Kota Thermal Power Station

Training Session May,09 June,09

Submitted By:Ankit Kulshreshtha EC-1 Roll No. 06/N/028

Industry at a glance :Location:- On the bank of river Chambal in Kota (Rajasthan) Produce electricity by coal Having 6 units (presently) producing continuously Produce almost 1024 MW energy ,second to Suratgardh power plant Get coal from Madhya Pradesh coal fields Have 4 big 180 meters height chimneys to control suspended particles Record of having 85% power factor, get clearance from CEA

Unit Details of KTPS

Units Date of synchronization on oil Date of synchronization on coal Date of declaration of Commercial Operation

Unit-1 Unit-2 Unit-3 Unit-4 Unit-5 Unit-6

17.1.83 17.7.83 25.9.88 01.5.89 26.3.94 30.07.2003

20.1.83 05.8.83 11.12.88 16.10.89 11.10.94 30.7.2003

01.04.83 01.04.84 11.03.89 06.03.90 18.07.95 01.08.2004

Basic Process of Thermal Power plant

The KTPS working is based on four Sections

Coal and Ash Air and gas Feed water and steam Cooling water

Air and gas

Cooling tower

Feed water Coal and ash

Detail Working of KTPS

Coal Handling
Coal is supplied Through rail Track by own trains By wagon tripler The coal is drawn Into underground hopper By means of two Belts coal is transferred To the Conveyer

From nozzle coal Is discharged to furnace

Coal is taken to Coal nozzle In wind box assembly

Now coal is fed to Mills Where coal is Crushed in pulverized form

Now coal is transferred to Crushing house and stored to bunkers

There are two types of Mills in KSTPS

 Bowl Mills Grinding chambers in form of Bowl  Centrifugal force is used to move coal against grinder  FD fan is used to dry the coal & drive it to furnace  Tube mills Constantly rotating tube around 20 rpm  Side at which gas gear is mounted is known as driving end  3 balls of diff. size is used  FD fan is used to dry the coal & drive it to furnace

Here hot air is used to remove moisture from coal and cold air is used to keep temp below flash point Power consumed by Coal Mill Motor is 340 MW. There are total 8 motor are installed 6 running 2 on stand by PA fans = 820 Kw ID fans = 850 kw FD fans = 300 kw

Burner :- Tangential type

discharge the fuel air mixture tangentially to an imaginary circle in the center of the furnace burners are placed at the four corners of the furnace Firing Mechanism-Fuel is introduced from wind nozzle located at lower corner inside the boiler

Boiler :- A apparatus where water is being converted into steam

 The water in the tube of boiler get vaporized by heat energy & steam is generated  The boiler weighs about 6000 Mega tons ,height about 50 to 60 meters  Whole height is divided in 13 diff. levels as per burning materials

Boiler Auxileries- To increase efficiency

Economiser
Used to preheat boiler feed water, before entering to boiler Deriving heat from the flue gases The economizer is placed in the main flue gas path between the boiler and the chimney. The waste flue gases flow outside the tubes and heat is transferred to the water flowing inside

Air Preheater
Tubular type heat exchanger The flue gases coming out of the economizer is used to preheat the air before supplying it to the combustion chamber. An increase in air temperature of 20 degrees can be achieved by this method. The pre heated air is used for combustion and also to dry the crushed coal Useful to increase efficiency (20% flue gas incrs 1% capacity) In KTPS Regenerative type is used (Having rotor move at 2.4 RPM )

Boiler Drum
To separate water from steam It is located 54 meter from ground Feed water coming out of Economiser enter to the Boiler Drum

Turbine :-A machine which convert Kinetic energy

to Mechanical energy
Flow chart for turbine
Parts of Turbine A.) Nozzle B.) Blade C.) Rotor shaft Steam is passed through nozzle Steam now falls on Turbine blade moves the turbine

The rotor shaft is made of steel, blade is fixed on it

Steam is entered from left and right inlets Two stage turbine is used Steam is recycled

Auxiliaries of turbine :Condenser

Here steam is exited by creating vaccum or very low atm pressure ,the cooling water is directly taken from chambal requirement as discharge from LPT is Liquid+vapour

Hotwell
It is located below the condenser ,to store condensate ,tank of size 5m in depth & 2 to 3m in dia.makeup of leakage of demineralised water also processed

Deaerator
It removes the dissolved gases like O2 , CO2 etc by means of pagging. requirement- As dissolved gases may corrode Boiler Drum

High Pressure Heater

It raise the temp & pressure of water which is required for further processing i.e. 165 kg/cm and 2500 C

Generator :-Machine that coverts Mechanical energy to the

Electrical energy

PrincipleBased on faradays law of electromagnetic induction

Statistics of generator at KTPS

KW : 210 Kw PF : 0.85 KVA : 247000 RPM : 3000 Hz : 50hz Coolant :Water + H2

Parts of Generator
Stator Frame
Welded construction of plate Used to contain and support the stator core winding, also provide H2 as coolant

Stator core
Built of Segmented ,annealed ,insulated ,high quality ,Silicon Sheet ,to give min electrical loss

Stator Bars
Each stator half coil bar is composed of alternate strip of double glass covered and bars copper transposed in straight position, each strip occupies every radial position

Rotor
It is forged on a single piece of special Cr, Ni & Mo alloy steel ,to get required mech prop.

Rotor Winding
It consist of two poles each having concentric coils of several turns Semi hold silver alloy copper of rectangular cross section is used, insulated by epoxy Glasses laminated stripes CONT

Rotor bearingSpecially designed bearing electronic apparatus to indicate the location of unbalance pole in magnitude and direction.

Slip Ring
Made of forged steel they are located side by side on exciter side of generator shaft

Generator Terminal Bushing

Have six output 3 larger and 3 shorter ,coming out of bottom, short terminals used for External connection ,conduction is through a Cu tube ,H2 as coolant is used.

Bush Gear Assembly

Made of natural composition of Graphite and winding materials, have low friction , self lubricating

Control Room:- Where controlling of various equipment taken

place
     CP I 1 Setup is done by Instrumentation Limited, kota From one unit control 2 adjacent unit can be controlled + local CS for boilers ,turbo jets ,boilers CR shows and record various parameters Automatic Scheme for feed water regulation and reheat temp computation is provided One CR have five desks as follows :FAN CONRTOL DESK a. Induced Fan draft b. Forced Fan c. Primary air Fan PRESSURE DESK a. Furnace pressure b. Primary Air Heater Pressure FUEL CONTROL DESK a. Coal air flow b. oil pressure c. temp of mill d. flow of air e. differential pressure of mill

2.

CP II 1

CONTD..

CP III 1. STEAM AND WATER DESK

a. Drum Level control b. Flow of Steam and Water c. Pressure of steam and water d. Temp of steam and water CP IV 1. TURBINE DESK a. Pressure Control b. Load control c. Speed control d. Valves control GENERATOR CONTROL DESK a. Voltage Control MVAR b. Stator rotor Temp c. For stator cooling a) Water b) H2

CP V 1.

Facts about KTPS

Kota Thermal Power Station has performed outstanding, from the very beginning, produced outstanding results and has continuously earned cash prizes and shields. Power station has received meritorious productivity awards given by the Ministry of power, Government of India, in the years 1984,1987, 1989, 1991 and continuously thereafter. The 6th unit of Kota Super TPS was commissioned and synchronized with the grid on 30.7.03 and full load was achieved on coal firing in less than 10 Hrs. The project was completed in 24 months which is a national record for this type of generating unit.

Conclusion : K.S.T.P.S. is the main super thermal power plant located in principle industry city, Kota.  It has established a record of excellence & earned various productivity award from The Ministry of power, Government of India.

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