Documente Academic
Documente Profesional
Documente Cultură
Undertaken at
Nashik Thermal Power Station,
Eklahare, MAHAGENCO
Dist. Nashik (Maharashtra)
Submitted in Partial Fulfilment of the Requirement
For the Award of Degree
of
Bachelor of Technology
In Department of Mechanical Engineering
to
Rajasthan Technical University,
Kota
2014-2015
Submitted to: Dr. JP Bhamu
Associate Professor
Department of Mechanical Engineering
ACKNOWLEDGEMENT
It is often said that life is a mixture of achievements, failure, experiences, exposures and
efforts to make your dream come true. There are people around you who help you realize
your dream. I acquire this opportunity with much pleasure to acknowledge the invaluable
assistance of Nasik Thermal Power Station and all the people who have helped me through
the course of my journey in successful completion of the summer training.
I would like to take this opportunity to thank all those who have contributed in this report
directly or indirectly. I offer my thanks to Mr. Santosh Kulkarni (Dy. Executive Engineer),
Mr. N.M. Shinde (Dy.Chief Engineer), Mr. K.M. Mane (Superintendent Engineer), Mr.
Kimbahune Vikrant V. (Power User, EAM), and O.R.Usrete (Sr. Chemist) for providing
whole hearted Co-operation.
I would personally like to my thank Mr. A.P. Netke (Assistant Engineer and Training Incharge) for helping me throughout my training.
I feel deep sense of gratitude towards Dr. JP Bhamu, Associate Professor in Govt.
Engineering College Bikaner, being a constant source of motivation and guidance. I also like
to thank all Faculty and all staff members of mechanical department of Govt. Engineering
College Bikaner.
I want to thank to all Staff and Workers of NTPS for their guidance and co-operation at each
& every step of my training.
I also acknowledge thank to my fellow students for discussing various points during the
course of training which proved very useful in preparing this report. I am grateful to my
friends who gave me the moral support in my times of difficulties. Last but not the least I
would like to express my special thanks to my family for their continuous motivation and
support.
Sagar Mehta
11EEBME753
Table of Contents
S. No.
1
Topics
HISTORY OF POWER SECTOR
1.1
1.2
Page No.
1
Introduction
Market Reform
1
2
Introduction
2.2
3
3
4
Introduction
3.2
6
6
6
4.1
Introduction
4.2
Installed Capacity
4.3
Transport
4.4
9
9
10
5.1
Power Plant
10
5.2
10
5.3
11
13
14
7.1
Introduction
14
7.2
Methodology
14
Introduction
15
15
8.2
Coal
15
8.3
Types of Coal
15
8.4
Coal in India
16
8.5
16
18
9.1
Introduction
18
9.2
18
10
11
21
22
ITS AUXILIARIES
12
11.1
Introduction
11.2
11.3
11.4
11.5
11.6
11.7
22
22
22
24
27
27
29
31
ITS AUXILIARIES
12.1
Introduction
31
12.2
31
12.3
31
12.4
31
12.5
Valves
12.6
32
12.7
33
12.8
33
12.9
Fixed Points
33
12.10
36
12.11
36
32
12.12
13
14
15
16
17
36
GENERATOR
37
13.1
Introduction
37
13.2
Principle of Generation
37
Introduction
14.2
39
39
39
Introduction
15.2
43
43
43
44
16.1
Introduction
44
16.2
44
16.3
45
16.4
45
16.5
45
Energy Conservation
17.2
Audit
48
48
48
18
CONCLUSION
49
19
SUGGESTIONS
50
S. No.
Figure Name
Page No.
2.1
2.3
2.3
4.1
5.1
5.2
5.3
6.1
Plant Layout
6.2
10
8.1
Constituents of Coal
15
11
8.2
16
12
9.1
19
13
9.2
19
14
11.1
23
15
11.2
23
16
11.3
26
17
12.1
33
18
12.2
33
19
13.1
Turbo-Generator
36
11
12
12
13
13
20
13.2
Generator Transformer
36
21
14.1
22
16.1
Electrostatic Precipitator
46
23
16.2
47
40
Table Name
24
4.1
Capacity of Units
25
8.1
17
26
8.2
17
27
9.1
20
28
11.1
23
29
11.2
Boiler Parameters
24
30
11.3
25
31
11.4
28
32
11.5
29
33
11.6
29
34
11.7
29
35
11.8
30
36
11.9
30
37
12.1
34
38
12.2
34
39
14.1
42
40
15.1
43
ABSTRACT
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 fuel sources. Some prefer to use the term energy centre
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 fuelled thermal power plants; efforts to reduce these outputs are various and
widespread. At present 54.09% or 93918.38 MW (Data Source CEA, as on 31/03/2011) of
total electricity production in India is from Coal Based Thermal Power Station. A coal based
thermal power plant converts the chemical energy of the coal into electrical energy. This is
achieved by raising the steam in the boilers, expanding it through the turbine and coupling the
turbines to the generators which converts mechanical energy into electrical energy.
CHAPTER 1
be within a mile of the consumers. While this could work in city centres, it would be unable
to economically supply suburbs with power.
The mid to late 1880's saw the introduction of alternating current (AC) systems in Europe and
the U.S. AC power had an advantage in that transformers, installed at power stations, could
be used to raise the voltage from the generators, and transformers at local substations could
reduce voltage to supply loads. Increasing the voltage reduced the current in the transmission
and distribution lines and hence the size of conductors and distribution losses. This made it
more economical to distribute power over very long distances. Generators (such
as hydroelectric sites) could be located far from the loads. AC and DC competed for a while,
during a period called the War of Currents. The DC system was able to claim slightly greater
safety, but this difference was not great enough to overwhelm the enormous technical and
economic advantages of alternating current which eventually won out.
1.2 MARKET REFORM: There has been a movement towards separating the monopoly parts of the industry, such as
transmission and distribution sectors from the1 contestable sectors of generation and retailing
across the world. This has occurred prominently since the reform of the electricity supply
industry in England and Wales in 1990. In some countries, wholesale electricity markets
operate, with generators and retailers trading electricity in a similar manner to share and
accuracy.
CHAPTER 2
development that has taken place, the power supply industry has been under constant pressure
to bridge the gap between supply and demand.
2.2 PRESENT ENERGY SCENARIO IN INDIA:
The electricity sector in India had an installed capacity of 205.34 Gigawatt (GW) as
In terms of fuel, coal-fired plants account for 56% of India's installed electricity
capacity, compared to South Africa's 92%; China's 77%; and Australia's 76%. After
coal, renewal hydropower accounts for 19%, renewable energy for 12% and natural
gas for about 9%.
As of January 2012, one report found the per capita total consumption in India to be
778 kWh.
India is the world's fourth largest energy consumer after United States, China and
Russia.
Thermal power plants convert energy rich fuel into electricity and heat. Possible fuels
include coal, natural gas, petroleum products, agricultural waste and domestic trash /
waste.
Coal and lignite accounted for about 70% of India's installed capacity.
India's electricity sector consumes about 80% of the coal produced in the country. A
CHAPTER 4
About 100 meters away from the powerhouse stack and further beyond are the installations
for fuel oil day storage and pump houses and bulk storages with pump house. Near the power
station is the coal storage yard and coal handling plant, comprising crusher house, surge and
reclaim hoppers, wagon tipplers, connecting belt conveyor system with inclined belt
conveyors leading to the power station.
NTPS a major driving force since 1971 pouring 910 MW and an apex of Golden triangle
of Mumbai, Pune & Nashik. Industrial house of giants like Mahindra, MICO, VIP, Siemens,
Gabriel, CEAT, Raymond, Crompton Greaves, HAL(Hindustan Aeronautics Limited),
Security Press are HT Consumers more than110 MW. The power plant has got ISO
Certification on April 2002.
4.2 INSTALLED CAPACITY: Nashik Thermal Power Station has an installed capacity of 890 MW. The plant has 5 units
under operation. The individual units have the generating capacity as follows.
Stag
e
Unit
Number
Installed
Capacity (MW)
Date of
Commissioning
Status
Stage I 1
140
August, 1970
Stopped(under
renovation)
Stage I 2
140
March, 1971
Stopped(under
renovation)
Stage II 3
210
April, 1979
Running
Stage II 4
210
July, 1980
Running
Stage II 5
210
January, 1981
Running
4.3 TRANSPORT: It is on the Bhusawal-Kalyan section of Central Railway. Coal-based thermal power stations
consume large quantities of coal. For example, the Nasik Thermal Power Station consumed
4,626,000 tonnes of coal in 2006-07. Around 80 per cent of the domestic coal supplies in
India are meant for coal based thermal power plants and coal transportation forms 42 per cent
of the total freight earnings of Indian railways.
4.4 SHAKTIMAN A SYMBOL OF VISIONARY RESOURCEFULNESS: NTPS built a scrap metal sculpture "SHAKTIMAN, weighing 27 tones, 17 meter tall one of
its kinds in ASEA recorded in the GUINNES book of records. No doubt its a symbol of
innovative idea emerged in word and sprit, inspiring visitors that wealth from waste can be a
reality.
Fig.
4.1
CHAPTER 5
Thermal Energy
Solar Energy
Atomic Energy
Hydro Power
Wind Power
Tidal Power
Geo-Thermal
From Gas
10
5.2 STEAM POWER PLANT: A steam-electric power station is a power station in which the electric generator
is steam driven. Water is heated, turns into steam and spins a steam turbine. After it passes
through the turbine, the steam is condensed in a condenser. The greatest variation in the
design of steam-electric power plants is due to the different fuel sources.
For a steam power plant, practical thermal cycle was suggested by Rankine called Ideal cycle
or Rankine cycle. A steam power plant continuously convert the energy stored in fossil fuels
(Coal, Oil, Natural Gas) or fissile fuels (Uranium, Thorium) into shaft power into shaft work
and ultimately into electricity. The working fluid is water, which is sometimes in liquid phase
and sometimes in the vapour phase during its cycle of operations. Figure below illustrate a
fossil-fuelled power plant as a bulk energy converter from fuel to electricity using water as
working medium. Energy released by burning of fuel is transferred to water by boiler (B) to
generate steam at a high pressure and temperature, which expands in the turbine (T) to a low
pressure to produced shaft work. The steam leaving the turbine condensed into water in the
condenser (C) where cooling water from river or sea circulates carrying away the heat
released during condensation. The water (condensate) is then fed back to the boiler by the
pump (P), and the cycle goes on repeating itself.
5.3 THERMAL POWER STATION WORKS ON RANKINE CYCLE
Main Components of TPS
1.
2.
3.
4.
5.
Boiler
Turbine
Condenser
Boiler feed pump
Generator
11
12
Furnace
Chemical to
Heat
Boiler
Heat energy
converts
water to
saturated
Steam
Generator
Mechanical
to Electrical
Energy
Turbine
Kinetic
energy into
Mechanical
Work
Turbine
Heat energy
into Kinetic
Energy
13
CHAPTER 6
14
CHAPTER 7
15
CHAPTER 8
Coal is a non renewable solid fuel formed by a series of geochemical process from the
percentage
Ultimate Analysis: Determines carbon, hydrogen, nitrogen, sulfur and oxygen within
coal.
ffffffigFf
Fig. 8.1 Constituents of Coal
8.3 TYPES OF COAL: According to quality (carbon content), the coal may be divided into following classes:
16
i.
Anthracite: - It is the best quality coal and its carbon content is as much as 92% with
a low volatile matter and very little moisture. It is hard and heavy and burns with
ii.
great heat.
Bituminous: - It is also of good quality coal next to Anthracite. Its carbon content is
iii.
iv.
v.
8.4 COAL IN INDIA: The common coals used in Indian industry are bituminous and sub-bituminous coal. The
calorific value of Indian coal ranges from 4000-5000 Kcal/kg. Apart from low calorific value,
Indian coal suffers from high ash content (15-45%) which is about 30-40%.The good thing
about Indian coal is its low sulphur content.
8.5 GENRAL WORKING OF CHP
17
A pulveriser or grinder is a mechanical device for the grinding of many different types of
materials. For example, a pulveriser mill (Coal Mill) is used to produce pulverize coal for
combustion in the steam generating furnaces of fossil fuel power plants.
Types of Coal Mills
i.
ii.
iii.
MAKE
CAPACITY
TYPE
HRDGROOV
E IN
MILL
OUTLET T
BHEL
MAKE
BHEL
31.4 T/HR
CAPACITY
320 KW
VOLTAGE
6.6 KV
72 % ( 200 MESH)
CURRENT
37 AMP
SPEED
990 RPM
80-85 C
MAKE
TYPE
CAPACITY
MITSUBHISHI
PIV ROTARY COAL
FEEDER
SPEED
1430 RPM
CURRENT
7.6 AMP
3.7 KW
VOLTAGE
415 V
18
CHAPTER 9
River water contains a lot of impurities such as algae, fungi, dead vegetation and
ii.
this treatment.
ii.
Second Stage: - Post Treatment
a) Demineralization: - Perfectly pure water is produced by ion exchange process by
passing the filtered water through the resins. This water is fed to the boiler feed water
system.
b) Softening: - Hardness causing elements such as Calcium and Magnesium are
removed in this process. This water is used for cooling water system.
c) Domestic water: - Chlorination / Bleaching Powder dosing is arranged to the filtered
water so as to make it suitable for drinking purpose.
Average Incoming River water Parameters are
TH Min 90 ppm
19
River water is taken at river water inlet chamber at W. T. Plant where the chemicals
ii.
FILTERED
WATER
SUMP
FILTERED
WATER
PUMP
BASE
EXCHANGER
SOFT
WATER
C. T.
POND
R Ca / Mg + Na
Hard Water
Soft Water
Regeneration of Base Exchanger resin is done by using Common Salt, Reaction of which is
R- Ca / Mg + NaCl
Salt
R Na + Ca / Mg
Resin
Effluent
Demineralization: Minerals are removed from the filtered water by ion exchange process. Cations (positive
ions) and Anions (Negative ions) are removed from the water one by one using Resin which
20
is an organic material having the capacity to exchange ions in the water with the active group
on the resin.
Chemical reactions in Regular Process are
i.
Na
+
RH
Mg SiO3
ii.
Cl
R ---Ca
Resin
H --- CO3
Mg
SiO3
Cl
+
SiO3
R OH
R--- SO4
Resin
+ OH - H / H2O
SiO3
Na Cl
+ HCl
R-H
Mg
ii.
Ca Cl2
Mg Cl2
ROH
Cl
Na--- SO4
SiO3
M/S BHEL
Parameters at NTPS
Recommendation
Phosphate
Phosphate
pH at 25 0 C
9.4 - 9.7
9.4 to 9.6
Conductivity at 25 0 C
100
< 35
mhos/cm
21
22
CHAPTER 10
D. M. water which is produced for feeding to boiler water system is having pH 7.0 and
ii.
iii.
make it acidic which is not desirable, so chemical dosing is done in boiler feed water.
Dissolved oxygen is also present in the D.M. water which is responsible for corrosion.
iv.
v.
residual dissolved oxygen in the system water to avoid corrosion of metal surface.
pH of D. M. make up water at condenser is about 6.8 to 6.9 ( which is not desirable ) is
increased to about 8.8 by dosing Ammonia solution along with Hydrazine through L.P.
vi.
dosing pump.
Colloidal Silica (which is not removed in D.M. Plant) gets transformed to active silica at
vii.
Temp. Above 250 deg. Cent. And it appears in boiler drum water.
Silica in the form of silicates is hazardous in boiler water as it gets evaporated to steam
and gets deposited directly on the turbine blades as too hard deposits.
CONCLUSION: i.
ii.
iii.
iv.
The rotation of water is decided by the Govt. as per the agricultural requirement.
Normally the water cycle is about 10 days per month throughout the year.
Due to these reasons, water gets contaminated for about 200 days per year.
Such type of contaminated water has to be treated in W.T. Plant before its utilization
v.
23
CHAPTER 11
iv.
v.
vi.
vii.
boiler.
Supplies superheated steam (5400C) of adequate temperature and pressure to turbines.
Extracting flue gases from the boiler and discharging them to atmosphere.
Removing bottom ash formed as a result of combustion process.
Removing fly ash from electrostatic precipitator hoppers.
11.3 TYPES OF BOILER USED IN POWER PLANTS: Conventional, Single Drum, Tangentially fired, balanced draught, Natural Circulation,
Radiant Reheat Type, Dry Bottom with Direct Fired Pulverized Coal with Bowl Mill or with
Fuel Oil.
24
25
BOILER TYPE
COAL
BITUMINOUS COAL
FURNACE
FC
VM
MOIST
37.30%
27.60%
10%
ASH
GRINDABILITY
CV
25%
50 HGI
5000 KCAL/KG
WIDTH
DEPTH
VOLUME
13.8C8M
10.592M
5495 M
TOTAL HEATING
22862.10 SQ.M
SURFACE AREA
700 T/HR
540 C
137 KG/CM
578.3T/HR
26
540 C
25.1 KG/CM
27 KG/CM
247 C
Coal mine - unshaped, unsized raw bituminous coal crusher bunker (stack).
Coal bunkers (20mm size coal) coal feeders (controlling input to coal mill) coal
mills.
Powder, pulverized coal lifted by primary air and sending through coal pipes - coal
dampers - to furnace for combustion.
Furnace Oil (FO) / Light Diesel Oil (LDO) Tanks Fuel Oil Pumps Heaters
(Steam) Oil Dampers - Oil Guns To Furnace
BOILER AUXILIARIES
QUANTITY IN NUMBERS
AIR HEATERS
02 NOS.
03 NOS.
COAL MILLS
06 NOS.
02 NOS.
02 NOS.
02 NOS.
27
03 NOS.
02 NOS.
02 NOS.
SCANNER FANS
02 NOS.
ELECTROSTATIC PRECIPETATOR
Primary Air Fans: Mixture cold & hot air supplies to lifting coal to furnace.
Forced Draft Fans: Supplies hot air required for combustion. The function of
forced draft fans is to supply the combustion air initially, when no coal firing is taking
place. But once the coal firing starts, the function of forced draft fan remains only to
supply air required for completing combustion process.
Balanced Draft: - Balanced draft is obtained through use of both induced and forced
draft. This is more common with larger boilers where the flue gases have to travel a
long distance through many boiler passes. The induced draft fan works in conjunction
with the forced draft fan allowing the furnace pressure to be maintained slightly
below atmospheric.
Primary Air: - This air lifts the pulverized coal from the coal mills & enters the
boiler with it. The primary air quantity is less with pressure higher so that it can lift
the coal. This air is also used to dry the coal.
Secondary Air: - As air supplied wet coal (Primary air) is less in quantity it is not
sufficient for complete combustion & some quantity of air must be supplied
additionally to complete combustion. This is called secondary air.
Seal Air Fans: - These fans take the suction from cold air duck of primary air system
& their discharge goes to the sealing of gear box of coal mills & its rollers for bearing
sealing.
Scanner Fans: - Scanner fans air supply the cooling air necessary for the cooling of
costly scanner heads. Scanner heads may get damaged if not cooled, leading to outage
28
of units. These fans take their suction from the discharge of FD in the discharge of
these fans goes to scanner after getting filtered. In case of AC failure when FD fans
trip, there is provision to provide suction to these fans from atmosphere.
Soot Blower System: - The fuel used in thermal power plants causes soot and this is
deposited on the boiler tubes, economizer tubes, air pre heaters, etc. This drastically
reduces the amount of heat transfer of the heat exchangers. Soot blowers control the
formation of soot and reduce its corrosive effects. The types of soot blowers are fixed
type, which may be further classified into lane type and mass type depending upon the
type of spray and nozzle used. The other type of soot blower is the retractable soot
blower. The advantages are that they are placed far away from the high temperature
zone, they concentrate the cleaning through a single large nozzle rather than many
small nozzles and there is no concern of nozzle arrangement with respect to the boiler
tubes.
Economizer: - Absorbs heat from flue gas and add this sensible heat to feed water
before water enters to Boiler. The justifiable cost of the economizer depends on the
total gain in efficiency. In turn this depends on the flue gas temperature leaving the
boiler and the feed water inlet temperature.
Air Pre-Heater: -Flue gases passes through Heater tubes and Cold air passes through
air heater heated up and Hot air used for combustion. An air preheater or air heater is
a general term to describe any device designed to heat air before another process (for
example, combustion in a boiler) with the primary objective of increasing the thermal
efficiency of the process. They may be used alone or to replace a recuperative heat
system or to replace a steam coil.
Super Heaters: - The super heater is a heat exchanger in which heat is transferred to
the saturated steam to increase its temperature. It raises the overall cycle efficiency. In
addition, it reduces the moisture content in the last stages of the turbine and thus
increases the turbine efficiency. The superheater consists of a superheater header and
superheater elements. Steam from the main steam pipe arrives at the saturated steam
chamber of the superheater header and is fed into the superheater elements.
Superheated steam arrives back at the superheated steam chamber of the superheater
29
header and is fed into the steam pipe to the cylinders. Superheated steam is more
expansive.
Whenever combustion takes place chemical energy converted into heat energy
(depends on CV).
Heat carried away through flue gas is used in Air Heater & Economizer to improve
Boiler Efficiency.
Temperature of the flue gases at various stages is given below in the index for (210
MW) Rated output plant. Parameters of flue gas may vary from one plant to other.
OUTLET TEMPERATURE
IN 0 C
FURNACE
PLATTERN SUPER HEATER
1123
1010
REHEATER FRONT
REHEATER REAR
FINAL SUPER HEATER
HORIZONTAL SUPER HEATER
ECONOMISER
AIR HEATER
E.S.P.
I.D.FAN
CHIMNEY
823
765
662
479
369
140
125
120
120
30
ASTM
Grade
Temperature
Specificatio
n
Carbon Steel
SA 210
A1
450oC
Carbon % MO Steel
SA 209
T1
480Oc
1 % Cr, % MO Steel
SA 213
T11
550oC
2 % Cr, 1 % MO Steel
SA 213
T22
580oC
SA 213
T304
Up to 700oC
UNIT NO.3
BHEL
1700
UNIT NO.4
BHEL
1300
31
UNIT NO.5
BHEL
1300
FAN
MAKE
CAPACITY
BHEL
232.5M/SEC
SPEED
VOLTAGE
990
6.6
990
6.6
990
6.6
CURRENT
175
138
138
AXIAL
IMPULSE
990 RPM
TYPE
SPEED
NO. OF FAN
/ BOILER
BHEL
MAKE
BHEL , KKK
CAPACITY
1250 KW
TYPE
VOLTAGE
6.6 KV
FAN SIZE
NDF-21 b U#3
FAN SIZE
NDFV-22b U#4&5
CAPACITY
70.33 M/SEC
SPEED
1480 RPM
MOTOR
UNIT NO.3
UNIT NO.4
UNIT NO.5
FAN
MAKE
BHEL
BHEL
BHEL
MAKE
BHEL
CAPACITY
630
750
750
CAPACITY
105.5 M/SEC
SPEED
990
1491
1491
TYPE OF
FAN
AXIAL
IMPULSE
VOLTAGE
6.6
6.6
6.6
FAN TYPE
AN 20e6 U#3
CURRENT
68
79
79
TYPE OF
FAN
IGV
OPERATIO
PNEUMATIC
HYDRAULI
C
HYDRAULI
C
FAN TYPE
AXIAL
REACTION
API-18/11
U#4&5
SIZE
27 VI 72
MAKE
NO OF AIR HEATERS
CAPACITY
32
INSTALLED POSITION
VERTICAL
VOLTAGE
415 V
1067 MM
CURRENT
22 AMP
HEIGHT OF
INTERMEDIATE LAYER
457 MM
SPEED
305 MM
141 C
DRIVE
MOTOR
1440 RPM
2 NOS.
CHAPTER 12
A steam turbine works on the principle of conversion of High pressure & temperature
ii.
steam into high Kinetic energy, thereby giving torque to a moving rotor.
For above energy conversion there is requirement of converging /Converging-
iii.
Diverging Sections.
Such above requirement is built up in the space between two consecutive blades of
fixed and moving blades rows.
12.3 TYPES OF STEAM TURBINE: According to the principle of action of the steam, turbine can be classified as:
i.
33
ii.
TURBINES IN NTPS NASHIK: 210 MW Turbine at Nashik is three cylinders (HP, IP, LP) Tandem compound with nozzle
governing, condensing & regenerative feed heating type.
The HPT comprises of 12 stages, the first stage being governing stage.
The LPT has 4+4 stages .Steam enters at middle & flows in opposite paths having
four stages.
Turbine rotors are supported on five bearings .The common bearing of HP & IP rotor is a
combined journal & radial thrust bearing. Rest four bearings are journal bearings.
12.4 CONSTRUCTION AND STEAM FLOW:
The turbine is tandem compound machine with HP, IP, & LP parts. The HP part is a
single flow cylinder & IP & LP parts are double flow cylinders.
The individual rotors & generator rotor are connected by rigid couplings.
The HP cylinder has a throttle control. The initial steam is admitted before the blading
HP cylinder.
The steam coming from the re heater is passed to the IP part via two combined reheat
stop & control valves cross around pipes connect the IP & LP cylinders.
Bleeds are arranged at several points of the turbine.
12.5 VALVES: It is a mechanical device to control the flow of fluid in pipe. Valves are said to be nerve
centre of power plant controlling high pressure steam & water.
The HP turbine is fitted with two initial steam stop & control valves.
A stop & control valve with stems arranged right angle to each other are combined in
a common body.
The stop valves are spring operated single-seat valves, the control valves, are also of
34
The reheat stop valves are spring loaded single seat valves.
The control valves, also spring loaded, have diffusers. The control valves operate in
operation even when turbo set is supplying only the station load.
Both the main & reheat stop & control valves are supported kinematically on
foundation ceiling below the machine floor before the turbo set.
All valves are individually operated by oil hydraulic servomotors.
governing system.
An electric system measures & controls speed & output, & operate the control valves
speed & keeps speed swings following sudden load shedding low.
The linear output frequency characteristic can be very closely set even during
operation.
A single oil supply system lubricates & cools the bearing, governs the machine
operates the hydraulic actuators & safety and protective devices & drives the
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Differential expansion between the shafting & turbine casing, measured at several
points.
Bearing pedestal vibrations, measured at all turbine bearings.
Relative shaft vibrations measured at all turbine bearings .absolute shaft vibrations,
obtained from bearing pedestal vibration & relative shaft vibration by calculation.
210 MW
RATED SPEED
3000 RPM
130 KG/CM
535 C
23.20 KG /CM
616 TON/HR
670 TON/HR
30 C
27000 M/HR
63.3 MM HG COL
36
MOTOR
MAKE
CAPACITY
VOLTAGE
CURRENT
SPEED
BHEL,HARIDWAR
200 KW
6.6 KV
21.8 AMP
985 RPM
PUMP
MAKE
SPEED
HEAD
DISCHARGE
37
12.10 STEAM TURBINE STARTS UP: When warming up a steam turbine for use, the main steam stop valves (after the boiler) have
a bypass line to allow superheated steam to slowly bypass the valve and proceed to heat up
the lines in the system along with the steam turbine. Also a turning gear is engaged when
there is no steam to the turbine to slowly rotate the turbine to ensure even heating to prevent
uneven expansion. After first rotating the turbine by the turning gear, allowing time for the
rotor to assume a straight plane (no bowing), then the turning gear is disengaged and steam is
admitted to the turbine, first to the astern blades then to the ahead blades slowly rotating the
turbine at 10 to 15 RPM to slowly warm the turbine.
12.11 PRECAUTIONS DURING RUNNING: Problems with turbines are now rare and maintenance requirements are relatively small. Any
imbalance of the rotor can lead to vibration, which in extreme cases can lead to a blade letting
go and punching straight through the casing. It is, however, essential that the turbine be
turned with dry steam. If water gets into the steam and is blasted onto the blades (moisture
carryover) rapid impingement and erosion of the blades can occur, possibly leading to
38
imbalance and catastrophic failure. Also water entering the blades will likely result in the
destruction of the thrust bearing for the turbine shaft. To prevent this, along with controls and
baffles in the boilers to ensure high quality steam, condensate drains are installed in the steam
piping leading to the turbine.
12.12 MATERIALS FOR STEAM TURBINE DESIGN: i.
ii.
Blades
Stainless Steel 403 & 422 (+Cr)
17-4 PH steel (+ Ti)
Super Alloys
Rotor
High Chrome Moley Steel Cr-Mo-V
Low Ni Chrome Steel Ni-Cr-Mo-V
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CHAPTER 13
GENERATOR
13.1 INTRODUCTION: In electricity generation, a generator is a device that converts mechanical energy to electrical
energy for use in an external circuit. The source of mechanical energy may vary widely from
a hand crank to an internal combustion engine and turbine used in power plants. Generators
provide nearly all of the power for electric power grids.
13.2 PRINCIPLE OF GENERATION: - GENERATION OF AC POWER
The basic requirements for generation of AC power are as follows.
i.
ii.
iii.
Conductor
Magnetic field
Relative speed
Thus maximum speed shall be achieved by 2 poles machine. However multi pole generators
are used for Hydro Power Stations as speed depends upon depth of reservoirs i.e., water
pressure, water head available at first stage of runner of turbine.
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41
CHAPTER 14
Condenser
ii.
Cooling tower
iii.
Hot well
iv.
v.
vi.
vii.
viii.
ix.
Deaerator
x.
Air Ejector
xi.
Drain Cooler
xii.
42
Condenser: The main purposes of the condenser are to condense the exhaust steam from the turbine for
reuse in the cycle and to maximize turbine efficiency by maintaining proper vacuum. As the
operating pressure of the condenser is lowered (vacuum is increased), the enthalpy drop of
the expanding steam in the turbine will also increase. This will increase the amount of
available work from the turbine (electrical output). By lowering the condenser operating
pressure, the following will occur:
a. Increased turbine output
b. Increased Plant efficiency
c. Reduced steam flow
43
Condensate Pump: There are two multistage centrifugal condensate pumps but both are capable of delivering
full load individually. It delivers condensate to SPE.
Cooling Tower: A cooling tower extracts heat from water by evaporation. In an evaporative cooling tower, a
small portion of the water being cooled is allowed to evaporate into a moving air stream to
provide significant cooling to the rest of that water stream.
Cooling Towers are commonly used to provide lower than ambient water temperatures and
are more cost effective and energy efficient than most other alternatives. The smallest cooling
towers are structured for only a few litres of water per minute while the largest cooling
towers may handle upwards of thousands of litres per minute. The pipes are obviously much
larger to accommodate this much water in the larger towers and can range up to 12 inches in
diameter.
When water is reused in the process, it is pumped to the top of the cooling tower and will
then flow down through plastic or wood shells, much like a honeycomb found in a bees nest.
The water will emit heat as it is downward flowing which mixes with the above air flow,
which in turn cools the water. Part of this water will also evaporate, causing it to lose even
more heat.
Steam Packing Exhauster (SPE): This is a surface type heat exchanger which transfers the heat energy of packing steam to the
condensate water and condenses packing steam (drip) in turn, which are drained to the
condenser through an atmospheric drain tank. Its shell is equipped with an Air Blower to
evacuate non-condensable gases to atmosphere.
Air Ejector: It is a double stage twin steam jet ejector which acts as an air pump. Its main function is to
maintain vacuum by pulling out air and non-condensable gases from the condenser. Exhaust
steam from jet ejector are made to pass from inter and after condenser where heat of jet steam
is transferred to condensate coming from SPE.
44
Drain Cooler: The air from condensate water, which is exhausted to atmosphere through a vent condenser.
The bled steam directly condenses and gets mixed with condensate water from heater, and
this is passed to storage tank.
Deaerator: A deaerator is a device that is used for removal of oxygen and other dissolved gases from the
feed water to steam-generating boilers. In particular, dissolved oxygen in boiler feed water
will cause serious corrosion damage in steam boiler systems by attaching to the walls of
metal piping and other metallic equipment and forming oxides (rust). Dissolved carbon
dioxide combines with water to form acid that causes further corrosion.
Feed Water Heaters: This item is installed to improve power generator efficiency by heating supplied water and
reducing breakage due to heat stress from temperature differences in boiler tubes. Because a
single heater consists of cooling areas, condensing areas, and heating areas, this item requires
thoughtful engineering and production.
Feed water heaters are classified as low and high pressure heaters with one heater consisting
of overheating, condensing and overcooling areas, making it difficult to design and produce.
Use one or more low pressure feed water heaters to raise the temperature of condensate from
condensate pump discharge temperature to the de-aerator inlet temperature. Use one or more
high pressure feed water heaters to raise the temperature of feed water from de-aerator outlet
temperature to the required boiler economizer inlet temperature.
Condenser Data: MAKE
COOLING SURFACE AREA
NO. OF COOLING TUBES
LENGTH OF COOLING TU
DIA.OF COOLING TUBE
NO. OF WATER PATHS FOR EACH
CONDENSER
DESIGNED CONSUMPTION OF COOLING
WATER
QUANTITY OF STEAM CONDENSING
MAIN EJECTOR
STARTING EJECTOR
45
BHEL
14650 M
15652
10M
30/28 MM
2
27000 M/HR
150 TO 500 T/HR
2 NOS.
1 NO
46
CHAPTER 15
MOTOR
MAKE
CAPACITY
VOLTAGE
CURRENT
SPEED
PUMP
BHEL , HARDWAR
4000 KW
6.6 KV
408 AMP
1485 RPM
HEAD
DISCHARGE
MAKE
TYPE
NO.OF STGES
SPEED
LUBRICATION
BHEL,HYDERABAD
200 KHI
6
4320 RPM
FORCED
1830 MLC
430 T/HR
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CHAPTER 16
Moisture 8%
16.2 TYPES OF COAL ASH: Coal ash is the residue of the coal combustion process involved in the thermal power plants.
The types of coal ash from coal based thermal power plants are:
i.
ii.
iii.
Silica
Alumina
Iron oxide
Calcium
48
Magnesium
Sulphate
Alkalis
16.4 FLY ASH SYSTEM: The system for all units is identical and following description is applied to both the units the
water compounded bottom ash hopper receives the bottom ash from the furnace from where it
is stores and discharged through the clinker grinder. Two slurry pumps are provided which is
common to all units & used to make slurry and further transportation to ash dyke through
pipeline.
Ash particles are separated by passing through electrical field (Electrostatic Precipitator).
Components in ESP:
Rapping mechanism
16.5 AREAS OF FLY ASH UTILISATION: Fly ash can be used for various applications. Some of the major areas of fly ash utilization are
as follow:
Sintered aggregate
49
Granite substitute
Ceramic tiles
50
51
52
CHAPTER 17
53
primary concern. Beyond simply identifying the sources of energy use, an energy audit seeks
to prioritize the energy uses according to the greatest to least cost effective opportunities for
energy savings.
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CHAPTER 18
CONCLUSION
It was a knowledgeable experience while taking practical training at NASHIK THERMAL
POWER STATION. It proved an opportunity for encounter with such huge machines like
tippler, turbine, boiler and generator. But there are few factors that require special mention.
From all the study it can be concluded that the Nasik thermal power project of 210X3 units is
fairly organized unit with the latest machinery available. The turbine is a very sophisticated
assembly of machinery which requires specific conditions of steam temperature and pressure
to work efficiently. Any alteration of the specific requirements may prove hazardous to the
turbine. Another interesting yet worrying fact is the quantity of coal consumed which
approximately 3276 tonne per day. The level of pollution is always controlled according the
established norms, but still I consider it to be quite enough. Well, efforts are always underway
in reducing the pollution and improving the efficiency of the plant. All in all, a thermal power
project is very large establishment with many components and it awesome to see how all the
components work in a synchronized manner.
The Electricity Act 2003 and subsequent National Electricity Policy and Tariff Policy have
Opened up several opportunities for the power sector. The Act allows the IPPs and captive
Power producers open access to transmission system, thus allowing them to bypass the SEBs
and sell power directly to bulk consumers. Slowly open access in distribution system is also
being allowed.
Assessment of the financial feasibility of the Proposed Project, delivers satisfactory financial
Parameters as per base financial model. It has also assessed the viability of the project under
the impact of various scenarios, which could be at variance with the base case scenario
assumed.
Company has proposed to set-up 660 MW Coal fired Thermal Power Project based on
Super Critical Technology. State Government has supported this Project and has issued letter
of support to provide all kind of administrative support required.
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CHAPTER 19
SUGGESTIONS
Power sector is an essential service and in the basis of industrialization and agriculture. It
plays a vital role in the socio-economic development. Therefore, improving efficiency of
these thermal power stations in addition to increasing their PLF (Plant Load Factor) has
become the need of the hour to bring the cost and maximize the generation levels. With this
objective in view, several actions have already been initiated by Ministry of Power (MOP)
and other various agencies like CEA, NTPC, State Electricity Boards, CBIP etc. to improve
the operating efficiency and PLF of thermal power stations.
Now I here make it sort with my suggestions for improving efficiency of power plant and for
various other factors on the basis of what I have learned during my training are:
With the deficit of electricity in our country, there is need of many projects and the
exposure limit should be increased to effectively assist the new projects.
Proper maintenance of ESP must be done with regular maintenance of boilers and
furnaces.
be reduced for the same load and that would provide better profit to the organization.
Recover the portion of heat loss from the warm cooling water existing the steam
condenser.
Reduce air, water, steam and flue gas leakages.
56