TRAINING REPORT

ON
FAMILIARISATION OF
THERMAL POWER PLANT
AT

KANTI BIJLEE UTPADAN NIGAM LIMITED

(A joint venture of NTPC Ltd. & BSEB)

MUZAFFARPUR THERMAL POWER STATION, KANTI, MUZAFFARPUR, BIHAR

Submitted for the partial fulfilment of the Requirement of

BACHELOR IN ELECTRICAL ENGINEERING

DURATION : 07.10.2021 to 03.11.2021

Under the guidance of :-

1. Nilesh Dangayach
AGM(OPERATIONAL)

2 . Mahesh Ram

SUBMITTED BY:-

AAKASH RANJAN GHOSH

COLLEGE : MUZAFFARPUR INSTITUTE OF TECHNOLOGY,

MUZAFFARPUR

COURSE : B. TECH. (ELECTRICAL ENGINEERING)

YEAR : 3rd year ( 5th Sem. )

REG NO : 19103107058 ROLL No . - 19E01

 ACKNOWLEDGMENT

This report pertains to take vocational training which was undertaken under KANTI
BIJLEE UTPADAN NIGAM LIMITED, KANTI, MUZAFFARPUR, BIHAR ( A joint venture
of NTPC & BSEB ) in partial fulfilment of the requirement for the BACHELOR IN
ELECTRICAL ENGINEERING from MUZAFFARPUR INSTITUTE OF TECHNOLOGY,
MUZAFFARPUR. The main purpose of the training was to acquaint myself with
practical experience of actual work condition in which we are required to work in
future. I learnt a lot from the practical experience of the engineering & other personals
under whom I was placed for training. This helped me to develop the habit of analysis
critically various aspects of problem at the time of decision making.

I would like to acknowledge to Mr. A. K. Gupta and Mr. Kamlesh

Kumar during training period who give me clear details & guidelines for the power
station .

Finally; I would like to express my thanks to all of the technical & non technical persons
for the co- operation & valuable guidance during my training period.
 INTRODUCTION ABOUT THE PLANT

KBUNL (Kanti Bijlee Utpadan Nigam Limited) which was formerly known as Vaishali
Power Generating Company Ltd(VPGCL) is situated in Kanti which is 12 km away from
main town Muzaffarpur.

It is totally coal fired Thermal power station.

There are two units of each 110MW and two units of each 195MW installed capacity,
thus total of 610MW supply.

RECENT DEVELOPMENT
On 17 April 2018, Bihar state cabinet, headed by chief minister Nitish Kumar, gave its
nod to handing over of Kanti Thermal Power Station to National Thermal Power
Corporation .On 15 May 2018, Bihar Government signed a memorandum of
understanding (MoU) to hand over the thermal plant to National Thermal Power
Corporation for a 33- years lease .

KANTI BIJLEE UTPADAN NIGAM LIMITED

This MoU was incorporated with Bihar State Electricity Board, a State run Electricity
Board in the State of Bihar with NTPC, engaged in generation, transmission and
distribution of electricity.
OBJECTIVE: To take over Muzaffarpur Thermal Power station(2*110MW
+2*195MW), a coal based power station at Kanti , for carrying our
restoration ,R&M and supplying power mainly to state of Bihar.
ABSTRACT

Any thermal power plant is converting the chemical energy of fossil fuel (coal) into
electrical energy. The process involved for this conversion is based upon the modified
Rankine cycle. The major components that are used to accomplish the modified
Rankine cycle are:

 Boiler feed pump,

 The steam generator water walls (evaporator),
 Steam generator super heaters,
 Steam turbine,
 Reheater,
 Condenser,
 Regenerative feed heaters etc.

All components of a power generating cycle are vital and critical in operation. In
Modified Rankine cycle, the two most important aspects that is added are reheating &
regenerative heating. By reheating we used to send the steam coming from exhaust of
the turbine back to the reheater of the boiler so that its enthalpy increases and more
work can be done by this steam the other purpose is to make steam dry so that no
harm will be done to the blades of turbine.

In MTPS Kanti, we have three turbines in Tandem coupling namely one H.P Turbine,
one I.P Turbine & one L.P Turbine coupled with the generator to which is synchronized
with the grid to produce electricity at 50Hz.

In all my modesty, I wish to record here that a sincere attempt has been made for the
presentation of this project report. I also trust that this study will not only prove to be
of academic interest but also will be able to insight into the area of technical
management.
 CONTENT

SI NO. Description Page-

No
01 An over view (NTPC) 03
02 Plant introduction 04-05
03 Schematic diagram of thermal power plant 06
04 Working principle 07
05 Process of generation of electricity 08
06 Coal to steam 09
07 Steam to mechanical 10-11
08 Power Generation, Transmission & Distribution 12-13
09 Single line diagram of grid 14
10 Transmission 15-18
11 Light up process 19
12 Main boiler components 19-21
13 Cooling water circuit 22
14 Types of fan 22-23
15 Types of pump 23-24
16 Types of turbine 24-25
17 Types of heater 25
18 Unit control desk and panels 25
19 References 26
An Overview
NTPC
NTPC Limited, formerly known as National Thermal Power Corporation Limited, is an
Indian Public Sector Undertaking, engaged in the business of generation of electricity
and allied activities. It is a company incorporated under the Companies Act 1956 and is
promoted by the Government of India. The headquarters of the company is situated at
New Delhi. NTPC's core business is generation and sale of electricity to state-owned
power distribution companies and State Electricity Boards in India. The company also
undertake consultancy and turnkey project contracts that involve engineering, project
management, construction management and operation and management of power
plants.

The company has also ventured into oil and gas exploration and coal mining activities.
It is the largest power company in India with an electric power generating capacity of
53,651 MW. Although the company has approx. 16% of the total national capacity it
contributes to over 25% of total power generation due to its focus on operating its
power plants at higher efficiency levels (approx. 80.2% against the national PLF rate of
64.5%).NTPC currently produces 25 billion units of electricity per month.

It was founded by Government of India in 1975, which now holds 64.74% of its equity
shares on 30.06.2016 [6] (after divestment of its stake in 2004, 2010, 2013, 2014, 2016,
& 2017)

In May 2010, NTPC was conferred Maharatna status by the Union Government of
India,one of the only four companies to be awarded this status. It is ranked 400th in
the Forbes Global 2000 for 2016. The NAVRATNA power giant today generates more
than one fourth of the total power in the country, ranked 5 th largest power generating
utility in the world, NTPC is the second most efficient in capacity utilization among the
top ten thermal generating companies according to a survey conducted by Data
monitor, United Kingdom. In a short span of two decades, NTPC has earned its prime
status by setting up a total generating capacity of 53,651MW, with 25% of India ’s
operating capacity, the company generates 26.7% of country electricity through its 13
coal & 7 gas based power plants spread all over the country.
Today, country needs a 10% sustained growth in power generation to ensure the
momentum for a 7% overall growth in the economy. Recognizing this, NTPC has
committed itself to achieving the status of a 30,000MW plus company by the year 2007
and 40,000MW plus company by the year 2012 and power generating capacity
addition programme of 51,000MW (including nuclear energy and non-conventional
sources of energy) for the tenth plan.

NEW TECHNOLOGY
 Super critical technology at NTPC Sipat project (3*600MW) to increase the
efficiency of the cycle and to decrease the green house gas emission,
 Closed cycle seawater cooling at Simhadri project for first time in India
 Introduction of IGCC (Integrated gasified combined cycle) for clean and efficient
utilization of coal.

ENVIROMENT MANAGEMENT

 Liquid water treatment plants at Farakka and Kahalgaon.

 Ash water recycling system at Kahalgaon and korba to reduce water
requirement for ash disposal at these stations.

PLANT INTRODUCTION
Salient Features of Boiler Plant
1. General

Type of boiler Single drum tangential firing & reheat type

(water tube)
Type of fuel used Pulverized coal (Main fuel), Heavy oil &
L.D.O (for light up & flame stabilization)
No. Of Mills 06
Type of Mills Pressurized type Bowl Mill
Furnace Balanced draught
P.A Fans 02 (each 60% capacity)
 F.D Fans 02 (each 60% capacity)
I.D Fans 03 (each 60% capacity, one standby)
Air heater 02
Types of Air Heater Trisector regenerative
Electrostatic Precipitator 01

2. M.C.R Parameter M.C.R. Value

S.H. Outlet steam flow 375 T/Hr

R.H. stem flow 331 T/Hr
Pressure at S.H. Outlet 141.5 Ata
Temp. at S.H. Outlet 540⁰c
Pressure at R.H. Inlet 37 Ata
Pressure at R.H Outlet 32.9 Ata
Temp. at R.H. Inlet 369⁰c
Temp. at R.H Outlet 540⁰c
Pressure in drum 148.69 Ata
Design pressure 158.0 kg/cm²
Flue gas temp. leaving 350⁰c
Economiser
Flue gas temp. leaving Air 142⁰c
Heater
Feed Water Temp. before 235⁰c
Economizer

Salient Features of Turbine

1. General

Type Of Turbine Reheat

No. Of Cylinders 3(HP,IP &LP)
No. Of LP Heater 05
No. Of HP Heater 02
Deaerator 01(Variable pressure type)
No. Of Extraction pump 03(one standby)
No. Of BFP 02(one standby)
M.C.R. Parameter M.C.R. Value

Rated output 110MW

M.S. Pressure at H.P. turbine 130 Ata
inlet
M.s. temp. at H.P. turbine inlet 535⁰c
H.R.H. temp. at I.P. turbine inlet 535⁰c
Turbine speed 3000 rpm
Condenser Vacuum 0.1 kg/cm²(abs)
No. Of Extraction 07
Quality of cooling water 15,400 m³/hr
Salient Features Of Generator

Rating Continuous
Active Output 110 MW
Rated Voltage 11000+/-5%V
Rated Current 7220 A
Power Factor 0.8 lagging
Frequency 50 Hz
Excitation System Static type
Field current at rated output 1335 A
Type of cooling system Hydrogen Cooled
Hydrogen Pressure 2 Ata
No. Of H₂ cooled elements 06
Cooling medium for H₂ Soft water

WORKING PRINCIPLE
The working principle of thermal power plant is based on Rankin cycle. A central steam
station basically works on the Rankin cycle. Steam is produced in the boiler , is
expanded in the prime mover (Turbine) and is condensed in a condenser to be fed into
the boiIer.

PROCESS OF GENERATION OF ELECTRICITY

MTPS Kanti is a Thermal Power Plant. The functioning of every Thermal power plant is
based on following process:-

1. Coal To Steam
2. Steam To Mechanical power
3. Power Generation, Transmission & Distribution.

Coal To Steam
Coal and water are the primary inputs to a thermal power plant.This process of
conversion of water to steam by using heat energy produced by burning of coal by
producing heat takes place in boiler and its auxiliaries. Coal burns in a furnace located
at the bottom part of the boiler. Feed water is supplied to the boiler drum by boiler
feed pumps, where water is heated and converted into saturated steam. This is further
superheated in the super heaters.

Steam To Mechanical Power

This is the most important process of a power plant. The superheated steam produced
in the boiler at high pressure and temperature is feed to the turbine giving up heat
energy, which is transformed into mechanical energy on turbine shaft. Thus,
mechanical power is obtained from the turbine shaft.

Power Generation, Transmission & Distribution

Mechanical power produced at the shaft of the turbine is used to rotate the rotor of an
electrical generator that produces electrical power. The electric power produced by the
generator is boosted to a high voltage by a generator transformer to reduce
transmission losses. This power at EHV i.e. 400 KV is transmitted and distributed by
EHV transmission lines.

Coal To Steam
We are taking coal from coal-yard as Wagon tippler load with the help of motor on
which the conveyer belt is mounted. As Wagon tippler consist of rotor & pinion. The
pinion use to rotate rotor. If in case Wagon tippler not working then mechanically coal
is transfer into hopper to the belt. We supply coal in coal bunker watching the load on
control room connected Ammeter & Voltmeter. Feeder is used to put coal on belt.
Small motors are connected to belt for support. Coal being passed through metal
detector after passing through metal detector it is passed through vibrating screen
where coal of 5mm seperated from large coal ane fed to crusher then magnetic
separator to remove iron particle from coal. Then fed to crusher to coal bunker.

Metal detector placed over conveyer belt

From coal bunker coal is supplied, to pulverising mill. There are six coal bunkers
supplying coal to each mill and are located at top of the mills to add in gravity feeding
of coal. Each bunker store coal which can be used for 12 hrs. Coal is supplied to the mill
by the four barriers. With the help of primary air fan we feed coal to pulveriser mill
with high pressure of air. There are five pipes connected to mill from on we feed coal to
mill and from other four pipes coal dust comes out from mill after pulverising. The coal
is converted into powered form in the mill. The mill is ball mill of MTPS power station.
With the help of primary air coal dust is feed into ignited boiler. The coal which we are
using for thermal power plant is of class c. In boiler heat of coal is used to convert
water into steam. Coal produces heat of 330⁰c and that of super heated stem is 535 ⁰c.

Steam to Mechanical power

The steam which being produced in the boiler are collected in boiler drum. This boiler
drum is mounted on top of the boiler. From boiler drum steam is passed through super
heater. There are three super heaters between boiler drum and high pressure turbine.
Super heaters are used to remove moisture or water droplets from steam which can
decrease efficiency of turbine.
The stem passing through high pressure turbine again given to reheater where steam is
reheated and then used on intermediate turbine from intermediate turbine steam is
directly used on low pressure turbine. The steam which is being used on low pressure
goes to condenser where it cools. The steam heated in reheater at 535⁰c and fed to
intermediate turbine of 20 kg/cm² and then fed to low pressure. And this produces
mechanical power on shaft on turbine. Where the turbine shaft is directly coupled with
the alternator rotor.

Turbine

Types of turbine
1. HP Turbine:-
HP turbine is a single flow design with eight stages of blading. Each stages
compromises stationary and moving blades which are positioned into the rotor
mounted on the diaphragms, directs steam into the rotor mounted on the moving
blades. HP turbine is double shell construction comprising inner and outer casing.
H.P steam enters the H.P turbine inner casing through inlet connection are mounted on
the top and bottom outer casing. The steam exhausts through the two branches in the
bottom half casing and returns to the boiler to be reheated to increase the
temperature of the steam to 535⁰c so that the efficiency increases.

2. I.P Turbine: -
Intermediate pressure turbine is a double flow design with seven stages on blading on
either side of central steam inlet. Each stage comprises stationary and moving blades
which are positioned so that the stationary blades mounted on diaphragm, directs the
steam into rotor mounted moving blades. The inner casing , diaphragm carrier ring and
outer casing are made in halves bolted together in the horizontal centre.

3. L.P Turbine:-
L.P Turbine is a double flow design with six stages in each of its front and rear flow
paths. Each stage consists of number of stationary blades incorporating in the
diaphragm located in the casing and a set of rotating blades mounted on the rotor
disc.

Power Generation, Transmission & Distribution

Mechanical power produced at the shaft of the turbine is used to rotate rotor. where
magnetic flux produced inside the stator conductor cuts by rotor conductor an electro
motive force will be induced due to Faraday ’s law of Electromagnetic induction and
produces electricity with the speed of 3000rpm and frequency of 50Hz. As generator
consists of stator which consist of stator winding and rotor consisting of rotor winding.
And we have three phase supply. For cooling purpose of generator we are using
hydrogen which is shielded with oil.

GENERATOR
A generator consists of rotor which consists of carbon brushes. The rotor rotates at
3000rpm in case of any fault if production of plants stops then we have bearing motor
which rotates shaft of turbine continuously and rotor at 65rpm. This is because if shaft
doesn’t rotate then due to load it may bend.

As generator produces 110MW or generates 11kV output. The output of generator is

step up to 220kV by using step up transformer or generating transformer. Three phase
is fed to station transformer. There are two station transformer1 and 2 which is step
down transformer. Here 220kV is step down to 6.6kV for internal purpose. This 6.6kV is
step down to 415V for low rating motors. At generating transformer we are using
lighting arrestor which protects G.T from lighting. This 220kV is given to grid
substation. In grid substation we are using some protective system before distribution
we have Bus isolator, SF6 breaker, Line isolator, CT, lightning arrestor. Similarly we
have two unit auxiliary transformer UAT-1 and UAT-2, which will step down voltage
from 11kV to 6.6kV and it will supply to unit auxiliary board 1BA, 1BB.

Similarly station transformer will supply to station board 9BA, 9BB. One unit is tied
with other unit because during the failure of any one of the unit other unit will able to
supply.

We are using web trap which changes the frequency 50Hz to 500Hz can be used for
communicate in power plant. As three phase fed to station transformer (Auto
transformer) by step up we fed to switchyard where circuit breaker is closed, when
terminal voltage and frequency matched with the bus-bar conductor.

Transmission
The KBUNL has capacity to generate 610MW of electricity. The transmission is done
through three phase, double circuit system with the help of transformer, we are
converting 11kV to 220kV and fed to substation. It is then step down to 132kV and fed
to BSEB and local areas.

Equipments used in transmission of power:-

1. Sub- Station
A. Control Room
B. Switchyard

Sub-Station:-
It is the place where power is changed, step down or step up and transmitted to other
places. It consists of various protection equipments, switching circuits etc.

A substation consists of
a) Bus isolators
b) circuit breaker
c) Line isolator
d) Current transformer
e) CVT
f) Lightning arrestor
g) Wave trap

A. Control Room:-
It is the brain of any sub-station. All the necessary steps about the transmission,
protection, charging etc. are carried out in the control room.

Measuring instruments of the control room:-

a) Relay circuit
b) Fault locator
c) Switch gears
d) Voltmeters
e) Ammeters
f) Power meter
g) CRT screen
h) Battery room
a) Relay circuit:- A relay is a protective device that operates during faulty
condition and gives command to circuit breaker to trip circuit.

Operating principle:-
1. Electromagnetic attraction
2. Electromagnetic induction

Components of electromagnetic relay:-

1. Shaded pole
2. Watt-hour meter
3. Induction cup
4. Single and double induction loop

b) Fault locator:- A simple beam relay would measure the current seen by
the relay with the voltage at the relaying point. By comparing these two quantities the
relay measure the line impedence (z=v/i) up to the point of fault.

c) Switch gear:- Switches are used in sub-station as a device for making or

breaking the electric circuit in convenient way i.e just by the simple motion of a knob or
a handle to connect together or disconnect two terminals to which cables are
connected. There are two types of switch gears Air switch and Oil switch.
d) Voltmeter:- It is an instrument, which measures the voltage along the
phase. It actually measures the potential difference between the two points of the
conductors.
e) Ammeter:- It is an instrument, which measures the current across the
conductor. It is mounted on the panel board. Where staff on duty can easily watch the
readings.
f) Power meter:- These instruments are used to measure the power in
standard units i.e in MW. This instrument is also mounted on the panel board for easy
watch for the operating staff.
g) CRT screen:- It is a computer arrangement in which current information
about the transmission line is seen. The circuit diagram of switchyard and control room
is stored in hard disk. It also displays the current status of the transmission line.
h) Battery room:- This room consists of several batteries and charges for
emergency purpose. When power failure is there, then power is supplied by the battery
to keep all the instrument or devices in ‘on’ status.

B. Switch yard:-
It is systematic arrangement of various components, where all the machines or
equipments are connected with each other, looping, step down, step upof transmission
line are done here only.

A switchyard consists of following equipments:-

a) Transformer
b) Tower
c) Conductor
d) Insulator
e) Circuit breaker

Transformer:- A transformer is an electrical device which works on the principle

of mutual induction. The autotransformer used in power station. It has three windings
primary, secondary and tertiary. The 220kv voltage is fed as input to primary by step
down 132kv fed MTPS as input.

a) Tower:- Tower is the an important part of transmission line. As tower

consists of guard ring. it is located at the bottom of the tower so that any unauthorised
person or animal cannot climb upto the tower.
We have suspension type tower called as ‘A’ type tower. The peak point angle is 0⁰ to
2⁰. In this type conductor is suspended with an insulator.

B-type : angle lies between (2⁰-15⁰)

C-type : angle lies between (15⁰-30⁰)
D-type: angle lies between (30⁰-60⁰)
C) Conductor:- A conductor is very essential equipment which is used for
transmission of power. It is generally made of aluminium. It is hanged on the tower
with the help of insulators. Aluminium cost is cheap and has good conductivity.

D) Insulator:- It is made up of porcelain material which is bad conductor of

electricity. For transmission purpose generally PIN-TYPE insulators are used. The
capacity of each disk is 20kv.

E) Circuit breaker:- These are mechanical devices designed to close or open

contact members thus closing or opening an electrical circuit under normal or
abnormal conditions. These circuit breakers are equipped with trip coil connected to
relay, design to open breaker automatically.

Connection with grid to synchronisation:-

1. The terminal voltage of alternator must be equal to the bus-bar voltage.
2. The running speed frequency must be equal to the bus-bar frequency.
( Ns=120f/P ) => ( f=PN/120 )

Where, f= frequency
P= no. of poles
N= speed of alternator
3. The terminal voltage of two conductor must be equal to the two bus- bar
terminal to placed the external resistance to reduce the voltage drop.

Light up process
MTPS, Kanti has direct firing system. In this system, a controlled quantity of crushed
coal is fed to each bowl mill (pulveriser) by its respective feeders and primary air is
supplied from the primary air fans which drives the coal as it is being pulverized and
transports the pulverized coal through the coal piping system to the coal burners.

There are six pulverisers out of which four are used and two remains in standby. The
raw coal feeders supply 74TPH of coal to each mill.

The pulverized coal and air discharge from the coal burners is directed towards the
centre of furnace to form fire ball. There are 24 tilting, tangentially fired coal burners
fitted at the four corners of the boiler at elevations.

The secondary air heating system supplies secondary air for combustion in the furnace
around the pulverized coal burners and through auxiliary air compartments directly
adjacent to the coal burner compartments. There are 12 air-atomizing ignitors per
boiler, which initially ignite the coal and air mixture.

Above a predictable minimum loading condition, the ignition becomes self-sustaining.

Combustion is completed as the gases spiral up in the furnace.

MAIN BOILER COMPONENTS

Boiler is a closed vessel in which water is converted into steam.
There are two types of boilers

a) Fire tube boiler

b) Water tube boiler

The major accessories of a steam-generating unit are listed as

follows :-
 Furnace
 Economiser
 Boiler drum
 Down comers
 Water walls
 Riser tubes
 Superheaters
 Reheaters
 De superheaters

Furnace:- A boiler furnace is the first pass of the boiler in which fuel is burned and
from which the combustion products pass to the super heater and second pass of
boiler. The combustion process is a continuous process, which takes place in first pass
of boiler and controlled by fuel input through coal feeders. It is a radiant type and
water-cooled furnace and inclosure is made up of water walls.

The furnace is open at the bottom to allow ash/clinkers to fall freely into the furnace
bottom ash hopper.

Economiser :- The function of an economiser in a steam generating plant is to

absorb heat from flue gases and add this as sensible heat to the feed water before the
feed water enters the evaporative circuit of boiler. This increases the efficiency of the
boiler.
The economiser is placed in the path of the flue gases leaving the boiler rear gas pass
below the rear super heater. The economiser is continuous ‘unfinned loop type ’ and
water flows in upward direction and gas flows in downward directions.

Boiler drum:- It is a cylindrical pressure vessel with hemispherical ends. It contains

two rows of cyclone separators, four rows of driver boxes, a perforated feed water
distribution pipe, and a chemical dosing pipe.
The boiler drum is located on the upper front of the boiler, it is suspended from roof
steel work by two U-shaped slings.
It forms a part of the water circulating system of the boiler. The drum serves mainly
two functions.

 The first and primary one is that it separates steam from the mixture of the
water and steam discharged into it and to reduce the dissolved solid contents of the
steam to below the prescribed limit of 1 ppm.
 Secondly, the drum houses all equipments used for purification of steam after
being separated from the water. These equipments are known as drum internals.

Down comers:- Down comer provide a passage for water from the boiler drum to
bottom ring header. From bottom ring header water goes to water walls for heat
absorption and conversion into steam heating. To achieve the circulation of water into
water walls boiler circulation pumps are provided in down comers.

Riser tubes:- A riser is a tube through which the mixture of water and steam pass
from an upper water wall header to the steam drum.

Cooling water circuit

A large quantity of cooling water is required to condense the steam in condenser and in
maintaining a low pressure in it. Cooling water may be taken from the upper side of
the river and after passing through condenser ( where it is heated ).

Where adequate quantity is not available water coming out from the condenser may
be cooled either in cooling pound or cooling tower. The cooling tower having fans
which is rotated with the help of motors. The blades of fen are set at an angle of 13⁰ to
15⁰. More angle of blade cause more cooling and more current drop. The motor rotates
at 1400rpm.

Cooling tower
Types of fan :-
A fan is a device by which the air is made to flow at required velocity and pressure in a
defined path imparting K.E of its impellers to air/flue gases. This pressure boost is used
to create a draught in the air and flue gases system. Fans mainly perform two
functions:

1. They supply air required for combustion in the furnace with required pressure
and flow.
2. They evacuate the product of combustion i.e. flue gases into the atmosphere
via chimney.

P.A fan:-
The primary air fan supplies heated air to the coal mills known as primary air, to give
dry and pulverized coal to the furnace for efficient combustion. There are two P.A fans
per boiler. The fan impeller is a double inlet, centrifugal wheel with backward curved
plate blades.

F.D fan:-
The forced draught fan system is provided to supply secondary air required for
pulverized coal combustion in the furnace, air for fuel oil combustion and over fire air
to minimize NOX production.
The F.D fan system comprises of two single stage axial flow, constant speed, and auto
variable pitch fans per boiler. These fans provide pressurized atmospheric air to the
boiler for combustion.

I.D fan:-
The induced draught fan system comprises of three centrifugal double inlet fans per
boiler, two operating and one standby. Each fan unit consist of a backward curved
plate bladed impeller, which is driven by an electric motor through a variable speed
hydraulic coupling. The I.D fan serves the purpose of evacuating the products of
combustion or the flue gases in the atmosphere via chimney.

Types of pump :-
1.Condensate Extraction pump (CEP):-
The function of condensate extraction pumps is to pump out the condensate to the
deaerator through, L.P heaters. The steam from the L.P cylinders exhausts into the
condenser shells where it is constrained to flow across the water tubes, through which
cooling water is circulated.

2.Air extraction pump (AEP):-

The function of air extraction pump is to raise and maintain the vacuum conditions in
the turbine main condensers, and to remove air and other non-condensable gases
vented to the condensers from the various parts of the turbine and feedweater heating
system.

3.Boiler feed pump (BFP):-

Boiler feed pump is the most critical component of a power plant. It is a rotary
machine, which is coupled to a motor through variable speed coupling or turbo
coupling. Under normal conditions two 50% boiler feed water pump sets are run in
parallel to undertake the complete load of feeding the boiler, while the third 50%
pump set is on standby duty.

Types of turbine
1. HP Turbine:-
HP turbine is a single flow design with eight stages of blading. Each stages
compromises stationary and moving blades which are positioned into the rotor
mounted on the diaphragms, directs steam into the rotor mounted on the moving
blades. HP turbine is double shell construction comprising inner and outer casing. H.P
steam enters the H.P turbine inner casing through inlet connection are mounted on the
top and bottom outer casing. The steam exhausts through the two branches in the
bottom half casing and returns to the boiler to be reheated to increase the
temperature of the steam to 535⁰c so that the efficiency increases.

I.P Turbine:-
Intermediate pressure turbine is a double flow design with seven stages on blading on
either side of central steam inlet. Each stage comprises stationary and moving blades
which are positioned so that the stationary blades mounted on diaphragm, directs the
steam into rotor mounted moving blades. The inner casing , diaphragm carrier ring and
outer casing are made in halves bolted together in the horizontal centre.

3. L.P Turbine:-

L.P Turbine is a double flow design with six stages in each of its front and rear flow
paths. Each stage consists of number of stationary blades incorporating in the
diaphragm located in the casing and a set of rotating blades mounted on the rotor
disc.

Types of heater
1. High pressure heater (HPH):-In the water cycle temperature of feed water
from BFP is increased to approx, 130⁰c by heating it in HP heater. As the heating of
feed water in HP heater is done by the extra steam coming out of the High Pressure
Turbine (HPT) hence, it is named as High Pressure Heater (HPH).
2. Low pressure heater(LPH):-In the water cycle, temperature of condensate
from CEP is raised to approx. 80⁰c by heating it in LP heater is done by the extra steam
coming out of the low pressure turbine(LPT) hence, it is known as low pressure heater.

Unit control desk and panel

The operation of each unit is envisaged from the central unit control room. It is located
in the control bay at 9.0m TG floor. It is adequately illuminated and is centrally air
conditioned. For operation convenience, the control room front wall has complete glass
panelling for TG hall view and the two double doors for entry from TG hall.

The control board has a special profile with three sloping surfaces for mounting a large
facias, instruments and controls. The automatic control station and drive control
switches and indications are located on the first sloping surface. The process
indicators/recorders and ammeters are mounted on the second sloping surface and the
alarm annunciation window facias are mounted on the top i.e. third sloping surface.
The unit control board are arranged in logical operating sequence from the left to right
starting with a) air and flue gas, b) fuel oil, c) ball mills, d) steam & feed water, e)
regenerative system, f) turbine and g) generator

References :-

Modern power station practice-volume-b, volume-

c.
 Power plant engg. By P.K NAG

Control & instrumentation – volume 1

Operation and maintenance manual (MTPS)- volume 2.