VOCATIONAL TRAINING

On
500MW THERMAL POWER PLANT

AT
NTPC LIMITED
RIHAND SUPER
THERMAL
POWER PROJECT,
RIHAND NAGAR SONEBHADRA (U.P.)
BY
DINESH SINGH RINGWAL
OF

PUNJAB POLYTECHNIC COLLEGE,
LALRU, DISTT. MOHALI (PB.)
UNDER THE EXPERT GUIDANCE OF
Mr. P.Kashya, D.G.M.(BMD)
Mr. V!"as "#$ar, Sr.E%&r.

CERTIFICATE
NATIONAL THERMAL POWER CORPORATION LTD.
(A GOVERNMENT OF INDIA ENTERPRISE)
RIHAND SUPER THERMAL PO'ER PROJECT
P.O.(R!ha%) Na&ar, D!s**. S+%,-ha)ra (U.P.)
. DATE(./0120.113
CERTI4ICATE
TO 'HOMSOEVER IT MAY CONCERN
ACKNO'LEDGEMENT
With feelings of joy and thanks, I placed in your
hand my Project report. It is my pleasant privileges
to thank all those who have help me in molding and
shaping my project. Without their guidance,
cooperation and best wishes it would have been
impossible for me to complete my dissertation
report. A big thanks to all those who helped me by
sparing time amidst their busy schedule and for
being kind enough to help me whenever I needed
them.
As man is a social animal. !e re"uires the
encouragement and affection of his parents and
friends to accomplish his goal and I have been
#ucky to get it and make this project report a
success.
$inally, I am thankful to all the respected E5,6#*!7,
,$8+y,,s !" N.T.P.C RIHAND,RIHANDNAGAR, for
providing me the necessary information, cooperation
in #OCATINAL TRAINING. I thank god almighty for
his abundant blessing because without it this project
was only a dream.
%I&'(! (I&)! *I&)WA#
III +ear
,echanical 'ngg.
CERTI4ICATE
-his is to certify that this summer training report has been prepared by DINESH SINGH
RINGWAL (./ (h. -rilok (ingh, a student of %IP#/,A. 0,'1!. '&))2 in the partial
fulfillment of re"uirement of vocational training at &-P1 *ihand.
-he matter was analy3ed by candidate under my guidance and this report embodies the work
done by him.
We wish him a bright future.
Approving Authority4 )uide4
A.5.-IWA*I P.5. 1!/6%!A*+
%), 07,%2 '&)I&''* 07,%2

A7/6- &.-.P.1.
-he &-P1 was formed in 89:; to meet the power re"uirement challenge faced by the nation
during the period. &.-.P.1. 0&ational -hermal Power 1orporation2 is an Indian )ovt. undertaking.
It has the installed capacity of <=,:>;,W including joint venture, contributing <?.:@ of the
nationAs power generation with only 89.8@ of IndiaAs total installed capacity.
7ased on 899B data, carried out by %ata monitor 65, &-P1 is the ?th largest in terms of thermal
power generation and the second most efficient in terms of capacity utili3ation amongst the
thermal utilities in the world.
&-P1Cs core business is engineering, construction and operation of power generating plants and
also providing consultancy to power utilities in India and abroad. As on date the installed capacity
of &-P1 is <=,:>9 ,W through its 8= coal based 089,>BD ,W2, : gas based 0=,9;; ,W2 and =
Eoint Fenture Projects 0=8> ,W2. &-P1 ac"uired ;D@ e"uity of the (AI# Power (upply
1orporation #td. 0(P(1#2. -his EF company operates the captive power plants of %urgapur 08<D
,W2, *ourkela 08<D ,W2 and 7hilai 0:> ,W2. &-P1 is also managing 7adarpur thermal power
station 0:D; ,W2 of )overnment of India.
*ecognising its eGcellent performance and vast potential, )overnment of the India has identified
&-P1 as one of the jewels of Public (ector H&avratnasAI a potential global giant. Inspired by its
glorious past and vibrant present, &-P1 is well on its way to realise itAs vision of being one of the
worldAs largest and best power utilities, powering IndiaAs growth.
R!ha%) S#,r Th,r$a8 P+9,r Pr+:,6*
(;5<11 M')
INTRODUCTION
..= SALIENT 4EATURE
L+6a*!+%4 7ijpur village, %istt. (onebhadra. 06.P2.
T+*a8 r++s,) 6aa6!*y4=DDD ,W, in = stages each of <J;DD,W

Pr,s,%* 6aa6!*y> <DDD ,W 0(-A)'I8 K (-A)'I<2
0(-A)'I= is planned for future2
T+*a8 8a%) (!% a6r,s)> 6P ,P -otal
>?BD 8:;< ?>=<
P+9,r E7a6#a*!+%> L.I;DD5v !F%1 7ipolar line to %adri 0%elhi2, >DDkF single
circuit A1 line to (haktinagar and 5anpur.
B,%,?!6!ary S*a*,s> 6P, !aryana, Punjab, *ajasthan, EammuK5ashmir,
!imachal Pradesh, 1handigarh and %elhi.
4!%a%6!%&> 'Gport 1redit of pound sterling =>>million, aid from )ovt. of
6.5.pound sterling 8:: million.)ovt.of India afforded the
rest cost of the project.
Ma:+r R,s+#r6,s>
COALI 0a2 (ource IAmlori mines.
0b2 ,aGimum consumptionI >=,=DD,-.%ay
for =DDD ,W 0'I)rade 1oal2.
0c2 ,ode of -ransportationI ,)* *ail
-ransportation (ystem.
'ATERI 0a2 (ourceI *ihand *eservoir.
0b2 ,aGimum 1onsumption M =DD cusecs.
0c2,aGimum cooling water re"uirementI
8;DDcusecs for 8DDD,W.
Ch!$%,y> <<>.;mts0*11 structure with steel flue2.
Ash )!s+sa8> Ash slurry pumped to Ash dyke.
C+$$,%6,$,%* +? 9+r"> D9.D<.89B=.
U%!*(= sy%6hr+%!@,)> =8.D=.89BB.
U%!*(. sy%6hr+%!@,)> D;.D:.89B9.
U%!*(/ sy%6hr+%!@,)> =8.D8.<DD;
U%!*(; sy%6hr+%!@,)> =8.D:.<DD;
U%!*(= 6+$$,r6!a8!@,) D8.D8.899D
U%!*(. 6+$$,r6!a8!@,)> D8.8D.8998.
*ihand super thermal power project 0*h(-PP2 has the current generation capacity of <DDD,W. -here
are four 6nits where each 6nit has the capacity of ;DD,W. 6nits 8 K < were commissioned in 89B9
and 6nit = K 6nit > were commissioned recently in August <DD;. -he power plant has two switchyards
of >DD5F K 8=<5F which are interconnected to each other. -hese switchyards feed the northern power
grid form where the transmission of power is done. /ne >DD5F bus is used for !.F.%.1. transmission
which delivers power from *ihand to %adri near %elhi. -he thermal plant intakes water from the near by
water reservoir the )ovind Fallabh Pant *eservoir based on *ihand river. -he reservoir rests on the
dam named *ihand dam, which also powers the !ydro power station of <;D,W. -he re"uirement of
coal is fulfilled from Amlori coal mines which are situated in ,adhya Pradesh.
-he *h.(.-.P.P. powers various (tates such as 6ttar Pradesh, %elhi, Punjab, !imachal Pradesh,
*ajasthan etc.
N,9 *,6h%+8+&y
(uper critical technology at &-P1 (ipat project 0=J?DD,W2 to increase the efficiency of
the cycle and to decrease the green house gas emission.
1losed cycle seawater cooling at (imhadri project for first time in India.
Introduction of I)11 0Integrated gasified combined cycle2 for clean and efficient
utili3ation of coal.
E%7!r+%$,%* $a%a&,$,%*
#i"uid water treatment plants at $arakka and 5ahalgaon.
Ash water recycling system at 5ahalgaon and 5orba to reduce water re"uirement for
ash disposal at these station


ABSTRACT

Any thermal power plant is converting the chemical energy of fossil fuel 0coal2 into electrical
energy. -he process involved for this conversion is based upon the ,odified *ankine 1ycle. -he
major components that are used to accomplish the ,odified *ankine 1ycle are
i2 7oiler feed pump,
ii2 -he steam generator water walls 0evaporator2,
iii2 (team generator super heaters,
iv2 (team turbine,
v2 *eheater, vi2 1ondenser,
vii2 *egenerative feed heaters etc.

All components of a power generating cycle are vital and critical in operation. In ,odified
*ankine 1ycle the two most important aspect that is added are reheating K regenerative heating .
7y reheating steam, coming from eGhaust of the turbines, is used to send back to the reheater of
the boiler so that its enthalpy increases and more work can be done by this steam the other
purpose is to make steam dry so that no harm will be done to the blades of the turbine.
In *!(-PP there are four turbines in -andem coupling namely one !.P -urbine, one #.P
-urbine K two #.P -urbine coupled with the generator to which is synchronised with the grid to
produce electricity at ;D!3.
. In all my modesty, I wish to record here that a sincere attempt has been made for the
presentation of this project report. I also trust that this study will not only prove to be of academic
interest but also will be able to provide an insight into the area of technical management.
MODI4IED RANKINE CYCLE
A thermal power station operates using a closed steam power cycle, which is a dual
0vapourLli"uid2 phase cycle. In this cycle, the working fluid i.e. water undergoes various
thermodynamic processes and is used repeatedly. Previously, rankine cycle was used in most of the
thermal power plants. !owever, in modern power plants the rankine cycle is modified to include
superheating of steam, regenerative feed water heating and reheating of steam.
= ;

< >

-

8 ?

(
-he modified cycle is represented on -I( diagram. Farious processes are4
8I< M Ideal pressure increase at constant entropy in boiler feed pump.
<I= M !eat addition in the boiler at constant pressure.
=I> M Isentropic eGpansion in !P turbine.
>I; M *eheating at constant pressure.
;I? M Isentropic eGpansion in IP and #P turbines.
?I8 M 'Gtraction of latent heat in condenser.
$actors affecting thermal efficiency of ,odified *ankine 1ycle are listed as under4
Initial (team Pressure.
Initial (team -emperature.
*eheat Pressure and -emperature.
1ondenser Pressure.
*egenerative $eed Water !eating.
ABSTRACT

Any thermal power plant is converting the chemical energy of fossil fuel 0coal2 into electrical
energy. -he process involved for this conversion is based upon the ,odified *ankine 1ycle. -he
major components that are used to accomplish the ,odified *ankine 1ycle are
i2 7oiler feed pump,
ii2 -he steam generator water walls 0evaporator2,
iii2 (team generator super heaters,
iv2 (team turbine,
v2 *eheater, vi2 1ondenser,
vii2 *egenerative feed heaters etc.

All components of a power generating cycle are vital and critical in operation. In ,odified
*ankine 1ycle the two most important aspect that is added are reheating K regenerative heating .
7y reheating steam, coming from eGhaust of the turbines, is used to send back to the reheater of
the boiler so that its enthalpy increases and more work can be done by this steam the other
purpose is to make steam dry so that no harm will be done to the blades of the turbine.
In *!(-PP there are four turbines in -andem coupling namely one !.P -urbine, one #.P
-urbine K two #.P -urbine coupled with the generator to which is synchronised with the grid to
produce electricity at ;D!3.
. In all my modesty, I wish to record here that a sincere attempt has been made for the
presentation of this project report. I also trust that this study will not only prove to be of academic
interest but also will be able to provide an insight into the area of technical management.
MAIN BOILER
A . BOILER 4UNDAMENTALS
Pr!%6!8,s +? 6+$-#s*!+%>
8. -he primary function of oil and coal burning systems in the process of steam generation is
to provide controlled efficient conversation of chemical energy of fuel into heat energy,
which is then transferred to the heat absorbing surfaces of the steam generator. When
combustion is properly completed the eGhaust gases will contain, 1/<, water vapour,
sulphur dioGide and a large volume of nitrogen, combining carbon and hydrogen with the
oGygen in air brings about combustion. When carbon burns incompletely it forms carbon
monoGide.
.. C+$+s!*!+% +? a!r>
a2 :9@ nitrogen and <8@ oGygen by volume.
b2 ::@ nitrogen and <=@ oGygen by weight.
/. E56,ss a!r>
In practice the theoretical "uantity is not sufficient to ensure complete combustion and
eGtra air has to be supplied. -his eGcess air is known as eGcess air.
>. I&%!*!+%4
$uel must be ignited before it can burn. *aising the temperature of the fuel
to its ignition temperature brings about combustion.
;. -he following factors in efficient combustion are usually referred to as -he three
-A(.
a2 TIME4 It will take a definite time to heat the fuel to its ignition
temperature and having ignited, it will also take time to burn.
b2 TEMPERATURE4 A fuel will not burn until it has reached its ignition
temperature. Preheating the combustion air increases the speed at which this
temperature will be reached.
12 TURBULENCE> -urbulence is introduced to achieve a rapid relative motion
between the air and the fuel particles. -his produces a "uick propagation of the flame
and its rapid spread throughout the fuel.air miGture in the combustion chamber.
?2 1ombustion efficiency4
,aGimum combustion efficiency depends on
c2 %esign of the boiler
d2 $uel used
e2 (kill in obtaining combustion with the minimum amount of eGcess air.
:2 -hermal efficiency of a boiler is measured by the amount of the heat transferred to the
water in the boiler by each 5g of the fuel used.
ARRANGEMENT O4 THE MAIN BOILER>
=). B+!8,r S*r#6*#ra8s4
-he boiler structurals are divided into two parts.
a2 (upporting (tructures4 boilerIsupporting structure consists of a systematic
arrangement of columns stiffened with hori3ontal beams and vertical diagonal
bracings and comprise of low carbon steel material. -he main columns support
the main boiler components vi3. drum, economi3ers air preheaters, burners and
galleries at various levels.
b2 )alleries and (tairways4 )alleries and stairways around the combustion and the
heat recovery areas are provided for approach to the boiler.
.) 4#r%a6,>
A 7oiler furnace is that space under or adjacent to a boiler in which a fuel is burned
and from which the combustion products pass into the boiler proper. It provides a
chamber in which the combustion reaction can be isolated and confined so that the
reaction remains under controlled force. In addition, it provides a support or
enclosure for the firing e"uipment. -he wall construction of the furnace is waterI
cooled walls i.e. the wall is of tube in which water is flowing continuously
/) B+!8,r )r#$>
-he boiler drum forms a part of the circulation system of the boiler. -he
drum serves two functions, the first and primary one being that of separating
steam from the miGture of water and steam discharged into it. (econdary,the
drum houses all e"uipments used for purification of steam after being
separated from water. -he purification e"uipment is commonly reffered to
as the drum intervals.
-he "uantity of water contained in the boiler below the water level is
relatively small compared to the total steam output. Primarily, the drum si3e
is determine by the space re"uired to accommodate the steam separating and
purifying e"uipments. -he steam space provided should be sufficient to
prevent priming and foaming.
,aterial4 -he boiler drum is made of carbon steam plates. -he materials
used should comply with the Indian 7oiler *egulations. 1omparing carbon
steel and alloy steel as material for drum, the carbon steel costs less per ton
of material but the overall weight of drum will be higher because that of
thickness.
DRUM INTERVALS>
%rum intervals are used to separate water from steam and to direct the flow
of water and steam in a manner so as to obtain the optimum distribution of
drum matal temperature in boiler operation.
-he arrangement of drum normally consists of two or more integrated
device, each of which may be "uite different in design and operate on
totally different principles. 'ach stage must have a higher separation
efficiency. -he greater the number of stages of separation,the lower the
re"uired efficiency of each stage .-hus, two stages at 99@ efficiency,three
stages at 9D@ efficiency and siG stages at :D@ efficiency will give similar
results.
Water level gauge is mounted on each end of the steam drum. If water level
goes outside of the prescribed operating limit then the boiler is
tripped.-hus,with increase in pressure,the separation of water from steam by
simple devices become more difficult.It become necessary to use more
efficient apparatus if primary separation is to be achieved in a confined area.
;) E6+%+$!s,r>
-he purpose of the economi3er is to preheat the boiler feed water before it is
introduced into steam drum by recovering heat from the flue gases leaving the
boiler. 'ntering first, the economi3er water is heated to about =D to >D deg 1 below
saturation temperature. $rom economiser the water enters the drum and thus joins
the circulation system. Water entering the drum flows down through the down
comer and and enters ring header at the bottom. It is located in the boiler second
pass below the superheater. -he economi3er is continuous loop type and water
flows in upward direction and gas in the downward direction. All tube circuits
originates from the inlet header and terminate at outlet header which are connected
with the economi3er outlet headers through three rows of hanger tubes.
<)D+9%6+$,rs>
%own comers provide a passage for water from the boiler drum to bottom ring
header. $rom bottom ring header the water goes to water walls for heat absorption
and conversion into steam heating .-o achieve the circulation of water into water
wall 7oiler circulation pumps are provided in down comers.
3)'a*,r9a88s>
Water walls are the necessary elements of the boiler. -hey serve as the means of
heating and evaporating the feed water supplied to the boiler from the economi3ers
via boiler drum and down comers. In large boilers, water walls completely cover
the interior surfaces of the furnace providing practically complete elimination of
eGposed refractory surface. -hey usually consist of vertical tubes membrane and are
connected at the top and at the bottom to headers. -hese tubes receive water from
the boiler drum by means of down comers connected between drum and water walls
lower header. Water walls absorb ;D percent of the heat released by the combustion
of fuel in the furnace, which is utili3ed for evaporation of feed water. -he miGture
of water and steam is discharged from the top of the water walls into the upper wall
header and then passes through riser tubes to the steam drum. -he design and
construction of the water walls depends upon the combustion and steam conditions
and the si3e of the boiler. /rifices installed in the inlet of each water circuit
maintain an appropriate flow of water through the circuit.
2)R!s,r *#-,s>
A riser is a tube through which the miGture of water and steam pass from an upper
water wall header to the steam drum.
A) S#,r H,a*,r>
-here are three stages of super heaterN the first stage consists of hori3ontal superheater of
convection miGed flow type with upper and lower banks located above economi3er
assembly in the second pass. -he upper bank terminates into hanger tubes, which are
connected into the outlet header of the first stage super heater. -he second stage
superheater consists of a pendant platen, which is a radiant parallel flow type. -he third
stage superheater pendant spaced is of convection parallel flow type.
In radiant super heaters heat is absorbed by direct radiation from the furnace and are
generally located at the top of the furnace. (ince the furnace temperature, and therefore the
amount of available heat from radiation, does not rise as rapidly as the rate of the steam
flow, thus the steam temperature drops as the steam flow rises.
1onvection superheaters absorb mainly by the impingement of flow of hot gases around
the tubes. A purely convection superheater has a rising steam temperature characteristic i.e.
the amount of available heat from convection, rise as rapidly as the rate of steam flow.
B)R,h,a*,r>
-he function of the reheater is to reheat the steam coming out from the high pressure
turbine to a temperature of ;>DO1. -he reheater is composed of two sectionsIone is front
pedant section and rear pedant section. -he rear pedant section is located above the furnace
arc and the rear water wall and the front pedant section is located between the rear water
hanger tubes and the superheater platen section.
-he cold reheat is the line from turbine to the boiler and is at a lower than the reheat
line from boiler to the turbine called hot reheat steam. %ue to resistance of flow through the
reheat section, the hot reheat steam is at a lower pressure compared to the cold reheat
steam.
=1)B#r%,rs>
-here are forty total pulveri3ed coal burners arranged on the corners at a height of 8B to
<; meters and twelve oil burners provided each in between corner two pulveri3ed twoIfuel
burner.
-he pulveri3ed coal burners are arranged in such a way that ten mills supply the coal to
burners at > corners, of the furnace. All the no33les of the burners are interlinked and can
be tilted as a single unit from L=D to M=D.
-he oil burners are fed with the heavy fuel oil till boiler load reaches to about <;@.
==)D,s#,rh,a*,rs>
A. A. S#,rh,a*,r D,s#,rh,a*,r> S#,rh,a*,r D,s#,rh,a*,r>
-he superheater desuperheater is fitted between stages > and ;0on transfer pipe2 to control the -he superheater desuperheater is fitted between stages > and ;0on transfer pipe2 to control the
superheated steam at the specified terminal temperature of ;>D superheated steam at the specified terminal temperature of ;>D
o o
1. -he maGimum design 1. -he maGimum design
temperature reduction at the superheater desuperheater is from >>? temperature reduction at the superheater desuperheater is from >>?
o o
1 to =BB 1 to =BB
o o
1. 1.
-he desuperheater comprises a spray no33le shell and associated spray assembly projecting -he desuperheater comprises a spray no33le shell and associated spray assembly projecting
into a section of the superheater steam line. -his section of the steam line forms the into a section of the superheater steam line. -his section of the steam line forms the
desuperheater shell. (team assisted spray no33le assembly provides a fine spray of water desuperheater shell. (team assisted spray no33le assembly provides a fine spray of water
which attemperates the steam passing through the desuperheater. which attemperates the steam passing through the desuperheater.
(pray water for desuperheater is taken from the boiler feed water pump discharge. In
addition, spray water regulating stations are provided further downstream in each line.
B. R,h,a*,r D,s#,rh,a*,r>
-he reheater desuperheater is only brought into use when the reheater outlet temperature
rises above the normal temperature.
-he reheater desuperheater comprises of a spray no33le shell and associated spray no33le
assembly projecting into a section of the steam line between the !P turbine outlet and the
reheater inlet headers. -his section of the steam line forms the desuperheater shell. Water is
fed into the shell from the discharge side of the boiler feed pumps via a reheater
desuperheater spray water regulating station.
When the reheater desuperheater is called into service water is fed via the water tube and
passes through the spray no33le thereby forming a spray which attemprates the steam passing
through the desuperheater and thus decreasing e -he "uantity of water in the boiler drum is
relatively small compared to the total steam output. (o, the drum si3e is determined by the
space re"uired to accommodate the steam separating and purifying e"uipments.
=.) B+!8,r 'a*,r C!r6#8a*!+%s P#$s>
'ach boiler water circulation pump consists of a single stage centrifugal pump on a wet stator
induction motor mounted with in a common pressure vessel. -he vessel consists of three
main parts a pump casing, motor housing and motor covers. -he motor is suspended beneath
the pump casing and is filled with boiler water at full system pressure. &o seal eGists between
the pump and motor, but a provision is made to thermally isolate the pump from the motor.
=/) I&%!*,rs>
!igh 'nergy Arc type electrical igniters are provided which can directly ignite the heavy
fuel oil. An eGciter unit stores up the electrical energy and releases the energy at a high
voltage and short duration. A spark rod tip, which is designed such a way that converts the
electrical energy into an intensive spark. A pneumatically operated retracts mechanism,
which is used to position the spark rod in the firing position and retract to the non firing
position. 'ach discrete spark provides a large burst of ignition energy as the current reaches
a peak value of the order of <DDD amps. -hese sparks are effective in lighting of a wellI
atomi3ed oil spray and also capable of blasting off any coke particle or oil muck on the
surface of the spark rod.
B. 'ATER CIRCULATION SYSTEM>

Water must flow through the heat absorption surface of the boiler in order that it is
evaporated into the steam. In drum type units the water is circulated from the drum
through the generating circuits and back to the drum where steam is separated and
directed to the superheater. -he water leaves the drum through the downcomers at a
temperature slightly below the saturation. -he flow through the furnace wall is at
saturation. !eat absorbed is the latent heat of vapori3ation creating the miGture of
steam and water.
At very a high pressure the density difference between steam and water becomes
progressively less and a point is reached where natural circulation is too slow.&atural
circulation is limited to boiler with drum operating pressure around 8:; kg.cmI<.
-o overcome this forced circulation is employed which uses pumps to speed up the
circulation of the water.


TECHNICAL DATA
Ma!% -+!8,r ;DD,W
Ty, 7alanced %raft ,%ry bottom,(ingle drum,*adiant $urnace,
1ontrolled 1irculation,-angentially $ired,-iltable &o33le.
Ma%#?a6*#r,r ,.( 7!'#01' %'(I)&2
4#r%a6, *y, 1ontrolled 1irculation.
Dr#$
a. /verall length <<D:D mm
b. %esigned pressure <D>.9 5sc.
c. %esigned temperature =??
o
1.
S#,rh,a*,r
a.&umber of stages ? stages
R,h,a*,r
a. &umber of stages = stages
S*,a$ ?8+9 a* MCR
a. (team at final superheater outlet 8:<; -P!
b. (team at reheater outlet 8;=D -P!
'a*,r ?8+9 a* MCR
a. $eed water entering economi3er 8:<;-P!
C+a8 ?8+9 a* MCR =8?.> -P!
S*,a$ r,ss#r, a* MCR ("s6)
A* ?!%a8 s#,rh,a*,r +#*8,* 8:B
A* r,h,a*,r +#*8,* >=.>?
A* r,h,a*,r !%8,* >;.B;
4r+$ )r#$ 89=.;
E6+%+$!@,r !%8,* 89?.?
BOILER AUCILIARIES
MILLING SYSTEM> (
COAL BUNKER4 I
-hese are inIprocess storage silos used for storing crushed coal coming from the coal handling
plant through conveyor belts. -here are ten coal bunkers supplying coal to each mills and are
located at top of the mills to aid in gravity feeding of the coal. 'ach bunker can store coal, which
can be used for 8<hrs.
COAL 4EEDER> (
-he purpose of coal feeder is to transfer coal at a preI determined rate, from coalbunker to the
mill.
-he coal feeder comprises two continuous chains with # sections flight bars mounted between
the chains at every fifth link .-he chains runs on sprockets mounted at each end of the feeder to
given an upper strand movement towards the driven ends and a lower strand movement in the
opposite direction. -he drive shaft is supported on two self aligning bearing mounted in the
Plummer block on support out side the feeder casing, shaft sealing is achieved by the lip seals in
the sealing housing and mounted in board of the bearing to abut the feeder casing.
-he tail sprocket shaft is mounted in adjustable bearing blocks adjacent to the feeder casing with
positioned which allow the feeder chain to be tensioned.
7oth upper and lower strands run over full width carrying plates with the lower strands located
by angle section guides mounted on the feeder wall. -he upper and lower carrying plates and the
inside wall are protected from wear by replace by replaceable stainless steel panels, chains are
kept clean by rubber wiper. $eeder input is achieved by roller chain drive to the conveyor via a
fiGed speed electric motor driving a variable speed gear boG, tor"ue limiter and fiGed out put gear
boG -he electric motor is flanged mounted to variable speed gear boG, coupled to the fiGed
output gear boG by a fleGible coupling and tor"ue limiter. -he principle of operation of coal
feeder is that coal flows from the bunker into the chain feeder via feed hopper and is conveyed to
the mill feed inlet chute, when the feeder is in the operation, the conveyor chain drag a fiGed
head of coal towards the driven ends of the feeder. At the end of the carrying plates the coal falls
through the conveyor onto the bottom plate, where it is picked up by the returning flight bars and
dragged back along the feeder to fall into the mill feed chute.
MILL CHUTE> (
,ill chute trans port coal directly from the coal feeder to its associated mill, in addition an
emergency chute is incorporated to allow coal to be removed from the coal bunker via coal
feeder in the event that outage time is more than one month, or if there is a danger from fire in
the mill chute area, coal feeder, or coal bunker.
'ach mill is provided which transport raw coal from the bunker to the inlet of mill at the desired
rate. -he rate of feeding is controlled by variable speed gear boG . !ere chain type feeder is
present in which continuous chain is moving round sprockets in which a sprocket is driven by a
variable speed %.1 motor and the other sprocket is a return .(procket on this chain ,at different
,( plates are connected which are called as scrapers .-his type chain feeder are called scraper
feeder. -he coal from the bunker falls on a platform which is below the scrapper feeder. When
the scraper moves it will scrap the coal and at the end of platform the coal falls into the
pulveri3er.
PULVERISER MILL>(
-here are ten mills for every ;DD ,W unit located adjacent to the furnace at D m level.
-hese mills pulveri3e coal to desired fineness to be fed to the furnace for combustion .
-he main structure of the pulverisering mill is fabricated from mild steel in three cylindrical
sections, the bottom section 0the mill housing support 2which support the entire unit and
encloses the mill drive gear unit, a center section 0the mill housing2that contains the rotary
grinding element and upper section 0the classifier housing 2comprising an accommodate the gas
loading cylinders of the mill loading gear .A platform around the upper section provide an access
to an inspection door and to the top of the mill routine maintenance and is served by detachable
ladder .
.
PULVERIDERS>
-he pulveri3ser eGclusive of its feeder, consists essentially of a grinding chamber with a
classifier mounted above it. -he pulveri3ing take place in a rotating bowl in which centrifugal
force is utili3ed to move the coal, delivery by the feeder, outwards against the grinding ring 0buil
ring2. *olls revolving on journals that are attached to the mill housing pulveri3e the coal
sufficiently to enable the air stream through the pulveri3er to pick it up. !eavy spring action
through the journal saddles, provide the necessary pressure between the grinding surfaces and the
coal. -he rolls do not touch the grinding rings , even when pulveri3er is empty. -ramp iron and
other foreign material is discharged through a suitable spout. -he air and coal miGture passes
upward the classifier with its deflector blades where the direction of the flow is changed
abruptly, causing the coarse particles to be returned to the bowl for further grinding. -he fine
particles, remaining in suspension, leave the classifier and pass on through the coal piping to the
windboG no33les.

LO' SPEED MILL>
-hese are commonly known as tube ball mills and operate at approGimately 8: to <D
rev.sec.(uch slow speed is essential with these types of mills as otherwise the balls will held
along the rorating surface due due to centrifugal force and no milling takes place.
Advantages of low speed mills4
082. Wearable part which needs replacement between annual overhaulsis only the ball and this
can be done when mill is in operation.
0<2. &o maintenance for long period.
0=2. this mill has no relects and does not give tramp iron problem.
0>2. -here is reverse of fuel within the mill which makes the mill output more stable.
%isadvantages of low speed mills4
082. power consumed per ton of coal pulverised is nearly to that of economic mills.
0<2. -his mill consumes more power.ton coal ground especially when not loaded fully as bulk of
power is consumed in rotating mass of heavy ball charge.
7/W# ,I##4
-he ball mill is one of the most advanced design of coal pulveriser.-he advantages of this mills
are 4
082. lower power consupton.
0<2. *eliability.
0=2. ,inimum maintenance.
0>2. Wide capacity08.: t.hr. to8DD t.hr.2.

MILL TECHNICAL DATA>(
,anufactureIIIIIIIIIIIIIIIIIIIIIIIIII,.( 7!'#
-ype of pulveriser 8DD=G *P
&o. of ,ill . boiler 8D
7ase capacity of ,ill ?B-onnes.!r.
(peed of pulveriser ><rpm
&ormal capacitywith design coal ;<.; -.!r
4ANS
A fan is a device by which the air is made to flow at re"uired velocity and pressure in a defined
path imparting 5.' of its impellers to air.flue gases . -his pressure boost is used to create a draught
in the air and flue gas system. $ans mainly performs two functions4
i. -hey supply air re"uired for combustion in the furnace with re"uired pressure K flow.
ii. -hey evacuate the product of combustion i.e. flue gases into the atmosphere via chimney.
P.A 4a% >(
-he primary air fan supplies heated air to the coal mills to give dry and pulveri3ed coal to
the furnace for efficient combustion.-he P.A fan also supply fresh air to prevent coal mills by
overheating.
-here are two P.A fans per boiler, each fan having pneumatically operated radial guide vanes at
the fan inlet to control the fan output. -he fan impeller is a double inlet, centrifugal wheel with
backward curved plate blades.
Ambient air is drawn into the P.A duct by two ;D@ duty, motor driven centrifugal fans.
-he air from each fan discharges into a hot air crossover duct via a steam air heater. -his duct
eGtends around to each side of the boiler to supply the hot air to mills duct, both of which are
branched to supply hot air to four coal mills.
4.D 4a%>
-he forced draught fan system is provided to supply air re"uired for pulveri3ed coal combustion in
the furnace, air for fuel oil combustion and over fire air to minimi3e &oG production. -he $.% fan
system comprises of two single stage aGial flow, constant speed, and auto variable pitch fans per
boiler. -hese fans provide pressuri3ed atmospheric air to the boiler for combustion. Ambient air is
drawn into the secondary air system by two ;D@ duty, motor driven, aGial flow forced draught
fans with variable pitch control. -he air from each fan discharges into a hot air crossover duct via a
main air heater. -his duct eGtends around to each side of the boiler furnace to form two secondary
air to burners ducts. At the sides of the furnace, each duct split to supply air to two corners, then
split again to supply air to each of the nineteen burner.air no33le elevations in the burner boG.
I.D 4a% sys*,$>
-he induced draught system comprises of three centrifugal double inlet fans per boiler, two
operating and one standby. 'ach fan unit consists of a backward curved plate bladed impeller,
which is driven by an electric motor through a variable speed hydraulic coupling. -he I.% fan
serves the purpose of evacuating the products of combustion or the flue gases in the atmosphere
via chimney. -he flue gases after being cleaned in the precipitators is directed towards the
atmosphere through the chimney.
S6a%%,r a!r ?a% >
(canner fans are installed in the boiler for supplying continuously cooling air to the flame scanner
provided for the flame supervision. &ormally one fan remains in service while the other one
remains available as standby. (canner air fan is centrifugal type. It takes suction from $.% fan
outlet and boosts the pressure further to provide cooling air to the scanners.
S,a8 a!r ?a%>
(eal air fan supplies sealing air, at a pressure higher than that inside the mill, to a brush sealing
around the stem of the coal mill yoke casting to prevent coal dust escaping to atmosphere. -here
are eight seal air fans one per mill to provide sealing air. 'ach fan is a close coupled, electrically
operated, centrifugal fan unit operated as part of the mill operating se"uence, which incorporates
an autoIstart facility.
P#r&, +r 6++8!%& a!r ?a%
-he function of the purge.cooling air system is to provide a continuous supply of clean air to cool
all soot blowers in the retracted position, and to purge each retractable soot blower lance whenever
it is in the retracted position. -here are two fans 0one operational, and one standby2 to provide
purging.cooling air to each of the soot blowers, and also to prevent furnace gas blowIback into the
sealing areas. 'ach fan comprises a close coupled, electrically driven centrifugal fan unit, which
initially, is manually operated but which contains an automatic standby.
<.E8,6*r+s*a*!6 r,6!!*a*+rs
-he ash content in the Indian coal is of the order of =D@ to >D@. When coal is fired in the boiler,
ashes are liberated and about BD@ of ash is carried along with the flue gases. If this ash is
allowed to atmosphere, it is ha3ardous to health. (o, it became necessary to incorporate an
electrostatic precipitator in the path of the flue gases going in the atmosphere. -he electrostatic
precipitators are preferred to mechanical precipitators because they are capable of precipitating
particles from sub micron to large si3es of particles. -he efficiency of the modern '(PAs is of the
order of 99.9@.
In &-P1 *ihand, the gas cleaning plant consists of two '(PAs that operate on the eGhaust gases
from each of the ;DD ,W steam generators. -he electrostatic precipitator consists of a large
chamber, which comprises of parallel rows of sheet type collecting electrodes suspended from
the precipitator casing with wire type discharge electrodes arranged midIway between them. At
the inlet of the chamber, gas distributor screens for uniform distribution of the gases in the
chamber, are provided. -he collectors are connected to earth at positive polarity while the
discharge electrodes are connected to a high voltage dc supply at negative polarity. When dustI
laden gas flows between the electrodes, the corona discharge causes the dust particles to become
charged, the particles then being attracted towards and, eventually, deposited on the collector
electrodes. -his dust falls as the collecting electrodes are continuously rapped through a rapping
system and is collected into the pyramid type hoppers, located beneath each collecting
electrodes, from where it is removed by the ash handling system.
3.A!r h,a*,rs
Air heater is a heat transferring device in which air temperature is raised by transferring heat
from flue gases. Air heaters are capable of reclaiming heat from the flue gases at low
temperature levels and thus reducing the amount of heat rejected to chimney. -his results in
increasing the boiler efficiency. $or every <D
D
1 drop in flue gas eGit temperature, the boiler
efficiency increases by about 8@. In &-P1 *ihand, recuperative type of air heaters is mainly
used. In recuperative air heaters, the heating medium i.e. flue gases flows through a closely
packed matriG structure and then air is passed through the matriG to pickup the heat. -here are
two recuperative type of main air heaters for heating up the air from fans, two recuperative type
air heaters for mill air heating.
S*,a$ a!r h,a*,rs
-his type of air heaters does not utili3e the heat from the boiler flue gases and so does not affect
the boiler efficiency. -hese are generally used during starting when the flue gases entering the
regular air heater is low and hence further heat eGtraction is not possible and low temperature
corrosion prevails. -here are two main steam air heaters and two mill air heaters. (team air
heaters comprises of round tubes carrying steam to be condensed. -hese heaters are provided
with air eGtraction system so that air entering with steam will not lock and prevent the operation
of air heater. In addition, the outlet temperature of air can be controlled easily.
2. 4!r!%& sys*,$
&-P1 *ihand has direct firing system. In this system, a controlled "uantity of crushed coal is fed
to each bowl mill 0pulveriser2 by its respective feeders and primary air is supplied from the
primary air fans which dries the coal as it is being pulveri3ed and transports the pulveri3ed coal
through the coal piping system to the coal burners. In this system, burners are set at each corners
of the furnace and are directed to strike the outside of an I,A)I&A*+ 1I*1#' at the centre of
the furnace. 7ecause the streams of fuel strike each other, eGtremily good miGing is obtained.
(ince the body of the flame produced is given a rotary motion is leads to a longer flame travel
and gases spread out and fill the combustion.
-here are ten pulveri3es out of which eight are used and two remains in standby. -he raw coal
feeders supply :> -P! of coal to each mill.
-he pulveri3ed coal and air discharged from the coal burners is directed towards the center of the
furnace to form firing circle. -here are =< tilting, tangentially fired coal burners fitted at the four
corners of the boiler at eight elevations.
-he secondary air heating system supplies secondary air for combustion in the furnace around
the pulveri3ed coal burners and through auGiliary air compartments directly adjacent to the coal
burner compartments. -here are 8? airIatomi3ing ignitrons per boiler, which initially ignite the
coal and air miGture. Above a predictable minimum loading condition, the ignition becomes selfI
sustaining. 1ombustion is completed as the gases spiral up in the furnace.
SOOT BLO'ING SYSTEM
I%*r+)#6*!+%
In *h(-PP, soot deposited in various regions of boiler is removed with the help of soot
blowers, which utili3e steam as the main working medium. -his part is mainly concerned
with the eGisting soot blowing system and the problems arising in the system during
operation.
-he removal of soot is very necessary for the efficient working of the plant. -his is because
soot acts as an insulator for the heat transfer taking place between the flue gases and
water.steam inside the tubes. /n the other side, it increases the metal temperature of
superheater and reheater tubes located inside the boiler. -his temperature increase may cause
damage of the tubes resulting leakages across the tubes. Which, in turn affect the working of
the boiler.
(o, regular soot blowing is very necessary in the boiler. (imilarly, soot is also deposited on
the air preheater baskets, which causes plugging of the baskets. Also in case of oil firing
during initial lightIup unburnt oil may deposit in baskets. -his deposited oil may cause fire
ha3ard in air heater. -o avoid these problems soot blowing is done in air preheater also.
S++* -8+9!%& r+6,ss>
-he complete soot blowing process can be divided into following three major se"uential parts4
A. S$%& '!() *+!,-..I -his part of the process step checks the close status of all the
valves.
7. W/+0 %* *+!,-..I In this step the valves according to the selected blower group open
to provide hot steam to the selected blower group at certain pressure level.
1. B1!(2)3 *+!,-..I In this se"uence actual blowing of steam takes place. -he blower
pairs under currently selected group when comes in to operation carries the steam
inside the boiler and continues to blow till it returns to its park position.
S*,a$ -8+9!%& s6h,$,>
When blowers go inside the boiler they carries steam, which is made available to the blowers
through the section valves dedicated for the blower group. -hese section valves are all
motori3ed and their positions are sensed by their end limit switches.
Falves are classified in four categories according to their operational involvement. -hey are
listed as follows4
a2 ,ain steam supply valves.
b2 (team pressure control valves.
c2 (ection valves.
d2 %rain valves.
-he main steam supply for soot blowing is obtained from two alternative sources each isolated
by a separate motori3ed isolating valve. /nly one source can be selected at a time. &ow, this
steam supply is distributed to four sections of the boiler and each section is isolated by a
motori3ed section valve. %own stream of which a pressure switch monitors the steam pressure.
-he air heaters can be cleaned using an auGiliary steam supply. -his supply is used eGclusively
for the air heater soot blowers when the air heater is re"uired to be cleaned during start up of
the boiler. -he auGiliary supply is connected downstream of the section valve, which remains
closed when this source is being used. -he drainage pipe work is isolated by a number of
motori3ed drain valves.
L+6a*!+% +? S++* B8+9,rs>
-he blowers are divided into groups, numbered from 8 to 9. )roup 8 to > comprises of wall
blowers and group ; to 9 comprises of long retractable soot blowers. -he soot blowers within
each group are listed in pairs, with an odd numbered soot blower paired with an even
numbered soot blower.
'a88 B8+9,r>
Presently there are BB wall blowers, which are numbered from 8 to BB. All wall blowers are
located at four levels, so grouped as groupI8, groupI<, groupI= K groupI>, of first pass of
boiler each having << blowers. )roupI8 is below furnace 3one and other three are above
furnace 3one.
L+%& R,*ra6*a-8, S++* B8+9,r>
#*(7s are kept in #!( and *!( of the boiler. /dd numbered #*(7s are kept in *!( and
even numbered #*(7s are kept in #!(. With an eGception of group ?, all soot blowers in a
particular group are operated in synchronous pairs in an automatic se"uence i.e. an odd
numbered soot blower with an even numbered soot blower
#*(7s are mainly used to penetrate between the tube banks of the economi3er, superheater
etc.It consists of a fabricated boG casing, steam lance tube, steam feed tube, steam isolating
valve, traverse and rotary chains, etcP
Whenever the signal to operate the soot blower is given from the control room, an electric
motor drives the traverse reduction gearboG from its parked position, at a preset distance the
steam isolating valve opens to allow steam to flow through the feed tube and out through the
lance tube no33les. -he pattern of the steam jet from the no33les is helical with a different pitch
on the inward stroke to that on the outward stroke. At about midIstroke a feed tube support
rises to abut the feed tube preventing sagging.
Whenever the eGtent of the stroke has been reached, a reverse limit switch is actuated causing
the main gearboG.lance tube to reverse and return to its parked position engaging the stop limit
ready for the neGt operation, having reIset the feed tube support mechanism and isolated the
steam isolating valve.
An air scavenge valve is fitted to the steam isolating valve which prevents the ingress of boiler
gases into the valve chest and provides a positive air flow when the soot blower is in the
parked position.
Air is also provided for the wall boG to prevent gas leakage from the boiler.
SOOT BLO'ER ARRANGEMENT
$*/&- WA## *'A* WA##
8<= 8<>
8<; 8<?
WA## %'(#A))'* AI* !'A-'* 7#/W'*
#/&) *'-*A1-A7#' (//- 7#/W'*
PP8 PP< PP= PP> PP; PP?
8 < = > ; ?
<= <> <; <? <: <B
>; >? >: >B >9 ;D
?: ?B ?9 :D :8 :<
8< 8= 8> 8; 8? 8:
=> =; =? =: =B =9
;? ;: ;B ;9 ?D ?8
:B :9 BD B8 B< B=
STEAM TO MECHANICAL PO'ER
INTRODUCTION
A thermal power plant is based upon the principle of conversion of heat energy into mechanical
energy. $or this conversion of energy a power plant re"uires a turbo machine. A turbo machine
is a power producing thermodynamic machine. In order to function, a turbo machine re"uires a
suitable working fluid, a source of highIgrade energy and a sink for lowIgrade energy. In a
thermal power plant water is used as a working fluid and it is converted into steam. A steam
turbine is a device that converts heat energy of the steam coming from the boiler into the
mechanical energy of shaft rotation. &-P1 *ihand has four ;DD ,W units. 'ach unit has one
steam turbine. $or large turbo machines, multicylinder designs are used. -he number of cylinder
depends on the terminal conditions of steam and speed of rotation. -he turbine with a number of
cylinders on a single shaft is described as a H-andem compound machineA. &-P1 *ihand is a
fossilIfired power station using a typical turbine of ;DD ,W output in each unit. 'ach of the two
turbines consists of a single flow !P, a double flow IP and two double flow #P turbines
0cylinders2 coupled to the generator shaft.
'ach section of steam turbine consists of a rotor from which project several rows of closely
spaced blades. 7etween each row of moving blades there is a row of fiGed guide vanes 0blades2
that projects inward from circumferential housing. -he vanes are carefully shaped to direct the
flow of steam against the moving blades at some angle and at a high velocity that will maGimi3e
the energy conversion. -he crossIsectional diameter of a turbine section increases continuously
and so the steam eGpands. In this process the temperature and pressure of the steam decreases
and volume increases continuously. -he #P section has the largest crossIsectional diameter,
whereas the !P has smallest crossIsectional diameter. (eparate stop valves and governing valves
are provided to control the steam inlet and outlet from the turbines.
-he main auGiliaries of a steam turbine are the rotor, blades, guide vanes, casing, bearings
and couplings, bolting, steam chests, valves and critical piping.

INTRODUCTION TO <11 M' PO'ER PLANT
BOILER>
-he boiler is a radient, controlled circulation drum, dry bottom type unit. -he boiler units are
designed for the following terminal conditions 0mcr24
'vaporation a2(! outlet 4 8,:<; t.hr
b2*! outlet4 8,;=D t.hr
Working pressure after stop valve48:B kg.cmI<
(team -emperature at (! outlet 4;>D deg 1
(team -emperature at *! Inlet 4=>>.8 deg 1
(team -emperature at *! Inlet 4>;.B; kg.cmI<
(team -emperature at *! Inlet 4>=.=? kg.cmI<
$eed Water -emperature at '1/ Inlet4<;? deg 1
$urnace %esign Pressure 4 L.I ??D mm wc0g2
-he boilers are of single furnace design,circulating pumps to provide assisted circulation.
'ach 7oiler corner is fitted with tilting tangential burner boGes comprising for high energy
ignitors, four lightIup heavy oil fired burners and eight pulveri3ed coal burners. -he angle of
tilt from the hori3ontal is about M=D deg to L=D deg. $eed water to the boiler passes through
!P feed heaters into the economi3er and then to the steam drum from where it flows into the
suction manifold and furnace wall circuits via the three boiler circulating pumps, returning to
the steam drum as a water.steam miGture.-his miGture is separated into three stages and first
two stages are incorporated into the turbo separators and the final stage takes place at the top
of the drum just before the steam enters the connecting tubes comprising of first stage
superheating . within the steam circuit there are a further four stages of superheating, making
five in total. -here are also three stages of reheat. superheater temperature control is provided
by spray attemperation situated in the connecting link between the superheater low
temperature pendant outlet header and the superheater division panel inlet headers.
Pulveri3ed coal system -he system for direct firing of pulveri3ed coal utili3es bowl mills to
pulveri3e the coal and a tilting tangential firing system to admit the pulveri3ed coal together
with the air re"uired for combustion0secondary air2 to the furnace.
As crushed coal is fed to each pulveriser by the feeder,primary air supplied from the primary
air fans which dries the coal as it is being pulveri3ed the transports the pulveri3ed coal
through the coal piping system to the coal no33les in the wind boG assemblies.
-he pulveri3ed coal and air discharged from the coal no33les is directed towards the center of
the furnace to form firing circle.
Primary air system
-he primary air draught plant supplies hot air to the coal mills to dry and convey pulveri3ed
coal to the burners.
-he P.A system comprises two P.A. fans,two steam coil air preheaters 0(1AP!2 and two
regenerative air preheaters.'ach fans, which is of sufficient rating to support ?D@
,1* load,discharges through a (1AP! into a common bus duct that has four outlets,two
directing air into the primary air preheater for heating, two direct cold air straight to the
pulveri3ed mills.
(econdary air system
-he secondary air draught plant supplies the balance of air re"uired for pulveri3ed coal
combustion, air for fuel oil combustion, and overfire air to minimi3e the production of nitrous
oGide0&/J2.
-he secondary air system,comprises two forced draft 0$.%.2 fans, two steam coil air preheaters
0(1AP!2 and two regenerative type secondary air preheaters.
$lue gas handing system
-he flue gas handling plant draws the hot flue gases from the furnace and discharges, them to
atmosphere through the chimney. %uring its passage to the chimney. %uring its passage to the
chimney, flue gas is passed through a feed water economi3er and four regenerative air preheaters
to improve boiler efficieny, and through four electrostatic precipitators to keep dust emission
from chimney within prescribed limits.
soot blowing system
/n load,gas side cleaning of boiler tubes and regenerative air heaters is achieved using 8<?
electronically controlled soot blowers which are disposed around the plant as follows4
BB I furnace wall blowers 4 steam
=> I long retractable soot blowers 4 steam
> I Air heater soot blowers primary
and secondary air heaters 4 steam
-6*7I&'
GENERAL DESCRIPTION
-he turbine is a reaction, condensing type, tandem compound with throttle governing and
regenerative system of feed water heating. It is coupled to directly to the generator. -he turbine
is suitable for sliding pressure operation to avoid throttling losses at partial loads. -he turbine is
a single shaft machine with separate !P, IP and #P turbines. !P turbine is a single flow cylinder
where as IP and #P are double flow cylinders. (team flow to !P -urbine is controlled by four
combined main stop and control valves by a simple throttle governing system. /n the two
eGhaust lines of !P turbine, swing check valves are provided which prevent hot steam from the
reheater flowing back into the !P turbine. -he hot reheat steam is admitted to the IP turbine
through the four combined stop and control valves. IP eGhaust is connected to the #P turbine by
cross over pipes without valve sat diametrically opposite points.
HP TURBINE
-he outer casing of the !P turbine is of the barrel type and has neither aGial nor a radial flange.
-he guide blade carrier is aGially split and kinematic ally supported. -he space between the outer
casing and the inner casing is fed from admission steam to !P turbine. -his steam is drained
through !P casing drain during start up which promotes "uicker heating of inner casing which
results in lesser problems of differential eGpansion. -he inner casing is attached in the hori3ontal
and vertical planes in the barrel casing so that it can freely eGpand radially in all directions and
aGially from a fiGed point. -he !P turbine is provided with a balance piston in the admission
side to counter act the aGial thrust caused by steam forces. !P turbine is provided with 8B stages
of reaction blades.
IP TURBINE
It is of double flow construction and consists of two casings. 7oth are aGially split and inner
casing kinematically supported and carries the guide blades. -he inner casing is attached to the
outer casing in such a manner as to be free to eGpand aGially from a fiGed point and radially in all
directions. IP turbine is having 8> reaction stages per flow. 'Gtraction steam to high pressure
heater no.; and deaerator are taken from IP turbine and the IPIeGhaust respectively.

LP TURBINE

-he casing of the double flow #P cylinder is of threeIshell design. -he shells are aGially split and
of rigid welded construction. -he inner shell taking the first rows of the guides blades, is
attached kinematically in the middle shell. Independent of the outer shell, the middle shell, is
supported at four points on longitudinal beams. -wo rings carrying the last guide blade rows are
also attached to the middle shell. #P turbine is provided with ? reaction stages.flow.

TURBINE SYSTEM
HP STEAM SYSTEM
-he high pressure and temperature steam is piped from the boiler stop valves to the steam inlet
ends via two steam legs or steam pipes. -hese two steam pipes are further branched into four
subIbranches. -hese branches endIup into four inlet valves of four hori3ontally arranged steam
chests, two on each side of the !P cylinder.
'ach of the steam chest contains a !P emergency stop valve and a !P governing valve arranged
coIaGially. -he !P stop valve is a crucial valve and is used only during emergency conditions.
(team leaves the governor valves through branch pipes to the top and bottom inlet tee pieces on
the !P cylinder. -he steam chest assemblies are mounted on the foundations close to the !P
cylinder. 'ach stop and governor valve is opened by a hydraulic operating gear and closed by
two coil springs.
IP STEAM SYSTEM
-he steam eGpands in the !P turbine and is fed into the reheater section of the boiler. $rom
reheater section of the boiler the steam is piped into the steam inlet ends of the intermediate
pressure turbine through four inlet pipes.
-here eGists four steam chests two on each side of the IP cylinder. 'ach steam chests contains an
IP intercept stop valve and an IP governing valve arranged
coIaGially. (team leaves the governor valves through branch pipes to the top and bottom tee
pieces on the IP cylinder.
-he opening and closing mechanism of the valves of the IP turbine is similar to that of the !P
stop valves and governing valves.
LP STEAM SYSTEM
IP steam after eGpansion is eGhausted through four stub pipes, two at each end at the top half of
the IP cylinder, and is ducted to the two #P cylinders by IP.#P crossover pipes. -he volume of
steam at the IP outlet is enormous and to handle such an enormous volume of steam two #P
turbines are provided.
-he steam from each of the #P turbines after eGpansion is fed into the condensers mounted
below the #P turbines. In the condensers the steam outlet from the #P turbines is condensed to
give condensate, which further undergoes a cyclic process to give feed water for the boiler input.

!ere, under slung condensers with BDD inclined tubes are used, using a connecting duct between
the turbine outlet flange and condenser inlet flange. As the condenser tubes are normally much
longer than the width of the turbine casing, so this duct is trape3oidal in shape.
-he heat energy carried by the steam is converted into mechanical power, which results into the
shaft rotation. -he turbine shaft is coupled with the generator shaft.
-his rotary motion of the generator shaft is converted into electrical power by the generator. -he
power output from the generator is at low voltage level of <D kFQ. -his low voltage is boosted to
high voltage level of >DD kF to reduce the transmission losses
.
TURBINE AUCILIARIES
T#r-!%, 6as!%&
(team turbine casings are the massive steel casings that encase the internal stationary and
rotating components of the turbine. -urbine casings have two critical functions4
a2 1ontaining the steam pressure and
b2 ,aintaining support and alignment of the internal components.
-here are generally two casings4
!) O#*,r 6as!%&
-he outer casing is divided on the hori3ontal centerline into top and bottom half casings. 7oth
the halves are bolted together with bolts and cap nuts at their hori3ontal joint flanges.
!!) I%%,r 6as!%&
-he inner casing is subjected to the highest temperatures and pressures, is also divided at the
hori3ontal centerline into top and bottom half casings, which are bolted together in a similar
manner at their hori3ontal joint flanges.
-he inner casing is supported within the outer casing in such a manner as to maintain proper
alignment and allow thermal eGpansion. 1racking of the casing can lead to steam leaks and,
in eGtreme situations, to bursting. 1racks in casings are typically located at the inlets of !P
and IP turbine sections, where the local thermal stresses are higher.
T#r-!%, B8a),s
7lades are the single most costly parts of the turbine. -he function of the turbine blades is to
convert the available heat energy carried by the steam into mechanical energy. 7lades fitted in
the stationary part are called Hguide bladesA or Hno33lesA and those fitted in the rotor are called
Hmoving bladesA.
S*,a$ 6h,s*s a%) 7a87,s
'ach of the !P, IP, #P cylinders of the turbine has four steam chests two on each side of the
turbine. (team chests are the pressure vessels or steam carrying spaces, which performs the
function of both carrying as well as transferring the steam at high pressure and high temperature
via valves into the turbine cylinders. -hese steam chests comprises of a stop valve and a
governing valve. -he steam from the superheaters outlets is admitted to the !P steam chests via
four !P steam mains. -he steam from the steam chests is admitted to the !P turbine steam inlet
pipe through the emergency stop valves and the associated governing valves which are housed in
steam chests. After eGpansion in the !P turbine the steam is fed into the reheater and then to IP
steam chests, through !P turbine steam outlet pipe. -he steam from IP steam chests is fed into
the IP turbine via IP stop valve and IP governing valves and then to #P steam chests.
S*+ 7a87,s
-he stop valves are emergency valves placed in the steam chests and are provided in the main
steam line. -he purpose of the emergency stop valves is to cut off the steam supply during
periods of shutdown and to provide prompt interruption of steam flow through the turbine
cylinders in an emergency trip.
&ormally, these valves are kept open fully but during emergencies these valves are fully closed
08DD@2. %uring such conditions, the plant is producing no power because no input is given to the
turbine.
G+7,r%!%& 7a87,s
-he governing valves are also situated in the steam chests. -hese are the control valves i.e. they
provide accurate control of the steam flow rate into the turbine, thus controlling the generator
load when the machine is synchroni3ed to the grid.
!P governing valves are the most important valves. -hey controls the amount of power
produced by the plant or unit. $or a unit producing ;DD ,W power, the !P governing valve
opening is kept as >DI>;@ of the total valve opening.
T#r-!%, O!8 Sys*,$>
/I# (6PP#+ (+(-',

-he oil supply system fulfills the following functions4
a2 #ubricating and cooling the bearings.
b2 %riving the hydraulic turning gear during interruptions to operation, on start up and shut
down R8S.
c2 Eacking up the shaft at low speeds 0turning gear operation, start up and shut down2 R8,<S.
OILSYSTEM
6nder normal operating conditions, the main oil pump 082 situated in the bearing pedestal and
coupled directly to the turbine shaft draws oil from the main oil tank 0<?2 and conveys it to the
pressure oil system.
-he suction of the main oil pump is aided by two injectors 0<;2. -he injectors produce pressure at
the suction connection to the main oil pump sufficient for all types of operation. -his guarantees
that the main oil pump takes over the safe supply of oil and cavitations that could occur due to
greater suction heads are avoided. -he amount of oil re"uired for driving is eGtracted from the
pressure oil circuit and adjusted by means of the throttle 0=82.
-he oil for the turning gear 0:2 is also eGtracted from the pressure oil system. /il is admitted to the
no33les by opening the shut off valve 0==2. -he pressure oil is cooled in the oil coolers 0892 and
reduced to lubricating oil pressure in the throttle 08B2. -he throttle is adjusted on the initial startI
up. -he amount of oil re"uired for each bearing is adjusted on start up by means of the oil throttles
08;2.
4ULL LOAD AUCILIARY OIL PUMPS
%uring turning gear operation and start up and shut down operation, one of the two three phase
a.c., full load auGiliary oil pumps 0<<,<>2 supplies the pressure oil system and takes over the
function of the main oil pump when this is not in operation because the turbine is running too
slowly.
-he full load submersible auGiliary oil pumps are situated on the oil tank 0<?2 and draw in oil
directly.
EMERGENCY OIL PUMP
When main and full load auGiliary oil pumps fail, the lubrication supplies oil directly to the
lubricating oil line, by passing the oil cooler and thus preventing damage to the bearing shells.
OIL RETURN SYSTEM
-he lubricating oil from the bearings is returned to the main oil tank via a header.
ECTRACTION O4 OIL VAPOUR
-he main oil tank is designed to the air tight. -he eGtractors 0<B2 produce a slight vacuum in the
main oil tank and the bearing pedestals to draw off any oil vapour.
4ILTERS
/il for the thrust bearing is passed through the dupleG oil filter which can be switched over and
cleaned during operation.
MAIN OIL TANK
-he main oil tank contains the oil necessary for the lubricating and cooling of the oil bearings and
for the lifting device. It not only serves as a storage tank but also for deaerating the oil. -he
capacity of the tank is such that the full "uantity of oil circulated not more than B times per hour.
-his result in a retention time of approG. : to B minutes from entry into the tank to suction by
pumps. -his time allows sedimentation and detainment of the oil.
/il returning to the tank from the supply system first flow through a submerged inlet into riser
section where the first stage deaeration takes place as the oil rises to the top of the oil tank. /il
overflows from the riser section through the oil strainer into the adjacent section of the tank where
it is then drawn off on the opposite side by the suction pipe of the oil pumps. ,ain oil tank has the
following mountings4
8. A1 auGiliary oil pump
<. %1 emergency oil pump
=. (haft lift oil pumps
>. /il injector
;. /il vapour eGtractor
?. /il level indicator
:. (onar level M limit switch
-he main oil pump is situated in the front bearing pedestal and supplies the entire turbine with oil
that is used for bearing lubrication, cooling the shaft journals and as primary and test oil. -he main
oil pump is driven direct from the turbine shaft via the coupling. -hese pump also convey oil in the
suction branches

MAIN OIL PUMP 'ITH HYDRAULIC SPEED TRANSMITTER
-he main oil pump is situated in the front bearing pedestal and supplies the entire turbine with oil
that is used for bearing lubrication, cooling the shaft journals and as primary and test oil. -he main
oil pump is driven direct from the turbine shaft via the coupling. -hese pumps also convey oil in
the suction branches of the main oil pump for oil injectors that maintain a steady suction flow to
main oil pump.
!ydraulic speed transmitter operates on the same principle as centrifugal pump impeller. -he
variation of the pressure in the primary oil circuit due to a speed variation serves as a control
impulse for the hydraulic speed governor. -he hydraulic speed transmitter is supplied with control
oil supplied from the control e"uipment rack. -he suction of the pump is always flooded and hence
maintains an uniform suction pressure.
AUCILIARY OIL PUMP
-he auGiliary oil pump is a vertical one stage rotary pump with a radial impeller and spiral casing.
It is fiGed to the cover of the oil tank and submerges into the oil with the pump body. It is driven
by an electric motor that is bolted to the cover plate of the main oil tank. -he pump shaft has a
sleeve bearing in the pump casing and a grooved ball bearing in the bearing yoke. -he bearings are
lubricated from the pressure chamber of the pumpN the sleeve bearing via a bore in the casingN the
grooved ball bearing via lube line.
DC BEARING OIL PUMP
-his is a vertical, centrifugal submerged type and serves for lubrication and cooling of the bearing
during emergency conditions when one of the other pump fails. -his is driven by a %.1. motor.
SHA4T OIL PUMP
-he lift oil pump is selfIpriming screw spindle pump with three spindles and internal bearings. -he
pump supplies the oil to lift the turbine rotor at low speeds.
OILVAPOUR ECHAUSTER
-he function of oil vapour eGhauster is to produce a slight negative pressure in the main oil tank
and in the bearing casing and thus draw off the oil vapour.

OIL COOLER
$unction of oil cooler is to cool the lubricating oil supplied to the bearing of the turbine. /il
cooler consists of the tube nest, the inner, outer shell and water boGes. -he tube nest through which
the cooling water flows is surrounded by the oil space formed by the outer shell. -he oil is to be
cooled enters the oil cooler and flows to the inner shell. -his shell supports the large baffle plates,
which are provided with an opening in the center. 7etween every two large plates there is a small
intermediate plate is smaller in diameter than the inner shell and leaves an annular gap. -his
arrangement serves to achieve a cross flow pattern forcing the oil flowing to the outlet branch to
flow through the middle of the large plates, while passing round the edge of the short ones.
T#r-!%, &8a%) s,a8!%& sys*,$>
!PI-urbine, IPI-urbine and #PI-urbine gland leak off are connected to seal steam
header and vapour eGhauster system. Initially gland steam re"uirement for all the three cylinders
is met by supplying auGiliary steam to the seal steam header and the header pressure is
maintained by the seal steam control valve. When the unit load is raised above =D to =;@ !P K
IPIglands start supplying gland leak off steam to the header to the re"uirement of #PIglands.
7eyond >D@ load, no auGiliary steam is re"uired. /nce the self sealing steam takes place, then
seal steam header pressure is maintained by opening the leak of steam control valve to the
condenser.
)land steam header is provided with a motor driven drain valve which helps to raise the gland
steam temperature during start up. -his drain valves normally remains open till the gland steam
temperature to #P gland increases beyond 8;DT.
CONDENSATE 'ATER SYSTEM>
-!' P6*P/(' /$ -!I( (+(-', I( -/ (-/*' A& A%'U6A-' U6A&-I-+ /$
%',I&'*A#IV'% WA-'* -/ ,''- -!' ,A5' 6P *'U6I*','&-( $/* &/*,A#
1+1#' $#61-6A-I/&( A&% $/* A7&/*,A# /P'*A-I&) 1/&%I-I/&( W!'&
(6PP#+ /$ %',I&'*A#IV'% WA-'* I( I&-'**6P-'%.
-his system will transfer condensate to and from storage tanks as to satisfy main cycle
re"uirements. -he main cycle flow and thermodynamic re"uirement is maintained by transporting
the condensate collected in the condenser hotwell through various stages of feed water heating and
other e"uipment to the deaerating feed water heater.
-he condensate eGtraction pumps normally deliver the condensate through the three low pressure
feedwater heaters, the deaerating feed water heater to the deaerating storage tank. -he low pressure
feed water heaters receive eGtraction steam as it passes through feedwater heater. -he deaerating
further preheats the condensate prior to its entry into the deaerating storage tank. -he deaeratig
feed water heater is warmed by eGtraction steam during the normal operation and auGiliary steam
K cold reheat steam are utili3ed as the heat source during start up and shut down condition.
-he normal make Mup to the condenser is supplied from deminerali3ing plant through the makeup
pumps. &ormally, on low level in the condenser hotwell, condensate will flow from the condensate
storage tank to hotwell by static head in the tank and differential pressure due to the condenser
vacuum, however, this flow will be inade"uate, the condensate, transfer will supplement the flow.
-his makeup is sprayed into the steam space above the tube bundles.
-he condenser hotwell is condensate collection vessel, integral with the condenser shell, and
located in a pit below the ground floor. 1ondensate collected in the hotwell is pumped by =W;D @
condensate eGtraction pumps to the feed storage tank through feedwater placed in series. -wo lines
from hotwell, make a common header where from three lines are connected at the suction of three
condensate eGtraction pumps.
-he suction piping to the pumps is vented back to the condenser, to insure that the nonIoperating
pumps stays completely flooded. -hese vent lines include manual valves on the vent for each
pump.
A minimum flow 0=;D -.hr2 recirculation line for each pump is provided, returning to the
condenser via a flow control valve and a locked open shut off valve.
-he shaft seals of these pumps are the waterIinjected type fed from a header to prevent the
suction of air, particularly the pump that is not operating while the condenser is under vacuum.
C+%),%sa*, E5*ra6*!+% P#$>
-he function of 1ondensate eGtraction pumps is to pump out the condensate to the deaerator
through gland steam cooler, and #P heaters. -he steam from the #P cylinders eGhausts into the
condenser shells where it is constrained to flow across the water tubes, through which cooling
water is circulated.
-he steam condensed on the tubes drain to the bottom of the shell .-he condensate is retained in
the condenser shell bottom by means of the condenser level control valve. -he water in a
condenser provides a head of water for the condensate eGtraction pump to suppress cavitations in
its suction impellers.
-here are two 8DD@ duty eGtraction pumps, one remains in duty and one remains stand by. With
all the necessary instruments such as suction and discharge valve isolating and dump valves to
insure efficient operation.
-he thrust bearings in the driving motors have temperatures sensor, which can trip the motors
automatically.
-he pump discharge the condensate via the gland steam condenser and the condensate polishing
plant to the #P feed heating system.
A!r E5*ra6*!+% P#$>
-he function of the air eGtraction pump is to raise and maintain the vacuum conditions in the
turbine main condensers, and to remove air and other nonIcondensable gases vented to the
condenser from various parts of the turbine and feedwater heating system.
G8a%) s*,a$ 6+%),%s,r
An automatic turbine gland sealing system is used to prevent the escape of steam into the turbine
hall, where it would condense on the walls and the plant.
It also prevents the ingress of air at the rotor ends of all the turbine cylinders. -his is done by
using the gland steam condenser.
-he function of the gland steam condenser is to maintain a subIatmospheric pressure at the
outermost leakIoff belt of the glands and thereby prevent the leakage of steam from the glands
into the turbine hall.-he gland steam condenser condenses the steam from the steam. air miGture
drawn from the outer pocket of the gland. -his heat given by the steam is absorbed by the
feedwater. 1ondensate formed in the shell drains to the gland steam condenser drain tank. -his is
again recirculated back to the condensers.
Dra!% 48ash C+%),%s,r
-he drain flash condenser receives heater drip or drain water from #P heaters. When the drain
water enters the flash condenser through the disperses, steam is flashed off. -his steam is drawn
into the tube nest where it condenses and cascade to the bottom of the shell. -he resulting drain
water is delivered to the main condenser.
-he water side of the %$1 is of the conventional to pass surface type in which
the feed water flows through the tube and steam passes over them. -he vessel comprises a tube
nest, a shell, an inlet and an outlet water boG. -he water boG has a dished end and incorporates
the feed water inlet and outlet connections. A flanged branch on the water boG is fitted with a
davit type hinged cover to give access to the tube bores.
A center plate and an end plate fitted with two stiffeners form a diversion plate, which
separates the incoming, and outgoing flows .-he end plate carries a cover, which is located and
bolted between the stiffening ribs.
-he %$1 is mounted on steel work on four attachment points at the water boG
bonded to upper and lower mild steel bearing plates.
B+!8,r 4,,) P#$s>
7oiler feed pumps are an important part of any boiler operation. -hey control the amount of
water fed to the boiler and the manner in which it is fed.
C,%*r!?#&a8 I 1ontinuous
T#r-!%, I Intermittent
In order to properly select a boiler feed pump five key points must be considered4
'!88 *h, #$s +,ra*!+% -, 6+%*!%#+#s +r !%*,r$!**,%*E
-his is an operational "uestion and is often answered by the type of level control found on the
boiler that the pump will be servicing. As a general rule of thumb, boilers with a capacity of
8D,DDD lbs..hr. or less utili3e a float type switch that starts and stops the boiler feed pump to
satisfy a predetermined water level within the boiler. -his is a classic intermittent operation.
7oilers with capacities eGceeding 8D,DDD lb..hr. typically employs a modulating feed water
regulator and will continuously feed water to the boiler at various rates depending upon the water
level in the boiler.
7y knowing which operation you are to satisfy, you can determine which pump design is best
suited for your application. As a general rule of thumb a turbine pump is used in an onIoff
situation and a centrifugal pump is used for continuous operation. 7ut remember, this is a
general rule and is some cases a centrifugal could be used for an onIoff application and a turbine
for continuous.
'ha* !s *h, *,$,ra*#r, +? *h, 9a*,r -,!%& #$,)E
It is also important to know the temperature of water you intend to pump. ,ost pumps can
usually handle <8;$ to <=D$, other pumps are available that can handle higher temperatures by
using eGternal waterIcooling. 5eep in mind that a deaerator pump must be able to handle higher
temperatures because they operate at a ; psi or <<:$.
'ha* !s *h, r,F#!r,) 6aa6!*yE
!ow much water you intend to pump is dependent upon the evaporation rate of the boiler the
pump will service. A safe figure for an onIoff application would be < times the evaporation rate
of the boiler. With a modulating level control, a factor of 8.= times the evaporation rate plus
recirculation is recommended.
'ha* !s *h, ),s!r,) )!s6har&, r,ss#r,E
When you pump directly into the boiler you will need to overcome the pressure in the boiler as
well as any piping losses. +ou can chose the right pump by looking at the pump curves to
determine which will accomplish this task. (hould you have a modulating valve in the discharge
line, the minimum you will need to add to the boiler operating pressure will be <D to <; lbs.
,ake sure that the pump can handle the pressure along with the flow rate needed. With an onIoff
level control the pumps should be designed for the relief valve pressure.
'ha* !s *h, NPSH +r %,* +s!*!7, s#6*!+% h,a) r,F#!r,)E
-his is the last piece of information that you will need. -his is the minimum absolute pressure at
the suction no33le at which the pump can operate. -o avoid pump cavitation, the &P(!A of the
system must be greater than the &P(!* of the pump. In other words, the available &P(! must
be higher than the re"uired. We have always si3ed our deaerator stands to be two feet higher than
the &P(! needed for the pump selection. *emember, the water level in the storage tank adds to
the safety margin.
TDB4P
-urbine driven 7$P uses turbine of 8> stages connected to condenser. -urbine is coupled with
main pump having engage.disengage unit called Power pack unit using oil pressure. 7etween
turbine and booster pump gear assembly is there.
Farious system of -%7$P are discussed below4
82 #ube /il (ystem

#ube oil system of both -%7$P( are provided with one ,ain /il -ank each in which oil level
is separately maintained. It has two A1 A/Ps, one E/P A1 and one %1 A/P connected to tank.
#ube oil pressure is maintained at =.DIkg.s". cm is called control oil which is used as governing
oil.
#ube oil after passing through coolers is led to various bearing of -%7$P system. %1 A/P
discharge oil, which is, used on failure of A1 A/Ps bypass the coolers. %uring barring of
-%7$P same lube oil at pr. >.DIkg. s". cm is used as power fluid in barring gear impellers. In
the lube oil pressure by changing the recirculation flow.
<2 (eal. Injection (ystem
,echanical seals are provided on 7P side for which continuous cooling is done by 1'P water.
$or 7$P side constant seal injection pressure around 8BIkg.s". cm is maintained with the help of
control valve. $ilters are also provided in this line. $rom this line small pipe provides water in
the eGhaust steam as eGhaust load spray. (eals drain is collected as clean drain into drain tank
and dirty drain flows into common drain header.
=2 (team (ystem
$or -%7$P there is three sources for steam namely 8. AuGiliary steam <. 1old reheat line =. IPI
#P cross over steam. 'Gtraction steam parameters are maintained at >.D kg.s" cm. K =DD degree
centigrade. %uring cold start when 1*! or IPI#P steam is not available, AuG. (teamis used for
rolling of -%7$P for initial boiler filling. /nce steam is insufficient for increasing the speed
beyond =;DD rpm, 1*! steam is automatically cut off.
>2 $eed Water (ystem
Water from deaerator is taken through two suction into booster pump and then fed into 7$P
suction. %rains K vents are provided in $W system for initial charging and venting of 7$P
during rolling.
;2 )land (ealing of -urbine
%ownstream steam from main turbine gland sealing is used for -%7$P sealing. 7efore opening
of eGhaust valve gland sealing should be done as this is line is connected to condenser.
?2 )overning (ystem
$or having the re"uired flow through 7$P, speed of turbine has to be adjusted and for what we
need perfectly efficient governing system. )overning system is using the control oil at 9 kg.s"
cm. which in turn depending on the position of starting device and speeder gear, will develop
secondary oil and auGiliary secondary oil pressure for operating the >,1Fs and one A1F
thereby adjusting the steam flow speed change is effected. )overning is achieved with the help
of two governorsA namely hydraulic and 'lectrohydraulic governors having '!) control and
!) follows it up.
BOOSTER PUMP>

'ach 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. /ne of the major damages which may occur to a boiler feed
pump is from cavitation or vapour bounding at the pump suction due to suction failure.
1avitation will occur when the suction pressure at the pump suction is e"ual or very near to the
vapour pressure of the li"uid to be pumped at a particular feed water temperature. -herefore all
the three feed pumps are provided with a main shaft driven booster suction line for obtaining a
definite positive suction pressure. -he boiler feed pump is coupled with its driving motor
through hydraulic coupling. -he hydraulic coupling serves the purpose of controlling the speed
of feed pump for maintaining a definite delivery head and delivered "uantity of the feed water as
per the re"uirement of the boiler.
D,a,ra*+r>
%eaerators are used to remove oGygen from boiler feedIwater. It performs the following
functions4
It serves as a feedwater heater.
$eedwater is deaerated by the removal of nonIcondensable gases present in the
feedwater and reduce the oGygen content to a level of about D.DD: ppm.
It acts as a HbufferA to the fluctuations of condensate feedwater flow that occur in
service durations.
-he tank height provides a hydrostatic head to satisfy the suction pressure
re"uirements of the boiler feed pumps.
-he presence of nonIcondensable gases in the feedwater causes the waterside corrosion or
thinning of the boiler tube walls and this further leads to the rupture of walls by the internal fluid
pressure.
!ere steam injectionItype deaerator is used to deaerate the feedwater. $eedwater from #P heaters
is admitted to the deaerator tank and steam is bled from two sources, one from the !P turbine
0which is known as cold reheat steam2, and the other from the IP turbine eGhaust. When this
steam and feedwater come in direct contact with incoming water is heated and also gets
deaerated.
(team initially enters the deaerator through a special, stainless steel Eet (pray atomi3ing valve.
-his valve is designed to fully atomi3e and provide complete deaeration under all load
conditions. -his design insures that the purest steam comes in contact with the purest water.
/nce this high velocity steam mechanically shakes out the last traces of nonIcondensable gases
from the water, it flows upward into the preIheater area where it meets the incoming makeIup
water and pumped returns. -his water continuously condenses the steam, which preheats and
releases the nonIcondensable gases into the internal vent condenser where they are metered
harmlessly to the atmosphere. -his action causes more steam to be drawn into ?the system to
complete the cycle.
$rom the bottom of the deaerator, feedwater is piped through three outlet pipes, each with a
strainer, to the three boiler feed pumps and the used up steam is recirculated back to condenser.
-he deaerator is mounted at a highIlevel with its centerline =>.?; m above the datum level.
-he deaerating heater utili3es steam by spraying the incoming water into an atmosphere of steam
in the preheater section 0first stage2. It then miGes this water with fresh incoming steam in the
deaerators section 0second stage2.
In the first stage the water is heated to within < T 1 of steam saturation temperature and virtually
all of the oGygen and free carbon dioGide are removed. -his is accomplished by spraying the water
through self adjusting sprat valves which are designed to produce a uniform spray film under all
conditions of load and conse"uently a constant temperature and uniform gas removal is obtained at
this point.
$rom the first stage the preheated water containing minute traces of dissolved gases flows into
the second stage. -his section consists of either distributor or a several assemblies of trays.
!ere the water is in intimate contact with an eGcess of fresh gas.free steam. -he steam passes into
this stage and it is miGed with the preheated water. %eaeration is accomplished at all the rates of
flow if conditions are maintained in accordance with design criteria. Fery little steam is condensed
here as the incoming water has high temperature caused by the preheating. -he steam then rises to
the first stage and carries small traces of residual gases. In the first stage most of the steam is
condensed and the remaining gases passes to the vent where the nonIcondensable gases flow to the
atmosphere.
-he water, which leaves the second stage, falls to the storage tank where it is stored for use. At this
time the water is completely deaerated and is heated to the saturated steam temperature
corresponding to the pressure within the vessel.
-he condensate pressure just before the entry to deaerators shall be = psi more than the deaerator
steam pressure.
4EED'ATER HEATERS
A feed water heater is a special form of a shell and tube heat eGchanger designed for the
application of recovering the heat from the turbine eGtraction steam by preheating the boiler feed
water. Its principal parts are a channel and a tube sheet, tubes, and a shell. -he tubes may be either
bent tubes or a straight tubes. $eed water heaters may be defined as highIpressure heaters when
they are located in the feed water circuit upstream from the high pressure feed water pump. #owI
pressure feed water heaters are located upstream from the condensate pump, whichAs takes its
suction from the condenser hot well. -ypically low pressure feed water heaters are designed for
feed water pressures between <: kg.cm s". and ;: kg.cm s"., high pressure feed water heaters
range from 88< kg.cm s". to ==; kg.cm s". for super critical boilers.
'ach feed water heater bundle will contain from one to three separate heat transfer areas and
3ones. -hese are condensing, desuperheating, and subIcooling 3ones. 'conomics og design will
determine what combination of the three is provided in each heater.
A condensing 3one is present in all feed water heaters. #arge volumes of steam are condensed in
this 3one and most of the heat is transferred here.
-he desuperheating 3one is a separate heat eGchanger contained within the heater shell. -his
3oneAs purpose is to remove superheat present in the steam. 7ecause of the high steam velocities
employed, condensation within the desuperheating 3one is undesirable.
-he subIcooling 3one is another separate counter heat flow heat eGchanger whose purpose is to
subIcooling incoming drains and steam condensate.
HEATER OPERATION4
Prior to opening the feed water valve, the channel start Mup vents are to be opened and
remain open until all passages have been purged and feed water begins to discharge.
-o remove air from the shell sides of a heater, which does not operate under vacuum, the shell
start up vent valves should be opened prior to the admission of the steam to the feed water
heater. -he eGtraction lines must be free of all the condensate to prevent the damage to the heater
internals by slug flow.when the drains outlet valve is opened, the shell start up vent valves are to
be closed and the operating air vent valves are to opened. 1ontinuous venting of air and other
nonIcondensable is assured by keeping the shell operating vent valves open.
/n initial plant start up of the hori3ontal feed water heaters, having integral drain coolers, the
li"uid level is to be kept just below the highIlevel alarm point.
/n initial plant startIup of hori3ontal feed water heaters, having integral drain coolers, the
li"uid level is to be kept just below the highIlevel alarm point. -his will avoid the possibility of
flashing at the subIcooler inlet and the possible tube damage that can result. Approach temperature
in eGcess of B degree centigrade indicate the probability of flashing at the subIcooler unit.
VENTING
Proper venting is necessary on feedwater heaters. All operating air vent connections must
be piped to permit continuous venting. -he venting system in a feedwater heater is designed to
assure that all points where nonIcondensable gases could collected are vented. $ailure to utili3e all
of the operating air vents can lead to corrosion damage and loss of performance due to air
blanketing.
Fent lines of heaters operating at a different shell pressure must not be piped to a common
manifold. $ailure to run individual vent lines from each heater has resulted in inade"uate or no
venting of heater operating at a lower shell side than other heaters, piped into a common manifold.
4EED'ATER BY(PASSING
A feedwater heater may be severely damaged by erosion and vibration, if it is operated for any
significant period or time with the neGt lower heaterAs feedwater flow by passed. When a heater is
by passed, its normal feedwater is passed on to the neGt higher heater. -his neGt higher heater will
come close to making up the duty of both the heaters. -his single heater will tend to draw a total
amount of eGtraction of steam approG. e"ual to the flow of both the heaters.
In case of heaters with desuperheating 3ones, the increased steam load due to by passing the
previous heater can cause an eGcessive pressure drop in the desuperheating 3ones, which can cause
an eGcessive pressure drop in the desuperheating 3one, which in turn can cause condensation. -he
condensate flowing at high velocity can lead to severe tube erosion.
'Gcessive steam flow to a heater, resulting from by passing the feedwater side of the previous
heater, can result in4
a2 #ocali3ed high velocity leading to vibration of the tubing.
b2 $lows, which cannot be ade"uately handled by the drain, control valve.
c2 1ondensation in the desuperheat 3one and high velocity impingement.
LP 4,,) H,a*!%& Sys*,$
-he lowIpressure 0#P2 feedwater heating system is provided to improve the thermal efficiency of
the heat cycle by heating condensate from the condenser with lowIpressure steam bled from the
#P cylinder.
#owIpressure 0#P2 feedwater heaters are basically simple straightforward Htube and shellA heat
eGchangers, with the condensate passing through the tubes and the bled steam being admitted to
the shell.
-here are total three #P heaters used in the feed heating cycle. (ince, there is a significant
volume of unused space between the eGhaust of a doubleIflow #P cylinder and on the top of
under slung condenser, this space is utili3ed by inserting two #P heaters in a hori3ontal altitude.
-his results in the lowIpressure drop and high temperature for the bled steam, which is used for
heating the condensate, with conse"uential improvement in cycle efficiency. -he #P heater &o. =
is located outside the periphery of the condensers.
-he heaters are HstackedA so that the ultimate #P heater can drain its bledIsteam condensate into
the condenser above the working level of condensate in its base.
HP 4,,) H,a*!%& Sys*,$
-he highIpressure 0!P2 feedwater heating system is provided to improve the thermal efficiency
of the heat cycle by raising the temperature of the feedwater before it enters the boiler. #ike #P
heaters !P feedwater heaters are also of traditional form, but are arranged in a hori3ontal altitude
to ensure free gravity drainage of their bledIsteam lines and heaterItoIheater drainage. 7led
steam to &o. ? !P heaters is fed from the !P turbine eGhaust system and to &o. ; !P heaters
from IP turbine.
-he system contains four !P heaters arranged hori3ontally in pairs with a drain flash vessel
situated above and between each pair. -he pairs are identified as bank HAA and bank H7A and each
contains a &o. ; !P heater, a &o. ? !P heater and the associated drain flash vessel. In the !P
feed heating system, water is supplied from the boiler feed pumps via the boiler feed regulating
station and is piped through three waysN one to each bank of heaters and one to the bypass pipe.
When this feedwater is passed through the !P heaters, its temperature is increased.
'ach heater bank has its own feedwater inlet and outlet isolating valves, which, with the
bypass pipe and its springIloaded valve, permits either bank to be taken out of service for minor
maintenance or repairs while plant is on load.
%rains from the !P heaters are taken either to the deaerator or to condenser A, depending on the
levels of water and pressures eGisting in the heaters, which in turn depends on the generator load.
-he drains are controlled by level controllers and at normal loads pass to the deaerator. At low
loads, drains are diverted to the condenser.

4,,) R,&#8a*!%& S*a*!+%
-o maintain the rate of feedIwater input to the boiler corresponding to the steam output from the
boiler under all conditions of loading, feed regulating station is used. $or this purpose, feed
regulating station has four regulating lines out of which one line remains standIby. Also to
ensure security of steam supply it has been considered necessary to provide a multiple feedIwater
regulating valve arrangement
-he threeIelement feedIflow regulating system has been developed to meet the re"uirements of
the boiler. -he essential factors that are mainly considered are the steam flow from the boiler, the
feed water flow to the boiler and the water level in the boiler drum.
By(ass sys*,$s>
-he byIpass system performs an important function. It permits the boiler to be operated
independently of the turbineIgenerator system. -he byIpass system comprises two main unitsI
!P 7yIpass system.
#P 7yIpass system.
HP By(ass sys*,$
-his system comprises of the operation of bypassing the !P steam without being passed through
the !P turbine. -he !P steam is taken from each of the main steam lines after the !P steam stop
valves. -he main steam passes into the cold reheat inlet pipes via four pressure control valves and
their associated isolating valves. -he valve include the spray water supply and control
e"uipment .-he !.P. valve will operate automatically to maintain upstream pressure on start .In
addition upon rapid load rejection .-hese valves will operate to relieve ?D@ of ,1* rated steam
flow to the reheat system .-he !XPXrelive valve mounted on the main steam pipe work will
operate to relive eGcess steam to atmosphere
LP By(ass sys*,$
-he #P byIpass system consists of four lines taken from the four hot reheat pipes 0upstream of
the IP turbine control valves2. -hese four lines are then converged into two. -he steams in each
line flows through an isolating valve, a pressure control valve and then into the condenser dump
tube, bypassing the IP, #P turbines.
G,%,ra*+r
-he two ;8> ,W turbineIgenerator sets are set aGially in line in the turbine hall. -he generator is
a <Ipole, =Iphase, hydrogen and waterIcooled machine, driven from the turbine. -he main
eGciter is solidly coupled to the rear end of the generator shaft. A brush less main eGciter
provides the eGcitation power for the generator. -he output from this eGciter is fed to the
generator rotor.
-he eGciter line is directly coupled to the turbine generator shaft and is driven at generator speed.
'ach generator has its own independent stator windings.
!ydrogen is used to cool the generator rotor winding and stator core, the stator winding is
directly waterIcooled.
G,%,ra*+r +,ra*!+%a8 8!$!*s>
*ated output ;8> ,W
*ated output ?D; ,FA
&ominal stator voltage <D kF
(peed =DDD r.min
Power factor D.B; #ag
$re"uency ;D !3
Ma!% ,56!*,r sys*,$
-he main eGciter system is a siGIpole, threeIphase, rotating armature generator. -he stator has
%.1. $ield system and A.1. winding is mounted on the eGciter rotor.
-he rotating rectifier is mounted on the eGciter unit shaft out board of the eGciter armature .-he
rectifier modules, one Lve and other Mve are contained within the Lve and Ive rectifier hubs
shrunk onto the eGciter unit shaft.
-he main eGciter is solidly coupled to the rear end of the generator shaft. !ere a brush less main
eGciter is used to provide the eGcitation power for the generator. -he output from this eGciter is
fed to the generator rotor.
-he eGciter line is directly coupled to the turbine generator shaft and is driven at generator speed
-he main eGciter is supplied with power by a pilot eGciter whose output is rectified and
controlled by the eGcitation control system 0'1(2. -his pilot eGciter is located to the front of the
main eGciter and is a salient pole, permanent magnet, a.c. generator of the hetropolar type. -he
pilot eGciter is airIcooled with an open, selfIventilated air system.
E8,6*r!6a8 -arr!%& &,ar
-he !P, IP and #P rotors must be turned continuously during startIup and shut down periods. -his
provides even heating or warm up in the initial start up stage of the turbine and cooling during a
shut down of the turbine.
-o perform this operation an automatic engaging and disengaging electrical barring gear is used.
-his electrical barring gear rotates the coupled turbine and generator rotors continuously at
approGimately =; r.min.
'lectrical barring gear is a motor driven machine i.e. it receives power to operate from the motor,
which is vertically mounted on a support plate outside the pedestal above the wormshaft. -his
motor supplies =: kW power for the barring gear operation. -his power transmission between
motor and barring gear takes place through worm and worm wheel arrangement.
-he motor driven electrical barring gear is mounted on a pedestal at the eGtreme rear of the
generator and eGciter and the drive to the turbine generator rotor is transmitted through a
H(ynchronous (elf (hiftingA 0(((2 clutch, which automatically engages to drive the turbine
generator rotor at a constant speed of approGimately =; r.min and automatically disengages when
the rotor speed, under steam, rises above this value.
If the electrical barring gear motor develops a fault or if the complete rotor re"uires turning for
maintenance checks, it can be turned manually. -he individual rotors of each cylinder can be
turned independently.
MAIN, COLD REHEAT AND HOT REHEAT STEAM LINE
MAIN STEAM LINE MAIN STEAM STOP VALVE
S
U
P
E HIGH PRESSURE
R TURBINE
H
E
A
T
E
R
MAIN STEAM LINE MAIN STEAM STOP VALVE
HP BYPASS SYSTEM
DESUPER HEATER
COLD REHEAT LINE
HOT REHEAT LINE IV
R R
E E
H H INTERMIDIATE PRESSURE
E E TURBINE
A A
T T
I O
N U
T

IV
TO LO' PRESSURE
DESUPER HEATER TURBINE
.