SUMMER TRAINING REPORT ON

BADARPUR THERMAL POWER STATION

Term Paper Report

A term paper report submitted in partial fulfillment of the requirement of

Bachelor of Technology
in
Electronics and Communication Engineering

Submitted By
Name of Student
Enrollment No.:------

Submitted to
Mr. Mahendra Singh Meena

Department of Electronics and Communication Engineering

Amity School of Engineering and Technology
Amity University Haryana
August 2015
ACKNOWLEDGEMENT
I would like to thank NTPC BADARPUR for providing me a golden opportunity to
work with them. The support and the environment provided to me during my project was
more than what anyone would have expected. I am very grateful to Mrs. RACHNA BHAL
(H.R.)who granted me the opportunity of working as a trainee at mechanical division of
power engineering. I would also like to thanks Mr. MANMOHAN SINGH
(DY.MANAGER), Mr. G.D SHARMA (TRAINING COORDINATOR) and my instructors
of B.M.D., P.A.M., T.M.D. and divisions without them I would not be able to perform such a
delightful job.
And at last I would like to thanks all the people involve in the training that helped me in
accomplishing it in such a wonderful way.

2
PREFACE

NTPC is one of the most important industriesfor producing the electricity. There are various
divisions in NTPC for various branches like mechanical division, electrical division etc. The
main objective of preparing this report has been to present the operations of BMD, PAM,
TMD of mechanical division in a logical, innovative and manner. The basic theory presented
in this report has been evolved out of simple and readily understood principles. A sincere
effort has been made to maintain physical concepts in various operations. An effort has been
made to give a balanced presentation of this report with the help of figures, different types of
data and related suitable theories as well as concepts. Eventually, again I would like to thank
BTPS.
 CONTENTS

TOPIC PAGE NO.

1. CHAPTER 1 ABOUT N.T.P.C…………………………………………….

(NATIONAL THERMAL POWER CORPORATION)
1.1INTRODUCTION…………………………………………………..
1.2POWER GENERATION…………………………………………...
1.3 INSTALLED CAPACITY…………………………………………..
1.4NTPC POWER STATIONS IN INDIA……………………….......
2. ABOUT B.T.P.S……………………………………………………………
(BADARPUR THERMAL POWER STATION)
2.1 INTRODUCTION………………………………………………. …
2.2 BASIC POWER PLANT……………………………………….. …

3. ABOUT PAM………………………………………………………………..
(PLANT AUXILIARY MAINTENANCE DEPARTMENT)
3.1 THEORY OF CIRCULATION OF WATER………………….. ….
3.2 ASH HANDLING PLANT…………………………………………….
3.3 CSP HOUSE…………………………………………………………..
3.4 WATER TREATMENT PLANT……………………………………..
4. ABOUT TMD……………………………………………………………….
(TURBINE MAINTENANCE DEPARTMENT)
4.1 STEAM TURBINE THEORY…………………………………........
4.2 STEAM CYCLE………………………………………………………..
4.3 TURBINE CLASSIFICATION……………………………………….
4.4 TURBINE CYCLE……………………………………………………..
4.5 DESCRIPTION OF MAIN TURBINE……………………………….
4.6 TURBINE AUXILLIARIES AND THEIR ARRANGEMENT……

4
 TABLE OF FIQURES
Figure 2-1 BTP .................................................................................................................. 11
Figure 2-2 components of a coal fired thermal plant ......................................................... 13
Figure 2-3 boiler maintenance department ........................................................................ 13
Figure 3-1 boiler maintenance department ........................ Error! Bookmark not defined.
Figure 3-2 Schematic diagram of typical coal-fired power plant steam generator ....Error!
Bookmark not defined.
Figure 3-3 furnance ............................................................ Error! Bookmark not defined.
Figure 3-4 boiler drum ....................................................... Error! Bookmark not defined.
Figure 3-5 super heater ...................................................... Error! Bookmark not defined.
Figure 3-6ECONOMIZER................................................. Error! Bookmark not defined.
Figure 3-7 air preheater ...................................................... Error! Bookmark not defined.
Figure 3-8 axial fans .......................................................... Error! Bookmark not defined.
Figure 3-9 Centrifugal Fan................................................. Error! Bookmark not defined.
Figure 3-10 ID FAN LUBE OIL SYSTEM ....................... Error! Bookmark not defined.
Figure 3-11 FD FAN LUB OIL SYSTEM ........................ Error! Bookmark not defined.
Figure 3-12 PA FAN LUBE OIL SYSTEM ...................... Error! Bookmark not defined.
Figure 3-13PULVERIZER ................................................ Error! Bookmark not defined.
Figure 3-14 ELECTROSTATIC PRECIPITATOR........... Error! Bookmark not defined.
Figure 4-1 boiler circulating system .................................................................................. 15
Figure 4-2 NATURAL CIRCULATION SYSTEM .......................................................... 16
Figure 4-3 COMBINED CIRCULATION SYSTEM........................................................ 17
Figure 4-4 COMPRESSOR HOUSE ................................................................................. 19
Figure 4-5 D.M.TANK ...................................................... Error! Bookmark not defined.
Figure 4-6 cooling tower .................................................... Error! Bookmark not defined.
Figure 4-7 CROSS-FLOW COOLING ............................. Error! Bookmark not defined.
Figure 4-8 COUNTER-FLOW COOLING ....................... Error! Bookmark not defined.
Figure 5-1 STEAM TURBINE .......................................................................................... 22
Figure 5-2 steam cycle ....................................................................................................... 23
Figure 5-3 impulse and reaction turbine ............................................................................ 24
Figure 5-4 VELOCITY COMPOUNDED TURBINE ...................................................... 25
Figure 5-5 curtis stage ........................................................................................................ 26
Figure 5-6 PRESSURE COMPOUNDED TURBINE ...................................................... 27
Figure 5-7 Pressure-Compounded Impulse Turbine .......................................................... 27
Figure 5-8 Three stages of reaction turbine indicating pressure and velocity distribution 28
Figure 5-9 The velocity diagram of reaction blading ........................................................ 29
Figure 5-10 Velocity diagram for maximum efficiency .................................................... 30
Figure 5-11 Different stage of a steam turbine .................................................................. 31
Figure 5-12 MAIN TURBINE ........................................................................................... 33
Figure 5-13 TURBINE CYCLE ........................................................................................ 34
Figure 5-14L.P ROTOR…………………………………………………………………36
Figure 5-15TURBINE BEARINGS .................................................................................. 37
Figure 5-16THRUST BEARINGS .................................................................................... 37
Figure 5-17 L.P. HEATERS .............................................................................................. 38
Figure 5-18 Gate Valve ...................................................................................................... 41
Figure 5-19 Regulating Valve ............................................................................................ 41
Figure 5-20 Non-Return Valve .......................................................................................... 42
Figure 5-21 Safety Valve ................................................................................................... 42
LIST OF TABLE
Table 1-1 installed capacity ................................................................................................. 8
Table 1-2 GAS BASED ....................................................................................................... 8
Table 1-3 COAL BASED: ................................................................................................... 8
Table 2-1 BTP capacity .................................................................................................... 10
Table 3-1 Indian Bituminous Coal ..................................... Error! Bookmark not defined.
Table 3-2INDUSTRIAL FANS ......................................... Error! Bookmark not defined.

6
 CHAPTER 1: ABOUT OF NTPC

1.1 INTRODUCTION

The year 1975 witnessed the birth of an organization that went on to achieve great feats in
performance in a sector that was then, characterized largely by lack of investment, severe
supply shortages and operational practices that mad the commercial viability of the sector
unsustainable.
NTPC symbolized hop of the country suffering from crippling power black-outs, the
Government of India, which was trying to pull an ailing, economy back on the track and he
World Bank, which was supporting the country in many development initiatives. Thus,
NTPC was created not only o redraw the power map of India but also excel in is performance
and se benchmarks for others to follow. It succeeded on both counts.
Today with an installed capacity of 39,174 MW, NTPC contributes one fourth of the
Nations Power generation, with only one fifth of India total installed capacity. An ISO
9001:2000 Certified company, it is world world`s 10th largest power generation in the world,
3rd largest in the Asia. NTPC is #1 independent Power Producer (IPP) IN THE WORLD.
Also it is 384th largest company in he world (FORBES 2011).
It is one of the largest Indian companies in terms of market cap. The corporation recorded
a generation of 222.07 billion unit(BUS) IN 2011-2012; through 16 coal based and 7 gas
based power plant spread all over the country and also has 07 plants in joint venture. Rated as
one of the best company to work for in India, it has developed into a multi-location and
multi-fuel company over the past three decades.

Revenue 501.8852 billion (US$10.01 billion)(2009–10)

1.2 POWER GENERATION

Presently, NTPC generates power from Coal and Gas. With an installed capacity of
39,174 MW, NTPC is the largest power generating major in the country. It has also
diversified into hydro power, coal mining, power equipment manufacturing, oil and gas
exploration, power trading and distribution. With an increasing presence in the power value
chain, NTPC is well on its way to becoming an “Integrating Power Major.”
1.3 INSTALLD CAPACITY

Be it the generating capacity or plant performance or operational efficiency, NTPC’s

Installed Capacity and performance depicts the company’s outstanding performance across a
number of parameters.

Table 0-1 installed capacity

NTPC OWNED NO. OF PLANTS CAPACITY(MW)
COAL 16 30,855
GAS/LIQUID FUEL 7 3,955
TOTAL 23 34,810
OWNED BY JVs
COAL AND GAS 7 4,364
TOTAL 30 39,174

1.3 POWER STATIONS IN INDIA

Table 0-2GAS BASED

SR. NO. PROJECT STATE INST. CAPACITY(MW)
1. NTPC ANTA RAJASTAN 413
2. NTPC AURAIYA UP 652
3. NTPC KAWAS GUJARAT 645
4. NTPC DADRI UP 817
5. NTPC JHANOR GUJARAT 648
6. NTPC KAYAMKULAM KERALA 350
7. NTPC FARIDABAD HARYANA 430
TOTAL 3955

Table 0-3COAL BASED:

SR. PROJECT STATEINST.
NO. CAPACITY
1. SINGRAULI SUPER THERMAL UTTARPRADESH 2000
POWER STATION
2., NTPC KORBA 2,600
CHHATTISGARH

3. NTPC RAMAGUNDAM ANDHRA 2,600

PRADESH
4. FARAKKA SUPER THERMAL WEST BENGAL 2,100
POWER STATION
5. NTPC VINDHYACHAL MADHYA 3,760
PRADESH
6. RIHAND THERMAL POWER UTTAR 2,500
STATION PRADESH
7. KAHALGAON SUPER THERMAL BIHAR 2.340
POWER STATION

8
8. NTPC DADRI UTTAR 1,820
PRADESH
9. NTPC TALCHER KANIHA ORISSA 3,000
10. FEROZE GANDHI UNCHAHAR UTTAR 1,050
THERMAL POWER PLANT PRADESH
11. TALCHER THERMAL POWER ORISSA 460
STATION
12. SIMHADRI SUPER THERMAL ANDHRA 1,500
POWER PLANT PRADESH
13. TANDA THERMAL POWER UTTAR 440
PLANT PRADESH
14. BADARPUR THERMAL POWER DELHI 705
PLANT
15. SIPAT THERMAL POWER PLANT CHHATTISGARH 2,980
16. NTPC ASSAM 750
BONGAIGAON (COMMISSIONING
2013 ONWARDS )
17. NTPC MOUDA (1 UNIT 500 MW MAHARASHTRA 1,000
IS COMMISSIONED IN APRIL
2012 )
18. RIHAND THERMAL POWER UTTAR 500
STATION (ERECTION PHASE) PRADESH
19. NTPC BARH (COMMISSIONING BIHAR 3,300
2013 ONWARDS )
TOTAL 31,995
 CHAPTER 2: ABOUT BTPS

2.1 INTRODUCTION

The Badarpur Thermal Power Plant has an installed capacity of 705 MW. The main plant
equipment was supplied by M/S. BHEL. The boiler ofStage-1 (3×95)MW units are of
CZECHOSOLOVAKIAN design and thatof 210 MW units are of COMBUSTION
ENGINEERING design. The Turbo-alternators, supplied by M/S BHEL, are of RUSSIAN
design and Control and Instrumentation for Stage-1 (3×95) and Stage-2 units are mostly of
RUSSIAN design and for Stage-3 are of KENT design and supplies by M/S Instrumentation
Ltd., KOTA.

Table 0-1 BTP capacity

STAGE UNIT INT. DATE OF STATUS
NUMBER CAPACITY(MW0 COMMISSIONING
First 1 95 July, 1973 Running
First 2 95 August, 1974 Running
First 3 95 March, 1975 Running
Second 4 210 December, 1978 Running
Second 5 210 December, 1981 Running

10
 Figure 0-1 BTP

2.2 BASIC THERMAL POWER PLANT

In thermal generating plants, fuel is converted into thermal energy to heat

water, making steam. The steam turns an engine (turbine), creating
mechanical energy to run a generator. Magnets turn inside the generator,
producing electric energy.
Coal, oil and gas are used to make thermal electricity. They all work
basically the same way (with a few exceptions: for example, in an oil- or gas-
fired plant, fuel is piped to the boiler).
1. Coal supply — After haulers drop off the coal, a set of crushers and
conveyors prepare and deliver the coal to the power plant. When the
plant needs coal, coal “hoppers” crush coal to a few inches in size and
conveyor belts bring the coal inside.
2. Coal pulveriser —the belts dump coal into a huge bin (pulveriser),
which reduces the coal to a fine powder. Hot air from nearby fans
blows the powdered coal into huge furnaces (boilers).
3. Boiler — The boiler walls are lined with many kilometres of pipe filled
with water. As soon as the coal enters the boiler, it instantly catches
fire and burns with high intensity (the temperatures inside the furnace
may climb to 1,300° C). This heat quickly boils the water inside the
pipes, changing it into steam.
4. Precipitators and stack — As the coal burns, it produces emissions
(carbon dioxide, sulphur dioxide and nitrogen oxides) and ash.The
gases, together with the lighter ash (fly ash), are vented from the boiler
up the stack. Huge air filters called electrostatic precipitators remove
 nearly all the fly ash before it is released into the atmosphere. The
heavier ash (bottom ash) collects in the bottom of the boilers and is
removed.
5. Turbine and generator — Meanwhile, steam moves at high speed to
the turbines, massive drums with hundreds of blades turned at an
angle, like the blades of a fan. As jets of high-pressure steam emerge
from the pipes, they propel the blades, causing the turbine to spin
rapidly. A metal shaft connects the turbine to a generator. As the
turbine turns, it causes an electro-magnet to turn inside coils of wire in
the generator. The spinning magnet puts electrons in motion inside the
wires, creating electricity.
6. Condensers and cooling water system — Next, the steam exits the
turbines and passes over cool tubes in the condenser. The condensers
capture the used steam and transform it back to water. The cooled
water is then pumped back to the boiler to repeat the heating process.
At the same time, water is piped from a reservoir or river to keep the
condensers constantly cool. This cooling water, now warm from the
heat exchange in the condensers, is released from the plant.
7. Water purification — To reduce corrosion, plants purify water for use
in the boiler tubes. Wastewater is also treated and pumped out to
holding ponds.
8. Ash systems — Ash is removed from the plant and hauled to disposal
sites or ash lagoons. Ash is also sold for use in manufacturing cement.
9. Transformer and transmission lines — transformers increase the
voltage of the electricity generated. Transmission lines then carry the
electricity at high voltages from the plant to substations in cities and
towns.

12
Figure 0-2 components of a coal fired thermal plant

Figure 0-3 boiler maintenance department

 CHAPTER 3
PLANT AUXILIARY MAINTENANCE DEPARTMENT

14
3.1 WATER CIRCULATION SYSTEM

THEORY OF CIRCULATION

Water must flow through the heat absorptionsurface of the boiler in order that it is
evaporated into steam. Indrum type units (natural and controlled circulation) the water
iscirculated from the drum through the generating circuits and then back to the drum where
the steam is separated and directed to thesuper heater. The water leaves the drum through the
down comersat a temperature slightly below the saturation temperature. Theflow through the
furnace wall is at saturation temperature. Heatabsorbed in water wall is latent heat of
vaporization creating amixture of steam and water. The ratio of the weight of the water tothe
weight of the steam in the mixture leaving the heat absorptionsurface is called

Figure 0-1boiler circulating system

Types of boiler circulating system:

•Natural circulation system
•Controlled circulation system
•Combines circulation system

NATURAL CIRCULATION SYSTEM

Water delivered to steam generator fromfeed heater is at a temperaturewell

below the saturation valuecorresponding to that pressure. Entering first the
economizer it isheated to about 30-
40˚C below saturation temperature. Fromeconomizer the water enters the drum and
thus joins the circulationsystem. Water entering the drum flows through the down
comer and enters ring heater at the bottom. In the water walls a part of thewater is
converted to steam and the mixture flows back to thedrum. In the drum, the steam
is separated, and sent to
superheater for super heating and then sent to the high pressure turbine.Remaining water mi
xes with the incoming water from theeconomizer and the cycle is repeated.The circulation in
this case takes place onthe thermo-siphon principle. The down comers contain relativelycold
water whereas the riser tubes contain a steam water mixture. Circulation takes place
at such a rate that the driving force and thefrictional resistance in water walls are balanced.
As the pressure increases, the difference in density between water and steam
reduces. Thus the hydrostatic head available will not beable to overcome the
frictional resistance for a flow
correspondingto the minimum requirement of cooling of water wall tubes.Therefore

Figure 0-2NATURAL CIRCULATION SYSTEM

natural circulation is limited to the boiler with drumoperating pressure around 175
kg/cm².

CONTROLLED CIRCULATION SYSTEM

Beyond 80 kg/cm² of pressure, circulationis to be assisted with mechanical pumps to

overcome the frictionallosses. To regulate the flow through various tubes, orifice
platesare used. This system is applicable in the high sub-critical regions(200 kg/cm²).

COMBINED CIRCULATION SYSTEM

Beyond the critical pressure,

phasetransformation is absent, and hence once through system isadopted.
However, it has been found that even at super critical pressure, it is advantageous
to recirculation the water
throughthefurnace tubes and simplifies the start up procedure. A typicaloperating
pressure for such a system is 260 kg/cm².

16
 Figure 0-3COMBINED CIRCULATION SYSTEM

3.2 ASH HANDLING PLANT

The ash produced in the boiler is transportedto ash dump area by means of sluicing type
hydraulic ash handlingsystem, which consists of Bottom ash system, Ash water
systemand Ash slurry system.

Bottom ash system

In the bottom ash system the

ashdischarged from the furnace bottom is collected in two water compounded
scraper through installed below bottom ash hoppers.The ash is continuously
transported by means of the scraper chainconveyoronto the respective clinker
grinders which reduce thelump sizes to the required fineness. The crushed ash
from the bottom ash hopper from where the ash slurry is further transportedto
operation, the bottom ash can be discharged directly into thesluice channel
through the bifurcating chute bypass the grinder.The position of the flap gate in
the bifurcating chute bypasses thegrinder. The position of the flap gate in the
bifurcating chute is to be manually changed.

Fly ash system

The flushing apparatus are provided

under E.P. hoppers, economizer hoppers, air preheaters, and stack hoppers. The fly ash
getsmixed with flushing water and the resulting slurry drops into
theash sluice channel. Low
pressure water is applied through thenozzle directing tangentially to the section of
pipe to createturbulence and proper mixing of ash with water. For themaintenance
of flushing apparatus plate valve is provided betweenapparatus and connecting
tube.

Ash water system

High pressure water required for bottom ashhopper quenching nozzles, bottom
ash hopper spraying, clinker grinder sealing scraper bars, cleaning nozzles, bottom
ash hopper seal through flushing, economizer hopper flushing nozzles andsluicing
trench jetting nozzles is tapped from the high pressurewater ring mainly provided
in the plant area.Low pressure water required for bottom ashhopper seal through
make up, scraper conveyor make up,
flushingapparatus jetting nozzles for all fly ash hoppers exceptingeconomizer hopp
ers, is trapped from low pressure water ringsmainly provided in the plant area.

Ash slurry system

Bottom ash and fly ash slurry of the systemis sluiced up to ash pump along the
channel with the acid of high pressure water jets located at suitable intervals along the
channel.
Slurry pump suction line consisting of reducing elbow with
drainvalve, reducer and butterfly valve and portion of slurry pumpdelivery line consisting of
butterfly valve, pipe & fitting has also been provided.

3.3 CSPH(CONTROL STRUCTURE PUMP HOUSE)

The control system has following pumps:-

•Chlorine pump-2(for chlorination of water)
•HP pump-6(for boiling of water)
•LP pump-3(for EP pump house)
•Fire pump-(incase of fire breakdown)
•TWS pump-3(for screening of water)
•CRW pump-3(supply water for water treatment)
This house is known as control house because amount of water to be supplied
for treatment is controlled from this house with thehelp of these pumps. Generally
2 CRW pumps out of 3pumpsremains opensimilarly, 1 F ,2 LP,4 HP,1 TWS pumps
remainsopen. If more water is needed then others pumps are opened.

3.4 COMPRESSOR HOUSE

An air compressor is anything that increases the amount of air that is contained
within a particular space. By packing in the air, the air pressure is increased. This creates
a force that is useful for a variety of purposes, such as industrial, manufacturing, commercial
and personal purposes. Stages
Another way to group air compressors is by the number of stages they have. A two-
stage aircompressor usually is used for heavy-duty use and offers a higher level of
compression than smaller, single-stage air compressors. Two-stage air compressors can
store air for future use and are more energy efficient because they produce more air per unit
of horsepower than single-stage compressors. Also, less heat is generated in a two-
stage compressor, which means that wear on the unit is reduced. Portable
electric air compressors also are available for light-duty applications.

18
 Figure 0-4COMPRESSOR HOUSE

3.5 WATER TREATMENT PLANT

As the types of boiler are not alike their working pressure and operating conditions vary
and so do the typesand methods of water treatment. Water treatment plants used
inthermal power plants are designed to process the raw water to water with very
lowin dissolved solids known as "dematerializedwater". No doubt, this plant has to be
engineered very carefullykeeping in view the type of raw water to the thermal plant,
itstreatment costs and overall economics

Actually, the type of demineralization processchosen for a power station depends on

three main factors:
•The quality of the raw water.
•The degree of de-ionization i.e. treated water quality
•Selectivity of resins.
Water treatment process which is generally made up of two sections:
•Pre-treatment section
•Demineralization section

Pre-treatment section
Pretreatment plant removes the suspendedsolids such as clay, silt,
organic and inorganic matter, plants andother microscopic organism.
The turbidity may be taken as of twotypes of suspended solids in water.
Firstly,the separable solids and
secondly the non separable solids (colloids). The coarsecomponents, such as sand, silt etc,
can be removed from the water by simple sedimentation. Finer particles however,
will not settle inany reasonable time and must be flocculated to produce the
large particles which are settling able. Long term ability to remainsuspended in water is
basically a function of both size and
specificgravity. The settling rate of the colloidal and finely divided(approximately 001 to 1
micron) suspended matter is so slow thatremoving them from water by plain
sedimentation is tank
shavingordinary dimensions is impossible. Settling velocity of finelydivided and collide
particles under gravity also are so small thatordinary sedimentation is not possible. It is
necessary, therefore, touse procedures which agglomerate the small particles into
larger aggregates, which have practical settling velocities. The term"Coagulation" and
"flocculation" have been used indiscriminatelyto describe process of turbidity
removal. "Coagulation" means to bring together the suspended particles. The process
describes theeffect produced by the addition of a chemical Al (SP) g to
acolloidal dispersion resulting in particle destabilization by areduction of force tending to
keep particles apart. Rapid mixing
isimportant at this stage to obtain. Uniform dispersion of thechemical and to increase opportu
nity for particles to particlecontact. This operation is done by flash mixer in thec1ariflocculat
or. Second stage of formation of settle able
particlesfrom destabilized colloidal sized particles is termed a"flocculation". Here coagulated
particles grow in size by attachingto each other. In contrast to coagulation where
the primary force iselectrostatic or intrinsic, "flocculation" occurs by chemical bridging.
Flocculation is obtained by gentle and prolonged
mixingwhich converts the submicroscopic coagulated particle intodiscrete, visible &
suspended particles. At this stage particles
arelarge enough to settle rapidly under the influence of gravityanomaly be removed
If pre-treatment of the water is not done efficiently thenconsequences are as follows:
•Si02 may escape with water which will increase the anion loading.
•Organic matter may escape which may cause organic
foulingin the anion exchanger beds. In the 'pre-treatment plant chlorine
addition provision is normally made to combat organic contamination.
•Cation loading may unnecessary increase due to addition of Ca (OH)2 in excess of
calculated amount for raising the pH of the water for maximum floe formation and also
AKOrDgmay precipitate out. If less than calculated amount of Ca
(OH)2 is added, proper pH flocculation will not be obtained and silica escape to
demineralization section will occur, thereby increasing load on anion bed.

20
 CHAPTER 4
. TURBINE MAINTENANCE DEPARTMENT
 4.1 STEAM TURBINE THEORY

Figure 0-1STEAM TURBINE

OPERATING PRINCIPLES

A steam turbines two main parts are the cylinder andthe rotor.As the steam passes
through the fixed blades or nozzles itexpands and its velocity increases. The high-velocity jet
of steamstrikes the first set of moving blades. The kinetic energy of thesteam changes into
mechanical energy, causing the shaft to rotate.The steam then enters the next set of fixed
blades and strikes thenext row of moving blades.As the steam flows through the turbine,
its pressure andtemperature decreases, while its volume increases. The decrease in pressure
and temperature occurs as the steam transmits .energy to the shaft and performs
work. After passing through the last
turbinestage, the steam exhausts into the condenser or process steamsystem.
The kinetic energy of the steam changes into mechanical erringly through the
impact (impulse) or reaction of thesteam against the blades.

4.2 STEAM CYCLE

The thermal (steam) power plant uses a dual (vapour +liquid) phase cycle. It is a closed
cycle to enable the working fluid(water) to be used again and again. The cycle used is
"RankineCycle" modified to include super heating of steam, regenerativefeed water heating
and reheating of steam.
On large turbines, it becomes economic to increase
thecycle efficiency by using reheat, which is a way of partiallyovercoming temperature limita
tions. By returning partiallyexpanded steam to a reheat, the average temperature at which
heatis added is increased and by expanding this reheated steam to

22
theremaining stages of the turbine, the exhaust wetness isconsiderably less than it would
otherwise be conversely, if themaximum tolerable wetness is allowed, the initial pressure of
thesteam can be appreciably increased.

Figure 0-2 steam cycle

4.3 TURBINE CLASSIFICATION

Impulse Turbine:In Impulse Turbine steam expands in fixed nozzles.The high velocity
steam from nozzles does work on moving bladeswhich causes the shaft to rotate.
The essential features of impulseturbine are that all pressure drops occur at nozzles and not
on blades.A simple impulse turbine is not very efficient because it doesnot fully use the
velocity of the steam. Many impulse turbines arevelocity compounded. This means they
have two or more sets of moving blades in each stage.
Reaction Turbine:In this type of turbine pressure is reduced at both
fixed& moving blades. Both fixed& moving blades act as nozzles. Work done by the impulse
effect of steam due to reversals of direction of high velocity steam. The expansion of steam
takes place on moving blades.A reaction turbine uses the "kickback" force of thesteam as it
leaves the moving blades and fixed blades have
thesame shape and act like nozzles. Thus, steam expands, loses pressure and increases in
velocity as it passes through both sets of blades. All reaction turbines are pressure-
compounded turbines.

Figure 0-3 impulse and reaction turbine

COMPOUNDING:

Several problems occur if energy of steam is convertedin single step & so

compounding is done. Following are the types of compounded turbine:

• VELOCITY COMPOUNDED TURBINE

The velocity-compounded impulse turbine was first proposed by C.G. Curtis to solve the
problems of a single-stage impulse turbine for use with high pressure and temperature steam.
The Curtis stage turbine, as it came to be called, is composed of one stage of nozzles as the
single-stage turbine, followed by two rows of moving blades instead of one. These two rows
are separated by one row of fixed blades attached to the turbine stator, which has the function
of redirecting the steam leaving the first row of moving blades to the second row of moving
blades. A Curtis stage impulse turbine is shown in Fig. 23.1 with schematic pressure and
absolute steam-velocity changes through the stage. In the Curtis stage, the total enthalpy drop
and hence pressure drop occur in the nozzles so that the pressure remains constant in all three
rows of blades.

24
 Figure 0-4VELOCITY COMPOUNDED TURBINE

Velocity is absorbed in two stages. In fixed (static) blade passage both pressure and
velocity remain constant. Fixed blades are also called guide vanes. Velocity compounded
stage is also called Curtis stage. The velocity diagram of the velocity-compound Impulse
turbine is shown in Figure
 Figure 0-5curtis stage

The fixed blades are used to guide the outlet steam/gas from the previous stage in such a
manner so as to smooth entry at the next stage is ensured.K, the blade velocity coefficient
may be different in each row of blades

Work done =

End thrust =
The optimum velocity ratio will depend on number of stages and is given

by
• Work is not uniformly distributed (1st >2nd)
• The first stage in a large (power plant) turbine is velocity or pressure compounded
impulse stage.

•PRESSURE COMPOUNDED TURBINE

This is basically a no. of single impulse turbines inseries or on the same shaft.The exhaust
of first turbine enters the nozzle of the next turbine.Total pressure drop of steam does not take
on first nozzle ring butdivided equally on all of them.

26
 Figure 0-6PRESSURE COMPOUNDED TURBINE

To alleviate the problem of high blade velocity in the single-stage impulse turbine, the total
enthalpy drop through the nozzles of that turbine are simply divided up, essentially in an
equal manner, among many single-stage impulse turbines in series. Such a turbine is called
a Rateauturbine , after its inventor. Thus the inlet steam velocities to each stage are
essentially equal and due to a reduced Δh.

Figure 0-7Pressure-Compounded Impulse Turbine

Pressure drop - takes place in more than one row of nozzles and the increase in kinetic
energy after each nozzle is held within limits. Usually convergent nozzles are used

We can write
 where is carry over coefficient

REACTION TURBINE

A reaction turbine, therefore, is one that is constructed of rows of fixed and rows of
moving blades. The fixed blades act as nozzles. The moving blades move as a result of the
impulse of steam received (caused by change in momentum) and also as a result of expansion
and acceleration of the steam relative to them. In other words, they also act as nozzles. The
enthalpy drop per stage of one row fixed and one row moving blades is divided among them,
often equally. Thus a blade with a 50 percent degree of reaction, or a 50 percent reaction
stage, is one in which half the enthalpy drop of the stage occurs in the fixed blades and half in
the moving blades. The pressure drops will not be equal, however. They are greater for the
fixed blades and greater for the high-pressure than the low-pressure stages.The moving
blades of a reaction turbine are easily distinguishable from those of an impulse turbine in that
they are not symmetrical and, because they act partly as nozzles, have a shape similar to that
of the fixed blades, although curved in the opposite direction. The schematic pressure line
shows that pressure continuously drops through all rows of blades, fixed and moving. The
absolute steam velocity changes within each stage as shown and repeats from stage to stage.
Figure shows a typical velocity diagram for the reaction stage.

Figure 0-8Three stages of reaction turbine indicating pressure and velocity

distribution
Pressure and enthalpy drop both in the fixed blade or stator and in the moving blade
or Rotor

Degree of Reaction =

or,
A very widely used design has half degree of reaction or 50% reaction and this is known
as Parson's Turbine. This consists of symmetrical stator and rotor blades.

28
 Figure 0-9The velocity diagram of reaction blading

The velocity triangles are symmetrical and we have

Energy input per stage (unit mass flow per second)

From the inlet velocity triangle we have,

Work done (for unit mass flow per second)

Therefore, the Blade efficiency

Put then

For the maximum efficiency and we get

 from which finally it yields

Figure 0-10Velocity diagram for maximum efficiency

Absolute velocity of the outlet at this stage is axial. In this case, the energy transfer

can be found out by putting the value of in the expression for

blade efficiency

is greater in reaction turbine. Energy input per stage is less, so there are more number
of stages.
Stage Efficiency and Reheat factor
The Thermodynamic effect on the turbine efficiency can be best understood by
considering a number of stages between two stages 1 and 2 as shown in Figure

30
 Figure 0-11Different stage of a steam turbine

The total expansion is divided into four stages of the same efficiency and pressure
ratio.

The overall efficiency of expansion is . The actual work during the expansion from 1
to 2 is

o
r,

Reheat factor (R.F.)=

o
r,
R.F is 1.03 to 1.04
If remains same for all the stages or is the mean stage efficiency.

or,
 We can see:

This makes the overall efficiency of the turbine greater than the individual stage
efficiency.The effect depicted due to the thermodynamic effect called "reheat". This does not
imply any heat transfer to the stages from outside. It is merely the reappearance of stage
losses an increased enthalpy during the constant pressure heating (or reheating) processes
AX, BY, CZ and D2.

•PRESSURE VELOCITY COMPOUNDED TURBINE

It is just the combination of the two compounding hasthe advantages of allowing

bigger pressure drops in each stage &so fewer stages are necessary. Here for given pressure
drop theturbine will be shorter length but diameter will be increased.

STEAM TURBINES MAY BE CLASSIFIED INTO DIFFERENT CATEGORIES

DEPENDING ON THEIR CONSTRUCTION, THE PROCESS BY WHICH HEAT
DROP IS ACHIEVED, THE INITIAL AND FINAL CONDITIONS OF STEAM USED
AND THEIR INDUSTRIAL USAGE
.
According to the direction of steam flow
•Axial turbines
•Radial turbines
According to the number of cylinder
•Single - cylinder turbines.
•Double- cylinder turbines.
•Three-Cylinder turbines.
•Four-Cylinder turbines.
•Multi - Cylinder turbines
According to the steam conditions at inlet toturbines
•Low-pressure turbines
•Medium -pressure turbines
•High-pressure
•Turbines of very high pressures
•Turbines of supercritical pressures
According to their usage in industry
•Turbines with constant speed of rotation primarily used for driving alternators.
•Steam turbines with variable speed meant for driving turbo blowers, air circulators,
pumps etc.
•Turbines with variable speed: Turbines of this type are usually
•employed in steamers, ships and railway locomotives (turbolocomotives)

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MAIN TURBINE

Figure 0-12MAIN TURBINE

The 210MW turbine is a tandem compounded typemachine comprising of H.P. & I.P.
cylinders. The H.P. turbinecomprises of 12 stages the I.P. turbine has 11 stages & the L.P.
hasfour stages of double flow. The H.P. & I.P. turbine rotor are rigidlycompounded & the I.P.
& the I.P. rotor by lens type semi flexiblecoupling. All the three rotors are aligned on five
bearings of whichthe bearing no.2 is combined with thrust bearing.The main superheated
steam branches off into twostreams from the boiler and passes through the emergency
stopvalve and control valve before entering, the governing wheelchamber of the H.P. turbine.
After expanding in the 12 stages inthe H.P. turbine the steam returned in the boiler for
reheating.
The reheated steam from the boiler enter I.P. turbine viainterceptor valves and
control valves and after expanding enters the L.P. turbine stage via 2 numbers of cross
over pipes.In the L.P. stage the steam expands in axially oppositedirection to counteract the
trust and enters the condenser
placeddirectly below the L.P. turbine. The cooling water flowingthroughout the condenser tu
bes condenses the steam and thecondensate collected in the hot well of the
condenser.Thecondensate collected is pumped by means of 3*50% duty condensate pumps
through L.P. heaters
todeaerator from where the boiler feed pump delivers the water to boiler through H.P. heaters
thus forming a closed cycle.

4.4 TURBINE CYCLE

Fresh steam from boiler is supplied to the turbinethrough the emergency stop valve. From
the stop valves steam issupplied to control valves situated on H.P. cylinders on the
front bearing end. After expansion through 12 stages at the H.P. cylinder steam flows back
to boiler for reheating and reheated steam from
the boiler cover to the intermediate pressure turbine trough twointerceptor valves and four
control valves mounted on the I.P.turbine.After flowing trough I.P. turbine steam enters the
middle part of the L.P. turbine through cross over pipes. In L.P. turbine theexhaust
steam condenses in the surface condensers welded directlyto the exhaust
part of L.P. turbine. The selection of extraction points and cold reheat
pressurehas been done with a view to achieve the highest efficiency.
Theseare two extractions from H.P. turbine, four from I.P. turbine
andone from L.P. turbine. Steam at 1.10 to 1.03 g/sq cm Abs issupplied for the gland
sealing. Steam for this purpose is obtainedfrom deaerator through a collection where pressure
of steam isregulated.From the condenser condensate is pumped with the helpof 3*50%
capacity condensate pumps to deaerator through the low pressure regenerative
equipments.

Figure 0-13TURBINE CYCLE

Feed water is pumped from deaerator to the boiler through the H.P. heaters by means of
3*50% capacity feed pumpsconnected before the H.P. heaters.

4.5 DESCRIPTION OF MAIN TURBINE

SPECIFICATION:
TURBINE MAIN DATA
Rated Power 210MW
Rated Speed 3000 rpmRated Steam(Pressure) before ESV 130 Kg`/cm2abs
Rated Steam Temp. Before ESV 5350C

34
 Rated Steam pressure Before IV 27 Kg/cm2Abs
RatedSteam temp. Before IV 5350C
Rated Steam Flow 670 T/Hr
HPT Exhaust Pressure 27 Kg/cm2
HPT Exhaust Temperature 3270C
Rated circulating water quantity 27000 m3
through condenser
Condenser back pressure 0.09 Kg/cm2
Critical Speed 1585,1881,2017&2489
Rated condenser cooling water inlet 240C to 330C
Temperature
Rated condenser cooling water 1.0 to 1 Kg/cm2
PressureType of governing Hydro mechanicalNozzle type
governingType of turbine condensing, tandem compoundThree cylinder,
HorizontalNos. of bearing 5 Nos.( for turbine side only &HPC front bearingis combined
thrust & journal bearingBarring gear 3.4rpm, ac motor of 30kw, 730rpm, 50c/s,415v, 220:1
RatioLocation of anchor point of At the middle foundation frame of frontthe turbine exhaust
part of the L.P. Cylinder

CONSTRUCTIONAL DETAILS:
H.P. CYLINDER: 12 stages (1stis governing stage) each stageConsists of a diaphragm &a
set of movingBlades connected on a disc.
BODY: In two valves made of Creep Resistance(Cr-Mo-V) steel
STUDS & NUTS: High Creep Resistance (Cr-Mo-V) steelForgings
NOZZLE & STEAM CHEST:4 Nos (2 on Top & 2 on sides) madeof High Creep
resisting (Cr-Mo-V)Steel casting
I .P. CYLINDER: 11 stages
BODY:2 parts (a ) Pressure part made of Creep Resisting (Cr-Mo-V) steel

MAIN COMPONENTS OF TURBINE:

EMERGENCY STOP VALVE
Steam from the boiler is supplied to the turbine throughtwo emergency stop valves. The
emergency stop valve operated byhydraulic servomotor shuts off steam supply to the
turbine whenthe turbo set is tripped. The emergency stop valves connected
tothe four control valves through four flexible loop pipes of Chromium-Molybdenum-
Vanadium steel.
H.P. CYLINDER
It is made of creep resisting Cr-Mo-V steel castingmade of two halves joined at the
horizontal plane.
The horizontal joint is secured with the help of studsand nuts made of high creep resisting
Cr-Mo-V steel forgings.
Toensure H.P. tightness the studs are tightened by heat to a predetermined temperature with
the help of electric heater.
H.P. ROTOR

The H.P. rotor has discs integrally forged with the shaftsand is mechanical forming single
Cr-Mo-V steel forging. A special process to prevent abnormal rotor deflection thermally
stabilizesthe rotor forging.
  L.P. ROTOR
It consists of shrunk fit discs on a shaft. The shaft is aforging of Cr-Mo-V
steelwhile the discs are of high strength Ni steel forging.The H.P. rotor
is connected by rigid couplings whole the I.P rotor and L.P. rotor are
connected by semi-flexible lens typecoupling. The rotors are dynamically
balanced to a very precisedegree.

Figure 0-14 L.P. ROTOR

36
  TURBINE BEARINGS
The three turbine rotors are supported on fine bearings.The second bearing from
pedestal side is a combined radial thrust bearing while all others are journal bearings.

Figure 0-15TURBINE BEARINGS

 THRUST BEARINGS
It is Mitchell type with bearing surface distributed over a number of bearing surfaces.
They are pivoted in housing on theside of I.P. rotor thrust collar.During operation on oil
film is forced between padsand thrust collar and there is a no metal-to-metal contact. A
secondring of pads on opposite side of thrust collar takes the axial thrust as may
occur under abnormal conditions.

Figure 0-16THRUST BEARINGS

  L.P. HEATERS
Turbine is provided with non-controlled
extractionswhichare utilized for heating the condensate from turbine bleedingsystem. There a
re four L.P. heaters. They are equipped withnecessary safety valves in steam space
level indicator for visual
Mauges are present for measurement of steam pressure.

Figure 0-17L.P. HEATERS

 GLAND STEAM COOLER

Gland steam cooler has been provided to suck and coolt h e a i r s t e a m m i x t u r e f r o m

t h e g l a n d s e a t s . I t e m p l o ys a s m a l l ejector for which the working medium is steam
of low parameters,which can be taken either from the deaerator or auxiliary
source.The pressure and temperature of this steam should of this steam isretrieved to the
fullest possible extent as the gland steam cooler isalso interposed in the condensate heating
cycle thereby improvingoverall efficiency of the cycle.

 CONDENSATE PUMPS

The function of these pumps is to pumps out thecondensate to the desecrator through
ejectors, gland steam cooler,and L.P. heaters. These pumps have four stages and since
thesuction is at a negative pressure, special arrangements
havebeenmade for providing sealing. This pump is rated generally for 160m3 hr. at a pressure
13.2 Kg/cm2.

38
Feed Water System

The main equipments coming under this system are:

•Boiler Feed Pump: Three per unit of 50% capacity eachlocated in the '0' meter
level in the TG bay.
•High Pressure Heaters: Normally three in number and aresituated in the TG
bay.
•Drip Pumps: Generally two in number of 100% capacity eachsituated beneath
the LP heaters.
• Turbine Lubricating Oil System: This consists of Main OilPump (MOP) Starting
Oil Pump (SOP), AC standby oil pumpsand emergency DC' oil pump and Jacking
Oil Pump (JOP) (oneeach per unit).

BOILER FEED PUMPS

Boiler feed pump is used to feed water to steam generator boiler drum at desired pressure
and temperature. Boiler feed pump extract water from de-aerator and feed it to the boiler
drum via H.P heaters and economizer. It works with the steam extraction from Intermediate
Pressure (I.P.) turbine exhaust
This pump is horizontal and of barrel design driven byan Electric motor through a
hydraulic coupling. All the bearings of pump and motor are forced lubricated by a suitable oil
lubricatingsystem with adequate protection to trip the pump if the lubricationoil pressure falls
below a preset value.The high-pressure boiler feed pump is very
expensivemachine which calls for a very careful operation and skilledmaintenance.
The safety in operation and efficiency of the feed pump depends largely on the
reliable operation and maintenance.Operating staff must be able to find out the
causes of defect at thevery beginning which can be easily removed without
endangeringtheoperator of the power plant and also without the
expensivedismantling of the high pressure feed pump.The feed pump consists of pump
barrel, into which ismounted the inside stator together with rotor. The hydraulic part
isenclosed by the high pressure cover along with the balancingdevice. The suction
side of the barrel and the space in the high pressure cover behind the balancing
device are enclosed by the low pressure covers along with the stuffing box casings.
The bracketsof the radial bearing of the suction side and radial and thrust bearing
of the discharge side are fixed to the low pressure
covers.The entire pumps are mounted on a foundation frame. Thehydraulic
coupling and two claws coupling with coupling guardsare also delivered along with
the pump. Water cooling and oillubricating are provided with their accessories.

TURBINE DRIVEN BOILER FEED PUMP

The single cylinder turbine is of the axial flow type.The live steam flows through the
emergency stop valve and thenthrough the main Control Valves 5 nos. (Nozzle governing).
Thesevalves regulate the steam supply through the turbine in accordancewith load
requirements. The control valves are cylinder mounted on the turbine casing.The journal
bearings supporting the turbine shaft arearranged in the two bearing blocks. The front end -
bearing block also houses the thrust bearing, which locates the turbine shaft andtakes up
"the axial forces”.There are 14 stages of reaction balding. The actuated by a lift bar which is
raised or lowered via a lever system by the relay balancing piston is provided at the. Steam
admission side to compensate theaxial thrust to the maximum extent. Since the axial thrust
varieswith the load, the residual thrust is taken up by the thrust bearing.The leak off from the
balancing piston is connected back to theturbine after 9th stage.The turbine is provided with
hydraulic andelectro-hydraulic governing system. A primary oil pump is used asa speed
sensor for hydraulic governing and shall Probes are used asa speed sensor for electro
hydraulic governing.Whenever steam is drawn from the cold reheat line
or auxiliary supply, steam flow is controlled by auxiliary controlvalve. During this period the
main control valves (4 nos.) willremain fully opened and the bypass valve across it will
remainclosed. (Bypass remains closed fora short period when change,over from IP steam to
CRH takes place).The steam exhaust for the BFP- Turbine is connected tothe main condenser
and the turbine glands are sealed by glandsteam.

HIGH PRESSURE HEATERS

These are regenerative feed water heaters operating

athigh pressure and located by the side of turbine. These aregenerally vertical type
and turbine bleed steam pipes are connectedto them.HP heaters are connected in
series on feed watersideand by such arrangement, the feed water, after feed pump
entersthe HP heaters. The steam is supplied to these heaters form the bleed point
of the turbine through motor operated valves.Theseheaters have a group bypass
protection on the feed waterside.In the event f tube rupture in any of the HPH and
the level of thecondensate rising to dangerous level, the group protection
devicediverts automatically the feed water directly to boiler, thus bypassing all the
3 H.P. heaters.
Following fittings are generally provided on the HP heaters
•Gauge glass for indicating the drain level.
•Pressure gauge with three way cock.
•Air Vent cock.
•Safety valve shell side.
•Seal pot.
•Isolating valves.
•High level alarm switch.

SPEED GOVERNOR

It is directly coupled to the turbine rotor

throughcoupling and has been designed to maintain automatically thespeed of the turbo set.
It is located with the front pedestals.

LOAD LIMITER

Turbine is equipped with the load limiter used in specialcases to limit the opening of
valves by speed governor.

40
 PURPOSE:

To limit the load rising beyond the set point, can bevaried over the entire load
range.
TURBINE OIL LUBRICATING SYSTEM

This consists of main oil pump, starting oil pump emergencyD.C. oil pump and
each per unit.

5.1TYPES OF VALVES USED AND MAINTAINED IN TMD

Figure 0-18Gate Valve

Figure 0-19Regulating Valve

Figure 0-20Non-Return Valve

Figure 0-21Safety Valve

Valves are made of cast iron, cast steel, carbon steel,alloy steel.
 Cast iron valves: 0-150 0 C temperature (used for water lines).
 Carbon steel valves: 150-4250 C temperature (used for water/steam lines).
 Alloy steel valves: 425-535 0 C (used for steam lines)

42