INPLANT TRAINING REPORT

AT
D.C.R.T.P.P
(Yamunanagar)

In the partial fulfillment of requirement for the award of degree

of
Bachelor of Technology
(Mechanical engineering)

From

Kurukshetra University, Kurukshetra

Submitted by:
(RAMMEHAR)
(1708594)
AUGUST, 2010

DEPTT OF MECHANICAL ENGINEERING

HARYANA COLLEGE OF TECHNOLOGY & MANAGEMENT,
KAITHAL
 FOREWORD

I was required to undergo on six weeks training during the 19 th july to 2nd September

towards the partial fulfillment of my B.Tech. Being a student of mechanical Engineering. I choose

to undertake this training at a Mechanical Engineering, since it is a highly progressive sector these

days, and the demand for power is on a rise. Therefore, I landed up at DCRTPP, Yamuna Nagar,

one of the largest power stations in Northern India and the main source of Electric power for the

state of Haryana, whose demand is estimated at around 600 MW. The training was a great

learning experience and I have tried to put what I learnt, through these pages.

2
 PREFACE

Electricity is one of the most convenient and important source of energy electricity is used

at home and in industry for various purposes such as lighting, heating operating machine and so

on.

Therefore, generation of electricity holds important place in our society. The generation of

electricity and its per capita consumption is an index to the prosperity of a nation. Man has found

a no. of ways to generate electricity. he began by tapping the energy generated by chemical

reaction for e.g., in a Daniel cell. However, this form was suitable only for very small application.

In addition, large amount of electricity could not be generated using this method and the output

voltage was not suitable. Therefore, man sought new ways of electric power generation. In this

question he invented huge power plants. The early plants used wood to generate steam for water,

which in term used to drive an electric generation. However, this quick depletion of forests led

man to look for alternative source of power. The power of falling water was used to generate

electricity. However, a need was felt for more power generation. In addition, the Hydel-power

station was costlier and tougher to establish, even though the cost of operations was lower

consequently, in the midtwenthieth century, coal was found to be a technologically and

economically viable option for steam power generation. Today, most of the world's electric energy

needs are met using coal Nevertheless, the progress can never stop. Even this cheap alternative

has some limitation. The greatest problem is that of ash disposal. A huge amount of ash is

generated in a coal-based station and it is highly harmful for man and his environment. According

to some experts, for sustainable development because of its low long-term availability can only be

a transition fuel. Indeed, hydrogen is stipulated to be the fuel of the future.

As such the consistent growth of power is vital to meet our day-to-day- requirements and

improve the living standards.

3
 ACKNOWLEDGEMENT

My training at Yamuna Nagar Thermal Power Station has been more than a learning

experience. It has been a pleasure learning and working with people who shared their knowledge.

I am immensely grateful to Er. J.P. Dhiman (XEN/BMD-I) for providing me an opportunity to

undergo training in the plant. I am also thankful to Er. Jagdish Chander Hooda (AE/BMD-I) and

all the staff members of division for their valuable guidance during my training.

I would also like to thank the training in charge of HARYANA COLLEGE OF

TECHNOLGY AND MANAGEMENT, KAITHAL and all the faculty members of

MECAHNICAL ENGINEERING department for their constant effort and co-operation

which have been significant factor in accomplishment of my industrial training.

Submitted To: Submitted By:

Arvind Kumar RAM MEHAR
Asst. Prof. in Mechanical
Mechanical Dpet. (1708594)

4
Table Of Contents :
Contents Page No.

1. Evolution of Thermal Power Plants in India 5

2. Introduction of D.C.R.T.P.P. 6

3. Three Major Input of D.C.R.T.P.P. 7

4. Different process undergoes at D.C.R.T.P.P. 9

a. Coal Handling

b. Combustion

c. Steam Generation

d. Electricity Generation

e. Feeding Water

f. Ash Disposal

5. Emission in Thermal Power Plant 39

5
 EVOLUTION OF THERMAL POWER PLANTS IN INDIA

The history of thermal power plants in India detes back to 1988 when the first station was

commissioned in Calcutta with an installed capacity of 1000 KW. During the first two decades of

the twentieth century steam power station at Kanpur, Madras and Calcutta of 2170 KW, 9000

KW, 15000 KW capacity respectively were commissioned. By the end of 1920 the total installed

capacity of thermal power plants was 50 MW. The installed capacity in 1951 was 1000 MW.

Efforts for organizing the power supply in industry in a rational manner began only after

the independence. With the launching of first five year plan in 1951 installed generating capacity

increased by 200 MW. During this plan the total thermal power generating capacity raised up to

1520 MW.

If we see the history of thermal power plants in Haryana we find the first plant of 15 MW

capacity was installed at Faridabad in 1960. After that five units of 60 MW each were installed in

1979, 1981, 1982, 1983 and 1985 respectively. Two units of capacity 110 MW each were installed

at Yamuna Nagar Thermal Power Station in 1979-1980 after the two more units of same capacity

were installed in 1985-1986. Fifth unit of 210 MW capacity was also commissioned by PTPS in

year 1990.

Thermal Power Plants in India

According to Central Electricity authority of India, there were 83 coal fired thermal power

plants and 305 hydro plants existing in India on March 31, 1998. Thermal power (Coal, Diesel

and Gas) generation during 1997-98 was 338104 and hydro power generation was 74582 GWH.

In addition to this, there were 1685 selected industrial units which had captive thermal power

plants of >1MW in 1997-98. The total installed capacity of captive plants was 13004 MW and

these had gross generation of 44050 GWH (i.e. 13% of the public utilities' generation) during the

year 1997-98.

6
 INTRODUCTION OF D.C.R.T.P.P.
The DEEN BANDHU CHHOTU RAM THERMAL POWER PLANT is a project under HPGCL

in Haryana. It is located in distt. Yamunanagar. In D.C.T.R.P.P power generation is based on

coal.It is stand cpacity 300MW in the total area 1107 acres since 2008. It is the first plant in

Haryana which produces the electricity at a very low cost of Rs. 3.49 Crore per MW.It was

the third power plant in Haryana which is completed under the Reliance Energy Ltd, The ideal

plant location in considered in term of aggregate cost advantages emerging from varing and

conflicting sectors.

7
 THREE MAJOR INPUTS TO POWER STATION
1. Water

Water for the power station has been taken from nearby Yamuna canal. This water is lifted

as raw water is stored in clear well where it is sent to the clarifier to remove turbidity in

water. the clear water is stored in the clear well form where it is sent to water treatment

plant, cooling water system and the service water system. The water treatment plant is

filtered and demineralized. The DM water is stored in storage tanks for the use in bioler

and filtered water which is not demineralized is sent plant and colony for personal use with

the help of portable pumps.

2. Fuel Oil

In the power station two types of oils are used for the initial preheating of the boiler.

a) LSHS (Lower Sulphate High Stock Oil)

b) High Speed Diesel Oil

c) Heavy Furnace Oil

The high speed diesel oil reaches the power station through the lorry tankers. The oil is

stored in large storage tanks for the future use in the boiler.

The heavy furnace oils comes in rail tankers. As the oils is thick, the oil is heated in bulk

storage coils. Heavy furnace oil is burnt in furnace after the atomizing with the steam.

Foe efficient burning of oil, the oil and the air is to be mixed thoroughly so the oil has to

be broken into the finer particles to readily combine with the air for combustion. This is known as

the atomization of oil. Atomization of oil can be done in following two ways.

1) Mechanical pressure atomizing.

2) Atomizing through external source.

8
 At D.C.R.T.P.P. atomizing with steam id done. In this method steam at the higher pressure

than oil is admitted into the burner, where it mixes with oil and breaks into finer particles on

emerging from the burner for combustion in the furnace.

High-speed diesel oil is stored in the storage tanks in oil storage yard and is conveyed to

the boiler front through as set of pumps and strainers. The atomizing medium for the light oil is

compressed air and is supplied from the plant service air system.

Heavy oil is storage tanks in oil storage yards and is conveyed to the front through a set of

pump and strainers. The whole length of piping from the boiler front is steam traced to maintain

the temperature and hence its fluidity so that it can freely flow in the pipelines.

3. Coal

The coal reaches the plant in the railway wagon. The unloading of coal is done

mechanically by tilting the wagons by tippler. The coal is sent to the coal storage yard

through the conveyor belts. The crushed coal from store is sent to the mill bunkers through

conveyor belts.

The air which takes away the coal dust passes upward into the classifier where the

direction of flow is changed abruptly. This causes the coarse particle in the air coal steam

to finer coal dust along with the primary air leaves the classifier onto the coal transport

piping from where it goes to nozzle. Pulverized coal obtained from coal mill cannot be

burnt directly.

9
DIFFERENT PROCESS UNDERGOES AT D.C.R.T.P.P

COAL HANDLING

1. Raw Material

2. Coal Transportation

3. Coal Unloaded

4. Preparation

5. Coal Conveyer Belt

6. Coal to Crusher

7. Coal Mill

10
 COMBUSTION

Furnace

The furnace which is employed in the D.C.R.T.P.P. is tangential fired. The furnace is

consist with coal nozzles, oil guns, igniter provided in each corner of the furnace. The six coal

nozzles and three air guns are provided at each corner of the furnace.

To start up the furnace the heavy furnace oil is sprayed by oil guns and it is fired by the

spark provided by igniter. when the desired temperature for burning of coal is achieved the

pulverized coal is used instead of the heavy furnace oil to provide the safety of igniter from the

high temp of furnace coal air is supplied.

FD Fan

The FD Fan is called Forced Draft Fan. The FD Fan move the air/gas continuously against

the moderate pressure. They feed the hot air in the boiler. FD fans are used in boiler for different

11
application, such as supplying air for combustion, removal of combustible products and air for

coaling equipments working at hot zone etc. it seeks the air from the atmosphere.

The FD Fan used in this unit is of axial type multistage pump which is made in Germany.

These are powered by electric motors. The no. of working fan in this unit are tow.

PA Fan

PA Fan is called Primary Fan. The purpose of primary air fan is to provide air at desired

pressure for carrying the coal from the coal mills to the furnaces. The air from the primary

air fan passes through the primary air preheater before entering the coal mill is to remove

moisture from coal particle and to provide required temp for proper burning of pulverized

coal. PA fan are used in this unit is also of axial type and it sucks the air from the

atmosphere. The no. of PA fan used in this unit are two for proper supply of primary air.

Air Heater

There are two types of air heater in used the first one is primary air preheater and other one

is secondary air heater. The air from FD fans passes through the secondary air heaters. A & B and

air from PA fans passes through primary air preheater. The purpose of using air heaters is to heat

air supplied to the furnace up to the required temperature for proper burning of full. The flue gases

come out from the furnace is used in air pre-heater to heat the air. The air rotary type b/w

economiser and electrostatic precipitator.

Burner

There are twenty four total pulverized coal burners arranged on the corner at the height of

18 to 26 m and twelve oil burners provided each in b/w two pulverized fuel buener. The

pulverized coal burner are arranged in such a way that six mill supply the coal to burners at 4

corners, of the furnace. All the nozzle of the burners are interlined and can be titled as a single

unit from +300 to -300

12
Igniter

There are twelve sides eddy plate oil igniter per boiler and capacity of each igniter is 50

kg/hr. The ignitor are located at AB, CD, EF. Four ignitor at a time. The ignitor are used for start

up coal flame stabilizing. there are two ignitor air fans are also provided in ignitor air system one

working and other standby. The design capacity of each fan is 1030 m3/hr and temp. and pressure

500C and 220 mmwc respectively.

STEAM GENERATION

Boiler

Boiler is a mechanical device used for producing steam under pressure. These are mainly

tow type of boiler.

a) Fire Tube Boiler

b) Water Tube Boiler

13
 In the fire rube boiler, the hot air passes through the pipes and the water flows around the

pipes and get heated.

In the water tube boiler, the water flow through the pipes and hot gases flow around the pipes and

water in the pipes gets heated.

Boiler used in this unit is water tube boiler. In the boiler the heat energy transfer takes

place through the tube walls. It is provided with water drum to maintain construction head of

feeding water. the steam generated in the boiler is firstly fed to super heater where the steam is

heated to super saturated state by the heat of flue gases. Boiler is provided with several mountings

like Pressure Relief valve, pressure Gauge, water indicator, temperature measuring devices etc.

When the vapour pressure in the boiler shell exceed the desired pressure. Then pressure

relief valve comes in play and maintain the required pressure relief valve may be spring operated

or dead weighted type.

Pressure Gauge provide the information about the pressure in the boiler shell. This is

employed with calibrated dial Guage or may be digital type.

Water level indicator indicates the exact water level in the boiler drum. The temperature

measuring devices are also used to measure the temperature inside the boiler.

The hot gases of the furnace comes in contact with water tubes of the boiler. The heat

transfer take place through the tube walls. Thus the water in the tube get heated. the hot water

vapours goes up and fresh water gets enter. After heating by the flue gases water converted into

wet steam. This steam goes to the super heater, where the temperature and pressure of the steam is

increased by heat of fuel gases. This super saturated steam fed to the HP turbine.

14
Super Heater

Super heater are meant to raise the steam temperature above the saturation temperature by

absorbing heat from the flue gases. It is placed just after the drum. By increasing the temp

of steam, efficiency of cycle is increased. Super heater desuperheater are provided in b/w

the LTSH> Section & played super heater for controlling super heated temperature.

Reheater

Reheater is placed b/w the HP turbine and IM turbine after the expansion in HP turbine,

the steam goes to the reheater. In the reheater the temp and pressure of the steam is again

increased. After that this steam is fed to the intermediate turbine. The steam is heated in the

reheater by the heat of flue gases, which are come from super heater after being processed.

15
Re-Generative System

It is the most important system in thermal power plant, to prevent wastage of de-

mineralized water. It is that system in which the electricity generate by the reuse of steam and

water.

In this system when steam is generated by the boiler at temp. 5400C and the pr.139kg/cm2

that steam goes through the pipes in the high pressure turbine's impeller revolves at high speed

then steam is goes to reheater for reheating, then steam is goes to IP turbine (intermediate

turbine). The steam has the same temperature of HP and pressure 34lgc2, after using the steam in

IP turbine, the steam is goes to LP turbine HP, IP, LP and generator are coupled by the rotor shaft

at same centre and radius. The turbine revolves the generator and generate the electricity of 250

MW. After use of steam in LP turbine, the steam goes to condenser to condensate the steam.

16
When steam is converted into water, water goes to hot well and hot water in the pipe of

condenser; hot water goes to cooling tower.

From the hot well the water goes to CEP. CEP is condensate extinction pump, which

pumps the water to ejector at temp. 400C and pressure 0.188 kg/cm2. Then water goes to LPH1.

(Low Pressure Heater) at temp 46.1400C and pressure 0.407 kg/cm2. Then water is heated by the

steam, which comes to HP turbine, it gives the heat to water and converted to cold water and go

back in hot well. The water of LPH1, goes to in the LPH2. The water is heated by the steam which

come to the LP turbine. The steam increases the temp. of water. Then water goes to CSC

(Chimaney Steam Condenser) where the water is heated by the steam which comes to the sealing

of the turbine.s Then water goes to GSC (Gland Steam Condenser). It also take the steam from the

gland sealing of turbine and heated the water at temp. 80.20 0C and pressure 0.952 kg/cm2. then

water goes to LPH3. It takes steam from the LP turbine for increase the temp. at 94.76 0C and

pressure 2.20 kg/cm2. After that water goes to LPH4. The steam comes to the IP turbine. Here the

temp. is reach 121.60C and pressure 5.133 kg/cm2. after that water is goes to LPH5 where the

steam is comes to the IP turbine which increase the temp. of water at 150.90C at this temp, the

water is goes to deareater where the steam comes to the IP and increase the temp. and pressure at

1580C and pressure 9.36 kg/cm2.

From the deareator the BFP suck the water pump it to HPH1 (High Pressure Heater).

HPH1 takes the steam for heating the water from IP. It increase the temp. of water and water goes

to HPH2. It takes the steam for heating the water from the HP turbine at pressure 32.12 kg/cm 2.

After that the water goes to boiler at temp. 230.950C. This water cycle is running continuous in the

thermal power plant.

17
 ELECTRICITY GENERATION

Steam Turbine

A prime mover in which firstly the energy of the steam is transformed in Kinetic energy

by means of nozzle. Then the K.E. of the impacting jet is converted into force doing works on the

rings of blades mounted on a rotating part is known as steam turbine.

In steam turbine there is direct conversion of heat energy into mechanical energy & this

energy is directly available at the rotating shaft.

18
Classification Of Turbines :

1. Impulse and Reaction Turbine

a) A turbine in which the steam expands in nozzle and remains at constant pressure

which passing over the blades is known as impulse turbine.

b) A turbine in which the steam pressure decreases gradually while expanding thought

he moving blades as well as its passage through the fixed blades (nozzle) is known

as reaction turbine.

There are most important classification.

1. According to the Number of Pressure Stages

a) Single stage turbine with one or more velocity stages usually of small capacity.

b) Multistage impulse & reaction turbine; they are made in a wide range of power

capacity varying from small to large

Here we use multistage turbine.

2. According to the direction of steam flow

a) Axial turbine in which steam flows in a direction parallels the axis of the turbine.

b) Radial turbine in which steam flows in a direction perpendicular to the axis of the

turbine; one or more low pressure stages in such turbines are made axial.

Here we use axial turbine.

3. According to the number of cylinders

a) Single Cylinder

b) Multi Cylinder

4. According to the steam condition at inlet to turbine

a) Low pressure turbine using steam at a pressure of 1.2 to 2 Ata.

b) Medium pressure turbine, using steam at pressure of upto 40 Ata.

19
 c) High pressure turbine utilizing at pressure above 40 Ata.d) Turbine of very high

pressure utilizing steams at pressure of 170 Ata & Temp. of 550*C.

e) Turbine of supercritical pressure using steam at pressure of 225 Ata and above.

Here we use high -pressure turbine.

5. According to their usage in Industry

a) Stationary turbine with constant speed.

b) Stationary steam turbine with variable speed

c) Non stationary turbine

Here we uses stationary turbine.

Blade M-------aterial

(a) Low Temp. Zone

Machined from bar material or from forging of Ferro magnetic corrosion resistance

chromium steel (*20 or 13).

(b) High Temp. Zone

Machined from bar material of chrome molybdenum vanadium steel *20 or

mov 121.

Blades

Shapes of balde (a) Cylindrical

(b) Twisted

Two types of stress exit on baldes

(a) Static Stress

Static stress is used to denote tensile stress as a result of centrifugal force. This is same for

both shape.

(b) Dynamic Stress

Alternating in nature & due to vibration of blades.

20
Rotor System

1. HP Rotor

It is integrate type because of high temp. HP shaft is monoblock forging. This means, the

Curtis and 8 other moving wheels, the thrust collar and flange for the HP-MP coupling is

forged internally with the main shaft. The shell has a longitudinal axial bore to conduct

boroscopic tests. The material taken out from this bore is used to determine the quality of

rorging. This bore incidentelly helps in better warming up of the shaft during starting.

It has 8 moving wheels spart from the Curtis strage of two sheel.

2. MP/IP Rotor

MP rotor is also a forging with a central hole for boroscopic tests. It has 12 moving wheels

of which first 8 are forged integrally and the last 4 are separately machined and shrunk on

to the shaft. Moving blades of the integrally forged wheels. The blades of the last stage are

made from forged profiles. Other blades are mulled out of bar stock.

All the moving wheel discs have press equalizing holes.

3. LP Rotor

This is of built up type. LP rotor is of double flow type. There are four shrunk on wheels in

each flow the interference being such that releasing of wheels does not occurs at any of the

expected operation condition

All the blades are fixed to the wheels by means of rivets. Blades of the first two rows are

made from rolled bars stock materials and those of third and the fourth wheels in each

flow are twisted in profile and are flame hardened at the inlet edge. They are dies forged.

21
Material Selection

It is based on following consideration:

(1) Capability of with standing the high temp. and press of steam.

(2) Material in the last zones of the turbine must withstand the corrosion and erosion effects of

the wet steam in these zones.

(3) Capable to withstand the strees developing during operation.

(4) Material selected should no yield higher dimension changes during operation due to temp.

or impress stress.

The material selected based on the above consideration should also satisfy the

manufacturing requirements.

The material chosen for various components are given below: -

1. Main steam stops, interceptor and governing valves.

Casting of chrome vanadium molybdenum steel GS 17 Cr. Mov 511.

2. HP & MP Rotor

Forging or chrome vandium molydbenum 21 Cr. Mov 511.

3. LP Rotor

Forging of chrome nickel molybdenum 21 Cr. Mov steels 36 CR NL MO4.

4. HP & MP inner casing

Chrome

5. HP & MP outer casing

Molybdenum vanadium steel Gs 17 Cr. Mov 511.

6. LP Casing

Front and rear parts fabricated from mild steel plates, middle part cast from cast iron.

7. Blade Material

22
 (a) High Temp Zone

Machined from bar material of chrome molybdenum vanadium steel * 20 Cr. Mov

121.

(b) Low temp. Zone

Machined from bar material or from forging of Ferro magnetic corrosion resistance

chromium steel (*20 Cr. 15).

Blading Design

Balding design consists of determining the following steps

(1) Selection of no. of stages

Axial Shift or rotor

The axial displacement of the rotor from its position is measure by means of a suitable

measuring device and the same is indicated and recorded continuously.

The thrust collar a part of turbine rotor exerts a press against the thrust shoes, which are

located on both sides of thrust collar. A small axial displacement is occurs when the electrical load

on the m/c is changes or due to the wear of the thrust shoes.

The measurement of axial shifts makes use of an electromagnetic pickup. The pickup is of

contact less differently transformer type. The pri winding of the pickup is supplied with a 240 v

supply through an insulating transformer, when the rotor and collar move, the air gap in b/w the

pole shoes and the collar vary which induces proportion v in the sec winding of the pickup. This

voltage is taken to the indicator ckt. for measurement. The above voltage signal is also fed to a

relay which operates on a preset value to a trip the unit in case of excessive rotor movement.

To have a foolproof tripping of the unit in cases of abnormal axial shifts of rotor, a

hydromechanical protection is also incorporated. In this system the tube oil is supplied to a slide

which moves along the rotor in case of its movement. As the rotor movement is occurring, the

draining of oil, which is due to the movement of slide, reduces the press of oil. When the

23
movement is 0.7 mm, the press drop in the oil is communicated, through a Monistat which gives a

tripping impulses to the turbine.

Before setting of the axial shift extreme limits are set with the rotor press the thrust shoe

towards the governor (normal position taken as 0 mm).

Differential Expansion of Rotor and Cylinder

When steam is admitted in turbine thermal expansion effects both the rotor and casing,

these will be no problem, but since the rotor is of a lighter mass than the casing, it will heat up fast

and therefore expands faster than the casing. Axial clearance b/w stator and rotor is are provided

to allow diff. expansion of the turbine.

Making use of electromagnetic pick-ups carries out the measurement of different

expansion of rotor and stator. There are two coils mounted with equal air gaps on both sides of the

reference collar when the rotor is pressed towards the generator. This position of the rotor with

reference collar in the middle is 0 position. The pri winding of pickup motor is fed with AC

voltage. When the unit is heated up and axial movement is occur the air gap on one side is

increases. This cause on tube in the circuitry and an electrical o/p signal proportional to the

different expansion is fed to the indicator recorder for measurement.

SHAFT ECCENTRICITY: When a unit is shut down the turbine rotor will tends to low

because of uneven cooling b/w upper and lower half of rotor. By rotating the rotor slowly on

turbine gear uniform heating of the rotor results, allowing the rotor to run true. Eccentricity

monitoring system enables the operating personnel to keep a constant watch over the rotor

deflection steady as well as changed condition of operation of turbine.

Shaft Eccentricity

When a unit is shut down, the turbine rotor will tends to bow because of uneven cooling

between upper and lower half of turbine rotor. By rotating the rotor slowly on turbine gear

uniformly heating of the rotor results, allowing the rotor run true. Eccentricity monitoring

24
enablesthe operating personnel to keep a constant watch over the rotor deflection during study as

well as changed condition of operation of turbine.

Bearing Vibration

Bearing vibration is one of the most imp parameter of to be monitored in the turbine

during the running condition. Excessive vibration may lead to mec. failure of turbine component

and called for extremely reliable monitoring system. Vibration picks up mounted on the bearing

for the vibration measurement.

The vibration detector consist of two permanent magnet rigidly fixed to the casing. The

two magnetic coil assemblies are arranged to sense vibration in to mutely perpendicular

directions. The e.m.f. induced in the detector coil is proportional to the relative velocity of the coil

and the magnet. Since the coil and stationery the induced e.m.f. is directly proportional the assault

value of vibration velocity of the unit caring the detector. The vibration of the bearing are

measured with an indicator and recorded in the multi point record to.

Emergencies on the Turbine

1. High Axial Shift of Turbine Rotor

The possible causes for high axial shift of the rotor may be:

(a) Sudden drop in superheated steam temp.

(b) Sudden fluctuation in load.

(c) Hydraulic shock.

(d) Fast rate of loading the machine.

(e) Failure of lubrication of the thrust bearing.

When there is a deviation of the axial shift from the normal value, check the followings.

(a) Temp at the outlet of the thrust bearing.

(b) Steam temp.

25
 TRANSFORMERS

The transformer is the most convenient and economical device for transfer of power from

one voltage to another voltage at the same frequency. It works on the principle of electromagnetic

induction there is hardly any installation without a transformer due to this equipment. It has been

possible to transmit bulk power to load centers from far off power houses and to various

machineries and switchgears or the power plant.

Main Parts of Power Transformers

 Primary Winding

 Secondary Winding

 Oil Tank

 Drain Coke

 Conservator

 Brether

 Tubes for Cooling

 Transformer Oil

 Earth Point

 Explosion Vent

 Temprature Guage

 Buchholz Relay

 Primary Terminals

 Secondary Terminals

26
 FEEDING WATER
Air & Gas Cycle

Air is supplied to combustion chamber to the boiler drum through the F.D. Fan, P. A. Fan

is used to carry pulverized coal to the furnace. The exhaust gases are passed through air pre heater

and various economizers and then send to the electrostatic precipitator before being send to

chimney with the help of I.D. Fan

Water Flow Process

The raw water taken from canal is send to the clarifier. There dust and salts are removed

by adding alum and CI. this water moves to D.M. plant where the minerals from the water are

removed. Then the water is fed to the boiler for the formation of steam, which is utilized for the

formation of electricity.

Details of the process are shown in the following cycle.

Raw Water (From Canal)

↓
Water Dept Standing
↓
Suspended Impurities Settle Down
↓
(Alum+CL) Added to H2O
(Suspended Impurities Removed)
↓
Churning of H2O
(Dissolved impurities of Bacteria's Removed)
↓
Water to Treatment Plant
↓
Pressure Plant
↓
Activeted Carbon Filter

27
(Impurities not separated by Alum, Removed by Absoption)
↓
Cation (Filter) Exchanger (+Ve Ion Removed)
↓
De Gas (Gases Removed)
↓
Anion (Filter) Exchanger
↓
Mixed Filter Bed
(Left Out+Ve & -Ve Ions Removed)
↓
Storage Tank
↓
Dozing of Sulphate Hydrazine
(pH Maintained)
↓
Pure H2O
↓
Ecconomiser
↓
To The Boiler
↓
Steam

28
Cooling Water Cycle
The quantity of water required for condensing the steam to water is quite large and is
therefore taken directly from the water source. This water is continuously circulated through the
condenser and sent to the cooling tower for the purpose of cooling.

WATER TREATMENT PLANT

The objective of the water treatment is to produce a boiler feed water so that there shall be

no scale formation causing resistance to passage of heat and burning of tube, no corrosion, no

priming and foaming problems. This will ensure that steam generated shall be clean and the boiler

plant will provide trouble free uninterrupted service.

Water treatment plant used in thermal power plant are designed to process the raw water

very low in dissolved solids known as demineralised water.

The type of demineralization process chosen for power station depend on three main

factors:

1. The quality of raw water.

2. The degree of deionisation i.e. treated water quality.

3. Selectivity of resins.

The water treatment process is generally made up of two sections:

1. Pretreatment Section.

2. Demineralization Section.

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Pretreatment Section
Pretreatment plant remove the suspended solids such as clay, slit, organic matter and

organic matter, plants and other microscopic organism. The turbidity may be taken as of two types

of suspended solids in water. Firstly the separable solids and secondly the nonseparable solids.

The coarse components, such as sand, silt etc. can be removed from the water by sedimentation.

Finer particles however, will not settle in any reasonable time and must be flocculated to produce

the large particles settable.

The term "Coagulation" and "Flocculation" have been used indiscriminately to describe

process of turbidity removal. "Coagulation" means to bring together suspended particles of

turbidity removal. The process describes the effect produced by the addition of a chemical AL2

(SP4)3 to a colloidal dispersion resulting in particles destabilization by a reduction of force

lending to keep particles apart. Second stage of formation of settable particles from destabilized

colloidal size particles is termed as' flocculation" Flocculation occurs by chemical bridging.

Flocculation is obtained by gentle and prolonged mixing which converts the submicroscopic

coagulated particles into discrete, visible and suspended particles.

Demineralization

This filter water is now used for demineralising purpose and is fed to cation exchanger

bed, but enroute being first dechloronated, which is either done by passing through activated

carbon filter or injecting along flow of water, an equipment among of sodium sulphate through

some stroke pumps. The residual chlorine which is maintain in clarification plant to remove

organic matter from raw water is now detrimental to cation resin and must be eliminated before its

entry to the bed.

o Resins have the ability to exchange one ion for another, hold it temporarily in

chemical combination and give it to strong electrolytic solution. Suitable treatment

is also given to them inn such a way that a particular group of ions. Resin, when

30
 absorbing and releasing cationic portion of dissolved salts, is called cation

exchanger resin and when removing anionic portion is called anion exchanger

resin.

Cation resin: RH+Na → Rna+H2SO4 (Removed by

K K Hcl aeration in
Ca Ca HNO3 degassing
Mg Mg tower)

(in the form of (resin in

Chloride, Sulphate exhausted
Nitrate, Bicarbonate) form)

Anion resin: ROH + H2SO4 → RSO4 + H2O

Hcl Cl
Hno3 No3
(Mineral acids (resin in
Obtained from exhausted form)
cation exchanger)

Recharging the exhausted form of resin i.e. regeneration employing 5% of acid / alkali as

below:

Catioon Resin:
Na Nacl
K +Hcl → RH + Kcl
R Ca Cacl2
Mg Mgcl2

(exhausted (fresh (removedby

resin resin) rinsing)

Anion resin:
RSO4 + NaOH → ROH + NaSO4
Cl Nacl
No3 NaNo3
(exhausted (fresh (removed by
resin) resin) rinsing)

d) Lub oil press.

e) Steam press

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 f) Press in the regulating stage

If any of the above parameters abnormal then the load on the m/c is to be reduced to an

extent where the rising tendency of the axial shift continuses to rise the unit in to the shut down

bearing. Do not wait for the protective.

 temp before H.P. turbine.

Steam Condenser

A steam condenser is a device in which steam condenses and heat relased by steam is

absorbed by water. It serves the following purpose:.

 It supplies to the boiler pure and hot feed water as the condensed steam, which is

discharged from the condenser and collected in a hot well, can be used as feed water for

boiler.

Classification of Condenser

Mainly, condenser is of two type:

(1) Jet conderiser:

In it the exhaust steam and water come in direct contact with each other and temp of the

condenser is same as that of cooling water leaving water the condensing.

(2) Surface Condenser:

The exhaust steam and water do not come in direct contact. The steam passes over the

outer surface of tubes through which a supply of cooling water is maintained.

Cooling Tower

In power plants, the hot water from the condenser is cooled in the cooling tower, so that is

can be reused in condenser for condensing of the steam. In a cooling tower water is made to tickle

down drop by drop so that it comes in contact with the air moving in the opposite direction. As a

result of this some water is evaporated and is taken away with air.

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 In evaporation the heat is taken away from the bulk of work, which is thus cooled.

Factor effecting cooling of water in cooling tower.

(a) Temp of air.

(b) Humidity of air

(c) Temp of hot air

(d) Size and height of tower

(e) Velocity of air entering the tower

(f) Arrangement of air in tower.

In this station we make use of concrete cooling tower, natural draught type cooling tower.

Working

The construction of cooling tower is as shown in fig. In it hot water from condenser is

make to fall from 6 m height. Air naturally blows in upward direction. This cool air comes in

contact with hot failling water and makes the hot water cool by evaporating some amount of hot

water. Now vapors strikes with plates and get cooled and fall down in pond.

Economiser

The purpose of economiser is to rehet the boiler feed water by absorbing heat from flue

gases and add its as sensible heat to the feed water before it is introduced into the steam drum by

recovering heat from the flue gases leaving the boiler. The economiser is located inthe boiler rear

gas pas below the rear horizontal super heater at 30 m level. The economiser is continue loop type

and water flow in the upwards direction and gas in the downward direction the heating surface of

the economiser is approxi. 5500m.

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 ASH DISPOSAL

ASH HANDLING SYSTEM

The ASH produced in the boiler is transported to ASH dump area by means of sluicing

type hydraulic ASH handling system. Which consists of bottom ash system, ash water system, fly

ash system ash slurry system which are explained as follows.

1. Bottom Ash System

In the bottom ash system. The ash slag discharge from the furnace bottom is collected into

water impounded scraper troughs in stalled bellows water ash system. The ash is

continuously transported by means of scrapper chain conveyor on the respective clinker

grinders which reduce the lump sixes to the required fineness. The crushed ash from the

clinker grinders falls into the ash sluice trench provided bellow the bottom ash hopper

from where the ash slurry further transported to ash slurry sump added by ash sluice

channel.

The water with high pressure coming out from the tip of the nozzle push the ash slurry

along it towards the sump. From the sump this ash slurry disposed from the plant through

the no of ash disposal pump. By creating the great vacuum by them.

2. Fly Ash System

The flushing hoppers are provided under EP hoppers (40nos), Economizer hopper (4nos),

air pre heater (4nos) and stack hoppers (2nos). The fly ash collected in these hoppers drop

continuously to flushing apparatus where fly ash get mixed with flushing water and the

resultant slurry drops into the ash sluice channel. Low- pressure water is applied through

the nozzel directing tangentially to the section of pipe, to create turulence and proper

34
 mixing of ash, with water. For the maintenance of flushing apparatus and connection

chute.

3. Ash Water System

High pressure water required for B.A. hoppers quenching nozzles, windows spraying,

clinker grinder sealing scrapper bars, cleaning nozzles, B.A. hoppers seal through flushing,

economizer hopper's flushing nozzles is tapped from the high pressure water ring main

provided in the plant area.

4. Ash Sullary System

Bottom Ash and Fly ash slurry of the steam is sluiced up to ash slurry sump along the

channel with the aid of high - pressure water get located at suitable interval along the

channel. Slurry pump suction line consisting of reducing elbow with drain valve, reducer

and butterfly valve and portion of slurry pump, delivery line consisting of butterfly valve,

pipe and fittings as also been provided.

Electrostatic Precipitator

It is an electric device which remove the ash particle from the smoke through furnace of

boiler. It helps in the prevention of air pollution. It works on the principles that a charge particles

is attracted towards opposite charge. Two plates of opposite polarity are fixede and smoke is

passed b/w them. When the dry ash come b/w the plates it gets charged and is attracted towards

the plate and collected by discharging the particles.

ID Fan

It is called induced draft fan, there are three different fans in every thermal plant, its main

function is to remove the combustible products flue gases to the atmosphere. These ID fans are

placed at chimney base to draw out gases from the chimney to the atmosphere by creating a draft.

35
Chimney

There are tall RCC structure with multiple flues. The height of these chimney vary

depending on the location consideration, anywhere between 150m to 220m.

36
 Emissions from Thermal Power Plants

----------------------------------------------------------The main emissions from coal combustion

at thermal power plants are carbon dioxide (CO2), nitrogen osides (NOx), sulfur oxides (SOx),

chlorofluorocarbons (CFCs), and air borne inorganic particles such as fly ash, soot, and other trace

gas species. Carbon dioxide, methane, and chlorofluorocarbons are greenhouse gases. These

emissions are considered to be responsible for heating up the atmosphere, producing a harmful

global environment. Oxides of initrogen and sulfur play an important role in atmospheric

chemistry and are largely responsible for atmospheric acidity. Particulates and black carbon (soot)

are of concern, in addition to possible lung tissue irritation resulting from inhalation of soot

particles and various organic chemicals that are known carcinogens. CO2, SO2, NO, and soot

emissions from each of the power plants have been computed. Emissions from combustion of the

supplementary fuels such as high-speed diesel (HSD) and furnace oil used in small quantities

(>1%) are not counted in the present calculations.

Carbon Dioxide Emissions

Utilities burn mostly coal with approximately 10-30% excess air. Total CO2 emissions for

1997 from all the power plants in India are estimated at 1.1 Teragrams (Tg) per day or 397 Tg per

year. Average CO2 emission per unit of electricity is 1.04 Gigagrams (Gg). Technological

improvements in efficient combustion of coal can lead to greater production of electricity per unit

of coal that will effectively reduce CO2 emission per unit pf electricity. Although the current per

capita carbon dioxide (CO2) emission in India is only one quarter of the world average and about

twenty times less than United State's averages.

Sulfur Dioxide Emissions

37
 The sulfur content in Indian coal is low compared to United States coal. Acid rain due to

sulfur dioxide emissions is presently not of great concern. However, increasing coal use or

blending Indian coal with imported coal of higher colorific value (further increasing electricity

production) needs to be carefully addressed through viable technological options. Average SO2

emissions per unit of electricity are 0.0069 Gg. Total SO2 emissions are estimated to be 7.33 Gg

per day or 2.7 Tg per year.

Emissions of Oxides of Nitrogen

Oxidation of nitric oxide (NO) discharged in combustion in products forms nitrogen

dioxide (NOx) in the atmosphere. These oxides of nitrogen are responsible for the formation of

photochemical smog. Nitric oxide emission per unit of electricity is estimated as approximately

0.00056 Gg. Total NO emissions are estimated to be 0.5 Gg per day and 0.185 Tg per year.

Nitrogen oxides are important chemical species in the atmosphere since they contribute to its

acidity; they also act as precursor gases for the formation of tropospheric ozone. Tropospheric

ozone is a greenhouse gas responsible or global warming and is also known to have an adverse

affect on plants. NOx emissions should be kept at a minimum possible level. Lower

concentratioons of NOx lessen the formation of tropospheric ozone even when other precursor

gases like carbon monoxide (CO) are present in higher concentrations.

Carbonaceous Material and Blank Carbon (SOOT)

Incomplete and/or inefficient combustion processes of fossil fuel generate soot. A recently

conducted Indian Ocean Experiment (INDOEX) suggests that the presence of soot carbon in the

atmosphere over the Nothern Indian Ocean hinders its natural heating processes by about 15%.

Enhancement of boundary layer.

38