A PRACTICAL TRANING REPORT ON NTPC POWER STATION, BADARPUR (III YEAR) SUBMITTED IN PRACTICAL FULFILLMENT OF THE REQUIREMENT BACHELORS

OF TECHNOLOGY. FOR THE AWARD OF IN MECHANICAL ENGINEERING

PROJECT BY NISHU GUPTA (09-ME-1238)

DEPARTMENT OF MECHANICAL Echelon Institute of Technology Kabulpur, Jasana-Manjawali Road, 12 k.m. from badkal chowk, Faridabad - 121101 Haryana

JULY 2011

ACKNOWLEDGEMENT
With profound respect and gratitude, I take the opportunity to convey my thanks to complete the training here. I do extend my heartfelt thanks to Ms. Rachna singh Bahel for providing me this opportunity to be a part of this esteemed organization. I am extremely grateful to all the technical staff of BTPS / NTPC for their co-operation and guidance that has helped me a lot during the course of training. I have learnt a lot working under them and I will always be indebted of them for this value addition in me. I would also like to thank the training incharge of Echelon Institute of Technology, Faridabad and all the faculty members of Mechanical Engineering Department for their effort of constant co- operation, which have been a significant factor in the accomplishment of my industrial training.

NISHU GUPTA EIT, FARIDABAD

CERTIFICATE

This is to certify that student of Batch Mechanical Branch IIird Year; Echelon Institute of Technology Faridabad has successfully completed his industrial training at Badarpur Thermal power station New Delhi for 27days from 4th July to 30th July 2011. He has completed the whole training as per the training report submitted by him.

Training Incharge BTPS/NTPC NEW DELHI

Training at BTPS
I was appointed to do eight-week training at this esteemed organization from 18th June to 11th august 2007. In these eight weeks I was assigned to visit various division of the plant which were 1. Boiler Maintenance Department(BMD I/II/III) 2. Plant Auxiliary Maintenance(PAM) 3. Turbine Maintenance Department(TMD)

This 27 days training was a very educational adventure for me. It was really amazing to see the plant by your self and learn how electricity, which is one of our daily requirements of life, is produced. This report has been made by self-experience at BTPS. The material in this report has been gathered from my textbooks, senior student report, and trainer manual provided by training department. The specification & principles are at learned by me from the employee of each division of BTPS.

NISHU GUPTA

INDEX

1. Introduction NTPC Badarpur Thermal Power Station 2. Basic steps of Electricity generation COAL TO STEAM STEAM TO MECHANICAL POWER COAL CYCLE ELECTRICITY FROM COAL

3. RANKINE CYCLE PROCESS OF RANKINE CYCLE RANKINE CYCLE WITH REHEAT

4. Boiler Maintenance Department BMD I BMD II BMD III 5. Plant Auxiliary Maintenance 6. Turbine Maintenance Department

ABOUT NTPC

NTPC Limited is the largest thermal power generating company of India. A public sector company, it was incorporated in the year 1975 to accelerate power development in the country as a wholly owned company of the Government of India. At present, Government of India holds 89.5% of the total equity shares of the company and FIIs, Domestic Banks, Public and others hold the balance 10.5%. Within a span of 31 years, NTPC has emerged as a truly national power company, with power generating facilities in all the major regions of the country. The total installed capacity of the company is 31134 MW (including JVs) with 15 coal based and 7 gas based stations, located across the country. In addition under JVs, 3 stations are coal based & another station uses naphtha/LNG as fuel. By 2017, the power generation portfolio is expected to have a diversified fuel mix with coal based capacity of around 53000 MW, 10000MW through gas, 9000 MW through Hydro generation, about 2000 MW from nuclear sources and around 1000 MW from Renewable Energy Sources (RES). NTPC has adopted a multi-pronged growth strategy which includes capacity addition through green field projects, expansion of existing stations, joint ventures, subsidiaries and takeover of stations. NTPC has set new benchmarks for the power industry both in the area of power plant construction and operations. Its providing power at the cheapest average tariff in the country.. NTPC is committed to the environment, generating power at minimal environmental cost and preserving the ecology in the vicinity of the plants. NTPC has undertaken massive a forestation in the vicinity of its plants. Plantations have increased forest area and reduced barren land. The massive a forestation by NTPC in and around its Ramagundam Power station (2600 MW) have contributed reducing the temperature in the areas by about 3c. NTPC has also taken proactive steps for ash utilization. In 1991, it set up Ash Utilization Division A "Centre for Power Efficiency and Environment Protection (CENPEEP)" has been established in NTPC with the assistance of United States Agency for International Development. (USAID). Cenpeep is efficiency oriented, eco-friendly and eco-nurturing initiative - a symbol of NTPC's concern towards environmental protection and continued commitment to sustainable power development in India. As a responsible corporate citizen, NTPC is making constant efforts to improve the socio-economic status of the people affected by its projects. Through its Rehabilitation and Resettlement programmes, the company endeavours to improve the overall socio economic status Project Affected Persons. NTPC was among the first Public Sector Enterprises to enter into a Memorandum of Understanding (MOU) with the Government in 1987-88. NTPC has been placed under the 'Excellent category' (the best category) every year since the MOU system became operative.

Harmony between man and environment is the essence of healthy life and growth. Therefore, maintenance of ecological balance and a pristine environment has been of utmost importance to NTPC. It has been taking various measures discussed below for mitigation of environment pollution due to power generation. Environment Policy & Environment Management System Driven by its commitment for sustainable growth of power, NTPC has evolved a well defined environment management policy and sound environment practices for minimizing environmental impact arising out of setting up of power plants and preserving the natural ecology.

National Environment Policy: At the national level, the Ministry of Environment and Forests had prepared a draft Environment Policy (NEP) and the Ministry of Power along with NTPC actively participated in the deliberations of the draft NEP. The NEP 2006 has since been approved by the Union Cabinet in May 2006. NTPC Environment Policy: As early as in November 1995, NTPC brought out a comprehensive document entitled "NTPC Environment Policy and Environment Management System". Amongst the guiding principles adopted in the document are company's proactive approach to environment, optimum utilization of equipment, adoption of latest technologies and continual environment improvement. The policy also envisages efficient utilization of resources, thereby minimizing waste, maximizing ash utilization and providing green belt all around the plant for maintaining ecological balance. Environment Management, Occupational Health and Safety Systems: NTPC has actively gone for adoption of best international practices on environment, occupational health and safety areas. The organization has pursued the Environmental Management System (EMS) ISO 14001 and the Occupational Health and Safety Assessment System OHSAS 18001 at its

different establishments. As a result of pursuing these practices, all NTPC power stations have been certified for ISO 14001 & OHSAS 18001 by reputed national and international Certifying Agencies. Pollution Control systems: While deciding the appropriate technology for its projects, NTPC integrates many environmental provisions into the plant design. In order to ensure that NTPC comply with all the stipulated environment norms, various state-of-the-art pollution control systems / devices as discussed below have been installed to control air and water pollution.

JOURNEY OF NTPC

1975
.

NTPC was set up in 1975 with 100% ownership by the Government of India. In the last 30

years, NTPC has grown into the largest power utility in India

1997 2004

In 1997, Government of India granted NTPC status of Navratnabeing one of the nine Jewels of India, enhancing the powers to the Board of Directors

NTPC became a listed company with majority government ownership of 89.5%. NTPC became third largest market capitalization of listed by companies.

The company rechristened as NTPC Limited in line with its changing business portfolio

2005 2008 2009 2012

And transforms itself from a thermal power utility to an integrated power utility.

National Thermal Power Corporation is the largest power generation company in India. Forbes Global 2000 for 2008 ranked it 411th in the world.

National Thermal Power Corporation is the largest power generation company in India. Forbes Global 2000 for 2008 ranked it317th in the world.

National Thermal Power Corporation has also set up to a plan to achieve a target of

50,000MW generation capacity.

2017

National Thermal Power Corporation has embarked on plans to became a

75,000MW Company by 2017.

ABOUT BTPS
Badarpur thermal power station started working in 1973 with a single 95 mw unit. There were 2 more units (95 MW each) installed in next 2 consecutive years. Now it has total five units with total capacity of 720 MW. Ownership of BTPS was transferred to NTPC with effect from 01.06.2006 through GOIs Gazette Notification. Given below are the details of unit with the year they are installed. Address: Telephone: Fax: Installed Capacity Derated capacity Location Coal source Water source Beneficary states Unit sizes Units Commissioned Badarpur, New Delhi -110044 (STD-011)-26949523 26949532 720 MW 705 MW New Delhi Jharia coal fields Agra canal Delhi 3x95 MW 2X210 MW Unit I- 95 MW - July 1973 Unit II- 95 MW August 1974 Unit III- 95 MW March 1975 Unit IV - 210 MW December 1978 Unit V - 210 MW - December 1981 Ownership of BTPS was transferred to NTPC with effect from 01.06.2006 through GOIs Gazette Notification

Transfer of BTPS to NTPC

BASIC STEPS OF ELECTRICITY GENERATION

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

COAL TO ELECTRICITY: BASICS

Coal to Steam
Coal from the coal wagons is unloaded in the coal handling plant. This Coal is transported up to the raw coal bunkers with the help of belt conveyors. Coal is transported to Bowl mills by Coal Feeders. The coal is pulverized in the Bowl Mill, where it is ground to powder form. The mill consists of a round metallic table on which coal particles fall. This table is rotated with the help of a motor. There are three large steel rollers, which are spaced 120 apart. When there is no coal, these rollers do not rotate but when the coal is fed to the table it packs up between roller and the table and ths forces the rollers to rotate. Coal is crushed by the crushing action between the rollers and the rotating table. This crushed coal is taken away to the furnace through coal pipes with the help of hot and cold air mixture from P.A. Fan.P.A. Fan takes atmospheric air, a part of which is sent to AirPreheaters for heating while a part goes directly to the mill for temperature control. Atmospheric air from F.D. 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 drum. Water from the drum passes through down comers and goes to the bottom ring header. Water from the bottom ring header is divided to all the four sides of the furnace. Due to heat and density difference, the water rises up in the water wall tubes. Water is partly converted to steam as it rises up in the furnace. This steam and water mixture is again taken to the boiler drum where the steam is separated from water. Water follows the same path while the steam is sent to superheaters for superheating. The superheaters are located inside the furnace and the steam is superheated (540C) and finally it goes to the turbine. Flue gases from the furnace are extracted by induced draft fan, which maintains balance draft in the furnace (-5 to 10 mm of wcl) with forced draft fan. These flue gases emit their heat energy to various super heaters in the pent house and finally pass through air-preheaters and goes to electrostatic precipitators where the ash particles are extracted. Electrostatic Precipitator consists of metal plates, which are electrically charged. Ash particles are attracted on to these plates, so that they do not pass through the chimney to pollute the atmosphere. Regular mechanical hammer blows cause the accumulation of ash to fall to the bottom of the precipitator where they are collected in a hopper for disposal.

Steam to Mechanical Power

From the boiler, a steam pipe conveys steam to the turbine through a stop valve (which can be used to shut-off the steam in case of emergency) and through control valves that automatically regulate the supply of steam to the turbine. Stop valve and control valves are located in a steam chest and a governor, driven from the main turbine shaft, operates the control valves to regulate the amount of steam used. (This depends upon the speed of the turbine and the amount of electricity required from the generator).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 cylinder wall.

These act as nozzles and direct the steam into a second ring of moving blades mounted on a disc secured to the turbine shaft. The second ring turns the shafts as a result of the force of steam. The stationary and moving blades together constitute a stage of turbine and in practice many stages are necessary, so that the cylinder contains a number of rings of stationary blades with rings of moving blades arranged between them. The steam passes through each stage in turn until it reaches the end of the highpressure cylinder and in its passage some of its heat energy is changed into mechanical energy. The steam leaving the high pressure cylinder goes back to the boiler for reheating and returns by a further pipe to the intermediate pressure cylinder. Here it passes through another series of stationary and moving blades .Finally, the steam is taken to the lowpressure cylinders, each of which enters at the centre flowing outwards in opposite directions through the rows of turbine blades through an arrangement called the double flow- to the extremities of the cylinder. As the steam gives up its heat energy to drive the 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 the turbine.

Mechanical Power to Electrical Power

As the blades of turbine rotate, the shaft of the generator, which is coupled to that of the turbine, also rotates. It results in rotation of the coil of the generator, which causes induced electricity to be produced.

(COAL CYCLE)

From Jharia mines

Railway wagon

BTPS wagon tripper

Magnetic separator

Crusher house

Coal stock yard

RC bunker

RC feeder

Bowl mill Furnace

ELECTRICITY FROM COAL

Coal from the coal wagons is unloaded with the help of wagon tipplers in the C.H.P. this coal is taken to the raw coal bunkers with the help of conveyor belts. Coal is then transported to bowl mills by coal feeders where it is pulverized and ground in the powered form.

This crushed coal is taken away to the furnace through coal pipes with the help of hot and cold mixture P.A fan. This fan takes atmospheric air, a part of which is sent to pre heaters while a part goes to the mill for temperature control. Atmospheric air from F.D fan in the air heaters and sent to the furnace as combustion air. Water from boiler feed pump passes through economizer and reaches the boiler drum . Water from the drum passes through the down comers and goes to the bottom ring header. Water from the bottom ring header is divided to all the four sides of the furnace. Due to heat density difference the water rises up in the water wall tubes. This steam and water mixture is again taken to the boiler drum where the steam is sent to super heaters for super heating. The super heaters are located inside the furnace and the steam is super heated (540 degree Celsius) and finally it goes to the turbine. Fuel gases from the furnace are extracted from the induced draft fan, which maintains balance draft in the furnace with F.D fan. These fuel gases heat energy to the various super heaters and finally through air pre heaters and goes to electrostatic precipitators where the ash particles are extracted. This ash is mixed with the water to from slurry is pumped to ash period. The steam from boiler is conveyed to turbine through the steam pipes and through stop valve and control valve that automatically regulate the supply of steam to the turbine. Stop valves and controls valves are located in steam chest and governor driven from main turbine shaft operates the control valves the amount used. Steam from controlled valves enter high pressure cylinder of turbines, where it passes through the ring of blades fixed to the cylinder wall. These act as nozzles and direct the steam into a second ring of moving blades mounted on the disc secured in the turbine shaft. The second ring turns the shaft as a result of force of steam. The stationary and moving blades together.

MAIN GENERATOR Maximum continuous KVA rating Maximum continuous KW Rated terminal voltage Rated Stator current Rated Power Factor Excitation current at MCR Condition Slip-ring Voltage at MCR Condition Rated Speed Rated Frequency Short circuit ratio Efficiency at MCR Condition Direction of rotation viewed Phase Connection Number of terminals brought out

24700KVA 210000KW 15750V 9050 A 0.85 lag 2600 A 310 V 3000 rpm 50 Hz 0.49 98.4% Anti Clockwise Double Star 9( 6 neutral and 3 phase)

MAIN TURBINE DATA Rated output of Turbine Rated speed of turbine Rated pressure of steam before emergency Stop valve rated live steam temperature Rated steam temperature after reheat at inlet to receptor valve Steam flow at valve wide open condition Rated quantity of circulating water through condenser 1. For cooling water temperature (degree Celsius) 1.Reheated steam pressure at inlet of interceptor valve in kg/cm^2 ABS 2.Steam flow required for 210 MW in ton/hour 3.Rated pressure at exhaust of LP turbine in mm of Hg 210 MW 3000 rpm 130 kg/cm^2 535 degree Celsius 535 degree Celsius 670 tons/hour 27000 cm/hour 24,27,30,33 23,99,24,21,24,49,24.82 68,645,652,662 19.9,55.5,65.4,67.7

BASIC POWER PLANT CYCLE

The thermal (steam) power plant uses a dual (vapour+ liquid) phase cycle. It is a close cycle to enable the working fluid (water) to be used again and again. The cycle used is Rankine Cycle modified to include superheating of steam, regenerative feed water heating and reheating of steam. On large turbines, it becomes economical to increase the cycle efficiency by using reheat, which is a way of partially overcoming temperature limitations. By returning partially expanded steam, to a reheat, the average temperature at which the heat is added, is increased and, by expanding this reheated steam to the remaining stages of the turbine, the exhaust wetness is considerably less than it would otherwise be conversely, if the maximum tolerable wetness is allowed, the initial pressure of the steam can be appreciably increased. Bleed Steam Extraction: For regenerative system, nos. of non-regulated extractions is taken from HP, IP turbine. Regenerative heating of the boiler feed water is widely used in modern power plants; the effect being to increase the average temperature at which heat is added to the cycle, thus improving the cycle efficiency.

FACTORS AFFECTING THERMAL CYCLE EFFICIENCY

Thermal cycle efficiency is affected by following: Initial Steam Pressure. Initial Steam Temperature. Whether reheat is used or not, and if used reheat pressure and temperature. Condenser pressure. Regenerative feed water heating.

RANKINE CYCLE
The Rankine cycle is a thermodynamic cycle which converts heat into work. The heat is supplied externally to a closed loop, which usually uses water as the working fluid. This cycle generates about 80% of all electric power used throughout the world, including virtually all solar thermal, biomass, coal and nuclear power plants. It is named after William John Macquorn Rankine, a Scottish polymath.. The Rankine cycle is sometimes referred to as a practical Carnot cycle because, when an efficient turbine is used, the TS diagram begins to resemble the Carnot cycle. The main difference is that heat addition (in the boiler) and rejection (in the condenser) are isobaric in the Rankine cycle and isothermal in the theoretical Carnot cycle. A pump is used to pressurize the working fluid received from the condenser as a liquid instead of as a gas. All of the energy in pumping the working fluid through the complete cycle is lost, as is most of the energy of vaporization of the working fluid in the boiler. This energy is lost to the cycle because the condensation that can take place in the turbine is limited to about 10% in order to minimize blade erosion; the vaporization energy is rejected from the cycle through the condenser. But pumping the working fluid through the cycle as a liquid requires a very small fraction of the energy needed to transport it as compared to compressing the working fluid as a gas in a compressor (as in the Carnot cycle). The efficiency of a Rankine cycle is usually limited by the working fluid. Without the pressure reaching super critical levels for the working fluid, the temperature range the cycle can operate over is quite small: turbine entry temperatures are typically 565C (the creep limit of stainless steel) and condenser temperatures are around 30C. This gives a theoretical Carnot efficiency of about 63% compared with an actual efficiency of 42% for a modern coal-fired power station. This low turbine entry temperature (compared with a gas turbine) is why the Rankine cycle is often used as a bottoming cycle in combined-cycle gas turbine power stations.

Description

A Rankine cycle describes a model of the operation of steam heat engines most commonly found in power generation plants. Common heat sources for power plants using the Rankine cycle are coal, natural gas, oil, and nuclear. The Rankine cycle is sometimes referred to as a practical Carnot cycle as, when an efficient turbine is used, the TS diagram will begin to resemble the Carnot cycle. The main difference is that a pump is used to pressurize liquid instead of gas. This requires about 1/100th (1%) as much energy as that compressing a gas in a compressor (as in the Carnot cycle).The efficiency of a Rankine cycle is usually limited by the working fluid. Without the pressure going super critical the temperature range the cycle can operate over is quite small, turbine entry temperatures are typically 565C (the creep limit of stainless steel) and condenser temperatures are around 30C. This gives a theoretical Carnot efficiency of around63% compared with an actual efficiency of 42% for a modern coal-fired power station. This low turbine entry temperature (compared with a gas turbine) is why the Rankine cycle is often used as a bottoming cycle in combined cycle gas turbine power stations. The working fluid in a Rankine cycle follows a closed loop and is re-used constantly. The water vapor and entrained droplets often seen billowing from power stations is generated by the cooling systems (not from the closed loop Rankine power cycle) and represents the waste heat that could not be converted to useful work. Note that cooling towers operate using the latent heat of vaporizationof the cooling fluid. The white billowing clouds that form in cooling tower operation are the result of water droplets which are entrained in the cooling tower airflow; it is not, as commonly thought, steam. While many substances could be used in the Rankine cycle, water is usually the fluid of choice due to its favorable properties, such as nontoxic and unreactive chemistry ,abundance, and low cost, as well as its thermodynamic properties. One of the principal advantages it holds over other cycles is that during the compressions tage relatively little work is required to drive the pump, due to the working fluid being in its liquid phase at this point. By condensing the fluid to liquid, the work required by the pump will only consume approximately 1% to 3% of the turbine power

and so give a much higher efficiency for a real cycle. The benefit of this is lost somewhat due to the lower heat addition temperature. Gas turbines, for instance, have turbine entry temperatures approaching 1500C. Nonetheless, the efficiencies of steam cycles and gas turbines are fairly well matched.

Processes of the Rankine cycle

Ts diagram of a typical Rankine cycle operating between pressures of 0.06bar and 50bar.There are four processes in the Rankine cycle, each changing the state of the working fluid. These states are identified by number in the diagram to the right i.Process 1-2 : The working fluid is pumped from low to high pressure, as the fluid is a liquid at this stage the pump requires little input energy. ii.Process 2-3 : The high pressure liquid enters a boiler where it is heated at constant pressure by an external heat source to become a dry saturated vapour. iii.Process 3-4 : The dry saturated vapour expands through a turbine, generating power.This decreases the temperature and pressure of the vapour, and some condensation may occur. iv.Process 4-1 : The wet vapor then enters a condenser where it is condensed at a constant pressure and temperature to become a saturated liquid. The pressure and temperature of the condenser is fixed by the temperature of the cooling coils as the fluid is undergoing a phasechange. In an ideal Rankine cycle the pump and turbine would be isentropic ,i.e., the pump and turbine would generate no entropy and hence maximize the net work output. Processes 1-2and 3-4 would be represented by vertical lines on the Ts diagram and more closely resemble that of the Carnot cycle. The Rankine cycle shown here prevents the vapour ending up in the superheat region after the expansion in the turbine, which reduces the energy removed by the condensers.

Real Rankine cycle (non-ideal) : Rankine cycle with superheat

In a real Rankine cycle, the compression by the pump and the expansion in the turbine are not isentropic. In other words, these processes are non-reversible and entropy is increased during the two processes. This somewhat increases the power required by the pump and decreases the power generated by the turbine. In particular the efficiency of the steam turbine will be limited by water droplet formation. As the water condenses, water droplets hit the turbine blades at high speed causing pitting and erosion, gradually decreasing the life of turbine blades and efficiency of the turbine. The easiest way to overcome this problem is by superheating the steam. On the Ts diagram above, state 3 is above a two phase region of steam and water so after expansion the steam will be very wet. By superheating, state 3 will move to the right of the diagram and hence produce a dryer steam after expansion.

Rankine cycle with reheat

In this variation, two turbines work in series. The first accepts vapour from the boiler at high pressure. After the vapour has passed through the first turbine, it re-enters the boiler and is reheated before passing through a second, lower pressure turbine. Among other advantages, this prevents the vapour from condensing during its expansion which can seriously damage the turbine blades, and improves the efficiency of the cycle.

Regenerative Rankine cycle

The regenerative Rankine cycle is so named because after emerging from the condenser (possibly as a sub cooled liquid) the working fluid is heated by steam tapped from the hot portion of the cycle. On the diagram shown, the fluid at 2 is mixed with the fluid at 4 (both at the same pressure) to end up with the saturated liquid at 7. The Regenerative Rankine cycle(with minor variants) is commonly used in real power stations. Another variation is where 'bleed steam' from between turbine stages is sent to feed water heaters to preheat the water on its way from the condenser to the boiler.

BOILER MAINTENANCE DEPARTMENT

Boiler and its description

A boiler is a closed vessel in which water or other fluid is heated. The heated or vaporized fluid exits the boiler for use in various processes or heating applications Construction of boilers is mainly of steel, stainless steel, and wrought iron. In live steam models, copper or brass is often used. Historically copper was often used for fireboxes(particularly for steam locomotives), because of its better thermal conductivity. The price of copper now makes this impractical. Cast iron is used for domestic water heaters. Although these are usually termed "boilers", their purpose is to produce hot water, not steam, and so they run at low pressure and try to avoid actual boiling. The brittleness of cast iron makes it impractical for steam pressure vessels. The boiler is a rectangular furnace about 50 ft (15 m) on a side and 130 ft (40 m) tall. Its walls are made of a web of high pressure steel tubes about 2.3 inches (60 mm) in diameter. Pulverized coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly burns, forming a large fireball at the centre. The thermal radiation of the fireball heats the water that circulates through the boiler tubes near the boiler perimeter. The water circulation rate in the boiler is three to four times the throughput and is typically driven by pumps. As the water in the boiler circulates it absorbs heat and changes into steam at 700 F (370 C) and 3,200 psi (22.1MPa). It is separated from the water inside a drum at the top of the furnace. The saturated steam is introduced into superheat pendant tubes that hang in the hottest part of the combustion gases as they exit the furnace. Here the steam is superheated to 1,000 F (540C) to prepare it for the turbine. The steam generating boiler has to produce steam at the high purity, pressure and temperature required for the steam turbine that drives the electrical generator. The generator includes the economizer, the steam drum, the chemical dosing equipment, and the furnace with its steam generating tubes and the superheated coils. Necessary safety valves are located at suitable points to avoid excessive boiler pressure. The air and flue gas path equipment include: forced draft (FD) fan, air preheated (APH), boiler furnace, induced draft (ID) fan, fly ash collectors (electrostatic precipitator or bag house) and the flue gas stack. For units over about 210 MW capacity, redundancy of key components is provided by installing duplicates of the FD fan, APH, fly ash collectors and ID fan with isolating dampers .On some units of about 60 MW, two boilers per unit may instead be provided.

The steam generating boiler has to produce steam at the high purity, pressure and temperature required for the steam turbine that drives the electrical generator. The boiler includes the economizer, the steam drum, the chemical dosing equipment, and The furnace with its steam generating tubes and the super heater coils. Necessary safety valves are located at suitable points to avoid excessive boiler pressure. The air and flue path equipment include: forced draft (FD)fan, air preheater (APH), boiler furnace, induced draft (ID) fan, fly ash collectors(electrostatic precipitator or baghouse) and the flue gas stack .

Schematic diagram of typical coal-fired power plant steam generator highlighting the air preheater (APH) location

SPECIFICATION:
. MAIN BOILER Evaporation Feed water temperature Feed water leaving economizer AT 100% LOAD 700t/hr 247C 276C

STEAM TEMPERATURE: : Drum Super heater outlet Reheat inlet Reheat outlet

341C 540C 332C 540C

STEAM PRESSURE: Drum design Drum operating Super heater outlet Reheat inlet Reheat outlet 158.20 kg/cm2 149.70 kg/cm2 137.00 kg/cm2 26.35 kg/cm2 24.50 kg/cm2

FUEL SPECIFICATION
:COAL Fixed carbon Volatile matter Moisture Grind ability DESIGN 38% 26% 8% 50% hard grove WORST 25% 25% 9% 45% hard grove

OIL: Calorific value of fuel oil 10,000 kcal/kg Sulphur content 4.5% W/W Moisture content 1.1% W/W Flash point 66C

HEAT BALANCE Dry gas loss Carbon loss Radiation loss Unaccounted loss Hydrogen in air and water in fuel Total loss Efficiency 4.63% 2% 0.26% 1.5% 4.9% 13.3% 86.7%

AUXILIARIES OF BOILER
1. FURNACE Furnace is primary part of boiler where the chemical energy of fuel is converted to thermal energy by combustion. Furnace is designed for efficient and complete combustion. Major factors that assist for efficient combustion area mount of fuel

inside the furnace and turbulence, which causes rapid mixing between fuel and air. In modern boilers, water-cooled furnaces are used. 2. BOILER DRUM

Drum is of fusion-welded design with welded hemi-spherical dished ends. It is provided with stubs for welding all the connecting tubes i.e. downcomers, risers, pipes, saturated steam outlet. The function of steam drum internals is to separate the water from the steam generated in the furnace walls and to reduce the dissolved solid contents of the steam below the prescribed limit of 1 ppm and also take care of the sudden change of steam demand for boiler.

The secondary stage of two opposed banks of closely spaced thin corrugated sheets, which direct the steam and force the remaining entertained water against the corrugated plates. Since the velocity is relatively low this water does not get picked up again but runs down the plates and off the second stage of the two steam outlets. From the secondary separators the steam flows upwards to the series of screen dryers, extending in layers across the length of the drum. These screens perform the final stage of separation.

3.

Classifier

It is an equipment which serves separation of fine pulverized coal particles medium from coarse medium. The pulverized coal along with the carrying medium strikes the impact plate through the lower part. Large particles are then transferred to the ball mill.

4.

Worm Conveyor

It is equipment used to distribute the pulverized coal from bunker of one system to bunker of other system. It can be operated in both directions.

5.

WATER WALLS:

Water flows to the water walls from the boiler drum by natural circulation. The front and the two side water walls constitute the main evaporation surface absorbing the bulk of radiant heat of the fuel burnt in the chamber. The front and rear walls are bent at the lower ends to form a water-cooled slag hopper. The upper part of the chamber is narrowed to achieve perfect mixing of combustion gases. The water walls tubes are connected to headers at the top and bottom. The rear water walls tubes at the top are grounded in four rows at a wider pitch forming the grid tubes.

6.

REHEATER

Reheater is used to raise the temperature of steam from which a part of energy has been extracted in high- pressure turbine. This is another method of increasing the cycle efficiency. Reheating requires additional equipment I.e. Heating surface connecting boiler and turbine pipe safety equipment like safety valve, non-return valve, isolating valves, high pressure feed pump, etc. Reheater is composed to two sections namely front and rear pendant section which is located above the furnace arch between water-cooled screen wall tubes and rear wall hanger tubes.

7.

Super heaters

Whatever type of boiler is used, steam will leave the water at its surface and pass into the steam space. Steam formed above the water surface in a shell boiler is always saturated and become superheated in the boiler shell, as it is constantly. If superheated steam is required, the saturated steam must pass through a superheater. This is simply a heat exchanger where additional heat is added to the steam.

In water-tube boilers, the superheater may be an additional pendant suspended in the furnace area where the hot gases will provide the degree of superheat required. In other cases, for example in CHP schemes where the gas turbine exhaust gases are relatively cool, a separately fired superheater may be needed to provide the additional heat.

Fig. A water tube boiler with a super heater

If accurate control of the degree of superheat is required, as would be the case if the steam is to be used to drive turbines, then an attemperator (desuperheater) is fitted. This is a device installed after the superheater, which injects water into the superheated steam to reduce its temperature.

8.

ECONOMISER

The function of an economizer in a steam-generating unit is to absorb heat from the flue gases and add as a sensible heat to the feed water before the water enters the evaporation circuit of the boiler. Earlier economizer were introduced mainly to recover the heat available in the flue gases that leaves the boiler and provision of this addition heating surface increases the efficiency of steam generators. In the modern boilers used for power generation feed water heaters were used to increase the efficiency of turbine unit and feed water temperature. Use of economizer or air heater or both is decided by the total economy that will result in flexibility in operation, maintenance and selection of firing system and other related equipment. Modern medium and high capacity boilers are used both as economizers and air heaters. In low capacity, air heaters may alone be selected.

An economizer

Stop valves and non-return valves may be incorporated to keep circulation in economizer into steam drum when there is fire in the furnace but not feed flow. Tube elements composing the unit are built up into banks and these are connected to inlet and outlet headers.

9.

AIR PREHEATER

Air preheater absorbs waste heat from the flue gases and transfers this heat to incoming cold air, by means of continuously rotating heat transfer element of specially formed metal plates. Thousands of these high efficiency elements are spaced and compactly arranged within 12 sections. Sloped compartments of a radially divided cylindrical shell called the rotor. The housing surrounding the rotor is provided with duct connecting both the ends and is adequately scaled by radial and circumferential scaling. Special sealing arrangements are provided in the provided in the air preheater to prevent the leakage between the air and gas sides. Adjustable plates are also used to help the sealing arrangements and prevent the leakage as expansion occurs. The air preheater heating surface elements are provided with two types of cleaning devices, soot blowers to clean normal devices and washing devices to clean the element when soot blowing alone cannot keep the element clean.

An air preheater

10.

PULVERIZER

A pulverizer is a mechanical device for the grinding of many types of materials. For example, they are used to pulverize coal for combustion in the steam-generating furnaces of the fossil fuel power plants.

A Pulverize

Types of Pulverize. i. Ball and Tube mills

A ball mill is a pulverizer that consists of a horizontal cylinder, up to three diameter sin length, containing a charge of tumbling or cascading steel balls, pebbles or steel rods. A tube mill is a revolving cylinder of up to five diameters in length used for finer pulverization of ore, rock and other such materials; the materials mixed with water is fed into the chamber from one end, and passes out the other end as slime.

ii.

Bowl mill

It uses tires to crush coal. It is of two types; a deep bowl mill and the shallow bowl mill. Bowl Mill: - One of the most advanced designs of coal pulverizes presently manufactured. Motor specification squirrel cage induction motor Rating-340 KW Voltage-6600KV Curreen-41.7A Speed-980 rpm Frequency-50 Hz No-load current-15-16 A

An external view of a Coal Pulverizer

Advantages of Pulverized Coal Pulverized coal is used for large capacity plants. It is easier to adapt to fluctuating load as there are no limitations on the combustion capacity. Coal with higher ash percentage cannot be used without pulverizing because of the problem of large amount ash deposition after combustion. Increased thermal efficiency is obtained through pulverization. The use of secondary air in the combustion chamber along with the powered coal helps in creating turbulence and therefore uniform mixing of the coal and the air during combustion. Greater surface area of coal per unit mass of coal allows faster combustion as more coal is exposed to heat and combustion. The combustion process is almost free from clinker and slag formation. The boiler can be easily started from cold condition in case of emergency. Practically no ash handling problem. The furnace volume required is less as the turbulence caused aids in complete combustion of the coal with minimum travel of the particles.

11.

CYCLONE SEPARATOR

Cyclonic separation is a method of removing particulates from an air, gas or liquid stream, without the use of filters, through vortex separation. Rotational effects and gravity are fine droplets of liquid from a gaseous stream.

A high speed rotating (air)flow is established within a cylindrical or conical container called a cyclone. Air flows in a spiral pattern, beginning at the top (wide end) of the cyclone and ending at the bottom (narrow) end before exiting the cyclone in a straight stream through the center of the cyclone and out the top. Larger (denser) particles in the rotating stream have too much inertia to follow the tight curve of the stream, and strike the outside wall, then falling to the bottom of the cyclone where they can be removed. In a conical system, as the rotating flow moves towards the narrow end of the cyclone, the rotational radius of the stream is reduced, thus separating smaller and smaller particles. The cyclone geometry, together with flow rate, defines the cut point of the cyclone. This is the size of particle that will be removed from the stream with a 50% efficiency. Particles larger than the cut point will be removed with a greater efficiency, and smaller particles with a lower efficiency.

PLANT AUXILIARY MAINTENANCE

1. WATER CIRCULATION SYSTEM Theory of Circulation Water must flow through the heat absorption surface of the boiler in order that it be evaporated into steam. In drum type units (natural and controlled circulation), the water is circulated from the drum through the generating circuits and then back to the drum where the steam is separated and directed to the super heater. The water leaves the drum through the down corners at a temperature slightly below the saturation temperature. The flow through the furnace wall is at saturation temperature. Heat absorbed in water wall is latent heat of vaporization creating a mixture of steam and water. The ratio of the weight of the water to the weight of the steam in the mixture leaving the heat absorption surface is called circulation ratio. Types of Boiler Circulating System i.Natural circulation system ii.Controlled circulation system iii.Combined circulation system

i.

Natural circulation System

Water delivered to steam generator from feed water is at a temperature well below the saturation value corresponding to that pressure. Entering first the economizer, it is heated to about 30-40C below saturation temperature. From economizer the water enters the drum and thus joins the circulation system. Water entering the drum flows through the down corner and enters ring heater at the bottom. In the water walls, a part of the water is converted to steam and the mixture flows back to the drum. In the drum, the steam is separated, and sent to super heater for superheating and then sent to the high-pressure turbine. Remaining water mixes with the incoming water from the economizer and the cycle is repeated. As the pressure increases, the difference in density between water and steam reduces. Thus the hydrostatic head available will not be able to overcome the frictional resistance for a flow corresponding to the minimum requirement of cooling of water wall tubes. Therefore natural circulation is limited to the boiler with drum operating pressure around 175 kg/ cm.

ii.

Controlled circulation System

Beyond 80 kg/ cm of pressure, circulation is to be assisted with mechanical pumps to overcome the frictional losses. To regulate the flow through various tubes, orifices plates are used. This system is applicable in the high sub-critical regions (200 kg/ cm).

1.

ASH HANDLING PLANT

The widely used ash handling systems are: i. Mechanical Handling System ii. Hydraulic System. iii. Pneumatic System. iv. Steam jet System.

Ash Handling System at Badarpur Thermal Power Station, New Delhi The Hydraulic Ash handling system is used at the Badarpur Thermal Power Station.

Hydraulic Ash Handling System

The hydraulic system carried the ash with the flow of water with high velocity through a channel and finally dumps into a sump. The hydraulic system is divided into a low velocity and high velocity system. In the low velocity system the ash from the boilers falls into a stream of water flowing into the sump. The ash is carried along with the water and they are separated at the sump. In the high velocity system a jet of water is sprayed to quench the hot ash. Two other jets force the ash into a trough in which they are washed away by the water into the sump, where they are separated. The molten slag formed in the pulverized fuel system can also be quenched and washed by using the high velocity system. The advantages of this system are that its clean, large ash handling capacity, considerable distance can be traversed, absence of working parts in contact with ash.

Fly Ash Collection

Fly ash is captured and removed from the flue gas by electrostatic precipitators or fabric bag filters (or sometimes both) located at the outlet of the furnace and before the induced draft fan. The fly ash is periodically removed from the collection hoppers below the precipitators or bag filters. Generally, the fly ash is pneumatically transported to storage silos for subsequent transport by trucks or railroad cars.

Bottom Ash Collection and Disposal

At the bottom of every boiler, a hopper has been provided for collection of the bottom ash from the bottom of the furnace. This hopper is always filled with water to quench the ash and clinkers falling down from the furnace. Some arrangement is included to crush the clinker sand for conveying the crushed clinkers and bottom ash to a storage site.

1.

WATER TREATMENT PLANT

As the types of boiler are not alike their working pressure and operating conditions vary and so do the types and methods of water treatment. Water treatment plants used in thermal power plants used in thermal power plants are designed to process the raw water to water with a very low content of dissolved solids known as demineralised water. No doubt, this plant has to be engineered very carefully keeping in view the type of raw water to the thermal plant, its treatment costs and overall economics.

A water treatment plant

The type of demineralization process chosen for a power station depends on three main factors. i. The quality of raw material. ii. The degree of de-ionization i.e. treated water quality. iii. Selectivity of resins.

Water treatment process is generally made up of two sections: Pre-treatment section. Demineralization section

Pre-treatment Section
Pre-treatment plant removes the suspended solids such as clay, silt, organic and inorganic matter, plants and other microscopic organism. The turbidity may be taken as two types of suspended solid in water; firstly, the separable solids and secondly the non-separable solids (colloids). The coarse components, such as sand, silt, etc: can be removed from the water by simple sedimentation. Finer particles, however, will not settle in any reasonable time and must be flocculated to produce the large particles, which are settling able. Long term ability to remain suspended in water is basically a function of both size and specific gravity.

Demineralization
This filter water is now used for demineralising purpose and is fed to cation exchanger bed, but enroute being first dechlorinated, which is either done by passing through activated carbon filter or injecting along the flow of water, an equivalent amount of sodium sulphite through some stroke pumps. The residual chlorine, which is maintained in clarification plant to remove organic matter from raw water, is now detrimental to action resin and must be eliminated before its entry to this bed.

A demineralization tank A DM plant generally consists of cation, anion and mixed bed exchangers. The final water from this process consists essentially of hydrogen ions and hydroxide ions which is the chemical composition of pure water. The DM water, being very pure, becomes highly corrosive once it absorbs oxygen from the atmosphere because of its very high affinity for oxygen absorption. The capacity of the DM plant is dictated by the type and quantity of salt sin the raw water input. However, some storage is essential as the DM plant may be down for maintenance. For this purpose, a storage tank is installed from which DM water is continuously withdrawn for boiler make-up. The storage tank for DM water is made from materials not affected by corrosive water, such as PVC. The piping and valves are generally of stainless steel. Sometimes, a steam blanketing arrangement or stainless steel doughnut float is provided on top of the water in the tank to avoid contact with atmospheric air. DM water make-up is generally added at the steam space of the surface condenser (i.e., the Vacuum side). This arrangement not only sprays the water but also DM water gets deaerated, with the dissolved gases being removed by the ejector of the condenser itself.

WTP-II

Flash mixture (Cl2 +Pac (Poly aluminium chorine) )

Clarifier tank

Storage tank

Clarifier pump(A or B)

+Cation anion Degasser tank (Co2 removed)

Active carbon filter

Pressure filter (A, B, C, D)

Degasser pump

-Anion (NaoH used)

Strong base anion

Mixed bed(6.57 ph)

DM Storage tank

Systematic arrangement of water treatment II

1.DRAUGHT SYSTEM There are four types of draught system: i.Natural Draught ii.Induced Draught iii.Forced Draught iv.Balanced Draught

Natural Draught System

In natural draft units the pressure differentials are obtained have constructing tail chimneys so that vacuum is created in the furnace. Due to small pressure difference, air is admitted into the furnace

A natural draught system

Induced Draft System In this system, the air is admitted to natural pressure difference and the flue gases are taken out by means of Induced Draught (I.D.) fans and the furnace is maintained under vacuum. Forced Draught System A set of forced draught (F.D.) fans is made use of for supplying air to the furnace and so the furnace is pressurized. The flue gases are taken out due to the pressure difference between the furnace and the atmosphere. Balanced Draught System Here a set of Induced and Forced Draft Fans are utilized in maintaining a vacuum in the furnace. Normally all the power stations utilize this draft system.

1. ID Fan

INDUSTRIAL FANS

The induced Draft Fans are generally of Axial-Impulse Type. Impeller nominal diameter is of the order of 2500 mm. The fan consists of the following sub-assemblies: Suction Chamber

Inlet Vane Control Impeller Outlet Guide Vane Assembly

ID Fans: - Located between electrostatic precipitator and chimney. Type-radical Speed-1490 rpm Rating-300 KW Voltage-6.6 KV Lubrication-by oil

An ID fan

FD Fan The fan, normally of the same type as ID Fan, consists of the following components: Silencer Inlet Bend Fan Housing Impeller with blades and setting mechanism FD Fans: - Designed to handle secondary air for boiler. 2 in number and provide ignition of coal. Type-axial Speed-990 rpm Rating-440 KW Voltage-6.6 KV

An FD fan

The centrifugal and setting forces of the blades are taken up by the blade bearings. The blade shafts are placed in combined radial and axial anti-friction bearings, which are sealed off to the outside. The angle of incidence of the blades may be adjusted during operation. The characteristic pressure volume curves of the fan may be changed in a large range without essentially modifying the efficiency. The fan can then be easily adapted to changing operating conditions. The rotor is accommodated in cylindrical roller bearings and an inclined ball bearing at the drive side absorbs the axial thrust. Lubrication and cooling these bearings is assured by a combined oil level and circulating lubrication system.

Primary Air Fan

PA Fan if flange-mounted design, single stage suction, NDFV type, backward curved bladed radial fan operating on the principle of energy transformation due to centrifugal forces. Some amount of the velocity energy is converted to pressure energy in the spiral casing. The fan is driven at a constant speed and varying the angle of the inlet vane control controls the flow. The special feature of the fan is that is provided with inlet guide vane control with a positive and precise link mechanism. It is robust in construction for higher peripheral speed so as to have unit sizes. Fan can develop high pressures at low and medium volumes and can handle hot-air laden with dust particles. Primary Air Fans: - Designed for handling the atmospheric air up to 50 degrees Celsius, 2 in number And they transfer the powered coal to burners to firing. Type-Double suction radial Rating-300 KW Voltage-6.6 KV Lubrication-by oil Type of operation-continuous

Primary air fan

1.

COMPRESSOR HOUSE

Instrument air is required for operating various dampers, burner tilting, devices, diaphragm valves, etc: in the 210 MW units. Station air meets the general requirement of the power station such as light oil atomizing air, for cleaning filters and for various maintenance works. The control air compressors and station air compressors have been housed separately with separate receivers and supply headers and their tapping.

A compressor house

Instrument Air System

Control air compressors have been installed for supplying moisture free dry air required for instrument used. The output from the compressors is fed to air receivers via return valves. From the receiver air passed through the dryers to the main instrument airline, which runs along with the boiler house and turbine house of 210 MW units. Adequate numbers of tapping have been provided all over the area. Air-Drying Unit Air contains moisture which tends to condense, and causes trouble in operation of various devices by compressed air. Therefore drying of air is accepted widely in case of instrument air. Air drying unit consists of dual absorption towers with embedded

heaters for reactivation. The absorption towers are adequately filled with specially selected silica gel and activated alumina while one tower is drying the air.

Service Air Compressor

The station air compressor is generally a slow speed horizontal double acting double stage type and is arranged for belt drive. The cylinder heads and barrel are enclosed in a jacket, while extends around the valve also. The intercooler is provided between the low and high pressure cylinder which cools the air between tag and collects the moisture that condenses Air from L.P. cylinder enters at one end of the intercooler and goes to the opposite end where from it is discharged to the high-pressure cylinder; cooling water flows through the nest of the tubes and cools the air. A safety valve is set at rated pressure. Two selectors switch one with positions auto load/unload and another with positions auto start/stop, non-stop have been provided on the control panel of the compressor. In auto start-stop position, the compressor will start.

TURBINE MAINTENANCE DEPARTMENT

TURBINE CLASSIFICATION: 1. Impulse turbine: In impulse turbine steam expands in fixed nozzles. The high velocity steam from nozzles does work on moving blades, which causes the shaft to rotate. The essential features of impulse turbine are that all pressure drops occur at nozzles and not on blades. 2. Reaction turbine: In this type of turbine pressure is reduced at both fixed and moving blades. Both fixed and moving blades act like nozzles. Work done by the impulse effect of steam due to reverse the direction of high velocity steam. The expansion of steam takes place on moving blades.

A 95 MW Generator at BTPS, New Delhi

COMPOUNDING: Several problems occur if energy of steam is converted in single step and so compounding is done. Following are the type of compounded turbine:

i.

Velocity compounded Turbine :

Like simple turbine it has only one set of nozzles and entire steam pressure drop takes place there. The kinetic energy of steam fully on the nozzles is utilized in moving blades. The role of fixed blades is to change the direction of steam jet and too guide it. ii. Pressure Compound Turbine : This is basically a number of single impulse turbines in series or on the same shaft. The exhaust of first turbine enters the nozzles of next turbine. The total pressure drop of steam does not take on first nozzle ring but divided equally on all of them. iii. Pressure Velocity Compounded Turbine: It is just the combination of the two compounding and has the advantages of allowing bigger pressure drops in each stage and so fewer stages are necessary. Here for given pressure drop the turbine will be shorter length but diameter will be increased.

MAIN TURBINE
The 210MW turbine is a cylinder tandem compounded type machine comprising of H.P. and I.P and L.P cylinders. The H.P. turbine comprises of 12 stages the I.P turbine has 11 stages and the L.P has four stages of double flow. The H.P and I.P. turbine rotor are rigidly compounded and the I.P. and L.P rotor by lens type semi flexible coupling. All the 3 rotor are aligned on five bearings of which the bearing number is combined with thrust bearing. The main superheated steam branches off into two streams from the boiler and passes through the emergency stop valve and control valve before entering the governing wheel chamber of the H.P. Turbine. After expanding in the 12 stages in the H.P. turbine then steam is returned in the boiler for reheating. The reheated steam from boiler enters I.P. turbine via the interceptor valves and control valves and after expanding enters the L.P stage via 2 numbers of cross over pipes. In the L.P. stage the steam expands in axially opposed direction to counteract the thrust and enters the condenser placed directly below the L.P. turbine. The cooling water flowing through the condenser tubes condenses the steam and the condensate the collected in the hot well of the condenser. The condensate collected the pumped by means of 3x50% duty condensate pumps through L.P heaters to deaerator from where the boiler feed pump delivers the water to the boiler through H.P. heaters thus forming a closed cycle.

STEAM TURBINE
A steam turbine is a mechanical device that extracts thermal energy from pressurized steam and converts it into useful mechanical work. From a mechanical point of view, the turbine is ideal, because the propelling force is applied directly to the rotating element of the machine and has not as in the reciprocating engine to be transmitted through a

system of connecting links, which are necessary to transform are reciprocating motion into rotary motion. Hence since the steam turbine possesses for its moving parts rotating elements only if the manufacture is good and the machine is correctly designed, it ought to be free from out of balance forces. If the load on a turbine is kept constant the torque developed at the coupling is also constant. A generator at a steady load offers a constant torque. Therefore, a turbine is suitable for driving a generator, particularly as they are both highspeed machines. A further advantage of the turbine is the absence of internal lubrication. This means that the exhaust steam is not contaminated with oil vapour and can be condensed and fed back to the boilers without passing through the filters. It also means that turbine is considerable saving in lubricating oil when compared with a reciprocating steam engine of equal power. A final advantage of the steam turbine and a very important one is the fact that a turbine can develop many time the power compared to a reciprocating engine whether steam or oil.

OPERATING PRINCIPLES
A steam turbines two main parts are the cylinder and the rotor. The cylinder (stator) is a steel or cast iron housing usually divided at the horizontal centre line. Its halves are bolted together for easy access. The cylinder contains fixed blades, vanes and nozzles that direct steam into the moving blades carried by the rotor. Each fixed blade set is mounted in diaphragms located in front of each disc on the rotor, or directly in the casing. A disc and diaphragm pair a turbine stage. Steam turbines can have many stages. A rotor is a rotating shaft that carries the moving blades on the outer edges of either discs or drums. The blades rotate as the rotor revolves. The rotor of a large steam turbine consists of large, intermediate and low-pressure sections. In a multiple-stage turbine, steam at a high pressure and high temperature enters the first row of fixed blades or nozzles through an inlet valve/valves. As the steam passes through the fixed blades or nozzles, it expands and its velocity increases. The high velocity jet of stream strikes the first set of moving blades. The kinetic energy of the steam changes into mechanical energy, causing the shaft to rotate. The steam that enters the next set of fixed blades strikes the next row of moving blades. As the steam flows through the turbine, its pressure and temperature decreases while its volume increases. The decrease in pressure and temperature occurs as the steam transmits energy to the shaft and performs work. After passing through the last turbine stage, the steam exhausts into the condenser or process steam system. The kinetic energy of the steam changes into mechanical energy through the impact (impulse)or reaction of the steam against the blades. An impulse turbine uses the impact force of the steam jet on the blades to turn the shaft. Steam expands as it passes through thee nozzles, where its pressure drops and its velocity increases. As the steam flows through the moving blades, its pressure remains the same, but its velocity decreases. The steam does not expand as it flows through the moving blades.

STEAM CYCLE
The thermal (steam) power plant uses a dual (vapor+liquid) phase cycle. It is a closed cycle to enable the working fluid (water) to be used again and again. The cycle used is Rankine cycle modified to include superheating of steam, regenerative feed water heating and reheating of steam.

MAIN TURBINE
The 210 MW turbine is a tandem compounded type machine comprising of H.P. and I.P. cylinders. The H.P. turbines comprise of 12 stages, I.P. turbine has 11 stages and the L.P. turbine has 4 stages of double flow. The H.P. and I.P. turbine rotors are rigidly compounded and the L.P. motor by the lens type semi flexible coupling. All the three rotors are aligned on five bearings of which the bearing no. 2 is combined with the thrust bearing. The main superheated steam branches off into two streams from the boiler and passes through the emergency stop valve and control valve before entering the governing wheel chamber of the H.P. turbine. After expanding in the 12 stages in the H.P. turbine the steam is returned in boiler for reheating. The reheated steam for the boiler enters the I.P> turbine via the interceptor valves and control valves and after expanding enters the L.P. turbine stage via 2 nos of cross-over pipes. In the L.P. stage the steam expands in axially opposite direction to counteract the trust and enters the condensers placed below the L.P. turbine. The cooling water flowing throughout the condenser tubes condenses the steam and the condensate

collected in the hot well of the condenser. The condensate collected is pumped by means of 3*50% duty condensate pumps through L.P. heaters to deaerator from where the boiler feed pump delivers the water to boiler through H.P. heaters thus forming a close cycle.

The main Turbine

TURBINE CYCLE
Fresh steam from the boiler is supplied to the turbine through the emergency stop valve. From the stop valves steam is supplied to control valves situated in H.P. cylinders on the front bearing end. After expansion through 12 stages at the H.P. cylinder, steam flows back to the boiler for reheating steam and reheated steam from the boiler cover to the intermediate pressure turbine through two interceptor valves and four control valves mounted on I.P. turbine. After flowing through I.P. turbine steam enters the middle part of the L.P. turbine through cross-over pipes. In L.P. turbine the exhaust steam condenses in the surface condensers welded directly to the exhaust part of L.P. turbine. The selection of extraction points and cold reheat pressure has been done with a view to achieve a high efficiency. These are two extractors from H.P. turbine, four from I.P. turbine and one from L.P. turbine. Steam at 1.10 and 1.03 g/sq. cm. Abs is supplied for the gland sealing. Steam for this purpose is obtained from deaerator through a collection

where pressure of steam is regulated. From the condenser, condensate is pumped with the help of 3*50% capacity condensate pumps to deaerator through the low-pressure regenerative equipments. Feed water is pumped from deaerator to the boiler through the H.P. heaters by means of 3*50% capacity feed pumps connected before the H.P. heaters

The turbine cycle

SPECIFICATIONS OF THE TURBINE

Type: Tandem compound 3 cylinder reheated type. Rated power: 210 MW. Number of stages: 12 in H.P., 11 in I.P. and 4*2 in L.P. cylinder. Rated steam pressure: 130 kg /sq. cm before entering the stop valve. Rated steam temperature: 535C after reheating at inlet. Steam flow: 670T / hr. H.P. turbine exhaust pressure: 27 kg /sq. cm., 327C Condenser back pressure: 0.09 kg /sq. cm. Type of governing: nozzle governing. Number of bearing; 5 excluding generator and exciter. Lubrication Oil: turbine oil 14 of IOC. Gland steam pressure: 1.03 to 1.05 kg /sq. cm (Abs) Critical speed: 1585, 1881, 2017. Ejector steam parameter: 4.5 kg /sq. cm. Condenser cooling water pressure: 1.0 to 1.1 kg /sq. cm. Condenser cooling water temperature: 27000 cu. M /hr. Number of extraction lines for regenerative heating of feed water: seven

TURBINE COMPONENTS Casing. Rotor. Blades. Sealing system. Stop & control valves. Couplings and bearings. Barring gear.

TURBINE CASINGS
HP Turbine Casings: Outer casing: a barrel-type without axial or radial flange. Barrel-type casing suitable for quick start-up and loading. The inner casing- cylindrically, axially split The inner casing is attached in the horizontal and vertical planes in the barrel casing so that it can freely expand radially in all the directions and axially from a fixed point (HP- inlet side). IP Turbine Casing: The casing of the IP turbine is split horizontally and is of double-shell construction. Both are axially split and a double flow inner casing is supported in the outer casing and carries the guide blades. Provides opposed double flow in the two blade sections and compensates axial thrust. Steam after reheating enters the inner casing from Top & Bottom.

LP Turbine Casing: The LP turbine casing consists of a double flow unit and has a triple shell welded casing. The shells are axially split and of rigid welded construction. The inner shell taking the first rows of guide blades is attached kinematically in the middle shell. Independent of the outer shell, the middle shell, is supported at four points on longitudinal beams. Steam admitted to the LP turbine from the IP turbine flows into the inner casing from both sides.

ROTORSHP Rotor: The HP rotor is machined from single Cr-Mo-V steel forging with integral discs. In all the moving wheels, balancing holes are machined to reduce the pressure difference across them, which results in reduction of axial thrust. First stage has integral shrouds while other rows have shrouding, riveted to the blades are periphery.

IP Rotor: The IP rotor has seven discs integrally forged with rotor while last four discs are shrunk fit. The shaft is made of high creep resisting Cr-Mo-V steel forging while the shrunk fit discs are machined from high strength nickel steel forgings. Except the last two wheels, all other wheels have shrouding riveted at the tip of the blades. To adjust the frequency of thee moving blades, lashing wires have been provided in some stages. LP Rotor: The LP rotor consists of shrunk fit discs in a shaft. The shaft is a forging of Cr-Mo-V steel while the discs are of high strength nickel steel forgings. Blades are secured to the respective discs by riveted fork root fastening. In all the stages lashing wires are provided to adjust the frequency of blades. In the last two rows, satellite strips are provided at the leading edges of the blades to protect them against wetsteam erosion.

BLADES Most costly element of the turbine. Blades fixed in stationary part are called guide blades/ nozzles and those fitted in moving part are called rotating/working blades. Blades have three main parts: Aerofoil: working part. Root. Shrouds. Shroud is used to prevent steam leakage and guide steam to next set of moving blades.

VACUUM SYSTEM
This comprises of: Condenser: 2 for 200 MW units at the exhaust of LP turbine. Ejectors: One starting and two main ejectors connected to the condenser located near the turbine. C.W. Pumps: Normally two per unit of 50% capacity.

CONDENSER
There are two condensers entered to the two exhausters of the L.P. turbine. These are surface-type condensers with two pass arrangement. Cooling water pumped into each condenser by a vertical C.W. pump through the inlet pipe. Water enters the inlet chamber of the front water box, passes horizontally through brass tubes to the water tubes to the water box at the other end, takes a turn, passes through the upper cluster of tubes and reaches the outlet chamber in the front water box. From these, cooling water leaves the condenser through the outlet pipe and discharge into the discharge duct. Steam exhausted from the LP turbine washes the outside of the condenser tubes, losing its latent heat to the cooling water and is connected with water in the steam side of the condenser. This condensate collects in the hot well, welded to the bottom of the condensers.

Typical water cooler condenser

EJECTORS
There are two 100% capacity ejectors of the steam eject type. The purpose of the ejector is to evacuate air and other non-condensation gases from the condensers and thus maintain the vacuum in the condensers. The ejector has three compartments. Steam is supplied generally at a pressure of 4.5 to 5kg /cm the three nozzles in the three compartments. Steam expands in the nozzle thus giving a high-velocity eject which creates a low-pressure zone in the throat of the eject. Since the nozzle box of the ejector is connected to the air pipe from the condenser, the air and pressure zone. The working steam which has expanded in volume comes into contact with the cluster of tube bundles through which condensate is flowing and gets condensed thus after aiding the formation of vacuum. The non-condensing gases of air are further sucked with the next stage of the ejector by the second nozzle. The process repeats itself in the third stage also and finally the steam-air mixture is exhausted into the atmosphere through the outlet.

CONDENSATE SYSTEM
This contains the following i. Condensate Pumps: 3 per unit of 50% capacity each located near condenser hot well. ii.LP Heater: Normally 4 in number with no.1 located at the upper part of the condenser and nos. 2,3 & 4 around 4m level. iii.Deaerator; one per unit located around 181 M level in CD bay.

Condensate Pumps
The function of these pumps is to pump out the condensate to the desecrator through ejectors, gland steam cooler and LP heaters. These pumps have four stages and since the suction is at a negative pressure, special arrangements have been made for providing sealing. The pump is generally rated for 160 m/ hr at a pressure of 13.2 kg/ cm.

L.P. Heaters
Turbine has been provided with non-controlled extractions, which are utilized for heating the condensate, from turbine bleed steam. There are 410 W pressure heaters in which the last four extractions are used. L.P. Heater-1 has two parts LPH-1A and LPH-1B located in the upper parts of the condenser A and condenser B, respectively. These are of horizontal type with shell and tube construction. L.P.H. 2, 3 and 4 are of similar construction and they are mounted in a row of 5m level. They are of vertical construction with brass tubes the ends of which are expanded into tube plate. The condensate flows in the U tubes in four passes and extraction steam washes the outside of the tubes. Condensate passes through these four L.P. heaters in succession. These heaters are equipped with necessary safety valves in the steam space level indicator for visual level indication of heating steam condensate pressure vacuum gauges for measurement of steam pressure, etc:

Deaerator
The presence of certain gases, principally oxygen, carbon dioxide and ammonia, dissolved in water is generally considered harmful because of their corrosive attack on metals, particularly at elevated temperatures. One of the most important factors in the prevention of internal corrosion in modern boilers and associated plant therefore, is that the boiler feed water should be free as far as possible from all dissolved gases especially oxygen. This is achieved by embodying into the boiler feed system a deaerating unit, whose function is to remove the dissolved gases from the feed water by mechanical means. Particularly the unit must reduce the oxygen content of the feed water to a lower value as far as possible, depending upon the individual circumstances. Residual oxygen content in condensate at the outlet of deaerating plant usually specified are 0.005/ litre or less. P

RINCIPAL OF DEAERATION
It is based on following two laws. Henrys Law Solubility The Deaerator comprises of two chambers: Deaerating column Feed storage tank Deaerating column is a spray cum tray type cylindrical vessel of horizontal construction with dished ends welded to it. The tray stack is designed to ensure maximum contact time as well as optimum scrubbing of condensate to achieve efficient deaeration. The deaeration

A Deaerator

Column is mounted on the feed storage tank, which in turn is supported on rollers at the two ends and a fixed support at the centre. The feed storage tank is fabricated from boiler quality steel plates. Manholes are provided on deaerating column as well as on feed storage tank for inspection and maintenance.The condensate are admitted at the top of the deaerating column flows downwards through the spray valves and trays. The trays are designed to expose to the maximum water surfaces for efficient scrubbing to affect the liberation of the associated gases steam enters from the underneath of the trays and flows in counter direction of condensate. While flowing upwards through the trays, scrubbing and heating is done. Thus the liberated gases move upwards along with the steam. Steam gets condensed above the trays and in turn heats the condensate. Liberated gases escapes to atmosphere from the orifice opening meant for it. This opening is provided with a number of deflectors to minimize the loss of steam.

FEED WATER SYSTEM

The main equipments coming under this system are: Boiler feed Pump: Three per unit of 50% capacity each located in the 0 meter level in the T bay. High Pressure Heaters: Normally three in number and are situated in the TG bay. Drip Pumps: generally two in number of 100% capacity each situated beneath the LP heaters.

Turbine Lubricating Oil System: This consists of the Main Oil Pump (MOP), Starting Oil Pump (SOP), AC standby oil pumps and emergency DC Oil Pump and Jacking Oil Pump (JOP). (One each per unit)

Boiler Feed Pump

This pump is horizontal and of barrel design driven by an Electric Motor through a hydraulic coupling. All the bearings of pump and motor are forced lubricated by a suitable oil lubricating system with adequate protection to trip the pump if the lubrication oil pressure falls below a preset value. The high pressure boiler feed pump is a very expensive machine which calls for a very careful operation and skilled maintenance. Operating staff must be able to find out the causes of defect at the very beginning, which can be easily removed without endangering the operator of the power plant and also without the expensive dismantling of the high pressure feed pump.

Function The water with the given operating temperature should flow continuously to the pump under a certain minimum pressure. It passes through the suction branch into the intake spiral and from there; it is directed to the first impeller. After leaving the impeller it passes through the distributing passages of the diffuser and thereby gets a certain pressure rise and at the same time it flows over to the guide vanes to the inlet of the next impeller. This will repeat from one stage to the other till it passes through the last impeller and the end diffuser. Thus the feed water reaching into the discharge space develops the necessary operating pressure.

Booster Pump
Each boiler feed pump is provided with a booster pump in its suction line which is driven by the main motor of the boiler feed pump. One of the major damages which may occur to a boiler feed pump is from cavitations or vapour bounding at the pump suction due to suction failure. Cavitations will occur when the suction pressure of the pump at the pump section is equal or very near to the vapour pressure of the liquid to be pumped at a particular feed water temperature. By the use of booster pump in the main pump suction line, always there will be positive suction pressure which will remove the possibility of cavitations. Therefore all the feed pumps are provided with a main shaft driven booster pump in its suction line for obtaining a definite positive suction pressure.

Lubricating Pressure
All the bearings of boiler feed pump, pump motor and hydraulic coupling are force lubricated. The feed pump consists of two radial sleeve bearings and one thrust bearing. The thrust bearing is located at the free end of the pump.

High Pressure Heaters

These are regenerative feed waters heaters operating at high pressure and located by the side of turbine. These are generally vertical type and turbine based steam pipes are connected to them. HP heaters are connected in series on feed waterside and by such arrangement, the feed water, after feed pump enters the HP heaters. The steam is supplied to these heaters to form the bleed point of the turbine through motor operated valves. These heaters have a group bypass protection on the feed waterside. In the event of tube rupture in any of the HPH and the level of condensate rising to dangerous level, the group protection devices divert automatically the feed water directly to boiler, thus bypassing all the 3 H.P. heaters.

An HP heater

Turbine Oil Lubricating System

This consists of main oil pump, starting oil pump, emergency oil pump and each per unit.