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Magnetic Separation

Magnetic separators shall be used in coal conveying systems to separate tramp iron
(including steel) from the coal. Basically, two types are available. One type
incorporates permanent or electromagnets into the head pulley of a belt conveyor.
The tramp iron clings to the belt as it goes around the pulley drum and falls off into
a collection hopper or trough after the point at which coal is charged from the belt.
The other type consists of permanent or electromagnets incorporated into a belt
conveyor that is suspended above a belt conveyor carrying coal. The tramp iron is
pulled from the moving coal to the face of the separating conveyor, which in turn
holds and carries the tramp iron to a collection hopper or trough. Magnetic
separators shall be used just ahead of the coal crusher, if any, and/or just prior to
coal discharge to the in-plant bunker or silo fill system.

Coal Crusher
Before the coal is sent to the plant it has to be ensured that the coal is of uniform
size, and so it is passed through coal crushers. Also power plants using pulverized
coal specify a maximum coal size that can be fed into the pulverizer and so the
coal has to be crushed to the specified size using the coal crusher. Rotary crushers
are very commonly used for this purpose as they can provide a continuous flow of
coal to the pulverizer.

Pulverizer
Most commonly used pulverizer is the Boul Mill. The arrangement consists of 2
stationary rollers and a power driven boul in which pulverization takes place as the
coal passes through the sides of the rollers and the boul. A primary air induced
draught fan draws a stream of heated air through the mill carrying the pulverized
coal into a stationary classifier at the top of the pulverizer. The classifier separates
the pulverized coal from the unpulverized coal.

An external view of a Coal Pulverizer

Tangential Burners
The tangential burners are arranged such that they discharge the fuel air mixture
tangentially to an imaginary circle in the center of the furnace. The swirling action
produces sufficient turbulence in the furnace to complete the combustion in a short
period of time and avoid the necessity of producing high turbulence at the burner
itself. High heat release rates are possible with this method of firing. The burners
are placed at the four corners of the furnace. At the Badarpur Thermal Power
Station five sets of such burners are placed one above the other to form six firing
zones. These burners are constructed with tips that can be angled through a small
vertical arc. By adjusting the angle of the burners the position of the fire ball can
be adjusted so as to raise or lower the position of the turbulent combustion region.
When the burners are tilted downward the furnace gets filled completely with the
flame and the furnace exit gas temperature gets reduced. When the burners are
tiled upward the furnace exit gas temperature increases. A difference of
100 degrees can be achieved by tilting the burners.

Ash Handling
The ever increasing capacities of boiler units together with their ability to use low
grade high ash content coal have been responsible for the development of modern
day ash handling systems. The widely used ash handling systems are
1. Mechanical Handling System
2. Hydraulic System
3. Pneumatic System
4. Steam Jet System
The Hydraulic Ash handling system is used at the Badarpur Thermal Power
Station.

Hydraulic Ash Handling System


The hydraulic system carried the ash with the flow of water with high velocity
through a channel and finally dumps into a sump. The hydraulic system is divided
into a low velocity and high velocity system. In the low velocity system the ash
from the boilers falls into a stream of water flowing into the sump. The ash is
carried along with the water and they are separated at the sump. In the high
velocity system a jet of water is sprayed to quench the hot ash. Two other jets force
the ash into a trough in which they are washed away by the water into the sump,
where they are separated. The molten slag formed in the pulverized fuel system
can also be quenched and washed by using the high velocity system. The
advantages of this system are that its clean, large ash handling capacity,
considerable distance can be traversed, absence of working parts in contact with
ash.

ELECTRIC MOTORS
An electric motor uses electrical energy to produce mechanical energy. The reverse
process that of using mechanical energy to produce electrical energy is
accomplished by a generator or dynamo. Traction motors used on locomotives and
some electric and hybrid automobiles often performs both tasks if the vehicle is
equipped with dynamic brakes.

A High Power Electric Motor

Categorization of Electric Motors


The classic division of electric motors has been that of Direct Current (DC) type vs
Alternating Current (AC) types. The ongoing trend toward electronic control
further muddles the distinction, as modern drivers have moved the commutator out
of the motor shell. For this new breed of motor, driver circuits are relied upon to
generate sinusoidal AC drive currents, or some approximation of. The two best
examples are: the brushless DC motor and the stepping motor, both being

polyphase AC motors requiring external electronic control. There is a clearer


distinction between a synchronous motor and asynchronous types. In the
synchronous types, the rotor rotates in synchrony with the oscillating field or
current (eg. permanent magnet motors). In contrast, an asynchronous motor is
designed to slip; the most ubiquitous example being the common AC induction
motor which must slip in order to generate torque.

Comparison of Motor Types

At Badarpur Thermal Power Station, New Delhi, mostly AC motors are employed
for various purposes. We had to study the two types of AC Motors viz.
Synchronous Motors and Induction Motor. The motors have been explained
further.

AC Motor

Internal View of AC Motors


An AC motor is an electric motor that is driven by an alternating current. It
consists of two basic parts, an outside stationary stator having coils supplied with
AC current to produce a rotating magnetic field, and an inside rotor attached to the
output shaft that is given a torque by the rotating field.
There are two types of AC motors, depending on the type of rotor used. The first is
the synchronous motor, which rotates exactly at the supply frequency or a sub
multiple of the supply frequency. The magnetic field on the rotor is either
generated by current delivered through slip rings or a by a permanent magnet.
The second type is the induction motor, which turns slightly slower than the supply
frequency. The magnetic field on the rotor of this motor is created by an induced
current.

Synchronous Motor
A synchronous electric motor is an AC motor distinguished by a rotor spinning
with coils passing magnets at the same rate as the alternating current and resulting
magnetic field which drives it. Another way of saying this is that it has zero slip
under usual operating conditions. Contrast this with an induction motor, which
must slip in order to produce torque.
Sometimes a synchronous motor is used, not to drive a load, but to improve the
power factor on the local grid it's connected to. It does this by providing reactive
power to or consuming reactive power from the grid. In this case the synchronous
motor is called a Synchronous condenser. Electrical power plants almost always
use synchronous generators because it's very important to keep the frequency
constant at which the generator is connected.

Advantages
Synchronous motors have the following advantages over non-synchronous motors:
Speed is independent of the load, provided an adequate field current is applied.
Accurate control in speed and position using open loop controls, eg. Stepper
motors.
They will hold their position when a DC current is applied to both the stator and
the rotor windings.
Their power factor can be adjusted to unity by using a proper field current
relative to the load. Also, a "capacitive" power factor, (current phase leads voltage
phase), can be obtained by increasing this current slightly, which can help achieve
a better power factor correction for the whole installation.
Their construction allows for increased electrical efficiency when a low speed is
required (as in ball mills and similar apparatus).

Examples:
Brushless permanent magnet DC motor.
Stepper motor.
Slow speed AC synchronous motor.
Switched reluctance motor.

Induction Motor
An induction motor (IM) is a type of asynchronous AC motor where power is
supplied to the rotating device by means of electromagnetic induction.

Three Phase Induction Motors


An electric motor converts electrical power to mechanical power in its rotor
(rotating part). There are several ways to supply power to the rotor. In a DC motor
this power is supplied to the armature directly from a DC source, while in an AC
motor this power is induced in the rotating device. An induction motor is
sometimes called a rotating transformer because the stator
(stationary part) is essentially the primary side of the transformer and the rotor
(rotating part) is the secondary side. Induction motors are widely used, especially
polyphase induction motors, which are frequently used in industrial drives.
Induction motors are now the preferred choice for industrial motors due to their
rugged construction, lack of brushes (which are needed in most DC Motors) and
thanks to modern power electronics the ability to control the speed of the motor.

Construction
The stator consists of wound 'poles' that carry the supply current that induces a
magnetic field in the conductor. The number of 'poles' can vary between motor
types but the poles are always in pairs (i.e. 2, 4, 6 etc). There are two types of
rotor:
1. Squirrel-cage rotor
2. Slip ring rotor
The most common rotor is a squirrel-cage rotor. It is made up of bars of either
solid copper (most common) or aluminum that span the length of the rotor, and are
connected through a ring at each end. The rotor bars in squirrel-cage induction
motors are not straight, but have some skew to reduce noise and harmonics.
The motor's phase type is one of two types:
1. Single-phase induction motor
2. 3-phase induction motor

Principle of Operation
The basic difference between an induction motor and a synchronous AC motor is
that in the latter a current is supplied onto the rotor. This then creates a magnetic
field which, through magnetic interaction, links to the rotating magnetic field in the
stator which in turn causes the rotor to turn. It is called synchronous because at
steady state the speed of the rotor is the same as the speed of the rotating magnetic
field in the stator. By way of contrast, the induction motor does not have any direct
supply onto the rotor; instead, a secondary current is induced in the rotor. To
achieve this, stator windings are arranged around the rotor so that when energised
with a polyphase supply they create a rotating magnetic field pattern which sweeps
past the rotor. This changing magnetic field pattern can induce currents in the rotor
conductors. These currents interact with the rotating magnetic field created by the
stator and the rotor will turn. However, for these currents to be induced, the speed
of the physical rotor and the speed of the rotating magnetic field in the stator must
be different, or else the magnetic field will not be moving relative to the rotor
conductors and no currents will be induced. If by some chance this happens, the
rotor typically slows slightly until a current is re-induced and then the rotor
continues as before. This difference between the speed of the rotor and speed of the
rotating magnetic field in the stator is called slip. It has no unit and the ratio
between the relative speeds of the magnetic field as seen by the rotor to the speed
of the rotating field. Due to this an induction motor is sometimes referred to as an
asynchronous machine.

SWITCHGEAR
The term switchgear, used in association with the electric power system, or grid,
refers to the combination of electrical disconnects, fuses and/or circuit breakers
used to isolate electrical equipment. Switchgear is used both to de-energize
equipment to allow work to be done and to clear faults downstream.
The very earliest central power stations used simple open knife switches, mounted
on insulating panels of marble or asbestos. Power levels and voltages rapidly
escalated, making open manually-operated switches too dangerous to use for
anything other than isolation of a deenergized circuit. Oil-filled equipment allowed
arc energy to be contained and safely controlled. By the early 20th century, a
switchgear line-up would be a metal-enclosed structure with electrically-operated
switching elements, using oil circuit breakers. Today, oil-filled equipment has
largely been replaced by air-blast, vacuum, or SF6 equipment, allowing large
currents and power levels to be safely controlled by automatic equipment
incorporating digital controls, protection, metering and communications.

A View of Switchgear at a Power Plant

Types

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