Power Plant Familiarization

Project Report
Submitted in partial fulfillment of the requirements for the degree of

Bachelor of Technology ([Link])

Submitted to:

Mr. Amit Dahiya

Mechanical Engineering
Submitted by:

Anand Kumar
ME/13/710
August 2016

Power Plant Familiarization

Project Report
Submitted in partial fulfillment of the requirements for the degree of

Bachelor of Technology ([Link])

Submitted to:

Mr. Amit Dahiya

Mechanical Engineering
Submitted by:

Anand Kumar
ME/13/710
Under the Supervision of
[Link]
XEN/T.G. Mtc.-IV, Unit-6
P.T.P.S Panipat

ACKNOWLEDGEMENT
This report gives the details of the project work done in six weeks Industrial training at
the end of 6th semester for partial fulfillment of the requirements for the degree of
Bachelor of Technology ([Link]), under the Supervision of [Link] (XEN/T.G.
Mtc.-IV, Unit-6), Er. Dhramvir (AEE/T.G. Mtc.-IV, Unit-6), Er. Krishan Kumar (J.E/T.G.
Mtc.-IV, Unit-6) and Mr. Amit Dilbagi (XEN/ Training Division).
I am highly obliged to department of training (P.T.P.S) for allowing me training at
TURBINE & GENERATOR MAINTANANC-IV and operators & technician of Turbine
& Generator section for the kind attention they have paid to me while instruction at the
plant site.
I have a profound sense of gratitude & appreciation to Electrical Engineer for directing
me for industrial training at Panipat Thermal power Station, Panipat.

_____________________
Signature of the Student
Name: _________________
Date: __________________

Table of Contents
1

INTRODUCTION.......................................................................................................8
1.1

THREE MAJOR INPUTS TO POWER STATION..............................................8

1.1.1

WATER..........................................................................................................8

1.1.2

FUEL OIL......................................................................................................9

1.1.3

COAL............................................................................................................9

1.2

FUNCTIONAL DESCRIPTION..........................................................................9

1.3

FAMILARIZATION WITH PLANT..................................................................10

1.3.1

BOILER.......................................................................................................10

1.3.2

TURBINE & GENERATOR (TG)..............................................................10

1.3.3

CONDENSER.............................................................................................11

1.3.4

COOLING TOWER....................................................................................11

1.3.5

ELECTROSTATIC PRECIPITATIOR........................................................12

1.3.6

ASH HANDLING PLANT.........................................................................12

1.3.7

SWITCH YARD..........................................................................................12

1.3.8

ELECTRICITY FROM COAL...................................................................13

STEAM TURBINE....................................................................................................15
2.1

GENERAL DESCRIPTION...............................................................................15

2.1.1

GLAND SEAL & LEAK-OFF....................................................................15

2.1.2

ROTORS, BEARING AND TURNING GEAR..........................................15

2.1.3

TURNING GEAR.......................................................................................16

2.2

STEAM TURBINE THEORY............................................................................16

2.2.1

STEAM TURBINE AS A PRIME MOVER................................................16

2.2.2

OPERATING PRINCIPLE..........................................................................17

2.2.3

STEAM CYCLE..........................................................................................17

2.3

DESIGN FEATURES.........................................................................................17

2.4

BARREL TYPE HIGH PRESSURE (HP) TURBINE.......................................18

2.5

INTERMEDIATE PRESSURE (IP) TURBINE.................................................19

2.6

LOW PRESSURE (LP) TURBINE....................................................................19

2.7

TURBINE SPECIFICATIONS...........................................................................21

3
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DIFFERENT VALVES..............................................................................................23
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3.1

COMBINED MAIN STOP VALVE AND CONTROL VALVE.........................23

3.2

COMBINED REHEAT STOP VALVE AND CONTROL VALVE....................23

TURBINE OIL SYSTEM..........................................................................................23

4.1

OIL SUPPLY DURING NORMAL OPERATION.............................................24

4.2

OIL SUPPLY DURING STARTUP AND SHUTDOWN...................................24

4.3

OIL SUPPLY DURING DISTURBANCES.......................................................24

4.4

OIL STRAINER AND VAPOUR EXHAUSTER...............................................25

4.5

OIL LEVEL INDICATOR..................................................................................25

4.6

TYPE OF OIL PUMPS.......................................................................................25

4.6.1

MAIN OIL PUMP (MOP)...........................................................................25

4.6.2

AUXILIARY OIL PUMP (AOP).................................................................25

4.6.3

D.C. EMERGENCY OIL PUMP (EOP)......................................................25

4.6.4

JACKING OIL PUMP (JOP).......................................................................26

4.7

OTHER ACCESSORIES....................................................................................26

4.7.1

MAIN OIL TANK.......................................................................................26

4.7.2

OIL PURIFIER............................................................................................26

4.7.3

OIL FILTER.................................................................................................26

COAL CIRCULATION.............................................................................................27
5.1

COAL MILL.......................................................................................................27

5.2

CONSTRUCTION..............................................................................................27

5.3

WORKING.........................................................................................................28

5.4

CIRCULATORY SYSTEM................................................................................28

5.5

DRAFT SYSTEM...............................................................................................29

WATER CIRCULATION SYSTEM..........................................................................29

CONDENSER...........................................................................................................31

ELECTROSTATIC PRECIPITATOR........................................................................32
8.1

8.1.1

CORONA GENERATION..........................................................................33

8.1.2

PARTICLE CHARGING.............................................................................33

8.1.3

PARTICLE COLLECTION.........................................................................34

8.1.4

PARTICLE REMOVAL...............................................................................34

8.2
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WORKING PRINCIPLE....................................................................................33

GENERAL DESCRIPTION...............................................................................34
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8.2.1

PRECIPITATOR CASING..........................................................................34

8.2.2

EMITTING AND COLLECTING SYSTEM..............................................34

8.2.3

HOPPERS....................................................................................................35

DUST COLLECTING HOPPER...............................................................................35

9.1

RAPPING MECHANISM..................................................................................35

9.2

GAS DISTRIBUTION SYSTEM.......................................................................35

10

9.2.1

ELECTRICAL SYSTEM............................................................................35

9.2.2

TECHNICAL SPECIFICATIONS OF ESP................................................36

9.2.3

ESP PROTECTIONS..................................................................................36

ASH HANDLING SYSTEM....................................................................................36

10.1

BOTTOM ASH SYSTEM...............................................................................36

10.2

FLY ASH SYSTEM........................................................................................37

10.3

ASH WATER SYSTEM..................................................................................37

10.4

ASH SLURRY SYSTEM................................................................................37

11

REGENERATIVE SYSTEM.....................................................................................38

12

HYDROGEN COOLING SYSTEM.........................................................................38

13

WATER CLARIFIER................................................................................................39
13.1

D.M. PLANT...................................................................................................39

13.2

STEAM CONDITION....................................................................................40

14

CHIMNEY.................................................................................................................40
14.1

15

FLY ASH AND FLUE GAS CONDITIONING.............................................40

FUNCTIONS OF VARIOUS PARTS OF THE CYCLE...........................................41

15.1

P.A. FANS.......................................................................................................41

15.2

AIR HEATER..................................................................................................41

15.3

SECONDARY AIR CYCLE...........................................................................41

15.4

F.D FANS........................................................................................................41

15.5

WIND BOX.....................................................................................................42

15.6

INDUCED DRAFT FANS (ID FANS)...........................................................42

16

CONCLUSION..........................................................................................................44

17

REFERENCES & BIBLIOGRAPHY.......................................................................45

18

CHECKLIST.............................................................................................................46

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List of Tables & Figures

Table No. 1: Different Stages of PTPS, Panipat..................................................................8
Fig. No. 1: Machinery Layout...........................................................................................10
Fig. No. 2: Arrangement of Cooling Tower.......................................................................11
Fig. No. 3: Cooling Tower.................................................................................................12
Fig. No. 4: Turbine Tube....................................................................................................18
Table No. 2: HP Turbine Features......................................................................................19
Table No. 3: IP Turbine Features.......................................................................................19
Table No. 4: LP Turbine Features......................................................................................20
Table No. 5 (a): Turbine Specification..............................................................................21
Table No. 5(b): Turbine Specification..............................................................................22
Fig. No. 5: Coal Handling Plant Coal Mill........................................................................28
Fig. No. 6: Condenser........................................................................................................31
Fig. No. 7: Condenser Tube...............................................................................................32
Table No. 6: Technical Specification of ESP.....................................................................36
Fig. No. 8: FD Fan.............................................................................................................42
Fig. No. 9: Induced Draft Fan............................................................................................43

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1 INTRODUCTION
Panipat Thermal Power Station is situated at a distance of about 12 km. from Panipat. It
is on Panipat-Jind Road near village Assandh. The power plant is one of the coal based
power plants of HPGCL. The first four units were bifurcated from the total 8 units of the
plant, so that to form Panipat Thermal Power Station I and II. Panipat Thermal Power
Station I has an installed capacity of 447.80 MW. The First unit was commissioned in
November 1979. In order to improve the performance of the all four units of the plant, the
Renovation and Modernization has been started. This plant has been constructed in five
stages as given below:
Name and Address

Stage

Units

Capacity

Panipat Thermal
PowerStation,
Panipat.

Stage 1

Unit- 1

117.8 M.W.

Unit- 2

110 M.W.

Unit- 3

110 M.W.

Unit- 4

110 M.W.

Stage 3

Unit- 5

210 M.W.

Stage 4

Unit- 6

210 M.W.

Stage 5

Unit- 7

250 M.W.

Unit- 8

250 M.W.

Stage 2
Phone: 01802561573
Fax: 0180-2566806

Total Generation Capacity

1367.8 M.W.

Table No. 1: Different Stages of PTPS, Panipat

1.1 THREE MAJOR INPUTS TO POWER STATION

1.1.1 WATER
Water has been taken from nearby Yamuna Canal. This water is lifted by raw water
pumps and is sent to clarifier to remove turbidity of water. The clear water is sent to
water treatment plant, cooling water system and service water system. The water is demineralized (DM) by water treatment plant. The DM water is stored in condensate
storage tanks from where it is used in boiler.

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1.1.2 FUEL OIL

The fuel oil used is of two types:
(a) Low sulphur high stock oil (LSHS)
(b) High speed diesel oil (HSD)
The high speed diesel oil reaches the power station through the lorry tankers. The oil is
stored in large tanks for the future use in the boiler. Heavy oil is stored in storage tanks in
oil storage yard and is conveyed to the front through a set of pumps and strainers. The
whole length of piping from the boiler front in stream traced to maintain the temperature
and hence its fluidity so that it can freely flow in the pipelines.

1.1.3 COAL
The coal reaches the plant in the railways wagons. 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 stream 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.

1.2 FUNCTIONAL DESCRIPTION

The Thermal Power Station burns fuel & uses the resultant to make the steam, which
derive the turbo generator. The Fuel i.e. coal is burnt in pulverized from. The pressure
energy of the steam produce is converted into mechanical energy with the help of turbine.
The mechanical energy is fed to the generator where the magnet rotate inside a set of
stator winding & thus electricity is produced in India 65% of total power is generated by
thermal power stations. To understand the working of the Thermal Power Station plant,
we can divide the whole process into following parts.

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Fig. No. 1: Machinery Layout

1.3 FAMILARIZATION WITH PLANT

1.3.1 BOILER
Boiler is a device used for producing steam. There are two types of boilers:
a) Fire tube boiler
b) Water tube boiler
Here, boiler used is of water tube type. In the boiler, heat energy transfer takes place
through tube walls and drum. The gases lose their heat to water in the boiler or
superheated. The escape heat is used to heat the water through economizer. ID and FD
fans are used to produce artificial draught. The fuel oil is used to ignite the boiler and
pulverized coal is lifted from the coal mills by PA fans.

1.3.2 TURBINE & GENERATOR (TG)

Turbine is form of heat engine in which available heat energy in the form of steam is
converted into kinetic energy to rotate the turbine by steam expansion in suitable shaped
nozzles In Thermal Power Station there are reaction turbines.
The turbine consists of three stages: high pressure, intermediate pressure and low
pressure. Steam enters the turbine at 350oC with maximum allowable temperature of
545oC. Cold reheat steam goes to boiler, reheated at 540oC, then fed to medium pressure
parts of the turbine. Then, after cooling it goes to the hot well. The shaft is coupled with
generator.
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The generator converts the kinetic energy of the rotating shaft to electric energy. Field
windings are excited by D.C. power using exciter. Shaft of generator rotates at 3000 rpm
speed.

1.3.3 CONDENSER
In condenser, the water passes through various tunes and steam passes through a chamber
containing a large number of water tubes (about 20000). The steam gets converted into
water droplets, when steam comes in contact with water tubes. The condensate is used
again in boiler as it is dematerialized water and 5-6 heats the water, which was in tubes,
during the process of condensation. This water is sent to cooling tower.

Fig. No. 2: Arrangement of Cooling Tower

1.3.4 COOLING TOWER

It is a structure of height 110m designed to cool the water by natural draught. The cross
sectional area is less at the center just to create low pressure so that the air can lift up due
to natural draught and can carry heat from spherical drops. The upper portion is also
diverging for increasing the efficiency of cooling tower. Hence it is named as natural
draught cooling tower.

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Fig. No. 3: Cooling Tower

1.3.5 ELECTROSTATIC PRECIPITATIOR

It is an electronic device, which removes the ash particles from smoke through furnace of
boiler. It helps in prevention of air pollution. It works on the principle that a charged
particle is attracted towards opposite charge. When the fly ash comes between the
opposites charged plated it gets charged and is attracted towards the plates and then
collected from the plates by the discharging particles.

1.3.6 ASH HANDLING PLANT

Ash is not discharged as such to pollute the land, air and water, but slurry of ash is made
in ash handling plant and this slurry is dumped in the wasteland, kept for the purpose.

1.3.7 SWITCH YARD

Switchyard is the area, which feed the grid supply to the station transformer and feed the
grid by the power generator by the unit. The power supply control is administrated here
and the units consumed and supplies are recorded in the control room. The connections of
220KV BUS to the station transformer is done by using the isolated and gas filled circuit
breakers.

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1.3.8 ELECTRICITY FROM COAL

Electric power generation takes place in the following steps:
1. Coal to steam
2. Steam to mechanical power
3. Switching and transmission

[Link] COAL TO STEAM

The boiler burns pulverized coal at rates up to 200 tons per hour. From the coal store, fuel
is carried on a conveyor belt and discharged by means of a coal tipper into the bunker. It
then falls through a weighed into the coal pulverizing mill where it is ground to a powder
as fine as flour. Air is drawn from the top of the boiler house by the forced draught fan
and passed through the air pre-heaters to the hot air duct. From here some of the air
passes directly to the burners and the remainder is taken through the primary air fan to the
pulverizing mill, where it is mixed with the powdered coal, blowing it along pipes to the
burners of the furnace. Here it mixes with the rest of the air and burns with great heat.
The boiler consists of a large number of tubes and the heat produced raises the
temperature of the water circulating in them to create steam, which passes to the steam
drum at very high pressure. The steam is then heated further in the super heater and fed
through outlet valve to the high pr. cylinder of the steam turbine.
When the steam has been through the first cylinder (high pr.) of the turbine, it is returned
to the repeater of the boiler and reheated before being passed through the other cylinders
(intermediate and low pr.) of the turbine. From the turbine the steam passes into a
condenser to be turned back into water condensate. This is pumped through feed heaters
where it may be heated to about 250 oC to the economizer where the temperature is raised
sufficiently for the condensate to be returned to the lower half of the steam drum of the
boiler. The flue gases leaving the boiler are used to reheat the condensate in the
economizer and then pass through the air pre-heaters to the electro-static precipitator.
Finally they are drawn by the induced draught fan into the main flue and to the chimney.

[Link] STEAM TO MECHANICAL POWER

From the boiler, a steam pipe conveys steam to the turbine through a stop valve and
through control valves that automatically regulate the supply of steam of the turbine, Stop
valve and control valves are located in a steam chest and a governor, driven from the
main turbine shaft, operates the control valves to regulate the amount of steam used.
Steam from the control valves enters the high pr. cylinder of the turbine, where it passes
through a ring of stationary blades fixed to the cylinder wall. These act as nozzles and
direct the steam mounted on a disc secured to the turbine shaft.

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This second ring turns the shaft as a result of the force of the steam. The stationary and
moving blades together constitute a stage of the turbine and in practice many stages are
necessary. The steam passes through each stage in turn until it reaches the end of the high
pr. cylinder and in its passage some of its heat energy is charged into mechanical energy.
The steam leaving the high pr. cylinder goes back to the boiler for reheating and is
returned to the intermediate pr. cylinder. Here it passes through another series of
stationary and moving blades.
Finally, the steam is taken to the low pr. cylinder each of which it enters at the center
flowing outwards in opposite directions through the rows of turbine blades- an
arrangement known as double flow-to the extremities of the cylinder. As the steam gives
up its heat energy to drive the turbine, its temperature falls and it expands. The turbine
shaft rotates at 3000 rpm at 50 Hz. The turbine shaft drives the generator to generate
alternating current.
When as much energy as possible has been extracted from the steam it is exhausted
directly to the condenser. This runs the length of the low pr. part of the turbine and may
be beneath or on either side of it. From the condenser, the condensate is pumped through
low pr. feed heaters by the extraction pump, after which its pr. is raised to boiler pr. by the
boiler feed pump. It passed through further feed heaters to the economizer and the boiler
for recon version into steam.

[Link] SWITCHING AND TRANSMISSION

The electricity is usually produced in the stator windings of the large modern generators
at about 25,000 volts and is fed through terminal connections to one side of a generator
transformer that steps up the voltage 132000, 220000 or 400000 volts. From here
conductors carry it to a series of three switches comprising an isolator, a circuit breaker
and another isolator.
The circuit breaker, which is a heavy-duty switch capable of operating in a fraction of a
second, is used to switch off the current flowing to the transmission lines. Once the
current has been interrupted the isolators can be opened. These isolate the circuit breaker
from all outside electrical sources.
From the circuit breaker the current is taken to the bus bars-conductors, which run the
length of the switching compound and then to another circuit breaker with its associated
isolates before feeding to the grid.
Three wires are used in a three-phase system for large power transmission. The center
of the power station is the control room. Here engineers monitor the output of electricity,
supervising and controlling the operation of the generating plant and high voltage switch
gear and directing power to the grid system as require

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2 STEAM TURBINE
The steam turbine is a prime mover that converts the stored mechanical energy in steam
into rotational mechanical energy. A turbine pair consists of a ring of fixed blade and a
ring of moving blades. The blades are so designed that the steam glides overt eh blade
surface without striking it. As the steam floes over the covered surface of blade, it exerts
a pressure on the blade along its whole length owing to its centrifugal force. The motive
force on the blade will be the resultant of the centrifugal pressures on the blade length
plus the effect of change of the steam as it flows over the blade.

2.1 GENERAL DESCRIPTION

The turbine consists of three casings, high, medium and low pressure. HP part consists of
two horizontally split casings-inner is placed inside, outer casing with scope for
expansion in all direction. Fixed point of inner casing in the axial directions is between
the nozzle chambers. Medium low pressure casing is split horizontally and comprise of 3
parts connected by vertical flanges. The outlet branches are connected rigidly with
condenser which is supported on springs. In the middle casing, tube nests of 1st and 2nd LP
heaters are mounted. The casings are inter connected by guide keys and fixed points in
the axial direction is at the central part of the LP casing. Total thermal expansion of the
casings is indicated at front bearing pedestal and is approximately 25 mm when casings
are fully stretched at rated steam parameters and at full load. The displacement of the
bearing pedestal; between HP & MP parts is about 15mm. Relative expansion of rotors
also are measured at 3 points.

2.1.1 GLAND SEAL & LEAK-OFF

Turbine glands are sealed by steam at fixed pressure. Seal-steam, during starting and on
low load period, is supplied from either cold R/H lines after N/R valves or from 11/6 ata
header.

2.1.2 ROTORS, BEARING AND TURNING GEAR

All the rotors including the rotor of the generator are mutually connected by means of
rigid coupling. The critical speed of the turbine rotors is best noticed between 1900-2350
rpm. Double sided axial thrust bearing is located in between HP & MP casings. Two
protections, one hydro-mechanical and one electro-magnetic are mounted near the axial
bearing to trip the machine, in case the rotor movement crosses the prohibited limit on
either side.
Differential expansions are measured at 3 points:

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on the front bearing pedestal

on the pedestal between MP & HP parts
Page 15

and between LP & Generator to access relative expansion of stator and rotor

There are seven radial bearings on which rotor are supported. With proper expansion of
all turbine parts, the load sharing is equal in all bearings. The bearings are placed in:

HP front standard
between HP& MP at MP end
both side of LP
both side of generator

The journals are lifted by high pressure oil supplied by jacking oil pump at the time of
putting machine on turning gear.

2.1.3 TURNING GEAR

This equipment is located on the bearing pedestal between LP and generator and turns the
rotor after shutdown or before start-up, at 62 RPM by an electric motor of 30 KW. The
motor starting is possible only when lubricating oil pressure is available. The oil pressure
required to put the swinging gear to engage with the coupling gear is 50 ata, supplied
from jacking oil pump to a servomotor through an electro magnet.

2.2 STEAM TURBINE THEORY

A turbine, being a form of engine, requires in order functioning a suitable working fluid,
a source of high-grade energy. When the fluid flows through the turbine, apart of the
energy content is continuously extracted and converted into useful mechanical work.
Steam and gas turbines use heat energy while water turbines use pressure energy.

2.2.1 STEAM TURBINE AS A PRIME MOVER

a) The steam turbine offers many advantages over other prime movers both
thermodynamically and mechanically. From a thermodynamic point of view the main
advantage of the steam turbine over, say a reciprocating steam engine is that in the
turbine the steam can be expanded down to a lower backpressure, thereby making
available a greater heat drop. The same amount of heat drop in the case of a
reciprocating engine would require very large cylinder, which would be impractical
and uneconomic.
b) From a mechanical point of view the turbine is ideal because the propelling force is
applied directly to the rotating element of the machine.
c) Another advantage of the turbine is the absence of internal lubrication. This means
that the exhaust steam is not contaminated with oil vapor and can be condensed and
fed back to the boiler.

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d) A final advantage of the steam turbine and a very important one is the fact that, size
for size, a turbine can develop many times the power compared to a reciprocating
engine whether steam or oil.

2.2.2 OPERATING PRINCIPLE

a) A steam turbines two main parts are the cylinder and the rotor. The cylinder
containers fixed blades, vanes and nozzles that direct the steam into the moving
blades carried by the rotor. The rotor is a rotating shaft that carries the moving blades.
b) In a multiple stage turbine, steam at a high pressure and high temperature enters the
first row of fixed blades through an inlet valves. As the steam passes through the
fixed blades, it expands and its velocity increases. The high velocity jet of steam the
first set of moving blades. The kinetic energy of the steam changes into mechanical
energy, causing the shaft to rotate. The steam then enters the next set of fixed blades
and strikes the next row of moving blades.
c) As the steam flows through the turbine, its pressure and temperature decreases, while
its volume increases. The decreases in the pressure and temperature occur as the
steam transmits energy to the shaft and performs work. After passing through the last
turbine stage, the steam exhausts into the condenser or process steam system.
d) The kinetic energy of the steam changes into mechanical energy through the impact
or reaction of the steam against the blades. Many large turbines use both impulse and
reaction blade. Blade rows require seals to prevent steam leakage where the pressure
drops.

2.2.3 STEAM CYCLE

The Thermal (steam) Power Plant uses a dual phase cycle. It is closed to enable the
working liquid (water) to be used again and again. The cycle used is Rankine cycle
modified to include super heating of steam, regenerative feed water heating and reheating
of steam.

2.3 DESIGN FEATURES

The turbine is of tandem compound design with separate High Pressure (HP),
Intermediate Pressure (IP) and Low Pressure (LP) cylinders. The HP turbine is of Single
Flow type while IP and LP turbines are of Double Flow type. The turbine is condensing
type with single reheat.
It is basically engineered on reaction principle with throttle governing. The stages are
arranged in HP, IP and LP turbines driving alternating current full capacity turbo
generator.

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The readily designed HP, IP and LP turbines are combined and sized to required power
output, steam parameters and cycle configuration to give most economical turbine set.
The design and constructional features have proved their reliability in service and ensure
trouble free operation over long operating periods and at the same time ensuring high
thermal efficiencies.

Fig. No. 4: Turbine Tube

2.4 BARREL TYPE HIGH PRESSURE (HP) TURBINE

The outer casing of the HP turbine is of barrel type construction without any massive
horizontal flange. This unique construction permits rapid startup from any thermal state
and high rates of load changes of the turbo set. The steam and metal temperature
matching requirements are also less stringent as there is no asymmetry of mass
distribution in traverse or longitudinal planes.
The barrel type outer casing does not cause any problems during over hauls and capital
maintenance as the assembly and disassembly of the turbine can be done in a relatively
short time as compared to the conventional design. The HP turbine is of single flow type
with 25 reaction stages.

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Inlet Temperature

535oC.

Outlet Temperature

343oC.

Inlet pressure

150 Kg/cm2.

Outlet Pressure

49 Kg/cm2.

Table No. 2: HP Turbine Features

2.5 INTERMEDIATE PRESSURE (IP) TURBINE

The IP turbine is double flow type with horizontal split, inner casing being kinematically
supported within the outer casing. It has 20 reaction stages. IP inner and outer casings as
well as LP inner casing are suspended from top halves to totally eliminate the effect of
TG centerline with the heating of the flanges. Although the casings are of horizontal split
design yet these do not impose any constraints in startup timings and rapid load
fluctuations.
Inlet Temperature

535oC

Outlet Temperature

340oC

Inlet pressure

37 Kg/cm2

Outlet Pressure

7 Kg/cm2

Table No. 3: IP Turbine Features

2.6 LOW PRESSURE (LP) TURBINE

LP turbine is also double flow type with exhaust area optimally selected for the expected
vacuum conditions. It has 8 reaction stages per flow. Special design measures have been
adopted to remove the moisture from the last stages by reducing the thickness of water
film on the guide blades. The axial clearances between the guide blades and the moving
blades have been so chosen so as to reduce the droplet sizes and attendant erosion of
leading edges. Low-pressure extraction has been optimized not only from thermodynamic
considerations but to effectively drain out moisture also.
The casing of LP turbine is connected with IP cylinders by two crosses around pipe, one
on either side of the machine and level with the floor. The horizontally split, fabricated
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LP casing is comprised of three shells. The bearing pedestals are mounted on the
foundation. Freestanding blades have been envisaged. The blades are designed to operate
in the speed range corresponding to 47.5 Hz to 51.5 Hz grid frequency.
Inlet Temperature

360oC

Outlet Temperature

45oC

Inlet pressure

7 Kg/cm2

Outlet Pressure

8 g/cm2

Table No. 4: LP Turbine Features

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2.7 TURBINE SPECIFICATIONS

Make

BHEL

Rated Speed

3000 rpm

Rated Power

24000 Kg

Weight of HP Rotor

5500 Kg.

Weight of MP Rotor

11000 Kg.

Weight of LP Rotor

24000 Kg

Steam Pr. (rated)

Initial Steam
Before MP casing

130 ata
31063 ata

Steam Temp. (rated)

Initial Stem

535oC.

IP Cylinder Stop Valve Inlet

535oC.

HP Cylinder Exhaust

343oC.

LP Cylinder Exhaust

49oC.

Turning Gear Speed

62 rpm

Table No. 5 (a): Turbine Specification

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Type of Turbine

HP cylinder

Regulating stage

Two rows Curtis wheel

Other impulse stage

8 Nos.

MP cylinder

Impulse stage

12 Nos.

LP body

Impulse stage

4 Nos

Oil Tank rated Capacity

12500 Lt.

For oil system of generator

4400 Lt.

Oil Supply

Table No. 5(b): Turbine Specification

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3 DIFFERENT VALVES
HP turbine is fed from 2 combined emergency stop and control valves. Each combined
valves consists of an emergency stop valve and control valve fitted in a common body
with the spindles at right angles and in the same plane. The valves are placed on the
mezzanine floor in front of the turbine. IP turbine is also fed from 2-combined reheat stop
and control valves, which are mounted in the same way as the HP valves.

3.1 COMBINED MAIN STOP VALVE AND CONTROL VALVE

The main stop valves rapidly interrupt the supply of the steam to the turbine after being
triggered by monitors should a dangerous conditions arises therefore they have been
designed for high-speed closing and maximum reliability. The control valve on the other
hand regulates the flow of steam to the turbine according to the prevailing load. One stop
valve and one control valve a share a common body in which steam is perpendicular to
each other and is placed in front of the turbine.

3.2 COMBINED REHEAT STOP VALVE AND CONTROL VALVE

Reheat stop valves are protective devices triggered by monitors in the event of dangerous
conditions to interrupt the flow of steam to the reheat system. The reheat control valves
are only operative in the lower range. Above this range, they remain fully open in order to
avoid throttling losses.

4 TURBINE OIL SYSTEM

Mineral oil with additives (for increasing the resistance to corrosion and aging) is used as
a fluid for actuating the governing system, lubrication of bearings and seal oil to
generator seals. During normal operation the main oil pump supplies oil at pressure 8 bar
approx. to the lubrication seal oil system and governing system. The oil system fulfills
the following functions:

Lubricating and cooling the bearings.

Driving the hydraulic turning gear during interruption operation, on startup and
shutdown.
Jacking up the shaft at low speed.

Under normal conditions, the MOP (Main Oil Pump) situated in the front bearing
pedestal and coupled directly to the turbine shaft, which draws oil from the main oil tank
and supplies it to the pressure oil system. The suction of the main oil is aided by to
injectors. The injector produces pressure at the suction connection to the MOP.
This guarantees that the MOP takes over the supply of oil and cavitations that could occur
due to greater suction heads and avoided. The amount of oil required is extracted from
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the pressure oil circuit and is adjusted by throttles. The oil for turning gear is also
extracted from the pressure oil system. Oil is admitted to the nozzles by opening the shut
off valve. Cooled oil from the oil cooler is reduced to the lubricating oil pressure in the
throttle. During turning gear operation and startup and run-down operation, one of the 3 AOP (Auxiliary Oil Pump) supplies the pressure oil system and takes over the function
of MOP when it is not in operation during turbine running too slow.
The submersible AOP is situated on the main oil tank and draws in oil directly. CheckValves behind the AOP prevents oil from flowing back via pumps that are not in
operation (i.e. MOP). When MOP and AOP fails, the lubrication oil supply is maintained
by Emergency Oil Pump. The pump supplies oil directly to the lubrication oil line, by
passing oil coolers and thus prevents damage to the bearings shells.
The AOP and EOP (Emergency Oil Pump) are automatically started control as soon as
the pressure switch limit has been reach. The function of pressure switches arranged in
the lubricating oil circuit is to operate the main trip valve when the lubricating oil
pressure drops below a said value. The lubricating oil the bearing is returned to the main
oil tank via a header. A loop in the return oil piping behind the seal oil reverse tank
prevents H2 gas reaching the main oil tank when there is any disturbance. Oil for the
Combined Journal and Thrust Bearing is passed through duplex oil filter, for cleaning
during operation.

4.1 OIL SUPPLY DURING NORMAL OPERATION

During the normal operation the main oil pump supplies oil to the lubrication, seal oil
system and governing system.

4.2 OIL SUPPLY DURING STARTUP AND SHUTDOWN

During the startup and shutdown 2 auxiliary oil pumps meet the oil requirement of the
TG set. They draw oil directly from the oil tank and discharged it into the pressure oil
line and continue in operation till the main oil pump takes over the oil supply. A pressure
switch in the pressure oil line gives an indication for switching off the auxiliary oil pump.
During the shutdown another pressure switch automatically switches on the auxiliary oil
pump.

4.3 OIL SUPPLY DURING DISTURBANCES

When the pressure in the pressure oil line falls below a set point pressure switches
automatically start the auxiliary oil pumps. The setting of pressure switches is arranged in
stages so that on fall in oil pressure firstly one auxiliary oil pump is started and the
second pump is stated only when the first pump fails to establish necessary oil pressure in
the pressure oil line. In case main and auxiliary oil pumps cease to operate
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simultaneously a pressure switch in the lubrication oil line starts D.C. emergency oil
pump.

4.4 OIL STRAINER AND VAPOUR EXHAUSTER

The basket type oil strainer is of stainless steel wire mesh of 0.25mm and is mounted in
the tank. The whole tank is made airtight, this produces vacuum in the pump when MOP
or AOP draws oil from main oil tank. Oil vapour exhauster produces a slight negative
pressure in the tank, in the return drain line and in the spaces in the bearing pedestal so
those oil vapours are drawn out.

4.5 OIL LEVEL INDICATOR

The main oil tank has a direct reading fluid level indicator and a fluid limit switch. This
permits signal to be transmitted to UCB when maximum and minimum levels have been
reached. Extra tank volume is proved between the normal operating level and the tank
cover to accept oil from the entire oil supply system when the turbine is shutdown.

4.6 TYPE OF OIL PUMPS

4.6.1 MAIN OIL PUMP (MOP)
The MOP is situated in the front bearing pedestal and supplies the entire turbine with oil
i.e. used for bearing lubrication, cooling the shaft journal and thrust bearing. It is driven
by the turbine and develops the rated discharge pressure at 90-95% rated speed. The main
pump is sized tot eh meet the normal requirements of Lubrication, Seal Oil and
Governing System.

4.6.2 AUXILIARY OIL PUMP (AOP)

It supplies the oil requirements of the turbo set during start-ups and shutdowns. The oil
pump can either be switched on manually or automatically through pressure switches,
which operate when the oil pressure drops to approximately 60% of the normal value.
The setting of the pressure switches is staggered so that one pump comes into operation
before the other one with second one remaining in reserve. The pump continues to remain
available for emergency service through the automatic control system. It is stopped after
the turbo generator set has come to full speed and main oil pump has taken over.

4.6.3 D.C. EMERGENCY OIL PUMP (EOP)

It is standby pump, which can be started manually or automatically through pressure
switch when the tube oil pressure drops to 50% of the normal value. This happens only
when main and auxiliary pumps fail to operate or there is a break down in the electricity
supply system to the pumps. This pump should therefore be fed from station batteries. It
has to be in operation and cater to the need of bearing lubrication and cooling of journals.
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4.6.4 JACKING OIL PUMP (JOP)

When the set is stationary, the shafts come into metallic contact with the bottom bearing
lining. The normal bearing oil supply at low speeds is unable to penetrate to these
surfaces and considerable force is required to initiate rotation of the shaft from rest. This
is overcome by forcing high pressure oil through bottom bearing shell, thereby lifting the
shaft in the bearings and allowing an oil film to form. Now shaft can be set in motion by
application of considerably smaller force. This is a high pressure and low discharge
pump.

4.7 OTHER ACCESSORIES

4.7.1 MAIN OIL TANK
All the oil pumps get supply from clean oil section of the tank. Bearing and other drains
from turbo generator collect in the dirty section from where oil passes through one coarse
and tow fine strainers. Strainers are removable from cleaning, during normal operation.
Oil samples for testing, can be collected above mud collector.

4.7.2 OIL PURIFIER

Removes water and foreign particles from turbine oil. Takes supply of oil from bottom of
mud collecting chamber.

4.7.3 OIL FILTER

Part of the oil supplied by MOP is distributed through a filter to main relay, to an orifice
for converting it to secondary oil and to speed sensing element.

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5 COAL CIRCULATION
5.1 COAL MILL
Coal mills are mainly used to curse the coal. It cursed the coal in powder form. The
powder form o coal is known as scream. In the Unit-5, 6 coal mills are present in the unit.
In which 5 are working & I is standby.

5.2 CONSTRUCTION
a) It has three rollers, which are inclined at 120 degree angle to each other.
b) A whirl shaft is mounted on a motor. It makes 1400 rpm.
c) A-550 H.P. Motor used for rotation. It attached with shaft & it also attached with a
gear, which further transfer power to three roller and gives motion.
d) Mainly three type bearing are used:
Radial
Thrust
Radial support
e) A pump is used for the lubrication oil, to transfer in the bearing & gear.
f) A gland is provided to prevent the leakage of oil & a indicator which gives
indication of oil motion.
g) An inlet pipe, coming from coal bunker is feed the coal in the mill.
h) R.C. feeder provides B/W the inlet pipe & coal bunker.
i) PA fan provide hot air from air pre-heater, for crushing purpose maintenance of
temperature.
j) Also cold air is provided to maintain the temp.
k) 4 pipe lines are used, which are used to transfer the scream coal to the furnace.
l) Conveyer belt is used to transfer out the unnecessary particle like concrete &
small rock part from the coal mill.

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Fig. No. 5: Coal Handling Plant Coal Mill

5.3 WORKING
Coal coming from CHM to coal bunker, which is small, feed able parts. RC feeder
control the feeds of the coal in the mill, three roller crushed the coal like as scream (as a
powder form). Hot air supplied by PA fan help to crush the coal & cold air maintain temp.
Gear present at the bottom is prevent the jamming by giving motion to the powder
[Link] fan maintain sufficient transfer pressure & the coal from 4 outlet pipe is given to
the furnace.

5.4 CIRCULATORY SYSTEM

Coal is transported from the coal mine with the help of train. Train wagons are emptied
with the help of tippler and stored in coal yard. From here it goes to the coal crusher,
where the big size coal is crushed and made into the required size. From coal crusher it
goes to the coal bunker through conveyor belt and from coal bunker it move to R.C.
feeder. R.C. feeder feeds coal to the coal mill, where the coal is ground into powder form.
Air from primary air fan is introduced into the coal mill and coal powder mixed with it
and goes to the classifier.
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The work of classifier is just to separate the un pulverized coal and feed it again to the
coal mill. The pulverized coal mixed with air enters in the furnace at the corner through
and forms a circle due to tangential fired. Here coal burns completely and releases heat
and becomes in ash form. Ash in the furnace is taken away by ID fan through the
Electrostatic precipitator. The purpose E.S.P. is to collect the ash. From the E.S.P. ash
goes to the ash handling plant. The particles of ash which are not collected in the E.S.P.
are goes to atmosphere through the chimney.

5.5 DRAFT SYSTEM

The force needed to draw air is called as draft. This force may be due to small pressure
difference in the stream of flue gases or in the air which cause the flow to take place. In
boiler it is necessary to supply sufficient quantity of air for proper combustion of the fuel
and it is essential to force the fuel gases out of air for proper combustion of fuel and it is
essential to force the fuel gases out of boiler. This is accomplished by suitable fans and
this system is termed as mechanical draft as against natural draft.
In mechanical draft system, there are two type of application namely force draft &
balance drafting. At P.T.P.S. balance draft system is used. Two fans are employed, one
termed force draft other termed as induced draft fan. The F.D. fan is utilized to force
atmospheric air into the furnace and then it is function of ID fan to such out the boiler
flue gases through the economizer, air pre heater etc. & discharging it out through the
stack. There two working together maintain a balance draft which is normally slightly
negative pressure in the furnace.

6 WATER CIRCULATION SYSTEM

In this system the water is delivered to a system generation from heaters at a temperature
well below the saturation value corresponding to that pressure. Entering the economizer,
first it is heated, too much near the saturation temp. From economizer the water enters the
drum and flows down through the drum comer and enters bottom of the riser tubes. In the
riser tube, a part of water is converted to steam and the mixture flows back to the drum.
In the drum, the steam is separated from water particles and fed to water value and,
saturated steam is fed to radiant roof. From here saturated steam is sent to steam cooled
water.
From steam cooled water valve, steam is given to LTSH. From LTSH steam is fed to
platinum super heater and then goes to final super heater. In final super heater,
temperature is up to 540oc and pressure is of 155 kg/cm2. At this temperature and
pressure, steam enters in the H.P. turbine. After doing work steam goes to boiler re-heater
at 38 kg/cm2 pressure and 380oc temp. In re-heater temperature raises 540 oc and pressure
falls to 36 kg/cm2.
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At this temperature and pressure steam enters into the I.P. turbine, here pressure falls to
11 kg/cm2 and 450oc and in this condition it enters in the L.P. turbine.
Turbine rotates at 3000 rpm and it is coupled to 6.6 KV generator which produces
electricity. From L.P. turbine, steam passes to condenser where it is condensed to water
that is collected in the hot well and it is extracted with the help of C.E.P. (condensate
extraction pump) and fed to de-aerator through L.P. heater.
Thus the hydrostatic head available will not be able to overcome the frictional resistance
for a flow corresponding to the minimum requirement of cooling of water wall tunes.
Therefore natural circulation to boiler is limited to pressure of 175 g/cm 2 and in our case
this pressure is about 138 kg/cm2 and hence natural circulation system is sufficient.
The process describes the effect produced by addition of alum to the colloidal suspended
dispersion resulting in particle destabilization by a reduction force which lends to keep
particle apart. Rapid mixing which is done in flash mixer in the clarifloculatior is done to
obtain uniform dispersion. Second stage of formation of particle from destabilized
colloidal fixed particle is termed as flocculation. Here coagulated particles grow in six
by attaching to each other. At this stage particles are large enough to settle rapidly under
the influence of gravity and may be removed. After this the water is passed through the
anthracites pressure filter to remove the suspended impurities and there after sent to the
activated carbon filter to de-chlorinate the filter water as the chlorine is harmful for the
resins through which the water is to pass next. The D.M. water is obtained by ion
exchange process. The filtered water is first passed through cation exchanger process
where the cations of dissolved impurities are removed. Then it is passed to the degassifier tower where most of CO2 is removed.
Thus the pure D.M. water is obtained which is stored in the storage tanks for make-up.
During the process of D.M. cation and anions resins get discharge and have to be
reactivated with the help of HCL and caustic soda D.M. of water is done to prevent the
scale sludge formation problem in the boiler drum which restricts the transfer of head of
water.

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7 CONDENSER
The steam after working in the turbine is condensed in condenser in each unit installed
below the LP exhaust. The condenser is of surface type made of fabricated construction
in single shell. The tube is of divided type double pass arrangement, having two
independent cooling water inlet, outlet and reserve and water boxes. The condenser is
provided with integral air-cooling zone at the centre from where air and non-condensable
gases are continuously drawn out with the help of mechanical vacuum pump.
The condensate is collected at the bottom portion of the condenser called the hot well
from where it is pumped up to the de-aerator by the condensate pumps through the
different heating stages. The function of the condenser is to condense the out coming
steam from LP turbine. In the condenser cooling water flows through the tubes and
exhaust steam from the turbine outside the pipes.

Area of condenser

9655m2.

Cooling water flow rate

2400m3/Hr.

Fig. No. 6: Condenser

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Fig. No. 7: Condenser Tube

8 ELECTROSTATIC PRECIPITATOR
Electrostatic Precipitator (ESP) is equipment, which utilizes an intense electric force to
separate the suspended particle from the flue gases. In India coal is widely used to
generate power. The exhaust gases from the furnace contains large amount of smoke and
dust. If these gases are emitted directly into the atmosphere, it will cause great
environmental problems. So it is necessary to extract this dust and smoke before emitting
the exhaust gases into atmosphere. There are various methods of extracting dust but
electrostatic precipitator is the most widely used. It involves electric changing of
suspended particles, collection of charge particles and removal of charged particles from
collecting electrodes. Its various other advantages are as follows:
a)
b)
c)
d)
e)

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It has high efficiency i.e. about 99%

Ability to treat large volume of gases at high temperature.
Ability to cope with the corrosive atmosphere.
It offers low resistance to the flow of gases.
It requires less maintenance.

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8.1 WORKING PRINCIPLE

The electrostatic precipitator utilizes electrostatic forces to separate dust particles from the
gases to be cleaned. The gas is passed through a chamber, which contains steel plates
(vertical) curtains. These steel curtains divide the chamber into number of parallel paths.
The framework is held in place by four insulators, which insulate it electrically from all
parts, which are grounded. A high voltage direct current is connected between the
framework and the ground, thereby creating strong electric field between the wires in the
framework curtains.

Strong electric field develops near the surface of wire creates Corona Discharge along the
wire. Thus ionized gas produces +ve and ve ions.
In the chamber plates are positively charged whereas the wire is negatively charged.
Positive ions are attracted towards the wire whereas the negative ions are attracted
towards the plates. On their way towards the curtains negative ions strike the dust
particles and make them negatively charged. Thus ash is collected on the steel curtain.
The whole process is divided into the following parts:
a) Corona Generation.
b) Particle Charging.
c) Particle Collection.
d) Particle Removal.

8.1.1 CORONA GENERATION

Corona is a gas discharge phenomenon associated with the ionization of gas molecules by
electron collision in regions of high electric filed strength. This process requires nonuniform electric filed, which is obtained by the use of a small diameter wire as one
electrode and a plate or cylinder as the other electrode. The corona process is initiated by
the presence of electron in strong electric field near the wire. In this region of corona
discharge, there are free electrons and positive ions. Both positive and negative coronas
are used in industrial gas cleaning.

8.1.2 PARTICLE CHARGING

There are two physical mechanisms by which gas ions impact charge to dust particles in
the ESP. Particles in an electric fields causes localized distortion in an electric filed so
that electric field lines intersect with the particles. The ions present in the filed tend to
travel in the direction of maximum voltage gradient, which is along electric field lines.
Thus ions will be intercepted by the dust particles resulting in a net charge flow to the
dust particles.

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8.1.3 PARTICLE COLLECTION

The forces acting on the charged particles are Gravitational, Inertial, Electrostatic and
Aerodynamically. The flow of gas stream is turbulent flow because it causes the particles
to flow in random path through ESP. Particles will be collected at boundary layers of
collector pates. But if flow is laminar, charge will act on particles in the direction of
collecting electrode. This force is opposite to viscous drag force and thus in the short
time, particle would achieve Terminal (Migration) velocity at which electrical and
viscous forces are equal. Thus the flow of the charged particles is decided by the vector
sum of these forces i.e. Turbulent.

8.1.4 PARTICLE REMOVAL

In dry removal of dust collected on plates, Rapping Mechanism is used. It consists of a
geared motor, which moves a long shaft placed near the support collector electrode and is
provided with cylindrical hammer. On rotating of shaft these hammers strikes the
supports causes plates to vibrates and dust is removed from plates. Removed dust is
collected in the Hoppers below the precipitator. So there is a chance of ash deposit at the
exit of the hopper thus causing problem of removing the ash. To avoid this, heaters are
provided which increase the temperature at the exit point of the hopper thus avoiding any
undue accumulation of ash at starting. In order method, the water is allowed to flow
down the collector electrode and hence dust is collected in hoppers below.

8.2 GENERAL DESCRIPTION

The whole Electrostatic Precipitator is divided into following two parts:
Mechanical System.

Electrical System.

Mechanical system: Mechanical system comprises of Precipitator Casing, Hopper,

Collecting and emitting system, and Rapping mechanism, Gas Distribution System.

8.2.1 PRECIPITATOR CASING

Precipitator Casing is made of 6mm mild steel plate with required stiffness. The
precipitator casing is all welded construction comprising of pre-fabricated walls and
proof-panels. The roof carries the precipitator internals, insulator housing, transformer
etc. Both emitting and collecting systems are hung from the top of the casing.

8.2.2 EMITTING AND COLLECTING SYSTEM

Emitting System is the most essential part of ESP. Emitting system consists of rigid
emitting frame suspended from four points on the top and emitting electrodes in the form
of open spiral. The four suspension points are supported on support insulators to give
electrical insulation to the emitting frame.
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The frame is designed to take up the retention forces of the emitting electrode. The
emitting electrodes consist of hard drawn spiral wires and are fastened with hooks to the
discharge frame. Collecting system mainly consists of collecting suspension frame,
collecting electrodes and shock bars. Collecting electrodes are made of 1.6mm thick Mild
Steel sheets formed in G Profile of 400mm width. Hook and guide are welded on one
end and shock iron on the other end on a fixture.

8.2.3 HOPPERS
Hoppers are seized to hold the ash for 8-hour collection and are provided under the
casing of ESP. It is of Pyramidal Shape and is 56 in number. It is preferred to evacuate the
hoppers at the earliest as long storage of dust in hopper leads to clogging of hopper. Also
at the bottom of hopper electrical heating is provided to avoid any condensation, which
could also lead to clogging of hopper. Baffle plates are provided in each hopper to avoid
gas leakage.

9 DUST COLLECTING HOPPER

9.1 RAPPING MECHANISM
During electrostatic precipitation a fraction of the dust will be collected on the discharge
electrodes and the corona will be suppressed as the dust layer grows. So, rapping is done
in order to remove this dust by hammering the electrodes. As the shaft rotates the hammer
tumbles on to the shock bar that transmits the blow to the electrode. The whole rapping
mechanism is mounted on a single shaft, which is coupled with the gear drive motor. The
rapping system avoids the collection of ash on the collecting electrode
Specification:
Voltage and Current

Power and Speed

415V and 5Amp

3.7KW and 710 rpm

9.2 GAS DISTRIBUTION SYSTEM

The good performance of the ESP depends on even distribution of gas over entire cross
section of field. Gas Distribution System distributes the gas evenly in ESP and maintains
its efficiency.

9.2.1 ELECTRICAL SYSTEM

In precipitator we require high voltage dc supply to generate sufficient electric field.
Electrical system comprises of High Voltage transformer Rectifier (HVR) unit with
Electronic Controller (EC), Auxiliary control panel, Safety Interlocks and Field
equipments.

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9.2.2 TECHNICAL SPECIFICATIONS OF ESP

Input to the thyristor controller
Output of T/F or input to ESP
No. of ESP per unit
No. of fields in series of gas path
Time of the flue gas pass through ESP
No. of electrode per boiler
No. of hoppers per unit
No. of rapping motors for collecting electrodes
Normal height of collecting electrodes

415 V (AC)
70 KV (DC)
2
7
32.31 sec
3780
56
14 per unit
12.5 m

Table No. 6: Technical Specification of ESP

9.2.3 ESP PROTECTIONS

Short Circuit Protection: By under voltage relay 10-50% of primary volts with time
delay from 10 sec to 80 sec can be adjusted.
Over-Load Protection: By thermal overload relay on primary side.

10 ASH HANDLING SYSTEM

It is very import to control the ash coming from the furnace.
a) WET ASH HANDLING SYSTEM
b) DRY ASH HANDLING SYSTEM
A pipe line from ESP which contains the ash in divided in two parts. Use of Dry ash
Evacuation instead of WET deashing System: Dry deashing system consumers less power
& also minimizes waste reduction. The dry ash is directly transferred by vacuum system
at desired place in plant it transfers to nearest cement factory. It is act as a good source of
income for the plant.
The wet ash is transferred to the wet ash handling, in this vacuum created by water flow.
Ash mix with the water and transferred to the ash pump from there it is drain out from the
plant in to the lake. From here it is given to the raw water storage. The ASH produced in
the boiler is transported to ASH dump area by means of sluicing type hydraulic ASH
handling system. This consists of bottom ash system. Ash water system, fly ash system,
ash slurry system which are explained as follows:

10.1 BOTTOM ASH SYSTEM

In the bottom ash system, the ash slag discharge from furnace bottom is collected into
water impounded scraper through installed 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
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clinker grinders falls in to the ash slurry further transported to ash slurry sump added by
ash sluice channel. If the clinker grinder is not in operation, bottom ash can be discharged
directly into the sluice channel through the bifurcating chute by passing the grinder. The
position of the top gate in the bifurcating chute is to be manually changed.

10.2 FLY ASH SYSTEM

The flushing hoppers are provided under EP hopper (40nos), Economizer hoppers (4nos),
air pre heater (4nos) & stack hoppers (2nos). The fly ash collected in these hoppers drop
continuously to flushing apparatus where fly ash get mixed with flushing water & the
resultant slurry drops into the ash sluice channel. Low-pressure water is applied through
the nozzle directing tangentially to the section of pipe, to create turbulence & proper
mixing of ash, with water.

10.3 ASH WATER SYSTEM

High pressure water required for B.A. hoppers quenching nozzles, window spraying,
clicking grinder sealing bars, cleaning nozzles, B.A. hoppers seal through flushing,
economizer hoppers, flushing nozzles is tapped from the high pressure water ring main
provided in the plant area.

10.4 ASH SLURRY SYSTEM

Bottom Ash and Fly Ash slurry of the stream is sluiced up to ash slurry 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 value, reducer and
butterfly value and portion of slurry pump, delivery line consisting of butterfly value,
pipe & fittings as also been provide.
Now the oil is first atomized in the oil guns under the pressure of steam through nozzles
and after atomization, the oil is sprayed at every corner of the furnace for initial ignition.
After this coal received from the mill in pulverized form is burnt in the furnace.
Combustion air is supplied through the forced air fans and primary air fans. The coal after
the combustion gives out the energy, which is used to heat up water in tubes and convert
this water into steam. The flue gases formed are taken through chimneys with the help of
induced fans.

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11 REGENERATIVE SYSTEM
The condensate and feed water are heated in 8 stages by the non-regulated extractions
from the turbine, comprising of 5 low pressure heaters, a de-aerator and two high
pressure heaters. In addition to this, the entire condensate flows to de-aerator, through
steam jet air ejector, chimney steam condenser and gland steam condenser.
The first and second stage of regenerative heating is done by two, double low pressure
heaters which are mounted directly in the low pressure casing of the turbine. In between
the 2nd and 3rd stages of heating, the chimney steam and gland steam condensers are
located.
3rd, 4th and 5th low pressure heaters form the individual stages of heating. The de-aerator
forms the next stage of heating, heated by the steam from Extraction-VI. The condensate
cycle is protected from any abnormal rise of pressure by relief safety valves.
The high pressure heaters are located in the feed water cycle between the feed water
pump and the boiler and heated by steam from the 7 th and 8th extractions. The 8th
extraction steam is taken from the cold reheat line.

12 HYDROGEN COOLING SYSTEM

Hydrogen gas is one of the best cooling media chosen for turbo-Alternator Cooling. Its
supremacy over other cooling medium and final selection for use is due to:
(a) Higher heat transfer co-efficient.
(b) Thermal conductivity 7.3 times better than air.
(c) Ability to transfer heat through forced convection 50% better than air.
(d) Permitting higher current densities for the same temperature rise and with more
efficient cooling. This allows higher outputs.
(e) Elimination of fire risk since hydrogen will not support combustion.
(f) Corona discharge is not harmful to insulation since oxidation is not possible.
(g) Smooth operation of machine in view of virtual elimination of windage noise and
the use of heavy gas tight enclosure.
(h) Its density begin approximately 1/14th that of air at a given temperature and
pressure due to which windage loss is 1/10 th in comparison of air as cooling
medium.
(i) Reduced machine maintenance because of gas tight enclosure and hence a dirt
proof casing.

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13 WATER CLARIFIER
It received impure water from raw water storage. In raw water storage big suspended
particle settle down.
In water clarifier the purification of raw water held in two processes.
I.
Coagulation
II.
Chlorination
In coagulation, Potash alum is added in the water. In this process the file suspended &
colloidal particles are removed from water.
In chlorination, chlorine gas is added to the water, which have disinfectant action & it kills
the harmful bacteria, germs & destroyed the pathogenic micro organism. Excess of chlorine
in water will effect to the taste of water.

13.1 D.M. PLANT

In the DM Plant the water is D-mineralized. The water is used for steam generation is
must be free from colloidal & dissolved impurities. All the colloidal impurities are
removed in the Water Clarifier. Then it supplied to the DM Plant.
Here the water contains dissolved impurities, which are mainly the salt of Ca, Na & Mg.
It mainly sulphates, chloride, CaSO4, NaCl, CaCl2 etc
In the DM Water Ist sent to the Sand filter & rest of the colloidal impurities are removed.
Sand filter AC filter Cation tank Gas tower Anion tank
Now the water goes to the Activated Carbon filter. Here the excess of the chlorine is
decomposed.
Then water supplied in the cation tank & in this cation (Ca++, Na+ , Mg++) are removed
& water with anion allow to pass ahead.
R-H+ + NaCl R Na + H Cl
HCl is added time to time to improve the conc. of the cation tank. The process is known
as the Regeneration.
Then it allows passing from the gas tower which removed the Co 2 which produced during
the purification process.
Then it pass from the anion tank & all the anion Cl -, So4- - are removed out. Also
regeneration are done by adding any base solution, like NaOH etc.

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At last it passed in the mixed bed all the minerals present in the water removed & the
water is completely free from minerals.

13.2 STEAM CONDITION

Tri sodium phosphate & ammonia is added to maintain the pH of the water at specified
value. Also another chemical N2H4 to remove the dissolved oxygen present in the water.
a) Air Pre-heater: Regenerative air pre-heaters cause temperature and SO3
stratification in the downstream gas flow. This problem is more severe in closely
coupled systems, where the precipitator is located closed to the air pre-heater.
Depending upon site-specific conditions, flow mixing devices may be installed in
the ductwork to the precipitator, or flue gas conditioning systems may be used to
equalize the gas flow characteristics.
b) Coal Burner: The operation of coal burners, together with the setting of the coal
mills and their classifiers, affects the percentage of unburned carbon (LOI or
UBC) in the fly ash. The use of Lo-NOx burners increases this percentage, and
caused re-entertainment and increased sparking in the precipitator. Further, the
UBC tends to absorb SO3, which in turn increases the fly ash resistivity. Over-fire
air optimization or coal re-burn systems may reduce UBC in the fly ash.

14 CHIMNEY
The gases produced due to burning of coal are comes out from chimney. The height of
chimney is designed with respect to the boiler layout. The temperature is also maintained
in the chimney. It is not more than 120 c. If it more than 120 c, then boiler will be
corrupt.

14.1 FLY ASH AND FLUE GAS CONDITIONING

Flur gas and fly ash characteristics at the inlet define precipitator operation. The
combination of flue gas analysis, flue gas temperature and fly ash chemistry provides the
base for fly ash resistivity involves both surface and volume resistivity. As gas
temperature increases, surface conductivity decreases and volume resistivity increases.
In lower gas temperature ranges, surface conductivity predominates. The current passing
through the precipitated fly ash layer is conducted in a film of weak sulfuric acid on the
surface of the particles. Formation of the acid film (from SO 3 & HO) is influenced by the
surface chemistry of the fly ash particles.
In higher gas temperature ranges, volume conductivity predominates. Current conduction
through the bodies (volume) of the precipitated fly ash particles is governed by the total
chemistry of the particles.
Fly ash resistivity can be modified (generally with the intent to reduce it) by injecting one
or more of the following upstream of the precipitator.
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Sulfur trioxide (SO3)

Ammonia (NH3)
Water

15 FUNCTIONS OF VARIOUS PARTS OF THE CYCLE

15.1 P.A. FANS
These fans are used to supply the hot air in order to dry powdered coal. To transport
pulverized coal to the furnace the speed of PA fans 1400 rpm and they supply 83800 m3
per hour. These are installed either side of boiler.

15.2 AIR HEATER

It is an essential part of a thermal power plant as hot air is necessary for rapid and
efficient combustion in the furnace and also for drying coal in the milling plant. At PTPS
tabular type air heater are being used it consists of large number of steel type welded to
the tube plates at the end. Gas is allowed to flow through the tubes and cold air passes
around these tubes and gets heated up. These air heaters provide primary as well as
secondary air.

15.3 SECONDARY AIR CYCLE

In this cycle FD FANS suck air from the atmosphere and supply it to the wind box of the
furnace through air heater and regulating dampers. Then it moves to the furnace as per
requirements.

15.4 F.D FANS

These are used to take air from the atmosphere at ambient temperature to supply it
to the furnace for combustion purpose.
Speed is about 990 rpm and it handles 203760 m3 of air per hour.
These are installed either side of boiler.

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Fig. No. 8: FD Fan

15.5 WIND BOX

This acts as distributing media for supplying secondary and excess air to combustion
chamber. These are generally located at right and left side of the furnace while facing the
chimney.

15.6 INDUCED DRAFT FANS (ID FANS)

These are used to suck the flues gases from the furnace and through it into the
stack so as to dispose them off into the atmosphere.
It handles flash laden gases at a temp. Of 125 to 200degrees
Its speed is around 970 rpm and it handles 453600 m3 of air per hour
These are installed at the outlet of electrostatic precipitator.

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Fig. No. 9: Induced Draft Fan

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16 CONCLUSION
This training focused upon increasing our knowledge and interest in toward the
Production of Electricity using Coal as a primary source/fuel. Because Electricity is most
efficient and necessary needs to peoples in these days so its production at most efficient
method with minimum cost and in proper sequence with less wastage. I learnt how to
produce it by turbine, generators, cooling towers, water and maintain it. It was a great
experience. It increases my practical skill thats the main thing which I learnt in the
training session. Thus, I believe that my training session will be beneficial for various
purposes & hence our efforts will be fruitful.

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17 REFERENCES & BIBLIOGRAPHY

I.

BOOK

Thomas C. Elliott, Kao Chen & Robert Swanekamp. Standard Handbook of

Powerplant Engineering (2nd ed.). McGraw-Hill Professional, 1997.

A. Yunus & A. Michael. Thermodynamics an Engineering Approach. Tata

McGraw Hill, New Delhi, 2007.

P. K. Nag. Power Plant Engineering, Tata McGraw Hill. New Delhi, 2007.

II.

SCHOLARLY JOURNAL ARTICLES

N. Arai, H. Taniguchi, K. Mouri and T. Nakahara, Exergy Analysis on

Combustion and Energy Conversion Processes, Energy, Vol. 30, No. 2-4, 2005,
pp. 111-117.

A. Bejan, Fundamentals of Exergy Analysis, Entropy Generation Minimization,

and the Generation of Flow Architecture, International Journal of Energy
Research, Vol. 26, No. 7, 2002, pp. 545-565.

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18 CHECKLIST
This checklist is to be attached as the last page of the report.
This checklist is to be duly completed by the student and verified by the Faculty

Project Coordinator.

1.

Is the report properly hard/ spiral bound?

Yes / No

2.

Is the Cover page in proper format?

Yes / No

3.

Is the Title page (Inner cover page) in proper format?

Yes / No

4.

(a) Is the Certificate from the Company in proper format?

Yes / No

(b) Has it been signed by the Manager?

Yes / No

(a)

Yes / No

5.

Is the Acknowledgement from the Student in proper

format?
(b) Has it been signed by the Student?
7.

Does the Table of Contents include page numbers?

Yes / No

(i).

Are the Pages numbered properly?

Yes / No

(ii).

Are the Figures numbered properly?

Yes / No

(iii).

Are the Tables numbered properly?

Yes / No

(iv).

Are the Captions for the Figures and Tables proper?

Yes / No

(v).

Are the Appendices numbered properly?

Yes / No

8.

Is the conclusion of the Report based on discussion of the work?

Yes / No

9.

Are References or Bibliography given in the Report?

Yes / No

Have the References been cited inside the text of the Report?

Yes / No

Is the citation of References in proper format?

Yes / No

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10.

A Compact Disk (CD) containing the softcopy of the Final Report

(preferably in PDF format) and a Final Project Presentation in
MS power point only has been placed in a protective jacket
securely fastened to the inner back cover of the Final Report.
Write the name and Roll No on the CD.

Yes / No

Declaration by Student
I certify that I have properly verified all the items in the checklist and
ensure that the report is in proper format as specified in the course
handout.

Name:
Place:
Date:
Signature of the Student:

Verification by Faculty Project Coordinator

I have duly verified all the items in the checklist and ensured that the report
is in proper format.
Name:
Place:
Date:
Signature of the Project Coordinator:

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