VOCATIONAL TRAINING

On
500MW THERMAL POWER PLANT

AT
NTPC LIMITED
RIHAND SUPER
THERMAL POWER
PROJECT,
RIHAND NAGAR SONEBHADRA (U.P.)
BY
Shivani Pan!"
O#

MADAN MOHAN MALAVIYA ENGINEERING COLLEGE, GORAKHPUR
UNDER THE E$PERT GUIDANCE
O#%
Mr. G. MISHRA, D.G.M.(BMD)
Mr. K. K. PURWAR, Dy.Supdt.(BMD)
Mr. P. K. CHOUDHARY, Sr.Engr.(BMD)

CERTIFICATE
NATIONAL THERMAL POWER CORPORATION LTD.
(A GOVERNMENT OF INDIA ENTERPRISE)
RIHAND SUPER THERMAL POWER PROJECT
P.O.-Rihand Nagar, Distt. Son!hadra "U.P.#
. DATE-$%&'(&$'')
CERTIFICATE
TO WHOMSOE*ER IT MA+ CONCERN
AC,NOWLED-EMENT
With feelings of joy and thanks, I placed in your
hand my Project report. It is my pleasant privileges
to thank all those who have help me in molding and
shaping my project. Without their guidance,
cooperation and best wishes it would have been
impossible for me to complete my dissertation
report. A big thanks to all those who helped me by
sparing time amidst their busy schedule and for
being kind enough to help me whenever I needed
them.
As man is a social animal. !e re"uires the
encouragement and affection of his parents and
friends to accomplish his goal and I have been
#ucky to get it and make this project report a
success.
$inally, I am thankful to all the respected E./0ti1
234o5s of N.T.P.C RIHAND,RIHANDNAGAR, for
providing me the necessary information, cooperation
in VOCATINAL TRAINING. I thank god almighty for
his abundant blessing because without it this project
was only a dream.
%!I&A'I PA'()*
III *ear
+echanical )ngg.
+.+.+.).,, -./A0!P1/
CERTIFICATE
This is to certify that this summer training report has been prepared by MR.
ABHAY KUMAR DUBEY S/O SHRI KAMLA KANT DUBEY, a student of
B.TECH. (MECH. ENGG) at R.I.T.S. BHOPAL in the partial fulfllment of
requirement of vocational training at NTPC Rihand.
The matter was analyzed by candidate under my guidance and this report
embodies the work done by him.
We wish him a bright future.
Approving Authority: Guide:
Mr. G.MISHRA Mr. K.K. PURWAR
DGM (BMD) Dy. SUPDT (BMD)

Mr. P.K. CHAUDHARY
SR. ENGG. (BMD
A2.13 '.3.P.,.
3he '3P, was formed in 4567 to meet the power re"uirement challenge faced by the nation
during the period. '.3.P.,. 8'ational 3hermal Power ,orporation9 is an Indian -ovt. undertaking.
It has the installed capacity of :;,6<7+W including joint venture, contributing :=.6> of the
nation?s power generation with only 45.4> of India?s total installed capacity.
2ased on 455@ data, carried out by (ata monitor 10, '3P, is the =th largest in terms of thermal
power generation and the second most efficient in terms of capacity utiliAation amongst the
thermal utilities in the world.
NTPC6s /or !0sinss is nginring, /onstr0/tion and o3ration o7 3o8r gnrating 34ants
and a4so 3ro1iding /ons04tan/5 to 3o8r 0ti4itis in India and a!road. As on dat th
insta44d /a3a/it5 o7 NTPC is $%,(9: MW thro0gh its ;% /oa4 !asd ";:,9<' MW#, ( gas !asd
"%,:== MW# and % Joint *nt0r Pro>/ts "%;9 MW#. NTPC a/?0ird ='@ ?0it5 o7 th SAIL
Po8r S03345 Cor3oration Ltd. "SPSCL#. This J* /o23an5 o3rats th /a3ti1 3o8r
34ants o7 D0rga30r ";$' MW#, Ro0rA4a ";$' MW# and Bhi4ai "(9 MW#. NTPC is a4so
2anaging Badar30r thr2a4 3o8r station "('= MW# o7 -o1rn2nt o7 India.
R/ognising its ./44nt 3r7or2an/ and 1ast 3otntia4, -o1rn2nt o7 th India has
idnti7id NTPC as on o7 th >84s o7 P0!4i/ S/tor CNa1ratnasD- a 3otntia4 g4o!a4 giant.
Ins3ird !5 its g4orio0s 3ast and 1i!rant 3rsnt, NTPC is 844 on its 8a5 to ra4is itDs 1ision
o7 !ing Eon o7 th 8or4dDs 4argst and !st 3o8r 0ti4itis, 3o8ring IndiaDs gro8thF.
Rihand S03r Thr2a4 Po8r Pro>/t
"9.='' MW#
INTRODUCTION
$.; SALIENT GEATURE
Lo/ationB 2ijpur village, (istt. %onebhadra. 81.P9.
Tota4 3ro3osd /a3a/it5B;CCC +W, in ; stages each of :D7CC+W

Prsnt /a3a/it5H :CCC +W 8%3A-)E4 F %3A-)E:9
8%3A-)E; is planned for future9
Tota4 4and "in a/rs#H 1P +P 3otal
<=@C 467: =<;:
Po8r E1a/0ationH GHE7CC0v !&(, 2ipolar line to (adri 8(elhi9, <CCk& single
circuit A, line to %haktinagar and 0anpur.
Bn7i/iar5 StatsH 1P, !aryana, Punjab, /ajasthan, IammuF0ashmir,
!imachal Pradesh, ,handigarh and (elhi.
Ginan/ingH )Jport ,redit of pound sterling ;<<million, aid from -ovt. of
1.0.pound sterling 466 million.-ovt.of India afforded the
rest cost of the project.
Ma>or Rso0r/sH
COALE 8a9 %ource EAmlori mines.
8b9 +aJimum consumptionE <;,;CC+3H(ay
for ;CCC +W 8)E-rade ,oal9.
8c9 +ode of 3ransportationE +-/ /ail
3ransportation %ystem.
WATERE 8a9 %ourceE /ihand /eservoir.
8b9 +aJimum ,onsumption K ;CC cusecs.
8c9+aJimum cooling water re"uirementE
47CCcusecs for 4CCC+W.
Chi2n5H ::<.7mts8/,, structure with steel flue9.
Ash dis3osa4H Ash slurry pumped to Ash dyke.
Co22n/2nt o7 8orAH C5HC:H45@;.
Unit-; s5n/hroniIdH ;4HC;H45@@.
Unit-$ s5n/hroniIdH C7HC6H45@5.
Unit-% s5n/hroniIdH ;4HC4H:CC7
Unit-9 s5n/hroniIdH ;4HC6H:CC7
Unit-; /o22r/ia4iId C4HC4H455C
Unit-$ /o22r/ia4iIdH C4H4CH4554.
Rihand s03r thr2a4 3o8r 3ro>/t "RhSTPP# has th /0rrnt gnration /a3a/it5 o7 $'''MW.
Thr ar 7o0r Units 8hr a/h Unit has th /a3a/it5 o7 =''MW. Units ; J $ 8r /o22issiond
in ;:<: and Unit % J Unit 9 8r /o22issiond r/nt45 in A0g0st $''=. Th 3o8r 34ant has t8o
s8it/h5ards o7 9'',* J ;%$,* 8hi/h ar intr/onn/td to a/h othr. Ths s8it/h5ards 7d
th northrn 3o8r grid 7or2 8hr th trans2ission o7 3o8r is don. On 9'',* !0s is 0sd 7or
H.*.D.C. trans2ission 8hi/h d4i1rs 3o8r 7ro2 Rihand to Dadri nar D4hi. Th thr2a4 34ant
intaAs 8atr 7ro2 th nar !5 8atr rsr1oir th -o1ind *a44a!h Pant Rsr1oir !asd on
Rihand ri1r. Th rsr1oir rsts on th da2 na2d Rihand da2, 8hi/h a4so 3o8rs th H5dro
3o8r station o7 $='MW. Th r?0ir2nt o7 /oa4 is 7047i44d 7ro2 A24ori /oa4 2ins 8hi/h ar
sit0atd in Madh5a Pradsh.
Th Rh.S.T.P.P. 3o8rs 1ario0s Stats s0/h as Uttar Pradsh, D4hi, P0n>a!, Hi2a/ha4 Pradsh,
Ra>asthan t/.
N8 t/hno4og5
%uper critical technology at '3P, %ipat project 8;D=CC+W9 to increase the efficiency of
the cycle and to decrease the green house gas emission.
,losed cycle seawater cooling at %imhadri project for first time in India.
Introduction of I-,, 8Integrated gasified combined cycle9 for clean and efficient
utiliAation of coal.
En1iron2nt 2anag2nt
#i"uid water treatment plants at $arakka and 0ahalgaon.
Ash water recycling system at 0ahalgaon and 0orba to reduce water re"uirement for
ash disposal at these station


ABSTRACT

Any thermal power plant is converting the chemical energy of fossil fuel 8coal9 into electrical
energy. 3he process involved for this conversion is based upon the +odified /ankine ,ycle. 3he
major components that are used to accomplish the +odified /ankine ,ycle are
i9 2oiler feed pump,
ii9 3he steam generator water walls 8evaporator9,
iii9 %team generator super heaters,
iv9 %team turbine,
v9 /eheater, vi9 ,ondenser,
vii9 /egenerative feed heaters etc.

All components of a power generating cycle are vital and critical in operation. In +odified
/ankine ,ycle the two most important aspect that is added are reheating F regenerative heating .
2y reheating steam, coming from eJhaust of the turbines, is used to send back to the reheater of
the boiler so that its enthalpy increases and more work can be done by this steam the other
purpose is to make steam dry so that no harm will be done to the blades of the turbine.
In /!%3PP there are four turbines in 3andem coupling namely one !.P 3urbine, one #.P
3urbine F two #.P 3urbine coupled with the generator to which is synchronised with the grid to
produce electricity at 7C!A.
. In all my modesty, I wish to record here that a sincere attempt has been made for the
presentation of this project report. I also trust that this study will not only prove to be of academic
interest but also will be able to provide an insight into the area of technical management.
MODIGIED RAN,INE C+CLE
A thermal power station operates using a closed steam power cycle, which is a dual
8vapourGli"uid9 phase cycle. In this cycle, the working fluid i.e. water undergoes various
thermodynamic processes and is used repeatedly. Previously, rankine cycle was used in most of the
thermal power plants. !owever, in modern power plants the rankine cycle is modified to include
superheating of steam, regenerative feed water heating and reheating of steam.
; 7

: <

3

4 =

%
3he modified cycle is represented on 3E% diagram. &arious processes areB
4E: K Ideal pressure increase at constant entropy in boiler feed pump.
:E; K !eat addition in the boiler at constant pressure.
;E< K Isentropic eJpansion in !P turbine.
<E7 K /eheating at constant pressure.
7E= K Isentropic eJpansion in IP and #P turbines.
=E4 K )Jtraction of latent heat in condenser.
$actors affecting thermal efficiency of +odified /ankine ,ycle are listed as underB
Initial %team Pressure.
Initial %team 3emperature.
/eheat Pressure and 3emperature.
,ondenser Pressure.
/egenerative $eed Water !eating.
MAIN BOILER
A . BOILER GUNDAMENTALS
Prin/i34s o7 /o2!0stionH
4. 3he primary function of oil and coal burning systems in the process of steam generation is
to provide controlled efficient conversation of chemical energy of fuel into heat energy,
which is then transferred to the heat absorbing surfaces of the steam generator. When
combustion is properly completed the eJhaust gases will contain, ,.:, water vapour,
sulphur dioJide and a large volume of nitrogen, combining carbon and hydrogen with the
oJygen in air brings about combustion. When carbon burns incompletely it forms carbon
monoJide.
$. Co23osition o7 airH
a9 65> nitrogen and :4> oJygen by volume.
b9 66> nitrogen and :;> oJygen by weight.
%. E./ss airH
In practice the theoretical "uantity is not sufficient to ensure complete combustion and
eJtra air has to be supplied. 3his eJcess air is known as eJcess air.
<. IgnitionB
$uel must be ignited before it can burn. /aising the temperature of the fuel
to its ignition temperature brings about combustion.
7. 3he following factors in efficient combustion are usually referred to as 3he
three 3?%.
a9 TIMEB It will take a definite time to heat the fuel to its ignition
temperature and having ignited, it will also take time to burn.
b9 TEMPERATUREB A fuel will not burn until it has reached its ignition
temperature. Preheating the combustion air increases the speed at which this
temperature will be reached.
,9 TURBULENCEH 3urbulence is introduced to achieve a rapid relative motion
between the air and the fuel particles. 3his produces a "uick propagation of the flame
and its rapid spread throughout the fuelHair miJture in the combustion chamber.
=9 ,ombustion efficiencyB
+aJimum combustion efficiency depends on
c9 (esign of the boiler
d9 $uel used
e9 %kill in obtaining combustion with the minimum amount of eJcess air.
69 3hermal efficiency of a boiler is measured by the amount of the heat transferred to the
water in the boiler by each 0g of the fuel used.
ARRAN-EMENT OG THE MAIN BOILERH
;#. Boi4r Str0/t0ra4sB
3he boiler structurals are divided into two parts.
a9 %upporting %tructuresB boilerEsupporting structure consists of a systematic
arrangement of columns stiffened with horiAontal beams and vertical diagonal
bracings and comprise of low carbon steel material. 3he main columns support
the main boiler components viA. drum, economiAers air preheaters, burners and
galleries at various levels.
b9 -alleries and %tairwaysB -alleries and stairways around the combustion and the
heat recovery areas are provided for approach to the boiler.
$# G0rna/H
A 2oiler furnace is that space under or adjacent to a boiler in which a fuel is burned
and from which the combustion products pass into the boiler proper. It provides a
chamber in which the combustion reaction can be isolated and confined so that the
reaction remains under controlled force. In addition, it provides a support or
enclosure for the firing e"uipment. 3he wall construction of the furnace is waterE
cooled walls i.e. the wall is of tube in which water is flowing continuously
%# Boi4r dr02H
3he boiler drum forms a part of the circulation system of the boiler.3he
drum serves two functions,the first and primary onebeing that of separating
steam from the miJture of water and steam discharged into it.%econdary,the
drum houses all e"uipments used for purification of steam after being
separated from water.3he purification e"uipment is commonly reffered to as
the drum intervals.
3he "uantity of water contained in the boiler below the water level is
relatively small compared to the total steam output.Primarily,the drum siAe
is determine by the space re"uired to accommodate the steam separating and
purifying e"uipments.3he steam space provided should be sufficient to
prevent priming and foaming.
+aterialB 3he boiler drum is made of carbon steam plates. 3he
materials used should comply with the Indian 2oiler /egulations.
,omparing carbon steel and alloy steel as material for drum,the
carbon steel costs less per ton of material but the overall weight
of drum will be higher because that of thickness.
DRUM INTER*ALSH
(rum intervals are used to separate water from steam and to direct the flow
of water and steam in a manner so as to obtain the optimum distribution of
drum matal temperature in boiler operation.
3he arrangement of drum normally consists of two or more integrated
device,each of which may be "uite different in design and operate on totally
different principles.)ach stage must have a higher separation efficiency.3he
greater the number of stages of separation,the lower the re"uired efficiency
of each stage .3hus,two stages at 55> efficiency,three stages at 5C>
efficiency and siJ stages at 6C> efficiency will give similar results.
Water level gauge is mounted on each end of the steam drum. If water level
goes outside of the prescribed operating limit then the boiler is
tripped.3hus,with increase in pressure,the separation of water from steam by
simple devices become more difficult.It become necessary to use more
efficient apparatus if primary separation is to be achieved in a confined area.

9# E/ono2isrH
3he purpose of the economiAer is to preheat the boiler feed water before it is
introduced into steam drum by recovering heat from the flue gases leaving the
boiler.)ntering first,the economiAer water is heated to about ;C to <C deg , below
saturation temperature.$rom economiser the water enters the drum and thus joins
the circulation system.Water entering the drum flows down through the downcomer
and and entersring header at the bottom.It is located in the boiler second pass below
the superheater. 3he economiAer is continuous loop type and water flows in upward
direction and gas in the downward direction. All tube circuits originates from the
inlet header and terminate at outlet header which are connected with the economiAer
outlet headers through three rows of hanger tubes.
=#Do8n/o2rsH
(own comers provide a passage for water from the boiler drum to bottom ring
header. $rom bottom ring header the water goes to water walls for heat absorption
and conversion into steam heating .3o achieve the circulation of water into water
wall 2oiler circulation pumps are provided in down comers.
)#Watr8a44sH
Water walls are the necessary elements of the boiler. 3hey serve as the means of
heating and evaporating the feed water supplied to the boiler from the economiAers
via boiler drum and down comers.
In large boilers, water walls completely cover the interior surfaces of the furnace
providing practically complete elimination of eJposed refractory surface. 3hey
usually consist of vertical tubes membrane and are connected at the top and at the
bottom to headers. 3hese tubes receive water from the boiler drum by means of
down comers connected between drum and water walls lower header.
Water walls absorb 7C percent of the heat released by the combustion of fuel in the
furnace, which is utiliAed for evaporation of feed water. 3he miJture of water and
steam is discharged from the top of the water walls into the upper wall header and
then passes through riser tubes to the steam drum.
3he design and construction of the water walls depends upon the combustion and
steam conditions and the siAe of the boiler.
.rifices installed in the inlet of each water circuit maintain an appropriate flow of
water through the circuit.

(#Risr t0!sH
A riser is a tube through which the miJture of water and steam pass from an upper
water wall header to the steam drum.
<# S03r HatrH
3here are three stages of super heaterL the first stage consists of horiAontal superheater of
convection miJed flow type with upper and lower banks located above economiAer
assembly in the second pass. 3he upper bank terminates into hanger tubes, which are
connected into the outlet header of the first stage super heater. 3he second stage
superheater consists of a pendant platen, which is a radiant parallel flow type. 3he third
stage superheater pendant spaced is of convection parallel flow type.
In radiant super heaters heat is absorbed by direct radiation from the furnace and are
generally located at the top of the furnace. %ince the furnace temperature, and therefore the
amount of available heat from radiation, does not rise as rapidly as the rate of the steam
flow, thus the steam temperature drops as the steam flow rises.
,onvection superheaters absorb mainly by the impingement of flow of hot gases around
the tubes. A purely convection superheater has a rising steam temperature characteristic i.e.
the amount of available heat from convection, rise as rapidly as the rate of steam flow.
:#RhatrH
3he function of the reheater is to reheat the steam coming out from the high pressure
turbine to a temperature of 7<CM,. 3he reheater is composed of two sectionsEone is front
pedant section and rear pedant section. 3he rear pedant section is located above the furnace
arc and the rear water wall and the front pedant section is located between the rear water
hanger tubes and the superheater platen section.
3he cold reheat is the line from turbine to the boiler and is at a lower than the reheat
line from boiler to the turbine called hot reheat steam. (ue to resistance of flow through the
reheat section, the hot reheat steam is at a lower pressure compared to the cold reheat
steam.
;'#B0rnrsH
3here are forty total pulveriAed coal burners arranged on the corners at a height of 4@ to
:7 meters and twelve oil burners provided each in between corner two pulveriAed twoEfuel
burner.
3he pulveriAed coal burners are arranged in such a way that ten mills supply the coal to
burners at < corners, of the furnace. All the noAAles of the burners are interlinked and can
be tilted as a single unit from G;C to K;C.
3he oil burners are fed with the heavy fuel oil till boiler load reaches to about :7>.
;;#Ds03rhatrsH
A. A. S03rhatr Ds03rhatrH S03rhatr Ds03rhatrH
3he superheater desuperheater is fitted between stages < and 78on transfer pipe9 to control the 3he superheater desuperheater is fitted between stages < and 78on transfer pipe9 to control the
superheated steam at the specified terminal temperature of 7<C superheated steam at the specified terminal temperature of 7<C
o o
,. 3he maJimum design ,. 3he maJimum design
temperature reduction at the superheater desuperheater is from <<= temperature reduction at the superheater desuperheater is from <<=
o o
, to ;@@ , to ;@@
o o
,. ,.
3he desuperheater comprises a spray noAAle shell and associated spray assembly projecting 3he desuperheater comprises a spray noAAle shell and associated spray assembly projecting
into a section of the superheater steam line. 3his section of the steam line forms the into a section of the superheater steam line. 3his section of the steam line forms the
desuperheater shell. %team assisted spray noAAle assembly provides a fine spray of water desuperheater shell. %team assisted spray noAAle assembly provides a fine spray of water
which attemperates the steam passing through the desuperheater. which attemperates the steam passing through the desuperheater.
%pray water for desuperheater is taken from the boiler feed water pump discharge. In
addition, spray water regulating stations are provided further downstream in each line.
B. Rhatr Ds03rhatrH
3he reheater desuperheater is only brought into use when the reheater outlet temperature
rises above the normal temperature.
3he reheater desuperheater comprises of a spray noAAle shell and associated spray noAAle
assembly projecting into a section of the steam line between the !P turbine outlet and the
reheater inlet headers. 3his section of the steam line forms the desuperheater shell. Water is
fed into the shell from the discharge side of the boiler feed pumps via a reheater
desuperheater spray water regulating station.
When the reheater desuperheater is called into service water is fed via the water tube and
passes through the spray noAAle thereby forming a spray which attemprates the steam passing
through the desuperheater and thus decreasing e 3he "uantity of water in the boiler drum is
relatively small compared to the total steam output. %o, the drum siAe is determined by the
space re"uired to accommodate the steam separating and purifying e"uipments.
;$# Boi4r Watr Cir/04ations P023sH
)ach boiler water circulation pump consists of a single stage centrifugal pump on a wet stator
induction motor mounted with in a common pressure vessel. 3he vessel consists of three
main parts a pump casing, motor housing and motor covers. 3he motor is suspended beneath
the pump casing and is filled with boiler water at full system pressure. 'o seal eJists between
the pump and motor, but a provision is made to thermally isolate the pump from the motor.
;%# IgnitrsH
!igh )nergy Arc type electrical igniters are provided which can directly ignite the heavy
fuel oil. An eJciter unit stores up the electrical energy and releases the energy at a high
voltage and short duration. A spark rod tip, which is designed such a way that converts the
electrical energy into an intensive spark. A pneumatically operated retracts mechanism,
which is used to position the spark rod in the firing position and retract to the non firing
position. )ach discrete spark provides a large burst of ignition energy as the current reaches
a peak value of the order of :CCC amps. 3hese sparks are effective in lighting of a wellE
atomiAed oil spray and also capable of blasting off any coke particle or oil muck on the
surface of the spark rod.
B. WATER CIRCULATION S+STEMH

Water must flow through the heat absorption surface of the boiler in order that it is
evaporated into the steam. In drum type units the water is circulated from the drum
through the generating circuits and back to the drum where steam is separated and
directed to the superheater. 3he water leaves the drum through the downcomers at a
temperature slightly below the saturation. 3he flow through the furnace wall is at
saturation. !eat absorbed is the latent heat of vaporiAation creating the miJture of
steam and water.
At very a high pressure the density difference between steam and water becomes
progressively less and a point is reached where natural circulation is too slow.'atural
circulation is limited to boiler with drum operating pressure around 467 kgHcmE:.
3o overcome this forced circulation is employed which uses pumps to speed up the
circulation of the water.


TECHNICAL DATA
Main !oi4r 7CC+W
T53 2alanced (raft ,(ry bottom,%ingle drum,/adiant $urnace,
,ontrolled ,irculation,3angentially $ired,3iltable 'oAAle.
Man07a/t0rr +H% 2!)#8,) ()%I-'9
G0rna/ t53 ,ontrolled ,irculation.
Dr02
a. .verall length ::C6C mm
b. (esigned pressure :C<.5 0sc.
c. (esigned temperature ;==
o
,.
S03rhatr
a.'umber of stages = stages
Rhatr
a. 'umber of stages ; stages
Sta2 74o8 at MCR
a. %team at final superheater outlet 46:7 3P!
b. %team at reheater outlet 47;C 3P!
Watr 74o8 at MCR
a. $eed water entering economiAer 46:73P!
Coa4 74o8 at MCR ;4=.< 3P!
Sta2 3rss0r at MCR "As/#
At 7ina4 s03rhatr o0t4t 46@
At rhatr o0t4t <;.<=
At rhatr in4t <7.@7
Gro2 dr02 45;.7
E/ono2iIr in4t 45=.=
BOILER AUKILIARIES
MILLIN- S+STEMH -
COAL BUN,ERB E
3hese are inEprocess storage silos used for storing crushed coal coming from the coal handling
plant through conveyor belts.
3here are ten coal bunkers supplying coal to each mills and are located at top of the mills to aid
in gravity feeding of the coal. )ach bunker can store coal, which can be used for 4:hrs.
COAL GEEDERH -
The purpose of coal feeder is to transfer coal at a pre- determined rate, from
coalbunker to the mill.
3he coal feeder comprises two continuous chains with # sections flight bars mounted between
the chains at every fifth link .3he chains runs on sprockets mounted at each end of the feeder to
given an upper strand movement towards the driven ends and a lower strand movement in the
opposite direction. 3he drive shaft is supported on two self aligning bearing mounted in the
Plummer block on support out side the feeder casing, shaft sealing is achieved by the lip seals in
the sealing housing and mounted in board of the bearing to abut the feeder casing.
3he tail sprocket shaft is mounted in adjustable bearing blocks adjacent to the feeder casing with
positioned which allow the feeder chain to be tensioned.
2oth upper and lower strands run over full width carrying plates with the lower strands located
by angle section guides mounted on the feeder wall. 3he upper and lower carrying plates and the
inside wall are protected from wear by replace by replaceable stainless steel panels, chains are
kept clean by rubber wiper.
$eeder input is achieved by roller chain drive to the conveyor via a fiJed speed electric motor
driving a variable speed gear boJ, tor"ue limiter and fiJed out put gear boJ 3he electric motor is
flanged mounted to variable speed gear boJ, coupled to the fiJed output gear boJ by a fleJible
coupling and tor"ue limiter.
3he principle of operation of coal feeder is that coal flows from the bunker into the chain feeder
via feed hopper and is conveyed to the mill feed inlet chute, when the feeder is in the operation,
the conveyor chain drag a fiJed head of coal towards the driven ends of the feeder. At the end of
the carrying plates the coal falls through the conveyor onto the bottom plate, where it is picked
up by the returning flight bars and dragged back along the feeder to fall into the mill feed chute.
MILL CHUTEH -
+ill chute trans port coal directly from the coal feeder to its associated mill, in addition an
emergency chute is incorporated to allow coal to be removed from the coal bunker via coal
feeder in the event that outage time is more than one month, or if there is a danger from fire in
the mill chute area, coal feeder, or coal bunker.
)ach mill is provided which transport raw coal from the bunker to the inlet of mill at the desired
rate. 3he rate of feeding is controlled by variable speed gear boJ . !ere chain type feeder is
present in which continuous chain is moving round sprockets in which a sprocket is driven by a
variable speed (., motor and the other sprocket is a return .%procket on this chain ,at different
+% plates are connected which are called as scrapers .3his type chain feeder are called scraper
feeder. 3he coal from the bunker falls on a platform which is below the scrapper feeder. When
the scraper moves it will scrap the coal and at the end of platform the coal falls into the
pulveriAer.
PUL*ERISER MILLH-
3here are ten mills for every 7CC +W unit located adjacent to the furnace at C m level.
3hese mills pulveriAe coal to desired fineness to be fed to the furnace for combustion .
3he main structure of the pulverisering mill is fabricated from mild steel in three cylindrical
sections, the bottom section 8the mill housing support 9which support the entire unit and
encloses the mill drive gear unit, a center section 8the mill housing9that contains the rotary
grinding element and upper section 8the classifier housing 9comprising an accommodate the gas
loading cylinders of the mill loading gear .A platform around the upper section provide an access
to an inspection door and to the top of the mill routine maintenance and is served by detachable
ladder .
.
PUL*ERILERSH
3he pulveriAser eJclusive of its feeder, consists essentially of a grinding chamber with a
classifier mounted above it. 3he pulveriAing take place in a rotating bowl in which centrifugal
force is utiliAed to move the coal, delivery by the feeder, outwards against the grinding ring 8buil
ring9. /olls revolving on journals that are attached to the mill housing pulveriAe the coal
sufficiently to enable the air stream through the pulveriAer to pick it up. !eavy spring action
through the journal saddles, provide the necessary pressure between the grinding surfaces and the
coal. 3he rolls do not touch the grinding rings , even when pulveriAer is empty. 3ramp iron and
other foreign material is discharged through a suitable spout. 3he air and coal miJture passes
upward the classifier with its deflector blades where the direction of the flow is changed
abruptly, causing the coarse particles to be returned to the bowl for further grinding. 3he fine
particles, remaining in suspension, leave the classifier and pass on through the coal piping to the
windboJ noAAles.
#.W %P))( +I##B
3hese are commonly known as tube ball mills and operate at approJimately 46 to :C
revHsec.%uch slow speed is essential with these types of mills as otherwise the balls will held
along the rorating surface due due to centrifugal force and no milling takes place.
Advantages of low speed millsB
849. Wearable part which needs replacement between annual overhaulsis only the ball and this
can be done when mill is in operation.
8:9. 'o maintenance for long period.
8;9. this mill has no relects and does not give tramp iron problem.
8<9. 3here is reverse of fuel within the mill which makes the mill output more stable.
(isadvantages of low speed millsB
849. power consumed per ton of coal pulverised is nearly to that of economic mills.
8:9. 3his mill consumes more powerHton coal ground especially when not loaded fully as bulk of
power is consumed in rotating mass of heavy ball charge.
2.W# +I##B
3he ball mill is one of the most advanced design of coal pulveriser.3he advantages of this mills
are B
849. lower power consupton.
8:9. /eliability.
8;9. +inimum maintenance.
8<9. Wide capacity84.6 tHhr. to4CC tHhr.9.

MILL TECHNICAL DATAH-
+anufactureEEEEEEEEEEEEEEEEEEEEEEEEEE+H% 2!)#
3ype of pulveriser 4CC;J /P
'o. of +ill H boiler 4C
2ase capacity of +ill =@3onnesH!r.
%peed of pulveriser <:rpm
'ormal capacitywith design coal 7:.7 3H!r
GANS
A fan is a device by which the air is made to flow at re"uired velocity and pressure in a defined
path imparting 0.) of its impellers to airHflue gases . 3his pressure boost is used to create a draught
in the air and flue gas system. $ans mainly performs two functionsB
i. 3hey supply air re"uired for combustion in the furnace with re"uired pressure F flow.
ii. 3hey evacuate the product of combustion i.e. flue gases into the atmosphere via chimney.
P.A Gan H-
3he primary air fan supplies heated air to the coal mills to give dry and pulveriAed coal to
the furnace for efficient combustion.3he P.A fan also supply fresh air to prevent coal mills by
overheating.
3here are two P.A fans per boiler, each fan having pneumatically operated radial guide vanes at the
fan inlet to control the fan output. 3he fan impeller is a double inlet, centrifugal wheel with
backward curved plate blades.
Ambient air is drawn into the P.A duct by two 7C> duty, motor driven centrifugal fans. 3he
air from each fan discharges into a hot air crossover duct via a steam air heater. 3his duct eJtends
around to each side of the boiler to supply the hot air to mills duct, both of which are branched to
supply hot air to four coal mills.
G.D GanH
3he forced draught fan system is provided to supply air re"uired for pulveriAed coal combustion in
the furnace, air for fuel oil combustion and over fire air to minimiAe 'oJ production.
3he $.( fan system comprises of two single stage aJial flow, constant speed, and auto variable
pitch fans per boiler. 3hese fans provide pressuriAed atmospheric air to the boiler for combustion.
Ambient air is drawn into the secondary air system by two 7C> duty, motor driven, aJial flow
forced draught fans with variable pitch control. 3he air from each fan discharges into a hot air
crossover duct via a main air heater.
3his duct eJtends around to each side of the boiler furnace to form two secondary air to burners
ducts. At the sides of the furnace, each duct split to supply air to two corners, then split again to
supply air to each of the nineteen burnerHair noAAle elevations in the burner boJ.
I.D Gan s5st2H
3he induced draught system comprises of three centrifugal double inlet fans per boiler, two
operating and one standby. )ach fan unit consists of a backward curved plate bladed impeller,
which is driven by an electric motor through a variable speed hydraulic coupling. 3he I.( fan
serves the purpose of evacuating the products of combustion or the flue gases in the atmosphere
via chimney. 3he flue gases after being cleaned in the precipitators is directed towards the
atmosphere through the chimney.
S/annr air 7an H
%canner fans are installed in the boiler for supplying continuously cooling air to the flame scanner
provided for the flame supervision. 'ormally one fan remains in service while the other one
remains available as standby.
%canner air fan is centrifugal type. It takes suction from $.( fan outlet and boosts the pressure
further to provide cooling air to the scanners.
Sa4 air 7anH
%eal air fan supplies sealing air, at a pressure higher than that inside the mill, to a brush sealing
around the stem of the coal mill yoke casting to prevent coal dust escaping to atmosphere. 3here
are eight seal air fans one per mill to provide sealing air. )ach fan is a close coupled, electrically
operated, centrifugal fan unit operated as part of the mill operating se"uence, which incorporates
an autoEstart facility.
P0rg or /oo4ing air 7an
3he function of the purgeHcooling air system is to provide a continuous supply of clean air to cool
all soot blowers in the retracted position, and to purge each retractable soot blower lance whenever
it is in the retracted position. 3here are two fans 8one operational, and one standby9 to provide
purgingHcooling air to each of the soot blowers, and also to prevent furnace gas blowEback into the
sealing areas. )ach fan comprises a close coupled, electrically driven centrifugal fan unit, which
initially, is manually operated but which contains an automatic standby.
=.E4/trostati/ 3r/i3itators
3he ash content in the Indian coal is of the order of ;C> to <C>. When coal is fired in the boiler,
ashes are liberated and about @C> of ash is carried along with the flue gases. If this ash is
allowed to atmosphere, it is haAardous to health. %o, it became necessary to incorporate an
electrostatic precipitator in the path of the flue gases going in the atmosphere. 3he electrostatic
precipitators are preferred to mechanical precipitators because they are capable of precipitating
particles from sub micron to large siAes of particles. 3he efficiency of the modern )%P?s is of the
order of 55.5>.
In '3P, /ihand, the gas cleaning plant consists of two )%P?s that operate on the eJhaust gases
from each of the 7CC +W steam generators.
3he electrostatic precipitator consists of a large chamber, which comprises of parallel rows of
sheet type collecting electrodes suspended from the precipitator casing with wire type discharge
electrodes arranged midEway between them. At the inlet of the chamber, gas distributor screens
for uniform distribution of the gases in the chamber, are provided.
3he collectors are connected to earth at positive polarity while the discharge electrodes are
connected to a high voltage dc supply at negative polarity. When dustEladen gas flows between
the electrodes, the corona discharge causes the dust particles to become charged, the particles
then being attracted towards and, eventually, deposited on the collector electrodes.
3his dust falls as the collecting electrodes are continuously rapped through a rapping system and
is collected into the pyramid type hoppers, located beneath each collecting electrodes, from
where it is removed by the ash handling system
).Air hatrs
Air heater is a heat transferring device in which air temperature is raised by transferring heat
from flue gases. Air heaters are capable of reclaiming heat from the flue gases at low temperature
levels and thus reducing the amount of heat rejected to chimney. 3his results in increasing the
boiler efficiency. $or every :C
C
, drop in flue gas eJit temperature, the boiler efficiency
increases by about 4>. In '3P, /ihand, recuperative type of air heaters is mainly used. In
recuperative air heaters, the heating medium i.e. flue gases flows through a closely packed
matriJ structure and then air is passed through the matriJ to pickup the heat. 3here are two
recuperative type of main air heaters for heating up the air from fans, two recuperative type air
heaters for mill air heating.
Sta2 air hatrs
3his type of air heaters does not utiliAe the heat from the boiler flue gases and so does not affect
the boiler efficiency. 3hese are generally used during starting when the flue gases entering the
regular air heater is low and hence further heat eJtraction is not possible and low temperature
corrosion prevails.
3here are two main steam air heaters and two mill air heaters. %team air heaters comprises of
round tubes carrying steam to be condensed. 3hese heaters are provided with air eJtraction
system so that air entering with steam will not lock and prevent the operation of air heater. In
addition, the outlet temperature of air can be controlled easily.
(.Giring s5st2
'3P, /ihand has direct firing system. In this system, a controlled "uantity of crushed coal is fed
to each bowl mill 8pulveriser9 by its respective feeders and primary air is supplied from the
primary air fans which dries the coal as it is being pulveriAed and transports the pulveriAed coal
through the coal piping system to the coal burners.In this system,burners are set at each corners
of the furnace and are directed to strike the outside of an I+A-I'A/* ,I/,#) at the centre of
the furnace.2ecause the streams of fuel strike each other,eJtremily good miJing is
obtained.%ince the body of the flame produced is given a rotary motion is leads to a longer flame
traveland gases spread out and fill the combustion.
3here are ten pulverisers out of which eight are used and two remains in standby. 3he raw coal
feeders supply 6< 3P! of coal to each mill.
3he pulveriAed coal and air discharged from the coal burners is directed towards the center of the
furnace to form firing circle. 3here are ;: tilting, tangentially fired coal burners fitted at the four
corners of the boiler at eight elevations.
3he secondary air heating system supplies secondary air for combustion in the furnace around
the pulveriAed coal burners and through auJiliary air compartments directly adjacent to the coal
burner compartments. 3here are 4= airEatomiAing ignitors per boiler, which initially ignite the
coal and air miJture.
Above a predictable minimum loading condition, the ignition becomes selfEsustaining.
,ombustion is completed as the gases spiral up in the furnace.
SOOT BLOWIN- S+STEM
Introd0/tion
In /h%3PP, soot deposited in various regions of boiler is removed with the help of soot
blowers, which utiliAe steam as the main working medium. 3his part is mainly concerned
with the eJisting soot blowing system and the problems arising in the system during
operation.
3he removal of soot is very necessary for the efficient working of the plant. 3his is because
soot acts as an insulator for the heat transfer taking place between the flue gases and
waterHsteam inside the tubes. .n the other side, it increases the metal temperature of
superheater and reheater tubes located inside the boiler. 3his temperature increase may cause
damage of the tubes resulting leakages across the tubes. Which, in turn affect the working of
the boiler.
%o, regular soot blowing is very necessary in the boiler. %imilarly, soot is also deposited on
the air preheater baskets, which causes plugging of the baskets. Also in case of oil firing
during initial lightEup unburnt oil may deposit in baskets. 3his deposited oil may cause fire
haAard in air heater. 3o avoid these problems soot blowing is done in air preheater also.
Soot !4o8ing 3ro/ssH
3he complete soot blowing process can be divided into following three major se"uential partsB
A. S!"# $o%& 'ro()**E 3his part of the process step checks the close status of all the
valves.
2. W+r, "' 'ro()**E In this step the valves according to the selected blower group open
to provide hot steam to the selected blower group at certain pressure level.
,. B-o%.&/ 'ro()**E In this se"uence actual blowing of steam takes place. 3he blower
pairs under currently selected group when comes in to operation carries the steam
inside the boiler and continues to blow till it returns to its park position.
Sta2 !4o8ing s/h2H
When blowers go inside the boiler they carries steam, which is made available to the blowers
through the section valves dedicated for the blower group. 3hese section valves are all
motoriAed and their positions are sensed by their end limit switches.
&alves are classified in four categories according to their operational involvement. 3hey are
listed as followsB
a9 +ain steam supply valves.
b9 %team pressure control valves.
c9 %ection valves.
d9 (rain valves.
3he main steam supply for soot blowing is obtained from two alternative sources each isolated
by a separate motoriAed isolating valve. .nly one source can be selected at a time. 'ow, this
steam supply is distributed to four sections of the boiler and each section is isolated by a
motoriAed section valve. (own stream of which a pressure switch monitors the steam pressure.
3he air heaters can be cleaned using an auJiliary steam supply. 3his supply is used eJclusively
for the air heater soot blowers when the air heater is re"uired to be cleaned during start up of
the boiler. 3he auJiliary supply is connected downstream of the section valve, which remains
closed when this source is being used. 3he drainage pipe work is isolated by a number of
motoriAed drain valves.
Lo/ation o7 Soot B4o8rsH
3he blowers are divided into groups, numbered from 4 to 5. -roup 4 to < comprises of wall
blowers and group 7 to 5 comprises of long retractable soot blowers. 3he soot blowers within
each group are listed in pairs, with an odd numbered soot blower paired with an even
numbered soot blower.
Wa44 B4o8rH
Presently there are @@ wall blowers, which are numbered from 4 to @@. All wall blowers are
located at four levels, so grouped as groupE4, groupE:, groupE; F groupE<, of first pass of
boiler each having :: blowers. -roupE4 is below furnace Aone and other three are above
furnace Aone.
Long Rtra/ta!4 Soot B4o8rH
#/%2s are kept in #!% and /!% of the boiler. .dd numbered #/%2s are kept in /!% and
even numbered #/%2s are kept in #!%. With an eJception of group =, all soot blowers in a
particular group are operated in synchronous pairs in an automatic se"uence i.e. an odd
numbered soot blower with an even numbered soot blower
#/%2s are mainly used to penetrate between the tube banks of the economiAer, superheater
etc.It consists of a fabricated boJ casing, steam lance tube, steam feed tube, steam isolating
valve, traverse and rotary chains, etcN
Whenever the signal to operate the soot blower is given from the control room, an electric
motor drives the traverse reduction gearboJ from its parked position, at a preset distance the
steam isolating valve opens to allow steam to flow through the feed tube and out through the
lance tube noAAles. 3he pattern of the steam jet from the noAAles is helical with a different pitch
on the inward stroke to that on the outward stroke. At about midEstroke a feed tube support
rises to abut the feed tube preventing sagging.
Whenever the eJtent of the stroke has been reached, a reverse limit switch is actuated causing
the main gearboJHlance tube to reverse and return to its parked position engaging the stop limit
ready for the neJt operation, having reEset the feed tube support mechanism and isolated the
steam isolating valve.
An air scavenge valve is fitted to the steam isolating valve which prevents the ingress of boiler
gases into the valve chest and provides a positive air flow when the soot blower is in the
parked position.
Air is also provided for the wall boJ to prevent gas leakage from the boiler.
SOOT BLOWER ARRAN-EMENT
$/.'3 WA## /)A/ WA##
4:; 4:<
PP4 PP: PP; PP< PP7 PP=
4 : ; < 7 =
:; :< :7 := :6 :@
<7 <= <6 <@ <5 7C
=6 =@ =5 6C 64 6:
4: 4; 4< 47 4= 46
;< ;7 ;= ;6 ;@ ;5
7= 76 7@ 75 =C =4
6@ 65 @C @4 @: @;
4:7 4:=
WA## ()%#A--)/ AI/ !)A3)/ 2#.W)/
#.'- /)3/A,3A2#) %..3 2#.W)/
STEAM TO MECHANICAL POWER
INTRODUCTION
A thermal power plant is based upon the principle of conversion of heat energy into mechanical
energy. $or this conversion of energy a power plant re"uires a turbo machine.
A turbo machine is a power producing thermodynamic machine. In order to function, a turbo
machine re"uires a suitable working fluid, a source of highEgrade energy and a sink for lowE
grade energy. In a thermal power plant water is used as a working fluid and it is converted into
steam.
A steam turbine is a device that converts heat energy of the steam coming from the boiler into the
mechanical energy of shaft rotation.
'3P, /ihand has four 7CC +W units. )ach unit has one steam turbine.
$or large turbo machines, multicylinder designs are used. 3he number of cylinder depends on the
terminal conditions of steam and speed of rotation. 3he turbine with a number of cylinders on a
single shaft is described as a O3andem compound machine?. '3P, /ihand is a fossilEfired power
station using a typical turbine of 7CC +W output in each unit. )ach of the two turbines consists
of a single flow !P, a double flow IP and two double flow #P turbines 8cylinders9 coupled to the
generator shaft.
)ach section of steam turbine consists of a rotor from which project several rows of closely
spaced blades. 2etween each row of moving blades there is a row of fiJed guide vanes 8blades9
that projects inward from circumferential housing. 3he vanes are carefully shaped to direct the
flow of steam against the moving blades at some angle and at a high velocity that will maJimiAe
the energy conversion.
3he crossEsectional diameter of a turbine section increases continuously and so the steam
eJpands. In this process the temperature and pressure of the steam decreases and volume
increases continuously. 3he #P section has the largest crossEsectional diameter, whereas the !P
has smallest crossEsectional diameter. %eparate stop valves and governing valves are provided to
control the steam inlet and outlet from the turbines.
3he main auJiliaries of a steam turbine are the rotor, blades, guide vanes, casing, bearings
and couplings, bolting, steam chests, valves and critical piping.

I'3/.(1,3I.' 3. 7CC +W P.W)/ P#A'3
2.I#)/B
3he boiler is a radient,controlled circulation drum,dry bottom type unit.3he boiler units are
designed for the following terminal conditions8mcr9B
)vaporation a9%! outlet B 4,6:7 tHhr
b9/! outletB 4,7;C tHhr
Working pressure after stop valveB46@ kgHcmE:
%team 3emperature at %! outlet B7<C deg ,
%team 3emperature at /! Inlet B;<<.4 deg ,
%team 3emperature at /! Inlet B<7.@7 kgHcmE:
%team 3emperature at /! Inlet B<;.;= kgHcmE:
$eed Water 3emperature at ),. InletB:7= deg ,
$urnace (esign Pressure B GHE ==C mm wc8g9
3he boilers are of single furnace design,circulating pumps to provide assisted circulation.
)ach 2oiler corner is fitted with tilting tangential burner boJes comprising for high energy
ignitors, four lightEup heavy oil fired burners and eight pulveriAed coal burners. 3he angle of
tilt from the horiAontal is about K;C deg to G;C deg.
$eed water to the boiler passes through !P feed heaters into the economiAer and then to the
steam drum from where it flows into the suction manifold and furnace wall circuits via the
three boiler circulating pumps, returning to the steam drum as a waterHsteam miJture.3his
miJture is separated into three stages and first two stages are incorporated into the turbo
separators and the final stage takes place at the top of the drum just before the steam enters
the connecting tubes comprising of first stage superheating .
within the steam circuit there are a further four stages of superheating, making five in total.
3here are also three stages of reheat.
superheater temperature control is provided by spray attemperation situated in the connecting
link between the superheater low temperature pendant outlet header and the superheater
division panel inlet headers.
PulveriAed coal system
3he system for direct firing of pulveriAed coal utiliAes bowl mills to pulveriAe the coal and a
tilting tangential firing system to admit the pulveriAed coal together with the air re"uired for
combustion8secondary air9 to the furnace.
As crushed coal is fed to each pulveriser by the feeder,primary air supplied from the primary
air fans which dries the coal as it is being pulveriAed the transports the pulveriAed coal
through the coal piping system to the coal noAAles in the wind boJ assemblies.
3he pulveriAed coal and air discharged from the coal noAAles is directed towards the center of
the furnace to form firing circle.
Primary air system
3he primary air draught plant supplies hot air to the coal mills to dry and convey pulveriAed
coal to the burners.
3he P.A system comprises two P.A. fans,two steam coil air preheaters 8%,AP!9 and two
regenerative air preheaters.)ach fans, which is of sufficient rating to support =C>
+,/ load,discharges through a %,AP! into a common bus duct that has four outlets,two
directing air into the primary air preheater for heating, two direct cold air straight to the
pulveriAed mills.
%econdary air system
3he secondary air draught plant supplies the balance of air re"uired for pulveriAed coal
combustion, air for fuel oil combustion, and overfire air to minimiAe the production of nitrous
oJide8'.D9.
3he secondary air system,comprises two forced draft 8$.(.9 fans, two steam coil air preheaters
8%,AP!9 and two regenerative type secondary air preheaters.
$lue gas handing system
3he flue gas handling plant draws the hot flue gases from thefurnace and discharges,them to
atmosphere through the chimney.(uring its passage to the chimney.(uring its passage to the
chimney,flue gas is passed through a feed water economiAer and four regenerative air preheaters
to improve boiler efficieny ,and through four electrostatic precipatators to keep dust emission
from chimney within prescribed limits.
soot blowing system
.n load,gas side cleaning of boiler tubes and regenerative air heaters is achieved using 4:=
electronically controlled soot blowers which are disposed around the plant as followsB
@@ E furnace wall blowers B steam
;< E long retractable soot blowers B steam
< E Air heater soot blowers primary
and secondary air heaters B steam
31/2I')
-ENERAL DESCRIPTION
3he turbine is a reaction, condensing type, tandem compound with throttle governing and
regenerative system of feed water heating. It is coupled to directly to the generator.3he turbine is
suitable for sliding pressure operation to avoid throttling losses at partial loads. 3he turbine is a
single shaft machine with separate !P, IP and #P turbines. !P turbine is a single flow cylinder
where as IP and #P are double flow cylinders. %team flow to !P 3urbine is controlled by four
combined main stop and control valves by a simple throttle governing system. .n the two
eJhaust lines of !P turbine, swing check valves are provided which prevent hot steam from the
reheater flowing back into the !P turbine. 3he hot reheat steam is admitted to the IP turbine
through the four combined stop and control valves. IP eJhaust is connected to the #P turbine by
cross over pipes without valve sat diametrically opposite points.
HP TURBINE
3he outer casing of the !P turbine is of the barrel type and has neither aJial nor a radial flange.
3he guide blade carrier is aJially split and kinematically supported. 3he space between the outer
casing and the inner casing is fed from admission steam to !P turbine. 3his steam is drained
through !P casing drain during start up which promotes "uicker heating of inner casing which
results in lesser problems of differential eJpansion. 3he inner casing is attached in the horiAontal
and vertical planes in the barrel casing so that it can freely eJpand radially in all directions and
aJially from a fiJed point. 3he !P turbine is provided with a balance piston in the admission side
to counter act the aJial thrust caused by steam forces. !P turbine is provided with 4@ stages of
reaction blades.
IP TURBINE
It is of double flow construction and consists of two casings. 2oth are aJially split and inner
casing kinematically supported and carries the guide blades. 3he inner casing is attached to the
outer casing in such a manner as to be free to eJpand aJially from a fiJed point and radially in all
directions. IP turbine is having 4< reaction stages per flow. )Jtraction steam to high pressure
heater no.7 and deaerator are taken from IP turbine and the IPEeJhaust respectively.

LP TURBINE

3he casing of the double flow #P cylinder is of threeEshell design. 3he shells are aJially split and
of rigid welded construction. 3he inner shell taking the first rows of the guides blades, is
attached kinematically in the middle shell. Independent of the outer shell, the middle shell, is
supported at four points on longitudinal beams. 3wo rings carrying the last guide blade rows are
also attached to the middle shell. #P turbine is provided with = reaction stagesHflow.

TURBINE S+STEM
HP STEAM S+STEM
3he high pressure and temperature steam is piped from the boiler stop valves to the steam inlet
ends via two steam legs or steam pipes. 3hese two steam pipes are further branched into four
subEbranches. 3hese branches endEup into four inlet valves of four horiAontally arranged steam
chests, two on each side of the !P cylinder.
)ach of the steam chest contains a !P emergency stop valve and a !P governing valve arranged
coEaJially. 3he !P stop valve is a crucial valve and is used only during emergency conditions.
%team leaves the governor valves through branch pipes to the top and bottom inlet tee pieces on
the !P cylinder. 3he steam chest assemblies are mounted on the foundations close to the !P
cylinder. )ach stop and governor valve is opened by a hydraulic operating gear and closed by
two coil springs.
IP STEAM S+STEM
3he steam eJpands in the !P turbine and is fed into the reheater section of the boiler. $rom
reheater section of the boiler the steam is piped into the steam inlet ends of the intermediate
pressure turbine through four inlet pipes.
3here eJists four steam chests two on each side of the IP cylinder. )ach steam chests contains an
IP intercept stop valve and an IP governing valve arranged
coEaJially. %team leaves the governor valves through branch pipes to the top and bottom tee
pieces on the IP cylinder.
3he opening and closing mechanism of the valves of the IP turbine is similar to that of the !P
stop valves and governing valves.
LP STEAM S+STEM
IP steam after eJpansion is eJhausted through four stub pipes, two at each end at the top half of
the IP cylinder, and is ducted to the two #P cylinders by IPH#P crossover pipes. 3he volume of
steam at the IP outlet is enormous and to handle such an enormous volume of steam two #P
turbines are provided.
3he steam from each of the #P turbines after eJpansion is fed into the condensers mounted
below the #P turbines. In the condensers the steam outlet from the #P turbines is condensed to
give condensate, which further undergoes a cyclic process to give feed water for the boiler input.

!ere, under slung condensers with @CC inclined tubes are used, using a connecting duct between
the turbine outlet flange and condenser inlet flange. As the condenser tubes are normally much
longer than the width of the turbine casing, so this duct is trapeAoidal in shape.
3he heat energy carried by the steam is converted into mechanical power, which results into the
shaft rotation. 3he turbine shaft is coupled with the generator shaft.
3his rotary motion of the generator shaft is converted into electrical power by the generator. 3he
power output from the generator is at low voltage level of :C k&P. 3his low voltage is boosted to
high voltage level of <CC k& to reduce the transmission losses
.
TURBINE AUKILIARIES
T0r!in /asing
%team turbine casings are the massive steel casings that encase the internal stationary and
rotating components of the turbine. 3urbine casings have two critical functionsB
a9 ,ontaining the steam pressure and
b9 +aintaining support and alignment of the internal components.
3here are generally two casingsB
i# O0tr /asing
3he outer casing is divided on the horiAontal centerline into top and bottom half casings. 2oth
the halves are bolted together with bolts and cap nuts at their horiAontal joint flanges.
ii# Innr /asing
3he inner casing is subjected to the highest temperatures and pressures, is also divided at the
horiAontal centerline into top and bottom half casings, which are bolted together in a similar
manner at their horiAontal joint flanges.
3he inner casing is supported within the outer casing in such a manner as to maintain proper
alignment and allow thermal eJpansion. ,racking of the casing can lead to steam leaks and,
in eJtreme situations, to bursting. ,racks in casings are typically located at the inlets of !P
and IP turbine sections, where the local thermal stresses are higher.
T0r!in B4ads
2lades are the single most costly parts of the turbine. 3he function of the turbine blades is to
convert the available heat energy carried by the steam into mechanical energy. 2lades fitted in
the stationary part are called Oguide blades? or OnoAAles? and those fitted in the rotor are called
Omoving blades?.
Sta2 /hsts and 1a41s
)ach of the !P, IP, #P cylinders of the turbine has four steam chests two on each side of the
turbine. %team chests are the pressure vessels or steam carrying spaces, which performs the
function of both carrying as well as transferring the steam at high pressure and high temperature
via valves into the turbine cylinders. 3hese steam chests comprises of a stop valve and a
governing valve.
3he steam from the superheaters outlets is admitted to the !P steam chests via four !P steam
mains. 3he steam from the steam chests is admitted to the !P turbine steam inlet pipe through
the emergency stop valves and the associated governing valves which are housed in steam
chests. After eJpansion in the !P turbine the steam is fed into the reheater and then to IP steam
chests, through !P turbine steam outlet pipe. 3he steam from IP steam chests is fed into the IP
turbine via IP stop valve and IP governing valves and then to #P steam chests.
Sto3 1a41s
3he stop valves are emergency valves placed in the steam chests and are provided in the main
steam line. 3he purpose of the emergency stop valves is to cut off the steam supply during
periods of shutdown and to provide prompt interruption of steam flow through the turbine
cylinders in an emergency trip.
'ormally, these valves are kept open fully but during emergencies these valves are fully closed
84CC>9. (uring such conditions, the plant is producing no power because no input is given to the
turbine.
-o1rning 1a41s
3he governing valves are also situated in the steam chests. 3hese are the control valves i.e. they
provide accurate control of the steam flow rate into the turbine, thus controlling the generator
load when the machine is synchroniAed to the grid.
!P governing valves are the most important valves. 3hey controls the amount of power produced
by the plant or unit. $or a unit producing 7CC +W power, the !P governing valve opening is
kept as <CE<7> of the total valve opening.
T0r!in Oi4 S5st2H
.I# %1PP#* %*%3)+

3he oil supply system fulfills the following functionsB
a9 #ubricating and cooling the bearings.
b9 (riving the hydraulic turning gear during interruptions to operation, on start up and shut
down Q4R.
c9 Iacking up the shaft at low speeds 8turning gear operation, start up and shut down9 Q4,:R.
.I#%*%3)+
1nder normal operating conditions, the main oil pump 849 situated in the bearing pedestal and
coupled directly to the turbine shaft draws oil from the main oil tank 8:=9 and conveys it to the
pressure oil system.
3he suction of the main oil pump is aided by two injectors 8:79. 3he injectors produce pressure at
the suction connection to the main oil pump sufficient for all types of operation. 3his guarantees
that the main oil pump takes over the safe supply of oil and cavitations that could occur due to
greater suction heads are avoided. 3he amount of oil re"uired for driving is eJtracted from the
pressure oil circuit and adjusted by means of the throttle 8;49.
3he oil for the turning gear 869 is also eJtracted from the pressure oil system. .il is admitted to the
noAAles by opening the shut off valve 8;;9. 3he pressure oil is cooled in the oil coolers 8459 and
reduced to lubricating oil pressure in the throttle 84@9. 3he throttle is adjusted on the initial startE
up. 3he amount of oil re"uired for each bearing is adjusted on start up by means of the oil throttles
8479.
$1## #.A( A1DI#IA/* .I# P1+P%
(uring turning gear operation and start up and shut down operation, one of the two three phase
a.c., full load auJiliary oil pumps 8::,:<9 supplies the pressure oil system and takes over the
function of the main oil pump when this is not in operation because the turbine is running too
slowly.
3he full load submersible auJiliary oil pumps are situated on the oil tank 8:=9 and draw in oil
directly.
)+)/-)',* .I# P1+P
When main and full load auJiliary oil pumps fail, the lubrication supplies oil directly to the
lubricating oil line, by passing the oil cooler and thus preventing damage to the bearing shells.
.I# /)31/' %*%3)+
3he lubricating oil from the bearings is returned to the main oil tank via a header.
)D3/A,3I.' .$ .I# &AP.1/
3he main oil tank is designed to the air tight. 3he eJtractors 8:@9 produce a slight vacuum in the
main oil tank and the bearing pedestals to draw off any oil vapour.
$I#3)/%
.il for the thrust bearing is passed through the dupleJ oil filter which can be switched over and
cleaned during operation.
+AI' .I# 3A'0
3he main oil tank contains the oil necessary for the lubricating and cooling of the oil bearings and
for the lifting device. It not only serves as a storage tank but also for deaerating the oil. 3he
capacity of the tank is such that the full "uantity of oil circulated not more than @ times per hour.
3his result in a retention time of approJ. 6 to @ minutes from entry into the tank to suction by
pumps. 3his time allows sedimentation and detainment of the oil.
.il returning to the tank from the supply system first flow through a submerged inlet into riser
section where the first stage deaeration takes place as the oil rises to the top of the oil tank. .il
overflows from the riser section through the oil strainer into the adjacent section of the tank where
it is then drawn off on the opposite side by the suction pipe of the oil pumps. +ain oil tank has the
following mountingsB
4. A, auJiliary oil pump
:. (, emergency oil pump
;. %haft lift oil pumps
<. .il injector
7. .il vapour eJtractor
=. .il level indicator
6. %onar level K limit switch
3he main oil pump is situated in the front bearing pedestal and supplies the entire turbine with oil
that is used for bearing lubrication, cooling the shaft journals and as primary and test oil. 3he main
oil pump is driven direct from the turbine shaft via the coupling. 3hese pump also convey oil in the
suction branches

+AI' .I# P1+P WI3! !*(/A1#I, %P))( 3/A'%+I33)/
3he main oil pump is situated in the front bearing pedestal and supplies the entire turbine with oil
that is used for bearing lubrication, cooling the shaft journals and as primary and test oil. 3he main
oil pump is driven direct from the turbine shaft via the coupling. 3hese pumps also convey oil in
the suction branches of the main oil pump for oil injectors that maintain a steady suction flow to
main oil pump.
!ydraulic speed transmitter operates on the same principle as centrifugal pump impeller. 3he
variation of the pressure in the primary oil circuit due to a speed variation serves as a control
impulse for the hydraulic speed governor. 3he hydraulic speed transmitter is supplied with control
oil supplied from the control e"uipment rack. 3he suction of the pump is always flooded and hence
maintains an uniform suction pressure.
A1DI#IA/* .I# P1+P
3he auJiliary oil pump is a vertical one stage rotary pump with a radial impeller and spiral casing.
It is fiJed to the cover of the oil tank and submerges into the oil with the pump body. It is driven by
an electric motor that is bolted to the cover plate of the main oil tank. 3he pump shaft has a sleeve
bearing in the pump casing and a grooved ball bearing in the bearing yoke. 3he bearings are
lubricated from the pressure chamber of the pumpL the sleeve bearing via a bore in the casingL the
grooved ball bearing via lube line.
(, 2)A/I'- .I# P1+P
3his is a vertical, centrifugal submerged type and serves for lubrication and cooling of the bearing
during emergency conditions when one of the other pump fails. 3his is driven by a (.,. motor.
%!A$3 .I# P1+P
3he lift oil pump is selfEpriming screw spindle pump with three spindles and internal bearings. 3he
pump supplies the oil to lift the turbine rotor at low speeds.
.I#&AP.1/ )D!A1%3)/
3he function of oil vapour eJhauster is to produce a slight negative pressure in the main oil tank
and in the bearing casing and thus draw off the oil vapour.

.I# ,..#)/
$unction of oil cooler is to cool the lubricating oil supplied to the bearing of the turbine. .il
cooler consists of the tube nest, the inner, outer shell and water boJes. 3he tube nest through which
the cooling water flows is surrounded by the oil space formed by the outer shell. 3he oil is to be
cooled enters the oil cooler and flows to the inner shell. 3his shell supports the large baffle plates,
which are provided with an opening in the center. 2etween every two large plates there is a small
intermediate plate is smaller in diameter than the inner shell and leaves an annular gap. 3his
arrangement serves to achieve a cross flow pattern forcing the oil flowing to the outlet branch to
flow through the middle of the large plates, while passing round the edge of the short ones.
T0r!in g4and sa4ing s5st2H
!PE3urbine, IPE3urbine and #PE3urbine gland leak off are connected to seal steam
header and vapour eJhauster system. Initially gland steam re"uirement for all the three cylinders
is met by supplying auJiliary steam to the seal steam header and the header pressure is
maintained by the seal steam control valve. When the unit load is raised above ;C to ;7> !P F
IPEglands start supplying gland leak off steam to the header to the re"uirement of #PEglands.
2eyond <C> load, no auJiliary steam is re"uired. .nce the self sealing steam takes place, then
seal steam header pressure is maintained by opening the leak of steam control valve to the
condenser.
-land steam header is provided with a motor driven drain valve which helps to raise the gland
steam temperature during start up. 3his drain valves normally remains open till the gland steam
temperature to #P gland increases beyond 47CS.
CONDENSATE WATER S+STEMH
3!) P1/P.%) .$ 3!I% %*%3)+ I% 3. %3./) A' A()T1A3) T1A'3I3* .$
()+I')/A#IU)( WA3)/ 3. +))3 3!) +A0) 1P /)T1I/)+)'3% $./ './+A#
,*,#) $#1,31A3I.'% A'( $./ A2'./+A# .P)/A3I'- ,.'(I3I.'% W!)'
%1PP#* .$ ()+I')/A#IU)( WA3)/ I% I'3)//1P3)(.
3his system will transfer condensate to and from storage tanks as to satisfy main cycle
re"uirements. 3he main cycle flow and thermodynamic re"uirement is maintained by transporting
the condensate collected in the condenser hotwell through various stages of feedwater heating and
other e"uipment to the deaerating feedwater heater.
3he condensate eJtraction pumps normally deliver the condensate through the three low pressure
feedwater heaters, the deaerating feedwater heater to the deaerating storage tank. 3he low pressure
feedwater heaters receive eJtraction steam as it passes through feedwater heater. 3he deaerating
further preheats the condensate prior to its entry into the deaerating storage tank. 3he deaeratig
feedwater heater is warmed by eJtraction steam during the normal operation and auJiliary steam F
cold reheat steam are utiliAed as the heat source during start up and shut down condition.
3he normal make Kup to the condenser is supplied from demineraliAing plant through the makeup
pumps. 'ormally, on low level in the condenser hotwell, condensate will flow from the condensate
storage tank to hotwell by static head in the tank and differential pressure due to the condenser
vacuum, however, this flow will be inade"uate, the condensate, transfer will supplement the flow.
3his makeup is sprayed into the steam space above the tube bundles.
3he condenser hotwell is condensate collection vessel, integral with the condenser shell, and
located in a pit below the ground floor. ,ondensate collected in the hotwell is pumped by ;V7C >
condensate eJtraction pumps to the feed storage tank through feedwater placed in series. 3wo lines
from hotwell, make a common header where from three lines are connected at the suction of three
condensate eJtraction pumps.
3he suction piping to the pumps is vented back to the condenser, to insure that the nonEoperating
pumps stays completely flooded. 3hese vent lines include manual valves on the vent for each
pump.
A minimum flow 8;7C 3Hhr9 recirculation line for each pump is provided, returning to the
condenser via a flow control valve and a locked open shut off valve.
3he shaft seals of these pumps are the waterEinjected type fed from a header to prevent the
suction of air, particularly the pump that is not operating while the condenser is under vacuum.
Condnsat E.tra/tion P023H
3he function of ,ondensate eJtraction pumps is to pump out the condensate to the deaerator
through gland steam cooler, and #P heaters. 3he steam from the #P cylinders eJhausts into the
condenser shells where it is constrained to flow across the water tubes, through which cooling
water is circulated.
3he steam condensed on the tubes drain to the bottom of the shell .3he condensate is retained in
the condenser shell bottom by means of the condenser level control valve. 3he water in a
condenser provides a head of water for the condensate eJtraction pump to suppress cavitations in
its suction impellers.
3here are two 4CC> duty eJtraction pumps, one remains in duty and one remains stand by. With
all the necessary instruments such as suction and discharge valve isolating and dump valves to
insure efficient operation.
3he thrust bearings in the driving motors have temperatures sensor, which can trip the motors
automatically.
3he pump discharge the condensate via the gland steam condenser and the condensate polishing
plant to the #P feed heating system.
Air E.tra/tion P023H
3he function of the air eJtraction pump is to raise and maintain the vacuum conditions in the
turbine main condensers, and to remove air and other nonEcondensable gases vented to the
condenser from various parts of the turbine and feedwater heating system.
-4and sta2 /ondnsr
An automatic turbine gland sealing system is used to prevent the escape of steam into the turbine
hall, where it would condense on the walls and the plant.
It also prevents the ingress of air at the rotor ends of all the turbine cylinders. 3his is done by
using the gland steam condenser.
3he function of the gland steam condenser is to maintain a subEatmospheric pressure at the
outermost leakEoff belt of the glands and thereby prevent the leakage of steam from the glands
into the turbine hall.3he gland steam condenser condenses the steam from the steamH air miJture
drawn from the outer pocket of the gland. 3his heat given by the steam is absorbed by the
feedwater. ,ondensate formed in the shell drains to the gland steam condenser drain tank. 3his is
again recirculated back to the condensers.
Drain G4ash Condnsr
3he drain flash condenser receives heater drip or drain water from #P heaters. When the drain
water enters the flash condenser through the disperses, steam is flashed off. 3his steam is drawn
into the tube nest where it condenses and cascade to the bottom of the shell. 3he resulting drain
water is delivered to the main condenser.
3he water side of the ($, is of the conventional to pass surface type in which
the feed water flows through the tube and steam passes over them. 3he vessel comprises a tube
nest, a shell, an inlet and an outlet water boJ. 3he water boJ has a dished end and incorporates
the feed water inlet and outlet connections. A flanged branch on the water boJ is fitted with a
davit type hinged cover to give access to the tube bores.
A center plate and an end plate fitted with two stiffeners form a diversion plate, which
separates the incoming, and outgoing flows .3he end plate carries a cover, which is located and
bolted between the stiffening ribs.
3he ($, is mounted on steel work on four attachment points at the water boJ
bonded to upper and lower mild steel bearing plates.
Boi4r Gd P023sH
2oiler feed pumps are an important part of any boiler operation. 3hey control the amount of
water fed to the boiler and the manner in which it is fed.
Cntri70ga4 E ,ontinuous
T0r!in E Intermittent
In order to properly select a boiler feed pump five key points must be consideredB
Wi44 th 3023s o3ration ! /ontin0o0s or intr2ittntM
3his is an operational "uestion and is often answered by the type of level control found on the
boiler that the pump will be servicing. As a general rule of thumb, boilers with a capacity of
4C,CCC lbs.Hhr. or less utiliAe a float type switch that starts and stops the boiler feed pump to
satisfy a predetermined water level within the boiler. 3his is a classic intermittent operation.
2oilers with capacities eJceeding 4C,CCC lb.Hhr. typically employs a modulating feed water
regulator and will continuously feed water to the boiler at various rates depending upon the water
level in the boiler.
2y knowing which operation you are to satisfy, you can determine which pump design is best
suited for your application. As a general rule of thumb a turbine pump is used in an onEoff
situation and a centrifugal pump is used for continuous operation. 2ut remember, this is a general
rule and is some cases a centrifugal could be used for an onEoff application and a turbine for
continuous.
What is th t23rat0r o7 th 8atr !ing 3023dM
It is also important to know the temperature of water you intend to pump. +ost pumps can
usually handle :47$ to :;C$, other pumps are available that can handle higher temperatures by
using eJternal waterEcooling. 0eep in mind that a deaerator pump must be able to handle higher
temperatures because they operate at a 7 psi or ::6$.
What is th r?0ird /a3a/it5M
!ow much water you intend to pump is dependent upon the evaporation rate of the boiler the
pump will service. A safe figure for an onEoff application would be : times the evaporation rate
of the boiler. With a modulating level control, a factor of 4.; times the evaporation rate plus
recirculation is recommended.
What is th dsird dis/harg 3rss0rM
When you pump directly into the boiler you will need to overcome the pressure in the boiler as
well as any piping losses. *ou can chose the right pump by looking at the pump curves to
determine which will accomplish this task. %hould you have a modulating valve in the discharge
line, the minimum you will need to add to the boiler operating pressure will be :C to :7 lbs.
+ake sure that the pump can handle the pressure along with the flow rate needed. With an onEoff
level control the pumps should be designed for the relief valve pressure.
What is th NPSH or nt 3ositi1 s0/tion had r?0irdM
3his is the last piece of information that you will need. 3his is the minimum absolute pressure at
the suction noAAle at which the pump can operate. 3o avoid pump cavitation, the 'P%!A of the
system must be greater than the 'P%!/ of the pump. In other words, the available 'P%! must
be higher than the re"uired. We have always siAed our deaerator stands to be two feet higher than
the 'P%! needed for the pump selection. /emember, the water level in the storage tank adds to
the safety margin.
TDBGP
3urbine driven 2$P uses turbine of 4< stages connected to condenser. 3urbine is coupled with
main pump having engageHdisengage unit called Power pack unit using oil pressure. 2etween
turbine and booster pump gear assembly is there.
&arious system of 3(2$P are discussed belowB
49 #ube .il %ystem

#ube oil system of both 3(2$P% are provided with one +ain .il 3ank each in which oil level
is separately maintained. It has two A, A.Ps, one I.P A, and one (, A.P connected to tank.
#ube oil pressure is maintained at ;.CEkgHs". cm is called control oil which is used as governing
oil.
#ube oil after passing through coolers is led to various bearing of 3(2$P system. (, A.P
discharge oil, which is, used on failure of A, A.Ps bypass the coolers. (uring barring of
3(2$P same lube oil at pr. <.CEkgH s". cm is used as power fluid in barring gear impellers. In
the lube oil pressure by changing the recirculation flow.
:9 %ealH Injection %ystem
+echanical seals are provided on 2P side for which continuous cooling is done by ,)P water.
$or 2$P side constant seal injection pressure around 4@EkgHs". cm is maintained with the help of
control valve. $ilters are also provided in this line. $rom this line small pipe provides water in
the eJhaust steam as eJhaust load spray. %eals drain is collected as clean drain into drain tank
and dirty drain flows into common drain header.
;9 %team %ystem
$or 3(2$P there is three sources for steam namely 4. AuJiliary steam :. ,old reheat line ;. IPE
#P cross over steam. )Jtraction steam parameters are maintained at <.C kgHs" cm. F ;CC degree
centigrade. (uring cold start when ,/! or IPE#P steam is not available, AuJ. %teamis used for
rolling of 3(2$P for initial boiler filling. .nce steam is insufficient for increasing the speed
beyond ;7CC rpm, ,/! steam is automatically cut off.
<9 $eed Water %ystem
Water from deaerator is taken through two suction into booster pump and then fed into 2$P
suction. (rains F vents are provided in $W system for initial charging and venting of 2$P
during rolling.
79 -land %ealing of 3urbine
(ownstream steam from main turbine gland sealing is used for 3(2$P sealing. 2efore opening
of eJhaust valve gland sealing should be done as this is line is connected to condenser.
=9 -overning %ystem
$or having the re"uired flow through 2$P, speed of turbine has to be adjusted and for what we
need perfectly efficient governing system. -overning system is using the control oil at 5 kgHs"
cm. which in turn depending on the position of starting device and speeder gear, will develop
secondary oil and auJiliary secondary oil pressure for operating the <+,&s and one A,&
thereby adjusting the steam flow speed change is effected. -overning is achieved with the help
of two governors? namely hydraulic and )lectrohydraulic governors having )!- control and !-
follows it up.
BOOSTER PUMPH

)ach boiler feed pump is provided with a booster pump in its suction line which is driven by the
main motor of the boiler feed pump. .ne of the major damages which may occur to a boiler feed
pump is from cavitation or vapour bounding at the pump suction due to suction failure.
,avitation will occur when the suction pressure at the pump suction is e"ual or very near to the
vapour pressure of the li"uid to be pumped at a particular feed water temperature. 3herefore all
the three feed pumps are provided with a main shaft driven booster suction line for obtaining a
definite positive suction pressure. 3he boiler feed pump is coupled with its driving motor
through hydraulic coupling. 3he hydraulic coupling serves the purpose of controlling the speed
of feed pump for maintaining a definite delivery head and delivered "uantity of the feed water as
per the re"uirement of the boiler.
DaratorH
(eaerators are used to remove oJygen from boiler feedEwater. It performs the following
functionsB
It serves as a feedwater heater.
$eedwater is deaerated by the removal of nonEcondensable gases present in the
feedwater and reduce the oJygen content to a level of about C.CC6 ppm.
It acts as a Obuffer? to the fluctuations of condensate feedwater flow that occur in
service durations.
3he tank height provides a hydrostatic head to satisfy the suction pressure
re"uirements of the boiler feed pumps.
3he presence of nonEcondensable gases in the feedwater causes the waterside corrosion or
thinning of the boiler tube walls and this further leads to the rupture of walls by the internal fluid
pressure.
!ere steam injectionEtype deaerator is used to deaerate the feedwater. $eedwater from #P heaters
is admitted to the deaerator tank and steam is bled from two sources, one from the !P turbine
8which is known as cold reheat steam9, and the other from the IP turbine eJhaust. When this
steam and feedwater come in direct contact with incoming water is heated and also gets
deaerated.
%team initially enters the deaerator through a special, stainless steel Iet %pray atomiAing valve.
3his valve is designed to fully atomiAe and provide complete deaeration under all load
conditions. 3his design insures that the purest steam comes in contact with the purest water.
.nce this high velocity steam mechanically shakes out the last traces of nonEcondensable gases
from the water, it flows upward into the preEheater area where it meets the incoming makeEup
water and pumped returns. 3his water continuously condenses the steam, which preheats and
releases the nonEcondensable gases into the internal vent condenser where they are metered
harmlessly to the atmosphere. 3his action causes more steam to be drawn into =the system to
complete the cycle.
$rom the bottom of the deaerator, feedwater is piped through three outlet pipes, each with a
strainer, to the three boiler feed pumps and the used up steam is recirculated back to condenser.
3he deaerator is mounted at a highElevel with its centerline ;<.=7 m above the datum level.
3he deaerating heater utiliAes steam by spraying the incoming water into an atmosphere of steam
in the preheater section 8first stage9. It then miJes this water with fresh incoming steam in the
deaerators section 8second stage9.
In the first stage the water is heated to within : S , of steam saturation temperature and virtually
all of the oJygen and free carbon dioJide are removed. 3his is accomplished by spraying the water
through self adjusting sprat valves which are designed to produce a uniform spray film under all
conditions of load and conse"uently a constant temperature and uniform gas removal is obtained at
this point.
$rom the first stage the preheated water containing minute traces of dissolved gases flows into
the second stage. 3his section consists of either distributor or a several assemblies of trays.
!ere the water is in intimate contact with an eJcess of fresh gasHfree steam. 3he steam passes into
this stage and it is miJed with the preheated water. (eaeration is accomplished at all the rates of
flow if conditions are maintained in accordance with design criteria. &ery little steam is condensed
here as the incoming water has high temperature caused by the preheating. 3he steam then rises to
the first stage and carries small traces of residual gases. In the first stage most of the steam is
condensed and the remaining gases passes to the vent where the nonEcondensable gases flow to the
atmosphere.
3he water, which leaves the second stage, falls to the storage tank where it is stored for use. At this
time the water is completely deaerated and is heated to the saturated steam temperature
corresponding to the pressure within the vessel.
3he condensate pressure just before the entry to deaerators shall be ; psi more than the deaerator
steam pressure.
GEEDWATER HEATERS
A feed water heater is a special form of a shell and tube heat eJchanger designed for the
application of recovering the heat from the turbine eJtraction steam by preheating the boiler feed
water. Its principal parts are a channel and a tube sheet, tubes, and a shell. 3he tubes may be either
bent tubes or a straight tubes. $eed water heaters may be defined as highEpressure heaters when
they are located in the feed water circuit upstream from the high pressure feed water pump. #owE
pressure feed water heaters are located upstream from the condensate pump, which?s takes its
suction from the condenser hot well. 3ypically low pressure feed water heaters are designed for
feed water pressures between :6 kgHcm s". and 76 kgHcm s"., high pressure feed water heaters
range from 44: kgHcm s". to ;;7 kgHcm s". for super critical boilers.
)ach feed water heater bundle will contain from one to three separate heat transfer areas and
Aones. 3hese are condensing, desuperheating, and subEcooling Aones. )conomics og design will
determine what combination of the three is provided in each heater.
A condensing Aone is present in all feed water heaters. #arge volumes of steam are condensed in
this Aone and most of the heat is transferred here.
3he desuperheating Aone is a separate heat eJchanger contained within the heater shell. 3his Aone?s
purpose is to remove superheat present in the steam. 2ecause of the high steam velocities
employed, condensation within the desuperheating Aone is undesirable.
3he subEcooling Aone is another separate counter heat flow heat eJchanger whose purpose is to
subEcooling incoming drains and steam condensate.
HEATER OPERATIONB
Prior to opening the feed water valve, the channel start Kup vents are to be opened and
remain open until all passages have been purged and feed water begins to discharge.
3o remove air from the shell sides of a heater, which does not operate under vacuum, the shell
start up vent valves should be opened prior to the admission of the steam to the feed water heater.
3he eJtraction lines must be free of all the condensate to prevent the damage to the heater
internals by slug flow.when the drains outlet valve is opened, the shell start up vent valves are to
be closed and the operating air vent valves are to opened. ,ontinuous venting of air and other
nonEcondensable is assured by keeping the shell operating vent valves open.
.n initial plant start up of the horiAontal feed water heaters, having integral drain coolers, the
li"uid level is to be kept just below the highElevel alarm point.
.n initial plant startEup of horiAontal feed water heaters, having integral drain coolers, the
li"uid level is to be kept just below the highElevel alarm point. 3his will avoid the possibility of
flashing at the subEcooler inlet and the possible tube damage that can result. Approach temperature
in eJcess of @ degree centigrade indicate the probability of flashing at the subEcooler unit.
*ENTIN-
Proper venting is necessary on feedwater heaters. All operating air vent connections must
be piped to permit continuous venting. 3he venting system in a feedwater heater is designed to
assure that all points where nonEcondensable gases could collected are vented. $ailure to utiliAe all
of the operating air vents can lead to corrosion damage and loss of performance due to air
blanketing.
&ent lines of heaters operating at a different shell pressure must not be piped to a common
manifold. $ailure to run individual vent lines from each heater has resulted in inade"uate or no
venting of heater operating at a lower shell side than other heaters, piped into a common manifold.
GEEDWATER B+-PASSIN-
A feedwater heater may be severely damaged by erosion and vibration, if it is operated for any
significant period or time with the neJt lower heater?s feedwater flow by passed. When a heater is
by passed, its normal feedwater is passed on to the neJt higher heater. 3his neJt higher heater will
come close to making up the duty of both the heaters. 3his single heater will tend to draw a total
amount of eJtraction of steam approJ. e"ual to the flow of both the heaters.
In case of heaters with desuperheating Aones, the increased steam load due to by passing the
previous heater can cause an eJcessive pressure drop in the desuperheating Aones, which can cause
an eJcessive pressure drop in the desuperheating Aone, which in turn can cause condensation. 3he
condensate flowing at high velocity can lead to severe tube erosion.
)Jcessive steam flow to a heater, resulting from by passing the feedwater side of the previous
heater, can result inB
a9 #ocaliAed high velocity leading to vibration of the tubing.
b9 $lows, which cannot be ade"uately handled by the drain, control valve.
c9 ,ondensation in the desuperheat Aone and high velocity impingement.
LP Gd Hating S5st2
3he lowEpressure 8#P9 feedwater heating system is provided to improve the thermal efficiency of
the heat cycle by heating condensate from the condenser with lowEpressure steam bled from the
#P cylinder.
#owEpressure 8#P9 feedwater heaters are basically simple straightforward Otube and shell? heat
eJchangers, with the condensate passing through the tubes and the bled steam being admitted to
the shell.
3here are total three #P heaters used in the feed heating cycle. %ince, there is a significant
volume of unused space between the eJhaust of a doubleEflow #P cylinder and on the top of
under slung condenser, this space is utiliAed by inserting two #P heaters in a horiAontal altitude.
3his results in the lowEpressure drop and high temperature for the bled steam, which is used for
heating the condensate, with conse"uential improvement in cycle efficiency. 3he #P heater 'o. ;
is located outside the periphery of the condensers.
3he heaters are Ostacked? so that the ultimate #P heater can drain its bledEsteam condensate into
the condenser above the working level of condensate in its base.
HP Gd Hating S5st2
3he highEpressure 8!P9 feedwater heating system is provided to improve the thermal efficiency
of the heat cycle by raising the temperature of the feedwater before it enters the boiler. #ike #P
heaters !P feedwater heaters are also of traditional form, but are arranged in a horiAontal altitude
to ensure free gravity drainage of their bledEsteam lines and heaterEtoEheater drainage. 2led
steam to 'o. = !P heaters is fed from the !P turbine eJhaust system and to 'o. 7 !P heaters
from IP turbine.
3he system contains four !P heaters arranged horiAontally in pairs with a drain flash vessel
situated above and between each pair. 3he pairs are identified as bank OA? and bank O2? and each
contains a 'o. 7 !P heater, a 'o. = !P heater and the associated drain flash vessel. In the !P
feed heating system, water is supplied from the boiler feed pumps via the boiler feed regulating
station and is piped through three waysL one to each bank of heaters and one to the bypass pipe.
When this feedwater is passed through the !P heaters, its temperature is increased.
)ach heater bank has its own feedwater inlet and outlet isolating valves, which, with the
bypass pipe and its springEloaded valve, permits either bank to be taken out of service for minor
maintenance or repairs while plant is on load.
(rains from the !P heaters are taken either to the deaerator or to condenser A, depending on the
levels of water and pressures eJisting in the heaters, which in turn depends on the generator load.
3he drains are controlled by level controllers and at normal loads pass to the deaerator. At low
loads, drains are diverted to the condenser.

Gd Rg04ating Station
3o maintain the rate of feedEwater input to the boiler corresponding to the steam output from the
boiler under all conditions of loading, feed regulating station is used. $or this purpose, feed
regulating station has four regulating lines out of which one line remains standEby. Also to ensure
security of steam supply it has been considered necessary to provide a multiple feedEwater
regulating valve arrangement
3he threeEelement feedEflow regulating system has been developed to meet the re"uirements of
the boiler. 3he essential factors that are mainly considered are the steam flow from the boiler, the
feed water flow to the boiler and the water level in the boiler drum.
B5-3ass s5st2sH
3he byEpass system performs an important function. It permits the boiler to be operated
independently of the turbineEgenerator system. 3he byEpass system comprises two main unitsE
!P 2yEpass system.
#P 2yEpass system.
HP B5-3ass s5st2
3his system comprises of the operation of bypassing the !P steam without being passed through
the !P turbine. 3he !P steam is taken from each of the main steam lines after the !P steam stop
valves. 3he main steam passes into the cold reheat inlet pipes via four pressure control valves and
their associated isolating valves. 3he valve include the spray water supply and control
e"uipment .3he !.P. valve will operate automatically to maintain upstream pressure on start .In
addition upon rapid load rejection .3hese valves will operate to relieve =C> of +,/ rated steam
flow to the reheat system .3he !WPWrelive valve mounted on the main steam pipe work will
operate to relive eJcess steam to atmosphere
LP B5-3ass s5st2
3he #P byEpass system consists of four lines taken from the four hot reheat pipes 8upstream of
the IP turbine control valves9. 3hese four lines are then converged into two. 3he steams in each
line flows through an isolating valve, a pressure control valve and then into the condenser dump
tube, bypassing the IP, #P turbines.
-nrator
3he two 74< +W turbineEgenerator sets are set aJially in line in the turbine hall. 3he generator is
a :Epole, ;Ephase, hydrogen and waterEcooled machine, driven from the turbine. 3he main eJciter
is solidly coupled to the rear end of the generator shaft. A brush less main eJciter provides the
eJcitation power for the generator. 3he output from this eJciter is fed to the generator rotor.
3he eJciter line is directly coupled to the turbine generator shaft and is driven at generator speed.
)ach generator has its own independent stator windings.
!ydrogen is used to cool the generator rotor winding and stator core, the stator winding is
directly waterEcooled.
-nrator o3rationa4 4i2itsH
/ated output 74< +W
/ated output =C7 +&A
'ominal stator voltage :C k&
%peed ;CCC rHmin
Power factor C.@7 #ag
$re"uency 7C !A
Main ./itr s5st2
3he main eJciter system is a siJEpole, threeEphase, rotating armature generator. 3he stator has
(.,. $ield system and A.,. winding is mounted on the eJciter rotor.
3he rotating rectifier is mounted on the eJciter unit shaft out board of the eJciter armature .3he
rectifier modules, one Gve and other Kve are contained within the Gve and Eve rectifier hubs
shrunk onto the eJciter unit shaft.
3he main eJciter is solidly coupled to the rear end of the generator shaft. !ere a brush less main
eJciter is used to provide the eJcitation power for the generator. 3he output from this eJciter is
fed to the generator rotor.
3he eJciter line is directly coupled to the turbine generator shaft and is driven at generator speed
3he main eJciter is supplied with power by a pilot eJciter whose output is rectified and
controlled by the eJcitation control system 8),%9. 3his pilot eJciter is located to the front of the
main eJciter and is a salient pole, permanent magnet, a.c. generator of the hetropolar type. 3he
pilot eJciter is airEcooled with an open, selfEventilated air system.
E4/tri/a4 !arring gar
3he !P, IP and #P rotors must be turned continuously during startEup and shut down periods. 3his
provides even heating or warm up in the initial start up stage of the turbine and cooling during a
shut down of the turbine.
3o perform this operation an automatic engaging and disengaging electrical barring gear is used.
3his electrical barring gear rotates the coupled turbine and generator rotors continuously at
approJimately ;7 rHmin.
)lectrical barring gear is a motor driven machine i.e. it receives power to operate from the motor,
which is vertically mounted on a support plate outside the pedestal above the wormshaft. 3his
motor supplies ;6 kW power for the barring gear operation. 3his power transmission between
motor and barring gear takes place through worm and worm wheel arrangement.
3he motor driven electrical barring gear is mounted on a pedestal at the eJtreme rear of the
generator and eJciter and the drive to the turbine generator rotor is transmitted through a
O%ynchronous %elf %hifting? 8%%%9 clutch, which automatically engages to drive the turbine
generator rotor at a constant speed of approJimately ;7 rHmin and automatically disengages when
the rotor speed, under steam, rises above this value.
If the electrical barring gear motor develops a fault or if the complete rotor re"uires turning for
maintenance checks, it can be turned manually. 3he individual rotors of each cylinder can be
turned independently.
MAIN, COLD REHEAT AND HOT REHEAT STEAM LINE
MAIN STEAM LINE MAIN STEAM STOP *AL*E
S
U
P
E HI-H PRESSURE
R TURBINE
H
E
A
T
E
R
MAIN STEAM LINE MAIN STEAM STOP *AL*E
HP B+PASS S+STEM
DESUPER HEATER
COLD REHEAT LINE
HOT REHEAT LINE I*
R R
E E
H H INTERMIDIATE PRESSURE
E E TURBINE
A A
T T
I O
N U
T

I*
TO LOW PRESSURE
DESUPER HEATER TURBINE

.