Industrial Training Report (MAHAGENCO)

Industrial
Training
Report
Chandrapur Super
Thermal Power Station
MAHAGENCO
(CSTPS)
By-
GIRISH M MADAVI
NBN Sinhgad School of Engineering, Pune
Dept. of Electrical Engineering
(07/12/2016 to 04/01/2017 )
Industrial Training Report 2016
➢ Table of Contents
Serial Content Page No.

No.
1. Overview 2
2. Chandrapur Super Thermal Power Station 3

(CSTPS)
3. Water Treatment Plant (WTP) 6
4. Coal Handling Plant (CHP) 20
5. Power Plant Components, Auxiliaries and its 23

Operation
5.1 Boiler 23
5.2 Turbine 32
5.3 Generator 38
5.4 Condenser 46
5.5 Generating Transformer 49
6. Electrostatic Precipitator (ESP) 57
7. Ash Handling Plant (AHP) 58
8. Effluent Treatment Plant (ETP) 60
9 Solar Power Plant (CSTPS) 61
9.1 Salient Features of Plant 64
9.2 Grid Interactive System 65
9.3 Solar Plant Activities 67
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1. OVERVIEW
The Mahanirmiti or Mahagenco (Maharashtra State Power
Generation Company Limited – (MSPGCL) formerly known as MSEB (
Maharashtra State Electricity Board) is the major power generating
company in the state of Maharashtra, Western India. With a total
generation of 10,737 MW, it is the second largest power producing
company in India. The power generated by Mahagenco is supplied
to the State of Maharashtra. It was a part of Maharashtra State
Electricity Board (MSEB) until 06th June 2005 MSEB is trifurcated in 3
companies as follows-
• Mahanirmiti or Mahagenco (Maharashtra State Power

Generation Company Limited (MSPGCL)
• Mahapareshan or Mahatransco (Maharashtra State Electricity
Transmission Company Limited (MSETCL)
• Mahavitaran or Mahadiscom (Maharashtra State Electricity
Distribution Company Limited (MSEDCL)
Fig. 1.1 MAHA GENCO
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2. Chandrapur Super Thermal Power Station (CSTPS)
Fig. 2.1 CSTPS
Chandrapur Super Thermal Power Station (often abbreviated as

CSTPS) is a thermal power plant located in Chandrapur district in the
Indian state of Maharashtra. The power plant is one of the coal
based power plants of MAHAGENCO. The coal for the power plant is
sourced from Durgapur and Padmapur Collieries of Western
Coalfields Limited. The plant was officially inaugurated by the then
Prime Minister Indira Gandhi on 8 October 1984.
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• Capacity
Unit Installed Date of

Stage
Number Capacity (MW) Commissioning
1st 1 210 1983 August
1st 2 210 1984 July
1st 3 210 1985 May
1st 4 210 1986 March
2nd 5 500 1991 March
2nd 6 500 1992 March
2nd 7 500 1997 October
3rd 8 500 2015 May
3rd 9 500 2016 March
Total 9 3340
Table 2.1 Capacity of CSTPS
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With the total capacity of 3340MW, the plant is largest power plant in
the Maharashtra and formely second largest in 1997 in world. It
accounts to more than 35% of total Maharashtra needs. The plant
gets water supply from Erai Dam when in normal conditions. In the
summer of 2010 due to less water in Erai, the plant also got water
supply from Chargaon Dam.
In thermal power station, steam driven turbine is a prime mover of

electrical generator . When water is heated in boiler, 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 and recycled to where it was heated;
this is known as a Rankine cycle.
Following energy conversion steps are used in the thermal power

station-
Chemical energy of coal
Heat energy of water due combustion of coal
Kinetic energy of steam in nozzle
Mechanical energy due to rotation of turbine
Electrical energy developed in generator armature due to

rotation
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3. WATER TREATMENT PLANT (WTP)

Water treatment is important component of thermal power plant.
water treatment plant working area are given below-
❖ Water treatment.
❖ Coal analysis.
❖ Oil tests.
❖ Flue gas analysis.
Out of above mentioned area water treatment has prime

importance. It is because of following reasons.
Water contains different types of impurities, when these
impurities enters inside boiler it will produce slice formation
inside boiler tube due to which heat will not transfer properly
hence tubes will melt. This impurities deposits inside the water
tubes & block the water tubes. Presence of oxygen & carbon
dioxide leads to corrosion of water tubes.
In CSTPS, raw water is come from “Erai Dam” through pipelines.
In Erai dam water is collected from the forest area near by it.
So chemical impurities are not in raw water, therefore
contamination of dam water is very less, but still following
impurities are present in raw water-
❖ Turbidity- It is due to mud, minerals.
❖ Organic Matter- Organic present is due to the decomposition
of dead animals, trees, leaves.
❖ Colour & odur- Colour & odur comes to water due to its
organic matter contains.
❖ Dissolved gases- Gases like carbon monoxide, oxygen are
dissolves in water.
❖ Living micro-organism
Water is goes through following processes during treatment
➢ Pre-treatment.
➢ Post treatment.
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175000m3 water is treated in one day in CSTPS.
Pretreatment of water- Pretreatment is used to kill disease-causing

organisms and help control taste and odor causing substances. A
pretreatment chemical could be any number of oxidants or
disinfectant.
In water pre treatment plant the suspending particles are removed

by screening the water. Following flow chart shows the water
treatment process sequence-
Water from Erai dam brought pipe lines
One day reserve tank
Flash mixture
Clariflocculator
Rapid gravity filter
Water sump
To post treatment plant
Function of each step is explain below
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One day reserve tank-
One day reserve tank is used to store sufficient water storage, which
will last long nearly one day. Sometimes water supply from dam is
interrupted due to certain interrupts. Therefore to continue plant
operation without any interrupts. Water from one day reserve is
taken out. Water is stored in this tank, due these suspended
particles, heavy impurities, silica particles settled down here.
Besides this, one day reserve tank is used as a water source during
any emergency.
Flash mixture
Alum & lime is added in water. Effect of adding alum & lime is
explain as follows-
Alum not only settles certain hazardous chemicals and suspended

solids but also bacterial colonies. Alum has a negative charge and
tends to disperse in water very fast and very well .
This causes it to join up with all of the offending particles and

neutralize them. Now that the particles don't have any repelling
charges, they tend to clump together into 'flocs'.
Addition of lime
Softening can be achieved by adding lime in the form

of limewater, Ca(OH)2, which, in a carbonatation reaction with CO2,
forms calcium carbonate precipitate, reacts next with multivalent
cat ions to remove carbonate hardness, then reacts with anions to
replace the non-carbonate hardness due to multivalent cations with
non-carbonate hardness due to calcium. The process requires
recarbonation through the addition of carbon dioxide to lower
the pH which is raised during the initial softening process.[3]
As lime is added to raw water, the pH is raised and the equilibrium
of carbonate species in the water is shifted. Dissolved carbon
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dioxide (CO2) is changed into bicarbonate (HCO3-) and then

carbonate (CO32-). This action causes calcium carbonate to
precipitate due to exceeding the solubility product. Additionally,
magnesium can be precipitated as magnesium hydroxide in
a double displacement reaction.
The byproduct from the reaction of water with lime produces
large volumes of calcium carbonate and magnesium hydroxide
sludge. This residual stream can substantially increase costs
associated with the process. The sludge can be used as an
agricultural soil amendment (it is an alkalinity supplement) and can
also be used as a filler material in certain cementitious materials such
as low strength concrete.
Clariflocculator-
Clariflocculator is a device in which flocculation & clarification

reaction takes place simultaneously. Clariflocculator contains two
concentric water tanks. The inner tank serves as a flocculation
chamber. And the outer tank serve as a clarifier chamber. stirrer are
used.
During flocculation reaction flocs hydroxide is formed & then settled

down. This floc is removed as a sludge by blowdown process.
Mechanism of clariflocculator is as follows-
• These provide gentle agitation by slow moving paddles.

• This action serves to break up the mass rotation of liquid and
promote mixing.
• The specially designed flocculation paddles enhance
flocculation of the feed solids
• Agglomeration of the destabilized colloids is achieved as a
result of particulate transport in the flocculation compartment
• Increased particle contact will promote floc growth and aids
faster settling.
There are 5 no. of clariflocculators are installed in CSTPS.
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Rapid gravity Filter-
Rapid sand filters contains relatively coarse sand and other granular
media like bolder to remove particles and impurities that have been
trapped in a floc through the use of flocculation chemicals—
typically salts of aluminium or iron. Water and flocs flows through
the filter medium under gravity or under pumped pressure and the
flocculated material is trapped in the sand matrix. Mixing,
flocculation and sedimentation processes are typical treatment
stages that precede filtration. Chemical additives, such as
coagulants, are often used in conjunction with the filtration system.
Fig. 3.1 Rapid gravity Filter
Rapid sand filters must be cleaned frequently, often several times a

day, by backwashing, which involves reversing the direction of the
water and adding compressed air. During backwashing, the bed
is fluidized and care must be taken not to wash away the media.
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Water sump-
Water sump is a water storage tank in which pretreated water is
stored. From thank water is sent for post treatment.
Post treatment is different for both-
• Demineralized water (D.M. water)
• Soften water
Demineralized water-
DM water is demineralized water . Dissolved impurities and dissolved
gases in water. Sometimes water is hard, temporary hardness or
permanent hardness and which is badly affects the boiler which
helps formation of scales in sides the boiler.
In D.M. water plant , water is passed through activated carbon filter
for absorbing dissolved carbon dioxide. For removing temporary
hardness and permanent hardness ion exchanging process used. By
Ion - exchange process from which the minerals have been
removed and get Demineralized water.
Demineralized water have following qualities-
❖ Neutral P.H (6.5-7.5).
❖ Conductivity of water (<10µs/cm).
During pretreatment for D.M. water, following process is carried out-
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screening
settling
Chemical dosing
coagulation
Screening-
During screening process all the suspended particles are removed in
this process.
Settling-
Water is stored in one day reserve tank for one day. During this
heavy particles are settled down.
Chemical Dosing- In chemical dosing alum & lime is added in
water.
Coagulation-
Coagulation is a process is a joining small particle together to form
large particles. Due to chemical dosing, floc is produced.
Post-treatment of Water-
Pretreated water send for post treatment. Post treatment method

for D.M water & soften water.
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Demineralised (D.M.) water Plant-

Demineralisation is a process of removing dissolved salts from water
by iron exchange process. In CSTPS, water with no chemical
substances is come from Erai dam. So the better quality D.M water is
obtained. During demineralization process water is passed through
following ion beds-
Pretreated water sump
Pressure sand filter (P.S.F.)
Activated charcoal filter (A.C.F)
Strong acid cation (S.A.C)
Weak base anion (W.B.A)
De-gaser
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De-gaser tank
Strong base anion (S.B.A)
Mixed bed (M.B)
De-mineralised (D.M) tank
Condensate storage tank (C.S.T)
Function of each of above mention beds are explain below-

Pressure sand filter (P.S.F)-
Pressure sand filter consist of a pressure vessel. it contain graded
sand which supported by graded pebbles & silex. Distributor nozzle
installed at top distributes water throughout the cross-section of filter.
To collect water under drain system is provided.
Working Principle-
In pressure sand filter raw water flows down wards through the filter
bed and as the suspended matter- which has usually been treated
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by addition of a coagulant like alum- is retained on the sand surface

ands between the sand grains immediately below the surface.
There is steady rise in the loss of head as the filtration process
continues and the flow reduces once the pressure drop across the
filter is excessive.
The filter is now taken out of service and cleaning of the filter is
effected by flow reversal. To assist in cleaning the bed, the
backwash operation is often preceded by air agitation through the
under drain system. The process of air scouring agitates the sand with
a scrubbing action, which loosens the intercepted particles. The filter
is now ready to be put back into service.
Activated charcoal filter (A.C.F)-

Activated charcoal means activated carbon. It is a form
of carbon processed to be riddled with small, low-volume pores that
increase the surface area available for chemical reactions.
Activated charcoal have good carbon trapping quality. due to this
property chemical & organic impurities can be removed.
Fig. 3.2 Activated charcoal filter
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Strong Acid Cation (S.A.C) –

Porus type synthetic resin is filled in strong acid cation exchanger.
SAC resins can neutralize strong bases and convert neutral salts into
their corresponding acids. SAC resins derive their functionality from
sulfonic acid groups (HSO3¯). When used in demineralization, SAC
resins remove nearly all raw water cations, replacing them with
hydrogen ions, as shown below-
The exchange reaction is reversible. When its capacity is exhausted,

the resin can be regenerated with an excess of mineral acid.
Strong acid cation exchangers function well at all pH ranges. These
resins have found a wide range of applications.
Weak Base Anion (W.B.A)-

Weak base anion bed absorb acid from the water . & convert it into
neutral salts. When this bed absorb acid after it is exhausted. it is
need to regenerate it.
Regeneration needs only to neutralize the absorbed acid: it need
not provide hydroxide ions. Less expensive weakly basic reagents
such as ammonia (NH3) or sodium carbonate can be employed.
Degasser-
Degasser is a device in which dissolved gases from water is removed.
It also removes small bubbles trappeped in water layer.
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Fig. 3.3 Degasser
Degasser tank-
In this tank water from the degasser is stored. this water is send to
strong base anion bed.
Strong Base Anion (S.B.A)-

In this bed anionic contamination is removed from water.
Mixed Bed (M.B.)-

The strong acid cation and strong based anion bed are intermixed.
The cation & anion is taking place over & over within resin bed.
Both anion & cation escaped from prior bed is trapped in mix bed.
By using mix bed high quality of D.M. water can be obtained.
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Fig. 3.4 Mixed Bed
Demineralised Water Tank-

Water passed from above process is stored in this tank. this water is
send as make up water in boiler.
Anion & cation vessels are exhausted during the treatment. This ion
bed is regenerative. In following ways this beds are regenerated-
Water
Vessel Impurities Regenerative capacity
element (M3)
Gelatinous Backwash by 8500
P.S.F. material filtered water
A.C.F. turbidity - - - 8500

S.A.C. (Ca^+2),(Mg^+2), HCl acid 8500
(Na^+2)
W.B.A. (Cl^-), (SO4^-2) NaOH solution 8500
S.B.A. silicates NaOH 8000
M.B. Any particles HCL +NaOH 13200
other than above
Table 3.1 Demineralised Water Tank
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Before feeding D.M. water to boiler chemical conditioning is done.

➢ D.M. water is corrosive by nature. Hence, ammonia (NH3) is
added.
➢ Hydrazine (N2H4) which is colorless is added , to remove
dissolved oxygen from D.M. water. This reaction gives water &
nitrogen gas.
➢ Phosphate (PO4) is dose directly in boiler drum. It form
phosphate of dissolved impurities.
After particular period blowdown is given to the
boiler. This phosphate form is removed during this process.
Soften Water Plant-
Water softening is the removal of calcium, magnesium, and certain

other metal cations in hard water. The resulting soft water is more
compatible with soap and extends the lifetime of plumbing. Water
softening is usually achieved using lime softening or ion-exchange
resins. Soften water is used for cooling purpose ,drinking purpose.
In CSTPS, there are 11 no. of stream and each stream contains
3 softening containers.
In 210MW plant 15000(M^3) soften water is required as a
makeup per hour. flow of each softener is 250(M3/Hr.).
Vessel Type of Impurities Regenerative

exchanger removed solution
Softener Strong acid hardness Brine solution

cation
Table 3.2 Soften Water Plant
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4. Coal Handling Plant (CHP)

Following is the function of the coal handling plant-
❖ Unloading of the coal received from coal mines.

❖ Carry coal to the bunker, & maintain bunker level.
❖ Storing of the coal in case of emergency.
Coal for operation of boiler in CSTPS is provide from -
❖ Durgapur and Padmapur Collieries of Western Coalfields

Limited.
❖ Mahanadi coalfields limited.
❖ Coal is also impetrated from Indonesia and other countries.
From WCL mine, we get ‘Bituminous coal’. It is dark brown to black in

colour. It is of higher quality than lignite coal but of poorer quality
than anthracite. Formation is usually the result of high pressure being
exerted on lignite. It also called as soft coal. This contains high
percentage of volatile substances which burnt with yellow flame.
Following table shows the percentage of various elements in
bituminous coal.
Name of Carbon Moisture Ash Calorific Heat

coal % % % value content
Kcal/kg MJ/Kg
4200 (for
imported
Bituminous 60-80 2.2-15.9 3.3-11.7 coal) 24-35
3600 (for
W.C.L.)
Table 4.1 Elements in bituminous coal
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Amount coal required to produce one unit of electricity is called as

coal factor.
The coal factor of the coal from WCL mines is 0.6Kg.
It is examined by the following analysis of coal-

❖ Proximate analysis
❖ Ultimate analysis
Random samples are taken out from various mines and above
analysis are done on that coal sample. According to it various
grades are give to the coal. In WCL mines ‘F.’ grade coal is seen.
Unit generated in 24 Hr.-
1unit=Kwh
Coal required for 3, 500MW & 4, 210MW plant is 39000MT.
Transportation of coal-
Transportation
Road Railway Rope way
Coal from coal Collieries contains magnetic materials, stones, and

other impurities. Magnetic materials are removed from coal by
employing magnet above the conveyor belt, which carries coal for
feeding boiler.
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Coal for 210MW, plant is brought by rope way. Capacity of rope

way is 300 tons per hour.
In following ways magnet are employed on conveyor belt-
❖ Suspended type magnet

❖ Rotary type magnet
To remove the non-magnetic material skilled labor are stand beside

the conveyor belt, remove impurities.
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5. Power Plant Component and its Operation

5.1 Boiler
Fig. 5.1 Boiler
Boiler is a very important component of the thermal power plant. it is

used to generate steam to drive the turbine. It is a closed vessel in
which liquid is heated. This boiler is made up of steel. temperature of
the boiler is in the range of 1400-1600 degree cel.
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Boilers are classified on different basis as follows
❖ According to circulation of steam.

Following different method are used for circulation of
steam
• Natural circulation- In circulation, difference in
density of steam water is used to circulate steam.
• Forced circulation- Force circulation method is used
when operating pressure is approaches to critical
pressure.
❖ According to firing type of boiler.

In which portion of the boiler burner are place, according to
which boiler are classified as follows-
• Front fire type
• Corner fire type
The source of the heat in boiler is combustion coal. In CSTPS water

tube type boiler is used. Water tubes filled with water are arranged
inside a furnace in a number of possible configurations: often the
water tubes connect large drums, the lower ones containing water
and the upper ones, steam and water; in other cases, such as a
monotube boiler, water is circulated by a pump through a
succession of coils. This type generally gives high steam production
rates, but less storage capacity than the above. Water tube boilers
can be designed to exploit any heat source and are generally
preferred in high pressure applications since the high pressure
water/steam is contained within small diameter pipes which can
withstand the pressure with a thinner wall. Cool water at the bottom
of the steam drum returns to the feed water drum via large-bore
'downcomer tubes', where it pre-heats the feed water supply. To
increase economy of the boiler, exhaust gases are also used to pre-
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heat the air blown into the furnace and warm the feedwater supply.
Such watertube boilers in thermal power station are also
called steam generating units.
In CSTPS , boiler is suspended from top, it is because of when water

tubes are heated . due to heating ,water tubes expands. If bottom
of the boiler is fixed then tubes will expand in upward direction,
above the boiler the boiler draft is fitted. So due to heavy weight of
boiler drum & tube expansion high stares are developed in boiler. So
it may harmful & reduces boiler & its peripheries life.
Fig. 5.2 Boiler at CSTPS
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A boiler equipped with a combustion chamber which has a strong

current of air (draft) through the fuel bed will increase the rate of
combustion, which is the efficient utilization of fuel with minimum
waste of unused fuel. The stronger movement will also increase the
heat transfer rate from the flue gases to the boiler, which improves
efficiency and circulation. The combustion rate of the flue gases
and the amount of heat transfer to the boiler are both dependent
on the movement and motion of the flue gases. Hence, due to
above reasons draught system holds high significance.
The difference between atmospheric pressure and the pressure

existing in the furnace or flue gas passage of a boiler is termed
as draft. The system, which maintain the draught in boiler is called as
a draught system.Draught is produced by rising the level flue gases in
stack.
In CSTPS,
➢ Balanced draft system is employed.

➢ -5mm of water column pressure is maintaining in boiler.
➢ Forced draft is induces secondary air in boiler. secondary air is
required for complete combustion of pulverized coal.
Generally, negative pressure is maintained inside the boiler.

And, it is in the range of “-5mm of water column”. Negative pressure
is maintain because of, when coal is burnt, positive pressure inside
boiler cause the flame to reach to boiler wall, which causes damage
to boiler wall & also reduces efficiency of boiler .hence draught
system is employed to take out the flue gases from boiler.
Following are the important periphery of boiler-
Coal Mill- coal mill is used to pulverized a coal.
➢ Unburned coal is found in bottom ash if coal is not completely

burned. Unburned coal is found 2-3% in bottom ash &
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about0.5% in fly ash.Major reason for incomplete combustion is

size of coal.
➢ In coal mill coal is grind to obtain a coal particles of size about
70 micron.
In CSTPS following type of coal mill is used-
• Ball & race type.
• Bowl type.
• Tube type.
Economizer-
A feedwater economizer reduces steam boiler fuel requirements by
transferring heat from the flue gas to incoming feedwater. Boiler flue
gases are often rejected to the stack at temperatures higher than
the temperature of the generated steam.
Primary heater- Air preheater is used to heat the air which is

required for combustion inside boiler , before it enter in boiler . it
helps in improving rate of combustion of coal in boiler.
Final superheater- It is a device in which the seam from the boiler is

dried. It means that total moisture is removed from the steam.
Platen superheater- It is a plate type heater.
Fans in boiler-
Following are the fans are used in boiler.
• Primary air fan (P.A. fan)-

Function of primary air fan-
➢ Carry the pulverized coal to boiler from coal mills.
➢ Remove moisture from coal.
• Forced Draft Fan-

Fans for boilers force ambient air into the
boiler, typically through a preheater to increase overall boiler
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efficiency. Forced Draft (FD) fans purpose is to provide a

positive pressure to a system.
• Induced draft Fan (I.D. Fan)-
Induced Draft (ID) fans are
used to create a vacuum or negative air pressure in boiler.
Boiler ID Fans are often used in conjunction with FD fans to
maintain system pressure which is slightly lower than ambient.
Cycles of boiler-
Following air cycles are in the boiler-
❖ Primary air cycle- functions of primary air is follows-

• Carry the pulverized coal from the coal mill to the
combustion chamber of boiler.
• Provide oxygen for combustion of coal particles.
Primary air cycle is shown as follows-
Primary air Fan
Air pre heater
Coal mill
Boiler combustion chamber
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❖ Secondary air cycle- function of secondary air is

• Provide oxygen for combustion of coal inside boiler.
• When pulverized coal particle burn, ash is deposits on the coal
particle which causes incomplete combustion of coal particle
Hence efficiency of boiler lowered down.
• If coal burn near the burner head & boiler wall. It may
damage it. This damage is avoided by forcing secondary air
inside the boiler as it causes coal burn away from these
peripheries.
Secondary air removes this deposition of ash on coal particle.
Secondary air cycle is as follows-
F.D.Fan
Air pre heater
boiler
❖ Flue gas cycle-

Flue gases are formed after combustion of coal. Flue gases
may contain carbo dioxide(co2),water vapors, sulpher
dioxide(so2),and poolution causing gases like carbon mono-
oxide(CO), particulate matter like soot, & fly ash.
These gases are cleaned by using –
Electrostatic precipitator for removal of soot & fly ash.
Flue gas cycle is as follows-

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Boiler
Air heater
Electrostatic precipitator
Induced draft fan
stack
Boiler Maintenance-
Blowdowns-
Boiler blowdown is removal of water from the boiler. It is done in
order to remove the amount of solids in the
water, and is performed as either bottom (sludge) blowdown, or
continuous (surface) blowdown. The blowdown frequency and
duration is primarily determined by the boiler water analysis. The
water quality will vary greatly
based on boiler type and size, amount of condensate return,
and boiler water treatment program.
Water tube cleaning-
After burning of coal two types of ash is formed, namely-
• Fly ash.
• Bottom ash.
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Fly ash is light in weight, and it flue with flue gases. It may deposite on
the water tube surface inside the boiler. Due which less heat is
absorbed by the water tube & hence efficiency of the boiler is
lowered down. Hence it is necessary to clean the boiler water tube
surface.
To remove this deposition suit blowing method is used. in this method

steam is forced to flow over water tube & boiler wall at a pressure of
150kg.following 2 type of suit blower are used-
Short soot blower.
It is used to clean to boiler walls & water tube surface near to boiler
walls.
Long soot blower
Two soot blower of 10m are used from both side of boiler.
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5.2 Turbine
Turbine is a device which converts the kinetic energy of the steam in

the mechanical rotational energy of rotor. Steam from the boiler is
passed over the blade of the turbine, which tends to rotate the shaft
of the turbine. Turbine shaft is mechanically coupled with generator
shaft .when turbine shaft rotate generator shaft also rotate.
Basically turbine is of following type-
❖ Impulse turbine.
❖ Reaction turbine.
On 5 different basis turbine is classified, those are as follows-
• Type of compounding.
• Type of blading.
• Division of flow.
• Type of steam flow.
• Type of exhausting condition.
Turbine used in CSTPS has following features-
Turbine set consist of 3 turbine defined on the basis of the pressure

inside it. These turbines with their type are as follows-
• High pressure turbine - impulse turbine.

• Intermediate pressure turbine – Reaction turbine.
• Low pressure turbine – Reaction turbine.
The Turbine contained one row of stationary blade & one row of
rotating blades alternatively. The fixed blades are carefully shaped
to direct the flow of steam against the moving blades at an angle
and a velocity that will maximize the conversion of the steam's heat
energy into the kinetic energy of rotary motion. Because the steam's
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temperature, pressure and volume change continuously as it

progresses through the turbine, each row of blades has a slightly
different length, and in certain parts of the turbine the twist of the
blade is usually varied along the length of the blade, from root to tip.
One set of stationary & rotating blade is called as stage. These nos.
of stages can b varied as per requirement.
In CSTPS, no of stages for a given turbine is given in following table
Type of turbine No of stages

H.P. turbine 18
I.P. turbine 8+8=16
L.P. turbine 6+6=12
Table 5.2.1 Turbine Stages
The steam from the boiler is initially provided to high pressure turbine
(H.P. turbine). Steam is expanded inside H.P. turbine .H.P. gives the
starting torque & operating speed to the turbine rotor. The
expanded steam from the H.P. turbine again brought into the boiler
for heating. After rising the temperature of steam, it is fed to the
intermediate pressure turbine (I.P.).then this steam is supplied to the
low pressure turbine (L.P.). The function of I.P. turbine & L.P. turbine is
to provide torque to the rotor.
As steam transferred from I.P. turbine to L.P. turbine, steam pressure

goes on the decreasing, and hence steam goes on expanding. In
L.P turbine steam is expand in huge amount hence it requirement of
space.
To overcome this limitation steam is bifurcated in L.P. turbine. turbine

is design so that steam enter at the middle part of the turbine & exit
from the both end. The blades in each half face opposite ways, so
that the axial forces negate each other but the tangential forces act
33 | P a g e
together. This design of rotor is called two-flow, double-axial-flow,

or double-exhaust. This arrangement is common in low-pressure
casings of a compound turbine.
This arrangement has following advantages-
• Required space is less.

• Vibration cause is less.
• Steam can be expands up to require amount.
• Maintain the correct rotor position and balancing, this
force must be counteracted by an opposing force.
Following are the turbine peripheries
Emergency stop valve (E.S.V)-
• Hydraulically operated.
• Operate live steam
Live steam is steam under pressure, obtained by heating water in

a boiler.
Control valves (C.V.)-
Control valves used to control the flow of steam in boiler. During light
load period, by controlling flow of steam we can generate limited
electricity. Control valves are mounted on casing of H.P. turbine at
the middle bearing side, it is common for H.P. & I.P turbine.
There are total 4 no. of C.V in one turbine.
Turbine rotor connection
Rotor of I.P. & L.P. turbine is connected by semi flexible rod.
➢ 3 rotors are supplied with 5 bearings.
H.P. & L.P. turbine is combined on radial bearing.
34 | P a g e
Barring gear- barring gear is structure to support the rotor during

sagging & hogging due to differential temperature between the top
of the rotor shaft and the bottom. Once the rotor is cooled
toambient temperature, unless there is a supplementary support
structure for the rotor, it should be barred periodically to avoid
sagging of the rotor under its own weight.
Cycles of turbine
❖ Cooling water cycle.-

➢ Two circulating water pump (C.W. pump) are circulating
water, taken from sump.
➢ Water from the condenser water tube is cooled in cooling
tower.
➢ 27000ton water per hour is cooled in one cooling tower.
➢ 14 C.T fans are employed in 210MW plant cooling tower.
➢ Temperature in cooling tower should be 28-30degree cel.
Following dia. shows the cooling water cycle-
Water sump
Cooling Tower Condenser
35 | P a g e
Regenerative feed water cycle-
Regenerative water is obtained from the condensate from the

condenser. When steam in condenser is passed over the cool water
tube, it condensate & collected in hot well. Hence regenerative
feed water starts from hot well & end at boiler drum. 2 condensate
extraction pumps are running & 1 pump is stand by. It is as follows-
Condenser
Hot well
C.E.P - C.E.P - C.E.P -

1 2 3
Low pressure heater (L.P.)
De aerator
Feed storage tank (F.S.T.)
36 | P a g e
❖ Feed water cycle-

In feed water cycle 2 boiler feed pumps (B.F.P.) are running & 1
is stand by at a time.
Feed water cycle is as follows-
Feed water cycle (F.S.T)
B.F.P.-1 B.F.P.-2 B.F.P.-3
High pressure heater (H.P.)
economizer
Boiler drum
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5.3 Generator
Generator is an electrical device which converts mechanical

energy into electrical energy. This Energy conversion is based on the
principal of the production of dynamically induced emf. Whenever
conductor cuts magnetic flux, dynamically induced emf is produced
in it according to Faraday’s Laws of electromagnetic induction. This
emf causes a current to flow if the conductor circuit is closed.
Synchronous generator ( Alternator) is used to generate A.C electric
power at a constant frequency 50Hz.
In A.C. generator, following are constructional important parts-
❖ A stationary element called as stator, on which armature

winding is mounted.
❖ A rotating part inside the stator called as rotor. this rotor is
driven by the rotational mechanical energy from the turbine
shaft at a constant speed.
In CSTPS, 210MW unit 2 pole alternator is used which generate

electricity at 3000rpm of frequency 50Hz.
Stator Construction-
Stator is a heaviest component of the entire generator. It contains

stator winding & stator body with a stator core. it is designed to
Withstand high internal pressure, which may arise due to unlikely
event of explosion of hydrogen air mixture without any residual
deformations. Stator body is a totally enclosed gas tight fabricated
structure made up of high quality mild steel and austenitic steel.
Stator winding-
Stator winding is made up of a hallow conducting pipe through

which water is circulated for cooling hydrogen gas. The stator
winding is placed in open rectangular slots of the stator core which
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are uniformly distributed on the circumference Bus bars are

connected to bring out the three phases & six neutrals. This bus
barware connected with terminal bushings. Both are water cooled,
connection is made by brazing the two lugs properly. The insulation is
highly resistant to high temperatures and temperature changes. The
composition of the insulation and synthetic resin permits the machine
to be operated continuously under conditions corresponding to
these for insulation class ‘B’ temperature.
END WINDING:
In the end winding, the bars are arranged close to each other.
Lower as well as upper layers of bars are braced with terelyne cord
with binding ring as well as with adjacent bars. Bus bars are
connected to bring out the three phases & six neutrals. These bus
bars are connected with terminal bushings. Both are water cooled,
connection is made by brazing the two lugs properly.
TERMINAL BUSHING :
Three phases and six neutral terminals are brought
out from the stator frame through bushings, which are capable of
withstanding high voltage, and provided with gastight joints. The
bushings are bolted to the bottom plate of the terminal box, with
their mounting flanges. The terminal box that is welded underneath
the stator frame at exciter end is made of nonmagnetic
Steel to avoid admissible temperature rise. The conductor of the
bushing is made of high conductivity copper tube. A copper pipe is
connected to circulate water for cooling. The terminal bar
conductor is housed in porcelain insulator which can be mounted
on the terminal box by means of ring.
The bushing is connected to terminal bus bar by means of flexible
copper leads for making the electrical connections conveniently.
Rotor Construction
In rotor construction following are the important parts of rotor, which
require very careful operation during its construction.
➢ Rotor winding.
➢ Rotor shaft.
39 | P a g e
Rotor winding –
Rotor winding is mounted on the rotor shaft. The field winding consists
of several coils inserted into the longitudinal slots of the rotor body.
The coils are wound around the poles so that one north magnetic
pole and one south magnetic pole are obtained on shaft. Rotor
winding is excited by the excitation voltage provided by excitation
system.
Rotor winding conductor are made up of hard drawn
silver bearing copper. Apart from low electrical resistance this grade
exhibits high creep resistance so that coil deformations due to
thermal cycling due to start and stop operation are minimum.
Insulation winding is made up of Layer of glass laminates insulates
the Individual turns from each other. This laminate is built by glass
prepped strips on the turn of copper and baked under pressure and
temperature.
Due to rotation & flow of current in winding heat is generated. if
excessive heat is generated, it may damage the winding insulation
& weaken the rotor. Hence winding cooling is necessary. It can be
done by hydrogen cooling. Hydrogen gas can be rich up to deepest
layer of winding hence efficient cooling is done.
Rotor shaft-
The rotor shaft is long forging measuring more than 9
meters in length and slightly more than one meter in diameter. The
main constituents of the steel are chromium, molybdenum. Nickel,
and vanadium. The shaft and body are forged integral to each
other by drop forging process.
On 2/3 of its circumference approximately, the rotor
body is provided with longitudinal slots to accommodate field
windings. The slots pitch is selected in such a way that two solid poles
displaced by 180 are obtained.
D.C exciter is also mounted on the generator shaft.
Fans-
Two single stage axial flow propeller type fans circulate the
generator cooling gas. Fitted on either sides of rotor body
Bearings-
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The rotor shaft is supported on pedestal type of bearings

which has spherical seating to allow self alignment. On the top of
bearings pedestal a vent pipe emerges connecting bearing
chamber to the atmosphere for venting out oil vapour or traces of
Hydrogen. A current collector located just above the rotor shaft and
touching it is also mounted on the bearing body to give, shaft
voltage for rotor earth fault protection. To prevent the flow of shaft
currents slip ring and bearing and connecting pipes are insulated
from earth.
Shaft Seal –
The locations where the rotor shaft passes through the stator casing,
are provided with radial seal rings. The seal ring is guided in the seal
body, which is bolted on to the end shield and insulated to prevent
the flow of shaft currents. The seal ring is lined with babbit on the
shaft journal side. The gap between the seal ring and the shaft is
sealed with seal oil. The seal oil is supplied to the sealing gap from
the seal body via radial holes and an annular groove in the seal ring.
To ensure effective sealing, the seal oil pressure in the annular gap is
maintained at a higher level than the gas pressure within the
generator casing.
Following flow chart shows generated electricity route
Generator
Generating transformer
National grid
41 | P a g e
Cooling-
In generator heat is generated due to windage loss ,Cu

losses, friction. The rise in temperature must be controlled to protect
the insulating material. the temperature with which these insulating
material can with stand is decided by the class of insulating material
to which it belongs.
For cooling generator components following cooling systems are
used-
➢ Hydrogen cooling.
➢ Demineralised water (D.M.) cooling.
• Hydrogen Cooling-
In CSTPS, 2 pole generator runs at 3000 rpm. So the rotor of large

diameter is used. To minimize the size of generator air gap should be
as small as possible & by increasing value of current density. But
increasing in value of current density increases the losses in
generator ultimately heat developed is also increased. If excess
amount of heat is developed, it may damage the winding insulation.
In Generator hydrogen gas may be leak from the bearings &
casing.
This hydrogen gas is highly explosive when it is in contact with
air. This may cause fire to the generator. To avoid this leakage
“Generator seal oil system is employed”.
In order to prevent the escape of Hydrogen from the
generator casing along the rotor shaft, shaft seals with oil under
pressure are used. The shaft seals are radial thrust type and are
mounted between the end shield and the bearing at either end of
the stator.
The seal oil supply system consists of an oil injector, two seal
oil pumps, one cooler, two oil filters, differential pressure regulator,
pressure oil regulator, damper tank, hydraulic seal, visual window, oil
check pipe etc.
42 | P a g e
• Demineralised (D.M.) Water Cooling-
Stator conductor are made hallow . through this hallow conductor

D.M. water is circulate . which absorb the heat from stator winding.
D.M. Cooling water is admitted to upper bar and it returns
through lower bar of next slot. The hot water then goes to expansion
tank which is maintained under a vacuum of about 300 mm of Hg.
This helps to remove gases from the water and thus corrosion is
minimsed. From expansion tank, water is pumped by primary stator
water pumps through DM/DM Coolers,
filters back to stator conductors.
➢ Exciter
According to Faraday’s Laws of electromagnetic induction,

“Whenever conductor cuts magnetic flux dynamically an induced
emf is produced in it”.
Due to this induced emf current is flows in closed circuit.
➢ Need of excitation to A.C. generator-
AC generators required a large magnetic field which cannot be

provided by permanent magnets. so dc generators called auxiliary
generators are used to provide constant magnetic field”.
Generator are connected in parallel with another generator or

infinite bus bars. An infinite bus means a large system whose voltage
and frequency
remain constant independent of the power exchange between the
synchronous generator and the bus, and independent of the
excitation of the synchronous generator. The generator excitation
which is controllable determines the flow of VARs into or out of the
generator.
Generally , D.C. generator as an exciter is mounted on
the generator shaft itself.
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Objectives of excitation control :

Besides maintaining the field current and steady state operating
point, the excitation
system is required to improve the natural damping behavior and to
extend the stability limits.
The operating conditions to be taken into consideration are :
• Good response in Voltage and reactive power control.
• Satisfactory steady state stability i.e. sufficient damping of
electromagnetic and electromechanical transients.
• Transient stability for all stated conditions.
• Quick voltage recovery after fault clearance.
➢ Generator Protection-
In CSTPS, near about 30 protection are given to the generator.
Following points shows the requirement of protection –
❖ Faults in generator reflect back on whole system.

❖ Generator faults may damage the generator winding which is
so much costly. Also, this may damage the stator core, due to
which severe mechanical torsion may produce.
❖ Fault current is flows through the winding even after generator
is tripped; it is because of presence of trapped flux with in
machine.
❖ There by increasing amount of fault damage.
❖ A fault produces high short circuit current.
Following are the major protection are given to the generator-
❖ Mechanical protection.
➢ Protection against failure against prime
mover.
➢ Failure of field.
➢ Over current.
➢ Over voltage.
➢ Over speed.
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❖ Electrical protection.
➢ Unbalanced load.
➢ Stator winding.
Governing & Lubricating System-
Turbine in CSTPS is equipped with hydraulic mechanical governing

system, which ensures smooth & safe operation of turbine &
generator. This system is as follows-
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5.4 Condenser
Fig. 5.4.1 Condenser
Condenser is used to condense the steam out from the L.P. turbine.
Cooled water is circulating inside the water tube of condenser. Heat
of the steam is transferred to cooled water inside water tube. Hence,
due to this steam gets condense. Condensate is collected in hot
well, which is just below the condenser. The heated water inside the
water tube is sent to the cooling tower in which temperature of this
water is decreased to the ambient temperature.
Following are the important component of condenser
Shell- The shell is the condenser's outermost body and contains the
heat exchanger tubes. The shell is fabricated from carbon
steelplates and is stiffened as needed to provide rigidity for the
shell. At the bottom of the shell, where the condensate collects, an
outlet is installed. In some designs, a hotwell is provided. Condensate
46 | P a g e
is pumped from the outlet or the hotwell for reuse as boiler

feedwater.
For most water-cooled surface condensers, the shell is
under vacuum during normal operating conditions.
Cooling water tubes- Generally the tubes are made of stainless
steel, copper alloys such as brass or bronze. Cooled water flows
through it. Which extract heat from the steam. Due to absorption of
heat tube gets elongate hence some clearance is provided for this
expansion.
Condensate extraction pump (C.E.P)- condensate extraction pump

(C..P) is generally a centrifugal pump used to extract the
condensate from the condenser.
In CSTPS, there are total 3 C.E. pumps are installed per condenser
unit in 210MW unit. Out of these 2 C.E. pumps are running &1 is stand
by at a time.
Cooling Tower-
Cooling towers Fig. 5.4.2 Cooling Tower are used to cool

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the water from the water tube of condenser. Water in water tube
take heat from the steam from the turbine.
Heat from water is transferred by following method-
Wet cooling method-
In this method evaporation phenomenon is used to transfer heat.
Dry cooling method-
In this method convention of heat phenomenon is used to transfer

of heat from water from water tube. Heat is transferred through a
surface that separates the water from ambient air, such as in a heat
exchanger.
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5.5 Generating Transformer
Transformer is a static device which step up or step down electrical

energy. Function of transformer in power plant is to step up the
voltage level to the transmission voltage level. Following table shows
the transformer component and its function.
Component Function
Core Provide path for magnetic lines of flux.
Primary winding Receive electrical energy from energy

source & creates magnetic field.
Secondary winding Receive electrical energy from primary
winding & deliver to the load
Enclosure Protect the above component from
environmental attack
Table 5.5.1 Transformer component and its function
Core is made up of CRGO steel which have high magnetic

properties due to which losses are reduced, & permeability is
increase
Transformer bushing- transformer bushing is used to take out the

terminal of the secondary winding to connect it to the transmission
lines. Electrical power is the product of voltage and current, the
insulation in a bushing must be capable of withstanding the voltage
at which it is applied, and its current carrying conductor must be
capable of carrying rated current without overheating the adjacent
insulation. The bushing must also be able to withstand the various
mechanical forces applied to it .
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Transformer insulation-
In power transformer ,insulation is provided on two places in stator

winding-
❖ Insulation between two winding turn in same layer. It is

called as basic insulation.
❖ Insulation between two layer of winding .
Basic insulation need not by excessive because the voltage

difference between a winding turn and its neighboring turn is small in
value and its the voltage across one winding turn. To insulate layer of
winding from the other layer of winding paper insulation is used.
Some of the salient features of our insulating materials are listed

below:
• Excellent flexibility.
• Heat resistant.
• Moisture resistant.
• Brilliant electrical properties.
• Resistant to smoke or odour.
In power transformer, when transformer is loaded with load. Current

is flows through the transformer winding which causes I2R losses in
transformer. Due to I2R losses heat is produced in transformer. hence
as load goes on increasing amount of heat developed also
increases.
Excess amount of heat is developed is main reason behind

transformer winding insulation breakdown.
It also adversely affects the life of the transformer.
Hence cooling system is employed in transformer.

50 | P a g e
Transformer cooling system-
In generating transformer, heat developed is extremely high. Natural

air cooling is not sufficient to maintain transformer temperature.
Hence oil cooling system is employed in power transformer.
Oil is used in transformer to insulate & cool the winding.
Transformer core & both winding are immersed in oil filled up in oil
tank. This transformer oil should have following properties-
Breather-
Whenever electrical power transformer is loaded, the temperature

of the insulating oil increases, consequently the volume of the oil is
increased. As the volume of the oil is increased, the air, above the oil
level in conservator, will come out. Again at low oil temperature the
volume of the oil is decreased, which cause, the volume of the oil to
be decreased which again causes air to enter into conservator tank.
The natural air always consists of more or less moisture in it and this
moisture can be mixed up with oil if it is allowed to be entered into
the transformer. The air moisture should be resisted during entering
the air into the transformer, because moisture is very harmful for
transformer insulation. A silica gel breather is most commonly used as
a means of filtering air from moisture. Silica gel breather for
transformer is connected with conservator tank by means of
breathing pipe.
Conservator –
It is the important periphery of transformer. Conservator is a tank

which conserves oil. When transformer is loaded, oil inside it is
heated. Due to heating oil expand. To provide extra volume
conservator is employed.
51 | P a g e
When oil gets cooled it returns to transformer oil tank.
Conservator tank is partially filled with oil.
So, the vacuum space is filled up by the atmospheric air. A filtering

device, called breather is attached with the conservator to ensure
that only dry and clean air can enter into the transformer. So, a
conservator ensures the safety operation of a transformer. High
temperature of oil also leads to generate sludge, which occurs in the
presence of air. If somehow the transformer is subjected to a major
fault, then the temperature rise becomes quite high and this causes
vaporization of a part of the oil. This oil vapour forms an explosive
mixture with air and can ignite and cause huge damage. So, to
prevent the contact of oil and moisture-enriched air, conservator
and breather assembly is used.
Buchholz Relay-
Principle of operation of buchholz relay is very simple. It is a

mechanical phenomenon
Whenever there will be a minor internal fault in the transformer such

as an insulation faults between turns, break down of core of
transformer, core heating, the transformer insulating oil will be
decomposed in different hydrocarbon gases, CO2 and CO. The
gases produced due to decomposition of transformer insulating
oil will accumulate in the upper part the Buchholz Container which
causes fall of oil level in it.
52 | P a g e
Fig. 5.5.1 Buchholz Relay
Fall of oil level means lowering the position of float and thereby tilting
the mercury switch. The contacts of this mercury switch are closed
and an alarm circuit energized. Sometime due to oil leakage on the
main tank air bubbles may be accumulated in the upper part the
Buchholz Container which may also cause fall of oil level in it and
alarm circuit will be energized. By collecting the accumulated gases
from the gas release pockets on the top of the relay and by
analyzing them one can predict the type of fault in the transformer.
Pressure release valve (P.R.V.)-
It is a oil pressure relief valve. When oil is heated in transformer tank, it

expands & it exerts pressure. If this pressure crosses certain limit then
this P.R.V. is operated.
Pressure relief is very simple construction. It contain an aluminum foil

of required thickness is fitted on the opening of valve. Whenever
surge developed in oil. The aluminum foil is busted.
53 | P a g e
Circuit Breaker-
Circuit breaker is nothing but the switch. Circuit breaker is enclosed

in a close vessel. It is operated by external media. When relay senses
faults. Then relay sends signal and then circuit breaker breaks the
circuit, Due to high voltage arc is produced in it. To extinguish it
following methods are used-
• Bulk oil
• Minimum oil
• Air blast
• Vacuum
• SF6 ( sulfur hexafluoride)
• CO2
Isolator-
Isolator is a switch which isolates the circuit. it is very simple in

construction, & mechanically operated switch.
Circuit breaker always trip the circuit but open contacts of breaker
cannot be visible physically from outside of the breaker and that is
why it is recommended not to touch any electrical circuit just by
switching off the circuit breaker. So for better safety there must be
some arrangement so that one can see open condition of the
section of the circuit before touching it. Isolator is a mechanical
switch which isolates a part of circuit from system as when required.
Electrical isolators separate a part of the system from rest for safe
maintenance works.
Other transformer used in CSTPS, Besides generating transformer

following transformer are also used.
These transformers have their own significance in power plant.

Following are those transformers-
54 | P a g e
❖ Unit auxiliary transformer.

❖ Station transformer.
Unit auxiliary transformer-
Unit auxiliary transformer is employed to provide electricity to the

auxiliaries like B.F.P., C.E.P., cooling pumps, of power plant unit.
Before starting power generation in plant, these auxiliaries must be

started. To start these auxiliaries initially power is taken from station
transformer. After generating 30MW electricity, this UAT is connected
to primary side of generating transformer. This arrangement has
following advantages-
Electricity can be taken from generator itself as well as from external

source.
When electricity is taken from generator itself, then CSTPS does not
need to pay for electricity required for power plant auxiliaries.
Primary side voltage of UAT is equal to the generating voltage level.

& secondary voltage is equal to rated voltage of auxiliaries.
General layout of UAT is as follows-
Fig.5.5.2 General Layout of UAT

transformer 55 | P a g e
Station transformer-
Station transformer is also called as start-up transformer. This station

transformer provides initial power to the plant auxiliaries, when no
power is available. Following are the function of station transformer-
Provide electricity to auxiliaries of power plant, during start-up.
During normal operation, power to the C.H.P. auxiliaries. it is because
of working of all unit is depends upon coal supply from C.H.P.
following auxiliaries are installed in C.H.P.-
➢ Motors of conveyor belts.
➢ Motors of crusher.
Lightening system provide power to the boiler feed pump (B.F.P.). it is

very important auxiliary of thermal power plant.
If boiler drum level is not maintain, then many complications
(like boiler over heating which damage boiler tubes & many other
components) are arises.
Hence power supply to B.F.P. must be maintained. To maintain this
supply power supply is taken from station transformer.
Station transformer is connected to the grid transmission lines, hence
power supply reliability is maintained, even though generating units
are tripped up.
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6. Electrostatic Precipitator-
An electrostatic precipitator (ESP), or electrostatic air cleaner is

a particulate collection device that removes particles from a flowing
gas using the force of an induced electrostatic charge. Electrostatic
precipitators are highly efficient filtration devices that minimally
impede the flow of gases through the device, and can easily
remove fine particulate matter such as dust and smoke from the air
stream.
Stack- stack is vertical pipe through which the flue gases are
exhausted to atmosphere from boiler.
Fig. 6.1 Electrostatic Precipitator
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7. Ash Handling Plant
Fig. 7.1 Ash Handling Plant System
System Description
The ash handling system handles the ash by bottom ash handling
system, coarse ash handling system, fly ash handling system, ash
disposal system up to the ash disposal area and water recovery
system from ash pond and Bottom ash overflow. Description is as
follows:
A. Bottom Ash Handling System
Bottom ash resulting from the combustion of coal in the boiler shall
fall into the over ground, refractory lined, water impounded,
maintained level, double V-Section type/ W type steel- fabricated
bottom ash hopper having a hold up volume to store bottom ash
58 | P a g e
and economizer ash of maximum allowable condition with the

rate specified. The slurry formed shall be transported to slurry sump
through pipes.
B. Coarse Ash (Economizer Ash) handling System
Ash generated in Economizer hoppers shall be evacuated

continuously through flushing boxes. Continuous generated
Economizer slurry shall be fed by gravity into respective bottom
ash hopper pipes with necessary slope.
C. Air Pre Heater ash handling system
Ash generated from APH hoppers shall be evacuated once in a

shift by vacuum conveying system connected with the ESP
hopper vacuum conveying system.
D. Fly Ash Handling System
Fly ash is considered to be collected in ESP Hoppers. Fly ash from

ESP hoppers extracted by Vacuum Pumps up to Intermediate
Surge Hopper cum Bag Filter for further Dry Conveying to fly ash
silo.
Under each surge hopper ash vessels shall be connected with Oil
free screw compressor for conveying the fly ash from Intermediate
Surge Hopper to silo. Total fly ash generated from each unit will be
conveyed through streams operating simultaneously and in
parallel.
E. Ash Slurry Disposal System
Bottom Ash slurry, Fly ash slurry and the Coarse Ash slurry shall be
pumped from the common ash slurry sump up to the dyke area
which is located at a distance from Slurry pump house.
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8. Effluent Treatment plant (E.T.P)-
Main function of E.T.P. is to clean gas clean plant (G.C.P.) effluent

& recycle it for further use. Sewage water is treated as per is
pollution control norms in E.T.P.
This water is used for ash handling.
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9. SOLAR POWER PLANT (CSTPS)
❖ Overview
• MAHAGENCO has commissioned 1.00 MWp Thin Film Solar PV

Power Project on 9th April 2010, 2 MWp Thin Film Solar PV Power
Project on 29th March 2012, 2 MWp Crystalline Solar PV Power
Project on 2nd May 2012 at their Chandrapur Super Thermal
Power Station (CSTPS) campus.
• 1 MWp Thin Film is 1st MWp capacity solar PV project in

Maharashtra.
❖ Location of site from thermal power plant
Fig. 9.1 Location of Solar Plant
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❖ Physics of Photovoltaic Generation
Fig. 9.2 Photovoltaic Generation
❖ PV Technology Classification
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Solar energy gathered by photovoltaic solar panels, intended for

delivery to a power grid, must be conditioned, or processed for use,
by a grid-connected inverter. Fundamentally, an inverter changes
the DC input voltage from the PV to AC voltage for the grid. This
inverter sits between the solar array and the grid, draws energy from
each, and may be a large stand-alone unit or may be a collection
of small inverters, each physically attached to individual solar panels.
See AC Module. The inverter must monitor grid voltage, waveform,
and frequency. One reason for monitoring is if the grid is dead or
strays too far out of its nominal specifications, the inverter must not
pass along any solar energy. An inverter connected to a
malfunctioning power line will automatically disconnect in
accordance with safety rules, for example UL1741, which vary by
jurisdiction. Another reason for the inverter monitoring the grid is
because for normal operation the inverter must synchronize with the
grid waveform, and produce a voltage slightly higher than the grid
itself, in order for energy to smoothly flow outward from the solar
array.
Grid-tied applications became increasingly popular over the past 10

years. This energy approach uses PV modules with high-voltage
string inverters to convert direct current from the modules to
alternating current of the grid, feeding the energy directly to the
grid. Users who adopted grid-tied systems enjoyed incentives from
federal and state programs, as well as from feed-in-tariffs that made
PV systems more cost-effective than utility-delivered power.
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➢ Salient Features of Plant
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❖ Grid Interactive System
Solar energy gathered by photovoltaic solar panels, intended for

delivery to a power grid, must be conditioned, or processed for use,
by a grid-connected inverter. Fundamentally, an inverter changes
the DC input voltage from the PV to AC voltage for the grid. This
inverter sits between the solar array and the grid, draws energy from
each, and may be a large stand-alone unit or may be a collection
of small inverters, each physically attached to individual solar panels.
See AC Module. The inverter must monitor grid voltage, waveform,
and frequency. One reason for monitoring is if the grid is dead or
strays too far out of its nominal specifications, the inverter must not
pass along any solar energy. An inverter connected to a
malfunctioning power line will automatically disconnect in
accordance with safety rules, for example UL1741, which vary by
jurisdiction. Another reason for the inverter monitoring the grid is
because for normal operation the inverter must synchronize with the
grid waveform, and produce a voltage slightly higher than the grid
itself, in order for energy to smoothly flow outward from the solar
array.
Fig. 9.3 Grid Interactive System
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❖ 1 MWp Plant
Fig. 9.4 1 MWp plant
❖ 2 MWp
• Thin Film Type
Fig. 9.5 Thin film
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• Crystalline Type
Fig. 9.6 Crystalline
❖ Solar Plant Activities

❖ Visual inspection of PV modules & measurement and recording
of all parameters (like voltage, current, power etc.)
❖ Replacement of faulty solar modules and their spares with the
new one of same ratings regularly in order to avoid generation
loss.
❖ Visual inspection and maintenance of Transformers, Inverters for
their reliability.
❖ Complete maintenance of Power Transformer (such as oil
checking, BDV top up, OLTC, Silica Gel replacement, routine
test of transformer, monitoring of OTI/WTI.
❖ Visual inspection of all SMJB’s, AJB’s and their tightening and
string current measurement.
❖ Periodic maintenance of LT/HT Panel and their associated parts
and spares.
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❖ Regular maintenance of batteries, charger circuits, circuit

breakers and on load tap changers.
❖ Regular checking of earth resistance of earth pits at plant
premises.
❖ Routine maintenance of lighting arrangement in plant area
and replacement of faulty lights if any.
Reporting plant performance report on daily/monthly basis in
required format to Technical Assistance to MD (Mahagenco),
CE (SPGD), HO (Mahagenco) and GCR.
❖ Grass/herbs cutting on regular basis.
❖ PV Module cleaning.
68 | P a g e

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Industrial

Serial Content Page No.

2. Chandrapur Super Thermal Power Station 3

4. Coal Handling Plant (CHP) 20

5. Power Plant Components, Auxiliaries and its 23

5.5 Generating Transformer 49

6. Electrostatic Precipitator (ESP) 57

7. Ash Handling Plant (AHP) 58

8. Effluent Treatment Plant (ETP) 60

9 Solar Power Plant (CSTPS) 61

9.1 Salient Features of Plant 64

9.2 Grid Interactive System 65

9.3 Solar Plant Activities 67

• Mahanirmiti or Mahagenco (Maharashtra State Power

Fig. 1.1 MAHA GENCO

2. Chandrapur Super Thermal Power Station (CSTPS)

Fig. 2.1 CSTPS

Chandrapur Super Thermal Power Station (often abbreviated as

Unit Installed Date of

1st 1 210 1983 August

1st 2 210 1984 July

1st 3 210 1985 May

1st 4 210 1986 March

2nd 5 500 1991 March

2nd 6 500 1992 March

2nd 7 500 1997 October

3rd 8 500 2015 May

3rd 9 500 2016 March

Table 2.1 Capacity of CSTPS

In thermal power station, steam driven turbine is a prime mover of

Following energy conversion steps are used in the thermal power

Chemical energy of coal

Heat energy of water due combustion of coal

Kinetic energy of steam in nozzle

Mechanical energy due to rotation of turbine

Electrical energy developed in generator armature due to

3. WATER TREATMENT PLANT (WTP)

Out of above mentioned area water treatment has prime

175000m3 water is treated in one day in CSTPS.

Pretreatment of water- Pretreatment is used to kill disease-causing

In water pre treatment plant the suspending particles are removed

Water from Erai dam brought pipe lines

One day reserve tank

Rapid gravity filter

To post treatment plant

Function of each step is explain below

One day reserve tank-

Alum not only settles certain hazardous chemicals and suspended

This causes it to join up with all of the offending particles and

Softening can be achieved by adding lime in the form

dioxide (CO2) is changed into bicarbonate (HCO3-) and then

Clariflocculator is a device in which flocculation & clarification

During flocculation reaction flocs hydroxide is formed & then settled

Mechanism of clariflocculator is as follows-

• These provide gentle agitation by slow moving paddles.

Rapid gravity Filter-

Fig. 3.1 Rapid gravity Filter

Rapid sand filters must be cleaned frequently, often several times a

During pretreatment for D.M. water, following process is carried out-

Pretreated water send for post treatment. Post treatment method

Demineralised (D.M.) water Plant-

Pretreated water sump

Pressure sand filter (P.S.F.)

Activated charcoal filter (A.C.F)