In Plant Tarining Repot Adani Electricity Final Version

Adani Electricity Industrial Training Report
``MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION MUMBAI
A
Report On
“INDUSTRIAL TRAINING”
At
Adani Electricity Mumbai Ltd.

SUBMITTED BY
Master Hrishikesh Karandikar
DEPARTMENT OF MECHANICAL ENGINEERING
ADANI ELECTRICITY MUMBAI LTD.

MUMBAI
ST. JOHN COLLEGE OF ENGINEERING AND MANAGEMENT
Power Plant Mechanical Engineering

TABLE OF CONTENT
SR. NO. CONTENT DURATION PAGE

NO.
1. INTRODUCTION
CHP
2. 1st WEEK
Turbine
3. 2nd WEEK
4. Boiler 3rd WEEK
5. Off Site 4TH WEEK
6. Certificates
2
INTRODUCTION
Adani Electricity is the brand for the Mumbai distribution business of Adani Electricity
Mumbai Limited. Adani Electricity Mumbai Ltd. is a constituent of the Adani Group, one of
the leading business houses in India. The company was incorporated in 1929. Adani
Electricity distributes electricity to over 2.5 million consumers across the premier Indian
city of Mumbai. Adani Electricity has been in the field of power distribution for over 83
years and has achieved the distinction of consistently operating its distribution network at
99.98 per cent reliability and the aggregate system loss of just around 9.5 per cent the best
in country by a fair margin and amongst best in world. It is one of the first utilities in India
to have the most advanced SCADA technology which enables the system to deliver a
seamless integrated platform with Geographical Information System for providing
customers with enhanced and superior service standards.
FOUNDER And CHAIRMAN:

Gautam Adani
CEO:
Kandarp Patel

HISTORY
Adani Electricity has been in the field of power distribution for over 83 years. Adani Electricity
Mumbai Limited (AEML) is a 100% subsidiary of Adani Transmission Ltd formed post acquisition
of Reliance Infrastructure Limited’s integrated Generation, Transmission and Distribution utility
powering Mumbai city. Adani Dahanu Thermal Power station is one of the power supplying
utilities of AEML. Adani Dahanu Thermal Power is 2×250MW plant which was set by BSES in
1989 and was taken over by Reliance group in 2003 and then by Adani Electricity Mumbai
Limited in 2019. It is 500MW pant and is located at 120km from Mumbai over 351.58 hectors.
DTPS has complete automatic control and monitoring of turbine, Boiler and auxiliaries by Digital
Distributed control monitoring and Information System. The plant utilize a mix of Indian washed
coal and imported coal as fuel. The ignited fuel is received from SECL (Korba) and imported
from various countries such as Indonesia and South Africa among others. Adani Dahanu
Thermal Power Plant has implemented integrated management system (IMS) in its processes
and is certified for quality management, environmental management, occupational health and
safety assessment studies, social accountability management, information security
management, energy management and accreditation for ADTPS coal testing laboratory. It has a
chimney of 275.3 m height for proper emission/ dispersion of boiler exhaust. An Electronic
Electrostatic Precipitator (ESP) of 99.9% efficiency to collect fly ash with In-house developed
Ammonia dosing system to improve collection efficiency. For ambient air quality monitoring
station to measure hazardous such as PM10, PM2.5, S02, NOx fuel gas Desulphurization unit of
100% capacity having efficiency greater than 90%, for removal of Sulphur and its oxides.
Advanced air pollution monitoring system. ADTPS has remarkable achievements on parameters
of average UNITE heat rate, Auxiliary power consumption (APC), Specific oil consumption and
DM water consumption by consistently maintaining them in lower than the national average for
a generation unit of this size. The organization’s social responsibilities towards the environment
is evident in the adaption of clean technology and stringently following the environmental
safety guards.

Power Generation process
High pressure superheated steam leaves the boiler, which is also referred to as steam generator, and
enters turbine. The steam expands in the turbine which enables the turbine to drive the electric
generator. The low-pressure steam leaves the turbine and enters the condenser where heat is
transferred from the steam (causing it to condense) through cooling water. Because of large number of
water requirement Thermal power plants are usually located near rivers or lakes.
The pressure of the condensate leaving the condenser is increased in the pump which leads the
condensate to flow into the steam generator. An economizer is simply a heat exchanger in which heat
is transferred from products of combustion to the condensate. The temperature of condensate is
increased but no evaporation takes place. In the other section of the steam generator, heat is
transferred from the product of combustion to the water causing it to evaporate. The temperature at
which evaporation occurs is called as the saturation temperature.
The air which is used for combustion is preheated in the air-preheater by transferring heat from stack
gates as they leave the furnace. The air is then mixed with fuel and combustion takes place in the
furnace. As the products of combustion pass through the furnace, heat is transferred to the water in
the superheater, the boiler, the economizer and to the air pre-heater. And then it is discharged.
ADTPS is totally based on modified Rankine’s cycle.
Modified Rankine’s Cycle:
The working fluid is condensable vapor which is in liquid phase during part of the cycle. The cycle
consists of succession of steady flow process with each process carried out in separate components
which is specially design for the purpose. Each consists of an open system and all the components are
connected in series so that the cycle is close.
Steam power plants operate in a cycle. That is, the working fluid undergoes a series of processes and
finally returns to the initial state. Steam power plant operates on closed cycle. We consider the
idealized four steady state, steady flow process cycle shown in fig., in which state 1 is saturated liquid
and state 3 is either saturated vapor or superheated vapor. This system is
termed the Rankine cycle and is the model for steam power plant.

To improve efficiency of Rankine’s cycle, Reheat cycle is developed
Reheat Cycle:
The efficiency of Rankine cycle could be increased by increasing the pressure during addition of heat.
However, the increase in pressure also increases the moisture content of the steam in the low-
pressure end of the turbine. The reheat cycle has been developed to take advantage of the
increased efficiency with higher pressures and yet avoids excessive moisture in the low-pressure stages
of the turbine. The unique feature of this cycle is that the steam is expanded to some intermediate
pressure in the turbine and then is reheated in the boiler after which it expands in the turbine to the
exhaust pressure. Basic advantage is in decreasing the moisture content to a safe value in the low-
pressure stages of the turbine.
Components of Thermal Power Plant:

1. Rail Unloading House 16. CEP (Condensate extraction Pump)
2. Junction House 17. Low pressure feed pump
3. Coal Conveyors 18. High pressure feed Pump
4. Coal Bunkers 19. Boiler Feed Pump
5. Coal feeder 20. Deaerator
6. Pulverizing or Coal grinding Mill 21. Economizer
7. Boiler Burner 22. Cooling Tower
8. HP Turbine 23. CWP
9. IP Turbine 24. SWP
10. LP Turbine 25. FGD
11. Air Heater 26. Main Chimney
12. Condenser 27. PA Fan
13. Electrostatic Precipitator 28. FD Fan
14. Boiler Reheater 29. ID Fan
15. Generator Transformer

Power Plant

CHP (Coal Handling Plant)
Following are the Functions of Coal Handling Plant:
1. Unloading of coal
2. Crushing of coal
3. Stacking of coal
4. Bunkering of coal
Main Equipment of CHP:
1. Wagon Tippler 7. Inline magnetic Separator.
2. Beetle Charger 8. Grizzly Feeder.
3. Apron Feeder 9. Stacker Reclaimer.
4. Belt Conveyors 10. Travelling tippler.
5. Belt Weigher 11. Dust extraction and dust separation.
6. Crushers
ADTPS use Indian as well as imported coal. Indian coal comes from Korba via train and imported coal
comes from Australia via ship. Raw coal & washed Coal is unloaded with the Help of Wagon Tippler and
imported Coal is Unloaded with help of Barges & Poclain. This coal then goes to primary crush house. Then
it goes to secondary crush house. Here raw coal is crushed into smaller pieces. There are three types of
crushers Double Roll crusher, Rotary Breaker & Impact Crusher. In CHP there are 4 yards each of capacity 1
lac MT. Raw coal of unloading is stacked in coal yard with the help of various conveyor belts, feeders,
crushers, flap gates and stacker reclaimers. Imported coal after unloading at JETTY is transported to coal
yards with the help of Dumpers & stacked by using Wheel Loaders, Dozers. This coal is blended on
conveyors (i.e two different grades of coal are mixed uniformly in predetermined proportion for achieving
desired calorific value). This blended coal then goes to TF.9 and then bunkered in coal bunkers. There are
12 bunker hoppers (06 / unit) at Bunker floor. Each Hopper is having a capacity of 1000 MT coal. From here
coal is transferred to coal mill via coal feeders. Here in the mill pulverization takes place. Pulverization
means breaking down of coal into coal powder. This coal powder is sent to boiler with the help of PA fan.
The air which blows the coal from the mill to the boiler, called the primary air, this air is supplied by a large
fan driven by a variable speed motor which is known as PA fan. Before entering boiler, this coal enters
classifier where fine powder is classified and sent to boiler and rejected coal is sent back to mill. All this
process takes place continuously and in closed path.

Coal Flow
Path
Coal Flow Diagram

TURBINE
INTRODUCTION:
Steam turbine is the heart of the Power Plant which is a rotating machine which converts heat
energy of steam to mechanical energy.
Steam turbines are of different capacities from 15 MW to 500 MW. The design material and
auxiliaries depend on the capacity of the system (Turbine)
Steam turbines of two type designs such as,
LMW - Soviet Russian made (Leningrad Metal works)

KWU - German made (Kraft Works Union)
In BSES Generation Division (D.T.P.S.) KWU design made of 250 MW turbines is used.

STEAM TURBINE
➢ Steam Turbine is a rotating machine which converts heat energy of steam to mechanical
energy. It is a type of heat engine that performs mechanical work using steam as the
working fluid.
➢ Aim is to produce the maximum amount of electrical energy in the minimum amount of
space.
➢ Heat cycle used is known as the Rankine cycle.
➢ About 70-80% of the world’s electricity is produced by steam turbine
It consists of 3 turbines –
➢ High Pressure Turbine

➢ Intermediate Pressure Turbine
➢ Low Pressure Turbine
The turbine rotors are rigidly coupled with each other and with generator rotor.
Type Stages Flow Casing Pressure Temperature
HPT 1 impulse stage Single Outer casing is Inlet = 145- 540’C

and 18 reaction flow barrel 150kg/cm^2
stages Inner casing is Outlet = 40
axially split. kg/cm^2
IPT 17 reaction Single Double casing Inlet = 37 340’C

stages flow Inner casing is kg/cm^2
axially split. Outlet = 7.5-8
kg/cm^2
LPT 8 reaction Double Three casings. All Inlet = 7.5- 350-370’C

stages per flow flow are axially split. 8kg/cm^2
Outlet =
0.8kg/cm^2

a. High Pressure Turbine (HPT): -
After the super heater steam comes into HPT, here the steam expands, and steam does the
work. After this the temperature and pressure of steam decreases. Then it goes to the reheater
to increase the pressure and temperature through the cold reheat line (CRH). The CRH is
provided with a non-return valve to prevent the back flow steam.
b. Intermediate Pressure Turbine (IPT):
Steam comes from the reheater where the pressure and temperature are increased. Hear the
steam is allowed to expand and heat energy is converted into mechanical energy. From here
the steam is lead to the LPT from the IPT exhaust duct.
c. Low Pressure Turbine (LPT):
Last three stages of LP rotor have twisted blades. Above blade design features reduces the
relative velocity between the droplets and the leading edges of the moving blades resulting into
less wear and tear. First five blades work in superheated region and rest three in wet region.
However, the leading edges of the final stage rotor blades are flame hardened to give
protection against erosion. These blades are free standing and have neither lacing wires nor
shrouding.
Impulse and reaction stages for turbines:
Two terms used in connection with turbines are impulse stage and reaction stage
1. Impulse Type:
In impulse turbine, steam is expanded (i.e. pressure is reduced) in fixed nozzles. In impulse type
of turbine, pressure drop occurs in nozzles only, not in moving blades.
2 Impulses - Reaction Type:

In reaction type of turbine pressure is reduced in both fixed and moving blades. They act like
nozzles and are of same shape .Work is done by the impulse effect due to the reversal of
direction of the high velocity steam plus a reaction effect due to the expansion of steam
through the moving blades
In BSES one impulse and other reaction blades turbine are used.

TURBINE GOVERNING SYSTEM:
Power Station Turbines are constant speed machines. In our country these are supposed to
rotate always at a speed or 3000 revolutions per minute (with in a small band of fluctuations on
either side) to enable the coupled generator to produce electricity at 50Hz frequency.
The main purpose of governor is to maintain this desired speed of turbine during fluctuation of
load on the generator by varying steam input to the turbine. Thus, the governing system
maintains an equilibrium between steam input and load output. Whenever equilibrium
disturbs, it tries to bring it back.
The governing system in addition to ensuring the falling load--speed
There are two types of governing – Nozzle Governing and Throttle governing. DTPS has both the
types of Throttle as well as Nozzle; Throttle is used at start up whereas nozzle is used at full
load.
Characteristic of the turbine (i.e. a characteristic of falling output power with raising shaft
speed above nominal value) also ensures the following functions:
1. The run of the turbine from rest to rated speed and synchronizing with the grid.
2. Meeting the system load variation in a predetermined manner, when running in
parallel with other machines.
3. Protecting the machines by reducing the load or shutting of completely in abnormal and
emergency situations.
DTPS has Electro-hydraulic governing system and turbine oil is used as governing fluid.
TURBINE AUXILIARIES:
The main objective of Turbine Auxiliaries is to facilitate proper functioning of turbine. The
arrangement of these auxiliaries at different locations is done on the basis of easy installation,
proper operation and maintenance and technical requirements.
The different auxiliaries are as follows: -

1. Condenser
2. Condensate Extraction Pump (CEP)
3. Low Pressure Heaters (LP heaters)
4. Vacuum pump
5. Deaerator
6. Boiler Feed Pump
7. High Pressure Heaters (HP heaters)
8. Turbine Lubrication Oil System
9. Centrifuge
10. Debris filter

Condenser:
The condensers used in DTPS are surface condensers. In this type of condensers, condensation
takes place on the outer surface of the tubes, which are cooled, by seawater flowing through
them.
The function of condenser is:
Condenser condenses the steam exhaust from LP turbine by producing vacuum in the
condenser in order to increase the heat drop and increase the efficiency of turbine by re-using
the condensate.
The cooling agent is sea water which is pumped by Cooling Water Pumps. The sea water is
cleaned in debris filter and then it is taken to condenser through two passes. Hence the
condenser in DTPS is a double pass single flow condenser. The pipes in the condenser are
Titanium cladded. These tubes are half degree inclined for self draining during tripping of
Cooling Water Pumps. The tubes are expanded in main tube plates and are supported by
support tube plates at intermittent points to prevent sagging and to curb flow induced
vibrations. The condenser is supported on springs to take the load variations when the
condenser is full and when the condenser is empty. The Vacuum Pump creates vacuum in the
condenser and extracts all non-condensable gases to increase the steam inlet in condenser.
(COLTS GAUGE – The online cleaning mechanism for the condenser tubes is called as Colts
gauge. In this system, there are balls called as colts which have diameter equal to that of the
tubes. These balls are passed through and due to the abrasive ball surface the tubes are
cleaned.)
Specifications:
1. Make BHEL Hardware

2. Type Surface type
3. Design inlet temp 33
4. C.W. flow per pass 19000tones/hr
5. C.W. temperature rise 7.1
6. Tube material Titanium
7. No of passes 2
8. Surface area 14643m2
9. No of tubes 17338
10. Size of tubes 22.225 x 0.7112 x 12200mm

Condensate Extraction Pump:
The main function of Condensate Extraction Pump is to draw condensate from the condenser
hot-well & feed it to Deaerator through LP Heaters.
The CEP is five stages, vertical canister type, double entry (at first stage), centrifugal pump. It is
generally required to operate on minimum Net Positive Suction Head (NPSH).
There are two 100% capacity condensate Extraction Pumps per unit. The Condensate Extraction
Pumps are of the centrifugal canister vertical type pumps and are driven by electric motor. The
pump stages (five) form an interconnected assembly which is attached to the underside of the
headpiece and is suspended within the canister. Recirculation line is provided (after discharge
valve) with a pneumatic valve which maintains a minimum flow of 280T/hr.
The head piece is provided with a stuffing box which contains mechanical seal to prevent pump
leakages. The head piece also supports the water-cooled oil lubricated thrust and journal
bearing.
The pump discharge branch and vent pipe are integral with the head piece and the pump
suction branch is integral with the canister.
Specifications:
1. Make BHEL Hyderabad

2. No per unit 2
3. No of stages 5
4. Flow 770m3/hr
5. Efficiency 82%
6. Motor Details
7. Rating 650 kW
8. Speed 1485 rpm
9. Rated current 71.2 amp
Low Pressure Heaters:
Regenerative system is provided to improve the cycle efficiency by increasing feed water
temperature
In regenerative system three LP heaters are provided. These LP heaters are installed after CEP
discharge in condensate cycle.

The type of LP heaters used in DTPS is of horizontal, U-tube, surface type of feed water heater
which are three in no which two passes per heater.
Baffles are provided to ensure that the steam is directed across the tubes. The upper section of
the quadrant of the tube nest, which carries the condensate in its last pass through the heater,
is totally enclosed by vertical baffles, so forming a flashed steam drain cooler section of the
heater.
The three LP heaters LPH-1, LPH-2, LPH-3 extractions are taken from the LP turbine and hence
this type of system is called regenerative feed heating system.
For LPH-1 bleed steam is taken from LP turbine stage 7.LPH-2 receives steam from LP turbine
stage 5. LPH-3 receives steam from LP turbine stage 3.
The drain outlet of LPH-3 enters drain inlet of LPH-2. The drain outlet of LPH2 is given to drain
inlet of LPH-1. LPH-1 is located at the neck of the condenser to reduce floor space. Air vents are
provided through which non-condensable gases pass out to the condenser, where these gases
are sucked by the Vacuum Pump.
Thus the main purpose of LP heaters to preheat the condensate before entering the boiler
thereby is increasing the efficiency of the plant
Vacuum Pump:
The vacuum pump is a two-stage liquid ring type pump. Rotor revolves without metal contact in
a circular body that contains a liquid compress ant. The rotor is eccentrically fitted into the
circular body. So, during each revolution liquid compress ant will be compressed (discharge of
air) to atmosphere and expanded (suction of air from the system).
Seal water from the separator tank is sucked by circulating water pump. The tank level is
maintained automatically by an external DM water source through a float operated make up
valve. The discharge of the pump passes through a strainer and water to water cooler and is fed
to vacuum pump for liquid ring formation and stuffing box sealing and lubrication.
There are two vacuum pumps per unit. The function of the vacuum is to absorb the gases and
air bubbles and to create vacuum in condenser.
Specifications:
1. Number of pumps: 2
2. Stages: 2
3. Speed: 500 rpm
4. Discharge Pressure: 1.003 kg/square cm

Deaerator:
The function of the Deaerator is to remove dissolved non-condensable gases and to heat boiler
feed water. It consists of a pressure vessel in which water and steam are
mixed in a controlled manner. When this occurs, water temperature rises, and all non-
condensable dissolved gases are liberated and removed and the effluent water may be
considered corrosion free from an oxygen or carbon dioxide stand point. Free air or other
non-condensable gases should be vented prior permitting the fluid to enter the Deaerator.
A Deaerator protects the feed pumps, piping, boiler and any other piece of equipment that is in
the boiler feed and return cycle from the effects of corrosive gases, i.e. oxygen and carbon
dioxide, to a level where they are no longer a corrosion factor.
This is achieved by a deaerating unit. Apart from this, a deaerator also serves the following:
1. Heating incoming feed water.
2. To act as a reservoir to provide a sudden or instantaneous demand.
Deaerator works on the following principle:
a) The solubility of any gas dissolved in a liquid is directly proportional to the partial pressure of
the gas. This holds within closed limits for any gas which does not react chemically with the
solvent.
b) Solubility of gas decreases with increase in solution temperature and or decrease in pressure.
The deaerator in DTPS is of spray trays type with storage tank capacity of 289m3 and operating
pressure of 6.64 kg/ cm2. There are 52 spray nozzles with 280 tray assemblies. The oxygen
concentration at outlet is 0.003ppm.
The Deaerator comprises of two chambers:
Deaerating column.
2. Feed storage tank.
Deaerator column is a spray cum tray type cylindrical vessel of horizontal construction. The tray
stack is designed to ensure maximum contact time as well as optimum scrubbing of condensate
to achieve efficient deareation. The deaerating column is mounted on the feed storage tank
which in turn is supported on rollers at two ends and a fixed support at the center.
The feed storage tank is fabricated from boiler quality steel plates.
Chemical Dosing is given in deaerator in the form of hydrazine resin to remove the residual
gases from condensate water.
F) Boiler Feed Pump:

The feed water supplied to the economizer is pumped through boiler feed pump. This is done
basically in two stages, first using a booster pump water pressure is to about 23 ksc which is
given as a suction to the main pressure stage pump.
In our Dahanu thermal power station (DTPS) we have 2*100% BFP i.e. there are two BFP per
unit having 100% capacity. This means that at full load one pump is in service and other is in
standby condition. This provision is made as BFP is a critical part in the system and if one fails
other pump should take care of the system.

Characteristics of the system:

Cartridge type assembly of the main pressure stage pump
Thus, pump assembly can be removed i.e. cartridge without disturbing the suction and
discharge piping.
Alignment of the pump and hydraulic coupling is thus not disturbed
Due to enclosed assembly the life of the pump increases.
Spare cartridge can be replaced with a wear one and pump can be taken in service in very short
time.
Working principle:
Water coming from the suction branch enters the suction port of the cartridge
It is then carried to the first stage of the pump i.e. to the impeller
Then it passes through diffuser where the water gains certain pressure rise
Further it is carried to the next stage impeller
Similarly, water flows through three stages of the pump before going to the discharge port
G) High Pressure Heaters:
High Pressure Heaters are of horizontal, U-tube, surface type. There are two HPH, HPH-5 and
HPH-6. High pressure heaters receive condensate from the Boiler Feed Pump.
HP Heaters consist of tubes made up of stainless steel. These tubes expand into the main tube
plates and are supported by support tube plates at intermittent points to prevent any sagging
of tubes.
HPH-5 receives steam from I.P. turbine 10th stage and HPH-6 receive steam from cold reheat
line. HP Heaters consist of air vents through which non- condensable bases are passed to the
flash tank. From there these gases go to the condenser where the Vacuum Pump sucks them
thus creating a clear path for steam. The drain outlet of HPH-6 is given to HPH-5.
HPH-5 HPH-6
1. Make BHEL Hardware BHEL Hardware
2. Type Horizontal, U-tube, Surface Horizontal, U-tube, Surface type
type
3. Steam inlet/outlet 165/204o C 204/246o C
temperature
4. Steam inlet pressure in kg/cm2 16.46 40.8
5. No of tubes 1110 1128

Specifications:
H) Turbine Lubrication Oil System:
This system fulfils the following important functions:

a) Provides a supply of oil to journal bearings to give an oil wedge as the shaft rotates.
b) Maintains the temperature of turbine bearings constant at the required level.
c) Provides a medium for hydraulically operating the governor gear and controlling the steam
admission valves.
d) Provides for hydrogen cooled generators a sealing medium to prevent hydrogen leaking out
along the shaft.
I) Debris Filter:
Debris such as shells, sticks, stones and plastic are a common cause of failure in condenser.
Improvements in primary screening would only lead to a partial solution. It would only solve the
problem of debris such from CW pump house. Secondary screening as close as possible to inlet
water box is fulfilled by Debris Filter.
The internal construction and design is based on cooling water flow, cooling water inlet
pressure, size, type and quantity of debris. The debris in cooling water is collected at inner
surface of V-shaped screen, housed inside the filter. A Differential Pressure Measuring System
(DPMS) indicates the level of debris fouling on filter screen across the screen when it reaches
the preset limit the DPMS initiates the debris removal operation.
The debris accumulated on the inside surface is removed by extraction assembly which guides
the debris along the basket into the debris discharge pipe connected to main cooling water
outlet pipe. The filter incorporates a high-pressure water-injecting arm which is run by the
Flushing Pump.
GENERATOR
The two-pole generator uses direct hydrogen cooling for rotor winding and indirect hydrogen
cooling for the stator winding. The losses in the remaining generator components such as iron
losses, friction and wind age losses, and stray losses are also decapitated through hydrogen.
The generator consists of following components.
1) Stator: stator frame, stator core, stator winding, hydrogen coolers
2) Rotor: rotor shaft, rotor winding, winding rings, field connections
3) Bearings: Journal bearings
4) Shaft seal: Mechanical seal.
The generator is provided with Oil system i.e. Seal oil system and lubrication oil system
and Gas system i.e. Hydrogen gas and Excitation system i.e. for Stator and rotor windings.

CHARCTERISTICS OF GENERATOR:
1. In exciter permanent magnet on the rotating shaft induces emf in its stator windings. The
output is passed through a complex thyristor-based circuit. The controlled D.C. supply is fed to
the main exciter stator winding.
2. Emf induced in the rotor winding of the main exciter is rectified and connected to the rotor
winding. Emf is induced in the stator winding of the generator
3. The generator bus duct is further connected to the Generator Transformer (GT). The output of
the Generator Transformer is connected to the switchyard which feed the consumers through a
network of substation connected by transmission lines.
4. Additionally, a Station Transformer (ST) connected to grid is provided which is used at the initial
start-up of the plant when both the units are not in service.
BOILER MAINTENANCE
DTPS BOILER SPECIFICATION:
Manufacturer: BHEL C.E. Design

Type: Natural Circulation
Balance Draft
Double Pass
Single Drum
Single Reheat
Direct pulverized coal fire
Water Impounded bottom
Boiler Design: 182 kg/cm2 and 540OC
Pressure & Temperature: 5240 x 11506, 199 x 142
Type of Firing: Tilting, Tangential
Total Heating surface: 24670 m3
Furnace Height: 39.965 m
BOILER PRESSURE PARTS:
✓ Boiler
✓ Economizer
✓ Boiler Drum
✓ Down comers
✓ Up risers
✓ Water walls
✓ Steam cooled walls
✓ Super heaters
✓ Reheater

✓ Desuperheater
✓ Safety valve
✓ Soot blowers
✓ Expansion and sealing
✓ Buck stays
✓ Wind box Assembly
BOILER ROTARY PARTS
✓ Coal mill
✓ Draught system
a. Primary fan (PA)
b. Forced draught fan (FD)
c. Induced draught fan (ID)
d. Air preheater
FIRING EQUIPMENT:
✓ Remotely controlled HEA igniter

✓ Air cooled oil guns
✓ Coal nozzles
Auxiliaries of Boiler:
✓ 2 air preheaters
✓ 3 tube mills,
✓ 2 primary Air fans,
✓ 2 forced Draft fans,
✓ 2 Induced Draft fans,
✓ 6 Seal Air Fans
✓ 1 four pass Electrostatic Precipitator
✓ ECONOMIZER:
Function: To preheat the boiler feed water

It increases efficiency
Location: Below the rear horizontal superheater
Temperature: 451oC
✓ BOILER DRUM: Water coming from economizer goes to boiler drum.

Functions:
1. Separation of saturated steam from the steam water mixture

produced by evaporating tubes.
2. Mixing feed water from economizer and water circulated from
steam water mixture and re circulate through the evaporating
tube.
3. Carrying out blow down for reduction of boiler water salt
concentration.
➢ Wet steam entering the drum from the riser tubes & furnace walls is collected in the
compartments called separating chambers.
➢ Feed water is supplied to boiler drum from the economizer through two economizer outlet
links.
➢ The separated feed water & water from economizer goes to furnace bottom water wall headers
through six down comers.
SPECIFICATIONS:
➢ Maximum operating pressure: 168.5 kg/cm2

➢ Designed temperature: 357oC
✓ DOWN COMERS:
➢ Down comers carry water from drum to bottom ring header

➢ These are outside the heating zone
➢ There are 6 down comers in DTPS boiler
✓ UP RISERS:
➢ Water steam mixture formed inside the evaporating tube is

➢ collected in the top headers.
➢ From the top headers the water steam mixture is brought to the
➢ boiler drum through up risers.
➢ Up risers are connected to one side of the boiler drum opposite
to the side where feed lines are connected.

✓ WATER WALLS:
➢ To have maximum utilization of heat the walls in boiler

➢ are made up of tubes connected to each other
➢ This water walls absorb latent heat
➢ They have fins for max. absorption
➢ Water from bottom ring header is carried to drum via water walls
✓ MEMBRANE WALLS:
➢ Total no of tubes: 482
➢ OD: 63.5 mm
➢ Thickness: 5.5 mm
➢ Pitch: 76.5 mm
➢ Design pressure: 185.5 bar
STEAM COOLED WALLS :
➢ Second pass is made up of steam cooled walls

➢ Water passes through steam cooled walls before entering LTSH
➢ It minimizes the heat loss
✓ SUPERHEATER:
➢ Function: Make steam moisture free (i.e. dry)

➢ Metal used for super heaters must have high temp. strength,
➢ high creep strength, high resistance to oxidation.
➢ Alloy steel having chromium & molybdenum is used.
➢ Superheaters are of three types
1.LOW TEMPERATURE SUPERHEATER (LTSH) :
➢ Location: Above the economizer coil in the second pass
2.PLATEN SUPERHEATER(PSH):
➢ Location: Above furnace in front of the furnace arch

➢ Function: It absorbs heat mainly by radiation
3.FINAL SUPERHEATER (FSH):
➢ Location: Behind the screen tubes

➢ Mode OF heat transfer: convection

LTSH PSH FSH

Mode of Convection Radiation Convection
heat
transfer
No of tubes 256 393 528
Total 5008 1341 2110
heating
surface area
m2
✓ REHEATER:
➢ It is composed of 2 stages: front & rear section

➢ Front section: located between rear water wall hanger tubes & SH platen coils
➢ Rear section: Located between water – cooled screen tubes & rear water wall hanger tubes
➢ Function: Reheat the steam after its expansion in HP turbine
✓ DESUPERHEATER:
➢ They are present in Superheater connection links and CRH line

➢ (Outside boiler)
➢ Controls temperature of in the circuit itself
➢ Injects spray water through the nozzles in the path
✓ SAFETY VALVES:
➢ Function: To release excess pressure developed in the system
➢ Avoid starvation of superheater tubes
✓ SOOT BLOWERS:
➢ Soot blowers are used to clean these deposits so that adequate heat transfer rate is maintained
➢ There are two types of soot blowers:
1. Wall blowers
2. LRSB
➢ Medium used: steam, low pressure air, sound to remove these soots
✓ EXPANSION AND SEALING:
➢ The provision of free expansion is vital in case of furnace water wall tube
✓ BUCKSTAYS:
➢ It gives external support
➢ To provide rigidity to water wall system

✓ WIND BOX:
➢ A rotative motion like that cyclone is imparted to the flame body which spreads out and
fills the furnace area.
➢ For this system wind box is provided at each corner of furnace.
BOILER DRUM:
Maximum pressure: 168.5 kg/cm2

Location: Above the furnace
Function: Separation of moisture content from mainstream
BOILER ROTARY PARTS:
COAL MILLS:
➢ Make: BHEL
➢ No per boiler: 3
➢ No in normal operation: 2
PRIMARY AIR FAN (PA) :
➢ Functions: drying the coal & transportation into the furnace

➢ Boiler is provided with 2 PA fans
➢ The hot primary air is then passes to coal mill from where it carries the pulverized coal to
furnace
FORCED DRAFT FAN (FD) :
FD is installed near the base of the boiler

Function: To supply excess air required for complete combustion
Boiler is provided with two FD fans
INDUCED DRAFT FAN:
The function of ID fan is to suck the gases out of furnaces & throw them into the stack
The boiler is provided with two ID fans
ELECTROSTATIC PRECIPITATOR (ESP) :
PRINCIPLE: The dust laden gases pass into a chamber where the individual particles of dust are
given an electric charge by absorption of free ions from a high voltage D.C. ionizing field.
The ESP utilizes electrostatic forces to separate ash particles from flue gas to be cleaned.

AIR PREHEATER:
Functions: It preheats the combustion air for rapid & efficient combustion in the furnace
Recovers the waste heat from the outgoing flue gas of the boiler
OFF SITE
❖ DE – MINERALISATION PLANT:
• Objective of D. M. Plant to produce high quality of mineral free water ie. DM water which is
used as Boiler feed.
• Process of removal of dissolved chemical impurities / ions is carried out in DM Plant using Ion
Exchange Process. For this purpose, various Ion Exchangers are used.
➢ SOURCES:
• Rainwater
• Surface water
• Ground water
➢ IMPURITIES:
• Non – ionic & undissolved

• Ionic & dissolved
• Gaseous

➢ PRESSURIZED SAND FILTER (PSF):
• This is pressurized sand filter

• Turbidity of water is removed
➢ ACTIVATED CARBON FILTER (ACF):
• Activated carbon filter

• Here chlorine is removed
• It mainly consists of charcoal
➢ STRONG ACID FILTER(SAC):
• This consist of R-H resin

• Here all cations are trapped, and acid is formed
➢ DEGASSER UNIT (DGT):
• Degasser is the unit where carbonic acid is removed from

• water in the form of carbon dioxide.
• Here water is sprayed from top, and air is blown with the help
• of two blowers from bottom
• Thus, CO2 escapes and water is collected in degasser tank
➢ WEAK BASE ANION (WBA) :
• This is Weak base anion

• Here Cl ions are removed in with the help of R-OH
➢ STRONG BASE ANION (SBA):
• This is strong base anion

• Here Si is removed with the help of R-OH
➢ MIXED BASE(MB):
• This is mixed base

• Here remaining cations and anions are removed
ION EXCHANGE PROBLEMS & REMEDIES:

Suspended matter in the influent water:

Iron
Aluminum hydroxide
Calcium sulfate
❖ COOLING WATER PUMP HOUSE (CMP) :
➢ The Cooling water circulating system is one of the most

important auxiliary system in power station
➢ In DTPS, sea water is used as cooling water, due to abundant availability.
➢ Condenser requires cooling medium to cool the steam exhausted from LP turbine.
The main parts of CW pump are

➢ DRAFT TUBE
➢ IMPELLER
➢ SHAFT
➢ CASING
➢ BEARINGS 1. LOWER GUIDE BEARING 2. UPPER THRUST CUM GUIDE BEARING
➢ DISCHARGE PIPE
➢ GEAR COUPLING
➢ DRAFT TUBE:
• Function: The draft tube is a conduit through which sea water reaches to the suction of
pump.
IMPELLER:
Function: Impeller whirls the water around; centrifugal force builds up

pressure forcing the water through the discharge outlet.
SHAFT:
Function: To transmit the torque, holds impeller & other rotating parts.
CASING COVER:
Function: Casing cover covers upper part of volute casing.

LOWER GUIDE BEARING:
Function: Lower guide bearing guides the shaft axially.

DISCHARGE PIPE:
ASH HANDLING PLANT
Earlier Coal ash was considered waste and was dumped in the ash dyke. But now, ash is
considered as by product of coal based thermal power plant & is to be completely utilized.
As an initial step to reduce the ash at source, DTPS.
Started blending Indian RAW coal with Higher C.V (6000 Kcal/kg), Low ash (1- 8%) Imported
coal. This resulted in reduction in the overall ash generation itself (30-32%)
Simultaneously, management took initiatives of using beneficiated Indigenous coal (washed)

since 1999 and subsequently it started using washed coal on a regular basis. Presently DTPS
blends washed coal with Beneficiated Imported coal, which further resulted in the reduction of
ash (24-26%)and further improvement of environment & operating parameters.

Further Ash utilization was also initiated in phased manner:
Annual collection of fly ash from ESP hoppers. Pond ash is being used by local brick
manufacturers. This has helped in an increase in the overall ash utilization. DTPS has set up its
own fly ash testing laboratory for determining various parameters of ash.
For 100% value addition, planning is done in three innovative stages as below:
First Phase: DTPS has set up and successfully commissioned a classification unit in March-05.
The classifier unit is designed to classify and separate the stream of particles. The classification
takes place under the combined action of controlled air flow, centrifugal force, and gravity.
Total fly ash collected from the first field is classified and separated in coarse and fine form in
approximately equal ratios and stored in the respective silos. The finer portion (550 T) can be
used as a value-added product (as an additive / substitute of cement), whereas coarser portion
(approximately 550T) is disposed in wet form.
In the second phase DTPS has planned utilization of this coarse ash from the classifier unit by
setting up a coarse ash grinding system. After setting of this unit DTPS will be able to add value
to nearly 80% of the total ash generated.
In the third phase, collection of bottom ash in dry form is being contemplated. For this, DTPS
has already initiated action. This action will address remaining 20% (bottom ash) to achieve 100
% ash utilization.
OPERATION of AHP:
Dry ash system:
The fly ash collected at the ESP hoppers are gravity fed into individual transmitter vessels
provided below each hopper. On initiation of dry fly ash collection system, the inlet valve opens
and allows the fly ash to be fed into the transmitter vessel for pre-determined time after which
the inlet valve closes.
Afterwards, the compressed air is allowed to flow into the transmitter vessel by opening the air
inlet valve. Once the desired conveying pressure is reached inside the vessel, the fly ash is
conveyed to the fly ash storage silo through transport piping. The conveying air is vented
through the bag filters mounted on top of the silo in order to limit the dust concentration in the
vented air.

Fluidizing Blowers: Blowers are used to supply hot air to the buffer hopper,ESP hopper, ash
silo’s fluidized bed so that ash remain freely inside the hopper and come down smoothly.
An electrical heating device is used for heating fluidizing air before it reaches the diffuser
elements in order to keep the ash free of moisture. This will help prevent the formation of
lumps in the ash and clogging of the elements
Compressors: Conveying air compressors used to supply high pr. air to convey the ash from
multi-DAC vessel to silo.
MultiDAC vessel: It is a transmitting vessel, where in ash from the hopper is temporarily stored
before conveying to the respective silo or buffer hopper, as the case may be. Each MultiDAC
vessel is equipped with a solenoid operated hemi centric valve (ash feeder valve). Ash flows by
gravity from each ESP hopper to Multi DAC vessel and subsequently conveyed to the silo by
compressed air.
Approximate filling time of Multi DAC vessels of each row is:
Row # 1AB,1CD,2AB,2CD: 10 seconds
Row # 3,4,5,6: 05 seconds.
• MultiDAC Vessel Sizing
1st & 2nd field ESP Hoppers: 10 cft
3rd to 6th field ESP Hoppers: 05 cft.
Classifier: Classifier function is to classify the fly ash into fines and coarse. It separates coarse
ash and fine ash through the combined action of air flow, centrifugal force, and gravity. The
heavier coarse ash dropping out in classifier is delivered into coarse ash silo and fine ash
segregated in each classifier is conveyed by air through a pipeline to bag filter mounted on the
fine ash silo. Fly ash is fed to the classifier and the separating air is passed into the classifier
from the side entrance. After fly ash and air mix thoroughly, both are carried to the separation
zone for classification. Coarse are rejected by the guide vanes and rejection rods and collected
into the grit cone. Particles which are selected by the rejection rods are carried by the
separating air and shall be collected in a Bag filter and these particles are the fines i.e. product
(< 45 micron). The dynamic rotor relates to gear box and motor (variable speed). The rotor is
provided with rejection rods which will cut the particle size depends on the rotor speed. The
rotor speed shall be varied depends on the product fineness.
The final product collected are transported to the fine ash silo. The rejects collected in the grit
cone will be fed to a coarse ash silo.
•
Buffer hopper: Buffer hopper is divided in to two half sections provided above the coarse ash
silo.
The hopper is provided with vent filter to vent out the air.
The ash particle sticking to the filter is thus separated and dropped off in the hopper by
sequential pulse jetting of filter bags by instrument air.
The vent filter unit is a continuous self-cleaning dust filter capable of removing dust particles as
small as sub-micron size from gaseous streams.

High ash collection efficiency is maintained under continuous operating condition without the
use of rapping mechanisms.
Dust laden air under suction or pressure enters the lower section of the Vent Filter. The air
travels through the filter bags, which retains the dust particles, on up through the Vent Filter
exhaust.
Wet ash system:

Bottom ash Hopper: -
The ash hopper is a storage receptacle, located at the bottom of the furnace, which acts as a
seal for the furnace & provides storage for the ash that issues from furnace. It not only provides
storage but allows for the efficient periodic removal of ash with a minimum of effect on the
operation of the furnace. The hopper bottom is sloped surface. The ash towards the ash gate
separating the storage hopper from the bottom ash transport system. Vertical walls & the
sloping sides have monolithic Castable refractory lining. The refractory lining protects the outer
shell from the furnace heating & resist the abrasive action of the ash. Water impounded ‘W’
type bottom ash hopper receives and stores furnace ash for its periodical removal. In the
maintained water level hopper, the water serves to chill to the hopper ash & prevent clinkering
of the same. The water will also serve to shield the refractory from the furnace heat. Cylinder
operated ash gates are provided for sealing ash hopper & to have a discharge part for the ash
into into the transport system.
The mixture of ash and water is discharged through feed gate to clinker grinder, which sizes
and clinkers. Crushed clinkers in slurry form falls to hydro ejector through ejector feed pump.
Hydro ejector provides jetting action by means by high-pressure water flowing through it to
convey the slurry through pipelines to slurry sump for its further disposal to dump area. Each
section of bottom ash hopper is provided with two outlets. Each outlet is having one number
each of hydraulically operated discharge gate, clinker grinder and hydro ejector. When the
hopper is empty it is refilled for maintaining the hopper temperature.
Coarse ash removal system:

Ash collected in twelve nos. of Economizers/Duct/APH hoppers will be removed once in a shift
in a sequence. Each coarse ash hopper is provided with one number manually operated hopper
isolation valve, pneumatically operated valve, expansion joint and feeder ejector. The
pressurized water fed to the feeder ejector mixes with the free-falling ash and the resultant
slurry will be conveyed into slurry trench connected to intermediate FA slurry sump.
ESP Fly ash removal system:

Forty-eight electrostatic precipitator hoppers, Four ESP hoppers constitute one group. Thus
there are twelve groups of Fly Ash Hoppers. Each group of Fly Ash Hoppers is operated one by
one in sequence. All the hoppers of one group opens / closes simultaneously.
Each fly ash hopper is provided with one no. manually operated hopper isolation valve,
pneumatically operated fly ash valve, expansion joint and feeder ejector. The feeder ejector
when fed with pressurized water serves to mix the free-falling fly ash with water and discharge
the resultant slurry into the slopping trench provided underneath, which is connected to main
slurry trench. The fly ash slurry extracted from various hoppers flows down through main slurry

trench, aided by high-pressure water jets, to the intermediate fly ash slurry sump. From there
the slurry is transported to the main slurry sump by means of one Fly Ash Slurry Pump in unit-I
and two fly ash pumps in unit-II.
Ash Disposal System:

The Bottom Ash, Coarse Ash & Fly Ash led to common slurry sump are pumped to the disposal
area by means of slurry pump sets & disposal lines. Four nos. of identical streams connected to
two nos. of slurry disposal lines. Out of four streams provided, single stream run continuously
for both units & the remaining three streams serve as standby. Make up valve & line flushing
are provided in each compartment to enable the slurry disposal pumps to run & flush the
disposal pipelines. Various level switches provided in each of the sump initiates high / low level
alarm, protects the pump from dangerously low level & also controls the makeup valves.
Ash slurry sump, which is common for both units, is a RCC tank with four compartments one for
each of the pump stream. Pneumatically operated suction & discharge valve for each stream of
pumps helps in isolation of the stream. Disposal piping has special EZY coupling joints to ensure
ease in periodical rotation of the pipes for uniform wear.
Ash Pond:
The Bottom Ash, Coarse Ash & Fly Ash led to common slurry sump are pumped to the disposal
area by means of slurry pump sets & disposal lines. Ash disposal area i.e. ash dyke covers
around 370 hectares area and is divided into 04 ash dykes.



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Adani Electricity Industrial Training Report

``MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION MUMBAI

Adani Electricity Mumbai Ltd.

Master Hrishikesh Karandikar

DEPARTMENT OF MECHANICAL ENGINEERING

ADANI ELECTRICITY MUMBAI LTD.

Power Plant Mechanical Engineering

SR. NO. CONTENT DURATION PAGE

4. Boiler 3rd WEEK

5. Off Site 4TH WEEK

FOUNDER And CHAIRMAN:

Power Plant Mechanical Engineering

Power Plant Mechanical Engineering

Power Generation process

Modified Rankine’s Cycle:

Power Plant Mechanical Engineering

To improve efficiency of Rankine’s cycle, Reheat cycle is developed

Components of Thermal Power Plant:

Power Plant Mechanical Engineering

Power Plant Mechanical Engineering

CHP (Coal Handling Plant)

Following are the Functions of Coal Handling Plant:

Main Equipment of CHP:

1. Wagon Tippler 7. Inline magnetic Separator.

2. Beetle Charger 8. Grizzly Feeder.

3. Apron Feeder 9. Stacker Reclaimer.

4. Belt Conveyors 10. Travelling tippler.

5. Belt Weigher 11. Dust extraction and dust separation.

Power Plant Mechanical Engineering

Coal Flow Diagram

Power Plant Mechanical Engineering

Steam turbines of two type designs such as,

LMW - Soviet Russian made (Leningrad Metal works)

Power Plant Mechanical Engineering

➢ High Pressure Turbine

Type Stages Flow Casing Pressure Temperature

HPT 1 impulse stage Single Outer casing is Inlet = 145- 540’C

IPT 17 reaction Single Double casing Inlet = 37 340’C

LPT 8 reaction Double Three casings. All Inlet = 7.5- 350-370’C

Power Plant Mechanical Engineering

a. High Pressure Turbine (HPT): -

b. Intermediate Pressure Turbine (IPT):

c. Low Pressure Turbine (LPT):

Impulse and reaction stages for turbines:

2 Impulses - Reaction Type:

Power Plant Mechanical Engineering

TURBINE GOVERNING SYSTEM:

The different auxiliaries are as follows: -

Power Plant Mechanical Engineering

1. Make BHEL Hardware

Power Plant Mechanical Engineering

Condensate Extraction Pump:

1. Make BHEL Hyderabad

Low Pressure Heaters:

Power Plant Mechanical Engineering

Power Plant Mechanical Engineering

F) Boiler Feed Pump:

Power Plant Mechanical Engineering

Characteristics of the system:

G) High Pressure Heaters:

Power Plant Mechanical Engineering

H) Turbine Lubrication Oil System:

This system fulfils the following important functions: