Report On Industrial Training (13th June to 13th July)

at Suratgarh Super Thermal Power Plant Rajasthan Rajya Vidhyut Utpadan Nigam Limited submitted for partially fulfillment of award of b.tech degree in Mechanical Engineering of Rajasthan Technical University, Kota

Submitted to:Mrs. Bhavana Mathur (Head of Department)

Submitted by:Vikas Kumar Chhimpa (B.Tech, 7th Semester)

Global Institute of Technology, Jaipur ITS-1, IT PARK, Sitapura, Jaipur-302022 (Accredited with A grade by NAAC-UGC)

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ACKNOWLEDGEMENT
Only until you've climbed the mountain can you look behind you and see the vast distance that you've covered, and remember those you've met along the way who made made your trek a little easier . Now that this book is finally finished after the many miles of weary travel, I look back to those who helped me turn it into a reality and offer my heartfelt thanks: To my lecturers , friends and employees of SSTPP for their contribution in completing of my training and preparation of project report successfully. A special valuable asset was the expect lecture delivered by all those engineers who are working in the plant control room. I am also grateful to safety department for the safety training that helped me to get safe in the plant. I am grateful to HR department for the assistance they provided me for my training. I hope this training, which is the fruit of long dedicated hours of efforts & consistent dedication, will be also be appreciated. No work can be perfect. I would like to express my deep gratitude & heartiest thanks to my Head of the Department Mrs. Bhavana Mathur & my respective Senior Faculty Member of the Department & my guiders Mr. Surenra Kumar & Mr. G.D. Sharama who inspired me with the spirit to work upon challenging field, which has its inspection in such a time when there is a fire need for new orientation.

Seminar guides: Mr. Madhvendra Saxena Mr. Naween Jha

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TABLE OF CONTENT

Seri al No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14

Chapter

Page no.

PREFACE ABOUT PLANT SSTPS ELETRICITY GENERRATION TURBINE LUBRICATION OIL SYSTEM BOILER BOILER FEED WATER CYCLE WATER TREATMENT PLANT CONDESTE SYSTEM COAL HANDLING PLANT ASH HANDLING PLANT CONCLUSION REFERENCE

4 5 6 7 9 13 14 19 21 24 28 34 38 39

PREFACE

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As engineers are only confined to theoretical knowledge, the practical training helps as engineers to enhance their knowledge in practical knowledge. I took my practical training at Suratgarh Super Thermal Power Station and learnt that how electricity is generated. The objective of writing this report is to make reader familiar with the generation of electrical power and the all basic operations involved in it, also to make reader understand various parts of the plant, the boilers, turbo generators, transformers, coal and ash handling and various types of auxiliary equipments. I would continue to welcome, in future also the advice and suggestions for improving the text as well as its usefulness to the readers of this report.

ABOUT PLANT

A thermal power station is a power plant in which the prime mover 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 4 G.I.T. JAIPUR

fuel sources. Some prefer to use the term energy center because such facilities convert forms of heat energy into electricity. Some thermal power plants also deliver heat energy for industrial purposes, for district heating, or for desalination of water as well as delivering electrical power. A large part of human CO2 emissions comes from fossil fueled thermal power plants; efforts to reduce these outputs are various and widespread.

Installed capacity

.
Stage Stage I Stage I Stage II Stage II Stage III Stage IV Unit Number Installed Capacity (MW) Date of Comisioning Status 1 250 May, 1998 Running 2 250 March, 2000 Running 3 250 October, 2001 Running 4 250 March, 2002 Running 5 250 June, 2003 Running 6 250 March, 2009 Running

ABOUT SSTPS PLANT

INSTALLED CAPACITY 5 G.I.T. JAIPUR

1500 MW (6*250)

LOCATION

27 KSOUTHEASTOF SURATGARH 5020 (BIGHA) 3810 (BIGHA) 431 (BIGHA) 425 (BIGHA) 60 (METERS) 220 (METERS) 8.5 (METER) 1.6 KM

TOTAL LAND ACQURED PLANT AREA COLONY AREA RAILWAY SITE HEIGHT OF BOILER HEIGHT OF CHIMNEY FOUNDATION DEPTH LENGTH OF INTAKE CANAL (Indira Gandhi Canal)

ELECTRICITY GENERATION AT SSTPS

Super Thermal Power Station burns the fuel and use the heat to raise the steam, which drives the turbogenerator. The fuel may be Fossil (Coal Oil Natural Gas) whichever fuel is used object is same, to 6 G.I.T. JAIPUR

convert to heat in to mechanical energy then to electrical energy by rotating a magnet inside the set of winding. In a coal fired Super Thermal Power Station other raw materials are air and water. The coal is brought to station by trains or other means travels from the coal handling system. By conveyer belts to coal bunkers from where it is fed to pulverizing mills. Mills grind it fine as face powder. Then powdered coal mixed with preheated air is blown into boiler by a fan known as primary air fan(PA Fan). When it burns more like a gas as solid in conventional domestic or industrial grate with additional amount of air called secondary air supplied by Forced Draft Fan. As the coal has been grinded so resultant ash is also as fine as powder. Some of its fine particle binds together to form lumps, which fall into the ash pit at the bottom of furnace. The water quenched ash from the bottom of furnace is carried out boiler to pit for subsequent disposal. Most of ash still in fine particles form is carried out to Electro Static Precipitators where it is trapped by electrodes charged with high voltage electricity. The dust is then conveyed to the disposal area or to bunkers for sale. Now after passing through ESP flue gases discharged up to chimney by Induced Draft Fans.

Meanwhile kilometers long tubes have absorbed the heat reloaded from the coal, which lie in boiler walls inside the tubes Boiler Feed Water which is transferred into turbine blades and rotate them . To the end of turbine, rotor of generator is coupled, so that when the turbine rotates the rotor turns with it. The rotor is housed inside the stator having coil of copper bars in which electricity is produced through the movement of magnetic field created by rotor. The electricity passes from the stator winding to the transformer, which steps up the voltage so that it can be transmitted effectively over the power line of grid.

The steam, which has given up its heat energy in, changed back into a condenser so that it is ready for reuse. The cold water is continuously pumped in condenser. The steam passing around the tubes losses heat and changes into water. But these two types of water (boiler feed water and cooling water) must never mix together. The cooling water is drawn from the river but the Boiler Feed Water must be pure than the portable water (DM Water).

PLANT OVERVIEW

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TURBINE
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STEAM TURBINE
INTRODUCTION
Turbine is a machine in which a shaft is rotated steadily by impact or reaction of current or steam of working substance (steam, air, water, gases etc.) up on blades of wheel. It converts the potential or 9 G.I.T. JAIPUR

kinetic energy of the working substance into mechanical power by virtue of dynamic action of working substance. When the working substance is steam it is called the steam turbine.

PRINCIPLE OF OPERATION OF STEAM TURBINE :

Working of the steam turbine wholly depends upon the dynamic action of steam. The steam is caused to fall in pressure in a passage of nozzle due to this fall in pressure a certain amount of heat energy is converted into mechanical and then to kinetic energy and the steam is set moving with a greater velocity. The rapidly moving particles of steam, enter the moving part of turbine and here suffer a change in direction of motion which gives rose to change of momentum and therefore to a force. This constitutes the driving force of the machine. The processor of expansion and direction changing may occur once or a number of times in succession and may be carried out with difference of detail. The passage of steam through moving part of the commonly called the blade is equal to that at the inlet inside. Such a turbine is broadly termed as impulse turbine. On the other hand the pressure of the steam at the outlet from the moving blade may be less than that at the inlet side of the blades. The drop in pressure suffered by the steam during its flow through the moving causes a further generation of kinetic energy within the blades and adds to the propelling force which is applied to the turbine rotor. Such a turbine is broadly termed as impulse reaction turbine . The majority of the steam turbine have therefore two important elements or sets of such elements. These are the nozzle in which the system expands from high pressure and a state of comparative rest to a lower pressure and a status of comparatively rapid motion. The blade or deflector, in which the steam particle changes its directions and hence its momentum changes. The blades are attach to the rotating elements are attached to the stationary part of the turbine which is usually termed as The Stator, Casing or Cylinder. Although the fundamental particles on which all steam turbine operate the same, yet the methods where by these principles carried into effect very end as a result, certain types of turbine have come into existence. Simple Impulse Steam Turbine. Pressure Compounded Impulse Turbine. Simple Velocity Compounded Impulse Turbine. Pressure-Velocity Compounded Turbine. Pure Reaction Turbine. Impulse Reaction Turbine.

1) Steam flow :
250 MW steam turbine is a tandem compound machine with HP, IP and LP parts. The HP part is single flow cylinder, IP & LP parts are double flow cylinders. The individual turbine rotors and generator rotors are rigidly coupled. The HP cylinder has a throttle control. Main steam is admitted before blending by two combined and main stop & control valves. The HP turbine exhaust (CRH) leading to reheated have low swing check valves that prevent back flow of hot steam from reheated into HP turbine. The steam coming from reheated called HRH is passed to turbine via. Two combined stop and control valves. The IP turbine exhausts directly goes to LP turbine by cross ground pipes. 10 G.I.T. JAIPUR

2) HP Turbine :
The HP casing is a barrel type casing without axial joint. Because of its rotation symmetry the barrel type casing remain constant in shape and leak proof during quick change in temperature. The inner casing too is cylindrical in shape as horizontal joint flange are relieved by higher pressure arising outside and this can kept small. Due to this reason barrel type casing are especially suitable for quick start up and loading. The HP turbine consists of 25 reaction stages. The moving and stationary blades are inserted into appropriate shapes into inner casing and the shaft to reduce leakage losses at blade tips.

3) IP Turbine :
The IP part of turbine is of double flow construction. The casing of IP turbine is split horizontally and is of double shell construction. The double flow inner casing is supported kinematically in outer casing. The steam from HP turbine after reheating enters the inner casing from above and below through two inlet nozzles. The center flow compensate the axial thrust and prevent the L.P. & H.P. rotor are connected to the rigid compiling & they have a common bearing. After passing through I.P. turbine, the steam enter the middle part of L.P. turbine through two cross pipes.

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LUBRICATING OIL SYSTEM

A lubricantis a substance introduced to reduce friction between moving surfaces. It may also have the function of transporting foreign particles and of distributing heat. The property of reducing friction is known as lubricity. Steam inlet temperature affecting brackets, bearings etc. The arrangements of inner casing confines high steam inlet condition to admission branch of casing, while the joints of outer casing is subjected only to lower pressure and temperature at the exhaust of inner casing. The pressure in outer casing relieves the joint of inner casing so that this joint is to be sealed only against resulting differential pressure. The IP turbine consist of 20 reaction stages. The moving and stationary blades are inserted in appropriately shaped grooves in shaft and inner casing. inner casing consist of outer shell with provision of free Super Thermal movement. Steam admitted to the LP turbine from IP turbine flows into the inner casing from both sides through steam inlet nozzle.

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BOILER
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BOILER

INTRODUCTION :

The utility boilers are large capacity steam generators used purely for the steam power generation. In boiler heat energy is released from the combustion of fossil fuel and heat is transferred to different fluids in the system and a parts of it is lost or left out as unutilized. It is therefore essential to study the general principle of heat transfer for understanding the design as well as the behavior of boiler during condition of operation .

HEAT TRANSFER MODES :

There are three modes of heat transfer viz. conduction, convection and radiation, one or more of these modes for which heat source should be at higher temperature than the receiver transfers heat energy hot surface to a heat recover. a) Conduction : Conduction is the heat transfer from one part of the body top another part of the same body or from one body to another in physical contact without appreciable displacement of the particles of the body. b) Convection : 14 G.I.T. JAIPUR

Convection is the heat transfer from one point to another within a fluid by mixing one part with another due to the movement of the fluid. When the movement of the fluid is caused solely by the differences in density resulting from temperature differences within the fluid. c) Radiation : Radiation is the transfer of heat energy from one body to another by electromagnetic waves which can travel even through vacuum when radiations impinges on the body, some of the radiant energy is re-radiated, some of it will be transmitted through the body and remainder will be absorbed.

Heat Transfer Surface Arrangement :

There are three general kinds of arrangements of heat transfer surfaces as the relative flow of fluid in concern. They are paralleled flow, counter flow and cross flow. In parallel flow both the fluids enter at the same relative physical location with respect to heat transfer surface, Resulting rapid rise in temperature. In counter flow, the two fluids enter at opposite ends of the heat transfer surface and flow in opposite direction over the surface resulting sudden rise in temperature. In cross flow the flow paths of the two fluids are perpendicular to each other resulting gradual rise in temperature. Heat Transfer Section : The various heat transfer section of a boiler can be grouped as follows :-

Furnace :The furnace design influenced by the fuel, surface, plain area (13.8610.59) volumetric (5470 m 3) and burner clearance. The major fuels used in the steam generation are coal, oil and gas.

Super Heater & Re-heater :The location of super thermal and re-heat is almost standard based on the past experience. Typical arrangement of super heater and re-heater is indicated in the elevation drawing.

Economizer :This is also convection heat transfer section located in a relatively cooler gas temperature zone and preheats the water entering the drum. The inlet temperature should not be less than 140C from the low temperature corrosion point of view. The outlet temperature should be 35-40C lower than the saturation point to avoid the streaming tendency in the economizers. 15 G.I.T. JAIPUR

Air Heaters :The technical developments of the air pre-heater provides regenerative type air heaters. The air temperature required for drying in the case of coal fired boiler decided the size of heaters.

Material Selection For Heat Transfer Surfaces :

The selections of the heat transfer surfaces are being done on the basis of the temperature of the mid metal temperature as well as the outer surface temperature complete water wall system is provided with only carbon steel where as super heater and re-heater are provided with whereas grades of ASTM specification.

Circulation System :
In natural circular system, water delivered to steam generator from feed heater which are at a temperature well below the saturation value corresponding to that pressure. Entering the economizer, it is heated to much greater the saturation temperature. From economizer the water enter the drum and thus joins the circulation system through down covering water wall tubes. In water wall tubes a part of the water is converted to steam due to boiler and the mixture flows back to the drum on the basis of the thermo siphon principle. In drum, The steam is separated out through the steam separators and passed to the super heaters. After the super heater when the temperature becomes high and pressure up to 150 Kg. Steam is allowed to enter the turbine to convert potential energy to kinetic energy. 147.5Kg/ Cm2 CM C 158.6Kg/ Cm2 3000r pm 195M W 50 Hz

BOILER DRUM TECHNICAL SPECIFICATION OF BOILER (250 MW UNITS) 16 Type Number of units : Direct fired, natural Circulation balance draught water tube boiler. : 2

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Make Capacity Steam pressure Efficiency Number of fans in service: ID fans FD fans PA fans Seal sir fan Scanner air fan Igniter fan Steam temperature No. of coal mills in device No. of soot blowers

: : : :

BHEL 375 tons per hour 139 Kg/Cm2 86.6%

: : :

: 2 Nos. : 2 Nos. : 2 Nos. : 1 No. : 1 No. : 1 No. 540C. 3 Nos. 70 Nos.

FUEL :

A) COAL : Type Quantity consumed Type of handling Ash disposal B)

: : : :

Slack coal 3074 tons per day. conveyer Wet system

OIL :
Type Quantity : HSD and fuel oil : a) HSD 5520 KL per year. b)Furnace oil:2880 KL per year. : : 1/2 : 180 m. 3 198m /sec

No. of chimney / stack Height of chimney Volume of gas Air emitted. Temperature of flue gas ESP

: 140C One for each unit.

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HIGH PRESSURE HEATER

GENERAL DESCRIPTION : Boilers are tangentially fired, balance draft, natural circulation, radiant type, dry bottom with direct fired pulverizing coal from blow mills. They are designed for burning low grade coal with high ash content. Oil burners are located between coal burners for flame stabilizations. Pulverized coal is directly fed from the coal mills to the burners at the four corners of the furnace through coal pipes. The pulverized fuel pipes from the mills to the bunkers are provided with the basalt lined bends to reduce erosion and to improve the life of these pipes. For the last stage of heat recoveries there are two regenerative air heater of trisected type. The air heater has separate section for heating the primary air (required for pulverize) & the section secondary air (required for the combustion process).

BOILER FEED WATER CYCLE

The fuel preparation section consists of primary for number bowl mill arranged for pressurized operation. Each mill has its own raw coal from each mill is carried through pipes to the burner to the burner to the four corners of furnace arranged for tiling tangentially arranged for firing. The burner wind-box section is located in four corner of the furnace owing to poor grade of coal there is a percentage of mill rejects. The mill rejects are conveyed in a sluice way to an under-ground tank. From this tank the mixture is taken to the overheads hydro-bin where water is decanted and the mill reject are disposed off by trucking. ESP with collection efficiency of 99.8% have been provided to reduce environmental pollution and to minimize induce draft fan wear. A multi-flue reinforced concrete stack with two internal flues has been provided 18 G.I.T. JAIPUR

Two boiler feed pumps each of 100% capacity are driven by AC motor through hydrogen coupling with scoop tube arrangement for regulating feed water pressure for each unit. The air required air combustion is supplied by two forced draft fans. Due to anticipated high abrasion of ID fans impellers. Three ID fans each of 60% capacity have been provided one ID fan to serve as standby. For ensuring safe operation of boilers, furnace safe guard supervisory system (FSS) of combustion engineering USA designed has been installed. This equipment symmetrically feed fuel to the furnace as per load requirement.

The UV flame scanners installed at two elevation in each of the four corners of the furnace, scan the flame conditions and in case of unsafe working conditions but out fuel and trip the boiler and consequently the turbine. Turbine-boiler interlocks safe guarding the boiler against possibility furnace explosion owing to flame failure. Facilities have been provided to simultaneously unload and transfer 10 light oil and 40 heavy oil tankers to the designated tanks. Oil preheating arrangement is provided on the tanks floors for the heavy oil tankers to the designated tanks. Oil preheating arrangement is provided on the tanks floors for the heavy oil tanks. Superheated steam temperature is controlled by attemperation. Re-heater steam temperature is primarily by tilting fuel burners through 30C and further control if necessary is done by attemperation.

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WATER TREATMENT PLANT

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WATER TREATMENT PLANT

The principle problem in high-pressure boiler is to control corrosion and steam quality. Internal corrosion costs power station crores of rupees in repair without strict control impurities in steam also form deposit over turbine blades and nozzles. The impurities present in water are as follows: Un-dissolved and suspended solid materials. Dissolved salts and minerals. Dissolved gases. Other materials (oil, acids etc.) Turbidity and Sediment. Silica. Micro Biological. Sodium and Potassium salt. Dissolved Sales Minerals. O2 gas. CO2 gas.

D.M. PLANT :-

In this plant process water is fed from all these dissolved salts. Equipment for demineralization cum softening plant is supplied and is erected by M/s. Wanson (India) Ltd., Pune. This plant consists of two streams, each stream with activated carbon filter, weak acid, cation exchanger mixed bed exchanger. The filter water to DM plant through 250 dia. Headers from where a heater top off has been taken to softening plant. Two filtered water boosters pumps are provided on filtered water line for meeting the pressure requirement in DM plant. Sodium Sulphate solution of required strength is dosed into different filtered water by means of dosing pump to neutralize chlorine prior to activated carbon filter. When water passed an activated carbon filter will remove residual chlorine from water. Provision is made for back washing the activated carbon filter the works acid cation unit. The deception water the weak base anion exchanger unit 21 G.I.T. JAIPUR

water than enters de-gasified unit where free CO2 is scrubbed out of water by upward counter flow of low primary air flow through degasified lower and degassed water is pumped to strong base exchanger (anion exchanger). Arrangement for dosing ammonia solution into de-mineralized water after mixed bed unit has been provided p+1 correction before water is taken into decondensate transfer pumps the DM water to unit condenser as make up. The softening plant is designed to produce 100m 3 of the softened water per stream. It is used for bearing cooling.

C.W. PLANT :
Circulating water pump house has pumps for condensing the steam for condenser. Five pump are used for condensing unit no. 1 & 2 and after condensing this water is discharged back into the river.

Each pump has the capacity of 8275 m3/hr, and develops pressure about 1.94Kg/Cm2. Three seal water pump are used for sealing circulating water pump shaft at 4.5Kg/Cm2. Two pump for unit 1 & 2 with one stand by is used for supplying raw water to chlorified chemical dosing is done between and chlorified water is taken through main line. From main line water passes through filter bed to filter the water. Chlorified water is pumped to 42m elevation by two pumps of capacity 270m 3/inch at discharge pressure of 6.9Kg/Cm2. At 42m elevation the water is stored in tank and used for cooling the oil coolers and returned back to river. Oil coolers are situated on ground and there are no. of trees for each unit.

B.C.W. PUMP HOUSE :-

Filter water after demineralization is used for bearing cooling from BCW pump house after passing through strainer and heat exchanger it returns at 30-25C and leave exchanger at 38C. The raw water used in ash handling plant and remaining quantity is stored in slump of BCW pump house . From here the water is pumped to CW pump by TWS (Traveling Water Screens) pumps are run by motor of 90 KW and has a capacity of 240 Cum/hr/pump at a pressure of 5Kg/Cm2. BCW here stand for water used for cooling oil used for cooling the bearing. In CW pump house water is discharged from nozzle and impinged for traveling water screens for cleaning it. 22 G.I.T. JAIPUR

CONDENSATE SYSTEM

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CONDENSATE SYSTEM
A typical condensate system consists of the following: Condenser (including hot well). Condensate pumps. Air extraction system. Gland coolers and LP Heaters. Dearator.

Condenser
The functions of condenser are: To provide lowest economic heat rejection temperature for the steam. Thus saving on steam required per unit of electricity. To convert exhaust steam to water for reuse thus saving on feed water requirement. dearation of make up water introduce in the condenser. To form a convenient point for introducing makes up water.

Type of Condenser
Condenser is basically a heat exchanger and hence can be of two types; Direct Contact Type, Surface Contact Type.

In this type, condensation of steam takes place by directly mixing exhaust steam and cooling water. Requirement of cooling water is much less as compared to surface type. But cooling water should be equal to condensate quality.

Direct Contact Type (Jet Condenser)

Surface Contact Type

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This type is generally used for modern steam turbine installation. Condensation of exhaust steam takes place on the outer surface of the tubes. Which are cooled by water flowing inside them. The condenser essentially consists of a shell which encloses the steam space. Tubes curving cooling water pass through the steam space. The tubes are supplied cooling water from inlet water box on one side and discharged after taking away heat from the steam, to the water outlet box on other side. Instead of one inlet and one outlet water boxes, there may be two or more pair of separate inlet, outlet water boxes, Each supplying cooling water to separate bundle of tubes. This enable cleaning and maintenance of part of tubes by turbines can be kept running on a reduced load.

Condensate extraction pumps are normally multistage, vertical, centrifugal pumps. They are generally required to operate on minimum Net Positive Suction Head (NPSH). The condensate pumps operate on few inches of suction submergence. A vent line connects the hot well, from the condensate pumps take suction with the condenser. This equalizes the vapour pressure of condenser and hot well. Number of stages in the pump is determine by the discharges pressure required for the condensate cycle in 110 MW unit. Three condensate pumps, each having 50% capacity, are provided for pumping the condensate to dearator. Condensate water is also used for: Sealing of glands of valves operating under vacuum. Temperature control of L.P. by pass system. Falling siphons of main ejector and 15 m siphon of drain expander. Actuating the force closing non-return waves of turbine steam extraction lines. Operating of group protection device for bypassing H.P. heaters. For cooling steam dumped through steam throw off device. Air extraction system is needed to extract air and non-condensable gases from the condenser for maintaining vacuum. Amount of air to be extracted from condenser during start up is quite large and extraction should be done as rapidly as possible so as to allow the turbine to be started. To guard against excessive water vapour extraction along with air, the space beneath the air extraction baffles has been provided with its own cooling tubes in order to condense as much water vapour as possible and thus preventing its removal from condenser.

CONDENSATE EXTRACTION PUMPS

AIR EXTRACTION SYSTEM

LOW PRESSURE HEATERS

The low pressure heater is of horizontal surface type consisting of two valves, each half has been located inside the upper part of each

The housing for the heater is fabricated from the M.S. plates with suitable steam inlet and drain connections. The tube plate is of mild steel and is secured to the water box and housing by means of studs and nuts. U shaped tubes have been used to ensure independent expansion of tubes and the shells. They are of solid drawn admiralty brass, 19mm external dia., 1mm and 0.75mm thick and are expanded by rolling into the tube plate at facilitate drawl for tube replacement and maintenance. Partitions mild steel plates have been provided for supporting the tubes at intermediate points and effective distribution of heat load all the zones of heater. 25 G.I.T. JAIPUR

It cools the steam mixture sucked from turbine and seals. It is of vertical type and has two sections. An ejector mounted on the cooler maintains constant vacuum in the first section. It also sucks the remaining air-steam mixture from first section to second where air is let off and steam is condensed. A part of main condensate, after main ejector, flows through the cooler tubes consisting of U-shaped brass tubes rolled in steel tube plate. Drain from cooler is led to condenser.

GLAND STEAM COOLER

GLAND COOLER

Gland cooler has been designed to condensate the leak off steam from intermediate chambers of end earthing of HP & IP turbines. The construction of this cooler is identical with low pressure heater no. 2,3 & 4. The main condensate flows through the tubes in four paths before leaving the cooler. The deal off steam enters the shell through a pipe and flow over the tube nest. The participation wall installed in the tube system lead to zigzag flow of steam over the tube nest. Condensate of leak off steam referred as drain trickles down the tube and is taken out from the lower portion of the shell by automatic level control valve, installed on the drain line.

The pressure of certain gases like Oxygen, Carbon Dioxide and Ammonia, dissolved in water is harmful because of their corrosive attack on metals, particularly at elevated temperatures. Thus in modern high pressure boiler, to prevent internal corrosion the feed water should be free as far as practicable of the dissolve gases, especially Oxygen. This is achieved by embodying into the freed system a deareating unit. Apart from this, a dearator also serves the following functions: Heating incoming feeder. To act as a reservoir to provide a sudden or instantaneous demand.

DEAERATOR

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COAL HANDLING PLANT

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COAL HANDLING PLANT

INTRODUCTION :

It can be called as the heart of Super Thermal Power Plant because it provides the main fuel for combustion in boiler. The coal is brought to the SSTPS through rails. There are fourteen tracks in all for transportation of coal through rails. The main coal sources for SSTPS are SECL (South Eastern Coalfields Limited), ECL (Eastern Coalfields Limited) and BCCL (Bharat Coking Coal Limited). Everyday 3 to 4 trains of coal are unloaded at SSTPS. Each train consist of 58 wagons and each wagon consist of 50 tons of coal. The approximate per day consumption at SSTPS is about 1400 metric tons. It costs approximately 2 crores of rupees per day including transportation expenses. The coal is firstly unloaded from wagon by wagon Tripler then crushed by crushers and magnetic pulley and pulverized to be transformed to the boiler. The whole transportation of coal is through conveyor belt operated by 3- Induction Motor. The coal handling plant can be broadly divided in three sections: Wagon Unloading System Crushing System. Conveying System.

WAGON UNLOADING SYSTEM :

Wagon Tripler :
It unloads the coal from wagon to hooper. The hooper, which is made up of Iron, is in the form of net so that coal pieces of only equal to and less than 200 mm. size pass through it. The workers with the help of hammers break the bigger ones. From the hooper coal pieces fall on the vibrator. 28 G.I.T. JAIPUR

It is a mechanical system having two rollers each at its end. The rollers roll with the help of a rope moving on pulley operated by a slip ring induction motor with specification: Rated output voltage : 71 KW. Rated Voltage : 415 V. Rated Current : 14.22 Amp. No. of Phases : 3. Frequency : 50 Hz. The four rollers place themselves respectively behind the first and last pair of wheels of the wagon. When the motor operates, the rollers roll in forward direction moving the wagon towards the wagon table. On the Wagon table a limit is specified in each wagon has to be kept otherwise the triple would not be achieved.

CRUSHING SYSTEM :

Crusher House :
It consist of crusher, which are used to crush the coal to 20 mm size. There are mainly two types of crushers working in SSTPS :Primary Crushers i.e. Rail crushers Secondary Crushers i.e. Ring granulators.

Primary Crushers :
Primary crushers are provided only in CHP stage 3 system, which breaking of coal in CHO Stage-1 & Stage-2 system is done at wagon Tripler hooper jail up to the size of (-) 25 mm.

Roll Crushers :
Type Capacity Feed material End product size Feed size Motor rating Crushers : : : : : : : 80, 5 A breaker. 1350 TPH Rates/1500 TPH Design. Rom coal. (-) 500 mm. (-) 1200 mm. 2 Nos. 125 KW, 100rpm. 225.

Rotatory Breaker :
29 Type Capacity Feed Material Feed size : : : : 1221 Rotary Breaker. 800 TPH Rated/1000 TPH Design. Coal with rejects. (-)0-500 mm.

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End product size Motor Rating Breaker rpm

: : :

(-)0-200 mm. 125 HP, 1500 rpm. 12.

Secondary Crusher :

Basically there are four ways to reduce material size

: impact attrition, : shearing and : compression. Most of the crushers employ a combination of three crushing methods. Ring granulators crush by compression accompanied by impact and shearing. The unique feature of this granulator is the minimum power required for tone for this type of material to be crushed compared to that of other type of crushers.

Construction & Operation :

Secondary crushers are ring type granulators crushing at the rate of 550TPH / 750 TPH for input size of 250 mm and output size of 20 mm. The crusher is coupled with motor and gear box by fluid coupling. Main parts of granulator like break plates, cages, crushing rings and other internal parts are made of tough Manganese (Mn) steel. The rotor consists of four rows of crushing rings each set having 20 nos. of toothed rings and 18 nos. of plain rings. In CHP Stage 1 & 2 having 64 nos. of ring hammers. These rows are hung on a pair of suspension shaft mounted on rotor discs.

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Coal Handling Plant

In coal handling plant a mass holding yard has been provided to receive the coal trains and unloading them. The wagons are positioned on the wagon Tripler with the help of wagon handling gear. Two wagon Tripler remain standing by having a capacity to handle 12 box of wagons per hour. Coal from wagon Tripler is discharged into two underground hooper is transferred by the two belt feeders to either of the conveyers of 675 tons per hour capacity either of the conveyers to take coal directly to the crusher house. Crushers of this type employ the centrifugal force of swinging rings stroking the coal to produce the crushing action. The coal is admitted at the top and the rings strokes the coal downward. The coal discharges through grating at the bottom. The spacing of the bar determines the maximum size of the finished product. CONVEYING SYSTEM :

Stacker Re-claimer :

The stacker re-claimer unit can stack the material on to the pipe and reclaim the stack filled material and fed on to the main line conveyer. While stacking material is being fed from the main line conveyor via Tripler unit and vibrating feeder on the intermediate conveyer which feds the boom conveyer of the stacker cum re-claimer. During reclaiming the material discharged on to the conveyer by the bucket fitted to the bucket wheel body and boom conveyer feeds the material on the main line conveyer running in the reverse direction.

Conveyer Belt Specification Of Stacker Re-claimer :

Belt width Speed Schedule of Motor Bucket Wheel Motor Boom Conveyor Motor Intermediate Conveyor Motor: Boom Housing Motor Slewing assembly Travel motor Vibrating Feeder Total installed power : : : : : : : : : : : 1400 mm. 2.2 m/sec. All 3- induction motor. 90 KW. 70 KW. 90 KW. 22 KW. 10 KW. 7.5 KW. 26 KW. 360 KW.

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Conveyer Specifications :
. Capacity No. of conveyer Horizontal length Angle of induction Lift (M) (approx) Belt width : : : : : : 1)1350 T/H. 2)750 T/H. 38. 28 m. As per conveyor profile drg. Variable to suit the system. 1400 mm

Flow Feeders :
This structure is erected to serve the purpose of storage. Under ground machines are installed known as plow feeder machines. These machines collect the coal from conveyor and drop it to the other from one conveyor with the help of jaws and this coal is taken to huge erected structure from where the coal falls to the ground. Jali chutes are used to prevent the dust.

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ASH HANDLING PLANT

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ASH HANDLING PLANT

This plant can be divided into three sub-plants as follows : Fuel and Ash Plant. Air and Gas Plant. Ash Disposal and Dust Collection Plant. Fuel and Ash Plant : Coal is used as combustion material in SSTPS, in order to get an efficient utilization of coal mills. The Pulverization also increases the overall efficiency and flexibility of boilers. However for light up and with stand static load, oil burners are also used. Ash produced as the result of combustion of coal is connected and removed by ash handling plant. Ash Handling Plant at SSTPS consists of specially designed bottom ash and fly ash in electro-static precipitator economizer and pre-heaters hooper. Air and Gas Plant : Air from atmosphere is supplied to combustion chamber of boiler through the action of forced draft fan. In SSTPS, there are two FD fans and three ID fans available for draft system per unit. The air before being supplied to the boiler passes through pre-heater where the flue gases heat it. The pre-heating of primary air causes improved and intensified combustion of coal. The flue gases formed due to combustion of coal first passes round the boiler tubes and then it passes through the super heater and then through economizer. In re-heater the temperature of the steam (CRH) coming from the HP turbines heated with increasing the number of steps of re-heater the efficiency of cycle also increases. In economizer the heat of flue gases after passing through the ElectroStatic Precipitator is exhausted through chimney. Ash Disposal and Dust Collection Plant : SSTPS has dry bottom furnace. Ash Handling Plant consist of especially designed bottom and fly ash system for two-path boiler. The system for both units is identical and following description is applied to both the units of water compounded bottom ash hooper receives the bottom ash from the furnace from where it is stored and discharged through the clinker grinder. Two slurry pumps are provided which is common to both units and used to make slurry and further transportation to ash dyke through pipeline. Dry free fly ash is collected in two number of 31 fly ash hooper, which are handled by two independent flu ash system. The ash is removed from fly ash hooper in dry state is carried out to the collecting equipment where it is mixed with water and resulting slurry sump is discharged.

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ELECTROSTATIC PRECIPITATOR

Scope and Principle of Operation :

For general mankind, today an Eco-friendly industry is must. As far as air pollution is concerned now a days various flue gases filter are there in services. The choice depends on size of suspended particle matter. These filters are E.S.P. Fabric filter high efficiency cyclone separation and sideling room. For fly ash where the size of particle vary from 0.75 microns to 100 micron use gradually ESP to purify the flue gases due to its higher efficiency and low running cost etc. In an ESP the dust lidded gas is passed through an intense electric field, which causes ionization of the gases and they changed into ion while traveling towards opposite charged electrode get deposited as particles and thus the dust is electrically deposited on electrode creating a field. It is continuous process.

CONTROLLER :

Now a days microprocessor based intelligent controllers are used to regulate the power fed to HVR. The controls the firing/ignition angle of Thyristors connected in parallel mode. Input out waves of the controller and HRV are also shown above, which clearly indicates that average power fed to ESP field can be controlled by variation of the firing angle of Thyristors. The output of controller with respect to time is also controlled by microprocessor so that ESP operation is smooth and efficient. The chars is as shown: As can be seen in the event of spark between electrodes the output of controller is reduced to zero or few millisecond for quenching the spark. Controller also takes place care of fault in KVR and gives a trapping and non-trapping alarm as per the nature of fault. HIGH VOLTAGE RECTIFIER TRANSFORMER : HVR receives the regulated supply from controller. It steps up to high voltage rectifier. The DC supply is fed to ESP field through its negative bushing. The positive bushing so connected to earth through small resistance, which forms a current, feed back circuit. A very high resistance column is also connected with negative bushing. It forms the voltage feed back circuit. These two feedbacks are used in the controller for indication and control purpose.

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ASH SLURRY SUMP

Mechanical precipitators consists of number of primary cells having vanes to impart the ash particles and coarse ash particles fall into the primary hooper. The ESP consists of a large number in which have no collecting electrodes. In it dust particles are charged and stick to the electrodes.

E.S.P. FIELD :

The field consist of emitting and collecting electrodes structure, which are totally isolated with each other and hanging with the top roof of field. The emitting is also isolated from the roof through the support insulators, which are supporting the emitting electrode frame works, and also the supply to these electrodes is fed through support insulators. The collecting electrodes are of the shape of plates. By several similar plates which the emitting electrode are of the shape of spring. Strong on the emitting frame work with the help of hooks in both the ends. The ash depositing on these electrode is rapped down by separate wrapping mechanism happens at the bottom of the field. From these hooper ash is evacuated by ash handling system and dispose to the disposal area. The wrapping system is automatically controlled with the help of programmable metal controller, located in the ESP auxiliaries control panels. The bottom of hooper is heated up by to avoid any information to wet mass of fly ash especially during rainy season. The heating effect helps the dry ash to flow freely during evacuation. Heaters are controlled with the help of thermostat.

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CONCLUSION

The first phase of practical training has proved to be a fruitful. It provides an opportunity for encounter with such huge machines like Wagon Tripler, 250MW Turbines and Generators. The architecture of the Power Plant, the way various units are linked and the way working of whole plant is controlled Make the student realize that engineering is not just learning the structured description and working of various machines, but the greater part is of planning management. It also provides an opportunity to learn how the technology is used at proper place and time can have a lot of labor e.g. Wagon Tripler (CPH). But there are few factors that require special mention. Training is carried out into its tree sprit. It is recommended that there should be some project specially meant for students where presence of authorities should be ensured. There should be strict monitoring of the performance of students and system of grading be improved on the basis of work done. However training has proved to be quite fruitful. It has allowed an opportunity to get an exposure of the practical implementation to theoretical fundamentals.

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REFERENCE

SSTPS. BRELI THERMAL PLANT, BIHAR . NTPC, HARIDWAR. BHEL, HARIDWAR. Power Plant Engineering by Dr. R.Yadav

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