CHAPTER 1

BRIEF DESCRIPTION OF TANDA THERMAL PROJECT

1.1 GEOGRAPHICAL LOCATION

The Tanda Thermal Power Project is located about 185kms from Lucknow. It is
nearly 55kms from Faizabad. The nearest rail ahead is Akhbarpur (now called as
Ambedkarnagar). The project lies in the Ambedkarnagar district and is about 22kms from the
nearest railway station. The complete project is situated on the bank of Saryu River. The
climate conditions are quite favourable with greenery all around. The installed capacity is 4
X 110 MW.

The water requirement of the station is met from the Saryu River through Mehripur
pumping Station constructed for feeding Mehripur Pump Canal. The coal linkages for the
station have been provided from North Karnpura . The power generation is evacuated through
220kV feeders connected to Sultanpur (2 feeders), Basti & Gorakhpur (1 each) 220kV
substations.

The total area of the power house including colony is 235 hectares and the land for
ash disposal is 170 hectares. The designed boiler efficiency, turbine heat rate and unit heat
rate are 84.7% and 2172.8kcal/kWh & 2565.3kcal/kWh respectively.

1.2 TANDA PLANT PLF

The Tanda Plant PLF is shown in the figure given below

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 2000 2006 2008

Fig. 1.1 Tanda Plant PLF

NTPC Tanda is providing electricity to 3 different cities (Gorakhpur, Basti &

Sultanpur).. In near future, generating capacity of plant is going to be increased by two units
of 660MW each. So NTPC is playing a major role in development of India.

1.3 DESCRIPTION OF THERMAL PLANT

The plant is in fact designed on the modern concept of unit system. Each of the turbo-
generator is connected to its individual steam generating plant. The steam turbine has inlet
steam pressure of about 130kg/cm2 and super heat type with a reheat temperature of 540 0C.
Regenerative feed heating with 8 stages heaters have been adopted. There are two high
pressure feed water heaters connected with the exhaust of the H.P. cylinder and the second
one from an extraction of I.P. cylinder.

Constant pressure de-aeration is adopted for de-aeration and is fed from auxiliary
system header of the plant which maintains the de-aeration pressure of 6kg/cm 2 under all load
conditions.

There are five low pressure heaters – two connected to the IP (Intermediate Pressure)
heaters. The heat input from the grand steam condenser and the ejector condenser is also
recovered to improve the cycle efficiency. Drip pump is also used to pump the drain from the
3rd LP (Low Pressure) heater back to the condensate system. This also adds to the efficiency

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of the system. Drains from various stages of steam turbine are treated so that the maximum
thermodynamics benefit is derived.

The plant is also provided with automatic control features. The operation of the Coal
Handling, Ash Handling, Water treatment Plant, River water Intake pump is provided with
remote as well as local manual control features to cope with the requirements of such large
units.

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 CHAPTER 2

PRODUCTION OF ELECTRICITY

The means and steps involved in the production of electricity in a coal-fired power station are
described below.

Fig.2.1 Block Diagram For production of Electricity

The coal, brought to the station by train or other means, travels from the coal handling
plant by conveyer belt to the coal bunkers, from where it is fed to the pulverizing mills which
grinds it as fine as face powder. The finely powdered coal mixed with pre-heated air is then
blown into the boiler by fan called Primary Air Fan where it burns, more like a gas than as a
solid in convectional domestic or industrial grate, with additional amount of air called
secondary air supplied by Forced Draft Fan. As the coal has been grounded so finely the
resultant ash is also a fine powder. Some of this ash binds together to form lumps which fall
into the ash pits at the bottom of the furnace. The water quenched ash from the bottom of the
furnace is conveyed to pits for subsequent disposal or sale. Most of ash, still in fine particles
form is carried out of the boiler to the precipitators as dust, where it is trapped by electrodes
charged with high voltage electricity. The dust is then conveyed by water to disposal areas or
to bunkers for sale while the cleaned flue gases pass on through Fan to be discharged up the
chimney.

Meanwhile he heat released from the coal has been absorbed by the many kilometres
of tubing which line the boiler walls. Inside the tubes is the boiler feed water which is

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transformed by the heat into the steam at high pressure and temperature. The steam super-
heated in further tubes (Super Heater) passes to the turbine where it is discharged through the
nozzles on the turbine blades. Just the energy of the wind turns the sail of the wind-mill, so
the energy of the steam, striking the blades, makes the turbine rotate.

Coupled to the end of the turbine is the rotor of the generator – a large cylindrical
magnet, so that when the turbine rotates the rotor turns with it. The rotor is housed inside the
stator having heavy coils of copper bars in which electricity is produced through the
movement of the magnetic field created by the rotor. The electricity passes from the stator
winding to the step-up transformer which increases its voltage so that it can be transmitted
efficiently over the power lines of the grid.

The steam which has given up its heat energy is changed back into water in the
condenser so that it is ready for re-use. The condenser contains many kilometres of tubing
through which the colder is constantly pumped. The steam passing around the tubes looses
the heat and is rapidly changed back to water. But the two lots of water (i.e. boiler feed water
& cooling water) must never mix. The cooling water is drawn from the river, but the boiler
feed water must be absolutely pure, far purer than the water we drink, if it is not to damage
the boiler tubes. Chemistry at the power station is largely the chemistry of water.

To condense the large quantities of steam, huge and continuous volume of cooling
water is essential. In most of the power stations the same water is to be used over and over
again. So the heat which the water extracts from the steam in the condenser is removed by
pumping the water out to the cooling towers. The cooling towers are simply concrete shells
acting as huge chimneys creating a draught (natural/mechanically assisted by fans) of air. The
water is sprayed out at the top of towers and as it falls into the pond beneath it is cooled by
the upward draught of air. The cold water in the pond is then circulated by pumps to the
condensers. Inevitably, however, some of the water is drawn upwards as vapours by the
draught and it is this which forms the familiar white clouds which emerge from the towers
seen sometimes.

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 CHAPTER 3

DIFFERENT CYCLES OF A POWER PLANT

Fig.3.1 Basic Power Plant Cycle

bcde - Heating at constant pressure

ef - Ideal expansion at constant entropy before reheating

fg - Reheating at constant pressure

ghi - Ideal expansion at constant entropy after reheating

id - Extraction of latent heat in condenser

db - Ideal pressure increase at constant entropy in feed pump

The above figure shows the ranking cycle graph which is used in a power plant. The
paths shown below the figure represents the complete the whole steam and heat cycle as
followed in different operation cycles of a power plant.

For proper functioning of a power plant, its working operation has been divided into
following main operation cycles.

(1)Steam cycle
(2)Feed water cycle

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(3)Condensate water cycle
(4)Primary air cycle
(5)Secondary air cycle

3.1 STEAM CYCLE

This cycle basically deals with the flow of steam at different pressure and temperature to
different turbines namely HP, MP and LP turbines which are connected to the generator. It
can be explained from the figure shown below

Fig3.2 Steam Cycle

Steam coming out from super heater at 540degree C and 139kg per square cm. Three
cylinders of 2 set of main stop and governing valve arrangement on either side of HP casing
and each set consist of one stop valve and 2 governing valve assembling series. The steam
from the boiler is admitted the reheater where it heated at original temp. The reheated steam
is taken to IP casing through combined stop and interceptor valve arrangement at either of IP
casing. The exhaust from the IP casing has taken directly the LP casing. The steam expanded
in the LP turbine to a very low blade pressure which is maintained by the condenser below
atmospheric pressure about 3% of makeup water is required to condensate the losses of
cooling water due to evaporation in cooling tower. Finally steam exhausted by LP turbine is
condensed in the surface type condenser type cooling water following through a large no. of

[7]
tubes. The HP, IP &LP turbine coupled in series and mechanical power generated from steam
transmitted to generator.

3.2 FEED WATER CYCLE

This cycle deals with the flow of water to boiler feed pump from feed storage tank,
which is later fed to the boiler drum passing through high pressure heater and economizer

Fig 3.3 Feed Water Cycle

This system plays an important role in the supply of feed water to the boiler at
requisite pressure and steam/water ratio. This system starts from boiler feed pump to feed
regulating station via HP heaters.

Boiler feed pump: this pump is horizontal and barrel design driven by an electric
motor through a hydraulic coupling. All the bearings of the pump and motor are forced
lubricated by oil lubricating system. The feed pump consists of pump barrel into which is
mounted the inside starter, together with rotor. Water cooling and oil lubricating are provided
with their accessories. The brackets of the radial bearing of the suction side and the radial and
thrust bearing of the discharged side are fixed to low pressure.
High pressure heater: these are regenerative feed water heater operating at high
pressure and located by the side of turbine. It is connected in series on feed water side and by

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such arrangement the feed water after feed pump enters the hp heater. the steam supply to
these heater from the bleed point of the turbine through motor operated valves.
3.3 CONDENSATE WATER CYCLE
It deals with the water flowing through the condenser which plays an important role in
increasing the efficiency of the plant. It consists of a feedback path from main ejector to hot
well.

Fig.3.4 Condensate Water Cycle

The steam after condensing in the condenser known as condensate, is extracted out of
the condenser hot well by condensate pump and taken to the de-aerator through ejectors,
gland steam cooler and series of LP heaters

Condensate pump: the function of these pumps is to pump out the condensate to the
deaerator taken to the de-aerator through ejectors, gland steam cooler and series of LP
heaters. This pump is rated generally for 160 cubic meter/hour at a pressure of 13.2 kg/cm
square.

3.4 PRIMARY AIR CYCLE

In this cycle, air is used to carry pulverized coal from mill to the burning zone of
boiler. Two P.A fans in a thermal power plant to produce air of required quality( pressure
around 700mm of water column) to elevate the powdered coal from the pulveriser to the

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burner. For supplying coal 2 each & every elevation one pulveriser is there & the temp. of
mixture of coal and air is controlled by mixing hot(through Air Pre Heater) and cold primary
air at the inlet of pulveriser.
3.5 SECONDARY AIR CYCLE
In this cycle, fuel is mixed with air (known as secondary air) for proper burning of
coal. Secondary air is made available from forced draft fans.
F.D fans take suction from the atmosphere and discharge through the wind box
arranged to both left & right of the boiler. First wind box is at the corner 1 & 2 and the other
at the corner 3&4.The required quantity of Secondary air into the furnace from the wind box
is measured in terms of oxygen in the flue gas is controlled by a no. of secondary air
dampers placed b/w wind box & furnace.(4 nos. for each elevation).

[10]
 CHAPTER 4

IMPORTANT EQUIPMENT OF PLANT

4.1MECHANICAL EQUIPMENTS
4.1.1 Mechanical Dust Collector & Electrostatic Precipitators
Combined – mechanical dust collector & electrostatic precipitator are provided to
arrange arresting of fly ash in order to reduce particle. Efficiency of about 98% is achieved in
this combined system.

4.1.2 Turbine Generator Unit

A standard multi-stage, tandem compound extraction type, reheat type, condensing

turbine with seven uncontrolled extractions, operating at 3000rpm is designed to operate with
steam condition of 130kg/cm2

The turbine is provided with hydraulic (oil) governing system. The turbo-generator is
complete with all auxiliary systems and equipments, lubrication systems, shaft, gland seal
system, motor operated turning gear. All necessary protective and supervisory instruments
are provided to ensure trouble free, safe and efficient operations of the units. The turbine –
generator is manufactured by BHEL.

4.1.3 Condensing Equipments

Turn surface condenser of identical design, capable of maintaining a vacuum of about
0.92kg/cm2 while condensing the steam at maximum rating of the turbine is provided. These
tubes are of aluminium–brass and tube sheet is of aluminium-bronze. The condensers are
spring mounted and directly connected to the exhaust flange of the turbine with its axis to the
right angles to that of the turbine.

4.1.4 De-aerating heater & Closed heaters

The unit is provided with a de-aerating heater and proper capacity of a feed water tank
of approximately 14min storage capacity when machine is running at full load.

4.1.5 Boiler
A steam generator is complex integration of following accessories:
1. Economiser

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2. Boiler drums
3. Down comers
4. Boiler drum level control
5. Water walls

Fig.4.1 Boiler

 Economiser

• Boiler Economiser is feed-water heaters in which the heat from waste gases is
recovered to raise the temperature of feed-water supplied to the boiler.
• It preheats the feed water by utilizing the residual heat of the flue gas.
• It reduces the exhaust gas temperature and saves the fuel.

 Boiler drum

• It is an enclosed Pressure Vessel

• Heat generated by Combustion of Fuel is transferred to water to become steam
 Serves two main functions.

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 Separating heat from the mixture of water and steam.
 It consists of all equipments used for purification of the steam after being
separated from water.

 Boiler drum level control

 Important for both plant protection and equipment safety.

 Maintain drum up to level at boiler start-up and maintain the level at constant steam
load.
 Decrease in this level will uncover boiler tubes and get overheated and damaged.
 Increase in this level will make separation between steam and moisture difficult
within drum.
 Controlled circulation is required to maintain the difference in the density between
water and steam with increase in pressure.
 Down comers
 It carries water from boiler drum to the ring header.
 They are installed from outside the furnace to keep density difference for natural
circulation of water & steam.
 Heating and evaporating the feed water supplied to the boiler from the economiser.
 Water wall
• These are membrane walls, no. of tubes are joined.
• Vertical tubes connected at the top and bottom of the Headers.
• Receives water from the boiler drum by down –comers.

4.1.6 HP & LP Bypass System

Provision of HP & LP bypass system is proposed having a capacity of 40% steam bypass,
making the unit suitable for quick restart as well as peaking purposes. This has been necessary on
account of grid conditions which shows very acute storage of peaking.

4.2 ELECTRICAL EQUIPMENTS

4.2.1 Generator
The generator is directly coupled with its respective turbine normally rated for 110
MW at 0.88 power factor (i.e. 125 MVA), 11kV, 3 phases, 50Hz. The hydrogen cooling

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mechanism is used for the generator. The neutral point of the generator is earthed through a
single phase Distribution Transformer, the secondary of which is shunted through a suitable
resistance.

The excitation system consists of high frequency AC mains and pilot exciters directly
driven from the main shaft, silicon rectifying unit and associated control gears.

4.2.2 Generator Transformer

The generation voltage of 11kV is stepped up to 220kV by generator-transformer (in
short GT) whose low voltages side is directly connected with the generator through an
isolated phase bus duct. The rating of generator-transformer is 125MVA, 11/220kV, 3 phase,
50 Hz having an ON/OFF cooling. The high voltage side of the transformer is connected to
the 220kV system in 220kV switchyard.

4.2.3 Unit Transformer

The bus-duct leading from the generator to the GT is tapped off conveniently for
connection to high voltage side of Unit Auxiliary Transformer used for stepping down the
voltage to 6.6kV for supplying power to the unit auxiliary loads of the power station. The
rating of the UAT is 15MVA, 11/6.6kV, 3-phase, 50 Hz.

4.2.4 Start-up cum Reserve Transformer

Each of the four units draw its start up power from the 220kV system through
two/three windings common start-up cum reserve transformer rated for 30/10/20 MVA,
220/33/6.6 kV, 3 phase, 50Hz. The transformer supplies the 33kV load requirements. This
transformer also meets the requirement of station loads like coal & ash handling, compressed
air and water treatment plant, station lightening and other common services as well as act as a
standby source of power to unit auxiliaries.

4.2.5 L.T. Auxiliary Transformer

For further step down of 6.6kV power from the reserve system for utilization at
medium voltage 16 nos. 1000kVA, 6.6kV/415V, 3-phase, 50Hz transformers have been
envisaged. The actual requirement is assessed after detail design of the system.

4.2.6 DC Supply System

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 A station battery unit, complete with battery charger and control & distribution
system is installed as required for supply to all loads either for normal operation or during
any emergency conditions. Exact rating is however determined after the detail study of all
loads and their durations.

4.2.7 Switchgear

The drives for auxiliary equipment rated 150kW and above are operated at 6.6kV and
drives having a rating below 150kW are operated at 415V, 3-phase, and 4-wire system having
a provision for single phase 230V. For starting up of these motors suitable
switchgears/starters are provided.

 6.6 kV Switchgears 6.6 kV power received from either Unit Auxiliary Transformer
or Reserve Transformer are connected to respectively 6.6kV switchgear bank through
suitable breakers for further distribution to motors and to transformers for further step
down to 415V.
 415 V Switchgear The 415V supply from each 1000kVA transformer are connected
to a suitable 415V bus having its distribution for different motors and starters. Motors
capacity above 90kW are controlled by a 415V breaker from respective bus and that
of lower capacity by magnetic contractors grouped together in a sheet metal cubicle
for a number of motors.
.
4.2.7 220kV Switch Yard

Generator Transformer step-up the 11 kV voltage generated by the Generator to 220

kV. This voltage is used to charge the three buses in the Switch yard which follows Double
Bus Bar with Transfer Bus Scheme. Switch yard provides protection between generator
transformer and transmission lines.

4.3 AUXILIARY SYSTEMS

The following auxiliary systems for the 4X110 MW as envisaged is described below:-

4.3.1 Coal Handling System

Railway is only the means of transport of coal to this power station. Annual coal
requirement for 4X110 MW units is estimated to be approximately 13.70 lakhs mega tonnes.

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The coal yard in the layout is adequate for about 30 days storage with two coal stock piles
and considering 3800 MT of coal requirement daily.

4.3.2 Fuel Oil System

The fuel oil is made available to the power station in tank wagon. The lighter grade
oil such as light diesel oil is made available for starting of boiler from cold condition &
furnace oil is made available for flame stabilisation purpose during low load operation and
during any other period when flame stability is not satisfactory. The oil received from the
tank wagon is pumped into the storage tank.

Oil from storage tank is pumped into day oil tanks. The day oil tank is located near
the boiler. Pumps and heaters sets of suitable design then pump the oil from day storage to
the burner. Return oil is fed back into the day tank. Similar installation is provided for the
light oil but the day tank is not present.

4.3.3 Ash Handling System

The ash disposal area is within the distance of 4~5kms from the power station and this
is a low lying area. The ash from the boiler hoppers is conveyed to the ash disposal area
either by direct sluicing or hydro-pneumatic system. Boilers manufactured by BHEL

The ash disposal area has adequate capacity for storage of ash for a 640 MW station
for over 15 yrs without reclamation. This area is now being used by Jaypee cement factory
for production of cement and ash bricks. However this area may also be used for agriculture
purposes by covering it with a layer of silt brought from the raw water reservoir in future.

4.3.4 Cooling Water Management

Water from the raw water reservoir is pumped through clariflocculators. The clarified
water from these clarifloccolator flows to the cooling water basin by gravity. A clarified
pump is present which pumps the clarified water to the plant. For this, three pumps are
involved. The outlets from the cooling water tower basins are connected to the common
tunnel which takes the water back to the power house.

4.3.5 Water Treatment Plant

A demineralising plant is provided for supplying make-up water for the heat cycle.
Clarified water is pumped from the clarified water storage pit which passes through pressure
filter, activated carbon filter, cation exchanger, degassifier, anion exchanger and mixed bed
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exchanger. There are four streams each rated 30m3/hr. Adequate facilities are provided for
unloading, handling and storage of chemicals. Waste effluent is neutralised before it is
discharged to outside drain.

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 CHAPTER 5

CONTROL AND INSTRUMENTATION UNIT

With the increasing size of modern plant, the distance between items of plants and
centralised control room. Also, with large no of instruments, it becomes very difficult to
watch many instruments and supervise the operation of such a large no of equipment.

A control unit relives the operator from routine tasks, leaving him free to concentrate
on the overall inspections. Also it is very difficulty the operation engineer to keep to keep
constant watch on these temperature gradients, but it’s become easy by using control units.

The conventional central control unit is rather a cumbersome system. Large no of

instruments must be observed to know what is happening inside the plant. The job is
simplified by collecting all measurements transmitted from the process, converting them into
digital form and printing them on to log sheets. All the important measurements at one time
are printed along arrow.

The major variables to be controlled are:-

 Super heater & re-heater outlet temperature at a preset value

 Feed water flow to the steam generator
 Mill temperature
 Combustion control by controlling fuel air Condensate recirculation from condensate
discharge line to the condenser
 Level control of heaters, condensers & clearator feed tan
 Boiler feed pump recirculation control
 Drum level

5.1 UNDERSTANDING A CONTROL SYSTEM

To under a control system, the diagram is given below

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 S.P. – Set Point
C.V.– Control Value
Fig. 5.1 Control System Unit

 It is a closed loop or feedback system.

 System is set to fixed value known as Set Point.
 Deviation of the measured value from set value describes the controlling action to be
performed.
 Control value to be sensed by sensor and the deviation from Set Pt. is measured and
an Error signal is generated.

5.2 MAXDNA

MAXDNA systems are used in many applications throughout the world including
electric power generation, co-generation, cement, glass, ceramics, primary metals, chemicals
and petroleum, water and waste-water treatment and incineration plants. 
The applications in Power Plant Controls are as listed.

o Steam Generator Controls

o Heat Recovery Steam Generator (HRSG) controls
o Steam Turbine controls
o Industrial Steam Turbine Controls
o Balance of plant controls
o Data Acquisition and information management
o Hydro Turbine Governing and Auto sequence controls
o Generator and Switchyard controls
o Electrical System controls
o Fossil power utility plants

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o Combined cycle power plants
o Captive power plants

Fig.5.2 Unit Display of MAXDNA

5.3 FURNACE SAFEGUARD SUPERVISORY SYSTEM (FSSS)

FSSS (Furnace Safeguard & Supervisory System) is used in almost all types of boilers
to ensure safe operation. The system has been designed to offer maximum protection,
minimum nuisance trips, minimum power consumption and maximum life of the components
used. It is to ensure the execution of the safe, orderly operating sequence in the start-up and
shutdown of fuel firing equipments in a boiler and to prevent errors which may be committed
by an operator due to ignorance. The system is complex one and has got multiple steps which
cannot be left at the discretion of operators to follow it in a sequential manner. The system is
designed in such a manner that it eliminates the possibility of the unburnt fuel accumulated
inside the furnace that may lead to explosion on sudden ignition.

The BMS (Burner Management System) or FSSS system shall be designed to perform
the following functions-

 Prevent firing unless a satisfactory furnace condition obtained (furnace purge

completed).

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  Prohibit start-up of the equipment unless certain permissive interlocks have been
completed.
 Monitor and control the correct component sequencing (manual or automatic) during
start-up and shutdown of the equipment.
 Conditionally allow the continued operation of the equipment only while certain
safety interlocks remaining satisfied.
 Provide component condition feedback to the operator and, if so equipped, to the plant
control systems.
 Provide automatic supervision when the equipment is in service and provide means to
cut out the fuel supply to the furnace in case of unacceptable firing conditions.
 Cut out fuel (MFT) upon certain adverse unit operating conditions.

5.4 TURBINE SUPERVISORY INSTRUMENTATION (T.S.I)

Some important are measured for supervision of the turbine are as follows:-

1. Turbine speed
2. Shaft eccentricity
3. Bearing vibrations
4. Differential expansions
5. Overall expansions
6. Axial shift

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 REGARDS

For the humble guidance and cooperation, we are thankful to

 Mr.Sanjeev Gupta (DGM)

 Mr.A.K.Mishra (DGM)
 Mr.Lalit Kr. Singh (DY.SUPT)
 Mr.K.S. Upadhyaya (Engineer)
 Mr. A.H.Rizvi (Engineer)

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