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Welcome

to

My Presentation

Presentation on

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An Overview of 16MW

PRAN

Power Stations

Prepared

by

Md.Salim Bhuiyan

ID#11105037

Prog#BSEEE

27 December 2014

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IUBAT-International University of Business Agriculture and Technology

Contents

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Introduction

Objective

Company overview

Power generation system

Operation and Distribution

Recommendations

Conclusion

Introduction

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Electricity generation is the process of generating electrical

power from other sources of primary energy

Electric Energy is the most popular form of energy

Due to failure of national grid, private industry and owners are

using their own power plants & generators combining with

national grid to meet the demand of electricity

Objective

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Broad objective:

The prime objectives of this practicum project are to extrovert my theoretical

knowledge to the practical field and understanding the performance of the

parameters in case of Power Generation, Operation, Distribution etc

Specific Objective:

To study on Power Generation Process

To study on Controlling Apparatus and maintenance

To coordinate the theories of power generation in a real life Situation

To perform in line with organizational needs & goals

Company overview

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PRAN STANDS FOR

Organization Overview

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PRAN started its operation in 1981 in Bangladesh

Bangladesh’s largest grower and processor of fruits and vegetables

PRAN Export 94 Countries of the world recently

PRAN at A GlanceCompany Name PRAN-RFL Group

Started its operation 1981

Business Type Manufacturer, Trading Company, Buying

Office, Distributor/Wholesaler

Mission “Poverty and Hunger are curses”

Vision “Improving Livelihood”

Company Aim To generate employment and earn dignity

and self-respect from compatriots through

Profitable Enterprises

Product/Service Juice, Drinks, Confectionary, Dairy,

Snacks, Powder Packed Spices

Number of Employees 58000

Export Inception 1991

First Export Country France

Total Export Countries 949

Power Generation System

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PRAN Power Station

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Main apparatus :

1. Generator

2. Alternator

3. Power panel

4. Bus bar

5. Power factor improvement plant (PFI)

6. Chiller

7. Different types of circuit breaker

8. Conventional copper wire

9. Current transformers

10. Potential transformers

11. Measuring instruments and so on

Introduction to a Gas Generator

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A gas generator usually refers to a device, often similar to a solid rocket or a liquid

rocket that burns to produce large volumes of relatively cool gas, instead of

maximizing the temperature and specific impulse

Fig : 1.5 MW Caterpillar G3516C Gas Generator of PPS

Specification of Caterpillar

G3516C Gas Generator

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Maximum continuous rating 1605 eKW

Fuel type Natural gas

Maximum electrical efficiency 40.1%

Maximum standby rating 1500 KW

Frequency 50/60 Hz

rpm 1500/1800 rpm

Engine model G3516C

Length 217.0 in

Width 72.0 in

Height 92.0 in

Dry weight genset 30315.0 Ib

Power Generation Process

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Though a generator is a single device that functionally converts fuel into

electricity, it is, in essence, two separate components that work together in

order to produce power

The two components- The engine and the electromagnetic generator are

connected by a crankshaft, facilitating the easy transfer of the mechanical

energy produced by the engine to the magnets of the generator assembly

A diesel engine burns diesel fuel where a gas engine burns natural gas in order

to produce mechanical energy in form of rotation, for the generator, which

converts the mechanical energy into electricity by using electromagnet

Working Procedure of a

Generator

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A generator consists of a rotating magnetic field called a Rotor and a stationary

coil of wire called a Stator

Natural gas generators, use natural gas (methane) that utilities supply through

underground lines to generate electricity

An internal combustion engine injects a mixture of fuel and air into a

combustion chamber, where a piston compresses the mixture

A spark plug ignites the fuel, driving the piston down and turning a crankshaft

Cont…..

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The crankshaft, in turn, spins the generator's rotor in an electromagnetic field

As the rotor turns, its magnetic field cuts across the stationary stator. A voltage

is induced into the stator windings. Regulated current delivered to the rotor is

called "Excitation" current

Excitation winding unregulated AC output is delivered to an electronic voltage

regulator

When an electrical load is connected across the Stator power windings, the

circuit is completed and an electrical current will flow

Cont…..

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Generating an electric current that can charge batteries, power appliances or even

run high-wattage tools, depending on the generator's size

Fig :Block diagram of a Gas Generator

Speed & Frequency

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The rotational speed of an alternator depends on the number of poles and the output

frequency.

The relation equation between speed and frequency is ,

Where

f = Frequency in Hz

P = Number of poles

N = Rotational speed in rpm

Poles RPM at 50 Hz RPM at 60 Hz

2 3000 3600

4 1500 1800

6 1000 1200

8 750 900

Main components of a generator

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The main components of an electric generator can be broadly classified as

follows:

(1) Engine

(2) Alternator

(3) Fuel System

(4) Voltage Regulator

(5) Cooling and Exhaust Systems

(6) Lubrication System

(7) Battery Charger

(8) Control Panel

(9) Main Assembly / Frame

Fig: Main Components of Generator

Engine

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Engine is the source of the input mechanical energy to the generator

The size of the engine is directly proportional to the maximum power output the

generator can supply

Fig: Engine set

Alternator

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The part of the generator that produces the electrical output from the mechanical

input

Contains two parts-

a. Stator – This is the stationary component. It contains a set of electrical

conductors wound in coils over an iron core

b. Rotor – This is the moving component that produces a rotating magnetic field

in any one of the following three ways:

(i) By induction

(ii) By permanent magnets

(iii) By using an exciter

Fig: alternator

Fuel System

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The fuel tank usually has sufficient capacity to keep the generator operational

for 6 to 8 hours on an average

Generator engines operate on a variety of fuels such as diesel, gasoline,

propane or natural gas

Smaller engines usually operate on gasoline while larger engines run on diesel,

liquid propane, propane gas, or natural gas

Automatic Voltage Regulator

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A voltage regulator is an electrical regulator designed to automatically

maintain a constant voltage level

A "Reference" voltage has been preset into the Voltage Regulator

An "Actual" ("sensing") voltage is delivered to the Voltage Regulator via

sensing leads

If actual (sensing) voltage is greater than the preset voltage, the Regulator will

decrease the regulated current flow to the Rotor

If actual (sensing) voltage is less than the preset voltage, the Regulator will

increase the regulated current flow to the Rotor

Cooling & Exhaust Systems

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Cooling System

Continuous usage of the generator causes its various components to get heated up

Essential to have a cooling and ventilation system to withdraw heat

Fig: cooling tower

Exhaust System

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Exhaust fumes emitted by a generator contain highly toxic chemicals that need to be

properly managed

In PRAN exhaust fumes use in a boiler to produce steam

Fig: smoke tube boiler

Lubricating System

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Moving parts of engine requires lubrication to ensure durability and smooth

operations for a long period of time

Internal combustions engines require lubrication in operation that moving parts

slide smoothly over each other

Insufficient lubrication causes uneven metal-to-metal contact, friction, heat

build-up etc

Battery Charger

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The start function of a generator is battery-operated

Starting motor of a generator is operated by 24v D.C battery

The battery charger keeps the generator battery charged by supplying required

voltage

All generators have customized housings that provide a structural base support

frame also allows for the generator to be earthed for safety

Main Assembly / Frame

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Operation and Distribution

Single Line Diagram

29Fig: Single Line Diagram of PPS

Flow chart from power generation to

distribution of PPS

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GENERATOR

Power Panel Circuit

Breaker

Bus Incoming

Main Bus Bar

Bus Out Going

Main Distribution

Board

(MDB)

Distribution Board

(DB)

Power panel

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Generated power from the generator first come to the power panel by 3 phase

system

In a power panel there is one ACB

Fig: Power panel

Bus Incoming

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From the power panel through wire power come to the bus incoming

Fig: Bus incoming

Main bus bar

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A bus bar is a band of copper or aluminium that conducts electricity within a

switchboard, distribution board, substation, battery bank or other electrical

apparatus

Fig: Main bus bar

Bus Out going

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From the main bus bar power then come to the bus out going’s incoming

terminal

Fig: Bus outgoing

Main Distribution board

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Generated power then come to the main distribution board

Fig : Main distribution board

Distribution Board

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Distribution boards are common place in most industrial installations and

commercial or residential buildings

From this DB power supplied to the required sites

Fig : Distribution board

Power Factor Improvement (PFI)

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Advantages of power factors improvement :

Reduced Demand Charges

Increased Load Carrying Capabilities

Improved Voltage

Reduced Power System Losses

Fig: inside view of a PFI

Demand vs. Capacity

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Total demand of power is 12 MW

Installed capacity is 16 MW

Fig : Total power

Cost Analysis

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Using Gas

Required gas for producing 1 KWh electricity = 0.30 m3

1 m3 gas = 4.20 tk.

1 KWh = (4.20 x 0.30= 1.26 tk.)

Using Diesel

1 KWh electricity cost = 18 tk.

From REB

1 KWh electricity cost = 6.30 tk.

Recommendations

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Need to think about other renewable energy source

For better efficiency they should use close type cooling tower instead of open

type

Instead of using conventional copper wire they need to think about using

BBT(bus bar trunking system)

Cont…..

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Renewable energy:

Gas is the main fuel source at PRAN power station and we are running out of it

Wind, solar, and biomass are three emerging renewable sources of energy

Solar energy can play a vital role in PRAN power stations

Possibilities:

If they able to use solar panel directly to their production machineries they can

get backup of power they required

Dependency on gas can be minimized

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Fig: BiomassFig: Wind turbine

Fig: solar panel

Cont…..

Open type cooling tower Close type cooling tower

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Less efficient

greater amount of water loss

Low cooling capacity

More efficient

No water loss

High cooling capacity

Fig : open cooling towerFig : close cooling tower

Cont…..

Conventional copper wire BBT (bus bar trunking system)

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Required more space

Less energy efficient than BBT

Not much economical

Less flexible than BBT

Compactness

Energy efficiency

Flexible

Safe & reliable

Economical

Fig: copper wire Fig: BBT

Conclusion

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In electricity crisis of Bangladesh the own power generation is a matter of

happiness which is done by PRAN-RFL Group. The main reason for the power

crisis is the shortage of supply. Demand is never meet by supply. Generation of

power needs to be increased transferred to the desired distribution centers of

power.

It had been a great experience for me. I am very glad that I did my internship in

such a field where I learned many things about power generation and

controlling system, which will be very helpful in my professional life.

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