National Thermal Power Corporation limited,

RAMAGUNDAM.

CERTIFICATE
This is to certify that the “Project report”
Entitled
“WORKING SYSTEM OF STEAM TURBINES & ITS
AUXILIRES”
Submitted by
K.Ram Reddy (16271A0318)
K.Laxman (16271A0312)
MD.Khaja Moinuddin (16271A0313)
J.Akshay kumar (17275A0314)
K.Divya (17275A0313)
Of Dept of MECHANICAL ENGINEERING
Has successfully carried out this project work under my supervision for
16 days (20/05/2019 to 04/06/2019). PROJECT GUIDE:
Project Coordinator

Mr.D.Prabhakar, Mr.N.Srinivas Rao,

Engineer (TMD). Sr.Manager (TMD).

 PROJECT REPORT
ON
“WORKING SYSTEM OF STEAM TURBINE & ITS
AUXILIARIES”
A dissertation submitted in partial fulfilment of the academic
requirements for the award of
BACHELOR OF TECHNOLOGY (MECHANICAL)
DEGREE FROM
Jawaharlal Nehru Technological University, Hyderabad.
By
K.RAM REDDY (16271A0318)
K.LAXMAN (16271A0312)
MD.KHAJA MOINUDDIN (16271A0313)
J.AKSHAY YADAV (17275A0314)
K.DIVYA (17275A0313)

JYOTHISHMATHI INSTITUTE OF TECHNOLOGY

and SCIENCE
(Approved by AICTE and Affiliated to JNTU, Hyderabad)
Nustulapur , Karimnagar-505 481.

Project done at
NTPC LTD
RAMAGUNDAM SUPER THERMAL POWER STATION
(A Govt. of India Enterprise)
 RAMAGUNDAM, PEDDAPALLY (dist), TELANGANA (state).

ACKNOWLEDGEMENT

The successful completion of our project is indeed practically

incomplete without mentioning of all those encouraging people who
genuinely supported us throughout the project.
We would like to express our sincere gratitude to Mr.
ALOKCHANDRA THAKUR AGM-(TMD) I/C who extended his
support and accepted the proposal of carrying out the project work on
“WORKING SYSTEM OF STEAM TURBINES & ITS
AUXILIRES”.
We are indebted to our project guide Mr.D.PRABHAKAR
(ENGINEER TMD) who spared his valuable time and energy to guide us
with patience and interactively throughout the training.
Our heartfelt thanks to Mr.N.SRINIVAS SR MANAGER TMD
project coordinator who has rich experience in this field and given us
valuable suggestion in completing the project work.
 We extend our thanks to Mr.A.D.N. RAO at RSTPS NTPC
LIMITED and all staff for their valuable advices and guidance to the
project work.
Finally, we thank one and all who have given their assistance
directly or indirectly.

ABSTRACT
Thermal power plants are major area for the generation of power.
Availability of coal leads to implementation of thermal power plant. Due
to continuous increase in power requirements both in domestic and
industrial sectors it is necessary to increase in generation of power.
A power plant can be roughly divided into three parts. Furnace
boiler, Turbine which includes condenser pump, feed water heater,
rejection system and electric generator. Steam from the furnace is
supplied in which K.E. of steam is used to drive the turbine to obtain
Mechanical Energy.
The combustion of coal is responsible for the generation of steam
from the water. There are many mountings supporting the efficient
functioning of the Turbine.
Our project deals with the study and application of concepts and
theories in the current industrial scenario by the study of turbine
maintenance and its auxillaries.
 CONTENTS:

CHAPTER 1...................................................................................................................1
INTRODUCTION TO NTPC....................................................................................1
1.1 INTRODUCTION TO NTPC:..........................................................................1
1.2 ABOUT NTPC..................................................................................................2
1.3 LEADING IN POWER SECTOR....................................................................2
1.4 INTRODUCTION TO RSTPS.........................................................................3
POLLUTION CONTROL MEASURES................................................................5
CHAPTER 2...................................................................................................................7
INTRODUCTION TO THERMAL POWER PLANT...............................................7
2.1 THERMAL POWER PLANT.........................................................................7
2.2 BASIC POWER PLANT CYCLE:...................................................................8
2.3 FUEL REQUIREMENTS:................................................................................8
2.4 WATER REQUIREMENTS:............................................................................9
2.5 ASH DISPOSAL:.............................................................................................9
2.6 ENVIRONMENT CONTROL:......................................................................10
CHAPTER 3.................................................................................................................11
ELECRICITY GENERATION FROM COAL.........................................................11
3.1 COAL AND FUEL PATH:..............................................................................11
3.2 ASH DISPOSAL:...........................................................................................12
3.3. FLUE GAS:...................................................................................................13
3.4 DISTRIBUTION PATH:.................................................................................16
CHAPTER 4.................................................................................................................17
BOILER AND BOILER AUXILIARIES.................................................................17
4.1 BOILER AND BOILER AUXILIARIES:......................................................17
4.2 AUXILIARIES:..............................................................................................20
4.3 POWER PLANT AUXILLIARIES:...............................................................23
CHAPTER 5.................................................................................................................28
TURBINE AND IT'S AUXILIARIES......................................................................28
5.1 TURBINE AUXILIARIES:............................................................................45
CONCLUSION............................................................................................................52
REFERENCES.............................................................................................................53
LIST OF FIGURES

Fig: 1. 1 NTPC...........................................................................................1
Fig: 1. 2 Plant Layout.................................................................................3
Fig: 1. 3 Overall Power Plant Layout..........................................................6
Fig: 2. 1 Energy Conversion Diagram........................................................7
Fig: 2. 2 T-S Cycle......................................................................................8
Fig: 2. 3 Coal..............................................................................................9
Fig: 3. 1 Electricity Generation from Coal..............................................11
Fig: 3. 2 Conveyor Belt............................................................................12
Fig: 3. 3 ASH Disposal Graph..................................................................12
Fig: 4. 1 Boiler..........................................................................................17
Fig: 4. 2 Blast Furnace.............................................................................18
Fig: 4. 3Economizer.................................................................................19
Fig: 4. 4 Boiler Drum...............................................................................19
Fig: 4. 5 Re-Heater Pips...........................................................................20
Fig: 4. 6 Pulverising Mills........................................................................20
Fig: 4. 7 PA Fan........................................................................................21
Fig: 4. 8 Forced Draught fan....................................................................21
Fig: 4. 9 200MW Lay Out........................................................................22
Fig: 4. 10 Coal Handling plant.................................................................24
Fig: 4. 11 DMP.........................................................................................25
Fig: 4. 12 Electro Static Precipitator........................................................26
Fig:4. 13 ID Fan.......................................................................................27
Fig: 5. 1 Turbine Plates.............................................................................28
Fig: 5. 2 Rotor..........................................................................................29
Fig: 5. 3 Different between impulse and reaction turbine.......................30
Fig: 5. 4 Velocity triangles........................................................................33
Fig: 5. 5 HP Rotor....................................................................................38
Fig: 5. 6 LP Rotor.....................................................................................39
Fig: 5. 7 Blades.........................................................................................39
Fig: 5. 8 Blade Diagrams..........................................................................39
Fig: 5. 9 Journal Bearings.........................................................................41
Fig: 5. 10 Turbine Overview....................................................................45
Fig: 5. 11 Turbine Shaft Arrangement......................................................46
Fig: 5. 12 Turbine Crass Section View.....................................................46
Fig: 5. 13 Condenser................................................................................47
Fig: 5. 14 Condensate extraction pumps..................................................48
Fig: 5. 15 Low Pressure Heater................................................................48
Fig: 5. 16 Deaerator..................................................................................49
Fig: 5. 17 Feed Pump...............................................................................50
Fig: 5. 18 High Pressure Heater...............................................................50
Fig: 5. 19 Generator..................................................................................51
LIST OF TABLES

Table: 1. 1 Important Features Of RSTPS..................................................4

 CHAPTER 1
INTRODUCTION TO NTPC

Fig: 1. 1 NTPC

1.1 INTRODUCTION TO NTPC:A Journey towards Excellence

established in 1975, NTPC Limited, a premier Public Sector Enterprise,
is India's largest power utility with an installed capacity of 55,126 MW
through 26 power stations including stations operated under Joint
Venture Companies on date. NTPC has emerged as an Integrated Power
Major with presence in Hydro Power, Coal mining, Oil & Gas
exploration, Power Distribution & Trading and also plans to enter into
nuclear power development. The Company contributed 29.25% of the
total electricity generated in the country during 2006-07 with 20.71%
share of the total installed capacity of the nation including capacity and
generation joint venture companies.

1
 NTPC Limited is the largest thermal power generating company
of India. A public sector company, it was incorporated in the year 1975
to accelerate power development in the country as a wholly owned
company of the Government of India.

1.2 ABOUT NTPC:

Power is an important infrastructure in developing countries.

Power development in INDIA received a big boost with the dawn of
National Thermal Power Corporation Limited (NTPC).

NTPC is established on seventh of November, 1975 to construct,

operate and maintain large capacity power stations (mainly installed at
coal pit heads)

VISION:"To Be the World's leading power company, energizing India's growth "
MISSION:
" provide reliable power and related solutions in an economical, efficient and envinorment
friendly manner, driven by innovation and agility "

1.3 LEADING IN POWER SECTOR:

NTPC, with an installed capacity of 31,134MW, (from 26

different stations spread throughout India) is generating 28.60% of the
country's entire power requirement. So it is recognized as the India's
largest power utility with excellent core values "COMIT" viz. Customer
focus, Organizational pride, Mutual respect, Initiative and speed and
Total quality.

Ash Utilization:

NTPC has also taken proactive steps for ash utilization. In 1991, it
has set up Ash Utilization Division to manage efficient use of the ash
produced at its coal stations. This quality of ash produced is ideal for
use in cement, concrete, cellular, concrete building material

2
1.4 INTRODUCTION TO RSTPS
RAMAGUNDAM SUPER THERMAL POWER STATION
(RSTPS) FOUNDATION STONE WAS LAID ON 14 th Nov. 1978. The
2600 MW plant is located in Ramagundam near Godavari River in
Karimnagar District of A.P.

RSTPS is located in Jyothinagar of Ramagundam. Anyone can

reach this place either by rail or by bus. There is a railway station in
Ramagundam and from there -one can catch a bus or an auto to
Jyothinagar. One can also reach this place by Godavarikhani bus from
Karimnagar bus station.

This is the biggest power station in southern India, supplying

power to all the southern states. The generating units are connected 400
KV switchyard through the step up generator transformer.

The station has got unique distinction of recording 93 days of trip

free operation and maximum of 406 days continuous run of its 500 MW,
Unit-VI during the year 1994-95.

POLLUTION CONTROL MEASURES:

 For the sake of ecological balance, it has under taken numerous

control measures. Some of them are listed below:

 Installation of most advanced Electrostatic precipitator (ESP) with

an efficiency of 99.95%. Setting of effluent treatment plant

 Construction of a 225 m stack for effective disposal of obnoxious

gases and prevention of ground level fall out.

 Fugitive dust control in coal handling areas

 Provision of well designed ash ponds and efficient waste with in

stipulated limits.

3
Distribution of Electricity:
Total Capacity of Ramagundam NTPC is 2600 MW of stage 1, 2 & 3 (i.e., 1, 2, 3, & 4,
5, 6 unit’s) distributing electricity to following states in MEGA WATT .

STATE MW % OF UTILITY
TELANGANA/AP 610 29%
TAMIL NADU 470 22%
KARNATAKA 347 16%
KERALA 245 12%
GOA 100 5%
PODICHERY 50 2%
Remaining 250 MW is used to any state, now it is used for A.P.

Overall Power Plant Layout:

Fig: 1. 3 Overall Power Plant Layout

4
1. Cooling tower 10. Steam governor valve 19.Super
heater
2. Cooling water pump 11. HPT 20.FD fan
3. Transmission line 12. Deaerator 21.Reheater
4. Unit transformer 13.feed heater 22.Air intake
5. Electric generator 14. Coal conveyor 23.Economiser
6. LPT 15. Coal hopper 24.Air pre-
heater
7. Boiler feed pump 16. Pulverised fuel mill 25.Precipitator
8. Condenser 17. Boiler drum 26.ID fan
9. IPT 18. Ash hopper 27.Chimney stack

CHAPTER 2
INTRODUCTION TO THERMAL POWER PLANT

2.1 THERMAL POWER PLANT

It is a known fact that when coal it is burnt releases heat energy.
The same phenomenon when chemically represented.

C + O2 = CO2+HEAT ENERGY {395 K J / MOLE}

In the boiler chemical energy is converted into thermal energy by

heating water and converting it into steam. The steam produced in the
boiler is expanded in turbine. In the Turbine the thermal energy of
steam is converted into kinetic energy. This motion of Turbine rotor is
transmitted to generator in which mechanical energy is converted into
Electrical energy, which is transmitted to various load centres through
transmission lines.

ENERGY CONVERSION DIAGRAM

CHEMICAL THERMAL KINETIC ELECTRICAL

5
 ENERGY ENERGY ENERGY ENERGY

BOILER TURBINE GENERATOR

Fig: 2. 1 Energy Conversion Diagram

In the thermal power plant the chemical energy stored in coal is

being converted into Thermal energy in the form of steam which in turn
is converted into kinetic energy of Turbine. This kinetic energy is
converted to electrical energy in the -generator

2.2 BASIC POWER PLANT CYCLE:

The thermal power plant uses a dual (vapour + liquid) phase cycle.
It is a closed cycle to enable the working fluid (water) to be used again
and again.

The cycle used is "RANKINE CYCLE" modified to include super

heated steam, regenerative feed water heaters and Re-heated steam.

Fig: 2. 2 T-S Cycle

6
2.3 FUEL REQUIREMENTS:
The entire requirement of coal for the plant was proposed to be
met from the nearby Singareni collieries mines, which are about 30 Km
away from the plant. The mines were possessing about 1800 million
tons of coal at the time of installation. A dedicated MGR system having
a length of 53km has been developed to haul the coal from nearby open
cast mines.

Fig: 2. 3 Coal

2.4 WATER REQUIREMENTS:

At the time of making feasible report several alternatives were
considered for meeting the water requirements of cooling water. A
detailed study indicated that it would not be possible to meet it through
direct circulation. So a dam was proposed. The Pochampad dam was
built on river Godavari. Measures were taken to ensure that station is not
required to be closed under closure of irrigation or during draughts.
Water requirement of the plant during such conditions can be met for 9-
10 weeks without any replenishment from the distributor canal.

7
2.5 ASH DISPOSAL:
Large area of land is required for the disposal of the waste like
coal ash. Ash being generated from the plant is pumped in a slurry form
through pipe-lines to the ash pond at Kundanpally (Village), which are
5km away from the power station. The ash disposed is utilized in
various forms.

2.6 ENVIRONMENT CONTROL:

Station is equipped with highly efficient ESP system and with tall
chimney of about 225mts, height. Effluent treatment plant was also
installed for reuse of decants ash water from ash pond.

8
 CHAPTER 3
ELECRICITY GENERATION FROM COAL

Fig: 3. 1 Electricity Generation from Coal

3.1 COAL AND FUEL PATH:

The coal is transported to the RSTPS by rail from Singareni and
Western coal fields. Coal system prepares the main fuel for the boiler
furnace firing. The raw coal from the collecting point is passed to the coal
handling plant, where the coal is cleaned off metallic parts and crushed to
less than 40mm size. The crushed coal is fed into mill bunkers through a
set of conveyors and belt ways. Whenever direct feeding is not required
to coal bunkers, the coal is stacked into coal yard to stackers. Whenever
there is no supply of coal, the requirements of units is met from stockyard
by reclaiming using stacker re-claimer. The coal is fed through
gravimetric feeder into pulverizes, where it is reduced to the pulverized
state to facilitate optimum combustion in the boiler.

9
 The pulverised coal is transported with the help of primary air,
from PA Fan to burners. The hot primary also removes moisture from
pulverised coal besides transporting it. The pulverised coal entering the
coal entering the furnace is initially ignited by oil burners which are
withdrawn after attaining stability.

The ignited coal gets required air from secondary air duct for the
complete combustion of the coal. When the coal is burn the heat released
is transmitted to the water in the boiler. The ash emitted is of two kinds,

 Bottom ash, which is being heavily collected at the bottom ash

hopper for transportation.
 Fly ash, which is being very light carried by the draft towards
chimney, on the way precipitated by ESP’s and transported to ash
dump area.

Fig: 3. 2 Conveyor Belt

10
3.2 ASH DISPOSAL:
60.84
55.74 28.75
47.94 24.1

31.16 18.63
21.49 10.55
15.78 7.6
11.25 5.66
3.84

01-02 02-03 03-04 04-05 '05-06'06-07'07-08

Fig: 3. 3 ASH Disposal Graph

Indian coals are generally low sulphur and high ash content. On an
average the ash content in Indian coals is approximately in the range of
35-40%. For a typical 500MW unit coal consumption is of the order of
300 tons per Hr. Ash generated in a 500MW unit per Hr is about 120tons.

The ash thus generated is collected at bottom ash hopper,

Economiser hopper, Air-Preheated hoppers, and ESP’s. The Ash collected
in the bottom ash hopper is very coarse and is generally referred as
Bottom ash. The ash collected is ESP is very fine and is generally referred
ash fly ash.

3.3. FLUE GAS:

The Flue gases leaving the boiler furnace are drawn by the Induced
Draft fans are used,

11
  To super heat the steam.
 To re-heat the steam,
 To Pre-heat the feed water in the Economiser and lastly,
 To pre-heat the air in air pre-heater (both primary and secondary)
before leaving to the ESP where the fine fly ash is removed before
sending to the chimney.

The ESP consists of metal plates, which are electrically charged.

Dust and grit in the flue gases are attracted on these plates, so that they
don’t pass through the chimney to pollute the atmosphere. Regular
mechanical hammer blows causes the accumulated ash dust and grit will
fall to the bottom of the precipitator where they collect in hopper beneath
the ESP. From the boiler, a steam pipe conveys steam to the turbine
through a stop valve (which can be used to shut off steam in an
emergency) and through the control valve that controls automatically the
regular supply of steam to the turbine. Steam chest and a governor, driven
from a main turbine shaft, operates the control valve to regulate the
amount of steam to be passed (this depends upon the speed of the turbine
and amount of electricity required from the generator). Steam from the
control valves enter the high pressure cylinder of the turbine where it
passes through a ring of stationary blades fed to the cylinder wall these
act as a nozzles and direct the steam on to a second ring of a moving
blades mounted on the disc secured to the turbine shaft as result of the
steam.

The stationary and moving blades together constitute a stage of the

turbine and in practice many stages are necessary, so that the cylinder
contains a number of rings of stationary blades with rings of moving
blades arranged between them. The steam passes through each stage in
turn until in turn until it reaches the end of high pressure cylinder and in
its passage some of its heat changes to mechanical energy.

12
 The steam leaving the high pressure cylinder goes back to the
boiler for re-heating and return by a further pipe to the intermediate
pressure cylinder. Here it passes through another stationary and moving
blade.

Finally the steam is taken to the low pressure cylinder, where it is

rotates very big turbine blades. As steam gives up its heat energy to drive
the turbine its temperature and pressure falls and it expands, because of
this expansion the blades are much larger and larger towards the low
pressure ends of the turbine.

The turbine shaft rotates at 3000 rpm. This is determined by the

frequency of the electrical system used in this country and is the speed at
which a 2-pole generator must be driven to generate alternating current at
frequency of 50 cycles per second.

When much energy is possible as been extracted from the steam it

is exhausted directly to the condenser. The condenser consists of the large
vessel containing some 20,000 tubes each about 25mm in diameter. Cold
water from the river estuary, sea or cooling water is circulated through
these and stem from the turbine passes round then is rapidly condensed
into water condensate, because water has a much smaller comparative,
volume than steam, a vacuum is created in the condenser. This allows the
steam to be used to pressure below that of normal atmosphere and more
energy can be utilized.

From the condenser, the extraction pump after which the boiler
feed pump pressurises it pumps the condensate through low pressure feed
heater. It is further through feed heaters to the economiser and the boiler
for re-conservation into steam.

13
 When the cooling water for the power station is drawn from larger
rivers, estuaries or the coast, it can be returned directly to the source after
use. Power stations situated on smaller rivers and in land don’t have such
vast water resources available. So the cooling water is passed through
cooling towers and (where its heat is removed by evaporation) and re-
used.

A power station generating 2, 00,000 KW of electricity requires

about 2, 27,500 cubic meters of water an hour for cooling purpose. Where
the cooling towers are used, about hundred part of the cooling water
evaporates and certain amount is returned through its source to carry
away any impurities that collect most of it, however, is re-circulated.

This is the general process used in the thermal station for the safe,
efficient and profitable run of the plant.

3.4 DISTRIBUTION PATH:

Switchyard is the place from where all the EHV transmission line
are emanating and power is transmitted to various load centres and other
generating stations. Each switchyard has got a control room equipped
with protective relays and control stations, various types of metres event
lager and PLCC equipment various switching operations are carried out
as and when required in case of total as partial power failure, the lines are
synchronized with generating stations and power being restored in
addition various electrical parameters like MW, volts and frequency and
MVAR are constantly monitored and controlled with in the unit.

14
 CHAPTER 4
BOILER AND BOILER AUXILIARIES

4.1 BOILER AND BOILER AUXILIARIES:

1. Boiler:

Boiler or the steam generator is the main part in the power

generation process. Boiler acts as a medium in which water is converted
into steam by using the heat released in the process of combustion of coal
in the presence of oxygen. The steam generator is a natural circulation,
single drum type, front fired, double fan and balanced draft unit designed
for the following conditions.

A) Main steam flow 6, 70, 000 kg/hrs,

B) Main steam pressure 150 kg/sq.cm,
C) Main steam temperature 540 ⁰C,
D) Re-heat steam flow 580 kg/hrs,
E) Re-heat steam temperature 540 ⁰C.

15
 Fig: 4. 1 Boiler

There are many mountings to the boiler, which are compulsory safe
run of the boiler. Also there are accessories which are increases efficiency
of the boiler.

2. Furnace:

The furnace takes coal from the coal mills, oil from oil guns, and
air from FD Fans respectively for the process of the combustion. The
furnace has four walls. The wind boxes which allow oil into the furnace,
coal inlets, oil guns are all arranged at the four corners of the wall of the
furnace. There are igniters which are at the corner ignite oil and air mixer
by producing high voltage spark. Fire from four corners is tangential to
the fire walls.

16
 Fig: 4. 2 Blast Furnace

3. Economizer:

The function of the economizer is to pre-heat the boiler feed water

flow before it is introduced into steam drum by recovery some of the heat
of the flue gases leaving the boiler. The economizer located in the boiler
the back pass. The feed water after heated, it goes into the boiler drum.
The economiser is used for increasing efficiency of the boiler.

Fig: 4. 3Economizer

4. Boiler Drum:

It is the main part of the boiler, in which steam and water separates.
Boiler water circulates from the steam drum into un heated down corner
pipes, then from the down into heated furnace wall tubes and then back
into the drum with the use of steam generating water circulating pumps
(SGWCP)

17
 Fig: 4. 4 Boiler Drum

5. Super Heater:

The wet steam from the boiler drum enters into the super heater
and gets heated up to a temperature of 535 ⁰C and pressure of 170 kg/sq
cm, by gaining heat from flue gases leaving the furnace. The steam
entering the super heater is spread through horizontal primary super
heater and then through secondary super heater territory super heater.
Thus steam is super heated in3 stages the super heated steam leaves
through the super heater outlet header to the high pressure turbine (HPT)

6. Re-heater:

The function of the re-heater is to increase the temperature of the

steam leaving HPT again to 540 ⁰C then the pressure up to 42 kg/ sq cm.
The re-heater steam temperature is achieved by gaining the heat from the
waste flue gases leaving the boiler. The flue gas flow is split into two
paths respectively for heat in the super heater and the re-heater. Then the
steam goes to the Intermediate Pressure Turbine (IPT).

Fig: 4. 5 Re-Heater Pips

18
4.2 AUXILIARIES:
A) Coal mill:

The coal mill contains powder of the 20mm size of the coal given
to it. The pulveriser is an electrical motor driven rotating mechanical
grinding mechanism that crushes the coal between a roller pulverise
which pulverises and a bowl and various types of impact grinding mills.
Ball mills are most successful in the pulverisation of very hard of
abrasive coals such as anthracite, or meta-anthracite coal.

Fig: 4. 6 Pulverising Mills

B) Primary air fan:

The primary air fans are used primarily to transport the pulverised
coal to the respective coal nozzles at each coal elevation in the furnace.
Similar to the FD fan the PA fan also heats the air in the primary air fan
pre-heater (PAPH) the source of heating in the PAPH is also the waste
fuel gas. These are two PA fans to each boiler.

19
 Fig: 4. 7 PA Fan

C) Forced Draught fan:

The FD fan sucks air from atmosphere pressurises it and sends into
the furnace prior sending it to furnace, the pressurised air is heated in
secondary air pre-heater (SAPH). The source of heating in SAPH is the
hot flue gas, which is leaving from the boiler. These are two FD fans for
each boiler. The pressurised hot air generally called secondary air acts as
a combustion medium in the furnace.

Fig: 4. 8 Forced Draught fan

D) Air pre-heater:

Each 200 MW boiler is provided with two bi-sector re-generative

air pre-heater which heat the air by using the heat of the exit flue gases.
Each Air pre-heater can meet maximum continuous rating (MCR) of the
steam generator.

20
 The heating elements (Baskets) are of specially made metal plates
and arranged compactly in three layers. The housing surrounding the
rotor is provided with duct connection both ends for air and gas. It
adequately sealed by radial, axial, circumferential sealing members which
form passages for air and flue gas. The rotor supported by Thrust bearings
at the top. Separate oil reservoir and level indicator are provided for each
bearing. As the rotor slowly rotates, the heating elements (baskets)
alternatively pass through the gas and air passages. Heat from the hot flue
gases absorbed by the basket while passing through the gas passage and
carried over to the air passage, thus transferring the heat to the air steam.

Fig: 4. 9 200MW Lay Out

E) Seal air fans:

Two sealing air fans are provided for each boiler. They supply air
fans to feeder, mills and inspection holes at full load one fan will be in
service and other in standby. These fans are centrifugal radial type having
constant speed. The housing is constructed with the carbon steel plates
while the shaft is made of rolled carbon steel. Each fan has single suction

21
with silencer and electrical motor as the primary mover. The delivery line
of seal air fan is of overhanging type and provided with a blow type
expansion joint.

F)Fuel oil piping:

The primary fuel coal has an ignition temperature of 540 ⁰C, and
can’t be ignite directly so additional oil is used as the start of fuel. The
fuel supply is from the common fuel oil supply system compressing a
pump which will serve oil units in the station. The fuel oil flow to the
burners for achieving initial ignition temperature is supplied from the
system through a fuel oil supply line to a header in the furnace. The oil
may be heavy oil used for firing boiler up to 20% MCR or the light oil
used for start-up and low load generation the boiler.

4.3 POWER PLANT AUXILLIARIES:

1. Fuel handling plant.
a) Coal handling plant.
b) Oil handling plant.
2. DM plant.
3. Ash handling plant.

Coal Handling plant:

The importance and magnitude of the business of coal handling is

emphasized by the fact that about 80% of stations are coal fired.

The supplies are usually by rail or road and distribution is usually

by conveyor belt to the stock yard, or boiler bunkers. Starting in track
hopper house, basement and belt conveyor, coal can be transferred over a
double line series of conveyor. The double line can be operated
simultaneously on different routes and to maintain a flow during break
down, coal may be transferred from one line to another by operating flap
valves to feed conveyors. On its passage to bunkers from the stocking

22
round or the track hoppers house coal is conveyed to the top of the screen
and crusher house where it is screened and crushed, when necessary. The
screen and crusher house from a junction for the stack out/reclaim and
track hopper to bunkers routes. This allows coal to feed reversible
conveyors, which can be used to supply different conveyors for the
bunkers or stocks. As the bunker capacity is normally only capable of
supplying the boiler for 12-24 hrs it is essential that the plant must be
reliable.

Fig: 4. 10 Coal Handling plant

De-Mineralised Plant (DMP):

This consists in the removal of dissolved substances from the raw

water supplied by filtration by ionic exchange methods. This type of plant
can take various forms depending on the supply to be treated, but usually
consists of a cat-ion unit, which removes metal ions.

E.g. Mg, Na, K replacing them with Hydrogen ions. This gives an
acid solution, which contains usually a very dilute solution of HCl,
H2SO4, HNO3, and H2 CO3. The carbonic acid is largely removed by
spraying down a degassing tower, of which is passing a current air.

The reminder is removed with the other mineral acids in the an-ion
unit unless this contains a weak base resin when the CO2 would be
removed in a mixed wet unit, which contains an intimate mixer of cat-ion
and an-ion exchange resins.

23
The equations included are,

RH+ + Mg (OH) 2  R2 Mg + H2O

ROH- + HCl  RCl + H2O

For re-generation of resin

R 2 Mg + HCl  RH+ Mg Cl2

Fig: 4. 11 DMP

Ash Handling plant:

ESP (Electro Static Precipitator):

The ESP system consists of alternative plates and windings, which

carry positive and negative charge respectively. The positive plates are
grounded, the potential that exists across the windings is in the range of
40-50KV. Due to this potential, very low density in the flue gas gets
separated and gets deposited on the windings. This deposited on windings
is either hammered or scrapped, which causes deposits ash fall into the
hopper. The ash is then mixed with water to form ash-slurry for disposal.

Fig: 4. 12 Electro Static Precipitator

24
25
ID Fan:

Induced draught fan extracts ash less flue gases from ESP system and
sends to the chimney. Chimney sends out the gases to atmosphere to a
greater height to prevent pollution.

Fig:4. 13 ID Fan
 CHAPTER 5
TURBINE AND IT'S AUXILIARIES

Fig: 5. 1 Turbine Plates

Turbine is a rotary engine that extracts energy from a fluid or air flow
and converts it into useful work.

The simplest turbine has one moving part, a rotor assembly, which is
a shaft or drum, with blades attached. Moving fluid acts on the blades, or
the blades react to the flow, so that they move and impart rotational
energy to the rotor. Early turbine examples are Wind mills and water
Wheels.

Gas, steam, and water turbines usually have a casing around the
blades that contains and controls the working fluid. Credit for invention
of the steam turbine is given both to the British Engineer Sir Charles
Parsons (1854-1931), for invention of the reaction turbine and to Swedish
Engineer Gustaf de Laval (1845-1913), for invention of the impulse
turbine. Modern steam turbines frequently employ both reaction and
impulse in the same unit, typically varying the degree of reaction and
impulse from the blade root to its periphery.

A device similar to a turbine but operating in reverse, i.e. driven, is

a compressor or pump. The axial compressor in many gas turbine engines
is a common example. Here again, both reaction and impulse are
employed and again, in modern axial compressors, the degree of reaction
and impulse will typically vary from the blade root to its periphery.

Fig: 5. 2 Rotor

Theory of Operation:

A working fluid contains potential energy (pressure head) and

kinetic energy (velocity head). The fluid may be compressible or
incompressible. Several physical principles are employed by turbines to
collect this energy
 Fig: 5. 3 Different between impulse and reaction turbine

Impulse Turbines:

These turbines change the direction of flow of a high velocity fluid

or gas jet. The resulting impulse spins the turbine and leaves the fluid
flow with diminished kinetic energy. There is no pressure change of the
fluid or gas in the turbine rotor blades (the moving blades), as in the case
of a steam or gas turbine all the pressure drop takes place in the stationary
blades (the nozzles).

Before reaching the turbine, the fluid's pressure head is changed to

velocity head by accelerating the fluid with a nozzle. Pelton wheels and
de Laval turbines use this process exclusively. Impulse turbines do not
require a pressure casement around the rotor since the fluid jet is created
by the nozzle prior to reaching the blades on the rotor. Newton's second
law describes the transfer of energy for impulse turbines.

Reaction Turbines:

These turbines develop torque by reacting to the gas or fluid's

pressure or mass. The pressure of the gas or fluid changes as it passes
through the turbine rotor blades. A pressure casement is needed to contain
the working fluid as it acts on the turbine stage(s) or the turbine must be
fully immersed in the fluid flow (such as with wind turbines). The casing
contains and directs the working fluid and, for water turbines, maintains
the suction imparted by the draft tube. Francis turbines and most steam
turbines use this concept. For compressible working fluids, multiple
turbine stages are usually used to harness the expanding gas efficiently.
Newton's third law describes the transfer of energy for reaction turbines.

In the case of steam turbines, such as would be used for marine

applications or for land based electricity generation. Parsons type reaction
turbine would require approximately double the number of blade rows as
a de Laval type impulse turbine, for the same degree of thermal energy
conversion. Whilst this makes the Parsons turbine much longer and
heavier, the overall efficiency of a reaction turbine is slightly higher than
the equivalent impulse turbine for the same thermal energy conversion.

Steam turbines and later, gas turbines developed continually during

the 20th Century, continue to do so and in practice, modern turbine
designs will use both reaction and impulse concepts to varying degrees
whenever possible. Wind turbines use an airfoil to generate lift from the
moving fluid and impart it to the rotor (this is a form of reaction).

Wind turbines also gain some energy from the impulse of the wind,
by deflecting it at an angle. Cross flow turbines are designed as an
impulse machine, with a nozzle, but in low head applications maintain
some efficiency through reaction, like a traditional water wheel. Turbines
with multiple stages may utilize either reaction or impulse blade at high
pressure.

Steam Turbines were traditionally more impulse but continue to

move towards reaction designs similar to those used in Gas Turbines. At
low pressure the operating fluid medium expands in volume for small
reductions in pressure. Under these conditions (termed Low Pressure
Turbines) blade becomes strictly a reaction type design with the base of
the blade solely impulse. The reason is due to the effect of the rotation
speed for each blade. As the volume increases, the blade height increases,
and the base of the blade spins at a slower speed relative to the tip. This
change in speed forces a designer to change from impulse at the base, to a
high reaction style tip.

Classical turbine design methods were developed in the mid 19th

century. Vector analysis related the fluid flow with turbine shape and
rotation. Graphical calculation methods were used at first. Formulae for
the basic dimensions of turbine parts are well documented and a highly
efficient machine can be reliably designed for any fluid flow condition.
Some of the calculations are empirical or 'rule of thumb' formulae and
others are based on classical mechanics. As with most engineering
calculations, simplifying assumptions were made. Velocity triangles can
be used to calculate the basic performance of a turbine stage. Gas exits
the stationary turbine nozzle guide vanes at absolute velocity Val. The
rotor rotates at velocity U. Relative to the rotor the velocity of the gas as
it impinges on the rotor entrance is Vr1. The gas is turned by the rotor and
exits, relative to the rotor, at velocity Vr2. However, in absolute terms the
rotor exit velocity is Va2.The velocity triangles are constructed using these
various velocity vectors.

Velocity triangles can be constructed at any section through the

blading (for example: hub, tip, midsection and so on) but are usually
shown at the mean stage radius. Mean performance for the stage can be
calculated from the velocity triangles, at this radius, using the Euler
equation:
 Fig: 5. 4 Velocity triangles

Classification of Turbines

Steam turbines may be classified into different categories depending

on their construction, the process by which heat drop (i.e., work done) is
achieved, the initial and final conditions of steam used and their industrial
usage. This has been detailed in the subsequent paragraphs.

Based on number of pressure stages:

Single-stage turbines with one or more velocity stages usually of

small power capacities, these turbines are mostly used for driving
centrifugal compressors, blowers and other similar machinery.

Multistage impulse and reaction turbines; they are made in a wide

range of power capacities varying from small to large

Based on the direction of steam flow:

Axial turbines in which, the steam flows in a direction parallel to the

axis of the turbine. Radial turbines in which the steam flows in a direction
perpendicular to the axis of the turbine with one or more low pressure
stages in such turbines being axial.

Based on the number of cylinder:

Single - cylinder turbines.

Double - cylinder turbines.

Three - Cylinder turbines

Four - Cylinder turbines

Based on the method of Governing:

Throttle governing: Here fresh steam enters through one or more

(depending on the power developed) simultaneously operated throttle
valves.

Nozzle governing: Here fresh steam enters through two or more

consecutively opening regulators.

Based on the principle of Action of steam:

Impulse turbines

Axial reaction turbine

Radial reaction turbines with stationary guide blades

Radial reaction turbines without any stationary blades

Based on the Heat drop process:

Condensing turbines with regeneration:In these turbines steam at a

pressure less than atmospheric pressure is directed to a condenser, steam
is also extracted from intermediate stages for feed water heating. The
latent heat of exhaust steam during the process of condensation is
completely lost in these turbines.

Condensing turbines with one or two intermediate stage extractions:

Turbines of this type have one or two intermediate stage extractions at
specific pressure for industrial and heating purposes

Back pressure turbines: The exhaust steam from this is utilized for
industrial or heating purposes.
Topping turbines: These turbines are also of the back pressure type with
the difference that the exhaust steam from these turbines is further utilized
in medium and low- pressure condensing turbines.

Back- pressure turbines with steam extraction from intermediate

stages at specific pressure: turbines of this type are meant for supplying
the consumer with steam of various pressure and temperature conditions.

Low-pressure (exhaust- pressure) turbines: In this the exhaust steam

from reciprocating steam engines, power hammers, presses, etc. is utilized
for power generation purposes.

Mixed pressure turbines: Turbines with two or three pressure stages,

with supply of exhaust steam to its intermediate stages. The turbines
enumerated under 'a' and 'h' usually have extractions for regeneration of
steam at specific pressures for ' other purposes.

Based on the steam conditions at inlet to turbines:

 Low-pressure turbines, using steam at pressure of 1.2 to 2 atm.

 Medium - pressure turbines, using steam at pressure of up to. 40
atm.
 High- pressure turbines, utilizing steam at pressure above 40 atm.
 Turbines of very high pressures, utilizing steam at pressures of 170
atm. and higher and temperature of 535 deg. C and higher.
 Turbines of supercritical pressures, using steam at pressure of 255
atm. and above.

Based on their usage in industry:

Turbines with constant speed of rotation are primarily used for

driving alternators. Steam turbines with variable speed meant for driving
turbo- blowers, air circulators, pumps etc.,
 Turbines with variable speed: Turbines of this type are usually
employed in steamers, ships and railway locomotives (turbo- locomotives).

500/200 MW Turbine Components

The Main Turbine

The 500/200 MW turbine installed in our power stations is

predominantly of condensing-tandem -compound, three cylinder,-
horizontal, disc and diaphragm, reheat type with throttle governing and
regenerative system of feed water heating and is coupled directly with A.
C. Generator.

Turbine Casings:

High Pressure Casing:

The high pressure casing is made of creep resisting Chromium

-Molybdenum - vanadium (Cr- Mo - V) steel casting. The top and bottom
halves of the casing are secured together at the flange joint by heat
tightened studs to ensure an effective seal against steam leakage. Four
steam chests, two on top and two on sides are welded to the nozzle boxes,
which in turn are welded to the casing at the middle bearing end. The
steam chests accommodate four control valves to regulate the flow of
steam to the turbine according to the load requirement. Nozzle boxes and
steam chests are also made of creep resisting Cr- Mo -V steel castings.

Intermediate Pressure Casing:

The intermediate pressure casing of the turbine is made of two parts.

Front part is made of creep resisting Chromium - Molybdenum - Vanadium
steel castings and the exhaust part is of steel fabricated structure. The two
parts are connected by a vertical joint. Each part consists of two helves
having a horizontal joint. The horizontal joint is secured with the help of
studs and nuts. These nuts and studs are made of creep resisting Cr- Mo- V
steel forgings. In the intermediate pressure turbine the nozzle boxes are
cast integral with the casing, the first stage nozzle segment of IPT is a
welded construction like other diaphragms and is mounted directly in the
casing. Next two diaphragms are also housed in casing while other 8
diaphragms are housed in three liners which in turn are mounted in casing.

Low Pressure Casing:

The L.P casing consists of three parts i.e. one middle part and two
exhaust parts. The three parts are fabricated from weld able mild steel. The
exhaust casings are bolted to the middle casings by a vertical flange. The
casings are divided in the horizontal plane through the turbine centre line.
The lower half of the L.P. casing has integral bearing pedestals which
houses the following:

Rotors

Each turbine is mounted on each rotor here and these rotors are
coupled together to give a net rpm.

The rotors are,

 High Pressure Rotor.

 Intermediate Pressure Rotor.
 Low Pressure Rotor.

High Pressure Rotor: The HP rotor is machined from a single Cr -Mo -

V steel forging with integral discs. The rotor forging is thermally stabilized
to prevent abnormal deflection. The blades are attached to their respective
wheels by "T" root fastening. In all the moving wheels, balancing holes are
machined to reduce the pressure difference across them, which results in
reduction of axial thrust. First stage has integral shrouds while other rows
have shrouding riveted to the blades at periphery.
 The number of blades connected by a single strip of shrouding is
called a blade packet and the number of blades per packet is decided from
vile (ration point of view).

Fig: 5. 5 HP Rotor

Intermediate Pressure Rotor: The IP rotor has seven discs integrally

forged with rotor while last four discs are shrunk fit. The shaft is made of
high creep resisting Cr- Mo -V steel forging while the shrunk fit disc is
machined from high strength nickel steel forgings. The blades on the
integral disc are secured by "T" root fastenings while on shrunk fit disc by
'fork root' fastening. Except the last two wheels, all other wheels have
shrouding riveted at the tip of the blades. To adjust the frequency of the
moving blades, lashing wires have been provided in some stages.

Low Pressure Rotor: The LP rotor consists of shrunk fit discs a shaft.
The shaft is a forging of Cr- Mo- V steel while the discs are of high
strength nickel steel forgings. Blades are secured to the respective discs by
riveted fork root fastening. In all the stages lashing wires are providing to
adjust the frequency of blades. In the last two rows satellite strips are
provided at the leading edges of the blades to protect them against wet
steam erosion.
 Fig: 5. 6 LP Rotor

Blades:

Blades are single most costly and primary elements of turbine

Fig: 5. 7 Blades

 Fixed blades/Guide blades: Blades fitted in the stationary part are

called guide blades or nozzles
 Moving blades/ working blades: Blades fitted in the rotor are called
moving or working blades.
Impulse Blades: Pressure doesn't drop across moving blades.

Reaction Blades: Pressure drop occurs at moving blades.

Fig: 5. 8 Blade Diagrams

Types of blades: The following are three main types of blades:

 Cylindrical blade.
 Tapered cylindrical
 Twisted and varying profile blades.

Blades have three main parts:

a) Aerofoil: it is working part of blade and is one of the types

described above,
b) Root: It is portion of the blade, which is held with disc, drum or
casing and
c) Shrouds.

Three types of root arrangements are commonly used. They are,

1. T-roots - For small blades

2. Fire tree or serrated roots - For longer blades.
3. Fork and pin root -For longer blades shrunk on disk
type rotors.

Sealing glands:

To eliminate the possibility of steam leakage to atmosphere from

the inlet and exhaust ends of the cylinder, labyrinth glands of the radial
clearance type are provided, which provided a trouble free frictionless
sealing.

Provision has been made to supply live steam at the front sealing of
HP and IP, rotor to control the differential expansion, when rotor goes
under contraction during a trip or a sharp load reduction. (More briefly
explained in gland steam system)

Emergency Stop Valves and Control Valves:

These valves are very important as they regulate steam flow in to turbine.
ESVs (emergency stop valves) are provided in the main stream line and
interceptor valves (IV) are provided in the hot reheat line.

 Emergency stop valves are actuated by servo motor controlled by

the protection system. ESV remains either fully open or close.
 CVs are actuated by the governing system through servo motors to
regulate steam supply as required by the load.

Bearings:

Main bearings here are journal and thrust.

Journal bearings

Are manufactured in two halves and usually consist of bearing

body faced with anti-friction tin based habiting to decrease coefficient of
friction. Bearings body match with adjustable seating assembly in the
pedestal. Bearings are usually forced lubricated and have provision for
admission of jacking oil.

Fig: 5. 9 Journal Bearings

Thrust bearing is normally Mitchell type and is usually combined with a

journal bearing, housed in spherically machined steel shell the bearing
between the HP and IP rotors is of this type; while the rest are journal
bearings.

Oil supply system and control fluid system:

This system is to cool the bearings and drives of the hydraulic

turning gear. The main pump driven off the turbine shaft draws oil from
the main oil tank. Auxiliary oil pumps maintain the oil supply on stat-up
and shut down, during turning gear operation and when main oil pump
starts functioning. When the turning air is started, a jacking oil pump
forces high-pressure oil under the shaft journal to prevent boundary
lubrication. The lubricating and cooling oil is passed through oil coolers
before being supplied to the bearings.
Barring gear:

The function of the barring gear is to rotate the turbo- generator

rotors slowly continuously during start-up and shut down periods. This
rotation is important so as to bring down the high temperature of turbine
and also to stabilize moment of inertia.

When a turbine shut down, cooling of its inner elements will

continuous for many of hours. If the rotor is allowed to remain stand still
during this cooling period, distortion of rotor begins almost immediately.
This distortion is caused by flow of hot vapours to the upper part of the
casing, resulting in upper half of turbine beings at a high temperature,
than lower half. Hence to eliminate the possibility of distortion during
shut-down, barring gear is used to keep the rotor revolving until the
temperature change has stopped and casings have cold.

Similarly, while starting of turbine direct impact of steam may

cause damage to turbine parts so it is made to rotate at a required speed
and then steam is allowed. Later functioning of barring gear is stopped.

Hydraulic turning gear:

Functioning of thesis similar to that of barring gear. The function,

of the hydraulic turning gear is to rotate the shaft system at sufficient
speed before start-up and after shut down. This avoids irregular heating
up or cooling down and thus the associated distortion of the turbine shaft.

Be rotated in the event of a failure of normal hydraulic turning

gear. The barring gear may only be operated after the shaft system has
been lifted with high pressure lift oil. If it is hard to start to turning by
means of the mechanical barring gear, this may be due to incorrect
adjustment of the shaft lift oil system or to a rubbing shaft.
Anchor Point Of Turbine:

Anchor points indicate those places at which turbine is rigidly

fixed. This is designed by giving attention to the expansion and
contraction of the machine during thermal cycling. Excessive stresses
would be caused in the components if the thermal expansion or
contraction were restricted.

The method of attachment of the machine is also a decisive factor

in determining the magnitude of the relative axial expansion between the
rotor system and turbine casings, which must be given careful attention
when determining the internal clearances.

The fixed points of the turbine are as follows:

 The bearing housing between the IP and LP turbines.

 The rear bearing housing of the IP turbine.
 The longitudinal beam of the IP turbine.
 The thrust bearing in rear bearing casing of HP turbine.
 Rear bearings of IP rotor.
 Coupling between IP and LP rotors.
 LP front rear bearings.
 Generator couplings.
 Generator bearing.
 Barring gear.

Steam enters the middle casing from top and then divides into two
equal, axially opposed flows, to pass through four stages. The last but one
stage on each side is "Baumann's stages". They expand a part of the steam
to the condenser pressure and allow rest of the steam to expand through
the last stages.

5.1 TURBINE AUXILIARIES:

Turbine:

44
 Turbine is shaft coupled to the generator. The turbine is divided
into three categories, which have small shaft coupling.

Fig: 5. 10 Turbine Overview

1. HPT (High Pressure Turbine)

2. IPT (Intermediate Pressure Turbine)
3. LPT (Low Pressure Turbine)

The function of HPT is to rotate the shaft by using high pressure

obtained from the sure heater tubes. Then the steam losses its energy and
has to re-heated before passing to the IPT which rotates the shaft by using
the reached steam. The LPT has two expansion chambers. The expanded
steam IPT is tapped and sent to LPT where the temperature of steam is
530 ⁰C and pressure decreases to negative (0.86 kg/sq cm) some quantity
of steam is tapped from HPT, IPT and is used to heat feed water in HPH
and LPH respectively. The expanded steam from turbine is directly sent
to condenser. The turbine shaft is used to rotate the generator and hence
produce electricity.

45
HPT IPT LPT

Fig: 5. 11 Turbine Shaft Arrangement

46
 Fig: 5. 12 Turbine Crass Section View

Condenser:

The steam after expansion through turbine goes to the condenser

the condenser is of single pass, horizontal surface type with the dry water
box at the rated output of the turbine, condenser pressure is 76 mm of Hg
absolute with the circulating inlet temperature with 33 ⁰C and cooling
water temperature rise of 89 ⁰C. The use of condenser improves the
efficiency of power plant, decreasing the exhaust pressure of the steam
below atmosphere. Another advantage of condenser steam can be

47
recovered and this provides a source of good and pure feed water to the
boiler and thereby reducing considerably the requirement of water.

Fig: 5. 13 Condenser

Condensate extraction pumps (CEP):

There are two 100% capacity two stage condensate pumps. The
first stage takes suction from condenser hot well and supplies condenser
through polishing plant to second stage and from the second stage pump
to deaerator through 3 LPHs.

Fig: 5. 14 Condensate extraction pumps

LPH (Low Pressure Heater):

It is a 3 stage heater in which the temperature of feed water is

increased to 130 ⁰C. It is situated between CEP and deaerator. The

48
pressurized from CEP passes through coils present inside this LPH
chamber. For heating these coils steam tapped from IPT and LPT is used.
This heat is exchanged between steam and water inside the coils.

Fig: 5. 15 Low Pressure Heater

Deaerator:

It is a 3 stage heater in which as the pressure of the steam in the

condenser is below atmosphere (vacuum). There is a chance of mixing
atmospheric air with steam, which damages the turbine blades. Therefore
deaerator is used to separate the atmospheric air. In deaerator water is
sprinkled from the top which makes the dissolved gases like O 2 from
water. There producing pure, gasless and harmless feed water. Thus pure
and gasless feed water is collected in the deaerator water storage tank.

Fig: 5. 16 Deaerator

BFP (Boiler Feed Pump):

49
 It takes water from the deaerator and pressurizes it to highest level
in the water tank circuit to about 200 kg/sq cm and sent it to boiler
through HPTs. There are three 50% capacity and are 30% capacity BFPs
in the boiler feed water supply system. The 50% pumps are used for
normal operation of the boiler and 30% are used for initial purpose. There
are 2 types of BFPs. They are differentiated on the way they are driven.

1. MDFP (Motor Driven Feed Pump)

2. TDFP (Turbine Driven Feed Pump)

A turbine rotated by the auxiliary steam driver. The turbine driven

boiler feed pump motor driven boiler feed pump is driven by electric
motor.

Fig: 5. 17 Feed Pump

HPH (High Pressure Heater):

HPH is a two stage pressure heater in which steam is tapped from

the HPH. It is used to heat the feed water. The feed water flows in a coil,
in which steam is sent in opposite direction of the feed water such that
maximum heat exchange takes place. Feed water regulating steam system
consists of Pneumatic valves, which regulates quality of feed water to
feed into water and controls the level of boiler drum. A flow nozzle

50
located in the high pressure heaters and control valves between located
down steams measures the feed water flow.

Fig: 5. 18 High Pressure Heater

Generator:

The generator is one of the important blocks in the power

production plant. The generator is coupled with the turbine, which rotates
due to the steam. The electrical generator consists of two important parts
namely,

A) Stator,
B) Rotor.

The stator consists of windings to generate electric flux with the

help of an excitation unit provided with the rotor is the rotating part,
which is coupled to the shaft with bearings.

The rotor is a conductor and as a conductor is cutting flux an EMF

is induced which is tapped as a power supply. This supply is 22 KV and it
is step up to 400 KV for transmission purpose by using step up
transformer.

Rated out - 500 MW

51
Power factor - 0.85 lag

Terminal voltage - 22 KV

Frequency - 50 Hz

Speed - 3000 rpm

Fig: 5. 19 Generator

CONCLUSION

The turbine installed in NTPC is predominantly of condensing tandem

compound three cylinder, horizontal, disc and diaphragm reheat type with
throttle governing and regenerating of feed water heating and is coupling
directly with AC generator.

52
 REFERENCES
 “Power plant engineering". P. K. Nag (2002). Tata McGraw-Hill.

Turbine, Encyclopedia Britannica Online.

 "Steam Turbines". www.leander-project.homecall.co.uk.

 "Historic Naval Ships Association". Historic Naval Ships Association.

53