TNEB

One of the best performing Power Utilities

REVENUE COLLECTION EFFICIENCY IS AT 99%
TRANSMISSION AND DISTRIBUTION LOSS IS
LOW AT 18%
MAXIMUM WINDMILL CAPACITY 3456 MW
(4TH PLACE IN THE WORLD, 1ST PLACE IN INDIA)
INCIDENCE OF POWER THEFT IS VERY LOW
PLANT LOAD FACTOR OF THERMAL STATIONS
ARE VERY HIGH
ONE OF THE FEW STATES, WHICH DO NOT HAVE
POWER CUTS
(courtesy:Power Line magazine, June-2007)

TNEB
POWERING TAMIL NADUS PROGRESS
Glorious Past
Dynamic Present
Promising Future
Over 50 Years (1957 2007 ), Tamil Nadu Electricity
Board has powered the State of Tamil Nadu to become
one of the most progressive States in our country in socio
economical aspects as well as in all the fronts (viz.,)
Agriculture, Industrial Production and Service sectors.
On this occasion of its GOLDEN JUBLEE on 1st July
2007, it reaffirms its, commitment for the sustained and
fruitful services to the state of Tamil Nadu.
(courtesy:Power Line magazine, June-2007)

TNEB
TNEB STEPPING IN THE GOLDEN
JUBLEE YEAR ( 1957 2007 )
INSTALLED CAPACITY IN MW

HYDRO
THERMAL
GAS
WIND MILL
PURCHASE

2174
2970
423
1361
4257

TOTAL

11185

WIND

INSTALLED CAPACITY IN MW

MILL

PRIVATE

HYDRO

1361

SECTOR

2174

1297

CENTRAL

THERMAL
GAS

SHARE
2960

TOTAL 11185 MW

423

2970

INSTALLED THERMAL CAPACITY

STATION

NO OF
UNITS

1.Basin Bridge
(Dismantled)

2
2

2.Ennore

2
3
5
4
5

3.Tuticorin
4.Mettur
5.North Chennai

EACH TOTAL YEAR

UNIT
MW
MW
15
30
1953
30
60
1958
60
110
210
210
210

120
330
1050
840
630

1970
1972
1979
1987
1994

PROPOSED THERMAL PROJECTS

STATION

NO OF
UNITS

CAPACITY
MW

North
Chennai

500

Metter

500

Ennore

500

Tutucorin

500

GAS / COMBINED CYCLE

GAS

STEAM

TOTAL

MW
4X30

MW
-

MW
120

KOVIKALAPPAL

70

37

107

2001

VALUTHUR

60

35

95

2003

KUTTALAM

64

37

101

2004

STATION
BASIN BRIDGE

YEAR
1996

PURCHASE OF POWER
STATION

NO OF EACH TOT YEAR

UNITS UNIT MW
MW
MADRAS ATOMIC
2
235
470 1983
POWER STATION
(KALPAKKAM )
NEYVELI TS-I
NEYVELI TS-II
NEYVELI TS I
(EXPANSION)

6
3
7
2

50
100
210
210

300
300
1470
420

1962
1967
1986
2003

INDEPENDENT POWER PROJECTS

STATION
GMR VASAVI (BB)
SAMALPATTI
PILLAIPERUMAL
NALLUR

FUEL MW YEAR
Naphtha 196 1998
Diesel

106

2001

Gas /
321
Naphtha

2001

SAMAYA NALLUR

Diesel

106

2001

NEYVELI ZERO UNIT

Lignit

250

2002

Gas

113

2005

ABAN POWER LTD

ATOMIC POWER STATIONS

STATION

MADRAS
(Kalpakkam)
KAIGA

NO OF EACH TOTAL YEAR

UNITS UNIT
MW
2
235
470
1983

220

440

2000

TAMIL NADU ELECTTRICITY BOARD

METTUR THERMAL POWER STATION

IS / ISO 9001:2000
CERTIFIED POWER PLANT

METTUR THERMAL POWER STATION

INSTALLED CAPACITY
4 X 210 MW
Mettur TPS is the one and
only inland thermal power
station of Tamil Nadu
Electricity Board.
The station is situated in
the left flank of the Ellis
Surplus course of the
Stanley Reservoir,
Mettur Dam

METTUR TPS UNITS COMMISSIONING DATES

INSTALLED CAPACITY 840 MW ( 4 X 210 MW )

Unit
No

Date of first
synchronisation

Date of first coal firing

07.01.1987

25.04.1987

II

01.12.1987

30.12.1987

III

22.03.1989

10.06.1989

IV

27.03.1990

29.03.1990

THERMAL POWER PLANT

THE PROCESS IN A THERMAL
POWER PLANT MAY BE BROADLY
DIVEDED INTO THREE BLOCKS
1. STEAM GENERATION IN BOILER
2. ELECTRICITY GENERATION IN
TURBO GENERATORS
3. ELECTRICITY TRANSMISSON
THROUGH TRANSFORMERS & HT
LINES

MAJOR EQUIPMENTS IN A
THERMAL POWER PLANT

BOILER & ITS AUXILRIES

TURBINE & ITS AUXILRIES
GENERATOR & ITS AUXILRIES
CONDENSER
FEED PUMP
WATER TREATMENT PLANT
COAL HANDLING PLANT
ASH HANDLING SYSTEM
COOLING WATER SYSTEM
CONTROL ROOM
SWITCH YARD AND ELECTRICAL LOAD
DESPATCHING

COAL HANDLING PLANT

MAIN EQUIPMENTS

WAGON TIPPLERS
CONVEYORS
PRIMARY CRUSHERS
SECONDARY CRUSHERS
COAL STOCK YARD
STACKER CUM RECLAIMER MACHINES

COAL LINKAGE
Mettur TPS is getting its coal supply from Mahanadhi Coal
fields, Orissa.
Coal from Paradeep Port, Orissa is conveyed through ship to
Ennore Port and from there by Rail to Mettur.
4 Nos. Wagon tipplers have been erected to tip the coal
wagons.
The coal is fed into the coal bunkers through mechanical
conveyor system.
There are two streams of coal conveyors with 1500 T/hr
capacity each.

COAL LINKAGE TO MTPS

TALCHAR COLLIERIES TO PARADEEP
PORT - BY TRAIN
PARADEEP PORT TO CHENNAI PORT - BY
SHIP
CHENNAI PORT TO METTUR THERMAL

WAGON TIPPLER

PRIMARY CRUSHER
CAPACITY
:1500 TPH
OUTPUT PRODUCT SIZE :150 mm
SCREEN DIA
:4082mm
MOTOR
:260KW
SCREEN PLATES :158 Nos
LIFTING SHELVES :40 NOS
SPECIAL BEAM RAIL :18 NOS
SCREEN RPM
:13 RPM

PRIMARY
CRUSHER

SECONDARY CRUSHER
TYPE

: RING TYPE GRANULATOR

2NOS IN ONE MACHINE
CAPACITY
: 850 MT/HR
OUT PUT SIZE : < 25MM
DRIVE
: V BELT DRIVE WITH GUARD
MOTOR
: 1000 HP,1440 RPM
CRUSHER ROTOR SPEED : 600 RPM
CRUSHER RINGS : 32 Nos TOOTHED, 30 Nos PLAIN

COAL STOCK YARD & STACKER CUM

RECLAIMER MACHINE

The daily requirement of coal for the Station is 14000 T

There is a coal yard with a space to stack 4.5 lakh tones of
coal which is sufficient to meet one months requirement
of all the 4 Boilers
There are two stacker-cum-reclaimers machines in the
yard to stack the crushed coal and to retrieve the coal to
the bunkers whenever necessary.

STACKER CUM RECLAIMING

MACHINE
CAPACITY
STACKING
: 1500 MT/HR
RECLAIMING : 1000MT/HR
BUCKET WHEEL
SPEED
: 5.42 RPM
BUCKETS
: 8 NOS
VOLUME
: 600 LTRS
CUTTING CIRCLE DIA : 6.5
MTRS

BOWL MILL
Bowl Mill Type
: XRP 803
with classifier
X : Supply Frequency (50 cycles/sec)
R : Founders Name (Raymond)
P : Pressurized Mill
80 : Diameter of Bowl in Inches
3 : Number of rollers
No of Mills/Boiler : 6 Nos
Base Capacity : 39.68 T/Hr
Mill Motor
: 340 KW
6.6 KV
990
rpm

UTILITY BOILERS
Steam conditions used have been mainly sub-critical although
a significant number of plants were built during 1960s and
1970s with super-critical steam conditions.
From Non-RH Type, The Technology today has Advanced to
Double Reheat Type. However, the Preference has Come Down
Over The Years For Double Reheat.
Operating pressures have also increased to above 300
atmospheres. To achieve better efficiencies.
Boilers have been designed to take care of the deterioration in
coal quality over the years resulting in bigger furnaces, large
size pulverisers and large size auxiliaries.

INDUSTRIAL BOILERS
Unit sizes have grown in capacities from 10 t/h. to
300 t/h., pressure from 15 ata to 120 ata,
temperatures from 200oc to 530oc, burning various
types of fuels.
Industrial boilers are designed with bi-drums or
single drum depending on the pressure.
For paper plants, unit size of chemical recovery
boilers have increased to burn about 675 tons per
day of dry solids from 140 tons/day of dry solids.

MAJOR CLASSIFICATION OF POWER BOILERS

SUB-CRITICAL
DRUM TYPE
NATURAL CIRCULATION
SINGLE RE-HEAT
TILTING TANGENTIAL CORNER FIRED
DRY BOTTOM
BALANCED DRAFT
DIRECT FIRED PULVERIZED COAL WITH BOWL MILL
COAL IS THE PRIMARY FUEL & OIL IS USED AS SECONDARY
FUEL
THE FUEL FIRING IS DONE BY BURNERS FROM THE FOUR
CORNERS OF THE FURNACE. THE POSITIONING OF THE
GUNS ARE SO DESIGNED THAT THE FIRING OCCURS
TANGENTIALLY

MAIN EQUIPMENTS
BOILER
The boilers of the Power
Station were supplied by
M/S B.H.E.L., Trichy.
Main Parameters
Capacity
:700 T/Hr
Temperature : 540C
Pressure
: 137 kg/cm2

BOILER

BOILER CIRCUITS
WATER AND STEAM CIRCUIT
AIR AND FLUE GAS CIRCUIT
COAL AND ASH CIRCUIT(Supporting fuel
LDO & HFO)
COOLING WATER CIRCUIT

FEED WATER TO STEAM

RH attemperator

Drum vents
To IPT inlet

Economiser
Vent

Drum

Steam to HPT inlet

SH attemperator

Uprisers
1 11 12

13

14

3L
3R

Platen
SH

D
o
w
n
C
o
m
e
r
s

RH

Steam from HPT outlet

10

FINAL
SH

LTSH

9
W
A
T
E
R

Furnace

W
A
L
L

W
A
L
L

Bottom Ring Header

W
A
T
E
R

EH
O/L

Economiser

EH
I/L

4L
5

4R

8
To SH / RH
Attemperation

E
C
O
R
C

E2
E
C
O
D
R
A
I
N

E1

LLCV

FLCV A

FLCV B

Feed Water
from BFP

FLOW DUE TO DENSITY DIFFERENCE

WATER CIRCUIT Consists of

1. Economiser
2. Boiler Drum
3. Water Wall Tubes

CIRCULATION RATIO =

TOTAL FEEDWATER FLOW THRO CIRCUIT

TOTAL STEAM GENERATED IN THE CIRCUIT

STEAM GENERATOR
Steam Generator covers the whole unit,
encompassing water wall tubes, super
heaters, air heaters and economiser

SCHEME OF STEAM GENERATION IN BOILER

- Process of steam generation in boilers (Water pre-heating to the
saturation temperature is done in an economizer, the formation of
steam takes place in evaporating heating surfaces and steam
superheating is carried out in a super-heater)
- In these process water in the economizer and steam in the superheater come only once in contact with the heating surfaces
- The economizer offers hydraulic resistance to the motion of water,
which must be overcome by provision of high head in the feed pump
- The pressure developed by the feed pump must exceed the pressure
at the entry to the zone of steam generation by the magnitude of the
hydraulic resistance of the economizer
- The motion of steam in the super-heater is due to pressure gradient
between the zone of steam generation and the steam turbine
- The combined motion of water and steam in evaporating tubes
which has to overcome the hydraulic resistance of these can be
effected in various ways:

ECONOMISER
Function:
Absorbing the flue gas temperature to heat
the feed water to its sensible heat.
Arrangements:
Staggered (fin or plain tube)
In-line (plain)

ECONOMISER BANKS

Eco inter headers

REPLACEMENT OF ECONOMISER ASSEMBLIES

DRUM & ITS INTERNALS

Function:
Separating the steam from steam water mixer and
discharging it
It houses all internals used for steam purification
after being separated

DRUM INTERNALS
Turbo separators (100 Nos.)
Screen Dryers
Economizers feed pipes (2 Nos.)
Continuous Blow Down(CBD) collection pipe
Emergency Blow Down(EBD) pipe
Phosphate dosing pipes

BOILER DRUM WITH OPENING FOR RISERS

DRUM

OPENING
FOR RISER

Water Wall Tubes

FUNCTION:
It forms the furnace wall eliminating exposed
refractory surfaces.
heating & evaporating the feed water supplied to
the boiler from economizer.
It consists of vertical tubes connected at top &
bottom headers.
50% of the heat is absorbed by water wall by
radiation

WATER WALL PANEL TUBES

WATER WALL TUBES

FLAME

Combustion in Tangential Corner Firing

Furnace

OPERATION & MAINTENANCE

The furnace pressure in the boilers is maintained by
the use of both forced draught fans and induced
draught fans.
The circulation of water is natural, i.e. from the drum
through the down comers and then through the
upraises to the water walls .
As the water flows down through the down comers
and fills the water walls, due to the firing in the
furnace it gets converted into steam and rises due to
lesser density.

STEAM CIRCULATION SYSTEM

This system consists of

Riser tubes
Super-heaters
Re-heater &
De-super heaters etc.,

Riser is a tube through which water & steam

mixture pass from an upper water headers to
drum.

SUPER HEATERS
Classified according to the position or heat received from flue
gas:
- Positioning of Super heater: Mainly depends on steam parameters and
the arrangements of evaporating tubes.
- SH coil ends are welded to round-section headers.
- SH tubes are bent into coils with a bending radius of not less than 1.9d.
- Multi-pass coils are employed in high-pressure boilers.
- With multi-pass coils, there may be not enough places on a header for
welding the tube ends. Furthermore the header wall may be weakened.
- Depending on the direction of flows of steam and gas SH may be parallel
flow, counter flow or mixed flow.
- A counter flow SH develops the highest temperature gradient between
steam and gas, which makes it possible to diminish the heating surface
area and metal used for fabrication.

RE-HEATER
Steam after expansion in HP turbine is heated to
the rated temp 540 C at constant pressure.
It consists of pendant assemblies and placed in
medium temperature region.
It consists of CRH, HRH lines, Desuperheating
and safety valves.

BOILER TUBE LENGTH & AREA

WATER WALL
ECONOMISER
LTSH
PSH
FSH
SCW
RE-HEATER
TOTAL

21.21 KM
19.5 KM
37.29 KM
10.6 KM
9.9 KM
13.1 KM
26.1 KM
137.62 KM

FANS
A fan continuously moves mass of air, gas or
vapour at the desired velocity by the action of its
rotor.
For achieving this objective there is a slight
increase in the gas pressure across the fan rotor.
However, the main aim of a fan is to move a gas
without an appreciable increase in pressure.

OPERATION & MAINTENANCE

PRIMARY AIR FANS (PA FAN)
The purpose of primary fans is to provide air that is used
to transport the pulverized coal from the mills and also to
warm up the coal to remove any moisture content that
might present in the coal.
The primary air flowing out of PA fan is divided into 2
portions, one portion enters the regenerative air preheater and comes out as hot air,while the 2nd portion is
cold air and both sent to the mill.Depending upon the
temp.requirement of the coal at mill outlet the flow of
primary air is controlled by dampers.

PA FAN-SPECIFICATION
Type
: NDV 22 TIEFSTACK
ND
Radial fan
V
Single suction simply supported fan
22
Nominal Diameter of Impeller in dm
TIEFSTACK Type of impeller

Capacity
: 1250 KW

Fan make
: BHEL

Flow
: 70 m3 / s

Speed
: 1480 RPM

Discharge Pr. : 1210 mmwc

Regulation
: Inlet Damper Control

Direction
: Clock wise from MNDE

Bearings
: Journal Bearings

Lubrication : FDE - Forced lubrication

: FNDE - Sump lubrication

No. of fans
: 2 Nos.in parallel

OPERATION & MAINTENANCE

BOILER AUXILIARIES
FORCED DRAUGHT FANS (FD FAN)
The main function of forced draught fan is to provide air for
combustion in addition to the air supplied by the primary air
fan.The air from the FD fans known as secondary air, is supplied
to the furnace through regenerative air pre-heater, wind box and
finally through secondary air damper controls.
Two FD fans are provided for each Boiler
It supplies secondary air to furnace for complete
combustion of fuel for more than stochiometric ratio 4%
It also supplies inlet air to scanner air fan for scanners
cooling and oil guns cooling

SPECIFICATION
TYPE : AN 18 e 6
AN - AXIAL NON PROFILED BLADES
18 - NOMINAL DIAMETER OF IMPELLER IN DM
e6 - TYPE OF DIFFUSER

Capacity
: 1250 KW
: 132.2 m3 / s

Flow

Discharge Pr. : 665 mmwc

Speed

: 1480 RPM

Regulation

: Inlet Guide Vane Control

Direction

: Counter Clock wise from MNDE

Fan make

: BHEL

Bearings

: Anti friction Bearings

Lubrication

: Grease lubrication

No. of fans

: 2 Nos.in parallel

INDUCED DRAFT FAN

It induces the exhaust flue gas through chimney to atmosphere
It controls the balanced draft system
VARIABLE SPEED HYDRAULIC COUPLING
It supports ID fan motor to overcome its initial torque
It regulates the speed of ID fan as per unit load
SPECIFICATION OF HYDRAULIC COUPLING
Type : 1150 SVNL 21 18.5 T
Working oil pr.
- 16 bar
Lub oil pr.
- 0.3 to 0.6 bar
Primary coupling - HBK 180
Secondary coupling - SBLK 180
Motor Speed
- 740 rpm
Full load slippage - 3.8 %
Max output speed - 711 rpm

INDUCED DRAFT FAN SPECIFICATION

Type : NDZV 31 SIDOR
ND
- Radial fan
ZV
- Double suction simply supported fan
31
- Nominal Diameter of impeller in dm
SIDOR - Type of impeller

Capacity
: 1500 KW

Flow
: 230 m3 / s

Discharge pr. : 400 mmwc

Variable speed : 710 RPM max

Regulation : Variable speed Hydraulic coupling (VOITH make)

Direction
: Counter Clock wise from MNDE

Fan make
: BHEL

Bearings
: Journal bearings

Lubrication
: Sump lubrication

No. of fans
: 2 Nos.in parallel

Most popular design is Two-pass.

- Because, fuel is supplied and gases are removed at
the bottom which is convenient for the removal of liquid
slag.
- Draft fans are mounted on the zero level so that their
vibration is not transferred to the boiler structure
Disadvantages:
1. The heating of convective surfaces and the
concentration of ash over the cross section of the
convective shaft may be uneven because the gases are
turned by 180 deg.
2. Convective shaft and second-pass pressure parts
erosion is more due to gas direction.

OPERATION & MAINTENANCE

INDUCED DRAUGHT FAN
The Induced Draught Fans are provided to evacuate
the flue gas and to maintain vacuum inside the
furnace to ensure effective combustion.
The ID fan is driven by a constant speed induction
motor. The speed variation of ID fan is effected using
hydraulic coupling. The oil used in the hydraulic
coupling is cooled by water which is circulated by a
separate pump.

AIR POLLUTION
Life on earth, weather it is of human being, of
animal, or of vegetation, is affected by air pollution.
One of prime causes for the air pollution is
mushroom growth of industries the developing and
developed countries. Thermal power stations which
burn coal as fuel and handle huge quantum of ash,
may greatly pollute the environment, unless
otherwise the particulate matter content in the flue
gas is separated-out fully.
In order to restrict the emission within the limits,
thermal power stations are bound to upkeep there
ash precipitator in good condition .

TYPES OF PRECIPITATOR

Mechanical type of precipitators

Electrostatic precipitators
ADVANTAGES OF ESP
Low pressure drop in the flue gas stream,
Less power consumption
Easy control
Sustained high collection efficiency
Capacity to handle particles of all sizes
Easy maintenance.
BAPCON
B
: BHEL
A
: Advanced
P
: Precipitator
CON : Controller

WORKING PRINCIPLE OF ESP

CORONA DISCHARGE
The emitting electrode being a wire of small
diameter with radius of curvature, creates a high
intensive electric field surrounding itself.The electron in
the outer orbits of flue gas atoms which travel close to
the electrodes gain sufficient energy by virtue of the
high intensity electric field. When atoms collide with
each other or with the surface of the emitting
electrode, the outer orbit electrons acquire adequate
energy to get themselves released from the bondage of
these atoms. The electrons thus liberated, are accelerated
towards the collecting plate due to the local electrical
field.

WORKING PRINCIPLE OF ESP contd

As they move,they gain more energy and bombard on
other atoms which results in liberation of more
number of electrons.Moreover, the atoms which lose
electrons, become positively charged and are attracted
by negatively charged discharge electrodes . When
they collide with these electrodes, they make enough
radiation to ionise the gas molecules. Thus, some sort
of chain reaction takes place, nearer to the discharge
electrodes resulting in a flood of electrons which starts
moving towards the collecting electrodes.This process
is known as the corona discharge.

ELECTRON
NAUTRALGAS MOL
POSITIVE ION
NEGATIVE ION
DUST PARTICLE
UNCHARGED
DUST PARTICLE

FIELD CHARGING
While the electrons stream away from the
discharge electrodes, the encounter with flue gas
molecules and dust particles.When gas molecules
receives electrons they are ionised with negative
charge and migrate towards the positive electrode,
they get collected over dust particles which
obstruct their way. The dust particles go on
collecting the ionised gas molecule and once it has
accumulated sufficient negative charge, they are
attracted by the positively charged collecting
electrodes.

SPECIFICATION

NO. OF RECTIFIER
NO. OF FIELDS
NO. OF HOPPERS
NO. OF COLLECTING
ELECTRODES
NO. OF EMMITING
ELECTRODES
NO. OF CRM MOTORS
NO. OF ERM MOTORS

: 24 Nos. / Boiler
: 24 Fields / Boiler
: 48 Nos.
: 5292 / Boiler
: 31104 / Boiler
: 12 Nos./ Boiler
: 24 Nos./ Boiler

SPECIFICATION
GAS FLOW RATE

: 363.1 m3 / s at 145 0 C

DUST CONCENTRATION

: 51.18 g / Nm 3

TYPE OF PRECIPITATOR

:FAA-6X36-2X72125-2

COLLECTION EFFICIENCY

: 99.64 %

PRESSURE DROP

: 15 MMWC

VELOCITY OF GAS

: 1.0025 m / s

TREATMENT TIME

: 21.55 sec

POLUTION LIMIT

: 150 mg /Nm3

ASH DISPOSAL
A dyke has been constructed across the
Perumpallam valley over an area of 1268 acres.
The dyke consists of Upper Ash Dyke, Lower Ash
Dyke and Two settling ponds in series.
The ash slurry is pumped into the dyke.Ash settles
down and the water flows into the primary pond and
then to the secondary pond from where clear water
is let into the river Cauveri.
The effluent water is tested for very high degree of
purity in accordance with the standards fixed by
TNPCB.

DRY ASH DISPOSAL THROUGH SILOS

90% of the ash content in the coal is collected as dry ash
MTPS got the National award for the second place in Dry
Fly Ash utilization for the year 2005-06

AIR PRE HEATER

IT PREHEATS THE PRIMARY
& SECONDARY AIR FROM
THE WASTE EXHAUST FLUE
GAS LEAVING AFTER THE
ECONOMISER TO IMPROVE
THE BOILER EFFICIENCY

SPECIFICATION OF REGENERATIVE
( LJUNGSTORM TYPE ) APH
27 VIM (T) 1850 (2000)
27 - Nominal diameter of APH in feet
VI - Vertical Inverted
M - Modular design
(T) - Tri sector
1850 - Heating element depth including 3
layers in mm
2000 - Heating element depth with Future
Element in mm

ADVANTAGE OF AIR HEATER

IN ADDITION TO INCREASE IN BOILER

EFFICIENCY THE OTHER ADVANTAGE
STABILITY OF COMBUSTION IS IMPROVED BY
USE OF HOT AIR.
INTENSIFIED AND IMPROVED COMBUSTION.
PERMITTING TO BURN POOR QUALITY COAL.
INTENSIFIED COMBUSTION PERMITS FASTER
VARIATION AND FLUCTUATIONS.
HOT AIR CAN BE USED FOR DRYING THE COAL
AS WELL AS FOR TRANSPORTING THE
PULVERIZED COAL TO BURNT.

GENERAL LAYOUT OF THERMAL POWER STATION

SUPERHEATED STEAM TO
HPT

STEAM TO LP
TURBINES

DRUM
PSH
RH
LTSH
ECO

HPT IPT

LPTS
GENERATOR

RE-HEATED STEAM TO IPT

Steam to heater

STEAM

CONDENSER

GENERATOR

DEAERATOR

CONDENSATE
EXTRACTION
PUMP

HP HEATERS
LP HEATERS
BOILER FEED PUMP

TURBINE
Main technical data:
Rated output (measured at generator terminals)
: 210 MW
Rated main steam and reheat steam temperature
: 535 C
Rated main steam pressure
: 130kgf/cm2
Max. Steam Flow(at valve wide open)
: 670 tons/hr
No. of heaters in regenerative feed water heating cycle : 8(including
Deaerator)
No. of extraction lines
:7
Final feed water temperature
: 242 C
Overall length of Turbine
: 20307 mm
Overall width of Turbine
: 8530 mm
Total weight of Turbine
: 560 Tons
General :The steam turbine of BHEL make is a condensing type, tandem
compound, three cylinder, horizontal, disc and diaphragm
(impulse) type with nozzle governing. Turbine is coupled to
directly driven A.C. Generator.

MAIN EQUIPMENTS - TURBINE

LMW-TURBINE
The Turbo
Generators were
supplied by
M/s BHEL Hardwar.
The turbine is a three
stage turbine.
Speed of the
Turbine :3000 RPM
Temperature : 535C
TURBINES

TURBINE

HP TURBINE
No.Of STAGES: 12

IP TURBINE
No.Of STAGES:11

LP TURBINES
No.Of STAGES: 2 X 4

MAIN EQUIPMENTS OF TURBINE

1. Main Turbine.
2. Oil system.
3. Condenser
4. Cooling water system.
5. Hot well & Condensate system
6. HP Heaters & LP Heaters
7. Feed Water system

Feed water heaters

1. OPEN HEATERS:
bled steam is allowed to mix with feed water
Deaerator is one of the open heater
2. CLOSED HEATERS: (steam is not allowed to mix with
water)
Feed water flows through the tubes in the heater
and the bled steam condenses on the outside of the
tubes in the shell.
The condensate sometimes called HEATER DRIP,
then passes through the next lower pressure heater
High pressure & low pressure heaters

TG BEARINGS & OIL SYSTEM

Seven journal bearings.
Thrust bearing is located at HPT along with the journal bearing.
An oil system from turbine MOP or SOP provides lubrication
to the bearings.
During supply failure, DCLOP provides lubrication to the
bearings.
Jack Oil Pump(JOP) is used to lift the Turbine shaft for Barring
gear operation.
Main Oil Tank(MOT) is for storage of oil system, support JOP,
AC & DC Lube oil Pumps & Starting Oil Pump (SOP) and
receive the drain oil from the bearings.
Oil coolers are used to reduce the oil temp before admitting to
the bearings.
Oil vapour fan removes vapour in the oil.
Governing oil is supplied from Main Oil Pump (MOP)
/Starting Oil Pump(SOP)

WHY CONDENSER IS REQUIRED

The steam after doing work in LPT was converted into water in
Condenser and send back to the Boiler.
By recycling, the requirement of DM water & cost is reduced.
Higher the condenser vacuum, higher the work done in the Turbine.
Act as a storage tank for CEP.
Dissolved air and non condensable gases in the water was removed in the
condenser.

COOLING WATER SYSTEM

OBJECTIVE OF COOLING WATER:
a) To condense the steam from LP Turbine
b) To cool the plant auxiliary equipments.
c) To flush the ash hoppers.
SOURCE OF COOLING WATER:
River water taken from the Cauvery river

How vacuum created in the condenser.

When condensing the Exhaust steam in Condenser
as water at a vacuum of 0.9 ksc, 15,000 times
volume reduction is taken place between steam and
water.
Due to this high reduction of volume while
condensing, vacuum is created inside the
Condenser.
Initial vacuum was created by Steam Ejectors/
Vacuum pump.
Air was sucked by Steam Ejectors/vacuum pump
through the line taken off from the condenser.

CONDENSER DETAILS
Condenser is located beneath the LPT.
The used up steam from LPT is directly sent to condenser
for condensing the steam to water.
Cooling water received from CWPH is passed thro the
cooling tubes to condense the steam.
A Vacuum around 665 mmHg is maintained inside the
condenser.
The condensed water(condensate) is collected in the
hotwell
The condensate is pumped to De-aerator thro Low
Pressure heaters (LPH) by CEP
Loss in the system was make up at condenser.

CONDENSER (FRONT)

CONDENSER TUBES
(7810 tubes on each side)
PARTING PLANE
AIR COOLING ZONE
HOT WELL
CEP

CONDENSATE EXTRACTION PUMP (CEP)

Mainly used to pump out condensate from Hot well
to De-aerator through LP heaters.
It will maintain the De-aerator level .
Two nos. pump available out of which one pump is
standby.
Driven by Electrical Motor of 500 KW capacity
Develops a pressure of 20 Ksc
Multistage (5 stages) vertical Centrifugal pump of
Capacity 675 T/Hr.

BFP BOILER FEED PUMP

The main function of BFP is to supply feed water to Boiler drum which
is under a Pr. of 160 Kg/Cm2 and to maintain the drum level .
Each pump can deliver 400 T/Hr.
Water from De-aerator at a pressure of 7 Kg is connected to BFP
Booster pump suction line which develops 15 Kg/Cm2.
There are 3 nos. BFP available out of which one pump is standby
No. of stages : 6
Driven by a Electrical motor of 3500 KW rating thro a variable speed
scoop coupling.
Feed Water from BFP is passed through HP heaters to pickup heat
before admitting into the Boiler via Economizer.
Certain minimum water flow will be established thro RC lines when the
water flow to Boiler drum is less.
Hydraulic coupling is provided
a.) to decouple when the pump ceases.
b.) To save energy & c.) To vary the flow & Pr

HIGH PRESSURE HEATERS (HPH)

The F.W pumped by BFP passes thro HPH 5, 6 & 7 in the
tube side to pickup heat .
Extraction from HP outlet CRH is used in HPH-6 at shell
side.
Extraction from IPT is used in HPH-5 in shell side.
The drain condensate is cascaded from HPH-7 to HPH-6,
HPH-6 to HPH-5 and then send to de-aerator.
Protection to isolate the HPH independently if the shell
level goes to Very high level to protect water entry into the
turbine.
The regenerative Feed Water Heaters increases the cycle
efficiency

PROGRESS OF AGRICULTURE PUMPSETS

2000000
N
U
M
B
E
R
O
F
P
U
M
P
S
E
T
S

1567317

1500000

1768052
1645329
1st 1951-56

1033556 1277501

1000000

681205

500000
0

2nd 1956-61
3rd 1961-66

805616

4th 1969-74
5th 1974-78

33440

256594

117695

6th 1980-85
7th 1985-90
8th 1992-97

PLAN PERIOD

10

9th 1997-02
10th 2002-07

MAIN EQUIPMENTS
GENERATOR
Make M/S BHEL
Voltage : 15.75 KV
Capacity : 210 MW
Coolant : Hydrogen gas

Stator water
in let and out
let line
( turbine end)

EVACUVATION OF POWER AT METTUR TPS SWITCHYARD

Neutral

 HYDROGEN GAS COOLING SYSTEM

ADVANTAGES OVER AIR
The density is lowest of all gases and is of that of
air
Lesser windage and friction loss due to less density
Requires less fan power
Increase in efficiency

The heat transfer capacity of hydrogen is about

twice that of air
Increase in pressure increase in out put
For every 1.0 ksc pressure increase 0.5% increase out
put
But more pressure will increase the density of gas in
turn will increase the windage loss

ADVANTAGES OVER AIR

High thermal conductivity and specific heat ensures
effective heat removal from heated surfaces ( approx.
10 times that of air)
Reduction of machine size
Reduction of size of hydrogen coolers
The degradation of insulation process cannot occur in
hydrogen atmosphere
Dirt and moisture free atmoshphere
Increase in machine life

HYDROGEN GAS CIRCULATION

The stator core and the rotor conductors are cooled by
High purity of hydrogen gas
Hydrogen enters the generator casing through an axially
oriented distribution pipe at the top
The rotor fans circulate hydrogen over the end windings
and through the stator core, while parallel flow passes
through the rotor.
Four hydrogen coolers are located horizontally inside
the casing for cooling the hydrogen gas
Regenerative heaters are provided for removing
moisture from hydrogen gas.

Why Generators are cooled by

Stator water ?
Since , electron flow in a conductor in Zig Zag
path, conductor heats up
If temperature increases, resistance value also
increases, which in turn limits the voltage
In order to increase the current carrying capacity
of the conductors
To reduce the degrading of stator coils and
insulating materials

EVACUVATION OF POWER AT METTUR TPS

FEEDERS 8 Nos.
GOBI
INGUR
15.75 KV

230 KV

230 KV TUNNEL
DAM PH

GENERATOR

SALEM 400 KV-I

POWER TRANSFORMER

SALEM 400 KV-II

METTUR AUTO SS
SINGARAPET

INSTALLED CAPACITY Vs SUSTAINED

DEMAND

4000

7513
6290
7924
6687
8268
6957
9319
7228
9531
7473
10031
8209

5580

7204

7120
5196

4918

6916

4875

6908

6908
4424

4360

6578
3948

6000

6158

8000

3676

10000

6090

12000

Though the installed capacity is more than the demand, actual

generation is less due to
i)Hydro Station are monsoon dependent and irrigation based
ii)Statutory overhauling of Thermal & Hydro Units.

2000
0
92-93 93-94 94-95 95-96 96-97 97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05 05-06
Installed Capacity ( MW)

PLAN

Sustained Peak Demand(MW)

PROGRESS OF DISTRIBUTION TRANSFORMERS

1st 1951-56

N
U
M
B
E
R

200000

2nd 1956-61

140860

150000

167120

O
F
T
R
A
N
S
F
O
R
M
E
R
S

3rd 1961-66
4th 1969-74

100000

84225

111522

5th 1974-78
6th 1980-85

43666

50000
0

63667
7th 1985-90

3773

10004 17360 37453

8th 1992-97

PLAN PERIOD

10

9th 1997-02
10th 2002-07

METTUR THERMAL POWER STATION-A JOURNEY TO EXCELLENCE

THE GOVT. OF INDIAS MERITORIOUS PRODUCTIVITY REWARDS
&
GOLDEN SHIELDS FOR THE OUTSTANDING PERFORMANCE
Sl.No

Year

1.

1992-93

2.

1993-94

3.

1994-95

4.
5.

1995-96
1996-97

Reward
Rs.15 Lakh &
Certificate
Bronze medal

Sl.No

Year

Reward

8.

2000-01

Gold medal

9.

2001-02

Gold medal

10.

2002-03

Gold medal

11.

2003-04

Gold medal

12.

2004-05

Target achieved

13.
14.

2005-06
2006-07

Target achieved
Target achieved

Bronze
Silver medal
Silver medal

6.

1997-98

Bronze medal

7.

1999-2K

Silver medal

Some TNEB firsts

FIRST TO DEVELOP
Wind power in the country
A high head hydroelectric scheme (Pykara hydro station)
Cascading-type hydroelectric station in a hill area
(Kundah system)
Cascading low-head barrage powerhouses across the
Cauvery river
Pumped storage hydro scheme to meet peak power
demand (400 MW Kadambarai)
(courtesy:Power Line magazine, June-2007)

Some TNEB firsts

FIRST TO COMMISSION
Extra high voltage, gas-insulated substation in Chennai
Distribution control centre with SCADA in Chennai
230 KV grid with a load despatch centre in Erode

FIRST TO INTRODUCE
RCC poles in LT and HT line work
Power line carrier communication in grid operation
Wireless communication system to attend to fuse-off calls
in Chennai
Complete rural electrification
(courtesy:Power Line magazine, June-2007)

USEFUL POINTS TO IMPROVE YOUR

QUALITY OF LIFE
BE HONEST AND BE FRANK TO BE ABLE
TO SPEAK THE TRUTH
DO NOT EXPECT OTHERS TO DO WHAT
YOU DO NOT WANT TO DO
BE A WILLING STUDENT THROUGHOUT
YOUR LIFE
LEARN EVERY DAY
IF YOU DONT KNOW, ASK
DO NOT PROCRASTINATE

KNOW SAFETY NO PAIN

NO SAFETY KNOW PAIN

Er.R.GABRIEL GERMANS, M.E., F.I.E.

Chief Engineer / Mettur Thermal Power Station
TNEB / Mettur Dam-6