1.

INTRODUCTION

ABOUT THERMAL POWER PLANT:

The basic principle based on which the thermal power plant works is law of
conservation of energy which states that energy is neither created nor destroyed but can be
transformed from one form to other. Here in thermal power plants heat energy is converted to
electric energy.

1.1 Introductory overview

In a coal based power plant coal is transported from coal mines to the
power plant by railway in wagons or in a merry-go-round system. Coal is unloaded from the
wagons to a moving underground conveyor belt. This coal from the mines is of no uniform
size. So it is taken to the Crusher house and crushed to a size of 20mm. From the crusher
house the coal is either stored in dead storage( generally 40 days coal supply) which serves as
coal supply in case of coal supply bottleneck or to the live storage(8 hours coal supply) in the
raw coal bunker in the boiler house. Raw coal from the raw coal bunker is supplied to the
Coal Mills by a Raw Coal Feeder. The Coal Mills or pulverizer pulverizes the coal to 200
mesh size. The powdered coal from the coal mills is carried to the boiler in coal pipes by high
pressure hot air. The pulverized coal air mixture is burnt in the boiler in the combustion zone.
Generally in modern boilers tangential firing system is used i.e. the coal nozzles/ guns form
tangent to a circle. The temperature in fire ball is of the order of 1300 deg.C. The boiler is a
water tube boiler hanging from the top. Water is converted to steam in the boiler and steam is
separated from water in the boiler Drum. The saturated steam from the boiler drum is taken to
the Low Temperature Superheater, Platen Superheater and Final Superheater respectively for
superheating. The superheated steam from the final superheater is taken to the High Pressure
Steam Turbine (HPT). In the HPT the steam pressure is utilized to rotate the turbine and the
resultant is rotational energy. From the HPT the out coming steam is taken to the Reheater in
the boiler to increase its temperature as the steam becomes wet at the HPT outlet. After
reheating this steam is taken to the Intermediate Pressure Turbine (IPT) and then to the Low
Pressure Turbine (LPT). The outlet of the LPT is sent to the condenser for condensing back
to water by a cooling water system. This condensed water is collected in the Hotwell and is
again sent to the boiler in a closed cycle. The rotational energy imparted to the turbine by
high pressure steam is converted to electrical energy in the Generator.

1.2 About KTPS:

Kothagudem thermal power station, K.T.P.S. is a place of pride in the thermal map of
India. It was the first major thermal power station to set up in Andhra Pradesh state electricity
board.

kothagudem thermal power station is basically the coal fired thermal power
generating station with total installed capacity of 1000 MW out of which stage-V consist of
units 9 & 10 each of 250 MW and stage-VI consist of units 11 each of 500 MW capacity.

Primary fuel supply:

The supply of coal to the KTPS is from the singareni collieries company ltd. located
in Manugur, Yellandu & Rudrampur mines. The minimum distance of S.C.C.L coal mines by
rail is around 50km.
Supply of water:
With the invention of steam engine for obtaining mechanical energy called non-
conventional methods i.e., wind, tidal, geothermal etc.., was obtained by as the involved was
high and also there was no flexibility for transportation of this form of energy. The
development of steam turbines and then electric generator completely replaced the non-
conventional methods .fossil fuels became the main source of energy. The sizes of thermal
plants are grown from a few KW to more than 1000MW as of today. The concept of
generating electrical energy using fossil fuel has changed completely. Super thermal power
plants have been found more economical in general to generate electrical energy.

Basically thermal power stations are two types:

1. Pit head stations

2. Load demand stations

Pit head stations are those which are near to the source of fuel and the load demand
stations are those which near to the load centers. As the transportation of electrical energy
involves much a large percentage of total capital cost & transmission line losses, installation
of plants near the pitheads saves all these.

Site selection for thermal power plant:

Land:
Generally 1000MW plants require 90 to 200 acres of land

Water:
Water requirement is in two stages 1st are for stem generation and the other is for
cooling purpose. Water for steam generation is low of the order 3 to4 tons per 1MW and
makeup quantity 2to3% of the same. The amount for water condensation is quite high.

Coal:
The coal resources existing in the country are of 1,30,000 million tons. Plant should
be located nearer to the coal mines thus reducing the cost of transportation.
Transportation Network:
Easy & enough access to transportation network is required in both plant construction
and operation periods.

Power Transmission Network:

To transfer the generated electricity to the consumers, the plant should be connected
to electrical transmission system. Therefore, the nearness to the electrical network can play
roll.

Geology & soil type:

The power plant should be built in area with soil and rock layer that should stand the
weight & vibrations of the power plant.

Water Resources:
For the construction and operating of power plant different volume of water are
required. This could be supplied from either rivers or underground water resources. Therefore
having enough water supplies in defined vicinity can be factor in these selections of the site.

Environmental Resources:
Operation of a power plant has important impacts on environment. Therefore, priority
will be given to the locations that are far enough from national parks, wildlife, protected areas
etc..,

Need for power:

In general the site should be near the areas that there is more need for generation
capacity, to decrease the amount of power loss and transmission expenses.

Climate:
Parameters such as temperature, humidity and wind action affect the productivity of
power plant and always should be taken into account.
Archeological and historical sites:
Usually historical buildings are fragile and at same time very valuable caused by
power plant can damage them, and a defined distance should be considered.
 2. PRINCIPLES OF OPERATION

The fundamental forms of energy with which thermal stations are principally
concerned are heat and work. Heat produces work and this work is further converted into
electrical energy through a medium i.e. electrical generator. For the purpose of understanding
of thermal plants, the phenomenon of the thermodynamic vapour cycle's explained here under

1. Rankine cycle

2. Reheat cycle

3. Regenerative cycle

2.1 RANKINE CYCLE:

This is simplest theoretical vapour cycle, which is basis for operation of a steam
plant. Super heated steam from the boiler is fed into the prime mover (Turbine). After which
is enters the condenser emerging as condensate. With the help of a pump this condensate is
again fed into the boiler.

All four components associated with the ideal Rankine cycle are steady-flow* devices and
thus all four processes that make up the Rankine cycle can be analyzed as steady-flow
process. The kinetic and potential energy changes of water are small relative to the heat and
work terms, are thus neglected. Energy analysis of the four components are given below.

Pump (process 1-2):

Pump pressurized the liquid water from

the condenser prior to going back to the boiler.
Assuming no heat transfer with the surroundings

Wpump, in = h2 - h1

Boiler (process 2-3):

Liquid water enters the boiler and is heated to

superheated state in the boiler. The energy
balance in the boiler is

Qin = h3 - h2 Fig. 2.1.1 Schematic of Rankine Cycle

Turbine (process 3-4):

Steam from the boiler, which has an elevated temperature and pressure,
expands through the turbine to produce work and then is discharged to the condenser with
relatively low pressure. Neglecting heat transfer with the surroundings

wturbine, out = h3 - h4

Condenser (process 4-1):

Steam from the turbine is condensed to liquid water in the condenser

Qout = h4 - h1

 The thermal efficiency of the Rankine cycle is determined from

ηth = wnet ,out/qin = 1 - qout/qin

 Where the net work output from the cycle is

wnet ,out = wturbine, out - wpump, in

The Rankine cycle is an ideal cycle if water passes through the four components without
irreversibilities and pressure drops. The ideal Rankine cycle consists of the following four
processes, as shown on the T-s diagram on the left:

 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

Fig. 2.1.2 T-S dia. of Rankine Cycle

2.2 REHEAT CYCLE:

In its simplest form the cycle involves with drawing the steam from the turbine at
some intermediate stage, returning it to the steam generator where a separate super heated is
provided in the gas path for re superheating the steam after which it re introduced into the
turbine at the following stage. It reduces the wetness of the steam at final stage and improved
the efficiency of the cycle.

Fig. 2.2.1 Schematic Dia. of Reheat e Cycle Fig. 2.2.2 T-s Dia. of Reheat e Cycle

2.3 Regenerative Cycle:

This cycle is an attempt to induce reversibility in the ordinary Rankine cycle and thus
to increase its efficiency.

Fig. 2.3.1 Schematic Dia. Regenerative Cycle Fig. 2.3.2 T-s Dia. of Regenerative Cycle
 The mixing of cold condensate with the saturated steam and water mixture in the
boiler constitute the principle irreversible process of the cycle and regeneration aims at
reducing this irreversibility by heating the feed water near to the saturation temperature
through the utilization of heat of steam which is partially expanded in the prime over. Since
the purpose is the thermal regeneration of condensate the cycle is known as regenerative.

2.4 COAL Cycle:

Coal from wagons is unloaded in coal handling plant. The coal is transported to the
raw coal bunkers with the help of conveyors. Coal is then transported to mills through feeders
where the coal is pulverized to powder form. This pulverized coal is taken away to the
furnace through coal pipes with the help of hot and cold air mixture from PA fan. PA fan
takes atmospheric air, a part of which is sent to air pre-heaters for heating while a part goes
directly to the mill or temperature control. Atmospheric air from FD fan is heated in the air
heaters and sent to the furnace as combustion air.

Water from the boiler feed pump passes through economizer and reaches the boiler
drums. Water from the drum passes through economizer and reached 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 in to all four sides of the furnace. Due to the heat and
density the water rises up in the furnace. This steam and water mixture is taken to the boiler
drum where steam is separated from water with the help of Turbo Separators. Water
follows the same path, while the steam is sent to super heaters for superheating. The super
heaters are located inside the furnace and the steam is superheated and finally it goes to the
turbine.
2.5 STEAM TO MECHANICAL POWER:
A Steam pipe conveys steam to the turbine through stop valves and control valves that
automatically regulate the supply of steam to the turbine steam from the control valves enters
the high pressure cylinder of the turbine where it passes through a ring of stationary blades
fixed to the a cylinder wall. These acts as nozzles and direct the steam into a second ring of
moving blades mounted on a disc secured to the turbine shaft. This ring turns the shaft as a
result of the force of the steam the. Stationary and moving blades together constitute a stage
of the turbine and in practice many stages are necessary so that cylinder contains a number of
rings of stationary blades with rings of moving blades arranged between them. Steam passes
through each stage insure until reaches the end of high pressure cylinder and in its passage
some of its heat energy is changed in to mechanical energy.

The steam leaving the high pressure cylinder goes back to the boiler through CRH
line for reheating and enters into the intermediate pressure cylinder through HRH lines hence
it passes through another series of stationary and moving blades.

Finally steam is taken to the low pressure cylinders each of which it enters at the
center for flowing outwards in opposite direction through the rows of turbine blades an
arrangement is known as double flow to the extremities of the cylinder as the steam gives up
its heat energy to drive turbine, its temperature and pressure fall and it expands. Because of
this expansion the blades are much larger and longer towards the low pressure ends of
turbine.

When as much energy as possible has been extracted from the steam it is exhausted
directly to condenser. This runs the length of low pressure part of turbine and may be beneath
or on either side of it. Cool water from river or sea or cooling tower is circulated through
tubes in condenser and as steam condensate.

From the condenser the condensate is pumped through CEP to low pressure
heaters by the extraction pump after which its pressure is raised to boiler pressure by the
boiler feed pump. It is passed through further feed heaters to the economizer and to the boiler
for conversion into steam.
2.6 MECHANICAL POWER TO ELECTRICAL POWER:
Basic principle of electrical power generation is from faradays law. It says that when
a conductor rotates in a magnetic field the E.M.F, will be induced in a conductor and is
proportional to the rate of change of flux lines cut by the conductor’s and capacity of the
magnetic field. For higher capacities of the generation vice versa principle is used, i.e. the
conductor are placed constantly (stator) and the magnetic field will be rotating
(rotor).Magnetic field is obtained from a separate system called an Excitation system and it is
classified into two types i.e. Static Excitation and Brush-less Excitation. Magnetic field
will be generated in rotor circuit to obtain the rate of change of flux lines, the rotor will be
rotated by a steam turbine at a constant speed.

The speed of the turbine is determined by the frequency of the electrical system used
in the country i.e. 50HZ proportional to this the speed of turbine is 3000rpm, and at this speed
a two pole generator must be driven to generate alternating current at a frequency of 50
cycles per second.

2.7 Electrical power transmission:

Electrical power is usually produced in the stator windings of large modern
generators at about 16.5 KV and is fed through terminal connections to one side of a
generator transformer that step up the voltage to 220 KV and transmitted. Now a day’s power
transmission is carried out even with a high voltage of 400 KV. Increasing of the
transmission voltage reduces the line losses and increases the efficiency of the overall system.
 3. GENERAL LAYOUT
A control system of station basically works on Rankin Cycle. Steam is
produced in Boiler is exported in prime mover and is condensed in condenser to be fed
into the boiler again.

The Thermal Power Station is divided in four main circuits:

 Fuel and Ash Circuit.

 Air and Gas Circuit.
 Feed water and Steam Circuit.
 Cooling Water Circuit.
3.1 FUEL & ASH CIRCUIT

Fuel from the storage is fed to the boiler through fuel handling device. The fuel used
in KTPS is coal, which on combustion in the boiler produces the ash. The quantity of ash
produced is approximately 35-40% of coal used. This ash is collected at the back of the
boiler and removed to ash storage tank through ash disposal equipment.

3.2 AIR AND GAS CIRCUIT

Air from the atmosphere is supplied to the combustion chamber of Boiler through the
action of forced draft fan and induced draft fan. The flue gases first pass around the boiler
tubes and superheated tubes in the furnace, next through dust collector (ESP) & then
economizer. Finally, they are exhausted to the atmosphere through fans.

3.3 FEED WATER AND STEAM CIRCUIT

The condensate leaving the condenser is first heated in LP heaters through extracted steam
from the lower pressure extraction of the turbine. Then it goes to de-aerator where extra
air and non-condensable gases are removed from the hot water to avoid pitting/oxidation.
From de-aerator it goes to BFP (boiler feed pump) which increases the pressure of the
water, then passes through the HP heater and enters into the boiler drum through
economizer. This wet steam passes through super heater. From super heater it goes into
the HP turbine then to IP turbine and finally to the LP turbine and then exhausted through
the condenser into hot well.

3.4 COOLING WATER CIRCUIT

A large quantity of cooling water is required to condense the steam in condenser and
marinating low pressure in it. The water is drawn from reservoir and after use it is drained
back into the river.
 4. MAJOR COMPONENTS OF POWER STATION

4.1 Coal handling plant:

4.1.1 Location criteria:-

1. Coal handling unit/Agency shall not use any agriculture land and shall be located at a
minimum distance of 250 meters away from the surrounding agriculture land.

2. Coal handling unit/Agency shall be minimum 500 meters away from the residential area,
school/colleges, Historical Monuments, Religious Places, Ecological sensitive area as well as
forests area.

3. Coal handling unit/Agency shall be located at a minimum 500 meters away from the
Railway line, express ways, National Highways, State ways and District Roads and from
water bodies like River, Nala, Canal, Pond etc.

4. In case of coal handling activities at the ports and jetties or extension thereof, the distance
and land use criteria may be relaxed and compensated by advanced/sophisticated pollution
control measures and mechanization & thick plantation, however all such ports and jetties,
where coal handling is carried out, shall provide closed conveyor belt and mechanization for
handling of coal.

4.1.2 Storage and handling criteria:

5. Coal handling unit/Agency shall store coal in such a way that coal

Heap should not be higher than 5 meter and clear distance between

Two adjoining heaps at G.L. should be 5 meters, so that in case of fire, approach is available.

6. There should be mechanized loading/ unloading system from the

loading /unloading area to the stacking yards and in to the vehicles.

7. Coal handling unit/Agency shall take all corrective steps to resolve the issue of air
pollution at permitted coal storage/handling area where coal is being stored.
 4.1.3 Transport criteria:
8. Coal handling unit/Agency shall ensure that all trucks before leaving the storage yard shall
be showered with water with adequate system, Shall be covered with tarpaulin or any other
effective measure/device completely and also that trucks are not over loaded as well as there
is no spillage during transportation.

9. The vehicle carrying the coal should not be overloaded by raising the height of carriage.
Weigh scale shall be provided within the loading area only and port / coal park authority shall
ensure that no

Overloading is done.

10. The top of the vehicle should be covered with fixed cover instead of tarpaulin cover to
avoid spillage or dusting of coal.

11. Coal handling unit/Agency shall obtain transport permission from the local
Administration under the relevant rules.
 4.2 MILLS

Mills are used for making pulverized

coal for efficient burning coal from bunker
house enters mills by gravity and pulverized
to a fineness of 70-80% there are different
types of mills;
Depending upon the speed, the mills are
divided in to three categories. They are

 Low speed mills

 Medium speed
mills
 High speed mills

4.2.1 LOW SPEED MILLS:

The speed of this mills will be approximately 15-20rpm these are also called horizontal
mills as the axis of mills i0s horizontal

EX: - Ball tube mills

BALL MILLS:

In ball balls are which pulverizes the coal when discharge into the mills, alloy
combustion chamber (furnace), the mixture of air and coal ignites and burns in suspensions
the motive behind the development of pulverized fuel firing system are:

 Efficient utilization of cheaper and low grade coals

 Flexibility in firing with ability to meet fluctuating loads
 The ability to used higher combustion air temperatures there by
increasing the overall efficiency of the steam generator
 High availability
 Better response to automatic control
4.2.2 MEDIUM SPEED MILLS:
The range of speed of these mills is 30 to 100rpm

EX: - Bowl mills or vertical, bell, race and roller mills

BOWL MILLS:

The bowl mill is one of the most advanced designs of coal pulverizes,
presently manufactured by M/S BHEL. The advantages are

 Low power consumption

 Reliability
 Minimum maintenance
 Quiet and vibration less operation
4.2.3 HIGH SPEED MILLS:

Speed of these mils lie between 500 to 100rpm and these are directly coupled to motors.

EX: - Hammer and beater wheel (using in neyveli units) mills.

4.2.4 PRINCIPLE OF OPERATION:

The raw coal is fed into the mill near the center of the revolving bowl. As the material
travels towards the outer periphery of the bowl due to centrifugal force, it passes between the
grinding ring and the revolving bowl, where it is pulverized by rolling under spring loaded
roller. The drying and transport of pulverized material from the mill is done by the hot air
entering the mill side below the bowl. As the air passes upwards around the bowl, it picks up
the pulverized coal. The heavier particles strike the separator body liners and return back for
further grinding. The lighter particles are carried upwards and through the deflector openings.
The deflector blades impart a spinning action to the material, with the degree of the spin set
by the angle of opening of the blades, determining the size of the finished product. Oversized
particles are returned down the inside of the inner cone for further grinding and the fine
particles leave the mill and enter the coal piping system. Any dense and difficult to grind
material in the feed is carried over the edge of the bowl and drops down on to the insulation
cover plate. The scraper pivoted to the skirt sweeps this material into the tramp iron discharge
spout.
 In order to obtain the rated capacity from the mill, it will be necessary to have
sufficient hot air entering the mill to dry the material, sufficient spring pressure to pulverize
it, and classifier deflector vanes, set to obtain the required fineness. For best operation, the
mill outlet temperature should be maintained as high as possible without exceeding the safe
limits. The safe limit is 95 degree C but the minimum mill outlet temperature should not be
less than 65 degree C. the mill is equipped to operate under pressure and the vertical shaft is
air sealed to prevent hot air and dust from leaking into the gear housing. Seal air is also
supplied through the center of each trunnion shaft to prevent material from entering the
journal bearings.
 4.3 BOILER

4.3.1 INTRODUCTION:

A boiler (or steam generator), one of the major components of the thermal plant is a closed
vessel in which water, under pressure is converted into steam. It is always designed to absorb
maximum amount of heat released in process of combustion, which is transferred to the
boiler by all the three modes of heat transfer i.e. conduction, convection and radiation.
4.3.2 CLASSIFICATION OF BOILERS:

4.3.2.1 FIRE TUBE BOILER:-

In this type the

products of combustion
pass through the tubes
which are surrounded
by water. These are
economical for low
pressure only.

Advantages of Fire Tube Boiler

1) Compact in construction.

2) Fluctuation of steam demand can be met easily.

3) Cheaper than water tube boiler.

Disadvantages of Fire Tube Boiler

1) Due to large water the required steam pressure rising time quite high.

2) Output steam pressure cannot be very high since the water and steam are kept in same
vessel.

3) The steam received from fire tube boiler is not very dry.

4) In a fire tube boiler, the steam drum is always under pressure, so there may be a chance of
huge explosion which resulting to severe accident.
 4.3.2.2 WATER TUBE BOILER:-

In this type of boiler water flows inside the tubes and hot gases flow outside the
tubes. These tubes are interconnected to common water channels and to steam outlet.

FEATURES

 High evaporation capacity due to availability of large heating surface.

 Better heat transfer to the mass of water.

 Better efficiency of plant owing to rapid and uniform circulation of water in tubes.

 Better overall control.

 Easy removal of scale from inside the tubes.

In KTPS, Natural circulation, tangentially fired, over hanged type, Water tube boilers
are used. Oil burners are provided between coal burners for initial start up and flame
stabilization. Firstly, light oil (diesel oil) is sprayed for initialization then heavy oil (high
speed diesel oil) is used for stabilization of flame. Pulverized coal is directly fed from the
coal mills to the burners at the four corners of the furnace through coal pipes with the help of
heated air coming from PA fan. The pressure inside boiler is negative so as to minimize the
pollution and losses & to prevent the accidents outside the boiler.

This equipment systematically feed fuel to furnace as per load requirement. The UV
flame scanners installed in each of the four corners of the furnace, scan the flame conditions
and in case of unsafe working conditions, trip the boiler and consequently the turbine.

4.3.3 FURNACE

Furnace is primary part of the boiler where the chemical energy available in the fuel is
converted into thermal energy by combustion. Major factors that assist for efficient
combustion are the temperature inside the furnace and turbulence, which causes rapid mixing
of fuel and air. In modern boilers, water-cooled furnaces are used.

4.3.3.1 PULVERISED FUEL SYSTEM

The boiler fuel firing system is tangentially firing system

in which the fuel is introduced from wind nozzle located
in the four corners inside the boiler.

The crushed coal from the coal crusher is

transferred into the unit coalbunkers where the coal is
stored for feeding into pulverizing mill through rotary
feeder. Then coal burners are employed to fire the
pulverized coal along with primary air into furnace. These
burners are placed in the corners of the furnace and they
send horizontal streams of air and fuel tangent to an
imaginary circle in the center of the furnace.

4.4.3.2 FUEL OIL SYSTEM

The functional requirement of the fuel burning system is to supply a

controllable and uninterrupted flammable furnace input of fuel and air and to continuously
ignite and burn the fuel as rapidly as it is introduced into the furnace. This system provides
efficient conversion of chemical energy of fuel into heat energy. The fuel burning system
should function such that fuel and air input is ignited continuously and immediately upon its
entry into furnace.
 Ignition takes place when the flammable furnace input is heated above the ignition
temperature. Ignition energy is usually supplied in the form of heat, provided by oil guns and
by igniters.

4.3.4 BOILER DRUM

The drum is a pressure vessel. Its function is to separate water and steam from the mixture
(steam & water) generated in the furnace walls. It provides water storage for preventing the
saturation of tubes. It also houses the equipment needed for purification of steam. The drum
internals reduce the dissolved solids content of the steam to below the acceptable limit. Drum
is made up of two halves of carbon steel plates having thickness of 133 mm.

Boiler drum is located at a height of 53m from ground. The drum form the part of
boiler circulating system i.e. movement of fluid from the drum to the combustion zone and
back to boiler drum. Feed water is supplied to the drum from the economizer through feed
nozzles. Water from the drum goes to water walls through six down comers.

4.3.4.1 Main parts of boiler drum are:-

 Feed pipe
 Riser tube
 Down comer
 Baffle plate
 Chemical dosing pipe
 Turbo separation
 Screen dryer
 Drum level gauge
4.3.5 Boiler make-up water treatment plant and storage

Since there is continuous withdrawal of steam and continuous return of

condensate to the boiler, losses due to blow down and leakages have to be made up to
maintain a desired water level in the boiler steam drum. For this, continuous make-up water
is added to the boiler water system. Impurities in the raw water input to the plant generally
consist of calcium and magnesium salts which impart hardness to the water. Hardness in the
make-up water to the boiler will form deposits on the tube water surfaces which will lead to
overheating and failure of the tubes. Thus, the salts have to be removed from the water, and
that is done by a water demineralising treatment plant

4.3.6 DRAFT SYSTEM

The combustion process in a furnace can take place only when it receives a steady
flow of air and has the combustion gases continuously removed. Theoretically balanced draft
means keeping furnace pressure equal to atmospheric pressure, but in practice the furnace is
kept slightly below atmospheric pressure.

4.3.6.1 DRAUGHT FANS

A fan can be defined as volumetric machine which moves quantities of air or

gas from one place to another. In doing this, it overcomes resistance to flow by supplying the
fluid with the energy necessary for contained motion. The following fans are used in boiler
house:

4.3.6.2 Primary air fan (P.A. fan) or Exhauster fan

Pulverized coal is directly fed from coal mills to the burners at the four corners
of the furnace through coal pipes with the help of heated air coming from PA fan. Secondly,
this fan also dries the coal.

4.3.6.3 Forced draught fan (F.D. fan)

The combustion process in the furnace can take place only when it receives a
steady flow of air. This air is supplied by FD fan. Thus FD fan takes air from atmosphere at
ambient temperature & so provides additional draught. Its speed is 1500 RPM
 4.3.6.4 Induced draught fan (I.D. fan)

The flue gases coming out

of the boiler are passed to the ESP & then
dust free gases are discharged up by the
chimney to the atmosphere through the ID
fan. Its speed is 745 RPM.

4.3.6.5 IGNITER AIR FAN

It is used to provide necessary combustion air to igniter. Two fans are usually
provided. One will run and 2nd will remain as stand by. A control damper is provided on the
discharge which modules to maintain a constant differential pressure across igniter when any
igniter is in service. Typical speed is 1460 RPM.

4.3.6.6 SCANNER AIR FAN

Used to provide necessary cooling air to the flame scanners. Two air fans are usually
provided. One will run and other will remain as stand by. When F.D. fans trip, the scanner air
fan will draw air from atmosphere through emergency damper. Typical speed 3000 RPM.

4.3.7 ECONOMIZER:

The function of an economizer in a steam-generating unit is

to absorb heat from the flue gases and add this as sensible heat to
the feed water before the water enters the evaporative circuit of the
boiler. Earlier the economizers were introduced mainly to recover
the heat available in flue gas that leaves the boiler and provision of
this additional heating surface increased the efficiency of steam
generation, saving in fuel consumption, thus the name
“Economizer” christened. In the modern boilers used for power generation feed water heaters
were used to increase the efficiency of turbine unit and feed water temperature and hence the
relative size of economizer is less than earlier units. This is a good proposition as the heat
available in boiler exit flue gas can be economically recovered using air heater which is
essential for pulverized fuel fired boilers.
4.3.8 HEATERS:

4.3.8.1 Air Pre-heater:-

An air pre-heater 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.

In particular, this article describes the combustion air pre-heaters used in large boilers found
in thermal power stations producing electric power from e.g. fossil fuels, biomasses or waste

The purpose of the air pre-heater is to recover the heat from the boiler flue gas which
increases the thermal efficiency of the boiler by reducing the useful heat lost in the flue gas.
As a consequence, the flue gases are also sent to the flue gas stack (or chimney) at a lower
temperature, allowing simplified design of the ducting and the flue gas stack. It also allows
control over the temperature of gases leaving the stack (to meet emissions regulations, for
example).

4.3.8.2 SUPERHEATERS:

Superheated steam is steam at a temperature higher than water's boiling point. If

saturated stream is heated at constant pressure, it increases toward 100% Dry Saturated
Steam. Continued heat input will then generate superheated steam. This will occur if
saturated steam contacts a surface with a higher temperature. The steam is then described as
superheated by the number of degrees it has been heated above saturation temperature

In a power plant, after the steam is conditioned by the drying equipment inside the
steam drum, it is piped from the upper drum area into tubes inside an area of the furnace
known as the super heater, which has an elaborate set up of tubing where the steam vapor
picks up more energy from hot flue gases outside the tubing and its temperature is now
superheated above the saturation temperature. The superheated steam is then piped through
the main steam lines to the valves before the high pressure turbine.
 4.3.8.3 REHEATERS:

Increased capacity of generators necessitates increased capacity units. The

steam entering high-pressure turbine does some work due to steam expanding through
various stages. The steam exhaust in high pressure turbine is again admitted in the reheater
circuit to reheat the steam at a constant pressure to raise its temperature to almost equal to
superheated steam. The heat energy in the steam is increased in the reheater and this reheated
steam is admitted into the IP Turbine and steam is expanded doing some additional work
before exhausting into condenser from LP Turbine.

The arrangement and construction of a reheater is similar to that of a superheater. In

large modern boiler plant, the reheat sections are mixed equally with superheater sections.
The reheat sections in modern boilers usually consist of pendant assemblies. These can be
used in combination with horizontal assemblies or a radiant wall located in the upper furnace.

The cold reheat is not cold to the sense of touch, but is the line from turbine to the
boiler and is at a temperature lower than the reheat line from boiler to the turbine called hot
reheat steam. Due to resistance of flow through the reheat section, the hot reheat steam is at
lower pressure compared to the cold reheat steam.

4.3.8.3.1 Low Temperature Reheater (LTRH)

It is located between the economizer and LTSH and is arranged for counter flow
(Between elevation 55.115m and 61.125m).

4.3.8.3.2 High Temperature Reheater (HTRH):

It is located between the ITSH and final superheater and is arranged for parallel flow
(between the elevation 41.33m and 44.55m).

One desuperheater is provided between the two sections of reheater and is used only
as an emergency device for controlling the reheat steam temperature. All the headers are
located outside the furnace area.
 4.4 TURBINE

4.4.1 INTRODUCTION:

The turbine is a reaction, condensing type tandem compound with throttle governing
and regenerative system of feed water heating .It is coupled directly to the generator. The
turbine is suitable for sliding pressure operation to avoid throttling losses at part loads.

The turbine has one single flow HP one double flow IP and one double flow LP
cylinders. The HP, IP & LP rotors are connected by rigid couplings .The critical speeds of HP
and IP rotors are well above the operating speed while that of LP rotor is below operating
speed.

Steam is admitted to the HP turbine through two nos. combined main steam stop and
control valves. The lines leading from two HP exhaust branches to the re-heater are provided
with check valves, which prevent flow of hot steam from the re-heater back to the HP turbine.
The steam coming from the re-heater goes to the IP turbine through two combined stop and
control valves and the exhaust from the IP turbine is taken to the LP turbine by two cross
around pipes one either side of the turbine at the operating floor level. This reduces the
requirements on the overall height of the turbine bay.

Turbine are mainly divided into 3types

 HP TURBINE
 IP TURBINE
 LP TURBINE

4.4.2 High Pressure (H.P) Turbine:

The outer casing of the hp turbine is of barrel type construction. This avoids mass
accumulation due to absence of flanges. As a result of the almost Complete rotation
symmetry the wall thickness is kept moderate and of nearly equal strength at all section .The
inner casing carries the guide blades and is axially split and Cinematically supported. The
space between the inner and outer shells is sealed from the neighbouring spaces by sealing
rings .As the inner casing is not subjected to large pressure drops the joint flange and bolts
are designed for less stringent conditions. The inner casing is fixed in the horizontal and
vertical planes in the outer casing so that it can freely expand radially in all direction and
axially from a fixed point when heating up while maintaining eccentrically. The barrel
construction permits rapid start up and higher rates of load changes due to absence of high
thermal stresses. Barrel type casing are also easy to cast which means the castings can be of
exceptionally good quality.

The connections of the main steam piping with the HP turbine are by means of sleeve joint
having buttress threads. These threads are located in the outer casing and connection with the
piping is made through breech nuts. This arrangement provides ease of opening the joint
during maintenance.
4.4.3 Intermediate Pressure (I.P) Turbine:

The IP casing is split horizontally and is of double shell and double flow
construction, with the inner casing carrying the guide blades and kinemetically supported
within the outer casing. The construction provides flexibility for choosing the locations of
bleed steam point to suit the best thermal efficiency. The reheated steam enters the inner
casing through the top & bottom .The arrangement confines the high steam temperature to the
admission branch of the casing while the joint of the outer casing is only subjected to lower
pressure and temperature at the exhaust of the inner casing. Although the casings are of split
design yet these do not impose restriction in start up timings and rapid load changes due to
the provision of suitable stress relieving grooves built in the inner casing. The hydraulic
turning gear blades are located on the coupling of the IP rotor.

4.4.4 Low Pressure (L.P) Turbine:

The LP casing is of triple shell fabricated construction. The outer casing consists of
the front & rear end walls ; two side members called longitudinal girders and top cover. The
shell inner casing is supported kinemetically at each end by two support arms resting on the
side members of the outer casing. The inner shell of the inner casing carriers the guide blade
carrier of the first idle blade carriers, which constitute the remaining stages of the turbine, are
bolted to the middle inner outer casing. The LP Turbine is provided with exhaust-hood spray
facility.

TURBINE AXILURYS

1. Condenser

2. Circulating Extraction Pumps (CEP)

3. Vacuum pumps

4. LP, HP heaters

5. Deaerator

6. Boiler feed pump (BFP)

 4.5 CONDENSER

Exhaust steam from LP turbine enters in to the condenser, where it condensates in

to water by exchanging its heat energy to the cooling water. Cold Water from the river, sea
are cooling tower is circulated through the tubes in the Condenser and as the steam from the
turbine passes round them it is rapidly condensed in to water. Because water has a much
smaller comparative volume them steam, a Vacuum is created in the condenser. This allows
the steam to reduce down, to presser bellow that of the normal atmosphere and more energy
can be utilize

This is the duty of the condenser in performance the above process as efficiency as possible.
For this reason it is the largest and most important of the heat exchanges in a power station.

4.5.1 TYPE OF CONDENSERS:

The condensers are mainly classified as

 mixing type of jet condensers

 non-mixing type or surface condensers
 non-conventional direct contact condensers
JET CONDENSER:

The jet condensers are mainly divided as parallel flow and counter flow jet
Condensers. In parallel flow condensers the steam and cooling water flow in the same
direction where as they flow in opposite direction in counters flow condensers.

Mixing type condensers are mainly classified in to 3 categories depending up and the
arrangement used for the removal of condensed as low level, high level and exactor
condenser.

This are mainly used in Morden high capacity power plants

PUMPS

4.6. CONDENSATE EXTRACTION PUMPS:

The function of these pumps is to pump condensate to the deaerator through ejectors,
gland steam cooler and L.P heaters. In a 120 MW unit three pumps (4stage pump) are
installed, having a pumping capacity of 50 percentages each. Two pumps are for normal
operation and one is stand by. Since the suction is at a negative pressure, these special
arrangements have been made for providing sealing to glands.

4.7 Vacuum pump

Description:

The vacuum pump is a two stage liquid ring type pump. Rotor revolves without
metal contact in a circular body that contains a liquid compressing. The rotor is eccentrically
fitted in to the circular body. So during each revolution liquid compress ant will be
compressed (discharge of air) to atmosphere and expanded (suction of air from the system).

Evacuated air discharge by the first stage of vacuum pump finds way to second stage
manifold.
4.8 FEED WATER HEATER

Low pressure feed water heaters are used in the condensate system between the
condensate pump discharge and boiler feed pumps, and utilize low pressure turbine extraction
or auxiliary turbine exhaust steam for heating the condensate.

High pressure feed water heaters are used in the feed water system
between the boiler feed pump discharge and the boiler, and utilize high pressure turbine
extraction steam for heating the feed water. The condensate or feed water temperature
increase for each feed water heater will be in the range of 28 to 56 degrees C with the actual
value determined by turbine manufacturer‟s stage location of steam extraction nozzles.
Depending on turbine size, some turbines offer alternate number of extraction nozzles with
usually a choice of using the highest pressure extraction nozzle. The selection, in this case, of
the total number of feed water heaters to use should be based on economic evaluation.

4.8.1 Low Pressure (L.P) Heater(S):

Use one or more low pressure feed water heaters to raise the temperature of
condensate from condensate pump discharge temperature to the de-aerator inlet temperature.
The heater drains are cascaded from the higher pressure heater to the next lower pressure
heater with the lowest pressure heater draining to the condenser.

4.8.2 High Pressure (H.P) Heater(S):

Use one or more high pressure feed water heaters to raise the temperature of feed
water from de-aerator outlet temperature to the required boiler economizer inlet temperature.
The heater drains are cascaded from heater to heater, back to the de-aerator in a fashion
similar to the heater drain system for the low pressure heaters.

4.8.3 Advantages:

(a) Fuel economy.

(b) Longer life of the boiler.

(c) Increase in steaming capacity.

A feed water heater is a power plant component used to pre-heat water delivered to a
steam generating boiler. Preheating the feed water reduces the irreversibility's involved in
steam generation and therefore improves the thermodynamic efficiency of the system. This
reduces plant operating costs and also helps to avoid thermal shock to the boiler metal when
the feed water is introduced back into the steam cycle.

In a steam power plant (usually modeled as a modified Rankine cycle), feed

water heaters allow the feed water to be brought up to the saturation temperature very
gradually. This minimizes the inevitable irreversibility's associated with heat transfer to the
working fluid (water).

4.9 DEAERATOR

INTRODUCTION:

The function of the Deaerator is to remove dissolved non-condensable gases

and to heat boiler feed water. It consists of a pressure vessel in which water and steam are
mixed in a controlled manner. When this occurs, water temperature rises, and all non-
condensable dissolved gases are liberated and removed and the effluent water may be
considered corrosion free from an oxygen or carbon dioxide stand point. Free air or other
non-condensable gases should be vented prior permitted the fluid to enter the Deaerator.

A Deaerator protects the feed pumps, piping, boiler and any other piece of
equipment that is in the boiler feed and return cycle from the effects of corrosive gases, I.e.,
oxygen and carbon dioxide, to a level where they are no longer a corrosion factor.

4.9.1 PRINCIPLES OF DEAERATION AND OPERATOION:

There is a physical law, which states that the solubility of any gas in a liquid is
directly proportional to the partial pressure of the gas above the liquid surface. Another law
states that the solubility of a gas in a liquid decreases with an increase in temperature of the
liquid. These principles are employed in the operation of Deaerator.

A Deaerator utilizes steam by spraying the incoming water into an atmosphere of

steam in the pre-heater section (first stage). It then mixes this water with fresh incoming
steam In the Deaerator section (second stage). In the first stage, the water is heated to within
2-4oC of steam saturation temperature and virtually all of the oxygen and free carbon dioxide
is removed. This is accomplished by spraying the water through self adjusting spray valves
which are designed to produce a uniform spray film under all conditions of load and
consequently a constant temperature and uniform gas removal is obtained at this point.

From the first stage the pre-heated water, containing minute traces of dissolved
gasses, flows into the second stage. This section consists of either a distributor or several
assemblies of trays. Here the water is in intimate contact with an excess of fresh gas free
steam. The steam passes into this stage and it is mixed with the pre-heated water.

Deaerator is accomplished at all rates of flow if conditions are maintained in

accordance with designed criteria. Very little steam is condensed here as the incoming water
has a high temperature caused by the pre-heating. The steam then rises to the first stage and
carries the small traces of residual gases. In the first stage most of the steam is condensed and
the remaining gases passed through the vent where the non-condensable gases flows to the
atmosphere. A very small amount of steam is also discharged to the atmosphere which
assures that the Deaerator is adequately vented at all times.

The water which leaves the second stage falls to the storage tank where it is stored for
use. At this time the water is completely deaerated and is heated to the stream saturation
temperature corresponding to the pressure within the vessel.
 4.10 BOILER FEED PUMP

INTRODUCTION:

Boiler feed pump (BFP) is a multi stage pump provided for pumping feed water to
economize. Generally three pumps each of 50 percentage of total capacity are provided. For
rated capacity two pumps will be working in parallel and the third will be in service.

The high pressure BFP is a very expensive machine, which can comply with the stated
requirements. The safety in operation and efficiency of the feed pump doesn’t only depend on
the current design and carefully manufacturing in the works, but also reliable operation and
maintenance, so the operation and maintenance staff should be well acquainted with the
instructions and procedures laid down by the supplier.

4.10.1 Principle of centrifugal pump:

A centrifugal pump is defined as machine, which increases the pressure energy of a fluid with
the help of centrifugal action. Whirling motion is imparted to the fluid by means of blades
mounted on the disc known as impeller. It consist mainly one or more impellers equipped
with the vanes, mounted on a rotating shaft and has kinetic energy and potential energy,
imparted to it by the vanes. As the fluid leaves the impeller at relatively high velocity, it is
collected in a volute or accompanied by decrease in the velocity. After the conversion is
accomplished, the fluid is discharged from the machine.

4.10.2 HIGH PRESSURE FEED PUMP:

The high pressure feed pump KHI of barrel type satisfy in all respects the latest
developments achieved for the design and operation of the feed pumps. It consists of the
pump barrelling into which is mounted on the inside stator together with the rotor. The
hydraulic part is closed by the HP cover along with the balancing device. The I.P covers
along with the stuffing box casings close the suction side of the barrel and the space in the HP
cover behind the balancing device. The bracket of the radial bearing of the suction side and
the bracket of the radial thrust bearing of the discharge side are fixed to the LP covers. The
entire pump is mounted on a foundation frame. The hydraulic coupling and the two claw
couplings with couplings guards are also provided. The water cooling and oil lubricating
connections are provided with their accessories. All the instruments are necessary for
observing a perfect run of the feed pump are mounted on the pump and on the piping.

4.10.3 WORKING PRINCIPLE OF BOILER FEED PUMP:

The water with the given operating temperature should flow to the pump under a certain
minimum pressure(NPSH); Water passes through the suction branch into the intake spiral and
from here is directed to the first impeller. After leaving through the impeller it passes through
the distributing passages of the diffused where it gets certain pressure raise and flows over to
guide vanes to the inlet of the next impeller.

This process repeats from one state to another till it passes to the last impeller and the end
diffuser thus feed water arriving into discharge space develops the necessary operating
pressure. A small part of feed water i.e. about 10 % is taken off from the space behind the last
impeller for the operation for the automatic balancing device to balance the hydraulic axial
thrust of the pump rotor.

4.11 Cooling tower

The cooling tower is a semi-enclosed device for evaporative cooling of water by contact with
air. The hot water coming out from the condenser is fed to the tower on the top and allowed
to tickle in form of thin sheets or drops. The air flows from bottom of the tower or
perpendicular to the direction of water flow and then exhausts to the atmosphere after
effective cooling.
 4.12 OTHER COMPONENTS

4.12.1 EJECTORS

INTRODUCTION:

The ejector group consists of a starting ejector and two main ejectors to extract non-
condensing gases from condenser and heat exchangers of turbine. The pressure and discharge
of non-condensing gases depend up on the conditions of working of condensers and ejectors.

4.12.2 ASH HANDLING SYSTEM:

The disposal of ash from a large capacity power station is of same importance as ash is
produced in large quantities. Ash handling is a major problem.
4.12.2.1 Manual handling:
While barrows are used for this the ash is collected directly through the ash outlet
door from the boiler into the container from manually.

4.12.2.2 Mechanical handling:

Mechanical equipment is used for ash disposal, mainly bucket elevator, belt conveyer.
Ash generated is 20% in the form of bottom ash and next 80% through flue gases, so called
Fly ash and collected in ESP.

4.12.2.3 Electrostatic precipitator:

From air pre-heater this flue gases (mixed with ash) goes to ESP. The precipitator has
plate banks (A-F) which are insulated from each other between which the flue gases are made
to pass. The dust particles are ionized and attracted by charged electrodes. The electrodes are
maintained at 60KV.Hammering is done to the plates so that fly ash comes down and collect
at the bottom. The fly ash is dry form is used in cement manufacture.
 4.13 ADVANTAGES AND DISADVANTAGES

ADVANTAGES OF COAL BASED THERMAL POWER PLANT

 They can respond to rapidly changing loads without difficulty
 A portion of the steam generated can be used as a process steam in different industries
 Steam engines and turbines can work under 25 % of overload continuously
 Fuel used is cheaper
 Cheaper in production cost in comparison with that of diesel power stations
DISADVANTAGES OF COAL BASED THERMAL POWER PLANT
 Maintenance and operating costs are high
 Long time required for erection and putting into action
 A large quantity of water is required
 Great difficulty experienced in coal handling
 Presence of troubles due to smoke and heat in the plant
 Unavailability of good quality coal
 Maximum of heat energy lost
 Problem of ash removing

5. CONCLUSION:

In this mini project all the components and parameters of various equipment involved in the
power generation are observed.

In the case study parameters like condenser duty, vacuum efficiency, cooling water flow ,
latent heat , performance of condenser and effect of vacuum are analyzed and components are
made.