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Summer Training Project report on NTPC BY Prateek Jain- VIT University

Summer Training Project report on NTPC BY Prateek Jain- VIT University

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SUMMER TRAINING REPORT

31st

June to 25th

July

Submitted By:-

Prateek Jain

B.Tech 2nd

year

VIT University

This is to certify that PRATEEK JAIN(08BEE110), student of 2008-2012

Batch of Electrical & Electronics Branch in 2nd

Year of Vellore Institute of

Technology, Vellore has successfully completed his industrial training at

Badarpur Thermal Power Station- NTPC, New Delhi for four weeks from

31st

May to 26th

June 2010. He has completed the whole training as per the

training report submitted by him.

Training In-charge

Badarpur Thermal Power Station

NTPC, Badarpur New Delhi.

Table of Contents

1. Acknowledgement

2. About the Company

3. Thermal Power Plant

Introduction

Operation

Functioning

4. Electricity Generation Process

5. EMD-I

6. EMD-II

7. Control & Instrumentation

Acknowledgement

With profound respect and gratitude, I take the opportunity to convey my thanks to

complete the training here. I express gratitude to the Program Manager and other

faculty members of Electrical & Electronics Engineering Department of SELECT

of Vellore Institute of Technology for providing this opportunity to undergo

industrial training at National Thermal Power Corporation, Badarpur, New Delhi.

I do extend my heartfelt thanks to Ms. Rachna Singh Bhal for providing me this

opportunity to be a part of this esteemed organization.

I am extremely grateful to Mr. G.D.Sharma, Superintendent of Im-Plant Training

at BTPS-NTPC, Badarpur for his guidance during whole training.

I am extremely grateful to all the technical staff of BTPS-NTPC for their co-

operation and guidance that helped me a lot during the course of training. I have

learnt a lot working under them and I will always be indebted of them for this

value addition in me.

Finally, I am indebted to all whosoever have contributed in this report work and

friendly stay at Badarpur Thermal Power Station, Badarpur, New Delhi.

ABOUT THE COMPANY

CORPORATE VISION

³A world class integrated power major, powering India's growth with increasing

global presence.´

CORE VALUES:

BCOMIT

B- Business ethics

C- Customer focus

O- Organizational & professional pride

M- Mutual respect & trust

I- Innovation & speed

T- Total quality for excellence

NTPC Limited is the largest thermal power generating company of India, Public

Sector Company. It was incorporated in the year 1975 to accelerate power

development in the country as a wholly owned company of the Government of

India. At present, Government of India holds 89.5% of the total equity shares of

the company and the balance 10.5% is held by FIIs, Domestic Banks, Public and

others. Within a span of 31 years, NTPC has emerged as a truly national power

company, with power generating facilities in all the major regions of the country.

NTPC's core business is engineering, construction and operation of power

generating plants and providing consultancy to power utilities in India and abroad.

The total installed capacity of the company is 31134 MW (including JVs) with 15

coal based and 7 gas based stations, located across the country. In addition under

JVs, 3 stations are coal based & another station uses naphtha/LNG as fuel. By

2017, the power generation portfolio is expected to have a diversified fuel mix

with coal based capacity of around 53000 MW, 10000 MW through gas, 9000 MW

through Hydro generation, about 2000 MW from nuclear sources and around 1000

MW from Renewable Energy Sources (RES). NTPC has adopted a multi-pronged

growth strategy which includes capacity addition through green field projects,

expansion of existing stations, joint ventures, subsidiaries and takeover of stations.

NTPC has been operating its plants at high efficiency levels. Although the

company has 18.79% of the total national capacity it contributes 28.60% of total

power generation due to its focus on high efficiency. NTPC¶s share at 31 Mar 2001

of the total installed capacity of the country was 24.51% and it generated 29.68%

of the power of the country in 2008-09. Every fourth home in India is lit by NTPC.

170.88BU of electricity was produced by its stations in the financial year 2005-

2006. The Net Profit after Tax on March 31, 2006 was INR 58,202 million. Net

Profit after Tax for the quarter ended June 30, 2006 was INR 15528 million, which

is 18.65% more than for the same quarter in the previous financial year. 2005).

Pursuant to a special resolution passed by the Shareholders at the Company¶s

Annual General Meeting on September 23, 2005 and the approval of the Central

Government under section 21 of the Companies Act, 1956, the name of the

Company "National Thermal Power Corporation Limited" has been changed to

"NTPC Limited" with effect from October 28, 2005. The primary reason for this is

the company's foray into hydro and nuclear based power generation along with

backward integration by coal mining.

A graphical overview

NTPC Limited

Type

Public

Founded

1975

Headquarters

Delhi, India

Key people

R S Sharma, Chairman & Managing Director

Industry

Electricity generation

Products

Electricity

Revenue

INR 416.37 billion (2008)

Net income

INR 70.47 billion (2008)

Employees

23867 (2006)

Website

http://www.ntpc.co.in

VISION

´A world class integrated power major, powering India's

growth with increasing global presence.µ

MISSION

Develop and provide reliable power related products and services at

competitive prices, integrating multiple energy resources with

innovative & Eco-friendly technologies and contribution to the society.

STRATEGIES

Technological Initiatives

Introduction of steam generators (boilers) of the size of 800 MW

Integrated Gasification Combined Cycle (IGCC) Technology

Launch of Energy Technology Centre -A new initiative for development of

technologies with focus on fundamental R&D

The company sets aside up to 0.5% of the profits for R&D

Roadmap developed for adopting µClean Development

Mechanism¶ to help get / earn µCertified Emission Reduction

Corporate Social Responsibility

As a responsible corporate citizen NTPC has taken up number of CSR

initiatives

NTPC Foundation formed to address Social issues at national level

NTPC has framed Corporate Social Responsibility Guidelines committing

up to 0.5% of net profit annually for Community Welfare

The welfare of project affected persons and the local population around

NTPC projects are taken care of through well drawn Rehabilitation and

Resettlement policies

The company has also taken up distributed generation for remote rural areas

Partnering government in various initiatives

Consultant role to modernize and improvise several plants across the country

Disseminate technologies to other players in the sector

Consultant role ³Partnership in Excellence´ Programme for improvement of

PLF of 15 Power Stations of SEBs.

Rural Electrification work under Rajiv Gandhi Garmin Vidyutikaran

Environment Management

All stations of NTPC are ISO 14001 certified

Various groups to care of environmental issues

The Environment Management Group

Ash Utilization Division

Afforestation Group

Centre for Power Efficiency & Environment Protection

Group on Clean Development Mechanism

NTPC is the second largest owner of trees in the country after the Forest

department.

JOURNEY OF NTPC

NTPC was set up in 1975 with 100% ownership by the

Government of India. In the last 30 years, NTPC has grown

into the largest power utility in India.

In 1997, Government of India granted NTPC status of

³Navratna¶ being one of the nine jewels of India, enhancing

the powers to the Board of Directors.

NTPC became a listed company with majority Government

ownership of 89.5%.

NTPC becomes third largest by Market Capitalization of

listed companies

The company rechristened as NTPC Limited in line with its

changing business portfolio and transforms itself from a

thermal power utility to an integrated power utility.

National Thermal Power Corporation is the largest power

generation company in India. Forbes Global 2000 for 2008

ranked it 411th in the world.

1975

1997

2005

2004

2008

National Thermal Power Corporation is the largest power

generation company in India. Forbes Global 2000 for 2008

ranked it 317th in the world.

NTPC has also set up a plan to achieve a target of 50,000

MW generation capacity.

NTPC has embarked on plans to become a 75,000 MW

company by 2017.

NTPC is the largest power utility in India, accounting for about 20% of India¶s

installed capacity.

2009

2017

2012

THEMAL POWER PLANT

Introduction

Classification

Functioning

INTRODUCTION

Power Station (also referred to as generating station or power plant) is an industrial

facility for the generation of electric power. Power plant is also used to refer to the

engine in ships, aircraft and other large vehicles. Some prefer to use the term

energy center because it more accurately describes what the plants do, which is the

conversion of other forms of energy, like chemical energy, gravitational potential

energy or heat energy into electrical energy. However, power plant is the most

common term in the U.S., while elsewhere power station and power plant are both

widely used, power station prevailing in many Commonwealth countries and

especially in the United Kingdom.

A coal-fired Thermal Power Plant

At the center of nearly all power stations is a generator, a rotating machine that

converts Mechanical energy into Electrical energy by creating relative motion

between a magnetic field and a conductor. The energy source harnessed to turn the

generator varies widely. It depends chiefly on what fuels are easily available and

the types of technology that the power company has access to.

In thermal power stations, mechanical power is produced by a heat engine, which

transforms Thermal energy (often from combustion of a fuel) into rotational

energy. Most thermal power stations produce steam, and these are sometimes

called steam power stations. About 80% of all electric power is generated by use of

steam turbines. Not all thermal energy can be transformed to mechanical power,

according to the second law of thermodynamics. Therefore, there is always heat

lost to the environment. If this loss is employed as useful heat, for industrial

processes or district heating, the power plant is referred to as a cogeneration power

plant or CHP (combined heat-and-power) plant. In countries where district heating

is common, there are dedicated heat plants called heat-only boiler stations. An

important class of power stations in the Middle East uses by-product heat for

desalination of water.

CLASSIFICATION

By fuel

‡ Nuclear power plants use a nuclear reactor's heat to operate a steam turbine

generator.

‡ Fossil fuelled power plants may also use a steam turbine generator or in the case

of natural gas fired plants may use a combustion turbine.

‡ Geothermal power plants use steam extracted from hot underground rocks.

‡ Renewable energy plants may be fuelled by waste from sugar cane, municipal

solid waste, landfill methane, or other forms of biomass.

‡ In integrated steel mills, blast furnace exhaust gas is a low-cost, although low-

energy density, fuel.

‡ Waste heat from industrial processes is occasionally concentrated enough to use

for power generation, usually in a steam boiler and turbine.

By prime mover

‡ Steam turbine plants use the dynamic pressure generated by expanding steam to

turn the blades of a turbine. Almost all large non-hydro plants use this system.

‡ Gas turbine plants use the dynamic pressure from flowing gases to directly

operate the turbine. Natural-gas fuelled turbine plants can start rapidly and so are

used to supply "peak" energy during periods of high demand, though at higher cost

than base-loaded plants. These may be comparatively small units, and sometimes

completely unmanned, being remotely operated. This type was pioneered by the

UK, Prince town being the world's first, commissioned in 1959.

‡ Combined cycle plants have both a gas turbine fired by natural gas, and a steam

boiler and steam turbine which use the exhaust gas from the gas turbine to produce

electricity. This greatly increases the overall efficiency of the plant, and many new

base load power plants are combined cycle plants fired by natural gas.

‡ Internal combustion Reciprocating engines are used to provide power for isolated

communities and are frequently used for small cogeneration plants. Hospitals,

office buildings, industrial plants, and other critical facilities also use them to

provide backup power in case of a power outage. These are usually fuelled by

diesel oil, heavy oil, natural gas and landfill gas.

‡ Micro turbines, Sterling engine and internal combustion reciprocating engines are

low cost solutions for using opportunity fuels, such as landfill gas, digester gas

from water treatment plants and waste gas from oil production.

FUNCTIONING

In a thermal power plant, one of coal, oil or natural gas is used to heat the boiler to

convert the water into steam. The steam is used to turn a turbine, which is

connected to a generator. When the turbine turns, electricity is generated and given

as output by the generator, which is then supplied to the consumers through high-

voltage power lines.

Process of a Thermal Power Plant

Detailed process of power generation in a thermal power plant:

1) Water intake: Firstly, water is taken into the boiler through a water source. If

water is available in a plenty in the region, then the source is an open pond or river.

If water is scarce, then it is recycled and the same water is used over and over

again.

2) Boiler heating: The boiler is heated with the help of oil, coal or natural gas. A

furnace is used to heat the fuel and supply the heat produced to the boiler. The

increase in temperature helps in the transformation of water into steam.

3) Steam Turbine: The steam generated in the boiler is sent through a steam

turbine. The turbine has blades that rotate when high velocity steam flows across

them. This rotation of turbine blades is used to generate electricity.

4) Generator: A generator is connected to the steam turbine. When the turbine

rotates, the generator produces electricity which is then passed on to the power

distribution systems.

5) Special mountings: There is some other equipment like the economizer and air

pre-heater.

An economizer uses the heat from the exhaust gases to heat the feed water. An air

pre-heater heats the air sent into the combustion chamber to improve the efficiency

of the combustion process.

6) Ash collection system: There is a separate residue and ash collection system in

place to collect all the waste materials from the combustion process and to prevent

them from escaping into the atmosphere.

Apart from this, there are various other monitoring systems and instruments in

place to keep track of the functioning of all the devices. This prevents any hazards

from taking place in the plant.

OPERATION

Introduction

‡ Steam Generator or Boiler

‡ Steam Turbine

‡ Electric Generator

Introduction

The operating performance of NTPC has been considerably above the national

average. The availability factor for coal stations has increased from 85.03 % in

1997-98 to 90.09 % in 2006-07, which compares favourably with international

standards. The PLF has increased from 75.2% in 1997-98 to 89.4% during the year

2006-07 which is the highest since the inception of NTPC.

Operation Room of Power Plant

In Badarpur Thermal Power Station, steam is produced and used to spin a turbine

that operates a generator. Water is heated, turns into steam and spins a steam

turbine which drives an electrical generator. After it passes through the turbine, the

steam is condensed in a condenser; this is known as a Rankine cycle. Shown here

is a diagram of a conventional thermal power plant, which uses coal, oil, or natural

gas as fuel to boil water to produce the steam. The electricity generated at the plant

is sent to consumers through high-voltage power lines.

The Badarpur Thermal Power Plant has Steam Turbine-Driven Generators which

has a collective capacity of 705MW.

The fuel being used is Coal which is supplied from the Jharia Coal Field in

Jharkhand.

Water supply is given from the Agra Canal.

Table: Capacity of Badarpur Thermal Power Station, (BTPS) New Delhi

There are basically three main units of a thermal power plant:

1. Steam Generator or Boiler

2. Steam Turbine

3. Electric Generator

We have discussed about the processes of electrical generation further. A complete

detailed description of two (except 2) units is given further.

Coal is conveyed (14) from an external stack and ground to a very fine powder by

large metal spheres in the pulverised fuel mill (16). There it is mixed with

preheated air (24) driven by the forced draught fan (20). The hot air-fuel mixture is

forced at high pressure into the boiler where it rapidly ignites. Water of a high

purity flows vertically up the tube-lined walls of the boiler, where it turns into

steam, and is passed to the boiler drum, where steam is separated from any

remaining water. The steam passes through a manifold in the roof of the drum into

the pendant super heater (19) where its temperature and pressure increase rapidly

to around 200 bar and 540°C,

sufficient to make the tube walls glow a dull red. The steam is piped to the high

pressure turbine (11), the first of a three-stage turbine process. A steam governor

valve (10) allows for both manual control of the turbine and automatic set-point

following. The steam is exhausted from the high pressure turbine, and reduced in

both pressure and temperature, is returned to the boiler reheater (21). The reheated

steam is then passed to the intermediate pressure turbine (9), and from there passed

directly to the low pressure turbine set (6). The exiting steam, now a little above its

boiling point, is brought into thermal contact with cold water (pumped in from the

Cooling tower) in the condenser (8), where it condenses rapidly back into water,

creating near vacuum-like conditions inside the condensor chest. The condensed

water is then passed by a feed pump (7) through a deaerator (12), and pre-warmed,

first in a feed heater (13) powered by steam drawn from the high pressure set, and

then in the economiser (23), before being returned

to the boiler drum. The cooling water from the condensor is sprayed inside a

cooling tower (1), creating a highly visible plume of water vapour, before being

pumped back to the condensor (8) in cooling water cycle. The three turbine sets are

sometimes coupled on the same shaft as the three-phase electrical generator (5)

which generates an intermediate level voltage (typically 20-25 kV). This is stepped

up by the unit transformer (4) to a voltage more suitable for transmission (typically

250-500 kV) and is sent out onto the three-phase transmission system (3). Exhaust

gas from the boiler is drawn by the induced draft fan (26) through an electrostatic

precipitator (25) and is then vented through the chimney stack (27).

Steam Generator/Boiler

The boiler is a rectangular furnace about 50 ft (15 m) on a side and 130 ft (40 m)

tall. Its walls are made of a web of high pressure steel tubes about 2.3 inches (60

mm) in diameter. Pulverized coal is air-blown into the furnace from fuel nozzles at

the four corners and it rapidly burns, forming a large fireball at the center. The

thermal radiation of the fireball heats the water

that circulates through the boiler tubes near the boiler perimeter. The water

circulation rate in the boiler is three to four times the throughput and is typically

driven by pumps. As the water in the boiler circulates it absorbs heat and changes

into steam at 700 °F (370 °C) and 3,200 psi (22.1MPa). It is separated from the

water inside a drum at the top of the furnace. The saturated steam is introduced

into superheat pendant tubes that hang in the hottest part of the combustion gases

as they exit the furnace. Here the steam is superheated to 1,000 °F (540 °C) to

prepare it for the turbine. The steam generating boiler has to produce steam at the

high purity, pressure and temperature required for the steam turbine that drives the

electrical generator. The generator includes the economizer, the steam drum, the

chemical dosing equipment, and the furnace with its steam generating tubes and

the superheater coils. Necessary safety valves are located at suitable points to avoid

excessive boiler pressure. The air and flue gas path equipment include: forced draft

(FD) fan, air preheater (APH), boiler furnace, induced draft (ID) fan, fly ash

collectors (electrostatic precipitator or baghouse) and the flue gas stack.

For units over about 210 MW capacity, redundancy of key components is provided

by installing duplicates of the FD fan, APH, fly ash collectors and ID fan with

isolating dampers. On some units of about 60 MW, two boilers per unit may

instead be provided.

Schematic diagram of a coal-fired power plant steam generator

Boiler Furnace and Steam Drum

Once water inside the boiler or steam generator, the process of adding the latent

heat of vaporization or enthalpy is underway. The boiler transfers energy to the

water by the chemical reaction of burning some type of fuel.

The water enters the boiler through a section in the convection pass called the

economizer. From the economizer it passes to the steam drum. Once the water

enters the steam drum it goes down the down comers to the lower inlet water wall

headers. From the inlet headers the water rises through the water walls and is

eventually turned into steam due to the heat being generated by

the burners located on the front and rear water walls (typically). As the water is

turned into steam/vapour in the water walls, the steam/vapour once again enters the

steam drum.

External View of an Industrial Boiler at BTPS, New Delhi

The steam/vapour is passed through a series of steam and water separators and then

dryers inside the steam drum. The steam separators and dryers remove the water

droplets from the steam and the cycle through the water walls is repeated. This

process is known as natural circulation. The boiler furnace auxiliary equipment

includes coal feed nozzles and igniter guns, soot blowers, water lancing and

observation ports (in the furnace walls) for observation of the furnace interior.

Furnace explosions due to any accumulation of combustible gases after a tripout

are avoided by flushing out such gases from the combustion zone before igniting

the coal. The steam drum (as well as the superheater coils and headers) have air

vents and drains needed for initial start-up. The steam drum has an internal device

that removes moisture from the wet steam entering the drum from the steam

generating tubes. The dry steam then flows into the superheater coils. Geothermal

plants need no boiler since they use naturally occurring steam sources. Heat

exchangers may be used where the geothermal steam is very corrosive or contains

excessive suspended solids. Nuclear plants also boil water to raise steam, either

directly passing the working steam through the reactor or else using an

intermediate heat exchanger.

Fuel Preparation System

In coal-fired power stations, the raw feed coal from the coal storage area is first

crushed into small pieces and then conveyed to the coal feed hoppers at the boilers.

The coal is next pulverized into a very fine powder. The pulverisers may be ball

mills, rotating drum grinders, or other types of grinders. Some power stations burn

fuel oil rather than coal. The oil must kept warm (above its pour point) in the fuel

oil storage tanks to prevent the oil from congealing and becoming unpumpable.

The oil is usually heated to about 100°C before being pumped through the furnace

fuel oil spray nozzles.

Boiler Side of the Badarpur Thermal Power Station, New Delhi

Boilers in some power stations use processed natural gas as their main fuel. Other

power stations may use processed natural gas as auxiliary fuel in the event that

their main fuel supply (coal or oil) is interrupted. In such cases, separate gas

burners are provided on the boiler furnaces.

Fuel Firing System and Igniter System

From the pulverized coal bin, coal is blown by hot air through the furnace coal

burners at an angle which imparts a swirling motion to the powdered coal to

enhance mixing of the coal powder with the incoming preheated combustion air

and thus to enhance the combustion. To provide sufficient combustion temperature

in the furnace before igniting the powdered coal, the furnace temperature is raised

by first burning some light fuel oil or processed natural gas (by using auxiliary

burners and igniters provide for that purpose).

Air Path

External fans are provided to give sufficient air for combustion. The forced draft

fan takes air from the atmosphere and, first warming it in the air preheater for

better combustion, injects it via the air nozzles on the furnace wall. The induced

draft fan assists the FD fan by drawing out combustible gases from the furnace,

maintaining a slightly negative pressure in the furnace to avoid backfiring through

any opening. At the furnace outlet and before the furnace gases are handled by the

ID fan, fine dust carried by the outlet gases is removed to avoid atmospheric

pollution. This is an environmental limitation prescribed by law, and additionally

minimizes erosion of the ID fan.

Auxiliary Systems

Fly Ash Collection

Fly ash is captured and removed from the flue gas by electrostatic precipitators or

fabric bag filters (or sometimes both) located at the outlet of the furnace and before

the induced draft fan. The fly ash is periodically removed from the collection

hoppers below the precipitators or bag filters. Generally, the fly ash is

pneumatically transported to storage silos for subsequent transport by trucks or

railroad cars.

Bottom Ash Collection and Disposal

At the bottom of every boiler, a hopper has been provided for collection of the

bottom ash from the bottom of the furnace. This hopper is always filled with water

to quench the ash and clinkers falling down from the furnace. Some arrangement is

included to crush the clinkers and for conveying the crushed clinkers and bottom

ash to a storage site.

Boiler Make-up Water Treatment Plant and Storage

Since there is continuous withdrawal of steam and continuous return of condensate

to the boiler, losses due to blow-down and leakages have to be made up for so as to

maintain the desired water level in the boiler steam drum. For this, continuous

make-up water is added to the boiler water system. The impurities in the raw water

input to the plant generally consist of calcium and magnesium salts which impart

hardness to the water. Hardness in the make-up water to the boiler will form

deposits on the tube water surfaces which will lead to overheating and failure of

the tubes. Thus, the salts have to be removed from the water and that is done by a

Water Demineralising Treatment Plant (DM).

Ash Handling System at Badarpur Thermal Power Station, New Delhi

A DM plant generally consists of cation, anion and mixed bed exchangers. The

final water from this process consists essentially of hydrogen ions and hydroxide

ions which is the chemical composition of pure water. The DM water, being very

pure, becomes highly corrosive once it absorbs oxygen from the atmosphere

because of its very high affinity for oxygen absorption. The capacity of the DM

plant is dictated by the type and quantity of salts in the raw water input. However,

some storage is essential as the DM plant may be down for maintenance. For this

purpose, a storage tank is installed from which DM water is continuously

withdrawn for boiler make-up. The storage tank for DM water is made from

materials not affected by corrosive water, such as PVC. The piping and valves are

generally of stainless steel. Sometimes, a steam blanketing arrangement or

stainless steel doughnut float is provided on top of the water in the tank to avoid

contact with atmospheric air. DM water make-up is generally added at the steam

space of the surface condenser (i.e., the vacuum side). This arrangement not only

sprays the water but also DM water gets deaerated, with the dissolved gases being

removed by the ejector of the condenser itself.

Electric Generator

The steam turbine-driven generators have auxiliary systems enabling them to work

satisfactorily and safely. The steam turbine generator being rotating equipment

generally has a heavy, large diameter shaft. The shaft therefore requires not only

supports but also has to be kept in position while running. To minimize the

frictional resistance to the rotation, the shaft has a number of bearings. The bearing

shells, in which the shaft rotates, are lined with a low friction material like Babbitt

metal. Oil lubrication is provided to further reduce the friction between shaft and

bearing surface and to limit the heat generated.

A 95 MW Generator at BTPS, New Delhi

Barring Gear (or Turning Gear)

Barring gear is the term used for the mechanism provided for rotation of the

turbine generator shaft at a very low speed (about one revolution per minute) after

unit stoppages for any reason. Once the unit is "tripped" (i.e., the turbine steam

inlet valve is closed), the turbine starts slowing or "coasting down". When it stops

completely, there is a tendency for the turbine shaft to deflect or bend if allowed to

remain in one position too long. This deflection is because the heat inside the

turbine casing tends to concentrate in the top half of the casing, thus making the

top half portion of the shaft hotter than the bottom half. The shaft therefore warps

or bends by millionths of inches, only detectable by monitoring eccentricity

meters. But this small amount of shaft deflection would be enough to cause

vibrations and damage the entire steam turbine generator unit when it is restarted.

Therefore, the shaft is not permitted to come to a complete stop by a mechanism

known as "turning gear" or "barring gear" that automatically takes over to rotate

the unit at a preset low speed. If the unit is shut down for major maintenance, then

the barring gear must be kept in service until the temperatures of the casings and

bearings are sufficiently low.

Condenser

The surface condenser is a shell and tube heat exchanger in which cooling water is

circulated through the tubes. The exhaust steam from the low pressure turbine

enters the shell where it is cooled and converted to condensate (water) by flowing

over the tubes as shown in the adjacent diagram. Such condensers use steam

ejectors or rotary motor-driven exhausters for continuous removal of air and gases

from the steam side to maintain vacuum. A Typical Water Cooled Condenser

For best efficiency, the temperature in the condenser must be kept as low as

practical in order to achieve the lowest possible pressure in the condensing steam.

Since the condenser temperature can almost always be kept significantly below

100 S

C where the vapour pressure of water is much less than atmospheric pressure,

the condenser generally works under vacuum. Thus leaks of noncondensible air

into the closed loop must be prevented. Plants operating in hot climates may have

to reduce output if their source of condenser cooling water becomes warmer;

unfortunately this usually coincides with periods of high electrical demand for air

conditioning. The condenser generally uses either circulating cooling water from a

cooling tower to reject waste heat to the atmosphere, or once-through water from a

river, lake or ocean.

A typical water cooled condensor

Feedwater Heater

A Rankine cycle with a two-stage steam turbine and a single feedwater heater. In

the case of a conventional steam-electric power plant utilizing a drum boiler, the

surface condenser removes the latent heat of vaporization from the steam as it

changes states from vapour to liquid. The heat content (btu) in the steam is referred

to as Enthalpy. The condensate pump then pumps the condensate water through a

feedwater heater. The feedwater heating equipment then raises the temperature of

the water by utilizing extraction steam from various stages of the turbine.

Preheating the feedwater reduces the irreversibility¶s involved in steam generation

and therefore improves the thermodynamic efficiency of the system.[9] This reduces

plant operating costs and also helps to avoid thermal shock to the boiler metal

when the feedwater is introduced back into the steam cycle.

A Rankine cycle with a 2-stage steam turbine and a single feedwater

heater

Superheater

As the steam is conditioned by the drying equipment inside the drum, it is piped

from the upper drum area into an elaborate set up of tubing in different areas of the

boiler. The areas known as superheater and reheater. The steam vapour picks up

energy and its temperature is now superheated above the saturation temperature.

The superheated steam is then piped through the main steam lines to the valves of

the high pressure turbine.

Deaerator

A steam generating boiler requires that the boiler feed water should be devoid of

air and other dissolved gases, particularly corrosive ones, in order to avoid

corrosion of the metal. Generally, power stations use a deaerator to provide for the

removal of air and other dissolved gases from the boiler feedwater. A deaerator

typically includes a vertical, domed deaeration section mounted on top of a

horizontal cylindrical vessel which serves as the deaerated boiler feedwater storage

tank.

Boiler Feed Water Deaerator

There are many different designs for a deaerator and the designs will vary from

one manufacturer to another. The adjacent diagram depicts a typical conventional

trayed deaerator. If operated properly, most deaerator manufacturers will guarantee

that oxygen in the deaerated water will not exceed 7 ppb by weight (0.005 cm3/L).

Auxiliary Systems

Oil System

An auxiliary oil system pump is used to supply oil at the start-up of the steam

turbine generator. It supplies the hydraulic oil system required for steam turbine's

main inlet steam stop valve, the governing control valves, the bearing and seal oil

systems, the relevant hydraulic relays and other mechanisms. At a preset speed of

the turbine during start-ups, a pump driven by the turbine main shaft takes over the

functions of the auxiliary system.

Generator Heat Dissipation

The electricity generator requires cooling to dissipate the heat that it generates.

While small units may be cooled by air drawn through filters at the inlet, larger

units generally require special cooling arrangements. Hydrogen gas cooling, in an

oil-sealed casing, is used because it has the highest known heat transfer coefficient

of any gas and for its low viscosity which reduces windage losses. This system

requires special handling during start-up, with air in the chamber first displaced by

carbon dioxide before filling with hydrogen. This ensures that the highly

flammable hydrogen does not mix with oxygen in the air. The hydrogen pressure

inside the casing is maintained slightly higher than atmospheric pressure to avoid

outside air ingress. The hydrogen must be sealed against outward leakage where

the shaft emerges from the casing. Mechanical seals around the shaft are installed

with a very small annular gap to avoid rubbing between the shaft and the seals.

Seal oil is used to prevent the hydrogen gas leakage to atmosphere. The generator

also uses water cooling. Since the generator coils are at a potential of about

15.75kV and water is conductive, an insulating barrier such as Teflon is used to

interconnect the water line and the generator high voltage windings. Demineralised

water of low conductivity is used.

Generator High Voltage System

The generator voltage ranges from 10.5 kV in smaller units to 15.75 kV in larger

units. The generator high voltage leads are normally large aluminum channels

because of their high current as compared to the cables used in smaller machines.

They are enclosed in well-grounded aluminum bus ducts and are supported on

suitable insulators. The generator high voltage channels are connected to step-up

transformers for connecting to a high voltage electrical substation (of the order of

220 kV) for further transmission by the local power grid. The necessary protection

and metering devices are included for the high voltage leads. Thus, the steam

turbine generator and the transformer form one unit. In smaller units, generating at

10.5kV, a breaker is provided to connect it to a common 10.5 kV bus system.

Other Systems

Monitoring and Alarm system

Most of the power plant¶s operational controls are automatic. However, at times,

manual intervention may be required. Thus, the plant is provided with monitors

and alarm systems that alert the plant operators when certain operating parameters

are seriously deviating from their normal range.

Battery Supplied Emergency Lighting & Communication

A central battery system consisting of lead acid cell units is provided to supply

emergency electric power, when needed, to essential items such as the power

plant's control systems, communication systems, turbine lube oil pumps, and

emergency lighting. This is essential for safe, damage-free shutdown of the units in

an emergency situation.

ELECTRICITY GENERATION PROCESS

(A BASIC OVERVIEW)

HOW ELECTRICITY IS GENERATED?

Thermal power station burns fuel and uses the resultant heat to raise steam which

drives the TURBO GENERATOR. The fuel may be µfossil¶(coal,oil,natural gas) or

it may be fissionable, whichever fuel is used, the objective is same to convert the

mechanical energy into electricity by rotating a magnet inside a set of winding.

COAL TO STAEM

Its other raw materials are air and water. The coal brought to the station by trains

or by other means, travels handling plant by conveyer belts, travels from

pulverizing mills, which grind it as fine as the face powder of size upto 20 microns.

The finely produced coal mixed with preheated air is then blown into the boiler by

a fan called primary air fan where it burns more like a gas than as a solid, in the

conventional domestic or industrial grate, with additional amount of air, called

secondary air supply, by forced draft fan.

As coal is ground so finally the resultant ash is also a fine powder. Some of it binds

together to form pumps, which falls into ash pits at the bottom of the furnace. The

water-quenched ash from the bottom is conveyed to pits for subsequent disposal or

sale. Most of ash, still in fine partical form is carried out of boilers to the

precipitator as dust, where electrodes charged with high voltage electricity trap it.

The dust is then conveyed to water to disposal area or to bunker for sale while the

clean flue gases are passed on through IP fans to be discharged through chimneys.

The heat released from the coal has been absorbed by the many kilometers tubing

which line the boiler walls. Inside the tubes the boiler feed water, which is

transformed by heat into staemat high temperature and pressure.. The steam

superheated in further tubes (superheaters) passes to turbine where it is discharged

through the nozzle on the turbine blades. Just as the energy of wind turns the sail of

the windmill, the energy of steam striking the blade makes the turbine rotate.

Coupled to the end of the turbine is the rotor of the generator. The rotor is housed

inside the stator having heavy coils of the bars in which electricity is produced

through the movement of magnetic field created by the rotor. Electricity passes

from stator windings to step-up transformer which increases its voltage so that it

can be transmited efficiently over lines of grid.

The staem which has given up its heat energy is cahnged back into water in a

condenser so that it is ready for re-use. The condenser contains many kilometers of

tubing through which cold water is constantly pumped. The staem passing around

the tubes looses heat.Thus it is rapidly changed back into water.

But, the two lots of water, that is, the boiler feed and cooling water must never

mix. Cooling water is drawn from river- bed, but the boiler feed water must be

absolutely pure, far purer than the water we drink (de-mineralized water),

otherwise it may damage the boiler tubes.

My summer training of 4 weeks (31st

May ± 25th

June) has been

scheduled as follows:

EMD-I (Electrical Maintenance Department-I)--- 1 week

EMD-II (Electrical Maintenance Department-II)--- 1 week

C & I(Control & Instrumentation)--- 2 weeks

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