the stator

and the rotor, with steam accelerating through the

stator and decelerating through the rotor, with no net

change in steam velocity across the stage but with a

decrease in both pressure and temperature, reflecting

the work performed in the driving of the rotor. These

types of turbines create large amounts of axial thrust,

therefore, anti-friction thrust bearings are utilized.

FLUE GAS STACK

A flue gas stack is a type of chimney,

a vertical pipe, channel or similar structure through


48/51

48

which combustion product gases called flue gases are

exhausted to the outside air. Flue gases are produced

when coal, oil, natural gas, wood or any other fuel is

combusted in an industrial furnace, a power plant's

steam-generating boiler, or other large combustion

device. Flue gas is usually composed of carbon

dioxide (CO2) and water vapor as well as nitrogen and

excess oxygen remaining from the intake combustion

air. It also contains a small percentage of pollutants

such as particulate matter, carbon monoxide, nitrogen

oxides and sulfur oxides. The flue gas stacks are

often quite tall, up to 400 meters (1300 feet) or more,

so as to disperse the exhaust pollutants over a

greater area and thereby reduce the concentration of

the pollutants to the levels required by governmental

environmental policies and regulations.

When the flue gases are exhausted from

stoves, ovens, fireplaces, or other small sourceswithin residential abodes, restaurants, hotels, or other

public buildings and small commercial enterprises,

their flue gas stacks are referred to as chimneys.


49/51

49

FINDINGS & CONCLUSIONS

Learning is a never ending process which continues

from birth of human being to his/her death. It can also

be done by reading book and through training andwork. Spending 6 days in SHRRE CEMENT LTD.

was good learning experience for me. After

completing the organization study I come to know that

academic learning is different and working in

organization and learning is different. After spending

such precious time in an organization my majorfinding in that particular organization are as follows:

Firstly, organization culture of Shree Cement is

formal, where every person cannot directly meet

to High authority with out any systematic way

which I considered was good because it

encourages employees at work. Secondly, organization structure of Shree

Cement is well formatted in which each and

every department plays important role.

Thirdly, in the organisation structure is divided

into to 4 part one is in Finance, Marketing,

Operation & Quality, Human and Resources

These all departments are headed by different

persons but at the same time they work for same

objective with full co-ordination which shows the

unity level about the organisation.


50/51

50

Fourthly, all the employees and labourers work

very hard towards achieving the goal. Even the

higher authorities work very hard without wasting

time towards the organization goal

Fifthly, security concern in shasun chemicals.

doesnt allow the outsiders to enter into the

factory without prior appointment or consulting

the higher authorities. They have a very effective

security system.

Sixthly, Administrative head role in an

organisation very important to make goodworking environment the practice which I

observed was that he was very hard working

person and he does his work very efficiently.

Seventhly, marketing department made me to

learn about, how the customers can be attracted

by giving him innovative thoughts and ideas and

benefiting to both the organization and the

common people.

Eighthly, an organisation study also makes me

learn that any objective cannot achieve with a

short span of time it has to be done through

systematic ways.

Finally, in any organisation time managementplay important role because each activity should

be done at a right time at right place.


51/51

BIBLIOGRAPHYwww.shreecement.com

www.google.com

Annual report of company for the year

07-08

www.wikipedia.com

Bseindia.com

Business world

Many online articles etc
http://www.shreecement.com/http://www.google.com/http://www.google.com/http://www.shreecement.com/

shyam training report

Documents