EXEPERIMENT NO.

AIM:- Identify the components of hydroelectric power plant by using charts, models, simulation
and videos.

DIAGRAM:-

APPARATUS:- Charts and videos.

THEORY AND WORKING:-

The purpose of hydroelectric power plant is to provide power from water flowing
under pressure. It has two forms of energy, kinetic energy and potential energy.
Kinetic energy depends upon the mass velocity of flow while the potential energy
exists as a result of difference in water level below two points. The turbine
converts potential and kinetic energy possessed by water in to mechanical energy.
Thus the turbine is a prime mover which when coupled to a generator produces
electricity.
ELECTRIC POWER:-
Hydroelectric power can be developed when water continuously flowing under pressure is
available. Dam is constructed to restrict the river water flow. Essential components of a
hydroelectric power plant are as follows:-

(1) STORAGE RESERVOIR:-

The water available from an attachment area is stored in a reservoir so that it can be utilized to
run the turbine for producing power according to requirement.

(2) DAM WITH CONTROL WORKS:-

Dam is a structure ejected on a suitable site to provide for the storage of water and create head.
Dam may be built to make an artificial reservoir from valley or it may be created in a river to
control the flowing water.

(3) WATER WAYS:-

Water way is a passage through which the water carried from the storage reservoir to the power
house. It may consist of tunnel control, force pipe and penstock. Tunnel is water passage made
by cutting the mountain to save the distance for bay in an enlarged section of a canal spread out
to accommodate the required width of intake. Its function is to store temporarily water ejected by
plant.

(4) PENSTOCK:-
It is a pipe of large diameter caring water under pressure from storage to turbine.

(5) POWER HOUSE:-

It is a building to house the turbine, penstock and other for operating the machines.

RATED QUANTITIES:-
The rated quantities refer to the parameter for which the turbine is designed.

EFFIENCY OF HYDROELECTRIC POWER PLANT:-

An appraisal of the performance of a hydraulic turbine is made by its overall
efficiency.

Result & Conclusion:- In this way we have studied components and working of hydraulic
power plant.
 EXEPERIMENT NO.2
AIM:- Identify the components of Gas turbine power plant by using charts, models, simulation
and videos.

Diagram:-

APPARATUS:- Charts and videos.

THEORY AND WORKING:-
The gas turbine plant essentially consists of compressor, combustion chamber and
turbine. The air is compressed in a compressor and the fuel is burned in the combustion chamber
when the compressed air is supplied from the compressor. The burned high temperature gases
are passed through the turbine. The part of the work developed by the gases passing through the
turbine is used to rum the compressor and remaining (30-35%) is used to generate the electrical
energy.
When the heat given to the air by mixing and burning the fuel in the air and the gases coming out
of the turbine are exhausted to the atmosphere, the cycle is known as open cycle power plant. If
the heat to the working medium (air or any other suitable gas) is given without directly burning
the fuel in the air and the same working fluid is used again and again, the cycle is known as
closed cycle power plant. On the basis of combustion process the gas turbines are classified as
(a) Continuous combustion or constant pressure type. The cycle working on this
principle is called as Joule or Brayton cycle.
(b) The explosion or constant volume type. The cycle working on this principle is
known as Atkinson cycle.

Methods of improving efficiency and specific output of Gas Turbine Plant:-

1. Regeneration:- This is done by preheating the air with the turbine exhaust which saves the fuel
consumption.
2. Improving turbine output by
 Reheating- The whole expansion in turbine is achieved in two or more stages and reheating is
done after each stage.
 Increasing the value of maximum cycle temperature means turbine inlet temperature which
requires
(a) Better quality of fuel
(b) New materials which can withstand high temperatures and pressures.
(c) Better blade cooling methods and cooling medium.
 Improved turbine efficiency:- It depends on design improvements of each component.
 Reducing compressor input. It may be done by
(a) Intercooling. Compressor work is reduced by intercooling the air between compressor stages.
(b) By lowering the inlet temperature to compressor. It is not possible because this will increase
the pressure ratio.
(c) By increasing the compressor efficiency. This depends upon the design improvement.
(d) Water injection.

Result & Conclusion:- In this way we have studied components and working of gas turbine
power plant.

EXEPERIMENT NO.3
AIM:- Maintenance of Diesel engine power plant.
APPARATUS:- Charts and videos.

DESCRIPTION:-
Service:-
1. Service Aspiration (intake and exhaust) System
a) Turbocharger is maintained based on PMS
b) Cleaning or replacement of air filter is done as indicated by air restriction indicator
c) Air filter casing is cleaned and freed of dust or foreign particles as cleaning or
replacement of filter occurs.
2. Service Lube Oil System
a) Oil cooler assembly is uninstalled and installed in accordance with the
manufacturer’s instruction
b) Oil cooler assembly are disassembled and assembled without causing damage to the
fins, oil cooler tubes and oil seals (o-rings) and in accordance with manufacturers
instruction.
c) Oil cooler tubes are cleaned and freed of scale or restrictions.
d) Change oil is performed according to SOP.
3. Service of Cooling System
a. Cooling System is checked for leaks visually.
b. Radiator is serviced following enterprise policy
c. Thermostat is checked in accordance with its operating temperature.
d. Replace or repair system components based on test result.
e. Coolant is refilled in accordance to the manufacturer’s instruction.
f. Maintain coolant pump in accordance with PMS.
4. Service Fuel System
a. Fuel filter is replaced in accordance with manufacturer’s instruction and PMS.
b. Fuel oil/water separator is drained to ensure that the system is free from foreign
elements.
c. Servicing and calibration of fuel injector is recommended in accordance with
enterprise policy.
5. Check condition of alternator
a. Loose connections are remedied and restored to normal
b. conditions in accordance with manufacturer’sinstructions.
c. Insulation and winding resistance are checked inaccordance with manufacturers
manual.
d. Revolving diodes and bridge rectifiers are checked inaccordance with
manufacturer’s manual.
e. AVR functionality is tested based on enterprise policy.
f. Air gap clearances are checked in accordance with manufacturer’s manual.
g. Service report is prepared and submitted in accordance with enterprise policy.

Range of Variables
1. PMS:-
a. Preventive Maintenance schedules can be:
b. 400 RH
 c. 1200 RH
d. 2400 RH
e. 4800 RH
f. 9600 RH
g. 20000 RH
h. other schedules indicated on the manual or enterprise policy
2. Cooling System
a. Radiator Assembly
b. Oil Cooler Assembly
c. Coolant Pump Assembly
d. Coolant Rail & Thermostat
e. Water Jackets
f. Charged Air Cooler Assembly
g. Cooling Fan

3. Operating Temperature
a. 3.1 The first thermostatic valve opens at 78 – 79 ◦C
b. 3.2 The second thermostatic valve opens at 80 – 84 ◦C
c. 3.3 The third thermostatic valve fully opens at 92 – 98 ◦C
4. Test Result
a. Operating Temperature of Thermostat
b. Axial/Radial Test of Coolant Pump Shaft
c. Visual Leak Test/Hydro Test
5. Foreign Elements
May include but not limited to:
a. Dirt
b. Rust
c. Grease/Oil
d. Water
6. Winding
a. Potential transformer windings
b. Current transformer windings
c. Main stator windings
d. Main rotor windings
e. Exciter-rotor windings
f. Exciter-stator windings
g. Auxiliary windings
h. Compounding transformer windings

7. Air gap clearances

a. Exciter rotor-stator air gap clearance
b. Compounding transformer air gap clearance

Results:- In this way maintenance of Diesel engine is carried out.

EXEPERIMENT NO. 4
AIM:- Maintenance of fuel nozzle, liners, Spark plugs, Flex hoses, check valves of Gas turbine
power plant.

APPARATUS:- Charts and videos.

DESCRIPTION:
Standby Mode:-
1. Check and verify operation of pre-lube pump. 8 hrs Check and verify operation of lube oil
heating system.
2. Check and verify operation of starting air compressors, battery charger, or other starting
system components.
3. Check and verify starting air pressure is correct, batteries are charged, and all other starting
system components are in ready-to-start condition.
4. Verify that control power is available to the control system and all controls are in the proper
position to allow automatic starting of the engines.
5. Check for any oil leaks.
6. Check for coolant leaks.
7. Check the day tank area for fuel leaks.
8. Check lube oil level, add if required. week Inspect air filter. Clean/replace if required.
9 . Check starting air lubricator. Fill if required.
10. Check level of hydraulic fluid in reservoir on hydraulic starting systems.
11. Check oil level in governor, add if required.
12. Record and report any discrepancies.

Operation mode:-
1) Inspect engine and listen for any unusual noise.
2) Check for fuel oil and lube oil leaks.
3) Note and record any excessive vibration.
4) Check and record the data indicated on the engine instrument panel. Note any unusual
readings and investigate.
5) Check lubes oil level in sump (Also check level in reduction gear if it is a separate system).
6) Check oil level in governor.
7) Check fuel strainers for water and drain if required.
8) Check day tank level.
9) Check lube oil and fuel filter pressure drop and change filters as required.
10) Inspect air filters and replace as required.
11) Inspect exterior of engine and auxiliary components for broken lock wires, loose nuts or
bolts, and general security of installation.
12) Check control linkage for freedom of movement, wear, and tightness of connections.
13) Check for unusual noises in gears, bearings, couplings, and pumps.
14) Check for excessive vibration of couplings, shaft extensions, and housing.
15) Remove and inspect magnetic plugs for accumulation of metal particles. Also perform
continuity check.
16) Check operation and calibrate speed and temperature control system.
17) Inspect engine mounts for cracks or decrease in vibration isolation.
18) Inspect electrical harness leads and cables for cracks or other signs of wear.
19) Check fuel manifold drain valve for proper operation.
20) Inspect igniters and liner supports.
21) Inspect fuel nozzles for carbon or other damage. If one or more nozzles need replacement,
replace full set. If contamination is found, replace high pressure fuel filter.
22) Inspect first stage turbine blades and vanes.
23) Inspect combustion liners.
24) Inspect thermocouples and wiring.
25) Check contact pattern of reduction gear teeth.
26) Verify proper operation of all safety shutdown controls and alarms. Immediately repair any
defective items.
27) Inspect bleed valves. Check valves for air leaks.
28) Inspect engine inlet and compressor assembly.
29) Grease/lubricate auxiliary pump bearings.
30) Clean breather element on reduction gear.
31) Inspect igniters and liner supports.
32) Inspect fuel nozzles for carbon or other damage. If one or more nozzles need replacement,
replace full set. If contamination is found, replace high pressure fuel filter.
33) Inspect first stage turbine blades and vanes.
34) Inspect combustion liners.
35) Inspect thermocouples and wiring.

Result:- In this way we have studied the maintenance procedure of Gas Turbine Power plant
components.

EXEPERIMENT NO. 5
AIM:- Identify the components of steam power plant by using charts, models, simulation and
videos.

APPARATUS:- Charts and videos.

DIAGRAM: -
Description:-
1.Coal and ash handling plant: The coal is transported to the steam power station by road or
rail and is stored in the coal storage plant. Storage of coal is primarily a matter of protection
against coal strikes, failure of the transportation system and general coal shortages. From the coal
storage plant, coal is delivered to the coal handling plant where it is pulverized (i.e., crushed into
small pieces) in order to increase its surface exposure, thus promoting rapid combustion without
using large quantity of excess air. The pulverized coal is fed to the boiler by belt conveyors. The
coal is burnt in the boiler and the ash produced after the complete combustion of coal is removed
to the ash handling plant and then delivered to the ash storage plant for disposal. The removal of
the ash from the boiler furnace is necessary for proper burning of coal.
2. Steam generating plant: The steam generating plant consists of a boiler for the production
of steam and other auxiliary equipment for the utilization of flue gases.
(i) Boiler: The heat of combustion of coal in the boiler is utilized to convert water into steam
at high temperature and pressure. The flue gases from the boiler make their journey
through super heater economizer, air pre-heater and are finally exhausted to atmosphere through
the chimney.
(ii) Super heater: The steam produced in the boiler is wet and is passed through a super
heater where it is dried and superheated (i.e.., the steam temperature increased above that of the
boiling point of water) by the flue gases on their way to the chimney. Super heating provides two
principal benefits. Firstly, the overall efficiency is increased. Secondly, too much condensation
in the last stages of the turbine (which would cause blade corrosion) is avoided. The superheated
steam from the super heater is fed to the steam turbine through the main valve.
(iii) Economizer: An economizer is essentially a feed water heater and derives heat from the
flue gases for this purpose. The feed water is fed to the economizer before supplying to the
boiler. The economizer extracts a part of the heat of flue gases to increase the feed water
temperature.
(iv) Air pre-heater: An air pre-heater increases the temperature of the air supplied for coal
burning by deriving heat from flue gases. Air is drawn from the atmosphere by a forced draught
fan and is passed through air pre-heater before supplying to the boiler furnace. The air pre-
heater extracts heat from flue gases and increases the temperature of air used for coal
combustion. The principal benefits of preheating the air are increased thermal efficiency and
increased steam capacity per square metre of boiler surface.
3. Steam turbine: The dry and superheated steam from the super heater is fed to the
steam turbine through the main valve. The heat energy of steam when passing over the blades of
the turbine is converted into mechanical energy. After giving heat energy to the turbine, the
steam is exhausted to the condenser which condenses the exhausted steam by means of cold
water circulation.
4.Alternator: The steam turbine is coupled to an alternator. The alternator converts
mechanical energy of turbine into electrical energy. The electrical output from the alternator is
delivered to the bus bars through transformer, circuit breakers and isolators.
5. Feed water: The condensate from the condenser is used as feed water to the boiler.
Some water may be lost in the cycle which is suitably made up from external source. The feed
water on its way to the boiler is heated by water heaters and economizer. This helps in raising the
overall efficiency of the plant.

6. Cooling arrangement: In order to improve the efficiency of the steam power plant, the
steam exhausted from the turbine is condensed by means of a condenser. Water is drawn from a
natural source of supply such as a river, canal or lake and is circulated through the condenser.
The circulating water takes up the heat of the exhausted steam and it becomes hot.

          This hot water coming out from the condenser is discharged at a suitable location down the
river. In case the availability of water from the source of supply is not assured throughout the
year, cooling towers are used. During the scarcity of water in the river, hot water from the
condenser is passed on to the cooling towers where it is cooled. The cold water from the cooling
tower is reused in the condenser.
Results: - In this way we have studied steam power plant.

EXEPERIMENT NO. 6
AIM:- Maintain economizer, condenser etc components of steam power plant.

APPARATUS:- Charts and videos.

Description: -
The definition of maintenance often states that maintenance is an activity carried out for any
equipment to ensure its reliability to perform its functions. Maintenance to most people is any
activity carried out on an asset in order to ensure that the asset continues to perform its intended
functions, or to restore to its favorable operating condition. The purpose of maintenance is to
extend equipment lifetime, or at least the mean time to the next failure the repair of which may
be costly. Furthermore, it is expected that effective maintenance policies can reduce the
frequency of service interruptions and the many undesirable consequences of such interruptions.
Maintenance clearly impacts on component and reliability; if too little is done ,this may result in
an excessive number of costly failures and poor system performance and therefore, reliability is
degraded, done often, reliability may improve but the cost of maintenance will sharply increase.
In a cost effective scheme, the two expenditures must be balanced. Maintenance is just one of the
devices for up keeping or if necessary improving the level of reliability of components and
systems. Over the years, many new strategies have been implemented as maintenance strategies
which are intended to overcome the problems which are related to equipment breakdown. Some
of the common maintenance strategies are as follows.

1. Breakdown Maintenance This is one of the earliest maintenance programs being implemented
in the industry. The approach to maintenance is totally reactive and acts only when equipment
needs to be fixed. This strategy has no routine maintenance task and it is also described as no
scheduled maintenance strategy. To rectify the problem, corrective maintenance is performed
onto the equipment. Thus, this activity may consist of repairing, restoration or replacement of
components. The strategy is to apply only the corrective maintenance activity, which is required
to correct a failure that has occurred or is in the process of occurring.

2. Preventive Maintenance:- This is the time-based maintenance strategy where on a

predetermined periodic basis, equipment is taken off-line, opened up and inspected. Based on
visual inspection, repairs are made and the equipment is then put back on-line. Thus under this
equipment maintenance strategy, replacing, overhauling or remanufacturing an item is done at
fixed intervals regardless of its condition at the time. Although this is a well-intended strategy,
the process can be very expensive as typically 95% of the time everything was alright.
Nevertheless, some preventive maintenance is necessary as some regulation such as DOSH
regulation require that annual/bi-annual boiler inspection to be conducted.

3. Predictive Maintenance: - Predictive maintenance is a more condition-based approach to

maintenance. The approach is based on measuring of the equipment condition in order to assess
whether an equipment will fail during some future period, and then taking action to avoid the
consequences of those failures. This is where predictive maintenance technologies (i.e. vibration
analysis, infrared thermographs, ultrasonic detection, etc.) are utilized to determine the condition
of equipment, and to decide on any necessary repairs. Apart from the predictive technologies,
statistical process control techniques, equipment performance monitoring or human senses are
also adapted to monitor the equipment condition. This approach is a more economically feasible
strategy as labors, materials and production schedules are used much more efficiently
4. Proactive Maintenance Unlike the three type of maintenance strategies which have been
discussed earlier, proactive maintenance can be considered as another new approach to
maintenance strategy. Dissimilar to preventive maintenance that biased on time intervals or
predictive maintenance concentrate on the monitoring and correction of root causes to equipment
failures. The proactive maintenance strategy is also designed to extend the useful age of the
equipment to reach the wear-out stage by adaptation of a high mastery level of operating
precision.
The table below summarizes the four different strategies of maintenance which are being
commonly practiced in the industry.

Result:- In this way maintenance of steam power plant components carried out.
 EXEPERIMENT NO. 7
AIM:- Maintain fludized bed combustion boiler by using charts, models, simulation and videos.

APPARATUS:- Charts and videos.

DIAGRAM: -
DESCRIPTION :-
DAILY MAINTENANCE CHECK LIST DURING OPERATION
 Check the correctness of water level in the control desk with direct level glass.
 Check the level indicator for proper illumination.
 Check the combustor for proper fluidization through peep holes.
 Drain the bed do check for unusual combustible in the bottom ash.
  Check fan unusual noise for steam/pumps.
 Check vibration in rotary equipment
 Check for air/gas leakage from dust & flue
 Check for hot spots bulging etc. on casting dusts etc
 Check the position of damper & cleanliness
 Check the bearing for lubrication & cooling water system.
 Check all alarm annunciations with respect to set position.
 Check for water, oil along with instrument air.
 Check for any unusual smoke conditions.

Do’s For Fbc Boiler

 Clear the materials before closing the man holes of pressure parts furnace & ducting.
 Maintain all instruments in good worker condition.
 All equipment interlocks should be always in line.
 Maintain normal water level in feed water tank, deaerater tab & boiler
 Maintain normal water quality as per the remedial limits.
 All dampers must be on smooth operation condition.
 Pressure rising from cold start must be done as per the cold start up curve.
 All the duct joints must be leak proof
 Use proper lubricants recommended by the manufacture regularly
 Boiler, piping, duct, feed water & oil tank must be properly emulated.
 Servicing of equipment should be done as per the manufacturer’s schedule.
 Maintain proper operation log sheets regularly
 Maintain the air face from moisture & oily matter of the pressure as recommended.
 Come out regular closing of direct water level gauges glass on feed water tank, deaerater
tanks & boiler drum.

Don’t’s For Fbc Boiler

 Don’t by pan any instrument of safety interlock
 Don’t throw water as boiler feed water.
  Don’t throw big size, wooden logs inside the furnace for slow firing
 Don’t start any fan with suction damper in open condition
 Don’t start any pump with the delivery valve in open condition
 Don’t run the boiler with furnace in pressurized condition
 Don’t throttle the feed water pump balancing leak off value while the pump & in
operation
 Don’t operate the furnace wall header drain valves while the boiler is in operation
 Don’t operate the boiler beyond the operation limits.
 Don’t leave the furnace door open while the boiler is in operation
 Don’t mix up different lubricants
 Don’t by pass compressed air dryer, if any problem attends to it at the earliest
 Don’t throw water inside the hot furnace.

Result: - In this way we have studied how to maintain FBC boiler.

EXEPERIMENT NO. 8
AIM:- Maintain temperature and feed water control system by using charts, models, simulation
and videos.

APPARATUS:- Charts and videos.

Description: -
1. Proper boiler feed water temperature management:-
 Prior to it entering the boiler, the plant manager has the opportunity to control both the boiler
feed water temperature as well as its quality. This involves introducing treatment and heating
that will provide optimal conditions for a long boiler life.

2. The issue of improperly heated feed water:-

An “Improperly Heated Feedwater” condition occurs when the feedwater coming to the
boiler is not adequately heated. Improperly heating feed water results in lower boiler efficiency,
incomplete mechanical deaeration, and can cause cracking and catastrophic failure to the
feedwater lines, boiler shell, and boiler tubes through thermal shocking. Low temperatures can
affect the boiler feed water quality as well, as it will result in higher levels of dissolved gases,
oxygen and carbon dioxide, that will corrode the internal metal surfaces the water comes in
contact with. Thermal shock also occurs any time there is a sudden change in temperature of a
metal or uneven temperatures throughout the boiler. Metal expands and contracts in relation to
temperature and temperature fluctuations may result in cracking at local sites of temperature
swings, boiler tube leaking, cracking of the tube sheets, or catastrophic boiler failure.

3. How to adjust your boiler feed water temperature:-

Pre-heating the feed water to achieve an ideal boiler feed water temperature will allow the
boiler to run most efficiently as the heat input required to raise the temperature of the water up is
reduced. The difference between 140°F and 180°F in boiler feed water temperature equates to
about a 3-4% difference in boiler efficiency. Feed water preheating typically occurs in either the
feed water tank or deaerator using supplementary steam. Pre-heating the feed water is the most
basic method of mechanical deaeration, or the process of removing dissolved oxygen from water.
According to the National Board, 70°F water at 0 psig contains approximately 8.6 ppm, 150°F
water at 0 psig contains approximately 4.3 ppm, and 212°F water at 0 psig contains
approximately 0.0 ppm. To avoid the “Improperly Heated Feed Water” condition described
above, the boiler feedwater should be heated to at least 180 °F when using a feed water tank and
227 °F when using a deaerator. This will minimize the chemical treatment required, provide
adequate mechanical deaeration, and greatly reduce the thermal shock experienced on the
internal components of the boiler.

4. The importance of boiler feed water chemistry

Although temperature plays a vital role in boiler feed water quality, it’s important to
remember to maintain your boiler feed water’s chemistry at acceptable levels. Untreated water is
full of minerals, gases and particulates that can cause critical damage to the health of both fire
tube and water tube boilers. Unless your boiler receives water of proper quality, the boiler’s life
will be needlessly shortened. The removal or otherwise ‘treatment’ of each of these is critical to
efficient boiler operation for different reasons. Each water supply source requires an independent
analysis. Depending upon this analysis, various pretreatment methods may be employed to
prepare makeup water for your boiler feed water system. Maintaining appropriate feed water
temperature and boiler feed water quality will help to ensure the boiler remains safe, operational,
and failure-free for many years of service.
Results:- In this experiment we have studied about how to maintain temperature and feed water
control system.