UTTAR PRADESH RAJYA VIDYUT UTPADAN NIGAM LTD.

THERMAL POWER STATION, ANPARA, SONEBHADRA

UTTAR PRADESH (U.P.R.V.U.N.L)

A TRAINING REPORT
ON
BOILER MAINTENANCE DIVISION(B.M.D)

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF

THE DEGREE OF

BACHELOR OF TECHNOLOGY
(Mechanical Engineering)

KIET GROUP OF INSTITUTION, GHAZIABAD

SUBMITTED BY:-

SANTOSH KUMAR GUPTA

B.TECH. (M.E.): 4th year
ROLL NO:-1402940126

.
DECLARATION

I hereby certify that the work, which is being presented in the Training report on “ BOILER
MAINTENANCE DIVISION(B.M.D)” in partial fulfillment of the requirement for the award of the
Degree of Bachelor of Technology submitted to the institution is an authentic record of my
own work carried out during the period 02-06-2017 to 01-07-2017 under the guidance of Er.
N.N. Singh and Er. Ganesh Kumar. I have worked with full dedication during these weeks
of summer training. I also cited the reference about the text, figures & tables from where they
have been taken.

Date: Signature of Student

SANTOSH KUMAR GUPTA
Univ.roll no.-1402940126
B.tech – ME, 3rd Yr.
KIET,Ghaziabad(U.P)
ACKNOWLEDGEMENT

I would like to place on record my deep sense of gratitude to Er.Nikhil Chaturvedi, executive
engineer of HRD division of thermal power station, Anpara for his generous guidance, help
and useful suggestions.

I express my sincere gratitude to Er.Sanjay Kumar Patel, executive engineer, Er. Ganesh
Kumar, assistant engineer, Er. N.N Singh assistant engineer of Boiler Maintenance
Division(BMD-I), ‘B’TPS Anpara, for his stimulating guidance, and continuous
encouragement .

I also wish to extend my thanks to Er. B.K Prasad and all the best mind of control unit of
‘B’TPS, Anparafor guiding and providing the knowledge related to machinery and processes.

I am extremely thankful to Prof. K.L.A Khan HOD(ME),KIET,Ghaziabad for valuable

suggestions and encouragement .

UTTAR PRADESH RAJYA VIDDUT UTPADAN NIGAM LTD.

 (U.P.R.V.U.N.L)

Uttar Pradesh RajyaViddutUttpadan Nigam Limited(U.P.R.V.U.N.L) is a state level

organization producing 2630MW energy and is the largest supplier of electricity in U.P.

(U.P.R.V.U.N.L,ANPARA)

Anpara Thermal Power Station

It is one of the best thermal power station (TPS) of Asia on the basis of availability of Major
inputs such as coal &water .

Plant Location:

Anpara Thermal Power Plant is located near village Anpara on the north bank of
RihandReservoir in districtSonebhadra, Uttar Pradesh.

It is situated 34 km from Renukut and approx. 200km from Varanasi.

Major Inputs :

Coal- Coal is supplied by Northern Coal Limited (NCL), Bina, Kakri, Khadiya,Singrauli,
Jhingur Dah,,etc through Merr-Go-Round system in which BOBR(Bottom Opening And
Bottom Reclosing) Wagons are used for the transport of 25000 MitricTonnes of coal per day.

Water- Water is supplied from Rihand Reservoir, Renukut.

Project Cost :

Anpara ‘A’TPS -- Rs.721 crores

Anpara ‘B’TPS -- Rs.2060 crores

Land Detail :

Plant area -- acres-1035.65

Ash dump area -- acres 1534.928

Unit Generation:
All the units of AnparaTPS is coal -fired thermal power plant, having total present generating
capacity of 2630MW and consists of following units-

Date of Original
Unit Installed Date of
Stage Derated Capacity commercial Equipment
No. Synchronisation
Capacity operation Manufacturers

Bharat Heavy
1 210 MW 210 MW 26.03.1986 01.01.1987
Electricals Ltd.

Bharat Heavy
A’TPS 2 210 MW 210 MW 28.02.1987 01.08.1987
Electricals Ltd.

Bharat Heavy
3 210 MW 210 MW 12.03.1988 01.04.1989
Electricals Ltd.

Mitsubishi
4 500 MW 500 MW 19.07.1993 01.03.1994 Corporation,
Japan

B’TPS

Mitsubishi
5 500 MW 500 MW 04.07.1994 01.10.1994 Corporation,
Japan

D’TPS 6 500MW 500MW 31.02.2015 08.05.2016 BHEL

7 500MW 500MW 23.02.2016 18.10.2016 BHEL

TABLE OF CONTENTS
Chapter 1: Introduction
 1.1 Basic Principle of Thermal Power Plant 9
1.2 Principle of Working of Thermal Power Plant 10-11
1.3 Plant Layout (Unit Overview) 12
Chapter 2: Boiler
2.1 General Description
2.2 Superheaters
2.3 Reheaters
2.4 Economiser
2.5 Furnace firing system
2.6 Electrostatic Precipitator
Chapter 3: Turbine 15-21
2.1 Steam Cycle
2.2 Condensate Cycle
2.3 Feed Water Cycle
Chapter 4: Electrical Generator 22
Chapter5: Conclusion

ABBREVIATIONS

CEP Condensate Extraction Pump

MAE Main Air Ejector

CPP Condensate Polishing Pump

LPHS Low Pressure Heaters

M-BFP Motorized- Boiler Feed Pump

T-BFP Turbo- Boiler Feed Pump

HPHS High Pressure Heaters

ECO Economizer

SH Super Heater

HP High Pressure

IP Intermediate Pressure

LP Low Pressure

RH Reheater

BRG Bearing

APH Air Pre Heater

AOP Auxiliary Oil Pump

MOP Main Oil Pump

EOP Emergency Oil Pump

MM WCL mm of Water Column

Chapter – 1

Introduction
1.1Basic Principle of Thermal Power Plant

Steam(Heat Energy) is produced from water by the combustion of fuel(coal) in the boiler i.e.
chemical energy(C.E.) of coal is converted into heat energy(H.E.).

This Heat Energy(H.E.) is converted into mechanical energy(M.E.),which produce shaft work
by Turbine.

This M.E. is used in running the rotor of an electric generator,which is directly coupled to the
shaft of turbine.

Thus Mechanical energy (M.E.) is converted into Electrical Energy(E.E.).

The Electric Power which is obtained from thermal energy(heat energy) is known as Thermal
Power.

C.hemical energy

Heat energy

Mechanical energy.

Electrical energy

Fig.1.1

1.2 Principle of Working of Thermal Power Plant

The basic cycle on which Thermal Power Plant works is Rankine Cycle, which is shown below
along with Temp.-Entropy(T-S) diagram:
 Fig-1.2.1

Cycle is consist of following four processes :

Process 1-2 Isentropic (Reversible Adiabatic) compression in a pump

Process 2-3 Reversible Constant pressure heat addition in a boiler
Process 3-4 Isentropic (Reversible Adiabatic) expansion in a turbine
Process 4-1 Reversible Constant pressure heat rejection in a condenser

In the vapor power cycle the working fluid, which is water undergoes a change of phase. Heat
is transferred to water in the boiler from an external source (furnace,where fuel is continuously
burnt) to raise steam, the high pressure high, high temperature steam leaving the boiler
expands in the turbine to produce shaft work, the steam leaving the turbine is condenses into
water into condenser (where cooling water circulates), rejecting heat, and then water is
pumped back to the boiler.

Thermal Efficiency, ƞ = Wnet / Qsuuplied = WT– WP /qin

For attaining higher thermal efficiency , thermal power plant works on combination of Reheat
& Re-generative cycle.
 Fig-1.2.2

Reheat Cycle - The process of increase the temp. of steam (increase degree of superheat) after
part of expansion in High Pressure (H.P.) turbine is called Reheat and the cycle is known as
Reheat Cycle.

Regenerative Cycle – Method for to heat the feed water from the hotwell of condenser
irreversibly by interchanging the heat within the system(L.P. Heater, Deaerator, H.P. Heater) is
called Regenerative feed heat and the cycle is called Regenerative Cycle.

1.3Plant Layout (Unit Overview)

 Fig.1.3

Working of Thermal Power Plant (Brief Description)

1.Coal is conveyed from track hopper to the primary crusher, secondary crusher and finally to
the mills (Ball Mill). In mills, the coal is crushed into very fine powder (size 0.75µm) by large
no of sphere.
2.Forced draught fan (F D FAN) suck the atmospheric air and deliver it to the secondary air
preheater(S-APH) and primary air preheater(P-APH) through primary air fan(P A FAN).

3.Fine powder of coal(fuel) is mixed with primary preheated air.

4.The hot air fuel mixture is forced into boiler where it ignites very rapidly.

5.Secondary preheated air is also forced into boiler for proper and complete combustion of
coal(fuel).

6.De-mineralized water(DM WATER) flows from boiler drum to the water wall bottom header
and then flows vertically in the tube-lined to walls of boiler , where it converted into steam and
collected in the boiler drum.

7.Steam is separated from the water in the boiler drum through separator(buffle –plate
arrangement) .

8.This collected steam is passed through 1’-superheater,2’-superheater(pendant type),3’-

superheater(platen type) and final- superheater, where it pressure and temperature increases
rapidly to 169KG/CM2 and 538⁰C.

9.This high pressure and high temp. steam is passed on High Pressure Turbine(HP Turbine),
where it works on turbine blades and rotate the shaft of turbine.

10.The exhaust steam from HP turbine, which is reduced in both pressure and temperature
,enters into boiler reheater, where steam temp. reaches to it’s initial temp. i.e. 538⁰C.

11.This reheated steam is passed on intermediate pressure turbine(IP Turbine) and then
directly to the low pressure turbine (LP turbine). Steam works on both IP and LP turbine and
rotate the shaft of turbine(i.e. produces M.E.).

12.The exhaust steam from LP turbine brought into thermal contact with circulating water
(which is pumped from circulating pump house(CW pump house)) in the Condenser. Steam is
condensed into water(DM Water) and this water is collected into Hot-Well.

13.In condenser proper vacuum is maintained by main air ejector(MAE) for the proper flow of
steam from LP turbine to the condenser.

14.Condensate extraction pump (CEP) is used to pumped the water from hot-well to deaerator,
which is flows through LP heaters for pre-warmed by steam(extracted from LP turbine).
15.InDeaerator , O2 is removed for the protection of various pipe lines from erosion &
corrosion.

16.Boiler feed pump (BFP) pumped the water from deaerator to economizer. Before entering
to the economizer water enters into HP heaters, where water is pre-warmed by the
steam(extracted from HP & IP turbine).

17.In the economizer feed water is again pre-warmed by the flue gases.

18.These all three sets of turbine (HP, IP, & LP) are coupled on same shaft as the 3-phase
electric generator.

19.As shaft of turbine rotates, rotor of generator also rotate and cut the magnetic field lines,
produced by stator and hence according to Faraday’s law electricity is generate. This generate
voltage is 21KV and current is 16196 Amp.

20.The exhaust gases from the boiler is drawn by induced draught fan(ID FAN) through an
electrostatic precipitator(ESP) and then passes through chimney.

21.The electrostatic precipitator(ESP) utilize electrostatic force to separate fly ash from flue
gas( exhaust gas).

CHAPTER -2
BOILER
 11.1 INTRODUCTION: -

Steam boiler or simply a boiler is basically a closed vessel into which water is heated until
the water is converted into steam at required pressure. The utility boilers are large capacity
steam generators used purely for the electrical power generation. In boiler heat energy is
released from the combustion of fossils fuel and heat is transferred to different fluids in the
system and a part of it is lost or left out as unutilized.

The basic working principle of boiler is very simple and easy to understand. The boiler is
essentially a closed vessel inside which water is stored. Fuel (generally coal) is bunt in a
furnace and hot gasses are produced. These hot gasses come in contact with water vessel
where the heat of these hot gases transfer to the water and consequently steam is produced in
the boiler. Then this steam is piped to the turbine of thermal power plant. There are many
different types of boiler utilized for different purposes like running a production unit,
sanitizing some area, sterilizing equipment, to warm up the surroundings etc.

11.2 BOILER MAIN PROCESS:-

 Send DM water to the boiler through boiler drum to boiler tubes.
 Sending fuel (furnace oil and coal) to the boiler through dampers (3000 MT/day).
 Sending required amount of primary (300T/hr) and secondary air (600T/hr) to
the boiler.

 Supplies superheated steam (5400C) of adequate temperature and pressure to

turbines.
 v. Extracting flue gases from the boiler and discharging them
tatmosphere. vi. Removing bottom ash formed as a result of
combustion process.
 vii. Removing fly ash from electrostatic precipitatohoppers.

11.3 TYPES OF BOILER USED IN POWER PLANTS:

-
Conventional, Single Drum, Tangentially fired, balanced draught, Natural Circulation,
Radiant Reheat Type, Dry Bottom with Direct Fired Pulverized Coal with Bowl Mill or with
Fuel Oil

FEED WATER CYCLE: -

DM Water – Feed Storage Tank – Boiler Feed Pump – HP Heaters –LP Heaters –
FeedStation – Economizer – Boiler Drum – Boiler Tubes

BOILER PARAMETERS:

MAIN STEAM FLOW @ SH OUTLET 700

T/HR
MAIN STEAM TEMP @ SH OUTLET 540 ºC

MAIN STEAM PRES @ SH OUTLET 137 KG/CM²

REHEAT STEAM FLOW 578.3T/HR

REHEAT STEAM TEMP @REHEAT OUTLET 540 ºC

REHEAT STEAM PRESSURE@REHEAT OUTLET 25.1 KG/CM²

REHEAT STEAM PRESSURE@REHEAT INLET 27 KG/CM²

FEED WATER TEMP. ECONOMISER INLET 247 ºC

Table 11.2 Boiler

Parameters
11.4 BOILER MAIN AUXILIARIES: -

Auxiliaries of steam boiler are devices that be installed to the steam boiler, and can make it
operates efficiently. These devices should be maintained and controlled, so steam boiler
can run in good condition. Some of auxiliaries which are installed in steam boiler are:

11.4.1 COAL CYCLE: -

Coal is pulverized and feed into the boiler in the following steps-

• Coal mine - unshaped, unsized raw bituminous coal –crusher – bunker (stack).

• Coal bunkers (20mm size coal) – coal feeders (controlling input to coal mill) –
coal mills.

 Powder, pulverized coal lifted by primary air and sending through coal
pipes - coal dampers

11.4.2 FUEL (FO / LDO) OIL CYCLE: -

• Furnace Oil (FO) / Light Diesel Oil (LDO) Tanks – Fuel Oil Pumps – Heaters

(Steam) – Oil Dampers - Oil Guns – To Furnace

• Furnace Oil Is Non Explosive, Difficult To Ignite In Bulk, No Spontaneous

Combustion

• Expensive Rs. 45-60 Thousand/Kl

BOILER AUXILIARIES QUANTITY IN NUMBERS

AIR HEATERS 02 NOS.

FUEL OIL PUMPS 03 NOS.

 OIL GUNS / IGNITORS 12 NOS. (4 NOS. AT 1
ELEVATION)
COAL MILLS 06 NOS.

PRIMARY AIR FANS 02 NOS.

FORCE DRAFT FANS 02 NOS.

INDUCED DRAFT FANS 02 NOS.

BOILER FEED PUMPS 03 NOS.

EMERGENCY LIFT PUMPS 02 NOS.

SEAL AIR FANS 02 NOS.
SCANNER FANS 02 NOS.

BOTTOM ASH GRINDERS 04 NOS.( 2NOS. FOR ONE

PASS)
ELECTROSTATIC PRECIPETATOR 24 ESP FIELDS (48 HOPPERS)

Table 11.3 Required Boiler Auxiliaries

11.4.3 AIR CYCLE: -

• Primary Air Fans: – Mixture cold & hot air supplies to lifting coal to furnace.

• Forced Draft Fans: – Supplies hot air required for combustion. The function of forced
draft fans is to supply the combustion air initially, when no coal firing is taking place. But once
the coal firing starts, the function of forced draft fan remains only to supply air required for
completing

Balanced Draft: - Balanced draft is obtained through use of both induced and forced
draft. This is more common with larger boilers where the flue gases have to travel a
long distance through many boiler passes. The induced draft fan works in
conjunction with the forced draft fan allowing the furnace pressure to be
maintained slightly below atmospheric.

• Induced Draft Fans: – Maintain continuity of combustion and maintain

negative pressure (-ve). Extract flue gases from furnace and discharge them to
atmosphere.

• Primary Air: - This air lifts the pulverized coal from the coal mills & enters
the boiler with it. The primary air quantity is less with pressure higher so that it
can lift the coal. This air is also used to dry the coal.
 • Secondary Air: - As air supplied wet coal (Primary air) is less in quantity it is
not sufficient for complete combustion & some quantity of air must be supplied
additionally to complete combustion. This is called secondary air.

• Seal Air Fans: - These fans take the suction from cold air duck of primary air system

& their discharge goes to the sealing of gear box of coal mills & its rollers for
bearing sealing.

• Scanner Fans: - Scanner fans air supply the cooling air necessary for the cooling
of costly scanner heads. Scanner heads may get damaged if not cooled, leading to
outage of units. These fans take their suction from the discharge of FD in the
discharge of these fans goes to scanner after getting filtered. In case of AC failure
when FD fans trip, there is provision to provide suction to these fans from
atmosphere.

• Soot Blower System: - The fuel used in thermal power plants causes soot and this
is deposited on the boiler tubes, economizer tubes, air pre heaters, etc. This
drastically reduces the amount of heat transfer of the heat exchangers. Soot blowers
control the formation of soot and reduce its corrosive effects. The types of soot
blowers are fixed type, which may be further classified into lane type and mass type
depending upon the type of spray and nozzle used. The other type of soot blower is
the retractable soot blower. The advantages are that they are placed far away from
the high temperature zone, they concentrate the cleaning through a single large
nozzle rather than many small nozzles and there is no concern of nozzle arrangement
with respect to the boiler tubes.

11.5 IMPROVING BOILER AND OVERALL EFFICIENCY OF PLANT: -

• Economizer: - Absorbs heat from flue gas and add this sensible heat to feed
water before water enters to Boiler. The justifiable cost of the economizer depends
on the total gain in efficiency. In turn this depends on the flue gas temperature
leaving the boiler and the feed water inlet temperature.

• Air Pre-Heater: -Flue gases passes through Heater tubes and Cold air passes
through air heater heated up and Hot air used for combustion. An air preheater or air
 heater is a general term to describe any device designed to heat air before another
process (for example, combustion in a boiler) with the primary objective of
increasing the thermal efficiency of the process. They may be used alone or to
replace a recuperative heat system or to replace a steam coil.

• Super Heaters: - The super heater is a heat exchanger in which heat is transferred
to the saturated steam to increase its temperature. It raises the overall cycle
efficiency. In addition, it reduces the moisture content in the last stages of the turbine
and thus increases the turbine efficiency. The superheater consists of a superheater
header and superheater elements. Steam from the main steam pipe arrives at the
saturated steam chamber of the superheater header and is fed into the superheater
elements. Superheated steam arrives back at the superheated steam chamber of the
superheater header and is fed into the steam pipe to the cylinders. Superheated steam
is more expansive.

• Reheater: - The reheater functions similar to the superheater in that it serves

to elevate the steam temperature. Primary steam is supplied to the high pressure
turbine. After passing through the high pressure turbine, the steam is returned to the
steam generator for reheating (in a reheater) after which it is sent to the low pressure
turbine. A second reheat cycle may also be provided.

11.6 FLUE GAS PATH: -

• Whenever combustion takes place chemical energy converted into heat energy

(depends on CV).

• Various gases CO2, SO2, N2, water vapor produced.

• Heat carried away through flue gas is used in Air Heater & Economizer to improve
Boiler Efficiency.
Temperature of the flue gases at various stages is given below in the index for (210

MW) Rated output plant. Parameters of flue gas may vary from one plant to
other.

FLUE GAS PATH OUTLET

TEMPERATURE

IN 0 C
FURNACE 1123
PLATTERN SUPER 1010
HEATER
REHEATER FRONT 823
REHEATER REAR 765
FINAL SUPER HEATER 662
HORIZONTAL SUPER 479
HEATER
ECONOMISER 369
AIR HEATER 140
E.S.P. 125
I.D.FAN 120
CHIMNEY 120

Table 11.4 Flue Gas Parameters at Various Stages

Materials used for the boiler tubes as per ASME: -
 Material ASTM Grade Temperature
Specification

Carbon Steel SA 210 A1 450oC

Carbon ¼ % MO Steel SA 209 T1 480Oc

1 % Cr, ½ % MO Steel SA 213 T11 550oC

2 ½ % Cr, 1 % MO Steel SA 213 T22 580oC

18% Cr, 8 % Ni Stainless SA 213 T304 Up to 700oC

Steel

Table 11.5 Materials for Boiler Tubes

11.7 BOILER AUXILIARIES SPECIFICATIONS: -

Induced Draft Fan: -

MOTOR UNIT NO.3 UNIT UNIT FAN

MAKE BHEL BHEL
NO.4 BHEL
NO.5 MAKE BHEL
CAPACIT 170 130 130 CAPACIT 232.5M³/SE
Y 0 0 0 Y C AXIA
L
SPEED 990 990 990 TYPE
VOLTAG 6.6 6.6 6.6 SPEED 990 RPM
NO. OF IMPULS
E E
CURREN 175 138 138 FAN /
BOILE
T R 2
23
 Chapter – 3
TURBINE
This division maintain and operate three cycle, which is given below:

3.1Steam Cycle (From boiler drum to condenser)

Steam is separated from boiler drum and passed through superheaters and passed on to the
turbines(HP,IP,LP) and finally into condenser.

3.2 Condensate Cycle –( from condenser to deaerator)

The condensate system delivers condensate from condenser to deaerator through condensate
extraction pump, the condensate polishing plant, the main air ejector, the gland steam
condenser and LP heaters , where condensate is cleaned, chemically treated, heated and
deaerated.

3.3 Feed Water Cycle - (From Deareator to Economizer)

The feed water system delivers feed water from deareator storage tank to boiler economizer
through boiler feed pump and HP- heaters, where feed water is heated and chemically treated.

1
Turbine

A steam turbine is prime mover in which the heat energy (potential energy) of steam
transformed into kinetic energy, and later it transformed into mechanical energy of rotation of
turbine shaft.

Classification of Turbine

1.The most important and common division being with respect to action of the steam, as:

Impulse Turbine:

Turbine working on pushing effect of the steam against the rotating blades are called impulse
turbine.

As the steam flows through the nozzle(or nozzle shaped fixed blade) its pressure falls from
steam chest pressure to lower pressure and steam leaves the nozzle with very high velocity.
This high velocity ( high kinetic energy) steam flows on moving blades. A portion of this
energy is absorbed by moving blades and kinetic energy of steam converted into mechanical
energy through impact of the steam against the rotating blades. When steam flows on moving
blade, its pressure does not alter and remains constant.

Fixed blade (nozzle shape) converted potential energy (heat energy) into kinetic energy and
rotating blade converted kinetic energy into torque.

Reaction Turbine:

Turbine working on kick back effect in the rotating blades are called reaction turbine i.e.
reaction of steam against the blades utilized to rotate the shaft.

This turbine is consist of fixed and moving blades. There is gradual pressure drop and takes
place continuously over the fixed and moving blades. The function of fixes blades is (the
same as the nozzle) that they alter the direction of steam as well as allow it expand to a larger
velocity. As the steam passes over moving blades its kinetic energy(obtained due to fall in
pressure) is absorbed by them, hence gives ‘reaction’ to moving blades. Hence the term
‘Reaction Turbine’.

2
Since pressure drop occur in both blades(fixed and moving) i.e. steam expand in both blades
,hence both blades are ‘Nozzle Shaped’.

2. According to Steam Condition at Inlet of Turbine

(i) Low pressure Turbine: using steam at a pressure of 10 to 0.1bar.

(ii) Medium pressure Turbine: using steam at a pressure upto 40bar.
(iii) High pressure Turbine: using steam at a pressure above 40bar

Type of Turbine
Three stationary turbine i.e. High Pressure (H.P.), Intermediate Pressure(I.P.) & Low
Pressure(L.P.) (which are mixed of both type i.e. ‘Impulse - Rection’ turbine) with constant
speed of rotation is used to rotate alternators.

Specification of Steam Turbine

Table-2.1.2.1

Type Tandem Compound, Two cylinders, Double Flow Exhaust Reheat

Turbine
Rated Speed 3000r.p.m.
Rated Capacity 500MW
Machine No. T-5969
Manufacturing Year 1991, by Toshiba Corporation ,Tokyo,Japan

Specification of Steam Condition

Table-2.1.2.2

Main Steam Pressure 169Kg/cm2

Main Steam Temperature 538⁰C (in M.S. line & at MSV inlet)
Reheat pressure 37.5 KG/CM2
Reheat temperature 538⁰C (in H.R.H. line & at CRV inlet)
Exhaust Pressure (Cond. Vac.) 76.6 mmHg(abs.)

3
No. of Stages in Turbine

Table-2.1.2.3

TOSHIBA 500MW KWU SET 500MW KWU SET 210MW

HP Turbine 07 18 25
IP Turbine 05 2×14 2×25
LP Turbine 2×5 2×6 2×8
TOTAL 22 58 81

Inlet & Outlet Condition of Turbines

Table-2.1.2.4

Inlet Press. & Temp. Outlet Press. & Temp.

HP Turbine 169KG/CM2,538⁰C 51KG/CM2,365⁰C
(In M.S. Line) (In C.R.H. Line)

IP Turbine 37.5KG/CM2,538⁰C 11KG/CM2,350⁰C

(In H.R.H Line) (In Cross-over pipe)

LP Turbine 11KG/CM2,350⁰C 76.6mmHg,45⁰C

(In Cross-over pipe) (In Condenser)

Since pressure drop occurs in each stage of turbine, hence volume of steam increases . So
diameter of turbine increases after each stage of turbine.

Since pressure drop in LP Turbine is more than in IP & HP Turbine and in IP turbine is more
than in HP turbine. So diameter of LP turbine is higher than IP & HP turbine and diameter of
IP turbine is higher than HP turbine. Hence LP Turbine is bigger in size .

SIZE OF TURBINE LP > IP > HP

4
Last Stage Blade Length of TOSHIBA Turbine – 1066.8mm(41”)
Cross Over Pipe Dia – 60”

Operating Principle of Turbine

In a multistage turbine, steam at high pressure & temperature enters the first row of fixed
blades or nozzles through an inlet valves (MSVs & CVs). Steam expands partially, pressure
drops and its velocity increases. Kinetic energy of steam increases due to increase in velocity.
Steam with high K.E. strikes the first set of moving blades. A portion of this energy is
absorbed by a row of moving blades i.e. K.E. is converted into M.E. , resulting in rotation of
shaft.

The steam then enters into next stage of fixed and moving blades. After the last stage of
turbine steam is exhausted to condenser where it condenses.

Fixed blade are mounted on turbine casing and Moving blade are mounted on shaft.

As the steam passes through turbine , pressure and temperature decreases and volume
increases.

Special Feature of Toshiba Turbine

1. Compact in size – only 2 cylinder, less no. of stages, reduced weight of rotor(HIP rotor-
HP & IP opposed flow single rotor 23.9MT & LP rotor – opposed flow 58MT) andsmaller
size of bearing.

2. Small installation space required & lower station cost.

3. Lesser steam leakage from HP section.

4. Double shell construction – stress and temp. gradient reduced in inner and outer casing ,
both steam leakage possibility minimized.

5. Easy vibration, very small level of operation & high reliability.

5
(KMU Set 210MW, LP- Turbine with turbine blade)
Fig. 2.1.2.1

(Combination of HP, IP, LP Turbine &Generator )

Fig.2.1.2.2

6
Turbine Driven Boiler Feed Pump (T-BFP)

Two sets of 60% turbine driven boiler feed pump are mounted on ground floor T/G house.
Each turbine driven boiler feed pump are consist of a suction booster pump (T-BFBP) and a
main pump (T-BFP).

Both T- BFP & T- BFBP are drives by steam turbine (BFP-T), where T-BFP is driven
directly and T-BFBP is driven through speed reduction gear.

The T- BFBP is double suction, single stage, horizontal and centrifugal pump.

The T- BFP is single suction, 4- stage, horizontal and centrifugal pump.

(Rotor of BFP-T)

2.3.2 Motor Driven Boiler Feed Pump( T-BFP)

Two sets of 30% motor driven boiler feed pump are mounted on ground floor T/G house.
Each motor driven boiler feed pump are consist of a suction booster pump (M-BFBP) and a
main pump (M-BFP).

Both M- BFP & M- BFBP are driven by electric motor, where M-BFP is drives through
hydraulic coupling and M-BFBP is driven directly.

The M- BFBP is double suction, single stage, horizontal and centrifugal pump

The M- BFP is single suction, 6- stage, horizontal and centrifugal

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 Chapter – 4

Electrical Generator

3.0 Electrical Generator

An electric generator is a device that converts mechanical energy of turbine into electrical
energy. The generation of electricity is based on Faraday’s Law of Electromagnetic
Induction.

The generator rotor is coupled to turbine shaft. When steam works on turbine, turbine shaft
will rotate and hence generator rotor also rotate.
Rotor rotate in static magnetic field produced by stator i.e. rotor cuts the magnetic flux. And
hence according to Faraday’s Law of electromagnetic induction an e.m.f. is produced.

Technical Description of A.C. Generator Unit

Table-3.0

Phase 3
Pole 2
Volts 21000V
Ampere 16194A
Frequency 50Hz
Rating Continuous
Power Factor 0.85
Rated Field Volt 392V
Field Ampere 4810A

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 Chapter - 5

Conclusion

During the training period a number of conclusions were derived which will further be laid as
foundation to other projects in the field of thermal engineering & technology.

 Thorough understanding of the major flow cycles applied in the Turbine Maintenance
Division of the Thermal Power Plant, Anpara.
 The theoretical knowledge of these flow cycles namely Steam Cycle, Condensate
Cycle & Feed-water Cycle remains to be a vital pre-requisite to operate & handle all
major thermal machinery.
 Adequate familiarity with the Process flow being followed in the Thermal Power
Plant, Anpara constitutes the use of respective thermal machinery:
o Steam Cycle – Boiler DrumSuperHeaterHigh Pressure TurbineRe-
HeaterIntermediate & Low Pressure Turbine Condenser.
o Condensate Cycle – CondenserCondensate Extraction PumpMain Air
EjectorGland Steam CondenserLow Pressure HeaterDeaerator.
o Feed-Water Cycle – DeaeratorBoiler Feed-pump High Pressure
HeaterEconomizer.

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