TRAINING REPORT

ON
KALISINDH THERMAL POWER PROJECT
JHALAWAR-RAJASTHAN

Submitted to-

Submitted by-

Dr. Ajay Jain

Abhineet Kumar Singh

Mechanical Engineering Deptt.

Roll No-1120370 (M-3)

N.I.T Kurukshetra

[1]

ACKNOWLEDGEMENT
I oblige to acknowledge my heartiest gratitude to all honorable people who helped me
during my summer training at KALISINDH THERMAL POWER PROJECT-JHALAWAR,
(RVUNL)RAJASTHAN.
I want to express my thanks to Mr. S. S. Meena Chief Engineer of KaTPP, S. P. Meena
(Training Co-ordinator) for granting me the permission for doing summer training at this
project and to give their valuable time and kind co-operation.
I am also thanks a lot to other staff members of RRVUNL, BGR & TCE for their further
co-operation to gain the better knowledge about the world class power plant project in Distt.
Jhalawar, Rajasthan.

ABHINEET KUMAR SINGH

B. Tech 2nd Year
Mechanical Engineering

[2]

CONTENTS
1. INTRODUCATION
1.1. Contribution of Thermal Power Plant In India...................................... 04
1.2. INTRODUCATION OVERVIEW OF KaTPP...05-07
1.3. ENERGY GENERATED IN KaTPP.. 08
1.4. PLANT OVERVIEW 08
1.5. PRINCIPLE OF OPERATION.................... 09
1.6. THERMAL PLANT OPERATION PROCEDURE.. 10-11
1.7. PULVERSIZED COAL FUELED POWER PLANT 11-12
2. COAL HANDLING PLANT (CHP)
2.1. INTODUCATION. 13
2.2. STAGES OF COAL HANDLING PLANT. 13-16
3. IMPORTANT PARTS OF THERMAL POWER PLANT
3.1. BOILER.. 17-18
3.2. TURBINE... 19-22
3.3. GENERATOR... 22-23
3.4. CONDENSER 24
3.5. COOLING TOWER.. 24-25
3.6. WATER TREATMENT PLANT. 25
4. ESP AND AHP SYSTEM
4.1. ELECTROSTATIC PRECIPITATOR (ESP). 26-29
4.2. ASH HANDLING PLANT (AHP). 29-30
5. CONTOLLING AND TRANSMISSION SYSTEM
5.1. CONTOL AND INSTRUMENTATION SYSTEM 31
5.2. SWITCHING AND TRANSMISSION. 32-33
6. EFFICIENCY AND CONCLUSION
6.1. EFFICIENCY.. 33
6.2. CONCLUSION 34
7. REFERENCE
REFRENCE. 35

[3]

1. INTRODUCATION
Everybody must be having a thought that a thermal power plant is a place where electricity is
produced. But do you know how it is produced? How the chemical energy stored in fuel is
converted into heat energy which forms the input of power plant i.e. steam and electrical energy
produced by generator? Power is the single most important necessity for common people and
industrial development of nation. In a conventional power plant the energy is first converted to a
mechanical work and then is converted to electrical energy .Thus the energy conversions
involved are:
The first energy conversion takes place in Boiler or Steam Generator, second in Turbine
and the last conversion takes place in the Generator.
A thermal power station is a power plant in which the prime mover is steam driven.
Water is heated, turns into steam and rotates the turbine which drives an electrical
generator after that steam pass through in a condenser where it condensed and recycled to
again in boiler; this whole cycle is known as RANKINE CYCLE.

[4]

1.1 CONTRIBUTATION OF THERMAL POWER PLANT IN INDIA

In India, Thermal Power Plant contribute about 60% of the total electricity produced.
Pie chart shows the electricity production percentage by different sectors-

Fig-percentage of electricity produced by different sectors

[5]

1.2 INTRODUCATION OVERVIEW OF KaTPP

Fig-KaTPP 3D VIEW

Kalisindh Thermal Power Project is about 760 K.M. from Kurukshetra Junction. It is
located in Jhalawar. The proposed capacity of coal based Thermal Power Project is 1200 MW.
The project site is about 12 km from Jhalawar (Distt.-Head quarter) and NH-12. Site is
comprising of 5 villages viz. Nimoda, Undal, Motipura, Singharia and Devri. It is 2km from state
highway No.19 and 8 km from Ramganj Mandi - Bhopal broad gauge rail line
[6]

Fig-route between Kurukshetra Junction to Kalisindh Thermal Power Plant

The site selection committee of Central Electricity Authority has visited the Nimodha and
its adjoining villages of Jhalawar Distt. And site was found techno- economical feasible for
setting up of a Power Project. The Govt. of Raj. have included that project in 11 th five year plan.
The estimated revised cost of the project is Rs.7723 Crores. M/s. TCE Banglore has been
appointed as the technical consultant for the project. The state irrigation department has allotted
1200 mcft water for the project from proposed Kalisindh dam. The origin of the Kalisindh river
is from northern slop of Vindya Mountains . The river enters from MP to Rajasthan near village
Binda. After flowing 145 km in Rajasthan, the Kalisindh river merges in Chambal river near
Nanera village of Distt. Kota.Its catchment area is about 7944 sq.km in Jhalawar & Kota Distt.
The existing Dam is located at Bhawarasa village, primarily for P.H.E.D. purpose is being
uplifted for providing a storage of 1200mcft water for this power project.
[7]

The GOR has allotted 842 bigha Government land and acquired 1388 bigha private
khatedari land for the thermal project .Phase-1 will be constructed on 1400 bigha land only.EPC
contract has been awarded to M/s. BGR Energy System Chennai on dt.09/07/08,through ICB
route at cost Rs.4900Crores. Ministry of coal, Govt. of India has allotted Paras east and Kanta
basin coal blocks to RVUN in Chhattisgarh state. The RVUN has formed new company under
joined venture with M/s. Adani Enterprises for mining of coal blocks and new company started
the work. Annual coal requirement for the project is 56 LacsTPA.GOR also decided to setup two
new units of2x660MW in next few years.

2x60 KALISINDH THERMAL POWERP ROJECT-JHALAWAR

OWNER

OWNERS
CONSULTANT
EPC
CONTRACTOR

RVUNL

TATA CONSULTING
ENERGY LTD. MUMBAI
BGR ENERGY SYSTEM LTD.
CHENNAI

[8]

1.3 ENERGY GENERATED IN KaTPP

Number of units=2
Electricity generated by one unit=600 MW
Total electricity negated by plant=2x600=1200 MW

1.4 PLANT OVERVIEW

Project

Kalisindh Super Thermal Power Project Jhalawar

Capacity

1200MW(2x600 MW)

Project Site

Village-Undel, Motipura, Nimoda, Singhania & Deveri of Tehsil

Jhalarapatan, Distt-Jhalawar

Project Location

The project site is about 12 km from NH-12, 2km from state highway
and 8 km from proposed Ramganj Mandi-Bhopal broad gauge rail line.

Land Aera

2230 Bigha/564 Hq.(1400 bigha/350 Hq. in I stage)

Water
Souce
quantity

and Dam on Kalisindh river and 3400CuM/Hrs.

Fuel Source
Quantity of
80% PLF)

Main Fuel-Coal from captive coal blocks(Paras east and kanta Basin in
Chhatisgarh state) Secondary Fuel-FO/HSD
fuel(at Coal-56 Lacs TPA FO/HSD-13000-14000 KL/A

ElectroStatic
Precipator

99.9 % Capacity

Stack Height

275 Mtr

Estimated revised cost

Rs.7723 Crores

1.5 PRINCIPLE OF OPERATION

[9]

For each process in a vapour power cycle, it is possible to assume a hypothetical or ideal
process which represents the basis intended operation and do not produce any extraneous effect
like heat loss.
1. For steam boiler, this would be a reversible constant pressure heating process of water to
form steam.
2. For turbine ,the ideal process would be a reversible adiabatic expansion of steam.
3. For condenser, it would be a reversible a constant pressure heat rejection as the steam
condenser till it becomes saturated liquid.
4. For pump, the ideal process would be the reversible adiabatic compression of liquid
ending at the initial pressure.
When all the above four cycles are combined, the cycle achieved is called RANKINE
CYCLE. Hence the working of a thermal power plant is based upon Rankine Cycle with some
modification.

1.6 THERMAL PLANT OPERATION PROCEDURE

[10]

The basic understanding of the modern thermal power station in terms of major systems
involved can be done under three basic heads viz. generating steam from coal, conversion of
thermal energy to mechanical power and generation & load dispatch of electric power.

COAL TO STEAM- The coal is burnt at the rate upto 200 tonnes per hour. From coal
stores, the fuel is carried on convey or belts to bunkers through coal tipper. It then falls in
to coal pulverizing mill, where it is grounded into powder as fine as flour. Air is drawn
into the boiler house by drought fan and passed through Preheaters. Some air is passed
directly to bunker and rest, through primary air fan, to pulverizing mill where it is mixed
with powdered coal. The mixture is then carried to bunker of furnace where it mixes with
rest of the air and burns to great heat. This heats circulating water and produces steam,
which passes to steam drum at very high pressure. The steam is then heated further in the
Superheater and fed to high pressure cylinder of steam turbine. . The spent steam is sent
to condenser, where it turns back to water called condensate. Condensate is sent tol ower
part of steam drum through feed heater and economizer. The flue gases leaving boiler are
used for heating purpose in feed heater, economizer, and air Preheater. The flue gases are
then passed to electro-static precipitator and then, through draught fan, to chimney.
STEAM TO MECHANICAL POWER- Steam first enters the high pressure cylinder of
turbine where it passes over a ring of stationary/fixed blades which acts as nozzle and
directs steam onto a ring of moving blades. Steam passes to the other cylinders through
reheater and the process is repeated again and again. This rotates the turbine shaft upto
3000rpm. At each stage, steam expands, pressure decreases and velocity increases.
MECHANICAL POWER TO ELECTRICAL POWER- To obtained the electrical
power from mechanical power we connect the shaft to an alternators armature. When the
armature is rotated and electric current is produced in the stators windings. The
generated electricity is of order 25,000 volts.
SWITCHING AND TRANSMISSION-The produced electricity is cant to transmitted
as this state so It is passed to a series of three switches called an isolator, a circuitbreaker, and another isolator. From circuit-breaker, current is taken to bus bars and then
to another circuit-breaker with its associated isolator before being fed to the main Grid.
Each generator has its own switching and transmission arrangement. Three-phase system
is used for power transmission.
CONTROL AND INSTRUMENTATION- Control and Instrumentation (C & I)
systems are provided to enable the power station to be operated in a safe and efficient
manner while responding to the demands of the national grid system. These demands
have to be met without violating the safety or operational constraints of the plants. For
example, metallurgical limitations are important as they set limits on the maximum
permissible boiler metal temperature and the chemical constituents of the Feed water. The
control and Instrumentation system provides the means of the manual and automatic
control of plant operating conditions to maintain an adequate margin from the safety and
operational constraints. Monitor these margins and the plant conditions, and provide
[11]

immediate indications and permanent records. Draw the attention of the operator by an
alarm system to any unacceptable reduction in the margins. Shut down the plant if the
operating constraints are violated.
1.7 PULVERIZED COAL FUELED POWER PLANT
A typical pulverized coal fueled power plant is based on Rankine Thermodynamic cycle.
A Rankine cycle is a vapour cycle Furnace that relies on the isentropic expansion of high
pressure gas to produce work.Let us see a super heat Rankine cycle:

This facility first produces steam in a boiler (steam generator). This steam is used to rotate
turbine which is connected to a shaft of generator. Hence electricity is produced here. The used
steam is then condensed in a condenser, and the condensed liquid is used again in the steam
generator. This is a simple phenomenon, understood by everybody. For all this we need a fuel. As
the name suggest here coal is used as fuel. Coal is one of the cheapest and most preferred fossil
fuel used as a key to most of the power plants. Usually delivered by train from Mines to the Coal
Handing Plant (CHP). The CHP unloads this it become more economical to unload the coal.
Then the coal stacked, reclaimed, crushed, and conveyed it to the storage silos near the steam
generator. Then it is fed through the Feeder to the Pulverizer. Feeder is mainly used to weight the
amount of coal going to the Pulverizer per hour. From the Feeder the coal is fed to the Pulverizer
which powders it and then it is carried to the steam generator using pressurized air. Within the
steam generator the coal is atomized and burned and the heat energy produced is used for
producing steam. Here two types of steam namely superheated & reheated steam are produced in
a cycle. The steam turbine generator converts the thermal energy of superheated and reheated

[12]

steam to electrical energy. The first energy conversion is carried in Boiler or steam generator; the
second is carried out in Turbine and the last one carried out in the Generator.

Initially the superheated steam is fed to High Pressure (HP) turbine. It has a temperature of
540 C (approx.) and a pressure of about 140 Kg/cm2. Then the exhausted steam from it is taken
to the reheater so that it can be reheated and fed back to Intermediate Pressure (IP) turbine. Here
the temperature is maintained the same as that of superheated steam but pressure is reduced to 35
Kg/cm2. Then the exhausted steam is directly fed to Low Pressure(LP) turbine having the
reduced temperature and pressure of about 1Kg/cm2. Then the exhausted steam from the LP
section is condensed in the condenser. The condensed liquid is moved from condenser by
Condensate Pumps through Low Pressure Regenerative Feed water heaters to a Deaerator. Boiler
Feed Pumps (BFPs) moves the deaerated liquid through HP heaters to the steam generators.
Extraction steam is supplied to the LP & HP regenerative heaters to improve cycle efficiency.
Then comes to the system of fans which keeps the system working by providing the valuable air
where required. There arethree pairsoffans, namely , ForcedDraft (FD)fan, Induced Draft (ID)
fan, Primary Air (PA) fan. FD fans supplies combustion air to the steam generator and PA fans
transports the coal into the steam generator. ID fans remove the flue gases from the steam
generator and exhaust it through chimney. Cooling water for the condenser is supplied by the
circulating water system, which takes the heat removed from the condenser and rejects it to the
cooling towers or other heat sink. This all working is controlled from a single place called
control room. It enables the operator to direct the plant operation for reliable and efficient
production of electrical energy. This is achieved by the control system installed by the C & I
group. These are DAS (Data Acquisition System), ACS (Analog Control System), FSSS
(Furnace Safeguard Supervisory System), and other relays governing numerous activities. Last
but not the least is the switching and transmission methods used here. The generated power
cannot be transmitted as such. It is stepped up to 132 KVA or 400 KVA then passed through a
series of three switches an isolator, a circuit breaker and an isolator. Three phase system is used
for the power transmission.Each generator has its own switchyard and transmission arrangement.

2. COAL HANDLING PLANT(CHP)

[13]

2.1 INTRODUCTION
Every thermal power plant is based on steam produced on the expanse of heat
energy produced on combustion of fuel. Coal is categorized as follows depending upon fixed
carbon, volatile matter and moisture content:
Anthracite having 86% fixed carbon
Bituminous having 46 to 86% fixed carbon
Lignite having 30% fixed carbon and
Peat having 5 to 10% fixed carbon
Coal from mines is transported to CHP in railway wagons. It is unloaded in track hoppers.
Each project requires transportation of large quantity of coal mines to the power station site.
Each project is established near coal mine which meets the coal requirements for the span of its
entire operational life. For the purpose each plant has Merry Go-Round (MGR) rail
transportation system. The loading operation of the coal rake takes place while it is moving
under the silo at a present speed of 0.8 Km/hr. the loading time for each wagon is one minute.
For unloading of coal from the wagons an underground track hopper is provided at the power
station.
The term coal handling plant means to store and to handle the coal which is transported by
the train and convey to the bunkers with the help of belt conveyers. Through the bunkers coal is
transferred to the coal mill and drifted to the furnace. The coal handling plant includes wagon
tippler, conveyer belt, crusher house, stacker & reclaimer, bunkers & coal mill.
COAL SUPPLY IN KaTPP-Ministry of coal, Govt. of India has allotted Paras east and
Kanta basin coal blocks to RVUN in Chhattisgarh state.
2.2 STAGES OF COAL HANDLING PLANT

WAGON TIPPLER-The term Wagon Tippler contains two words WAGON & TIPPLER
.Wagon means the compartment of train which is just like a container which is used to
carry the coal from mines to generating stations & the word Tippler means a machine,
which is used to unload the wagon into the hopper. Hopper is just like a vessel which is
made of concrete & it is covered with a thick iron net on its top. Here big size coal pieces
are hammered by the labors to dispose it into the hopper.

Capacity

90 tonnes

Types of Tipplers

1.Weighing type,2.Non weighing type

[14]

Angle of Tip

30 to35

Wire Ropes

1.Hoisting Ropes, 2.Counter Weight Ropes

Drive unit

Motor 37.3 KW

Operating Cycle

10 wagons/Hour on 1 wagon Tippler

Time consume for one cycle

6 minutes

FEEDER- It is used to control the supply of crushed coal to the mill depending upon
load condition.It is installed under wagon tippler and hopper.In KaTPP there are 4
unbalanced Motor Vibrating Feeder installed in unit 1st.
CHRUSHER/RING GRANULATOR-In ring granulator the material is fed in to the
crushing chamber and is crushed by the rind hammers with impact and rolling action
across the feed, with concentrated pressure.This cracks the coal producing a granulator
product with a minimum of fines upto 20 mm square.

Capacity

500 Tonnes/hr

Machine Weight

30 Tonnes(approx.)

Max Feed Rate

500 Tonnes/hr

Rotor Speed

720 r.p.m

Motor

550 H.P

Volts

606 Kv

Phase

3 Phase motor

CONVEYORS-Conveyor belt is used to sent the coal from coal storage yard and also
used to sent crushed coal from store to mill bunkers. The carrying capacity of conveyors
belt is 750 tonnes/hrs that are installed in KaTPP.
Conveyor belt used in coal handling plant(CHP) are of 2 types
1. 5 ply x1000 mm width with 5 mm rubber top side and 5 mm rubber bottom side.
Total thickness of belt:-17 to 18 mm
Power:-1000KN/m2
2. 4 Ply x1000 mm width with 5mm rubber top side and 5 mm rubber bottom side.
[15]

Total thickness of belt:-17mm

Power:-800KN/m2
Cold joint are used in joining the conveyor, conveyor belts run with the help of electric
motor , gear box, fluid coupling geared coupling are installed at head of all conveyors.

PARTS OF CONVEYORS:
1) Flap Gate-it provide
crusher/conveyors.

under

coal

transfer

chutes

for

replacements

of

2) Deflector Plate-Deflector plates are installed in the chutes coming on conveyors to

keep the coal direction in the centre of the conveyors.
3) Skirt board and Skirt rubber-These are provided on tail end chutes to avoid
spillages of coal from Conveyors.
4) Stone picker-Stone picker pick the stones from the running belt manually.
5) Metal Detactor-Electromagnets are provide on conveyors to avoid and to save
crusher parts and entry of iron pieces in crusher. It also stop the entry of iron pieces in
coal bunker to save damage of coal mills.
6) Guide Idlers-These idlers help to train/guide the conveyors.
7) Return Idlers-These idlers carries the conveyors belts in return side.
8) R.T.I (Return Training Idler)-These idlers are provided on return side to guide the
conveyors.
9) Impact Idler-These Rubber idlers are provided under chutes through which coal falls
on conveyors.
10) Carrying Idlers-These are installed to run the conveyor.
BUNKERS-Bunckers are fabricated to store the coal before sending to coal mills. Coal is
fed in the bunkers with the help of tripper trolleys installed at 37 m height for unit 1 st and
2nd.These are 20 bunkers for unit 1st and 2nd.
Capacity of a bunker=500 tonne/bunker.

COAL BUNKERS-These are in process storage used for storing crushed coal from the
handling system. Generally these are made up of the welded steel plates with vibrating
arrangement of the outlet to avoid chocking of coal, normally there are six bunker supply

[16]

coal to the corresponding mills. These are located on the top of mills so as to add gravity
feeding of coal.
RECLAIM YARD-After filing the coal bunkers extra coal is taken to reclaim yard after
crushing of coal to storage.
COAL CIRCULATION-Coal is transported from the coal mine with the help of train.
Train wagons are emptied with the help of wagon tipplers and sent to the crusher for
crushing. From coal crusher it goes to the bunker through conveyor belt and from coal
bunker it move to R.C feeder feeds coal to the coal mill, where the coal is ground in to
powder from.

[17]

3. IMPORTANT PARTS OF THERMAL POWER PLANT

3.1 BOILER
Boiler can simply defined as the device where any liquid is boiled or Boiler may be
defined as a device that is used to transfer heat energy being produced by burning of fuel to
liquid, generally water, contended in it to cause its vaporization. Boiler, in simple terms, can be
called Steam Generator.
In simple way, boiler is a device used for producing steam. There are two types of boiler
(depending upon tube content):
a) Fire tube boiler
b) Water tube boiler
Here, boiler used is of water 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.
WATER TUBE BOILER USED IN KaTPP WITH 97M HIGHT
Various motors use in boiler are different rating and parameters 32KW ,15KW ,11KW ,& 3.3KW
Parameter in 15KW motor
Manufacturing

CQ.GEAR BOX LTD.CHINA

Motor rating

15 KW

Speed

970 r.p.m

Rated voltage

416 V

Rated current

28.4 A

Impedance voltage

80.0 %

Oil weight

20 Kg

Core+winding weight

224 Kg

Total weight

600 Kg

[18]

Temp rise

50-55 deg cel.

BOILER AUXILIARIES-Efficiency of a system is of most concerned. Thus it is very important

to maintain a system as efficient as possible. So Boiler auxiliaries help in improving boilers
efficiency. Following are the important auxiliaries used

ECONOMISER: Its purpose is to preheat feed water before it is introduced into

boiler drum by recovering heat from flue gases leaving the furnace.
SUPER HEATER: It increase the temperature of steam to super heated region.

REHEATER: It is used for heat addition and increase the temperature of steam

coming from high pressure turbine to 540 deg.

DRAFT FANS: They handle the supply of air and the pressure of furnace.

BOILER MOUNTINGS-These are used for the safe operation of boiler. Some example of
mountings used are water level indicator in drum, furnace temperature probe, reheat release
valve, pressure gauges indicating steam pressure etc.
3.2 TURBINE
[19]

Turbine is an m/c in which a shaft is rotated steadily by the impact of reaction of steam
of working substance upon blades of a wheel. It converts the potential energy or heat energy of
the working substance into mechanical energy. When working substance is steam it is called
Steam Turbine
In the steam turbine the pressure of the steam is utilized to overcome external resistance
and the dynamic action of the steam is negligibly small.

PRINCIPLE-Working of the steam turbine depends wholly upon the dynamic action of
steam. The steam is caused to fall with pressure in a passage of nozzle, due to this fall in
pressure, a whole amount of heat energy is converted into mechanical energy & steam is
set moving with the reactor velocity. The rapidly moving particle of steam enter the
moving part of turbine and here suffers a change in the direction of motion which gives
rise to change of momentum and therefore to a force. This constitutes a driving force to a
turbine.

The passage of them/through the moving part of the turbine commonly called the blade,
may take place in such a manner that the pressure at the outlet sides of the blade is equal to that
of the inlet side. Such a turbine is broadly termed as outlet turbine or Impulse type.
On the other hand, the pressure of the steam at outlet from the moving blade may be less
than that at type inlet side of the blade. The drop of pressure suffered by the steam during its
flow through the moving blades causes a further generation of kinetic energy within the blades
and adds to the propelling force which is applied to the turbine rotor, such a turbine is broadly
termed as Reaction Turbine. Here in Kalisindh Thermal Power Project N600-16.7/587/537,ReHet,Three Casing,Four Exhaust, Tandem Compound Condenser Type Turbine Used.
The turbine is of tandem compound design with separate High Pressure(HP),Indermediate
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 consdensing 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.
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 feature have proved their reliability in service and ensure trouble free
operation over long operating periods and at the same time ensuring high thermal efficiencies.

[20]

[21]

TURBINE SPECIFICATIONRated output with extraction flow

600 MW

Speed

3000 r.p.m

Main steam throttle flow at HP Inlet

1848.5 TPH

Main steam pressure to HP turbine inlet

167 kg/sq.cm

Main steam temp. to HP turbine inlet

538 deg.cel

Re-heater steam flow at IP inlet

1587.942 TPH

Re-heater steam temp. at IP inlet

538 deg.cel

Steam pressure at LP inlet

35.12 kg/sq.cm

Steam flow at LP inlet

1353.7 TPH

Rotation Direction(view from turbine)

anticlock wise

Number of stages

42

High pressure turbine-

1 governing and 8 pressure

a) Intermediate pressure

5 pressure stage

b) Low pressure turbine

28 pressure stage

c) Governing system

DEH(digital electro hydrolic)

Inlet steam flow governing type

Nozzle+throttle

Rated exhaust pressure

0.09 kg/sq.cm

Type of bearing turbine

6 journal +1 thrust

Turbine allowable frequency

47.5 to 51.5 Hz

Turning gear rotation speed

1.5 r.p.m

Ist critical speed of HP & LP rotor

1722 r.p.m

Ist critical speed of LP-A rotor

1839 r.p.m

Ist critical speed of LP-b rotor

1903 r.p.m

Heat regenerative extraction system

3 HP heater +1 deaerator +4 LP
heater

Final feed water temperature

274.9 deg.cel
[22]

Maximum bearing vibration

0.076 m

Maximum allowable exhaust temp.

80 deg.cel.

Colling water design flow at condenser

70200 TPH

3.3 GENERATOR
Generator is the important part of thermal power plant.It is device which convert the
mechanical engery into electrical energy.Generator is driven by coupled steam turbine at a speed
of 3000 r.p.m.Due to rotation at high speed it get heat.So there is cooling construction enclosing
the winding core of the geretator.So that during the operation is being in normal temperature.
In KaTPP , Each of the 2 units have been provided with 3-phase turbo generator rated
output 706MVA, 18.525KA, 22KV, 0.85 lagging p.f., 984 rpm and 50 cycles/sec .The generator
has closed loop of hydrogen gas system for cooling of the stator and rotor at a pressure of
4.5kg/sq-cm(g).

[23]

GENERATOR SPECIFICATION FOR UNIT I AND II:Make

CQ GEARBOX China

Type

QFSN

Apparent output

706 MVA

Active output

600 MW

Power factor

0.85 lagging

Rated voltage

22 KV

Rated current

18525 Amp

Rated speed

3000 r.p.m

Frequency

50 Hz

Phase connections

Double gen.star

Cooling mode

H20-H2-H2

Rated H2 pressure

4.5 Kg/sq-cm

Terminal in generator

DIESEL GENERATOR SET

It is used to emergency porpuse to supply auxillary system of power plant.3 Set Diesel
generator are use in which one is standby. parameters of generator are as
Make BY

STAMFOARD MAHARASTRA INDIA

Rating

1900 KVA

Speed

1500 R.P.M

Rated Current

2643.37 A

Rated Temp

40 Deg cel

AMPS

3.6 A

3.4 CONDENSER

[24]

In condenser, the water passes through various tubes 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.
Condenser is 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 reverse and water boxes. This
arrangement facilitates the operation of one half of condenser when the other half is under
maintenance. 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.

Area of condenser = 9655 sq m

Cooling water flow rate = 2400 cubic m/Hr.
3.5 COOLING TOWER

It is a structure of height 202 m (tallest in the world) designed to cool the water(coming
from condenser) by natural draught. The cross sectional area is less at the centre just to create
low pressure so that ate 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.
In KaTPP two natural draught cooling towers (2 NDCT) is present with height 202 m each
for each unit.

[25]

Fig-Cooling Tower

3.6 WATER TREATMENT PLANT

As everyone know that the cost of any thermal power plant is cores of rupees. So major
problem of any thermal power plant is that how to prevent the corrosion. The water available
cant be used in boilers as such. The objective of water treatment plant is to produce the boiler
feed water so that there shall be.

No scale formation
No corrosion
No priming or forming problems

Water used in thermal power plant is called Dematerialized Water or DM Water.

[26]

4. ESP AND AHP SYSTEM

4.1 ELECTROSTATIC PRECIPITATOR (ESP)
Electrostatic Precipitator (ESP) is equipment, which utilizes an intense electric force to
separate the suspended particle from the gases. In India coal is widely used to generate power.
The exhaust gases are emitted directly into the atmosphere, it will cause great environmental
problems. So it is necessary to extract this dust and smoke before emitted 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 particle, collection of charge
particles and removal of charge particles from collecting electrode. Its various other advantages
are as follows:

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.

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. Theses 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 the 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 particle and make them negatively charged. Thus is collected on the
steel curtains.
The whole process is divided into the following parts:

Corona Generation
Particle Charging
Particle Collection
Particle Removal

Details of the following are given below[27]

Corona Generation- Corona is a gas discharge phenomenon associated with the

ionization of gas molecules by electron collision in regions of high electric field strength.
This process requires non-uniform electric field, which is obtained by the use of 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.
In case of negative corona, positive ions generated are attracted towards the negative
electrode or wire electrons towards collecting plates. On impact of negative and serve as
principle means of charging dust.
Particle Charging- These 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 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. The ions will be held to the
dust particles by an induced image charge force between the ion and dust particle and
become charged to a value sufficient to divert the electric field lines from particles such
that they do not intercept.
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 particle is decided
by the vector sum of these forces i.e. Turbulent.
Particle Removal- In dry removal of dust collected on plates, Rapping Mechanism is
used. It consider of a geared motor, Which moves along shaft paced near the support
collector electrode and is provided with cylindrical hammer. On rotating of shaft these
hammers strikes the supports causes plate to vibrates and dust is removed from plates.
Removed dust is collected in the Hoppers below the precipitator. At the time of starting of
precipitation of dust from flue gases, the hoppers are at normal temperature but the ash
collected is very hot. So there is a chance of ash deposit at the exit of the hopper thus
causing problem of removing the ash. To avoid this , heater are provide which increase
the temperature at the exit point o the hopper thus avoiding any undue accumulation of
ash at starting . In other method, the water is allowed to flow down the collector electrode
and hence dust is collected in hoppers below.

GENERAL DESCRIPTIONThe whole ESP is divided into two parts[28]

Mechanical System
Electrical System

Here we will discuss only Mechanical System (i.e. Precipitator Casing, Emitting and
Collecting System and Hopper).
Precipitator Casing-Precipitator Casing is made of 6mm mild steel plates 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.
Emitting and Collecting System- Emitting System is the most important part of ESP.
Emitting system consists of rigid emitting frame suspended from four points on the top of
rigid 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. The
frame is designed to take up the retention forces of the emitting electrode. The emitting
electrode consists of hard drawn spiral wires and are fastened with hooks to the discharge
frame.
Collecting system mainly consists of collecting suspension frame, collection electrodes
and shock bars. Collecting electrode are made of 1.6 mm thick Mild Steel sheets formed
in G Profile of 400mm width. Hook and guide are welded on one end and shock iron on
the dipped in rust preventive oil tank. Collecting electrodes bundles are properly bundled
in order to avoid any damage to electrode.
Hoppers- Hoppers are seized to hold the ash for 8-hour collection and is 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.
RAPPING MECAHISM FOR COLLECTING SYSTEM- During electrostatic precipitation a
fraction of dust will be collected on the discharge 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 collection of ash on the collecting electrode.

[29]

Fig-Electrostatic Precipitation Unit

4.2 ASH HANDLING PLANT (AHP)
The ash produced on the combustion of coal is collected by ESP. This ash is now required to
disposed off. This purpose of ash disposal is solved by Ash Handling Plant (AHP). There are
basically two types of ash handling process undertaken by AHP.

Dry Ash System

Ash Slurry System

DRY ASH SYSTEM- Dry ash is required in cement factories as it can be directly added to
cement. Hence the dry ash collected in the ESP hopper is directly disposed to silos using pressure
pumps. The dry ash from these silos is transported to the required destination.
ASH SLURRY SYSTEM- Ash from boiler is transported to ash dump areas by means of
sluicing type hydraulic system which consists of two types of system

Bottom Ash System

Ash Water System
[30]

BOTTOM ASH SYSTEM- In this system, the ash slag discharged from the furnace is collected
in water impounded scraper installed below bottom ash hopper. The ash collected is transported
to clinkers by chain conveyors. The clinker grinders churn ash which is then mixed with water to
form slurry.
ASH WATER SYSTEM-In this system, the ash collected in ESP hopper is passed to flushing
system. Here low pressure water is applied through nozzle directing tangentially to the section of
pipe to create turbulence and proper mixing of ash with water to form slurry. Slurry formed in
above processes is transported to ash slurry sump. Here extra water is added to slurry if required
and then is pumped to the dump area.
FLY ASH SYSTEM-Even though ESP is very efficient, there is still some ash, about 0.2%, left
in flue gases. It is disposed to the atmosphere along with flue gases through chimney.

[31]

5. CONTROLLING , SWITCHING AND TRANSMISSION

5.1 CONTROL AND INSTRUMENTATION SYSTEM
Control and Instrumentation (C & I) systems are provided to enable the power station to be
operated in a safe and efficient manner while responding to the demands of the national grid
system. These demands have to be met without violating the safety or operational constraints of
the plants. For example, metallurgical limitations are important as they set limits on the
maximum permissible boiler metal temperature and the chemical constituents of the Feed water.
The control and Instrumentation system provides the means of the manual and automatic control
of plant operating conditions to maintain an adequate margin from the safety and operational
constraints. Monitor these margins and the plant conditions, and provide immediate indications
and permanent records. Draw the attention of the operator by an alarm system to any
unacceptable reduction in the margins. Shut down the plant if the operating constraints are
violated.

[32]

5.2 SWITCHING AND TRANSMISSION

The electricity is usually produced in the stator winding 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 centre of
the power station is the control room. Here engineers monitor the output of electricity,

[33]

supervising and controlling the operation of the generation plant and high voltage switch gear
and directing power to the grid system as required.
6. EFFICIENCY AND CONCLUSION
6.1 EFFICIENCY
Efficiency is defined as the ratio of output to input. Efficiency of any thermal power plant
can be divided into four parts1)
2)
3)
4)

Cycle Efficiency
Boiler Efficiency
Generator Efficiency
Turbine Efficiency

Efficiency of thermal power plant is defined as in the term of overall efficiency

i.e. overall efficiency = cycle x boiler x generator x turbine efficiency
CYCLE EFFICIENCY- Cycle efficiency is defined as the ration of energy available for
conversion in work to the heat supplied to the boiler.
BOILER EFFICIENCY- Efficiency of boiler depends upon the following factors:
a) Dry flue gas loss: Increase by excess air in boiler.
b) Wet flue gas loss: Moisture in coal.
c) Moisture in combustion loss: Hydrogen loss.
GENERATOR EFFICIENCY- Efficiency of generator is about 98% also its efficiency depends
upon:
a) Copper and iron loss
b) Windage losses
TURBINE EFFICIENCY-It means the efficiency of steam turbine in converting the heat
energy made available in the cycle into actual mechanical work.

[34]

6.2 CONCLUSION
This is my first practical training in which I learned lot of things and seen lot of huge
machine like Turbine, Boiler, Generator, cooling tower and many other things.
The architecture of the power plant, the way various units are linked and the way working
of whole plant is controlled make the student realize that engineering is not just learning the
structure description and working of various machine but the great part is of planning proper and
management.
I think training has essential for any student. It has allowed an opportunity to get an
exposure of the practical implementation to theoretical fundamentals.

[35]

7.REFERENCE

www.rvunl.com
www.googleindia.com
Generation of electrical power By B. R. Gupta, S CHAND PUBLICATION
Steam and Gas Turbine By R. Yadav , CPH
Engineering Thermodynamics By P. K. Nag, TMH

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