VOCATIONAL TRAINING SUMMER BATCH 2018

INDUSTRIAL IN – PLANT TRAINING REPORT

CHANDRAPUR SUPER THERMAL POWER STATION

UNDER THE GUIDANCE OF

COURSE CO- ORDINATOR GROUP CO- ORDINATOR

Mr. S. S. KHADATKAR Mr. SHUBHAM BORKAR

SUBMITTED BY

1. TUSHAR S. BHANARKAR 10.NETRA B. WARTHI

2. DIKSHA N. BHANARKAR 11.KOMAL V. BOPATE
3. SNEHA G. CHAVHAN 12.SHUBHAM V. BANSOD
4. PAYAL D. BAGDE 13.ABHIJIT KUMAR
5. KUNAL D. KARKADE 14.SHIVANI S. TIWARI
6. SHIVANI P. MENDOLE 15.AKSHAY KARWATKAR
7. SAMRUDDI D. KOTHARI 16.KARAN KAMBLE
8. KOMAL R. DIGHADE 17.SWAPNIL KHEWALE
9. ASHISH A. DESHPANDE

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 ACKNOWLEDGEMENT
I take this opportunity to thank Shri. Jayant Bobde Sir Chief Engineer CSTPS, Executive
Engineer Training, Industrial Training co-ordinator Mr. S.S. Khadatkar Sir and group co-
ordinator Mr. Shubham Borkar Sir under Chandrapur Super Thermal Power
Station(C.S.T.P.S) for allowing us to work on such an interesting and informative topic.

I and my team also express special thanks to our entire training faculty namely Shri. Naval
Damle Sir, Shri R. K. Sonekar Sir, Shri Jayant Dethe Sir, Shri S. M. Sheikh Sir, Shri B.
M. Jumane Sir, Shri P. P. Kathale Sir, Shri A. B. Bopche Sir and various distinguished
faculty for their guidance and word of wisdom. They always diverted us to the right direction
during the course of this project work. We are thankful to them for making us visit various sites
like CHP, Boiler, AHP/OHP, WTP, Turbine, Electrical Maintenance, ETP and providing all
the technical expertise and knowledge required in order to run a thermal power plant efficiently.

Success in such comprehensive report cannot be achieved single handedly. It is the team effort
that sail the ship to the coast. I am thankful to my team who made this entire training session a
beautiful memory by working together and ccoordinating properly with each other to bring out
this project report successfully.

Also a special thanks to all the faculties who helped us gain all the practical knowledge required
during the in plant visits. Lastly I would like to thank all those who have directly or indirectly
contributed to this training session.

(Shivani S. Tiwari)

Date: Team Leader

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 INDEX
SR. NO. NAME OF TOPICE PAGE NO.
1. ABSTRACT 4
2. INTRODUCTION 5
3. PURPOSE OF VISIT 6

4. SCHEMATIC DIAGRAM OF THERMAL POWER 7

PLANT
5. WORKING OF THERMAL POWER PLANT 8
6. EQUIPMENT’S REQUIRED IN CSTPS 9
7. COAL HANDLING PLANT (CHP) 10-14
8. WATER TREATMENT PLANT (WTP) 15-16
9. BOILER 17-19
10. TURBINE 20-22
11. CONDENSER 23
12. GENERATOR 24
13. ASH HANDLING PLANT (ASP) 25-28
14. COOLING TOWER 29
15. CONTROL ROOM 30
16. SWITCH YARD 31
17. ADVANTAGE AND DISADVANTAGE OF 32
THERMAL POWER STATIONS

18. CONCLUSION 33
19. REFRENCES 33

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1. ABSTRACT
Chandrapur Super Thermal Power Station (CSTPS) is one of the coal based
power plants of MAHAGENCO situated in the Chandrapur District of Maharashtra. 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.
With the total capacity of 3340MW, the plant is largest power plant in the Maharashtra. It
accounts to more than 25% of total Maharashtra needs. The plant gets water supply from Erai
Dam .Mahagenco has the highest overall generation capacity and the highest thermal installed
capacity amongst all the state power generation utilities in India. In terms of installed capacity, it
is the second highest generation company after NTPC.
Mahagenco having generation capacity of 11237 MW comprising 7980 MW thermal,
2585 MW hydel and 672 MW gas turbine was established by government of Maharashtra under
the central electricity act-2003 with the principal objective of engaging in the business of
generation of electricity, & mahagenco produces cheapest power for consumers in state.
It is is committed to expanding the generation capacity to meet the ever-growing power
supply need of maharashtra. The company is implementing a huge capacity addition programme.
It generates power for more than 1,50,00,000 end consumers in Maharashtra at economical and
affordable rates. It believes in quality management. All major thermal, hydel and gas turbine
power stations have adopted the ISO 9001:2000 certification.
It is an eco-friendly power generating company and has received certification under
ISO:14001 and ISO:18001 for its major power stations at Chandrapur, Koradi, Khaperkheda,
Nasik, Parli and at Koyna and Uran power stations also.
Mahagenco has a gross fixed asset base of Rs. 28346 crores (March 2014) with an annual turn
over of about Rs. 16538 crores (March 2014).It is powered by a dedicated and committed highly
skilled work force of more than 15000.

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2. INTRODUCTION
With the total capacity of 3340MW, the plant is largest power plant in the Maharashtra. It
accounts to more than 25% 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. A thermal power station is a power station in which heat
energy is converted to electric power. In most of the places in the world The turbine is steam-
driven. Water is heated, turns into steam and spins a steam turbine which drives an electrical
generator. After it passes through the turbine, the steam is condensed in a condenser and recycled
to where it was heated; this is known as a Rankine cycle. The greatest variation in the design of
thermal power stations is due to the different heat sources fossil fuel dominates here, although
nuclear heat energy and solar heat energy are also used. Some prefer to use the term energy
center because such facilities convert forms Of heat energy into electrical energy. Certain
thermal power stations also are designed to produce heat energy for industrial purposes, or
district heating, Or desalination of water, in addition to generating electrical power. The thermal
power plant has serious impact on land, soil ,and various social impact the thermal power plant
are also said to emit large amount of mercury and generate large amount of water. Due to these
problem they required which is not done judiciously in our country.

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3. PURPOSE OF VISIT
The main reason to visit the power plant was to understand and get complete knowledge about
practical overview of energy generation plant. Since we are studying the theoretical working and
details about various thermal plants in our syllabus.

A plant tour provides an opportunity to observe how work actually gets done. Even the most
lucid description of how work flows are managed around a shop or how operators use charts and
diagrams to solve problems is no substitute for seeing things happens in practice. By actually
seeing a system work, visitors are able to develop a clear mental picture of it.

They can then answer questions related to it with ease. Plant tours are important vehicles for
bringing new knowledge to the tour’s host. An expert’s insights are much more powerful and
credible when shared in person on the plant floor than they are when submitted to the plant’s
staff in the form of a written report.

For example, a plant network manager can add tremendous value by transporting the best
practices of one plant to another and demonstrating how those practices might be applied on the
floor. Without regular visits, it is difficult to transfer this knowledge effectively.

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4. SCHEMATIC DIAGRAM OF THERMAL
POWER PLANT

FIG NO 1. SCHEMATIC DIAGRAM OF THERMAL POWER

PLANT
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5. WORKING OF THERMAL POWER PLANT
The thermal power station converts heat energy of coal into electrical energy. The coal handling
plant supplies coal to the boiler. The ash formed in the boiler is disposed of by ash handling
plant. Air is taken from atmosphere by induced or drought fans and thus air is heated in
preheated before fed to the boiler. The flue gases pass through the dust collector, air preheated
and economizer before being discharged to the atmosphere through chimney. The boiler
vaporizes water into steam which is further heated in super heater and fed to the high pressure
turbine. After expanding gear system the steam is heated again in the boiler and fed to the
pressure turbine. The exhaust steam from low pressure turbine is condensed by condenser as
shown in fig and condensate along with the makeup water is passed through economize before
being fed to the boiler in this way electrical energy is produced by rotating turbine using steam
which is coupled to the alternator of required rating.

Chemical energy of coal

Heat energy of water due combustion of coal

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6. EQUIPMENT’S REQUIRED IN CSTPS
There are different equipment’s required for running CSTPS they are :-

1. COAL HANDLING PLANT (CHP)

2. WATER TREATMENT PLANT (WTP)
3. BOILER
4. TURBINE
5. CONDENSOR
6. GENERATOR
7. ASH HANDLING PLANT (AHP)
8. COOLING TOWER
9. CONTROL ROOM
10.SWITCH YARD

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7. COAL HANDLING PLANT (CHP)
Coal handling plant is the starting and much important for CSTPS. It is the base of generation of
electricity. CHP is a facility that washes coal of soil and rock, crushes it into graded sized
2chunks (sorting),stockpiles grade preparing it for transport to market , and more often than not,
also loads coal into rail cars, barges in CHP following work is done.

1. Unloading of received coal.

2. Convey coal to bunker.
3. Maintain bunker level
4. Stacking the coal for emergency.

7.1. COAL CHARACTERISTICS

• Moisture 6-7%
• Ash 24-33%
• Volatile matter 24-28%
• Gross Calorific Value 4778-4944 kcal/kg
• Hardness index 45-50
• Density 0.8MT/m3
• Size 250mm

7.2.COAL SUPPLY & IT’S HANDLING

The coal for operation of boiler is CSTPS is provided from durgapur and padmapur collieries of
WCL and mahanadi coalfield limited kinds of coal in increasing order of alteration are lignite,
sub-bituminous, bituminous and anthracite. As time passes lignite increases in maturity by
becoming darker and harder & is then classified as Sub-bituminous coal which is preffered in the
plant.In a coal based thermal power plant, the initial process in the power generation is ―Coal
Handling‖. So in this article i will discuss the overall processes carried out at a Coal Handling
plant in a coal based thermal power generating station.

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 WAGON PLACEMENT SYSTEM

Car puller

By attaching rope to rear pulling loop on

Side Arm Charger for hauling rake of wagons,
placement of wagons on tippler table and
evacuation of empty wagons from tippler table.
car, front of car can be brought somewhat
beyond position of single sheave block.
locomotive

Beetle charger

FIG NO 2. WAGON PLACEMENT SYSTEM

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Rabbit charger
7 TH JUNE 2018
7.3. OPERATION OF PADDLE FEEDER:
The Paddle Feeders feed the coal on the conveyor belt from the Track hopper at a controlled rate.
The paddle blades projected in the hopper slot scoop the coal from hoppers and discharge it on
the conveyor belt running below.

The following points need to be checked before taking any paddle feeder into service.

a. The paddle arms are free from any obstruction.

b. There is no leakage at gearboxes and fluid couplings and the oil levels are correct.
c. There is no leakage of hydraulic oil, in the case of hydraulically driven paddle feeders,
and the oil levels are correct.
d. The cable reeling drums for correct winding and unwinding.
e. The paddle feeder is operating only in interlock mode.

7.4. OPERATION OF CONVEYOR:

Various conveyors are provided for transporting the coal from Track hopper to Bunkers.
The following precautions are to be taken before taking any conveyor into service:

a. There is no oil leakage at gearboxes / fluid couplings and the oil levels are correct.
b. The Discharge and Receiving chutes are free from jamming and choking.
c. The Flap Gates are in correct positions.
d. All inspection doors are in the closed position.
e. All pull-cords are reset and the EPB is released and ensure that all protections are
healthy.
f. The Alarm Siren is in working order.
g. Communication facility is available.
h. The lighting is adequate.
i. No Permit To Work (Isolation) is pending against that conveyor.

7.5. OPERATION OF CRUSHER:

Ring Granulator type crushers are provided to crush the coal generally from (-) 250 mm/100 mm
size to (-) 20 mm size. The following points need to be checked before returning any crushers to
service:

a. The crusher shall be clear from any jamming.

b. All doors are in the closed position and locked. inspection
c. There is no leakage at gearbox and fluid couplings and the oil levels are correct.

The huge amount of coal is usually supplied through railways. A railway siding line is taken into
the power station and the coal is delivered in the storage yard. The coal is unloaded from the
point of delivery by means of wagon tippler. It is rack and pinion type. The coal is taken from

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the unloading site to dead storage by belt conveyors. The belt deliver the coal to 0m level to the
pent house and further moves to transfer point 8.

The transfer points are used to transfer coal to the next belt. The belt elevates the coal to breaker
house. It consists of a rotary machine, which rotates the coal and separates the light dust from it
through the action of gravity and transfer this dust to reject bin house through belt.

The belt further elevates the coal to the transfer point 7 and it reaches the crusher through belt.
In the crusher a high-speed 3- phase induction motor is used to crush the coal to a size of 50mm
so as to be suitable for milling system. Coal rises from crusher house and reaches the dead
storage by passing through transfer point 8.

1. Pulverizer: Pulverize is s mechanical system for grinding of mant different types of

materials for example they are used to pulverize coal for combustion in steam generating
furnances of fossils fuel power plants. There are various types of ball mills such as ball
and Tube mills, Ring and ball mills, demolition.
2. Dryers: they are used in order to remove moisture of excess freon coal mainly wetted
during transport. As the presence of moisture will result in fall in efficiency due to
incomplete combustion and also result in CO emission.
3. Magnetic sepertors: Coal which is brought may contain iron particlrs. This iron particle
may result in wear and tear. The iron particles may include bolts, nuts wire fish plates, etc
so this is unwanted and removed with the help of magnetic separators.

7.6. COAL UNLOADING:

There are mainly three type of mode of transportation

7.6.1. ROADWAY:
Coal is carried in trucks.8-10 mt coal per truck is carried out. It Requires more time and
manpower.Coal mines should be near to power station. i.e. (100-150 km). But Coal is lost /
waste in transit.Hence it is not in use for large power stations.

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FIG NO. 3 ROPEWAY
 7.6.2.RAILWAY
Coal is Unloaded with the help of WAGON TIPPLER. It is the most convenient way of
transportation. One Rack consist of 52-56 Wagons.
The rate of tripling is 13/25 wagons per hour. Each wagon contains 55-58 MT of coal. This
Wagon movements are controlled by ―Bettle Chargers‖ and Demurrage charges on racks.(11 ½
hrs.)It is also a popular mode of transport.

FIG NO. 4 RAIWAYS

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8. WATER TREATMENT PLANT (WTP)
 Water treatment is important component of thermal power plant.
 Water contains different types of impurities when this impurities enters boiler it will
produce slice formation inside boiler tubes due to which heat will not transfer properly
hence tubes will melt.
 Presence of oxygen and carbon dioxide leads to corrosion of water tubes.
In CSTPS raw water is come from Erai dam through pipe lines. The following impurities
are present in raw water :
 Turbidity: It is due to mud, minerals.
 Oraganic matter : Oraganic is present due to the decomposition of dead animals, trees,
leaves.
 Dissolved gases: Gases like carbon monoxide, oxygen are dissolves in water.

Water is goes through following process.

1) PRE-TREATMENT

2) POST-TREATMENT

175000 Cubic meter water is treated in one day in CSTPS.

FIG NO. 4 DAM

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FIG NO. 5 WATER TREATEMENT PLANT

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9. BOILER
 Boiler means an cleared vessel exceeding 22.75 LH in capacity used for steam generation
under pressure.

 The first boiler developed in 1725 and working pressure was 6-10kg/cal.

 Boiler is a very important component of the Thermal power plant. It is used to generate
steam to drive the turbine.

 Boiler is made up of steel. Temp of boiler is in the range of 1400-1600 degree cel.

 The source of heat in boiler is combustion coal. In CSTPS water tube type boiler is used.

 There are two types of boilers:

1. Fire tube boilers

2. Water tube boilers

• According to pressure boilers are called-

1) Drum type sub critical boiler: When boiler pressure is 130 kg/sq.cm to 180 kg/sq.cm.

2) Critical pressure boiler: When boiler pressure is 221.2 kg/sq.cm.

3) Super critical boiler: When boiler pressure is 240 kg/sq.cm.

FIG NO. 6 SINGLE LINE DIGRAM OF BOILER 17

9.1 AUXILLARIES IN BOILER
9.1.1. ECONOMIZER
A feed water economizer reduces steam boiler fuel requirement b transferring heat from
the flue gas to incoming feed water. Boiler flue gases are often rejected to the stack at temp
higher than the temp of the generated steam.

FIG NO. 7 ECONOMIZER

9.1.2. 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.

9.1.3. FINAL SUPERHEATER

It is a device in which the steam from the oiler is dried. It means that total moisture is
removed from the steam.

Platen superheated – It is a plate type heater.

9.1.4. 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

18
the flow of gases through the device, and can easily remove fine particulate matter such as dust
and smoke from the air stream

9.2. FANS IN BOILERS

 Following are the fans are used in boiler

1. PRIMARY AIR FAN (P.A.FAN)

Function of primary air fan

 Carry the pulverized coal to boiler from coal mills.

 Remove moisture from coal.

2. FORCED DRAUGHT FAN (F.D. FAN)

 Fans for boilers force ambient air into the boiler.

 Typically through a preheater to increase overall boiler efficiency.

 Forced draught fan purpose is to provide a positive pressure to a system.

3. INDUCED DRAUGHT FAN (I. D. FAN)

 Induced draft fan 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.

9.3. BOILER MAINTENANCE

Blow downs-

 Boiler blow down 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 blow down or continuous
blow down.

 The blow down frequency and duration is primarily determine 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.

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10. TURBINE
The turbine generator consists of a series of steam turbines interconnected to each other and a
generator on a common shaft. There is a high pressure turbine at one end, followed by an
intermediate pressure turbine, two low pressure turbines, and the generator. As steam moves
through the system and loses pressure and thermal energy it expands in volume, requiring
increasing diameter and longer blades at each succeeding stage to extract the remaining energy.
The entire rotating mass may be over 200 metric tons and 100 feet (30 m) long. It is so heavy
that it must be kept turning slowly even when shut down (at 3 rpm) so that the shaft will not bow
even slightly and become unbalanced. This is so important that it is one of only six functions of
blackout emergency power batteries on site. Other functions are emergency lighting,
communication, station alarms, generator hydrogen seal system, and turbo generator lube oil.

FIG NO. 8 A CUT SECTION OF TURBINE

Superheated steam from the boiler is delivered through 14–16-inch (360–410 mm) diameter
piping to the high pressure turbine where it falls in pressure to 600 psi (4.1 MPa) and to 600 °F
(320 °C) in temperature through the stage. It exits via 24–26-inch (610–660 mm) diameter cold
reheat lines and passes back into the boiler where the steam is reheated in special reheat pendant
tubes back to 1,000 °F (540 °C). The hot reheat steam is conducted to the intermediate pressure
turbine where it falls in both temperature and pressure and exits directly to the long-bladed low
pressure turbines and finally exits to the condenser.

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 FIG NO. 9 ASSEMBLY OF TURBINES

Turbine set consist of 3 turbine define on the basis of pressure inside it.

1. High pressure turbine – Impulse turbine

2. Intermediate pressure turbine – Reaction turbine

3. Low pressure turbine – Reaction turbine

The turbine contained 1 row of stationary blade and 1 row of rotating blades alternatively.

This arrangement has following advantages –

1) Required space is less.

2) Vibration cause is less.

3) Steam can be expand up to require amount.

4) Maintain the correct rotor position and balancing, this force must be counteracted by an
opposing force.

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FIG NO. 10. FINS OF TURBIN

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11. CONDENSER
The condenser condenses the steam from the exhaust of the turbine into liquid to allow it to be
pumped. If the condenser can be made cooler, the pressure of the exhaust steam is reduced and
efficiency of the cycle increases. The function of condenser is

1. To provide lowest economic heat rejection temperature for steam.

2. To convert exhaust steam to water for reserve thus saving on feed water requirements.
3. To introduce make up water.

The heat absorbed by the circulating cooling water in the condenser tubes must also be removed
to maintain the ability of the water to cool as it circulates. This is done by pumping the warm
water from the condenser through either natural draft, forced draft or induced draft cooling
towers (as seen in the image to the right) that reduce the temperature of the water by evaporation,
by about 11 to 17 °C (20 to 30 °F)—expelling waste heat to the atmosphere. The circulation flow
rate of the cooling water in a 500 MW unit is about 14.2 m³/s (500 ft³/s or 225,000 US gal/min)
at full load.

FIG NO. 11. CONDENSER

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12. GENERATOR
The generator voltage for modern utility-connected generators ranges from 11 kV in smaller
units to 22 kV in larger units. The generator high-voltage leads are normally large aluminium
channels because of their high current as compared to the cables used in smaller machines. They
are enclosed in well-grounded aluminium bus ducts and are supported on suitable insulators. The
generator high-voltage leads are connected to step-up transformers for connecting to a high-
voltage electrical substation (usually in the range of 115 kV to 765 kV) for further transmission
by the local power grid.

The necessary protection and metering devices are included for the high-voltage leads. Thus, the
steam turbine generator and the transformer form one unit. Smaller units may share a common
generator step-up transformer with individual circuit breakers to connect the generators to a
common bus.

FIG NO. 12. CUT VIEW OF SYNCHRONOUS AC GENERATOR

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13. ASH HANDLING PLANT (AHP)
When the Coal combustion takes place in the boiler, some part of the coal remains un burnt and
that un-burnt particles are called the Ash, which is approximately 26% to 40% of the total coal
providing combustion. Basically this is nothing but the residual part of the coal. This ash will be
extracted out in the form of Bottom Ash & Fly Ash according to the places of collection after the
combustion.

If we calculate the ash percentage in any plant, then it will be as following:

Total Ash = 40% of the coal combusted

Bottom ash = 20% of the total ash

Fly ash = 80% of the total ash

So whatever the Ash generated during the combustion process has to be sent out of the plant as it
is of no use in the plant processes. Also Now-a-days the Government Norms are very strict as far
as the environmental issues are concerned. So we have to handle the Ash in a proper manner in
order to avoid any environmental issues. Generally most of the power plants have a tie-up with
the Cement making companies and the power plants supply the Fly Ash to those Cement making
companies for making cement from the Fly ash and coming to the bottom ash, which is not
having any fine particles as compared to the Fly Ash. So we use it for road filling and for making
Fly Ash bricks.

Ash Handling System mainly consists of the transportation of Fly ash and Bottom ash from
boiler to the respective storing points and the system adopts transporting methods such as

SYSTEMS FOR BOTTOM ASH:

Bottom Ash Transportation with SSC (Submersed Scrapper Conveyor)

Bottom Ash Transportation with High Pressure Water or Jet Pumps

SYSTEMS FOR FLY ASH:

Fly Ash Slurry Transportation with the bottom ash

Fly Ash Dry Pneumatic Transportation

FLY ASH HANDLING SYSTEM

In Fly Ash Handling System, the major objective is to collect and transport the fly ash
from the ash hoppers of the ESP to the Fly ash silo or to the Ash Slurry making tank. Generally
the power plants prefer Dry Fly ash Disposal instead of making Ash Slurry from the Fly ash and

25
the reason is that the fly ash collected from the ESP Bottom Hopper is very fine and suitable for
Cement making, if we are making slurry of it then it will not be suitable for Cement making and
economically also it is very good if you are selling the Ash to the Cement Plants. So these are the
reasons why most of the plants are going for Fly ash Disposal instead of Slurry Disposal (Ash
Water).

SLURRY TYPE FLY ASH DISPOSAL SYSTEM:

This is one of the simplest system for ash disposal from ESP hopper to the slurry
pond.High Pressure water and fly ash is mixed below the ESP hopper .

DRY TYPE FLY ASH DISPOSAL SYSTEM:

Fly Ash from the ESP Hoppers is collected in the Ash Vessels and from there it is
transported to the Fly Ash Silos by the help of Compressed air and from the Ash Silos, the ash is
transported to the Bulkers(Sealed Vessel Trucks).

ESP HOPPER:

Hopper is a large conical type container used for dust or ash collection. After the field
charging in ESP we go for hammering of collecting plates and the fly ash deposited on the
collecting plates gets stored in the hopper. To ensure free flow of ash into the ash vessels from
the hopper, the lower portions of the hoppers are provided with electric heaters. Because if the
temperature of the ash falls below the ash fusion temperature then the ash will form big clusters
and may choke the entire conveying system.

DOME VALVE:

It is situated between the ESP hopper and Ash vessel; it is a special type of valve which
is highly leak proof. It consists of a dome type structure with a rubber seal which is continuously
getting supply from the compressed air.

AIR VENT LINE:

To remove the trapped air from the vessel, we use vent line and due to this line air from
the vessel is transported to Hopper and ash come down. It basically does two things, first of all
by removing the air from the vessel, it is removing the back-pressure from the Vessel and
simultaneously it is pressurizing the ash hopper.

COMPRESSOR:

A compressed air station is set up in the plant. The compressed air station provides air
for the pneumatic conveying system and purging of fabric filters as we already explained in ESP.

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After compressing the air, we have to remove all the moisture content from the air. To remove
the moisture from air we use Adsorbent Air Drier (AAD) and Refrigeration Air Drier (RAD).The
pressure of the compressor is depended on the system design.

ASH VESSELS:

Ash vessels are present just below the ESP hoppers with the Dome Valve assembly.They
are supposed to contain the fly ash for a certain amount of time which will be carried to the fly
ash silos.Their ash holding capacity is depended on the conveying capacity of the ash line to the
Ash Silos.

FLY ASH SILOS :

Fly Ash Silos store the fly ash generated by the Boiler in the maximum continuous
operating conditions (BMCR).The bottom of each fly ash silo is equipped with two ash
discharging chutes. One ash discharging chute is used for discharging the comprehensively used
dry fly ash and the other one is connected with a wet mixer, discharging the wet fly ash. The wet
ash mixer is just a back-up for the dry ash disposal system. Each fly ash silo is equipped with the
bag filters and bag filter cleaning facilities with exhaust fans.

AIR EXTRACTION FAN:

It is used to create a negative pressure inside the vessel of the silo and the air goes out
through the bag filters.

EXTRACTOR:

It is used to evacuate the Air from the Bulkers (Closed Vessel Truck), which is
connected to the ash disposal chute and the discharge is connected to ash vessel.

DIVERTING AND DUMP VALVE:

If one ash silo will not work we divert the line into another silo with the help of diverting
valve and to dump the ash into ash silo dump valve is used.

WET FLY ASH DISPOSAL SYSTEM:

Up to the hopper part it is same as that of Dry Fly Ash handling system. After the hopper
instead of going into the vessel, the ash gets mixed with a high Pressure water and this mixture
goes to a slurry tank for further pumping. The slurry formed is further pumped through a series
of pumps or a single GEVO pump for dumping in the Ash yard. For mixing of fly ash with
water, a tapping is provided for High Pressure water below the hopper.

Bottom ash handling System

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The bottom ash quantity is around 20% of the total Ash generation and there are mainly two
types of bottom ash disposal systems.

Dry Type Bottom Ash Disposal

Wet Ash Slurry Disposal

Dry Type Bottom Ash Disposal: First of all we will discuss about the Dry type bottom ash
disposal system.

CLINKER GRINDER:

A clinker grinder is provided at the outlet of SCC to control the bottom ash size as in the
bottom ash there will be some big clinkers and to make the ash of even size we use a clinker
grinder.The output of the bottom ash after the clinker grinder is around 25mm to 50mm,it is
adjustable.

SLURRY TYPE BOTTOM ASH DISPOSAL:

Here the bottom ash from the 2nd pass of the Boilers goes to the Clinker Grinder in the
1st pass by the help of high pressure water and from the Clinker Grinder all the ash goes to a
slurry sump for further pumping.

FIG NO. 13. ASH DISPOSAL AREA CSTPS

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14. COOLING TOWER
A cooling tower is a heat rejection device which rejects waste heat to the atmosphere through
the cooling of a water stream to a lower temperature. Cooling towers may either use the
evaporation of water to remove process heat and cool the working fluid to near the wet-bulb air
temperature or, in the case of close circuit dry cooling towers, rely solely on air to cool the
working fluid to near the dry-bulb air temperature.

Common applications include cooling the circulating water used in oil refineries, petrochemical
and other chemical plants, thermal power stations and HVAC systems for cooling buildings. The
classification is based on the type of air induction into the tower: the main types of cooling
towers are natural draft and induced draft cooling towers.

Cooling towers vary in size from small roof-top units to very large hyperboloid structures (as in
the adjacent image) that can be up to 200 metres (660 ft) tall and 100 metres (330 ft) in diameter,
or rectangular structures that can be over 40 metres (130 ft) tall and 80 metres (260 ft) long. The
hyperboloid cooling towers are often associated with nuclear power plants although they are also
used to some extent in some large chemical and other industrial plants. Although these large
towers are very prominent, the vast majority of cooling towers are much smaller, including many
units installed on or near buildings to discharge heat from air conditioning.

FIG NO. 14. COOLING TOWERS

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15. CONTROL ROOM
The control room, in case of remote control, houses all the necessary measuring instructions for
each panel or alternator and feeder, synchronizing gear, protective gear, automatic voltage
regulator, communication arrangement etc.

TYPES OF CONTROL PANEL

 Fuel gas panel
 Combustion Panel
 Primary Air and coal panel
 Steam panel(boiler)
 Feed Water panel
 Condensate & cooling water panel
 Turbovisory panel

FIG NO. 15. CONTROL ROOM

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16. SWITCH YARD
Switch yard forms an integral part of power plant. The supervisory control and data acquisition
system(SCADA) of switch yard consists of operator stations, engineers station, historical
storage, computers and associated peripherals and the switch yard bay control systems
interconnected through a high speed network. The system constitutes several operator work
stations and engineers work stations with high resolution color display monitors, touch screen
function key board, mouse track ball and printers.
The System collects digital and analog information available throughout the plant and presents
information in various graphics display, alarms, logs, reports. The operator can perform control
via CRT.

FEATURES:
Monitoring of status of switch yard equipments like isolators, breakers, ground switches. Issue of
close or open commands of isolators and breakers. Monitoring of system parameters like voltage,
current, frequency, MW, MVAR energy presentation of information useful to operators in
different forms.

FIG NO. 16. SWITCH YARD

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17. ADVANTAGES AND DISADVANTAGES OF
THERMAL POWER STATIONS:
17.1 ADVANTAGES:
1. Economical for low initial cost other than any generating plant.
2. Land required less than hydro power plant.
3. Since coal is main fuel and its cost is quite cheap than petrol or diesel so generation cost is
economical.
4. These are having easier maintenance.
5. Thermal power plant can be installed in any location where transportation and bulk of water
are available.

17.2 DISADVANTAGES:
1. The running cost for a thermal power station is comparatively high due to fuel maintenance
etc.
2. Large amount of smoke causes air pollution. The thermal power station is responsible for
global warming.
3. Overall efficiency of thermal power plant is low like 30%.

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18. CONCLUSION
After visiting this power station I came to know about the practically generation process of
electrical energy. I understood the function of various components in thermal power station,
there importance, there arrangements and precaution to be used for the safety in the power
plants. In our engineering we studied about the various components in theory, thus by visiting
CSTPS we came to know about this components and their working practically. This visit to
CSTPS chandrapur was an exciting experience, since the hard work of Mahagenco and mutual
cooperation of their staff and workers is really appreciable. I would like to thank our staff
members for arranging this quality visit.

19. REFRENCES
1. www.mahagenco.in
2. www.google.com

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