FAMILIARIZATION WITH THE

FUNCTIONING OF THE BTG

SYSTEM
IN THE THERMAL POWER
GENERATION
PLANT (HALDIA)
ORGANISATION: HIRANMAYE ENERGY LIMITED
 Cover letter

To
Mr Prasanta Kumar roy
Chief Manager-Mechanical Maintainence
M/S HIRANMAYE ENERGY LIMITED
Haldia,West Bengal

Respected sir,
I am Puja Halder pursuing B.tech course 3rd year
Haldia Institute Of Technology ,Haldia want to declare that I have
completed my summer internship program on the topic titled
as”FAMILIARIZATION WITHNTHE FUNTIONING OF BTG SYSTEM IN
THE THERMAL POWER GENERATION PLANT “ in the Mechanical
Maintainance project Department from 17th June to 17th July at
HIRANMAYE ENERGY LIMITED ,HALDIA.

Thanking You
Puja Halder

Mentor: Mr Pransanta Kumar Roy

 Introduction

Power plant is a power station in

which heat energy is converted into
electric power. Water is heated ,turns
into steam and spins a steam turbine
which drives an electric generator
.After it passes through the turbine
,the steam is condensed in a
condenser and recycled to where it is
heated. The fuel which is used may be
fossil(coal ,oil ).Whichever fuel is used
the objective is same to convert heat
energy into mechanical energy in
turbine ,and to convert mechanical
energy to electrical energy in
generator.
Content
A. INTRODUCTION
B.STEAM TURBINE
1. PRINCIPLE:- RANKINE CYCLE
2. CONDENSOR
3.CONDENSATE EXTRACTION PUMP
4.BOILER FEED PUMP
C.STEAM GENERATOR
D.BOILER MOUNTINGS & ITS
AUXILLARIES :
1. FAN
2. ECONIMISER
3. COAL FEEDER
4. BOILER DRUM
5. COAL MILL
6. SUPERHEATER
7. FUEL OIL SYSTEM
8. REHEATER
9. BURNER ARRANGEMENT
10. AIR PRE-HEATER
11.ELECTROSTATIC PRECIPITATOR
E.MAINTENANCE
 RANKINE CYCLE

• Process 1-2 : Isentropic expansion of the fluid through the turbine from
saturated vapour to the condenser pressure.
• Process 2-3 : Heat transfer at constant pressure through the condenser
to saturated liquid.
• Process 3-4: Isentropic compression of fluid to compressed liquid.
• Process 4-1: Heat transfer at constant pressure through the boiler to
saturated vapour
In addition to being able to work with the
Ideal Rankine Cycle ,you should also be
prepared to evaluate performance that
includes the following modifications

Superheating:

Heating of the fluid past a saturated vapour and well

into the superheated region by the steam generator.

Reheating:
Reheating fluid after it has passed through first turbine at
high pressure and before passing through a second turbine
at low pressure.

Regenerative Feed water heating:

Some of the steam is bled off and used to partially reheat
the condensate flow & feed water flow
 Turbines

• A steam turbine is a device that extracts thermal

energy from pressurized steam and uses it to do
mechanical work on a rotating output shaft.
The process involves:
1.High pressure steam enters through nozzles.
2. The stationary blades direct the srteam flow changes its
flows through the moving blades .
3.The direction of the steam flow changes as its flows
through the moving blades.
4.The change of flow direction generates a force on the moving blades.
5.This force drives the turbine.

turbine
 Classification of turbine
According to steam
flow:
Axial flow turbine

Radial flow turbine

According to number of
cylinders:
Single cylinder
turbines
Double cylinder
turbines
Three cylinder
turbines
Four cylinder
turbines

According to pressure of
turbine:
High pressure turbine

Medium pressure
turbine
Low pressure turbine

According to
application:
utility turbine

Industrial turbine
Marine turbine
 HIRANMAYE ENERGY LIMITED
(TURBINE)
SINGLE CYLINDER
Unit of AXIAL FLOW REHEAT TURBINE
measurement
Descriptio Data
n

1. Rated speed RPM 3000

2.Heat Rate Kcal/kWh 1985.5

3.Auxillary MW 10.3
Power
Consumption

4.Steam ATa 133

Pressure

5.Steam 540
Temperature

6.Steam Flow TPH 484.6

 Condensor

• In thermal power plant the purpose of condenser is

to condense the exhaust steam from a steam
turbine to obtain maximum efficiency ,and also to
convert the turbine exhaust steam inti pure water
(referred to as steam condensate)so that it may be
reused in the steam generator or boiler as boiler
feed water.

•
• CONDENSOR
 TYPES OF COMDENSER

1.Jet condenser: It is a mixing type condenser where the exhaust

steam
is condensed mix up with cooling water .High power
is required for condensation .Different types of jet condenser are:
a)Low level jet condenser
b) High level jet condenser
c)Ejector condensor

2.Surface condenser: It is commonly termed as a water –cooled

shell and tube
heat exchanger installed to exhaust steam from a steam turbine
in thermal power stations .These condensers are generally heat
exchangers
which convert steam from its gaseous to its liquid state at a pressure
below atmospheric pressure. Different types of surface condenser
are:
a)Down flow condenser
b) Central flow condenser
c)Evaporation condensor
Diagram of Surface
Condenser
 HIRANMAYEE ENERGY LIMITED
Condensate extraction pump (CEP)

It pumps the condensate from the Hot well through a

series of low pressure water heaters to a deaerator
heater.
Description Unit of Data
measure-
ment
1.Total head MLC 250
at design
capacity
2.Drive KW 600
motor
rating
3.Rated RPM 1485
speed
4.Voltage Volt 6600

5.Power _ 0.85
factor
6.Weight Kg 4850

7.Efficiency % 94.5
 Hiranmaye energy limited
Boiler feed pump(Bep)

Role:
1. Supplies feeding water to economizer.
2. Increase the discharge pressure of feed water to boiler.

Descript- Unit of Data

ion Measure-
ment
1.Temper 170.7
ature
2.Density Kg/m3 897
3.Flow m3/hr 600
rate
4.Dischar Kg/cm2 193.257
ge
pressure
 Steam generator
A steam generator is a form of of low water-content boiler, similar to a flash steam
boiler .The usual construction is as a spiral coil of water tube, arranged as a single or
monotube coil.Circullation is once-through and pumped under pressure,as a single
forced-circulation boiler.

Boiler ,Mountings & its Auxillaries

1.Economizer
2.Boiler drum
3.Super heater
4.Re heater
HIRANMAYEE ENERGY LIMITED(BOILER)
5.Air pre heater
Description Unit of Data
6.Fans
measure-
7.Coal mill & feeder ment
8.Fuel oil system
1.Main TPH 505
9.Burner arrangement steam flow
10.Electrostatic precipitator
2.Main Kg/cm2 138
11.Water level indicator steam
12.Pressure gauge pressure
13.Safety valves 3.Main 540
14.Stop valve steam
15.Feed check valve temperatur
e
4.Reheat TPH 509.9
steam flow
5.Steam at Kg/cm2 35.03
reheat
BOILER
 hiranmaye energy limited
Fans
• Fans are machines whose primary function is to provide large flow of
air to provide large flow of air to various processes this is achieved by
rotating number of blades ,connected to a shaft.
Types of fan and its function:-
1.Primary Air Fan
Function: to transport the coal to furnance.

2.Forced draught fan

Function :to provide optimum air for proper combustion.

3.Induced draught fan

Function :to draw the gases from the boiler to maintain
the pressure balance in the combustion chamber.

4.Scanner fan
Function :to provide flow of air to the scanners for cooling.

5.Seal air fan

Function :to provide air to the mills7feeders for air sealing.
Economizer

Economizer is provided to extract the heat from the waste flue gas & add it as either
sensible heat alone or sensible heat & latent heat tp the feed water .It is a tube & shell
type heat exchanger. It is situated in the second pass of the boiler.

hiranmaye
energy limited(ECONOMIZER)

Descript- Unit of Data

ion measure-
ment
1.Specifica ASTS/DIN/ ASTM A210Gr
A1
tion of BS ASTM A210 C
material A1
2.Tube mm 38.1
diameter
3.Total Sq. m. 4775
heating
surface
area
4.Flue gas m/sec APPROX
velocity 10 m/s
@100%
BMCRDC
 Boiler drum

Boiler drum is found in such type of boiler which is operated under sub critical pressure.It
provides uinterrupted feed water supply to furnance water wall tubes through downcomers.
FUNCTION
1.To provide the necessary space for separation
of steam from mixture of steam and water.
2.To maintain the pH level of boiler water,
phosphate dosing is done.
3.To provide a water storage for preventing
the starvation of tube.

hiranmaye energy limited(boiler drum)

Descrip unit data

tion
1.Specifi ASTM/ ASTM
cation of DIN/BS A299
material
2.Design Kg/cm^ 164
pressure 2(g)
 Boiling Water – Steam Circuit

Feed Regulation Station

Economizer

( Water + Hot Air )

Drum Boiler Water Walls Water Wall Headers

( Riser Tubes )

Backpass Steam
Cooled Wall

LTSH Platen SH Final SH Main Steam HP Turbine

LP Turbine IP Turbine HRH Reheater CRH

CONDENSER
 Coal feeder

Coal feeder is used to feed coal in the mill in a controlled way.

Different types of coal feeder:
1.Volumetric feeder
2.Gravitimetric feeder

Hiranmaye energy limited(FEEDER)

Descript Data
ion Unit
1.Type - Gravitimet
feeder ric

2.Capacity TPH 8.84(max)

44.2(min)

3.Working mmwc 500

pressure
 Coal mill
The function of coal mill is to pulverise the coal at desired size
for combustion in the furnance.
Features :
1.Grinding chamber
2.Classifier mounted over it.
3.Pulverisation takes place in between rotating bowl and rollers .
4.Heavy springs are provided between the coal and the rolls.

5.Rolls do not touch the roll rings.

Types :
1.Ball mill
2.Bowl mill

Hiranmaye energy limited(mill)

Unit Data
Descripti
on
1.Total no.of no 5
mills
2.Mill TPH 39.7
capacity
3.Grinding - Carbide insert
element
material
 Superheater

A super heater is a device which removes the last

traces of moisture from the steam which is
saturated and on its way to furnace by leaving the
boiler tubes and it also increases its temperature
above the saturation temperature used in thermal
power plants.

Types:
1. PLATEN SUPERHEATER
2. RADIANT SUPERHEATER
3. CONVECTIVE SUPERHEATER
4. SEPARATELY FIRED SUPERHEATER
5. HORIZONTAL TYPE SUPERHEATER

PLATEN SUPERHEATER
 Reheater

A reheater is basically a superheater that

superheats steam exiting the high pressure
stage of a turbine.
The reheated steam is then sent to the low
pressure stage turbine.
Hiranmaye energy limited(reheater)

Descripti Unit Data

on

1.Specific ASTM/DI ASTM

ation of N/BS A213
material T11/T22/
T91

2.Heating Sq.m 1583

surface
area

3.Flue m/sec APPROX

gas 10m/sec
velocity
 Air Pre-
heater

Air Pre- heaters are simple heaters that heat the air
before it enters the combustion chamber .
Hence, result on the fuel consumption and increasing
the thermal efficiency .
Types :
1.Regenerative Air Pre-heaters.
2.Recuperative Air Pre-heaters.

hiranmaye energy limited(Air Pre-heater)

Description Unit Data

1.Main drive KW 7.5

AC motor

2.Model no. - 25.5 VIT

3.Weight 379
Tons
4. Effective m^2 13400
Heating surface
area
 Burner Arrangement

Coal burning in large thermal

power plant boilers takes place in
different ways:
1.By pulverising to a fine powder and being piped into
different burners placed in the furnace of the boilers.
2.By circulating fluidized bed where large coal particles
spread on to the bottom of the furnace and the air pressure
from the bottom keeps it floating to give good combustion
3.By spreading coal on a moving or stationary grate ,ad the
combustion air is admitted from below.

Types of burner arrangement:

1.Tangential firing
2.Wall firing
Tangential firing system

In this type ,the coal feeds into the furnace at the corners

of the furnace .This produces a cyclones effect in the furnace

ensuring proper mixing of air & fuel that is essential for

proper combustion. The combustion air also enters the

furnace tangentially above and below these burners .

Each pulveriser supplies coal to one level so that firing is

always balanced .In most of the tangential firing system ,

the burner can tilt 30 degrees up or down which aids

in controlling temperature and combustion chambers .

 Fuel oil system

• Purpose :
1. To support the furnace flame during low load operation.
Hiranmaye energy limited(fuel oil motor)
2. To establish initial boiler light up.
It consists of:
1.Fuel oil pumps
2.Filters

Atomization
This process breaks the fuel into fine particles
that readily mixes with air for combustion.
Small particles results in effective atomization.
It is applicable to large capacity range.
Description Unit Data

1.motor - AC induction Motor ,TEFC,IP55

2.Rated output KW 30

3.speed RPM 2945

4.voltage V 415

5.current Amps 51/15

6.efficency % 92

7.Power factor - 0.89/Continuous –S1

Types of Oil burner

• Air atomized burners

• Steam atomized burners
• Mechanically atomized burners
(Air atomizing burners are not preferred as they tend to chill the coil and decrease
atomization quality.)

Types of oils:
HIRANMAYE ENERGY LIMITED (oil burner)
i) Light diesel oil(LDO)
ii) Heavy fuel oil(LFO)
iii) Low sulphur heavy stock
(LSHS) Unit Data
Description

1.Fuel - LDO ,IS1460

2.Oil flow/Gun Kg/hr 960(MAX)

3.Oil pressure Kg/cm^2 6.0(MAX)

4.No. of guns no.s 12

OIL GUN COMPARTMENT
Electrostatic Precipitator

An electrostatic precipitator (ESP) is a filtration

device that removes fine particles, like dust
and smoke, from a flowing gas using the force
of an induced electrostatic charge minimally
impeding the flow of gases through the unit.
In contrast to wet scrubbers which apply energy
directly to the flowing fluid medium, an ESP
applies energy only to the particulate matter
being collected and therefore is very efficient in
its consumption of energy (in the form of electricity).
MAINTENANCE

Maintenance involves fixing any sort of

mechanical or electrical device which as
become out of order and also performing
routine actions which keep device in working
order or prevent trouble from arousing.

Objectives :
To increase functional reliability of production facilities.
To useful life of equipment's .
To maximize production capacity from the given
equipment.
To minimize total production cost.
Types of maintenance

• Preventive maintenance
• Predictive maintenance
• Corrective maintenance

Advantages:
1. Maximize production.
2.Reduce breakdown.
3.Reduce downtime.
4.Improves equipment efficiency
5.Providing budgetary control
Thank you