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SHANKARA INSTITUTE OF
TEHCNOLOGY, JAIPUR
ACKNOWLEDGEMENT
We wish to express our deep sense of gratitude to our training & placement
officer Mr. Naveen Sharma and H.O.D. Mr. Neeraj for suggest and valuable
guidance us for S.T.P.S. It is our proud privilege to express our sense of
gratitude to Assistant Engineers for providing us adequate facilities to
undergo training at S.T.P.S.
We are thankful to Mr. B.P. Gautam (SE), Mr. Udaybhan Singh Shekhawat
(JEN) & Mr. Sandeep (JEN) for their valuable guidance and co-operation
without which it was not possible to get so much knowledge. We are also
Grateful to Mr. Ghanshyam Agarwal (AEN) & Mr. Ramesh Sethi (AEN),
their persistent help and for providing some of the technical data.
And at last we want to thank our colleagues. Without their help guidance and
suggestions it was not possible to produce this report.
PREFACE:-
A very important element in curriculum of an Engineering student is the
Practical Training.
After passing few stages the flue gasses taken from boiler
by IDM
(Intermediate Draft Fan) and send to chimney through ESP
(Electro Static Precipitator). The Electro Static Precipitator
which use electric force to remove the dust from the gases
steam some ash send to ash dyke threw pipes in a slurry
form with the help of number of pumps.
Boiler drum is situated at the top of the furnace throw the
boiler tubes which are situated in the furnace. The water is
used to produce steam. First of all water comes in
Economizer after this its temperature increases up to 307°c.
After this water goes in the boiler drum and heater, which
are mounted on the top of the furnace, then the water flows
in the tubes. These tubes are connected with the flame in
the furnace. Due to heating the water converted into the
steam. This steam is collected in boiler drum. The
temperature of the
steam is about 538°c with the help of super heater.
This steam moves the blades of the all their turbines that as
these blades rotates on the same shaft, which are connected
to the Generator. As the blade moves are the rotor of the
generator is also rotates at 3000 RPM at effective load. Thus
rotation of the rotor occurs. The magnetic field results for the
generation of electricity.
After this water feed into HPB (High Pressure Boiler) by the
help of BFP (Boiler Feed Pump). For this the temperature of
water is about 250°c. In the last stage the water is feed into
the Economizer. This cycle works regularly and it is same for
all units in this Super Thermal Power station.
The general layout of plant consists of mainly four circuits. The four
circuits are
GENERATOR:-
Generator is the electrical end of turbo generator set. It is a
cylindrical pole synchronous generator. It is generally known
as a piece of equipment that actually converts the
mechanical energy of turbine into electricity. The generation
of electricity is based on the principle of electromagnetic
induction.
1. Stator
2. Rotor
3. Excitation system
4. Cooling system
5. Sealing system
Stator:-
The stator is the component that embodies the armature
core and armature winding. It is totally enclosed gas tight
fabricated structure. It is the single heaviest load in the
whole turbo generator. The major part of this load is stator
core. The stator comprises of an inner frame and outer
frame. The outer frame is a rigid fabricated structure of
welded steel plates.
STATOR CORE:-
The stator is built up from a large no of vanished insulated
punching or thin sections of thin (generally 0.35 mm to 0.5
mm) steel plates. The use of cooled rolled grain-oriented,
loss less steel iron which the punching are made can
contribute to reduction in the weight of stator core for two
main reasons.
ROTOR:-
ROTOR WINDING AND RETAINING RINGS:-
The rotor carries the field windings. Silver bearing copper
(containing 0.03 to 0.1 % silver) is used for the winding with
mica as the insulation between conductors. A mechanically
strong insulator such as micanite is used for lining the slots.
Later designs of windings for circulation of the cooling gases
throw the actual conductors. When rotating at high speed,
centrifugal force tries to lift the winding out of the slots and
duralumin wedges contain them. The end turns outside the
slots are covered by non magnetic steel retaining end rings
are secured to a turned recess in the rotor body. By shrinking
or screwing and support at the other end by fitting the rotor
body.
Coolers:-
Because of these properties, hydrogen will extract more
heat per unit
volume/min. Thus for a given rise of temperature, machine
capacity can be increased. It has been estimated that by use
of Hydrogen 20% reduction in active construction materials
can be affected. At 0.035 kg/cm² of hydrogen, machine
rating is increased by 22-25% and at 2.109 kg/cm² the rating
increase is 35%.
TRANSFORMER:-
A transformer may be defined as equipment based on
electromagnetic induction, alternating current and voltage
without is altered affecting frequency. It is static equipment
i.e. it has no moveable parts. The fundamental theory of
transformer is that if on a magnetic core two winding are
placed than the current produced in primary winding an
account of alternating voltage imposed in secondary and if
the circuit is closed then current in the secondary winding.
Transforms are generally shell type or core type. They may
be single phase or three phases.
Installed Transformers
Main generator transformer:-
Station Transformer:-
When the unit is running, power required for L.T. and H.T.
switchgear is also be provided by this transformer. The rating
of this transformer is 220KV/6.6KV. In this type of
transformer primary and secondary is star connected.
Specification of Generator
Transformer:-
Type of cooling ONAN/ONAF/OFAF
Rating in MVA 160/240/315
No load voltage (HV) (kV) 420
No load voltage (LV) (kV) 16.5
Line current (Amp.)
HV 219.9/329.9/433.01
LV 5598.5/8397.8/11022.1
Temp rise in oil (°c) 45°c over Ambient of 50°c
Temp rise in windings (°c) 50°c over Ambient of 50°c
No load loss/load loss/
Auxiliary loss (kW) 145/600/19
Short circuit capacity
HV: 40KA/3sec
LV: 101KA/3 sec
Phases 3
Frequency 50 Hz
Connection symbol yndII
HV LV normal tapping 14.5%-10%
HV LV max. Tapping 14.27% approximately
HV LV min. Tapping 14.47% approximately
Core and winding weight 112500 Kg.
Weight of oil 56810 Kg
Total weight 287545 Kg
KVA 40000/50000
/50000
Volts (no load) 220KV HV
.6 KV LV
Ampere line 105/135 HV
/4189 LV
Phases 3
Frequency 50
Type of cooling ONAN/ONAF
Connection symbol Ynyn0
Mass of core and winding (Kg) 44470
Mass of oil (Kg) 22780
Total mass 86210
Untankin mass (Kg) 45230
Oil in tank 25600
Min. temp of oil 40°c
Max. temp of oil 50°c
Electrical System:-
High voltage transformer rectifier (HVR) with electronic
controller (EC):-
Hoppers:-
Precipitator hoppers are designed to completely discharge
dust load on demand. Typically, precipitator hoppers are
rectangular in cross-section with sides of at least 60-degree
slope. These hoppers are insulated from the neck above the
discharge flange with the insulation covering the entire
hopper area. In addition, the lower 1/4- 1/3 of the hopper
wall may be heated. Discharge diameters are generally 8" -
12".
Insulation:-
Insulation provides protection for facility personnel as well
as working to retain as much hopper wall temperature as
possible. Hopper wall
temperature retention discourages condensation on the
inside of the hopper. Heaters are added to ensure hot metal
surfaces immediately above the fly ash discharge.
Facilitating hopper discharge:-
Hopper discharge problems are caused by compaction of
the fly ash in the hopper. Compaction characteristics are
affected by moisture content, particle size and shape, head
of material, and vibration. The flow of fly ash out of the
hopper can be facilitated by the use of external vibrators.
These can operate on the outside wall of the hopper or on an
internal hopper baffle.
Hopper fluidizers:-
Hopper fluidizers have a membrane that permits air flow to
the fly ash directly above. This air flow fills the voids
between the fly ash particles at a slight pressure, changes
the repose angle of the particles, and promotes gravity flow.
Gas Distribution:-
Efficient precipitator performance depends heavily upon
having similar gas conditions at the inlet of each electrical
field or bus section and at the inlet of each gas passage of
the electrical field or bus section. Uniformity of gas velocity
is also desirable - good gas velocity distribution through a
precipitator meets these requirements:
Collecting Plates:-
Collecting plates are designed to receive and retain the
precipitated particles until they are intentionally removed
into the hopper. Collecting plates are also part of the
electrical power circuit of the precipitator. These collecting
plate functions are incorporated into the precipitator design.
Plate baffles shield the precipitated particles from the gas
flow while smooth surfaces provide for high operating
voltage.
Discharge Electrodes:-
Discharge electrodes emit charging current and provide
voltage that
generates an electrical field between the discharge
electrodes and the collecting plates. The electrical field
forces dust particles in the gas stream to migrate toward the
collecting plates. The particles then precipitate onto the
collecting plates. Common types of discharge electrodes
include:
Rigid masts
Rigid frames
Spiral wires
Electric vibrators
Tumbling hammers
Switch-Yard
A switchyard provides a connection point for transmission
lines of the same voltage. The proposed Eastern Terminal
switchyard requires approximately 4 hectares of land,
However, Western Power is looking for an area of
approximately 20 hectares to ensure that the switchyard can
be adequately screened and to accommodate a terminal
substation, in case future major development in the hills
area trigger the need for increased power.
Isolators:-
Elegant Design
TURBINE SECTION
INTRODUCTION:-
Steam turbine is a device which consist heat energy
mechanical energy. In India, steam turbine of different
capacity varying from 15-500MW, are employed in the field
of thermal power generation. The design material auxiliary
system etc. Very widely from each other depending on the
capacity and manufacture of the sets.
WORKING PRINCIPLES:-
When steam is allowed to expand through a narrow orifice.
Reaction
turbine is used in Suratgarh thermal power station. In this
turbine in which some expansion of steam in fixed blade and
some expansion in moving blade. It assumes kinetic energy
at the expense of its enthalpy (heat energy). This kinetic
energy of steam is changed to mechanical energy through
the reaction of steam against the blades. After this the rotor
rotates with some speed.
BOILER SECTION:-
Boiler is as equipment which is used to generate the steam.
The steam gives a main role for generate for the electricity.
Initially water entered the boiler at a temperature of 300°c
and gives output Temperature is 500°c of steam. For this
purpose Drum, Economizer, Pre heater, Super heater
equipments are used. A path of water which was comes in
boiler as given below:-
Condensate water comes in the LPH (Low Pressure Heater)
with the help tubes and water goes in the Dearator. Dearator
is a devise which is use to remove the oxygen practical in
water. Dearator water comes in the high pressure heater
with the help of boiler feed pump, after this water comes in
Economizer and the temperature of water 360°c and last
stage water comes in boiler drum after this water flows in
the tubes and converts in steam.
GENERAL CONSTRUCTION OR
OPERATION:-
This boiler has divided by into these zones. In the zone first
transfer is preheated by radiation as the flam in the zone is
diffused yellow flam, which radiates much more than the
premixed blue flam. As the burnt gases upward and
secondary air is added. The effect of radiation is reduced,
becomes predominate as the flam changes from diffused to
premix.
Initially the liquid fuel is used to generate the heat. The air
is also used with coal powder in the furnace of boiler for
generate the flame heat. A stage reaches when water begins
to boil without temperature change at this stage steam is
formed and according to density this steam goes in the drum
and then turbine.
FURNACE:-
SUPERHEATER:-
AIR PREHEATER:-
The air preheater is now essential boiler auxiliary, because
hot air is
necessary for rapid and efficient combustion and also for
drying coal in the milling plant.
There are two main type of air preheater in use today: static
recuperative plate or tube type and the rotatory
regenerative type. Here in STPS rotatory regenerative type is
used.
ECONOMIZER:-
MILL SECTION:-
INTRODUCTION:-
Coal handling plant deals with the under loading of the coal
racks, rushing of coal at different stages to stack the crusher
coal at the tock pile to feed the crushed coal to the coal
bunkers either irectly from the rack or stockpile stacked coal
through declaimer.
In the third stage is feed either from the stacked coal at the
stockpile or directly from the rotary barker. While conveying
coal to the third stage crusher, as ILMS {In Line Magnetic
Separator} comes into the way. Here iron materials pieces
etc. get separated. The coal is feed to third stage crusher
where it is crushed into size of 10 mm. this coal feed to the
bunkers from where it is feed to the coal mills.
Wagon tippler :-
Roll crusher:-
Roll Crushers are compression type crushers, and were once
widely used in mining. They have, within the last 10 or so
years, fallen into dis-favor among mining and processing
companies. The probable reason is because the large mines
require very large crushed product output with minimal cost,
makes the roll crusher uncompetitive. The roll crushers are
not nearly as productive as cone crushers, with respect to
volume, and they do have a little higher maintenance
associated with them. Roll crushers do, however, give a very
close product size distribution, and if the ore is not too
abrasive, they do not have high maintenance costs.
Vibrating Feeder:-
Apron Feeder:-
TENGL Apron Feeders are engineered for heavy-duty operation and for
primary or subsequent application stages. These custom-built machines are
designed to suit individual requirements of capacity, size and material
handled.
Construction based on undercarriage components.
Rotary Breaker:-
A rotary coal breaker is designed to receive run-of-mine coal.
The coal breaker provides both positive control of the top size
and liberation of rock from coal.
1.Ring Granulator:-
2.Grizzly Feeder:-
The grizzly feeder is used for separation of fines from
primary feed or secondary feed to the crushing plant.
TECHNICAL DATA:-
Application Ball tube mill
System type Pressurized direct firing
Eff. Dia. of shell 4.7 m
Eff. Length of shell 7.2 m
Shell (rpm) 15 RPM
Total weight of balls 80 tones/period
No. of lines 600 each mill
Main motor reducer gain ratio 12.5:1
Bearing type ball and roller bearing
Coupling type Fluid coupling
Lubricant oil temp. 40°c
Main motor rating 2400 KW
Auxiliary motor rating 1500 KW
Coal Feeder:-
The coal has come back into the spotlight as an alternative
energy source in thermal power generating facilities around
the world. The coal-fired power plant is increase in the
privately owned electrical power facilities.
Speed Reducer:-
Speed Reducers feature wash down coating. January 10,
2005 - Suited for speed reducers, Stainless Bost-Kleen™
utilizes
Bisphenol-F type epoxy, which offers chemical, pressure, and
thermal
resistance to prevent wear and cracking caused by caustic
chemicals and high-pressure wash downs as well as
scratches that may occur from contact during installation
and operation. Coating is USDA and FDA accepted, BISCC
certified, and available on all speed reducers.
Valve or Damper:-
Not only are Beck drives designed to eliminate the
shortcomings of other actuators, the many unique design
features make them easy to install, easy to operate, reliable,
maintenance-free and durable. The design also results in
unbeatable control performance that remains consistent
over time and with changing conditions.
Ash slurry in boiler is 3KM away from plant with the help of
pump house.
PLANT HIGHLIGHTS
The teco-economic clearness for the project was issued
by CEA in June 1991.
The updated or total cost of the stage-1 and stage-2
projects is estimated at 2300 crores or 2050 crores
(including IDC).
It is one of the thermal power station of Rajasthan
which was produces a 1250 MW and 250 MW in each
unit of power.
In STPS the computerized coutronic-E band control and
instrumentation system. The main advantage of this
system is that of any engineer in harmony could be
operates any problems in STPS stage system.
This thermal plant was made before completes its time
or period. So that a lot of money was saved.
The cooling (air conditioner) process is also so good at
all section of STPS.
In this plant the 400 KV and 200 KV switchyard has
been consisted it is first in our country.
Bibliography:-
www.powerelectrical.blogspost.com
www.softech-engr.com
www.titanindia.com
www.springerlink.com
www.worldwes.com
A complete book on Thermal Plant Engg. By H.G.Hugg.
STPS Workers
www.dte.rajasthan.gov.in
www.en.wikipedia.org