THE REPORT FILE

OF INDUSTRIAL VISIT
AT
WANAKBORI T.P.S.
DATE: 21/10/2013

GUIDEDBY:

SUBMITTED BY:

S.E-I.M.PATEL (TRG)

ANKIT KUMAR

E.E-B.N.JOSHI (TRG)

9th SEMESTER
M.Tech.(DD), EE+EE
Sgvu091123248

DEPARTMENT OF ENERGY ENGINEERING

SURESH GYAN VIHAR UNIVERSITY,

MAHAL, JAGATPURA, JAIPUR

PREFACE

The globe is shrinking. The world is taken over by the technicians. A day after day a new
technology arises. A technicians without practical knowledge is zero, dont matter how many
books you have studied. Practical know how is must to be successful. Industrial visit is the
bridge for a student that takes him from the world of theoretical knowledge to that of practical
one.
Industrial visit in a good sector is highly conductive for:1. Development of solid foundation
of knowledge and personality. 2. Confidence building. 3. Pursuit of excellence and discipline. 4.
Enhancement of creativity through motivation and which helps to produce professional and well
trained for the rigorous of the job/society.

ACKNOWLEDGEMENT
Success is the manifestation of motivation inspiration, diligence, perseverance and
innovation for completion any task triumphantly; it required not only help and support of many
but, also constant source of inspiration. The task of executing the project would not have been
possible without the amount of support that is received by E.E, D.E and J.E of the
WANAKBORI THERMAL POWER PLANT. It therefore task of acknowledging the roll that
each one of them played in encouraging us to learn how things work in government sector like
WANAKBORI THERMAL POWER PLANT even more challenging I hope that we will able to
justice to all of them here.

Submitted by:
Arvind Kumar
sgvu091123250
M.Tech. (DD), EE+EE
5th year, 9th sem.
Sec. B (B1)

CONTENT
Overview..06
1 INTRODUCTION...07
1.1Introduction of Wanakbori TPS..07
1.2 E.H.T. Lines from wanakbori TPS.09
1.3 Thermal power station is consisting of mainly five processes..09
1.4 Coal handling plant.10
1.5 Ash handling.11
1.5.1 Bottom Ash system.11
1.5.2 Fly Ash system11
2 MECHANICAL ASPECT...13
2.1Introduction13
2.1.1 Coal and Ash Circuit.13
2.1.2 Air & Gas Circuit..13
2.1.3 Feed water & steam circuit..13
2.1.4 Cooling water circuit.14
2.2 Boiler...14
2..2.1 Classification of boilers.14
3 BOILER PRESSURE PARTS.17
3.1Introduction.17
3.2 Economizer.17
3.3 Boiler drum.18
3.4 Water wall system..16
3.5 Super heater19
3.6 Re-heater.19
4 STEAM TURBINES..20
4.1 Introduction20
4.2 Dematerialized plant.21
5 ELECTROSTATIC PRECIPITATOR..23
5.1 Introduction23
5.2 Principle of operation23
5.3 Working..24

5.4 Generator...26
5.5 Transformer...27
5.6 Switch yard.28
5.7 Circuit Breaker..29
5.8 Protection29
5.9 Control Room.31
Conclusion.33

OVERVIEW
Gujarat Electricity Board (GEB) was established along with the formation of Gujarat
State in the year 1960 under Section 5 of the Electricity (Supply) Act 1948. Starting with a
generation capacity of 315 MW and a consumer base of 1.40 million consumers, GEB today is
the lifeline for over 7.3 million consumers across the State of Gujarat.
During 1970s and 80s, the major thrust was on the supply of electricity in the rural areas.
It was largely due to GEBs unwavering focus on rural electrification that Gujarat became the
first state to achieve the landmark of 100% Electrification of Villages. As per the 1991 Census,
17,940 villages out of a total of 18,028 have been electrified which is close to 100%.
GEB continues to focus on its key objectives of generation, transmission and equitable
distribution of power to achieve an all-round economic growth of the State. Till date it has
installed 1,72,662 (as on 31-03-2003) transformer centers and in the past four decades its per
capita consumption has increased from 48 KWH (In 1960) to 932 KWH (as on 31-03-2003). For
the development of rural areas in the state, GEBs holistic Rural Electrification Programmer
covers electrification of new villages, conversion of villages electrified through Solar system to
conventional method and supplying power to pump sets, paraphrase (Hamlets) and Harijan
Bastis by availing finance mainly from REC., New Delhi and the State Government. GEB stands
committed to build Gujarat as a power hub of the nation.

CHAPTER-1
INTRODUCTION

1.1 Introduction of Wanakbori TPS

Wanakbori Thermal Power station of GSECL is a ISO 9001 : 2000 Certified Power Station
and will achieve ISO 14001 certification too in nearest future.
Wanakbori TPS is situated 07kms away from Sevalia Railway Station and 11 Kms away from
Balasinor. It is located on the bank of River MAHI SAGAR in Kheda District; A Main Narmada
Canal is also passing beside this Power Station.
There are seven nos. of 210 MW each Unit in this Power Station. Its total installed Capacity is
1470 MW. This Power Station is called a Super Thermal Power Station of Gujarat.
In Stage I, three units each of 210 MW are commissioned by using Russian LMW design Steam
Turbines. Total Cost of these three units was 259.09 crores.
Unit No. 1 : 23rd March, 1982
Unit No. 2 : 15th January, 1983
Unit No. 3 : 15th March, 1984
In Stage II, three units each of 210 MW are commissioned by using West Germany KWU
design Steam Turbines. Total Cost of these three units was 318.18 crores.
Unit No. 4 : 09th March, 1986
Unit No. 5 : 23rd September, 1986
Unit No. 6 : 18th November, 1987
In Stage III, one unit is commissioned by using West Germany KWU design Steam Turbine
and equipped with complete Computer controlled instrumentation. Total Cost of this unit was
528.90 crores.
Unit No. 7 : 31st December, 1998
All these seven units are supplied and commissioned by BHEL.
Wanakbori TPS details are as below.

Installed Capacity : 7 210 = 1470 MWs

Total Area of Project : 1571 Acres
PLF % : Between 84.64 to 91.24
Plant Area : 626.2 ha
Ash Dump Area : 215.7 hector

 Cooling Water Quantity Required : From canal of Mahi River

Cusecs / month

Reservoir 60 to 70

Fuel :

Fuel : Bituminous Coal

Linked Coal Mines : CCL,NCL,SECL,BCCL
From Bihar, Orissa, M.P., West Bangal, Andhra Pradesh
Generally 400 Wagons [ Approx. 07 Racks ] received per day
Record of Unloading Max. Wagons : 690 Wagons / Day
Gross Calorific Value of Coal : 4400 Kcal/Kg
Nos of Wagon Tipplers : 05 Nos.
Coal Quantity Required :
With Design Coal : 16000 MT / Day
With Actual Coal : 18000 to 21000 MT / Day
Storage Capacity: 02 Lacks MT ( Approx.)
Area : 48000 m2
Oil : Light Sulpher Heavy Stroke Oil / Light Diesel Oil

A
B
C
D

6200 & ABOVE

E
3361 TO 4200
5601 TO 6200
F
2401 TO 3360
4941 TO 5600
G
1300 TO 2400
4201 TO 4940 UNGRADE BELOW 1300

Diesel Generators:
05 Nos. of Diesel Generators are provided in DG Set House of Wanakbori TPS for Serious
problems like Cascading & Natural Calamities. Any one DG set can be used for any Unit.
[1] Kirloskar makes for emergency buses of Unit # 1 & 4
[2] Kirloskar makes for emergency buses of Unit # 2 & 5
[3] Kirloskar makes for emergency buses of Unit # 3 & 6
[4] Caterpillar make for emergency bus of Unit # 7
[5] Caterpillar makes for emergency bus of Unit # 7
Other Informations:
[1] Height of Chimneys: Stage I & II 150 Mtrs.
Stage III 220 Mtrs.
[2] Height of Cooling Towers -- 112.5 Mtrs
[3] Height of Boiler Structure -- 64 Mtrs.
[4] Daily Average Consumption of LSHS 35 KL
[5] Daily Average Consumption of LDO 04 KL
[6] Daily Consumption of water for Station 1, 60,000 Cubic Meters
[7] Total Length of Conveyor belts 16.1 Kms.
[8] Wagon Tipplers 05 Nos.

[9] Maximum Wagons Unloaded on {29/01/2001}

611 Nos. -- Say 10.5 Racks
[10] Total Employees 1643 Nos.
[11] Total Quarters in WTPS Colony - 2074 Nos.

1.2 E.H.T. Lines from Wanakbori TPS:

220 KV Lines
Dhansura-1
Dhansura-2
Kpadvanj
Asoj-1
Asoj-2
Ranasan
Godhra

58.70km
58.70km
35.77km
65.50km
65.50km
78.50km
27.10km

400 KV Lines
Soja
Dehgam
Asoj

96km
67km
62km

The under mentioned major power-stations are situated in Gujarat and operate in
interconnection with Gujarat Grid.

OWNED BY GSECL:
OWNED BY LICENCEES :
[1]WANAKBORI TPS
[1] SABARMATI [A.E.Co.]
[2] GANDHINAGAR TPS
[2] VATVA [A.E.Co.].
[3]UKAI TPS
[4]DHUVARAN TPS
[5]SIKKA TPS
[6]PANANDHRO TPS
[7]UKAI HYDRO PS
[8]KADANA HYDRO PS
[9]SARDAR SAROVAR HYDRO PS

1.3 Thermal power station is consisting of mainly five processes.

1. ) Transformation of coal
2. ) Pulverization of coal
3. ) Combustion of coal
4. ) Production of steam
5. ) Generation of electricity

The main purpose of power station is the production of electricity with the highest
efficiency. The efficiency of thermal power station is not highest but from economic point of
view it is suitable for electricity production.
Here, the coal is supplied by the railway to the power plant. This coal is goes for a
crushing. This crushed coal is further pulverized and supplied to boiler

in the boiler the

combustion of the coal takes place and it heat the water and produces steam This steam is heated
further and becomes superheat and goes to turbine. Turbine rotates by high temperature and
pressure steam. The generator is coupled with the turbine and produces electricity. The power
plant is based upon Rankine cycle. The four element of power plant are boiler, turbine,
condenser, and feed pump.

1.4. Coal handling plant

Coal handling plant is a key plant for generation of coal base thermal power station. The
coal handling plant of WANAKBORI TPS is supplied and erected by M/s. Elecon
engg.Co.Ltd.V.V.Nagar the coal wagons from the railway yard are being brought to wagon
trippler tracks by the shutters .Weigh bridges are provided on both the wagon trippler. Wagon is
placed on a trippler hopper and total weight of wagon with coal is first taken. Wagon is then
tippled in the tippler hopper by wagon tippler and after certain predetermine time delay empty
wagon comes down. .
Suspension magnet provided on the belt will pick up the ion coming with the coal and
there by damages to be crusher can be avoided. Along with the coal, stones and wooden pieces
are also coming. These are removing manually. From this belt coal falls into the surge hopper
and from that through gates and vibrator coal feed into the crusher for crushing.
The crushed coal is fed into the pulverized from the bunkers by the feeders which control
the amount of coal to be fed into the boiler depending on the boiler load. In 210 MW units boiler
has seven bowl mills it is major equipment for a pulverized fuel burning system includes sealed
air fans, pulverized mill, feeder, primary air fans and coal piping. In our system known as the
direct fire system.
The operation of the bowl mill is that the coal is fed to the mill fall to the centre of the
revolving bowl, where it is thrown by centrifugal force between the revolving bowl and the
rollers. The pressure of the grinding is imparted to the rollers by spring. The air enters the mill
housing below the bowl and is directed upward past the bowl. The partially pulverized coal is
picked up by the air and is carried into the adjustable classifier where a spinning action is
imparted to the mixer and from that the pulverized coal is fed to the furnace.

1.5 Ash handling

The water impounded bottom ash hopper receives the bottom ash from the furnace, where
it is stored and periodically discharged hydraulically to the clinker grinder and hydro ejector for
transfer through transport line to disposal area.
Dry free flowing fly ash, collected in a total of fifteen fly ash hopper is handed by two
independent fly ash systems. Fly ash is removed from the hopper in the dry state by pneumatic
means and is carried up to an elevated steel tank, where it mixed with water .So that ash slurry is
formed and it is disposed to the disposal area. The ash handling system is generally operated by
two systems.
1. BOTTOM ASH SYSTEM
2. FLY ASH SYSTEM
1.5.1 Bottom ash system:The water filled ash hopper receives furnace ash from boiler, chills it as it enters the
water to minimize clinkering and stores it for periodic removal. The mixture of ash and water is
discharged through an inclined feed gate and clinker grinder, which reduce the size of clinker to
about 50 mm size. Crushed clinker and ash falls through ejector feed pump and is fed to hydro
ejector, which provides the pressurized water to carry the mixture through discharge line to
disposal area.
The clinker grinder is provided with reversing mechanism, if over load occur than it
automatically stops and reverse and a grinder keeps running in reverse direction for a 10sec and
stops. And after 20 sec. the grinder again starts running in the forward direction. In that control
air pressure should be 5 to 7 kg/cm2 and suction water pressure is 0.5 to 0.75 kg/cm2.
1.5.2 Fly ash system:Below each hopper one air electric, self feeding non overloading type material handling
valve is mounted. Each valve has a stainless steel slide gate to sagrate the hopper from the
transport line The water operated hydro vector located above air separator tank on steel tower
exhaust air from the transport line running to the air electric operated material handling valve
located at the bottom of the ESP. the operation of the ESP is based on the principal of the

electrically charged particles being attracted by around plates. The equipment mainly consists of
precipitation chamber in which the suspended particles are electrified and separated from the fuel
gas. In addition it includes high voltage transformer rectifier unit and rappers and vibrates to
dislodge ash particle from the plates and electrodes and collect them in the ash hopper below.
The entering fuel gate ionized and imparts negative charge to the solid particles. These
are attracted towards the +ve plate which is arounded. Rapping plates mechanism provided to
rape the metal plates at periodic interval for removing the collected ash deposit. There are two
number of precipitator per boiler.
Due to the flow of fly ash is convent from this hoper through this hydro vector due to
vacuum. In this hoper fly ash is mixed with water and is discharged through the transport line by
gravity to the disposal area. This two systems are operated time by time when bottom ash system
is operated at that time fly ash system is closed and vice versa.
Being Coal Based Thermal Power Station Ash dyke availability will be the main concerned.
1.
2.
3.

Ash
generated
per
day
(7x210
Total
area of Land
available
for
Additional land acquired. - 110 Acres.

MW)
-7000
to
ash disposal.-About

8000M.T./day.
600 Acres.

CHAPTER-2
MECHANICAL ASPECT
2.1 INTRODUCTION
The general layout of the thermal power plant consists of 4 main. ckts.
1.

Coal & ash circuit

2.

Air & Gas circuit

3.

Feed Water & Steam circuit

4.

Cooling water circuit

Modern thermal power plant using steam as working fluid works basically on the rankine
cycle. Steam is produced in boiler, expanded in prime mover & condensed in condenser and fed
into boiler again. In practice how ever there are numerous modifications and improvement in
cycle so as to affect the heat economy & to increase thermal efficiency of plant.

2.1.1 Coal and Ash circuit:In this circuit, the coal from storage or from crusher house is feet to boiler through belt
conveyor then after the mills in boiler house will makes pulverized fuel required for boiler. Ash
produced as a result of combustion of coal is removed through bottom ash collecting system as
well as fly ash is collected in ESP and bag house collector &, then it is stored and discharged.

2.1.2 Air & Gas Circuit:Air from atmosphere is supplied to combustion chamber of the boiler through the action
of FD and/or ID fans. The air before being supplied to boiler passes through air pre heaters,
where it is heated by flue gases. The dust from air is removed before being supplied to
combustion chamber. The flue gases first passed around the boiler tubes and superheated tubes
in furnace, air pre heaters, through dust collector & then to economizer. Finally they are
exhausted to atmosphere through chimney.

2.1.3 Feed Water & Steam Circuit:The condensate leaving condenser is first heated in closed feed water heater through
extracted stream from lowest pressure extraction point of turbine. This water then passes through
dearater and few more water heater before it goes to boiler through economizer. A small part of
Steam & water (1 to 2 %) is lost in passing through component of system. therefore some feed

water is added in feed water cycle & it is known as make up water.

In the boiler drum & tubes. Water circulates because of difference in density in lower &
higher temperature section of boiler.

Wet stream from drum is further passed through

Superheated & then it is supplied to p rim em over. The Steam after its expansion in H. P turbine
is taken to reheat in boiler Where it is brought to its original dryness & then being passed
allowed to I. P. & then to L.P. turbine. From L.P. turbine the Steam is condensed in condenser
situated below L.P.

2.1.4 Cooling water Circuit:A large quantity of cooling water is required to condenser the team in condenser & in
maintaining a low pressure in it. The open cycle system of cooling water is used. It is generally
taken from deep Sea & discharged nearby Sea shore. If adequate quantity of cooling water is not
available then closed cycle System has to use.

2.2. BOILER
In simple a boiler may be defined as a closed vessel in which steam is produced from water
by combustion of fuel.
According to American Society of Mechanical Engineers (A.S.M.E.) a steam generating
unit is defined as:
A combination of apparatus for producing, furnishing of recovering heat together with the
apparatus for transferring the heat so made available to the fluid being heated and vaporized.
The steam generated is employed for the following purposes:
i) For generating power in steam engines or steam turbines.
ii) In the textile industries for sizing and bleaching etc. and many other industries like
sugar mills; chemical industries.
iii) For heating the buildings in cold weather and for producing hot water for hot water
supply.
The Primary requirements of steam generators of boilers are:
i) The water must be contained safely.
ii) The steam must be safely delivered in desired condition (as regards its pressure,
temperature, quality and required rate).

2.2.1Classification of boilers:
The boilers may be classified as follows:
1. Horizontal, vertical or inclined

If the axis of the boiler is horizontal, the boiler is called as horizontal, if the axis is
vertical, it is called vertical boiler and if the axis is inclined it is known as inclined boiler.
The parts of a horizontal boiler can be inspected and required easily but it occupies more
space. The vertical boiler occupies less floor area.
2. Fire tube and water tube
In the fire tube boilers, the hot gases are inside the tubes and the water surrounds the
tubes. Examples: Cochran, Lancashire and Locomotive boilers.
In the water tube boilers, the water is inside the tubes and hot gases surround them.
Examples: Babcock and Wilcox, Stirling, Yarrow boiler etc.
3. Eternally fired and internally fired
The boiler is known as externally fired if the fire is outside the shell. Examples: Babcock
and Wilcox boiler, Sterling boiler etc.
In case of internally fired boilers, the furnace is located inside the boiler shell. Examples:
Cochran, Lancashire boilers etc.
4. Stationary and portable
Primarily, the boilers are classified as either stationary (land) or mobile (marine and
locomotive)
Stationary boilers are used for power plant-steam, for central station utility power
plants, for plant process steam etc.
Mobile boilers or portable boilers include locomotive type, and other small units
for temporary use at sites (just as in small coalfield pits).
5. Single tube and multi-tube boilers
The fire tube boilers are classified as single-tube and multi-tube boilers, depending upon
whether the fire tube is one or more than one. The examples of the former type are
Cornish, simple vertical boiler and rests of the boilers are multi-tube boilers.
Essentials of a Good Boiler
A good boiler should possess the following features:
1. The boiler should produce the maximum weight of steam of the required quality at
minimum expenses.
2. Steam production rate should be as per requirements.
3. It should be absolutely reliable.
4. It should occupy minimum space.
5. It should be light in weight.
6. It should be capable of quick starting.
7. There should be an easy access to the various parts of the boiler repairs and inspection.
8. The boiler components should be transportable without difficulty.
9. The installation of the boiler should be simple.
10. The tubes of the boiler should not accumulate soot or water deposits and should be
sufficiently strong to allow for wear and corrosion.

11. The water and gas circuit should be such as to allow minimum fluid velocity (for low
frictional losses).

Figure (1): Boiler

CHAPTER-3
BOILER PRESSURE PARTS
3.1Introduction:
In a steam generator the parts through which the feed water and steam flows where the
pressure of the system, is much higher then atmospheric pressure, are generally termed as
BOILER PRESSURE PARTS Most of the heat released by the fuel in the Boiler is transferred to
the working fluid (Feed Water/Steam) in these pressure parts. As such these parts form the heat
absorbing/heat recovery surface of the boiler.
The following parts of the Boiler are generally coming under the category of Boiler
Pressure Parts.
1. Economizer
2. Boiler Drum
3. Water Wall System
4. Super heater
5. Re-heater

Figure (2) Boiler Parts

3.2 Economiser:

REQUIREMENT: Economizer are provided in the boilers to improve the efficiency of the boiler
by extracting the heat from flue gases and add it as either sensible heat alone or sensible heat and
latent heat to the feed water before the water enters the evaporating surface of the boiler.
ADVANTAGES:
Provision of economizer in a boiler brings in two major advantages.
As the economizer recover the heat in flue gas that leaves the boiler and transfer to
working fluid there will be savings in fuel consumption.
As the feed water is preheated in the economizer and enters the boiler tubes at an elevated
temperature (Near to saturation temperature) the heat transfer area required for the
evaporation surface required will be reduced considerably. As such the size of the boiler
also will be reduced.

ECONIMISER TYPES: The economizer, broadly based on whether both sensible and
latent heat are added or only sensible heat is added to the feed water, can be classified as
Steaming Economizer
Non-steaming economizer

3.3Boiler drum:
In a sub-circulation boiler, the drum plays an important functional role. In the erection of a
Power Boiler, the lifting of the boiler drum is the first mile stone activity. The functions of the
drum are.
Separation of saturated steam from the steam-water mixture produced by the evaporating
tubes.
Mixing feed water from economizer and water separated from steam-water mixture, and
re-circulation through the evaporating tubes.
Carrying out blow down for reduction of boiler water salt concentration.
Treatment of boiler water by chemicals.

As the quantity of water contained in the drum below the water level is relatively small
compared to the total steam output, the function of water storage in drum is not
significant.

3.4Water wall system:

Any boiler needs primarily an evaporating surface for the conversion of water into steam. In
the early periods of boiler development the evaporating surfaces are formed by placing many
coils of tubes or tube banks across the flow path of the hot gases from the furnace and circulating
water through these tubes. With the need for increase in steaming capacity of boilers and to
minimize the furnace heat losses by radiation, in modern boiler the evaporating surface is made
of water walls, which form the major part, if not all, of the furnace enclosure. The water walls
are tube panels through which the water for steam generation will be circulated. In the water wall
only heat is added to evaporate the feed water to steam.
ADVANTAGES OF WATER WALLED FURNACE:

o A boiler with water walled furnace has many advantages compared to furnace of
any other type.
o The major advantages of water walled furnaces are:
In furnace not only combustion but also heat transfer is taking place simultaneously.
The maintenance work involved in repairing the firebricks (which is otherwise necessary)
is completely eliminated.
Due to heat transfer in the furnace, temperature of the flue gas leaving the furnace is
reduced to the acceptable level of the superheating surfaces.
Higher heat loading in the furnace is possible, as heat is being simultaneously removed
by heat transfer, and hence economy in surfacing.
Providing a Gas tight seal to the combustion chamber to prevent air infiltration.

3.5 Superheaters:
Super heaters are provided in the boiler to raise the steam temperature above the saturation
temperature by absorbing heat from flue gas. Use of superheated steam by a steam turbine brings
in number of advantages.
By increasing the temperature of the steam, the useful energy that can be recovered
economically increases thus the efficiency of the cycle.
Superheating of steam eliminates the condensation of steam during transporting of steam
in pipelines and inside the early stages of turbines which is harmful to the turbine blades
and pipe lines.
Limits the work done by turbine stages to avoid excessive erosion of blades.
For every 38 C of superheat above saturation temperature, the heat gain in station heat
rate is approximately 3%.

3.6Re-heaters:
Development of large capacity steam turbines with more number of stages posed a problem
of retaining the steam within vapour phase till the last stage. It is because even with a larger
steam turbine the inlet steam temperature is kept at 540 C only due to the super heater
limitations. To overcome this problem it becomes necessary to raise the temperature of steam
after part of the energy is extracted from it in the steam turbine. This is called as re heating of
steam which increases the cycle efficiency. This re heating of the steam is done in the boiler,
which supplies super heated steam to the turbine. Itself as the heating surfaces called Re-heaters.
Though the cycle efficiency increases with number of stages of re-heating, it requires
additional equipment and so additional investment, complexity in operation and reduced
availability of such system. This offsets the efficiency gain of the system and hence normally a
single reheat can be economically applied only for capacity above 100 MW and two re-heat for
capacity above 500 MW.

CHAPTER-4
STEAM TURBINES
4.1 Introduction
This steam turbine is a prime-mover in which the potential energy of the steam is
transformed into kinetic energy and latter in its turn is transformed into the mechanical energy of
rotation of the turbine shaft. The turbine shaft, directly or with the help of a reduction gearing, is
connected with the driven mechanism. Depending on the type of the driven mechanism a steam
turbine may be utilized in most diverse fields of industry, for power generation and for transport.
Transformation of the potential energy of steam into the mechanical energy of rotation on the
shaft is brought about by different means.
1. no loss due to initial condensation of steam.
2. It can utilize high vacuum very advantageously.
Considerable overloads can be carried at the expense of slight reduction in overall efficiency.
Classification of Steam Turbines:
There are several ways in which the turbines may be classified. The most important and
common division being with respect to the action of the steam as:
a) Impulse.
b) Reaction
c) Combination of impulse and reaction
Advantages of Steam Turbine over the Steam Engines:
The following are the principal advantages of steam turbine over steam engines:
3. The thermal efficiency of a steam turbine is much higher than that of a steam engine.
4. The power generation in a steam turbine is at a uniform rate, therefore necessity to use a
flywheel (as in the case of steam engine) is not felt.
5. Much higher speeds and greater range of speed is possible that in case of a steam engine.
6. In large thermal stations where we need higher outputs, the steam turbines prove very
suitable as these can be made in big sizes.
7. With the absence of reciprocating parts (as in steam engine) the balancing problem is
minimized.
8. No internal lubrication is required as there are no rubbing parts in the steam turbines.
9. In a steam turbine there is
Turbine:

 Type: Stage I: Three Cylinder, Condensing Tandem Compound Horizontal split, Reheat
Type with Seven Extractions & 30 % HP/LP bypass.

Stage II : Three Cylinder, Condensing Tandem Compound Horizontal

Reaction, with Six Extractions & 60 % HP/LP bypass.

Makes : LMW ( Russia, USSR), -- Unit 1,2 & 3

KWU (West Germany) -- Unit 4, 5, 6 & 7
Nos. of Stages :
Stage I : HP 12, IP -11, LP Double Flow Each having 4 stages Stage II
: HP 25, IP Double Flow Each having 20 stages, LP Double Flow
Each having 4 stages
Stage III : HP 25, IP 40, LP 16
HPT : Inlet Steam Pr.- 130-135 Kg/Cm2 Exhaust Pr. 26 Kg/Cm2
IPT : Inlet Steam Pr.- 24 Kg/Cm2 Exhaust Pr. Less than 01 Kg/Cm2
LPT Exhaust Pr. 0.1055 Kg/Cm2

4.2 Demineralized plant

This is the process used to remove all dissolved salt from water. The system consists of
filter, catayan bed and anayan bed, degasified, mixed bed, D M storage tank and CST tank. The
water which is clear by mixing alumina in a clarifier plant is again clear by removing the
alumina from the filter. In our unit there are five numbers of filters are provided. The inlet
pressure of filter is 1.1 Kg/cm2 and outlet pressure is 0.8 Kg/cm2. From the filter the clear water
is past through the cation container which contain +Ve resins bed. So the +Ve element like Ca+,
Mg+, Na+ and O2 are remove from the water and it does not contain any silica particles. There
are three numbers of cation containers provided. The inlet pressure of cation container is 2.4
Kg/cm2 and outlet pressure 1.6 Kg/cm2.
From the cation container the water is flow in another container in which O2 is supplied
by the air blower and Co2 is formed. This Co2 is removed in open air through this container.
After that the water is stored in a degasified. The outlet pressure of degasified is 0.6 Kg/cm2.
Now this water is passing through the anion containers which contain Ve resins bed
which will remove Ve ion like Cl-, F-, Br- etc. there are three numbers of anion container. The
inlet pressure of anion container is 4 Kg/cm2 and outlet pressure is 3.2 kg/cm2. Then the water is
passed through the mixed bed container which contain +Ve and Ve ion resin bed. It will remove

+Ve and Ve ions which are still present in the water. The inlet pressure of the mixed ion bed
container is 2.6 Kg/cm2 and the outlet pressure is 2.4 Kg/cm2.
This water is final deminarlized water which collects in demineralized storage tank
240m3. There are two numbers of DM storage tank in our plant. From this the demenerlized
water is supplied in condensate storage tank (CST). And from that tank the water is supplied to
boiler and other unit.
Power plant generally operated in a closed cycle, it means the working fluid goes on a series
of process, thus changing from once state to another in generating power and final returning to
the initial state. The water from the CST tank is supplied to the condenser and from the
condenser to the hot well. It is then pump in to the system through the heaters, the pump taking
their suction from the hot well and after the water will enter to the L.P.Heater by two control
valves which in turn are operated by the hot well level controller.
From the L.P.Heater the condensate passes to the dearator. It consists of a cylindrical
storage tank upon which is mounted a dearatoring chamber and vent condenser. Dearator reduces
the oxygen contain of the feed water to the value of 0.007 p.p.m and provides the water for the
boiler feed pump at suitable suction head. Under normal condition the dearator tank contains 70
tons of water providing an 11.7 minute supply at maximum continuous rating. Dearator outlet
becomes the suction for boiler feed pump in the common suction header hydrogen and
morpholine dosing is done. The boiler feed pumps are high speed multistage pump. The function
of the boiler feed pump is to delivered feed water from dearator to boiler drum via H.P.Heater
and economizer. There are two number of H.P.Heater are provided. The numbers of the heaters
in the cycle depend upon economic analysis of the system. When the heaters are not in a service
feed water flows through the spring load by pass valves. The feed water from the H.P.Heater is
supplied to the economizer. The function of the economizer is to pre heat the boiler feed water
before it introduce to steam drum, by recovering some of heat of the flue gases leaving the
boiler. The economizer is arranged in between two stages of air heater. The heating surface of
the economizer is 3840 m2. After passing through the economizer feed water enters to the boiler
drum. In our unit boiler drum is made of alloy steel plates and has outside diameter of 1800 mm.
The drum dished ends are provided with man holes and man holes covers. The steam and water
mixture from the water wall is delivered inside the baffle and passes to the cyclones to separate
the steam from the water by imparting a whirling motion to the mixture. The water being
delivered to the inside of baffle, to which large bore down comers are connected. Final
separation is done at the SH separator. The water which are going to down by means of down
comers is again supplied to boiler drum by means of the rising header and riser tube.

CHAPTER-5
ELECTROSTATIC PRECIPITATOR
5.1 Introduction:In thermal power station flue gases of the coal fired boiler contains Ash particles. These
Ash particles are req. to remove from the flue gases before stacking according to environmental
norms. For this purpose special arrangement takes place called precipitations located between
APH oil gas duct& ID fan suction duct. Precipitators are generally of two types:1]Cyclone duct collector: - works on the principle of centrifugal force due to turbulence of flue
due turbulence of flue gas in cyclone chamber. Heavy particles are separated & collected in
collection chamber. This method is used where low precipitation / emission level.
2] Electrostatic precipitator: - This process is based on the principal that neutral particles can be
charged positively or negatively. The particles in gas are in general negatively electrically
charged by a negative corona discharge brought about by a high- tension /low current DC.

5.2 Principle of operation:

An electrical field is build-up between two sets electrodes-emitting & collecting

electrodes. The corona discharge brought about in the normal way ionizes the gas
molecules which in turn after collision impart charge to the dust particles. The ve
charged dust particles are deposited on the +ve collecting Electrode which is Earthed.
The negatively charged gas ions also encounter dust particles in the gas stream on their
comparatively long & curved path towards the collecting Electrode.

The deposition of the Electrons on the particle increases as the square of the voltage
applied between the Electrodes.

Collection Efficiency of a precipitator is give as n=1-e*-Ve[A/Q]

Where:-A=Total collection Area in m2

V=Effective Migration velocity of gas in Cm/Sec.

Q=Flue gas flow in m3/Sec.

Efficiency increases with A&V increased & decreases when Q increases

Figure (3): Electric field generation

5.3 Working:
Works for particles down to 1m Collects 99% of the total mass but only 5% of total
number of particles. Uses about 50,000 Volts

Figure (4): Conductor connection

Can also use fabric filters to remove even smaller particles. Works like a filter on a
vacuum cleaner. Removes up to 99.9% of particles. Effective for particles down to 0.1m. A
1000 MW power plant burning 10,000 tons of coal per day can generate 4000 tons per day of
concentrated aqueous waste. Big disposal problem. Account for 10-15% of construction
costs in new power plants. Energy required is 3-7% of plant output

Figure (5): Components

5.4 Generator
A Steam generator generates steam of the desired rate of the desired pressure and
temp. By desired built in its furnace. Steam generator is used in both fossil fuel and nuclear fuel elect .Generating Power Stations. A steam generator used in Steam power plant is a complex
integration of Equipments like furnace, super heater, reheater, boiler or, evaporator, economizer
and airpreheater along with various auxiliaries such as pulverizes burners, fans. Stokers, dust
collector and precipitators, ash-handling equipment and damage or Stock. Apart from
mechanical equipment as electrical equipment such as an exciter connected with generator unit.
Cooling system is also required for proper cooling of generator different parts due to heating.

Figure (6): Steam generator

1.

Utility Steam Generator

:-

Utilization for Electrical power generating plants.

2.

Industrial Steam generator:Process industries like Sugar, paper, jute and on and institution like hospitals,
commercial and residential building complexes.

3.

Marine Steam Generator:Used in marine ships and ocean liners driven by steam turbines.

Fig (7): Schematic of turbo generator

5.5 Transformer:
Transformer is a static (or stationary) piece of apparatus by means of which electric power
in one circuit is transformed to electric power of the same frequency in another circuit. It can
raise or lower the voltage in a circuit but with a corresponding decrease or increase in current.
In its simplest form, it consists of two inductive coils, which are electrically separated by
magnetically linked through a path of low reluctance as shown in Fig 53. The two coils possess
high mutual inductance. If one coil is connected to a source of alternating voltage, an alternating
flux is set up in the laminated core and it produces mutually induced e.m.f. If the second coil
circuit is closed, a current flows in it and so electrical energy is transferred from the first coil to

the second coil. The first coil, in which electric energy is fed from the a.c supply mains, is called
primary winding, while the second coil is known as secondary winding.
The necessity of the transformer arises when voltages are required to be changed. For
example, the generated voltage of the alternators will be around 15 KV. It is not economical to
have transmission and distribution systems at this voltage as, for the same power transmitted, the
current will be more when compare to high voltage transmission i.e., as the transmission voltage
increases, for the same power transmitted, the current through the conductor is reduced and
thereby copper losses are reduced. As the current through the conductor is reduced the conductor
diameter can be reduced resulting in saving on the cost of conductor material and on the weight
of the support structures. Thus for stepping up of voltage from the generating voltage to
transmission voltage we need a step up transformer. There are situations where the voltages will
require stepping down also.

5.6 switch yard:

Figure (8): Switch yard

The SWITCH YARD is an important part of the Thermal Power Station. The main function
of the switch yard in generator station in to step up the generated voltage for transmission at high
voltage. It also comprises another transformer which is known as unit auxiliary transformer etc.

The main components of 220 KV switch yard is: Circuit Breakers >A.B.C.B. (Air blast circuit breaker)
Isolator
Bus Bars
Lighting Arrester
Capacitor Voltage Transformer
Wave Trapper
Current Transformer
Potential Transformer
Air Compressor

5.7 Circuit Breaker:The Circuit breakers generated generally under over voltage or over current due to any
fault on the line. For operation of circuit beaker the signal is given by relay. The relay sends the
signal to circuit breaker and circuit breaker isolates the faulty section from the line. Generally the
circuit breakers are provided before the equipment for safety. It also put up where bur bars are
sectionalized.
Types of Circuit breaker:o Oil Circuit Breaker
o Air Blast Circuit Breaker
o SF6 Circuit Breaker
o Vacuum Circuit Breaker
A Circuit Breaker essentially consists of fixed and moving contacts, called Electrodes.
Under normal operation, there contacts regain, closed and will not open automatically unless
system becomes faulty. The contacts are moved apart by some mechanism under fault. When the
contacts of circuit breaker are separated under fault conditions, an arc is struck between them.
The current is thus able to continue until the discharge cease.

5.8 Protection:
Generator are the most expansive pieces of equipment ,n the a-c power system, A 210
Mw turbo generator which

includes an alternator, a steam turbine, a boiler and

auxiliaries costs about 70 Crores rupees; The generator also represent the most complicated unit
& demand extensive protection system comprising a large number of protective relays. The
disconnection of a large generator may overload the rest of the system & cause power oscillator
resulting in an unstable power system. On other hand, failure to clear a fault promptly may cause
extensive damage to the generator. One of the main difficulty with generator protection is that
opening a breaker to isolate the defective generator from system is not enough to prevent further
damage Since generator will continue to supply power its own fault until its field has been
suppressed. It is therefore necessary to remove the Held supply, Shutoff; the steam supply to
prime move, Water supply to boiler and shut off all auxiliaries of generator. Now a days unit
System of generator connection is used, here generator is connected to H.V side of main Step up
transformer & H.V side of unit auxiliary transformer. The H.V side of main transformer is
connected to bus bar Via Switch gear. The H.V side of unit auxiliary transformer feeds the power
to auxiliaries directly concerned with unit. The generator & main transformer from a "unit" and
each unit has a boiler, turbine, Condenser, alternator & other auxiliaries. Major faults &
abnormal conditions case of generator are as under.
1.

Failure of insulation of Stator winding,

2.

Failure of insulation of rotor winding.

3.

Unbalanced loading,

4.

Field failure.

5.

over load.

6.

Failure of prime mover.

7.

Loss of Synchronism.

8.

over voltage.

9.

under frequency.

10. Overheating.
Following are employed for generator protection.
1. Differential protection.
2. Inter turn fault protection.
3. Stator earth fault protection,
4. Over current & earth fault protection.
5. Rotor earth fault protection.
6. Negative phase sequence protection.
7. Field failure protection.
8. Over voltage protection.

9. Reverse power protection.

10. over load protection.
11. Pole slipping protection.
12. Under frequency.

5.9 Control room:

In a power station the control room (or the operating room) acts as the never center. The
following controls are located in a control room.
i)
ii)
iii)
iv)
v)

Circuit breakers
Load and voltage adjustment
Transformer tap changing
Emergency tripping of the turbines etc.
The instruments for indicating the load, voltage, frequency, power factor,
wingding temperature and water levels in the case of hydrostation and so on.
vi) Synchronizing equipments
vii) Voltage regulators
viii) Relays
ix) Integrating meters and other appliances
x) A mimic diagram and suitable indicating equipments to show the open or closed
position of circuit breakers, isolators etc.
The control room location in relation to other sections of the station, important and suitable
position should be obtained. It should be located in the following manner:
i) Should be located near the switch house so that lengths of the multicore cables
are shortened.
ii) Should be located away from noise sources.
iii) From the control room there should be an access to the turbine house.
iv) The location of the control room should be such that is should not be affected of
any fire erupts in the switch house.
The control room should be well arranged as follows:
i) Control room should be clean and comfortable.
ii) Should be ventilated and well lighted.
iii) Should be free from draughts.
iv) There should be no glare.
v) The colors schemes should be soothing to eyes.
vi) The instruments should have clear scales properly calibrated.
vii) All the apparatus and circuits should be labeled so that they are clearly visible.
Control boards. These are of the following three forms:
i) Linear
ii) Horse shoe shaped
iii) Semi-circular.

Equipment/Instruments used in Control Room:Indicating instruments,Recorders,Controllers ,

Relay,Annouceator

CONCLUSION
A per our Industrial visit we have conclude that, during the days We are familiar with the
working, operation and maintenance of the wanakbori thermal power plant.
The thermal power plant is the combination of all the small units and it is vastly designed to
get max. Efficiency. Moreover the modern monitoring control and protection devices ensure
reliability and safety to the operator and technicians. The regular maintenance is done in
wanakbori plant which in the end leads to smooth operation of each unit.
And we are very thankful to all those people who help me to get knowledge of power plant.