SEMINAR ON

STUDY OF POWER GENERATING SYSTEM IN CAPTIVE

POWER PLANT(VSP)
By
M. Sivakoti Reddy
Reg. No. 17131D5311
III Sem. M.Tech.(PSCA)
Under the Esteemed guidance of
Y. C V Kondaiah
Asst. Professor (EEE)

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

GAYATRI VIDYA PARISHAD COLLEGE OF ENGINEERING
(AUTONOMOUS)
VISAKHAPATNAM- 530 048.
2018-19
 ACRONYMS
• VSP Visakhapatnam Steel plant
• BF Blast Furnace
• TPP Thermal Power Plant
• GETS Gas Expansion Turbine
• BPTS Back Pressure Turbine Station
• PA Primary Air
• ID Induced Draft
• FD Forced Draft
• BFP Boiler Feed Pump
• ESP Electro Static Precipiators
• CEP Condensate Extraction Pump
• HP High Pressure
• LP Low Pressure
• KSCA Kilogram Per Square Centimeter Area
2
 CONTENTS
• Acronyms.

• Captive Generation Sources

• Process flow chart of TPP-1

• Back pressure turbine station

• Gas expansion turbine station

• Observations

• Conclusion

• References

3
 POWER
GENERATION
 SOURCES OF POWER
 CAPTIVE POWER PLANT
• INSTALLED CAPACITY = 536.6MW

 STATE ELECTRICITY GRID

• CONTRACT MAXIMUM DEMAND = 235 MVA
CAPTIVE GENERATION SOURCES

• Thermal Power Plant

• Back Pressure Turbine Station
• Gas Expansion Turbine Station ,TRT
• Coke Oven Battery-4 & 5(COB-4 &5) Power Plant
• CPP -2, NEDO (SHRP)
 Captive Generation Sources
• Total Installed Capacity = 536.6 MW
• Thermal Power Plant (315 MW)
• COB-4 PP (14 MW)
• COB-5 PP (14 MW)
• Back Pressure Turbine Station (15 MW)
• Gas Expansion Turbine Station (24 MW)
• TRT (14 MW) , NEDO (20.6 MW)
• CPP -2 (120 MW)
 TPP & BH OBJECTIVES
• To Supply uninterrupted Cold Blast to Blast Furnaces as per
Furnace requirements .
• To supply uninterrupted Essential Power.
• To supply 13 ata process steam for other units of Steel
Plant.
• To supply quality DM water to meet both internal and plant
needs.
• To supply Chilled Water to meet both internal and plant
needs.
• To Maintain Power Generation for meeting the Plant Load
 MAIN EQUIPMENT OF TPP
• Boilers
• Turbo-Generators
• Turbo-Blowers
• Chemical Water Treatment Plant
• CDCP Boilers
• Back Pressure Turbine Station & CWP-1
• Chilled Water Plant -2
• Gas Expansion Turbine Station
• COB-4 & 5 Power Plant
COAL CONVEYING SYSTEM OF TPP & BH
JUNCTI
ON
HOUSE
12

RM
HP ISB
H CC
CC 63
62

JUNCTION
HOUSE 14

CC
66
JUNCTI
ON
TPP BUNKER CC
HOUSE
FLOOR CC 68 67 13

CC
69

BUNKERS
 PROCESS FLOW CHART PROCESS STEAM
WATER
MAIN STEAM
TURBINE GENERATOR POWER
CHEMICAL WATER DM WATER
TREATMENT PLANT

COLD BLAST
TURBINE BLOWER
DEAERAT- 140°C 4.75 KSCA, 135°C
OR 6067 NM3/hr

110 Ksca
BOILER DRUM SUPER HEATER 17Kg/Cm2
440°C 10°C
COAL HANDLING
PLANT 1.0196 KSCA
BFP LP
FLUE GAS
HEATER CONDEN-
1035 °C,422 t/hr CER AIR
BOILER AIR PRE -
148Ksca 140°C
FURNACE COOLER
530°C
PULVERI-
SER 54°C CEP
112.5 Ksca 230°C 8°C
ECONOMI- HP
283°C SER HEATER 860 M3/hr
PA FAN
VOLUME 2300
m3
RC PUMP CHILLED
CO GAS 200 mmWC,
HOUSE WATER
40°C 367°C PLANT
AIR FROM
BF GAS 300 mmWC AIR
FD FAN ATMOSPHERE
HEATER
40°C

COOLING
150°C MAKEUP TOWER
FUEL OIL STATION HSD
450 t/hr WATER

CHIMNEY
ELECTRO
ID FLUE GAS
STATIC
PRECIPITA- FAN
TOR

FLY ASH
BOTTOM ASH ASH HANDLING
PLANT TO ASH POND
 BOILERS
• Boilers: 6 (5 working + 1 Standby)

• Capacity: 330 tons/ hr

• Pressure: 101 ata

• Temperature: 540o C
• Fuels: 1. Pulverised Coal
2. BF Gas
3. CO Gas
4. Furnace oil / LSHS
 Thermal Power Plant

OIL
0.07%
BFG 23%
COAL 46.8%
COG
30%

Typical Fuel Mix in Boilers

BOILER SCHEMATIC
 TURBO GENERATORS
5 TGs : ( 3 × 60MW + 2 × 67.5MW )

Main Features :
• Electro Hydraulic Turbine Governing System.

• Controlled extraction at 13 ata and 4 ata for process steam

requirement (Only in TG#1, 2 & 3).

• Central admission of steam to reduce axial thrust.

• Air cooled Generators.

BACK PRESSURE TURBINE STATION,
CO-4 & CHILLED WATER PLANT NO.1
(BPTS& CWP-1)
1. 2 NOS. OF 7.5 MW BACK PRESSURE TURBINES
2. 2.5 ATA EXHAUST STEAM IS UTILISED FOR
PRODUCTION OF CHILLED WATER IN CWP-1.
3. 7 ATA EXTRACTION STEAM FORPROCESS
REQUIREMENTS OF CO&CCP ZONE.
4. THE CWP-1 HAS 5 CHILLERS OF CAPACITY 330M3/Hr
(Each of 1000 TR capacity)
5. 14 MW TURBINE AT COB -4
STEAM FLOW FROM CDCP BOILERS
 GAS EXPANSION TURBINE
STATION (GETS)
• MAKE : RUSSIAN
• CAPACITY : 2 * 12 MW
SPECIFICATION FOR GENERATION @ 8 MW / 12 MW
• GAS FLOW (LACS NM3/Hr) 3 / 3.6
• GAS PRESSURE (KG/CM2) 2 / 2.4
• GAS TEMP (deg C) 120 / 140
SPECIAL FEATURES:
• FIRST OF ITS KIND IN INDIA
• MOTOR MODE OPERATION
• WATER WASHING OF STATOR & ROTOR BLADES
• VARIABLE STATOR VANES
• * TRT (14 MW) ADDED DURING EXPANSION
CAPTIVE POWER
PLANT - 2
A unit of THERMAL POWER
PLANT
 Introduction
• CPP-2 (Captive Power Plant) is a part of the 6.3MTPA
expansion project of M/s. RINL (Visakhapatnam Steel
Plant)
• Plant comprises of
– 2(two) nos. of BFG fired Boilers
– 1(one) no. of 120MW Turbo-Generator
– DM Plant
– Re-Circulation Water Pump House (RCWPH)
– Compressor and Chiller house
– Fire fighting Pump House
– Fuel oil Handling station
– And other allied Electrical and Mechanical equipment
which run round the clock.
 BOILER
• By-Product gases namely Blast Furnace Gas and Coke Oven gas are used
as fuels in Boilers
• These gases are generated in the steel making process have calorific values
of ~750kCal/Nm3 & ~ 4200kCal/Nm3 respectively.
• These unit is envisaged to fully utilise the surplus BFG gas (which comes
into picture with 03(three) nos. of Blast Furnaces in operation) for power
generation.
• The Boilers are supplied by M/s. Thermax. The features of the boilers are:
– Capacity = 223 T / Hr
– Pressure = 115 kg/sq.cm
– Temperature = 540 +/- 5 deg C
– Fuels = CO Gas, BF Gas, LDO (for boiler start-
up),
HFO for low load
 SALIENT FEATURES
 The power is generated at 15.75kV by Generator and stepped up to 220kV
through 160 MVA Generator Transformer
 220kV GIS system is provided to export full generation capacity of the
Generator to the plant network
• 02(Two) nos. of Unit auxiliary transformer of 25 MVA (15.75/6.9 kV) are
provided to step down power to 6.6 kV level to feed the BTG auxiliary HV
loads and other HV loads of plant.
• 12 nos. of Auxiliary transformer of 2 MVA (6.6/433V) are provided to step
down power to 415 V level to feed the BTG auxiliary LV loads and other LV
loads of plant.
• 02 nos. of Auxiliary transformer of 800kVA (6.6/433V) are provided to meet
the lighting requirement of the unit and proximate areas.
• The start-up power required for Turbo-generator is met from 220kV grid
through Generator transformer.
• Further to this, two feeders from existing plant network system are connected
to the two 6.6kV switchgears of CPP-2 to feed the loads required in blackout
condition
ELECTRICAL SYSTEM – CPP-2

220KV GIS

Generator
Transformer
(GT) 160MVA
220/15.75 KV
IPBD Busduct

Unit Auxiliary
G Transformer
CB (UAT-2) 25MVA
15.75/6.6 KV
USG-1 USG-2

For In plant Loads

~
For In plant
Loads
 CONCLUSION
1. The industry that we visited is Visakhapatnam Steel Plant. We
have completed industrial training in Thermal Power Plant
department of VSP. The estimated power generation in TPP
and its auxiliaries is 536.6 MW, which comprises of
i. 315MW from 5 turbo generators in TPP-1,
ii. 120MW from TPP-2,
iii. 15MW from BPTS -1&2,
iv .28MW from COB-1&2,
v. 24MW from GETS-1&2,
vi. 14MW from Top Recovery Turbine,
vii.20.6MW from NEDO

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2. In VSP, the power generation is for the utilization by the plant
itself and not for economic purpose, such a generating plant is
called Captive Power Plant.
TPP-1 utilizes multiple fuels such as:
• Coke at elevation stage 1
• Oil at elevation stage 2
• BF Gas at elevation stage 3
• CO Gas at elevation stage 4 for the process.
• These are fired tangentially into the boiler furnace.

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3.TPP-2 utilizes only gas based fuels such as:
• BF Gas
• CO Gas
• These are fired axially into the boiler furnace.
• The main advantages of TPP-2 are it is dust-free because the
fuels used do not contain
• coal and hence no ESPs are required. Moreover, this plant
uses the by-product gases of
• the other departments such as blast furnace and coke oven
which are available for free of
• cost to TPP-2. So this plant is an added asset to VSP.

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 REFERENCES

1. Mohammed Kabiruddin, Report on Various Components of Power

Plant, University of Petroleum and Energy Studies.
2.http://www.reitzindia.com/blog/95-types-of-centrifugal-fans-used-
in-power-plantboilers
3. https://www.mbl.in/ash-handling-system.

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 THANK YOU
AND
SUGGESTIONS

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