Abhijeet MADC Nagpur Energy Private Limited (AMNEPL)

INDUSTRIAL TRAINING REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT OF THE COURSE OF B.Tech

Undertaken at
MIHAN THERMAL POWER PLANT, NAGPUR (MAHARASHTRA)

FROM: 31 May to 28 June, 2012

CERTIFICATE

This is to certify that Mr.Abhay Khedia( 09BME261) student of Bachelor of Technology in Mechanical engineering Stream, 4th Year of VELLORE INSTITUTE OF

TECHNOLOGY,VELLORE has successfully completed his industrial training at MIHAN Thermal power station Nagpur for four weeks from 31 may to 28th june, 2012.

Date : 15/06/2012 Training Incharge (Abhijeet MADC Nagpur energy pvt Ltd )

ACKNOWLEDGEMENT
With profound respect and gratitude, I take the opportunity to convey my thanks to complete the training here.

I do extend my heartfelt thanks to Mr.NCSV Raju (AGM-HR) and Mr. Ninad Sherekar (HOD-C&I) for providing me this opportunity to be a part of this esteemed organization. I sincerely thank to,Mr. Prashant Wagadre (HR) and Mr. for their co-operation and our co-ordinators support.

I am extremely grateful to all the technical staff of Mihan Power Plant for their co-operation and guidance that helped me a lot during the course of training. I have learnt a lot working under them and I will always be indebted of them for this value addition in me. I would also like to thank the training in charge of and all the faculty member of Electrical & Electronics department for their effort of constant co-operation, which have been significant factor in the accomplishment of my industrial training.

Training at MIHAN POWER PLANT (MPP)

I was appointed to do four-weeks training at this well established organization from 26th April to 24th May 2012. In these four weeks I was allotted the job to visit various division of the plant and to study instrumentation used in plant.

This four-week training was a very educational adventure for me. It was really amazing to see the Power Plant by yourself and learn how electricity, which is one of our daily requirements of life, is generated.

This report has been made by self-experience at MPP. The material in this report has been gathered from my textbooks, senior student report, and trainer manual provided by training department. The specification & principles are learned by me from the employee of each division of MPP.

INTRODUCTION ABHIJEET GROUP

Abhijeet Group of Nagpur promoted by Mr. Manoj Jayaswal The Group is a well-diversified business entity with significant presence in the core sector areas of Power, Mining, Ferroalloys, Steel and Roads. Abhijeet Group is a thorough professionally managed organization and takes immense pride in its highly committed, dedicated and dynamic workforce. Various companies of the Abhijeet group in past have successfully completed Build-Operate-Transfer (BOT) projects.

MADCL- Maharashtra Airport Development Company Limited

MADCL was incorporated in 2002, by the Government of Maharashtra as the nodal agency for implementing project Multi-modal International Cargo Hub and Airport at Nagpur(MIHAN )along with development of airports in the State of Maharashtra. As on March 31, 2009 the company was managed by a 14-memberBoard of Directors with Mr. A.S. Chavan ( Honble Chief Minister of Maharashtra) being the Chairman

AMNEPL- ABHIJEET MADC NAGPUR ENERGY PRIVATE LIMITED

AMNEPL is promoted by Abhijeet Infrastructure Limited (AIL) (74% stake) and MADCL(26%). Mr. Manoj Jayaswal is the Chairman of the company and Mr. B. K. Bonde is the representative Director from MADCL. They are assisted by a team of qualified, professional and experienced management with significant experience in the industry. AMNEPL is setting up a thermal power plant at Nagpur for exclusively supplying power to the upcoming SEZ and MIHAN

MIHAN POWER PALNT

The MIHAN Power Plant, being developed by our 74.00% owned Subsidiary, Abhijeet MADC Nagpur Energy Private Limited (AMNEPL) near Khairy Khurd village, in Nagpur district, Maharashtra, will have four coal-fired sub-critical generating units of 61.5 MW each and a 25 MW back-up diesel generator , with a combined installed capacity of 271 MW. This MPP is basically built to fullfil the requirements of MIHAN. The engineering, procurement and construction contracts for the power project have been awarded to Abhijeet Projects Limited (APRL), a Group Company. In turn, APRL has awarded the boiler, turbine and generator contract to DF Power Systems Private Limited. First unit of 61.5 MW was commissioned in January 2011 and the second unit of 61.5 MW was commissioned in April 2011. The third unit of 61.5 MW is commissioned in May 2011. The power project is expected to be fully commissioned by June-2011 5

INDEX 1. Coal to electricity basics8 1.1 Coal to steam 1.2 Steam to mechanical 1.3 Mechanical to electrical 2. Basic power plant cycle10 2.1 factors affecting thermal cycle efficiency 2.2 regenerative feed water heating 3. Coal handling plant 12 3.1 Components of coal handling plant 3.2 Coal lab overview 4. Boiler 15 4.1 Boiler specification 4.2 Structure of boiler 4.3 Flow of water and steam 4.4 High efficiency cyclone separator 4.5 Drum and its specification 4.6 Combustion equipment 4.7 Economizer 4.8 Air pre heater 4.9 Soot blower 5. Fan21 6. Turbine 22 6.1 Main technical specification 6.2 Steam turbine cycle 6.3 Components of turbine 6.4 Lubrication system for turbine and generator 7. Water treatment plant26 7.1 Pre treatment plant
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7.2 Demineralization 7.3 Water softening plant 7.4 Effluent treatment plant 8. Cooling towers29 9. Ash handling plant..29 9.1 Bottom ash handling system 9.2 Economizer and air pre heater ash removal syatem 9.3 Dry fly ash extraction and transportation system 9.4 Dry ash disposal system 10.Mechanical maintenance.31 11.Switch yard..32

1. Coal to electricity basics

The basic steps in the generation of electricity from coal involves following steps: Coal to steam Steam to mechanical power Mechanical to electrical power Coal to electricity basics The basic steps in generation of electricity from coal to steam are shown below :

COAL

Super heated steam

Turbine torque

AC in stator

ASH

HEAT ENERGY LOSS IN CONDENSOR

MECHANICAL ENERGY LOSS

ELECTRICAL ENERGY LOSS

CHEMICAL ENERGY

THERMAL ENERGY

KINETIC ENERGY

ELECTRICAL ENERGY

1.1 COAL TO STEAM Coal from the coal trucks is unloaded in the coal yard .In the C.H.P, this coal is taken to the raw coal bunkers with the help of conveyor belts. Coal is then transported to crushers by coal feeders where it is reduced to size from 9mm. This crushed coal is taken away to the furnace through coal belt conveyor with the help of Primary air fan. This fan takes atmospheric air, a part of which is sent to pre heaters while a part goes to the mill for temperature control. Atmospheric air from S.A. fan in the air heaters and sent to the furnace as combustion air. Water from boiler feed pump passes through economizer and reaches the boiler drum. Water from the drum passes through the down comers and goes to the bottom ring header. Water from the bottom ring header is divided to all the four sides of the furnace. Due to density difference the water rises up in the water wall tubes. This steam and water mixture is again taken to the boiler drum where the steam is sent to super heaters (LTSH and HTSH) for super heating. The super heaters are located inside the furnace and the steam is super heated (540 degree Celsius) and finally it goes to the turbine.

Fuel gases from the furnace are extracted from the induced draft fan, which maintains balance draft in the furnace with P.A and S.A fans. These fuel gases heat energy to the various super heaters and finally through air pre heaters and goes to electrostatic precipitators where the ash particles are extracted. This ash is mixed with the water to form slurry and is pumped to ash dyke. The steam from boiler is conveyed to turbine through the steam pipes and through stop valve and control valve that automatically regulate the supply of steam to the turbine. Stop valves and controls valves are located in steam chest and governor driven from main turbine shaft operates the control valves the amount used. Steam from controlled valves enter high pressure cylinder of turbines, where it passes through the ring of blades fixed to the cylinder wall. These act as nozzles and direct the steam into a second ring of moving blades mounted on the disc secured in the turbine shaft. The second ring turns the shaft as a result of force of steam. The stationary and moving blades together. After that the steam is taken out from the 6 extractions and fed to the feed-water heaters (LP and HP). 1.2 Steam to mechanical power From boiler a steam pipe conveys steam to the turbine to the stop valve (which can be use dto shut off the steam in case of emergency ) and through control valves that automatically regulate the supply of the steam to the turbine . stop valve and control valve are located in steam chest and governor, driven from the main turbine shaft , operates the control valves to regulate the amount of steam used ( this depends upon the speed of the turbine and amount of the electricity required from the generator ) 1.3 Mechanical to electrical power As the blades of the turbine rotates, the shaft of the generator,which is coupled to that of the turbine also rotates. It results in the rotation of the coil of the generator, which causes induced electricity to be produced.

2. Basic power plant cycle

The ideal Rankine cycle consists of the following four processes:

1-2 Isentropic compression in a pump 2-3 Constant pressure heat addition in a boiler 3-4 Isentropic expansion in a turbine 4-1 Constant pressure heat rejection in a condenser Water enters the pump at state 1 as saturated liquid and is compressed isentropically to the operating pressure of the boiler. The water temperature increases somewhat during this isentropic compression process due to a slight decrease in the specific volume of water. The vertical distance between states 1 and 2 on the T-s diagram is greatly exaggerated for clarity. Water enters the boiler as a compressed liquid at state 2 and leaves as a superheated vapor at state 3. The boiler is basically a large heat exchanger where the heat originating from combustion gases, nuclear reactors, or other sources is transferred to the water essentially at constant pressure. The boiler, together with the section where the steam is superheated (the superheater), is often called the steam generator. The superheated vapor at state 3 enters the turbine, where it expands isentropically and produces work by rotating the shaft connected to an electric generator. The pressure and the temperature of steam drop during this process to the values at state 4, where steam enters the condenser. At this state, steam is usually a saturated liquidvapor mixture with a high quality. Steam is condensed at constant pressure in the condenser, which is basically a large heat exchanger, by rejecting heat to a cooling medium such as a lake, a river, or the atmosphere. Steam leaves the condenser as saturated liquid and enters the pump, completing the cycle. In areas where water is precious, the power 10

plants are cooled by air instead of water. This method of cooling, which is also used in car engines, is called dry cooling. Remembering that the area under the process curve on a T-s diagram represents the heat transfer for internally reversible processes, we see that the area under process curve 2-3 represents the heat transferred to the water in the boiler and the area under the process curve 4-1 represents the heat rejected in the condenser. The difference between these two (the area enclosed by the cycle curve) is the net work produced during the cycle.

2.1 Factors affecting thermal cycle efficiency

Initial steam pressure Initial steam temperature Whether reheat is used or not,if used reheat pressure and temperature Condenser pressure Regenerative feedwater heating In our plant we are using regenerative feed water heating to increase the efficiency of thermal power plant . 2.2 Regenerative feed water heating :In Rankine cycle heat is transferred to the working fluid in boiler at a relatively low temperature. This lowers the average heat addition temperature and thus the cycle efficiency. To remedy this shortcoming, we look for ways to raise the temperature of the liquid leaving the pump (called the feedwater) before it enters the boiler.A practical regeneration process in steam power plants is accomplished by extracting, or bleeding, steam from the turbine at various points. This steam, which could have produced more work by expanding further in the turbine, is used to heat the feedwater instead. The device where the feedwater is heated by regeneration is called a regenerator, or a feedwater heater (FWH). Regeneration not only improves cycle efficiency, but also provides a convenient means of deaerating the feedwater (removing the air that leaks in at the condenser) to prevent corrosion in the boiler. It also helps control the large volume flow rate of the steam at the final stages of the turbine (due to the large specific volumes at low pressures). A feedwater heater is basically a heat exchanger where heat is transferred from the steam to the feedwater either by mixing the two fluid streams (open feedwater heaters) or without mixing them (closed feedwater heaters). 11

3.Coal handling plant (CHP)

As coal is the prime fuel for the thermal power plant , adequate emphasis should be given for its proper handling and storage.also it is equally important to have a sustained flow of this fuel to maintain uninterrupted power generation. There are four units of power generation. Each unit requires 700-800 tonnes of coal per day to generate 61.5 MW of electricity. Basic coal handling plant cycle

250mm

70mm

9mm

Coal yard

Primary crusher

Secondary crusher
If 9mm

Screening house

boiler 3.1 Components of coal handling plant : Primary crusher : In primary crusher there are two horizontal cylinders between it 70mm space. It crushes coal below 70mm size. It capacity is 440TPH.( tonnes per hour). It has two rollers one is fixed and one is flexible and both are rotating in opposite directions. There are two primary crushers in the plant. Secondary crusher : The secondary crusher is reversible impact type of crusher. impact is made by hammer to crush the coal. There are 64 hammers of average weight of 12 kg which rotates at 440 rpm. It crushes the coal below 9mm. its capacity is 550 tph. There are total 4 secondary crushers in the plant. Vibrating screen: The function of vibrating screen to send the coal to the secondary crusher if the size of the coal is greater than 9 mm.the screen house consist of three vibrating screens. These screens have rotational as well as translational motion in order to have uniform distribution and to protect the screen from getting damaged.There are three screens arranged linearly as follows :

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1 screen - 2030mm 2 screen-916mm 3 screen-916mm. Hopper and vibrating feeder. Each crusher has surge hopper in order to distribute the coal uniformly. Vibrating feeder is used to feed the coal on the underground conveyor belt from where coal goes to bunkers . coal from the stock yard with the help of JCBs is taken to the vibrating feeder via hopper and underground conveyor belt. A tripper is provided in conveyor to stack the material at the desired location on either side or along the conveyor with the help of chute or chute fitted with the tripper itself. The tripper is provided with wheels which move on rails parallel to conveyor. There are three types of trippers :

1. Motorized tripper 2. Bell-propelled manually operated tripper 3. Winch driven tripper.

Conveyor Belts There are 14 conveyors in the plant. They are numbered so that their function can be easily demarcated. Conveyors are made of rubber and move with a speed of 150-180 m/min. Motors employed for conveyors has a capacity of 150 HP. Conveyors have a capacity of carrying coal at the rate of 400 tons per hour. Few conveyors are double belt, this is done for emergency so that if a belt develops any problem the process is not stalled. The conveyor belt has a switch after every 25-30 m on both sides so stop the belt in case of emergency. The conveyors are 1m wide, 3 cm thick and made of chemically treated vulcanized rubber. The max angular elevation of conveyor is designed such as never to exceed half of the angle of response and comes out to be around 20 degrees.

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3.2 Coal lab overview

FLOW CHART

Purchase of coal from supplier

Sample of coal is collected from coal yard

Record this detail in proper formed

Collection of the sample on random basis as per SOP Received the sample and prepare as per lab size

Preparation of five number Quality sample packet

Three sample after signatue & seal kept in the plant

One quality sample One quality sample packet send to coal packet reefed for lab sample

Analysis of sample as per SOP

Preparation of test report at Lab Circulating Quality report to top management

The following test are performed in coal lab : Inherent moisture : inherent misture means moisture that exists as an integral part to the coal seam in its natural state, including water in pores, but excluding that present in macroscopically visible fractures. Total moisture : the coal which has been exposed to the contact with water in seam or in washery , or coal or coke wetted by rain may carry free or visible moisture .this water plus the moisture within the material is referred as total moisture. 14

 Volatile matter: it is the amount of gases that are entrapped in the coal. Fixed carbon : the amount of elemental carbon present in the coal GCV(gross calorific value): the amount of heat generated by burning 1 gm of coal completely in presence of oxygen.

4. Boiler
4.1 Boiler specification : Rated evaporation (MCR): 250 t/h Peak capacity: 275 t/h1/2 hr every 12hs Rated steam temperature5400-5DegC Rated steam pressure: 9.8MPa(gauge) Rated feed water temperature: 235 DegC Boiler flue gas discharge temperature: ~140 DegC Blowdown ratio: 2 % Ambient temperature at design state: 35DegC PA & SA ratio:~ 6040 Circulation ratio: 2030

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4.2 The structure of boiler The boiler is of high pressure & high temperature, with single drum horizontally placed, single furnace, natural circulation, full overhung construction and steel structure disposed in type. The part above the operation level is arranged at the open air and the part below the operation level is sealed. At the elevation of 11m of the operation level the steel construction platform is placed. The furnace adopts the membrane type water wall. The center portion of the boiler is the scroll case type steam cooled cyclone separator. The two stages of 3 groups of convection super heaters are arranged inside the silo flue gas path. Under the super heaters there are three sets of economizers, three sets of primary air preheaters and two sets of secondary air preheaters. The boiler is circulating fluidized bed (CFB) boiler, which is a new product manufactured based on the vast experiences of manufacturing of the CFBC boiler of WHBC in corporation with the Physical Research Institute of Chinese Academy of Science. In the combustion system the coal is fed into the furnace through the coal chute by means of coal feeder. The primary and secondary air fans provide the required volume of air for combustion of the boiler separately. The air supplied by the primary air fan will be guided into the air paths (left and right side) after passing through the air preheater to be preheated and then the same will enter into the combustion chamber through the air nozzles on the water cooling grid plate. The air supplied by the secondary air fan, after passing through the air preheater to be preheated, will be guided into the furnace of the boiler to makeup the requirements of the air to increase the turbulence in the furnace for proper combustion. The same will enter into the furnace through the spouts/Nozzles on the front and rear walls of the furnace. The fuel combusts with the circulated materials under the fluidized condition inside the furnace and when the concentration of the mixed materials reaches to a certain requirements the majorities of the materials will move upward from the inlet portion inside the furnace and then starts the heat exchanges process with the heating surfaces when it moves downward along with the wall by means of the inner circulation mode. The small particles in the flue gas (often carries large amount of carbon particles) flying out of the furnace will enter into the cyclone separator to be separated and whatever not passed through the separator will again return to the furnace to be combusted. The clean flue gas will be drained out from the end of the gas path after passing through the guiding chamber, high temperature super heater, low temperature super heater, economizer, and the primary and secondary air preheaters. Owing to the adoption of the mode of the combustion of the circulation fluidized bed and by adding the limestone into the furnace the content of the SO2 in the flue gas can be significantly 16

reduced and at the same time the generation of the NOx can be efficiently controlled by means of combustion technology of the low temperature and stage wise air supplies. The ash coming out of the ash coolers and other ash drain points are to be removed by the customer with proper ash handling system to avoid the environmental problems. 4.3 The flow of the water and steam: The feed water will enter into the drum after heated by the 3 sets of economizers that are horizontally placed. The water in the drum will first enter into the water cooled membrane type furnace through the down comer & distribution pipes and bottom headers, after heat transfer in the furnace water and steam mixture enter in to the drum through the upper header and raisers. The steam and water separation device is arranged inside the drum. The saturated steam by means of the steam connecting pipe on the top of the drum, after passing through the steam cooled cyclone tubes, enclosure pipes on the enclosure wall, low temperature super heater, 1st stage attemperature, screen super heater, 2nd stage attemperature, high temperature super heater, will be guided into the steam turbine.

4.4 High efficiency cyclone separator: The purpose of cyclone is to refeed the unburned coal into the furnace. It is based on the centrifugal principal. The cyclone separator is the very important component of the CFBC boiler.The CFBC boiler adopts the high efficiency scroll case steam cooled cyclone separator technology, which is a patent of the Chinese Academy of Science. The 2 numbers of cyclone separators are placed parallel at the outlet of the furnace, the diameter of the separator is 4400mm, with the shell of the cyclone made up with the 386 tubes. The inlet mode is scroll case type. This type of separator has the features of high efficiency separation as well as increasing the combustion. The separated materials from the flue gas will be returned to the furnace through the return material inlet whereas the flue gas will flow to the rear convection-heating surface. The working temperature of the materials separation and the return materials circuit is around 950 degree. The steam cooled heating surface of cyclone separator could absorb the heat from the after-combustion of the material, prevent the agglomeration forming by the high temperature, expand the scope of coal adapted for the boiler and because the flameresisting layer is relatively thinner, the boiler start-up time could be shorten.

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 Anchors inside the separator and the special anti-wearing plastic material with the thickness of 60mm could protect the inner surface of the separator and increase the service life of the cyclone separator. The outlet of the cyclone separator adopts the alloy materials for high temperature resistance and the material adopted is 1Cr25Ni20Si2. The inlet of the separator has the manhole and the sealing property is ensured. The thermocouple socket as well as the peephole is designed in the return materials device to monitor the movement of the materials. The steam-cooled separator can be performed as part of the superheated heating surface.

4.5 The drum and its specification The drum ID is 1600mm and wall thickness is 100 mm, head cover thickness 100mm and the length of the cylinder is 14000mm the total length of the drum is ~13870mm. The material is SA-299 GrA. The normal water level of the drum is 180mm below the centerline of the drum. The gap between the high water level or the low water level and the normal water level is 50mm. The single stage vaporization system is adopted which has the arrangement of cyclone separator, cleaning sieve plate and the top shutters, etc. 4.6 The combustion equipment The combustion equipment consists of coal feeding system, air distribution system, deslagging system, limestone feeding system, ignition system, materials returning system. The coal feeding system The boiler adopts the front feeding mode and 4 numbers of belt feeders are provided. Interfaces for Indian coal, limestone and bed material are set on the feeders. The feeders are connected with the coal chutes by means of expansion joints to satisfy the expansion requirement (147mm) between the feeders and the furnace water wall. The fed quantity of the coal is designed based on the principle that the three feeders can guarantee to feed the sufficient quantity of coal to satisfy the 100% rated output of the boiler even the other one feeders are not functioning. The air distribution system The air chamber consists of the rear water wall that is bending forward and the sides water walls. There is 100mm thickness concrete that is cast inside the air chamber to 18

avoid the overheating of the fins during the ignition and reduce the water-cooling degree inside the air chamber. The required primary air by the combustion chamber is guided inside through the sides air ducts that are located on the left and right side. In between the air chamber and furnace there is the air distribution plate that is welded with the water wall by flat steel. The sectional area of the air distribution plate is 8770mm 3200mm with 1011 uniformly scattered air nozzles. The primary air will enter into the furnace through the air nozzles to fluidize the bed materials. The materials of the nozzles are anti wearing and high temperature alloys, the horizontal and vertical pitch of the nozzles are 160mm. In order to protect the air distribution plate the cast fireproof materials on the air distribution plate is 150mm. The deslagging system The ash generated by the combustion of the coal will be taken out by means of the bottom slag from the bottom of the furnace and by means of the flying ash from tail. The type of coal, the size and the property of forming of ash will affect the ratio of the slag and the flying ash. The bottom slag will be taken out of the furnace from the 5 slag discharge pipes that are connected to the water-cooling air distribution plate. The limestone feeding system The boiler is designed to add the limestone for desulfurization purpose. The limestone will be fed into the furnace through the coal chute by means of coal feeders. the consumption of the limestone is 1.8 tons per hour by design coal. The desulphurization is 80% based on the calculation of the ratio of 2.5 between calcium and sulfur. The secondary air system The secondary air will be guided into the different level height of the lower side of the furnace through the air spouts that are located on the front and rear wall of the furnace. The velocity at the air spouts is 70m/s. The working pressure of the secondary air will not be less than 6000 Pa. In order to control the air volume to guarantee the combustion the electric driven air gate and the air checking devices fixed on the air pipes are designed accordingly. The start up burner under bed There are two start-up burners that are arranged at the rear of the water cooling air chamber of the furnace. The start-up burner consists of oil gun, electronic ignite and the flame sensor device. The adopted fuel is LDO(low diesel oil) and will be 19

mechanical pulverized by the oil gun. Each oil gun has the output of 900Kg/hour with the pressure of 2.5Mpa. 4.7 Economizer The function of an economizer in a steam generating unit is to absorb heat from the flue gases and add as a sensible heat to the feed water before the water enters the evaporation circuit of the boiler Earlier economizer were introduced mainly to recover the heat available in the flue gases that leaves the boiler and provision of this addition heating surface increases the efficiency of the steam generator.in the modern boilers used for power generations feed water heaters are used to increase the efficiency of turbine unit and feed water temperature Use of economizer or air heater or both is decided by the total economy that will result in the flexibility in operation, maintenance and selection of firing system and other related equipment. There are 3 sets of economizers are designed and the tube size is Dia. 324,with in line arrangement. The material used for the tube is SA-210A1. 4.8 Air preheater An air preheater absorbs heat from the flue gases and transfers the heat to incoming cold air,by means of continuously rotating heat transfer element of especially formed metal plates. The 5 rows tubes of the preheater for PA and SA heating. The 2 sets of the air preheater in the middle are used for SA preheat, while the 2 sets at the top and lower part are used for heat the PA. Horizontal in line arrangement is applied here, and 800mm space is made between the 2 different tube banks for easy inspection and exchange. Special sealing arrangements are provided in the air pre heater to prevent the leakage between the air and the gas sides. Adjustable plates are also used to help the scaling arrangements and the prevent the leakage as expansion occurs. The air pre heaters heating surface elements are provided with two types of cleaning devices, soot blowers to clan normal devices and washing devices to clean the element when soot blowing alone cannot keep the element free. 4.9 Soot blower For the fuel alkali and sulfur content is high, by forming of ash deposit, the normal operation of boiler could be affected. For purpose to clean the ash deposit on the 20

boiler heating surface, protect the boiler efficiency and output from influenced, soot blower points are arranged at each side wall of the back-end flue gas duct, steam soot blowing is applied here. Retracting type soot-blowers are applied at the high temperature superheater on the top, and other soot-blowers are the fixed type.

5. FANS:
A fan is a device by which the air is made to flow at required velocity and pressure in a defined path imparting K.E of its impellers to air/flue gases. The main function of the fans is to supply air for combustion in the furnace with required pressure & flow and to evacuate the product of combustion i.e. flue gases into the atmosphere via chimney. There are four type of fans in this plant they are Primary air fans. Secondary air fans. Induced draft Fans. J-seal blower. PRIMARY AIR FAN: The function of P.A fan is to provide air to combustion chamber for proper burning of the coal and also used for carrying coal in to the combustion chamber. SECONDARY AIR FANS: The function of S.A fan is to restrict the flow of unburnt coal with the flue gas inside the combustion chamber. INDUSED DRAFT FANS: The function of the induced draft fan is to remove flue gases in the atmosphere through chimney. J-SEAL BLOWER: The function of J-SEAL BLOWER is to fluidization. Byfluidization the unburnt coal are collected in cyclone are carry into the combustion chamber.

6. Turbine
6.1 Main technical specification 1. Type : impulse type ,high pressure,high temperature,single cylinder,condensing steam turbine 2. Gyrantee output: 61.5 MW 3. Maximum power : 63 MW 4. Rated condition parameters Main steam pressure : 8.83 MPa Main steam temperature: 5370C 21

Main steam flow : 238T/ph Back pressure: 9KPa Inlet temp of cooling water : 33oC Make up water temp : 242.9oc

5.Maximum steam flow : 244.6t/ph 6.Rotation direction : clockwise when viewed n the direction from turbine to generator 7. Rated speed : 3000rpm 8. shafting critical speed : 1810rpm(steam turbine 1st step ) 4610rpm(steam turbine 2nd step) 1679.7rpm(generator 1st step) 9. number of stages : 21 stages in total,consisting of 1 governing stage+20 pressure stages 10.Regenerative extractions : 6 stages consisting of 2 HP heaters + 3 LP heaters + 1 deaerator

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6.2 Steam turbine cycle :

A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into rotational energy. Its modern manifestation was invented by Sir Charles Parsons. Different types of turbine may be condensing, Non-condensing, reheat, extraction and induction type. No-condensing or back pressure turbines: These are most widely used for process steam applications. The exhaust pressure is controlled by a regulating valve to suit the needs of the process steam pressure. These are commonly found at refineries, district heating units, pulp and paper plants, and desalination facilities where large amounts of low pressure process steam are available. Condensing turbines: These are most commonly found in Thermal power plants. These turbines exhaust steam in a partially condensed state, typically of quality near 90%, at a pressure well below atmospheric into a condenser. Reheat turbines: These are also used almost exclusively in electrical power plants. In a reheat turbine, steam flow exits from a high pressure section of the turbine and is returned to 23

the boiler where additional superheat is added. The steam then goes back into an intermediate pressure section of the turbine and continues its expansion. Extracting type turbines: These are common in all applications. In an extracting type turbine, steam is released from various stages of the turbine, and used for industrial process needs or sent to boiler feed water heaters to improve overall cycle efficiency. Extraction flows may be controlled with a valve, or left uncontrolled. Induction turbines: These introduce low pressure steam at an intermediate stage to produce additional power.

6.3.Components of turbine : Condenser : In thermal plants, the primary purpose of surface condenser is to condense the exhaust steam from a steam turbine to obtain maximum efficiency and also to convert the turbine exhaust steam into condensate water so that it may be reused in the steam generator or boiler as boiler feed water. By condensing the exhaust steam of a turbine at a pressure below atmospheric pressure, the steam pressure drop between the inlet and exhaust of the turbine is increased, which increases the amount of heat available for conversion to mechanical power. Most of the heat liberated due to condensation of the exhaust steam is carried away by the cooling medium (water or air) used by the surface condenser. The condensed water is stored in condenser hot well at its bottom. From here it aging goes to Boiler through CEP, Heaters, Deaerator & Economizer. Condenser extraction pump : The condensate water is drawn from the hot well by the extraction pump and sent to the low pressure feed heaters. This pump has four stages and since the sucton is at negative pressure , special arrangements have been made for providing sealing. Ejectors: There are two 100% capacity ejectors of the steam eject type. The purpose of the ejector is to Evacuate air and other non condensating gases from the condenser and thus maintain the vaccum in the condenser. Low pressure and high pressure heaters : These heaters are used to pre-heat water delivered to a steam generating boiler. Preheating the feed water reduces the irreversible involved in steam generation and therefore improves the thermodynamic efficiency of the system.This reduces plant operating costs and also helps

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to avoid thermal shock to the boiler metal when the feed water is introduces back into the steam cycle. This involves two stages1) Low pressure heating in LP heater (3 in no. per unit) 2) High pressure heating in HP heater (2 in no. per unit)

Out of 6, extraction 1 and 2 goes to HP heater 1 and 2 respectively , extraction 3 to Deaerator and extraction 4,5 and 6 go to LP heater 3,2 and 1 respectively. These heaters are equipped with necessary safety valves in the steam space level indicator for visual level indication of heating steam condensate pressure vaccum gauges for measurement of steam pressure. Deaerator : A dearator is a device for removal of non condensable gases like oxygen, co2 etc and used to remove dissolved gases (an alternate would be the use of water treatment chemicals) from boiler feed water to make it non-corrosive. A dearator typically includes a vertical domed deaeration section as the deaerated boiler feed water storage tank. A Steam generating boiler requires that the circulating steam, condensate, and feed water should be devoid of dissolved gases, particularly corrosive ones and dissolved. The gases will give rise to corrosion of the metal. The solids will deposit on the heating surfaces giving rise to localized heating and tube ruptures due to overheating. Under some conditions it may give to stress corrosion cracking. Boiler feed pump : This pump is horizontal and of barrel design driven by electric motor through a hydraulic coupling. All the bearings of the pump and motor are forced lubricated by a suitable oil lubricating system with adequate protection to trip the pump if the lubrication oil pressure falls below a preset value . The water with the given operating temperature should flow continuously to the pump under a certain minimum pressure. It passes through the suction branch into the intake spiral and from there it is directed to the first impeller. After leaving the impeller it passes through the distributing passages of the diffuser and thereby gets a certain pressure rise and at the same time it flows over to the guide vanes to the inlet of the next impeller. This will repeat from one stage to other till it passes trough the last impeller and last diffuser. Thus the feed water reaching into the discharge space develops the necessary operating pressure.

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6.4 Lubricating system for turbine and generator It reduces friction between rotating and fixed part of turbine and generator.It also removes heat from bearing which may either be generated by friction or by the conduction along the shaft of turbine. Main Oil Pump It supplies oil in the turbine and generator system by means of an actuating mechanism which is controlled by an LVDT depending upon requirement of speed to be achieved at high pressure under normal conditions. Auxiliary Oil Pump It has two functions1) It supplies oil during start up and shutdown when shaft is not rotating fast enough for the main oil pump to deliver the required pressure and flow. 2) It works as stand by oil pump when main oil pump fails. Emergency Oil Pump It supplies oil to the bearing during the time of slow down of turbine from running stage to stop. This time is typically 20-45 minutes. Jack Oil Pump It is used in large turbine-generator systems and is used only when shaft is rotated by turning gear. Oil purification system During operation the oil becomes contaminated by several undesirable impurities like water, fibres, sludge, organic compounds metals etc. so for reuse of it, it is purified using oil purifiers. The temperature of oil also increased so oil coolers are also provided with the unit. Centrifugal purifiers are used for purifying oil and water or heat may be deliberately added for the action.

7. Water treatment plant

As the types of boiler are not alike their working pressure and operating condition vary and so do the types and methods of the water treatment . water treatment plants used in thermal power plants are designed to process the raw water to water with the very low content of dissolved solids known as demineralized water . Water treatment process is generally made up of two sections : Pre treatment section Demineralization section 26

7.1 Pre treatment section :

Pre treatment plants removes the suspended solids such as clay , silt , organic and inorganic metal , plant and other microscopic organisms. The turbidity may be taken as of two types of suspended solids in water , firstly the separable solids and secondly non separable solids.(colloids). The coarse components such as sand, silt can be removed from the water by simple sedimentation. Finer particles , however will not settle in any reasonable time and must be flocculated to produce the large particles which are settable . 7.2 Demineralization The filter water is now used for demineralizing purpose and is fed to cation exchanger bed, but enroute being first dechlorinated which is either done by passing through activated carbon filter or injecting along the flow of water an equivalent amount of sodium sulphite through some store pumps . the residual chlorine which is maintained in clarification plant to remove organic matter from the raw water is now detrimental to action resin and must be eliminated before its entry to this bed. A DM plant generally consist of cation, anion and mixed bed exchanger. The final water from this process consist of hydrogen ions and hydroxide ions which is the chemical composition of pure water. The DM water being very pure becomes highly corrosive once it absorbs oxygen from the atmosphere because of its very high affinity for oxygen absorption. The DM water make up is generally added at the steam space of the surface condenser ( that is the vaccum side ) this arrangement not only sprays the water but also DM water gets deaerated, with the dissolved gases being removed by the ejector of the condenser itself. 7.3 Water softening plant Mainly water is softened here by removing the hardness causing ions which are calcium and magnesium Equipment used to remove the hardness from boiler feed water. A sodium zeolite water softener uses an ion exchange process to remove calcium and magnesium ions from water and replaces them with sodium using NaCl.

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Reservoir 1 Pump house Reservoir 2 Multi grade filter for suspended solids

SAC (strong acid cation ) for Ca and Mg ions

Degasser Blower (for CO )

Ultra filtration colloidal silica removal

Intermediate tank

MIX BED For remaining salts removal polishing.

SBA (strong base anionSilica & Carbonates

WBA (weak base anions) for Silica, carbonates and bicarbonates

DM storage TANK (A and B)

Condensate Storage Tank

7.4 Effluent (Waste Water) Treatment Plant Water quality factors affecting cooling towers are those that lead to deposition on the cooling tower fills, such as suspended solids. Those leading to cooling tower surface scaling include water hardness and biological fouling. All three contaminants - deposition, scaling, and biological fouling - contribute to plugging of cooling tower fill.

Holding tank

Clarifier (lime+polyel ectrolite+FeC l3)

Storage Tank

Ultra filtration

UF product tank

Reverse osmosis (97% salt rejection)

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CT make-up

Degasifier

8. Cooling tower :
Cooling Towers are evaporative coolers used for cooling the water. Cooling Towers use evaporation of water to reject heat from processes such as cooling the circulating water used in oil refineries, Chemical plants, power plants and building cooling. The tower varies in size from small roof-top units to very large hyperboloid structures that can be up to 200 meters tall and 100 meters in diameter. The primary use of large, industrial cooling tower system is to remove the heat absorbed in the circulating cooling water systems used in power plants. The absorbed heat is rejected to the atmosphere by the evaporation of some of the cooling water in mechanical forced-draft or induced draft towers. Cooling water pumps are used to pump the water from CT fore-bay to Condenser. There are 15 cooling towers in this plant. And the main function of cooling tower is to cool the water from the different parts of the plant such as from various machines etc. There are 16 different pumps used to draw the water from cooling tower and send it in different plant. The pumps used are CWP, AWP etc.

9. Ash handling plant :

Ash handling plant is used to control the ash content in the smoke. There are various processes in AHP to control the ash content such as bag filters are used in boilers to lessen the ash content after that we purge the ash down. In AHP we used bed ash coolers to collect the ash and pass it on to filters and then to completely minimize the ash content we then 29

purge it to ESP i.e electrostatic precipitator. In ESP we charge the plate so that all ash particles are stucked to that plate and there is no ash content is smoke of chimney and collected ash is then sent to ash dack by using HD PUMPS. 9.1 Bottom Ash Handling System The Bed Ash handling system shall be of dry type with water cooled ash coolers and for intermittent removal. The bed ash resulting from the combustion of coal in the boiler shall fall into bottom hopper provided under the furnace bottom.The cooled ash is transported to Silo or it can be directly to ash dyke through trucks. 9.2 Economizer and Air Pre-heater Ash Removal System Ash collected in economizer, economizer bypass duct, primary air heater and secondary air heater hoppers will drop continuously through suitable vertical pipe connections to the flushing connections provided beneath each of the hoppers. The flushing equipment serves to mix the ash with the water and discharge the ash in the form of slurry. 9.3 Dry Fly Ash Extraction and Transportation System The dry fly ash handling system consists of ESP and duct hopper ash removal systems. A two stage conveying system shall be provided. The first stage shall include extraction of dry fly ash from under the various ESP / duct hoppers to the intermediate surge/buffer hoppers/ collector tanks located near the ESPs which are known as ASH SILO. In the second stage ash shall be conveyed/ transported from under these buffer hoppers to the storage silos located outside plant boundary. A vacuum system shall be provided for extraction of dry fly ash in the first stage, for second stage, viz., transportation of dry fly ash to the main storage silos, located outside plant boundary shall be necessarily by the pressure conveying system only. 9.4 Ash Disposal System For both the units, bottom ash from discharge of jet pumps, economizer and air preheater slurry from discharge of flushing apparatus and fly ash slurry from wetting head, collector tanks and air-washer units provided upstream of buffer hoppers shall be led to a common slurry sump of combined ash slurry disposal pump house. From where it can be send to cement industries where it can be used. In ash handling plant two different type of compressors Instrument air compressor. Service air compressor.

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COMPRESSOR-The function of compressor is to compress the air. If we want moisture free compressed air then we used instrument compressor along with tri-air. This compressed air is used

power cylinder Control wall

If only compressed air required then service air is used. This compressed air is used in For conveying system there are 4 instrument compressor and 8 service air compressor in ash handling plant.

10.Mechanical maintenance
Predictive maintenance The art of predictive maintenance is to monitor the machine with appropriate technologies frequently enough to detect the anticipated failure modes which is also known as condition based maintenance . It results in Increased uptime Decreased unexpected returns Reduced maintenance cost Maintenance is performed and it is planned Improve plant safety

Machines normally give off some signs before failing The sign may be change in sound level,vibraton,pressure,temperature etc Change in performance Metal particles in lubricant Change in motor current

Proactive maintenance It is also known as precision maintenance and reliability based maintenance. The motto here is to Fix it once & Fix it right Knowledge based maintenance Shared information among all users Root cause analysis-design problems out off machines,fix the problems not the symptom. Corrective maintenance- This type of maintenance occur when any small parts gets wear and required to replace it like change of spring, bolt, or blade of the machine. 31

Break down maintenance- It occurs when the equipment causes fail to work. The cost of break down maintenance is more. It causes more time to repair. Periodic maintenance- This type of maintenance occur over a period of time it include lubrication of the equipment to increases the life of the machine.

11.Switch yard
A Switchyard or substations, consisting of large breakers and towers, is usually located in an area close to the plant. The substation is used as the distribution centre where Electrical power is sent from the plant. SWITCHYARD EQUIPMENTS:1. BREAKERS 2. ISOLATORS 3. INSULATORS 4. CURRENT TRANSFORMER (C.T.) 5. POTENTIAL TRANSFORMER (P.T.) 6. POWER LINE CARRIER COMMUNICATION(P.L.C.C) 7. BUS BARS 1. BREAKERS:A circuit breakers is an automatically-operated electrical switch designed to protect an electrical circuit from damage caused by over load or short circuit. its basic function is to detect a fault condition and, by interrupting countinuity to immediately discontinues electrical flow. Types of breakers:1. Oil circuit breaker 2. SF-6(Sulphuric hexafluoride) breaker 3. Air circuit breaker. 2. ISOLATORS:It is also called as disconnect. They are used to disconnect the main supply or isolate the busbars for the maintenance purposes. 3. INSULATORS:An insulator also called a dielectric, it is that material that resists the flow of electric current. Example of insulator materials are rubber-like polymer is still good enough to insulate electrical wiring and cables. These insulators with a conductor inside them are called Bushings.

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4. LIGHTNING ARRESTERS:It is a device used on electrical power systems to protect the insulation on the system from the damaging effect of lightning.The typical lightning arresters also known as surge arrester has a high voltage terminal and a ground terminal. 5. CURRENT TRANSFORMER (C.T.):A current transformer is used for measurement of electric currents. A current transformer together with voltage transformer (VT) are known as instrument transformers. 6. POTENTIAL TRANSFORMER (P.T.): Potential transformer, also known as capacitor voltage transformer (CVT), or capacitance coupled voltage transformer(CCVT) is a transformer used in power systems to step down extra high voltage signals and provide a low voltage signal 8. BUSBAR:The electrical power distribution, a busbar is a thick strip of copper or aluminium that conducts electricity within a switchboard, distribution board, substitution busbar are used to carry very long currents, or to distribute current to multiple devices within switchgear

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