Summer Training

Report
at
Kalisindh Thermal Power Plant
Jhalawar- Rajasthan

Submitted By:
Ramniwas Dhakar
19113070
IPE-Final year

Dr B R Ambedkar National Institute of Technology, Jalandhar

 ACKNOWLEDGEMENT

I oblige to acknowledge my heartiest gratitude to all honorable

people who helped me during my summer training at Kalisindh
Thermal Power Plant, Jhalawar-Rajasthan

I want to express my thanks to Mr. P. K. Garg Training Manager

of KaTPP, for granting me the permission for doing summer training
at this project and Mr. Lokendra Singh (Training Coordinator) to
teach me about various process in thermal power plant like Boiler,
Turbine etc. and give their valuable time and kind co-operation.

I am also thanking a lot to other staff members of RRVUNL, BGR

& TCE for their further co-operation to gain the better knowledge
about the world class power plant project in Distt. – Jhalawar,
Rajasthan.

Finally, I must say that no height is ever achieved without some

sacrifices made at some end and it is here where I owe my special
debt to our parents and our friends for showing their generous love
and care throughout the entire period of time

1
 CONTENTS

Sr.no Topics Page

1. Introduction 3-14

2. Coal Handling Plant (CHP) 15-19

3. Main Parts of Thermal Power Plant 20-29

4. ESP And AHP System 30-35

5. Controlling and Transmission System 36-37

6. Efficiency and conclusion 38-39

7. References 39

2
 1. INTRODUTION

Everybody must be having a thought that a thermal power plant is a

place where electricity is produced. But do you know how it is
produced? How the chemical energy stored in fuel is converted into
heat energy which forms the input of power plant i.e., steam and
electrical energy produced by generator? Power is the single most
important necessity for common people and industrial development
of nation.
In a conventional power plant, the energy is first converted to a
mechanical work and then is converted to electrical energy.

Thus, the energy conversions involved are:

The first energy conversion takes place in Boiler or Steam
Generator,
Second in Turbine and the last conversion takes place in the
Generator.

A thermal power station is a power plant in which the prime mover

is steam driven. Water is heated, turns into steam and after high
pressure steam is thrown on turbine blades which rotates the turbine
which drives an electrical generator after that steam pass through in
a condenser where it condensed and recycled to again in boiler; this
whole cycle is known as RANKINE CYCLE

3
 1.1 Thermal Power Plant in India
In India, Thermal Power Plant contribute about 61% of the total
electricity produced.
Pie chart shows the electricity production percentage by different
sectors.

Pie Chart showing the distribution of power sources

4
1.2 AN OVERVIEW OF KaTPP

5
Kalisindh Thermal Power Project is located in Jhalawar. The
proposed capacity of coal based Thermal Power Project is 1200
MW. The project site is about 12 km from Jhalawar (Distt. -Head
quarter) and NH-12. Site is comprising of 5 villages viz. Nimoda,
Undel, Motipura, Singharia and Deveri. It is 2km from state
highway No.19 and 8 km from Ramganjmandi Bhopal broad gauge
rail line

The site selection committee of Central Electricity Authority has

visited the Nimodha and its adjoining villages of Jhalawar Distt.
And site was found techno- economical feasible for setting up of a
Power Project. The Govt. of Raj. have included that project in 11th
five-year plan. The estimated revised cost of the project is Rs.7723
Crores. M/s. TCE Banglore has been appointed as the technical
consultant for the project. The state irrigation department has
allotted 1200 mcft water for the project from proposed Kalisindh
dam. The origin of the Kalisindh river

is from northern slop of Vindya Mountains . The river enters from

MP to Rajasthan near village Binda. After flowing 145 km in
Rajasthan, the Kalisindh river merges in Chambal River near
Nonera village of Distt. Kota. Its catchment area is about 7944
sq.km in Jhalawar & Kota Distt. The existing Dam is located at
Bhaurasa village, primarily for P.H.E.D. purpose is being uplifted
for providing a storage of 1200mcft water for this power project.
The GOR has allotted 842 bigha Government land and acquired
1388 bigha private khatedari land for the thermal project. Phase-1
will be constructed on 1400 bigha land only. EPC contract has
been awarded to M/s. BGR Energy System Chennai on
dt.09/07/08,through ICB route at cost Rs.4900Crores. Ministry of
coal, Govt. of India has allotted Paras east and Kanta basin coal
blocks to RVUN in Chhattisgarh state. The RVUN has formed new
company under joined venture with M/s. Adani Enterprises for

6
mining of coal blocks and new company started the work. Annual
coal requirement for the project is 56 Lacs TPA. GOR also decided
to setup two new units of2x660MW in next few years.

Owner • RVUNL

Owner's • TATA Consulting

Consultant Energy Ltd.

EPC
• BGR Energy System Ltd
Contractor

7
 1.3 ENERGY GENERATED IN KaTPP

 Number of units=2
 Electricity generated by one unit=600 MW
 Total electricity negated by plant=2x600=1200 MW

1.4 PLANT OVERVIEW

Project Kalisindh Super Thermal Power Project

Jhalawar
Capacity 1200MW(2x600 MW)
Project Site Village-Undel, Motipura, Nimoda, Singhania
& Deveri of Tehsil Jhalarapatan, Distt-
Jhalawar
Project Location The project site is about 12 km from NH-12,
2km from state highway and 8 km from
proposed Ramganjmandi-Bhopal broad
gauge rail line
Land Aera 2230 Bigha/564 Hq. (1400 bigha/350 Hq. in I
stage)
Water Source and quantity Dam on Kalisindh river and 3400CuM/Hrs.
Fuel Source Main Fuel-Coal from captive coal blocks
(Paras east and kanta Basin in Chhattisgarh
state) Secondary Fuel-FO/HSD
Quantity of fuel (at 80% PLF) Coal-56 Lacs TPA FO/HSD-13000-14000
KL/A
Electrostatic Precipator 99.9 % Capacity
Stack Height 275 Mtr
Estimated revised cost Rs.7723 Crores

8
 1.5 PRINCIPLE OF OPERATION

For each process in a vapor power cycle, it is possible to assume a

hypothetical or ideal process which represents the basis intended
operation and do not produce any extraneous effect like heat loss.

1) For steam boiler, this would be a reversible constant pressure

heating process of water to form steam.
2) For turbine, the ideal process would be a reversible adiabatic
expansion of steam.
3) For condenser, it would be a reversible a constant pressure
heat rejection as the steam condenser till it becomes saturated
liquid.
4) For pump, the ideal process would be the reversible adiabatic
compression of liquid ending at the initial pressure

When all the above four cycles are combined, the cycle achieved is
called RANKINE CYCLE. Hence the working of a thermal power
plant is based upon Rankine Cycle with some modification

9
 1.6 THERMAL PLANT OPERATION PROCEDURE

The basic understanding of the modern thermal power station in

terms of major systems involved can be done under three basic heads
viz. generating steam from coal, conversion of thermal energy to
mechanical power and generation & load dispatch of electric power

 COAL TO STEAM- The coal is burnt at the rate up to 200

tones per hour. From coal stores, the fuel is carried on convey
or belts to bunkers through coal tipper. It then falls in to coal
pulverizing mill, where it is grounded into powder as fine as
flour. Air is drawn into the boiler house by drought fan and
passed through Preheaters. Some air is passed directly to
bunker and rest, through primary air fan, to pulverizing mill
where it is mixed with powdered coal. The mixture is then
carried to bunker of furnace where it mixes with rest of the air
and burns to great heat. These heats circulating water and
produces steam, which passes to steam drum at very high
pressure. The steam is then heated further in the Superheater
and fed to high pressure cylinder of steam turbine. The spent
steam is sent to condenser, where it turns back to water called
condensate. Condensate is sent toll owner part of steam drum
through feed heater and economizer. The flue gases leaving
boiler are used for heating purpose in feed heater, economizer,
and air Preheater. The flue gases are then passed to electro-
static precipitator and then, through draught fan, to chimney.

 STEAM TO MECHANICAL POWER- Steam first enters

the high-pressure cylinder of turbine where it passes over a
ring of stationary/fixed blades which acts as nozzle and directs
steam onto a ring of moving blades. Steam passes to the other
cylinders through reheater and the process is repeated again
and again. This rotates the turbine shaft up to 3000rpm. At

10
 each stage, steam expands, pressure decreases and velocity
increases.

 MECHANICAL POWER TO ELECTRICAL POWER-

To obtained the electrical power from mechanical power we
connect the shaft to an alternator’s armature. When the
armature is rotated and electric current is produced in the
stator’s windings. The generated electricity is of order 25,000
volts.

 SWITCHING AND TRANSMISSION-The produced

electricity is can’t to transmitted as this state so it is passed to
a series of three switches called an isolator, a circuitbreaker,
and another isolator. From circuit-breaker, current is taken to
bus bars and then to another circuit-breaker with its associated
isolator before being fed to the main Grid. Each generator has
its own switching and transmission arrangement. Three-phase
system is used for power transmission.

 CONTROL AND INSTRUMENTATION- Control and

Instrumentation (C & I) systems are provided to enable the
power station to be operated in a safe and efficient manner
while responding to the demands of the national grid system.
These demands have to be met without violating the safety or
operational constraints of the plants. For example,
metallurgical limitations are important as they set limits on the
maximum permissible boiler metal temperature and the
chemical constituents of the Feed water. The control and
Instrumentation system provides the means of the manual and
automatic. Control of plant operating conditions to maintain an
adequate margin from the safety and operational constraints.

11
 Monitor these margins and the plant conditions, and provide
immediate indications and permanent records. Draw the
attention of the operator by an alarm system to any
unacceptable reduction in the margins. Shut down the plant if
the operating constraints are violated.

1.7 PULVERIZED COAL FUELED POWER PLANT

A typical pulverized coal fueled power plant is based on Rankine

Thermodynamic cycle. “A Rankine cycle is a vapour cycle Furnace
that relies on the isentropic expansion of high-pressure gas to
produce work”. Let us see a super heat Rankine cycle:

This facility first produces steam in a boiler (steam generator). This

steam is used to rotate turbine which is connected to a shaft of
generator. Hence electricity is produced here. The used steam is then
condensed in a condenser, and the condensed liquid is used again in
the steam generator. This is a simple phenomenon, understood by
everybody. For all this we need a fuel. As the name suggest here
coal is used as fuel. Coal is one of the cheapest and most preferred
fossil fuel used as a key to most of the power plants. Usually

12
delivered by train from Mines to the Coal Handing Plant (CHP). The
CHP unloads this it become more economical to unload the coal.
Then the coal stacked, reclaimed, crushed, and conveyed it to the
storage silos near the steam generator. Then it is fed through the
Feeder to the Pulverizer. Feeder is mainly used to weight the amount
of coal going to the Pulverizer per hour. From the Feeder the coal is
fed to the Pulverizer which powders it and then it is carried to the
steam generator using pressurized air. Within the steam generator
the coal is atomized and burned and the heat energy produced is used
for producing steam. Here two types of steam namely superheated
& reheated steam are produced in a cycle. The steam turbine
generator converts the thermal energy of superheated and reheated
steam to electrical energy. The first energy conversion is carried in
Boiler or steam generator; the second is carried out in Turbine and
the last one carried out in the Generator.

Initially the superheated steam is fed to High Pressure (HP) turbine.

It has a temperature of 540° C (approx.) and a pressure of about 140
Kg/cm2. Then the exhausted steam from it is taken to the reheater
so that it can be reheated and fed back to Intermediate Pressure (IP)
turbine. Here the temperature is maintained the same as that of
superheated steam but pressure is reduced to 35 Kg/cm2. Then the
exhausted steam is directly fed to Low Pressure (LP) turbine having
the reduced temperature and pressure of about 1Kg/cm2. Then the
exhausted steam from the LP section is condensed in the condenser.
The condensed liquid is moved from condenser by Condensate
Pumps through Low Pressure Regenerative Feed water heaters to a
Deaerator. Boiler Feed Pumps (BFPs) moves the deaerated liquid
through HP heaters to the steam generators. Extraction steam is
supplied to the LP & HP regenerative heaters to improve cycle
efficiency. Then comes to the system of fans which keeps the system
working by providing the valuable air where required. There are
three pairs of fans, namely, Forced Draft (FD)fan, Induced Draft
(ID) fan, Primary Air (PA) fan. FD fans supplies combustion air to

13
the steam generator and PA fans transports the coal into the steam
generator. ID fans remove the flue gases from the steam generator
and exhaust it through chimney. Cooling water for the condenser is
supplied by the circulating water system, which takes the heat
removed from the condenser and rejects it to the cooling towers or
other heat sink. This all working is controlled from a single place
called control room. It enables the operator to direct the plant
operation for reliable and efficient production of electrical energy.
This is achieved by the control system installed by the C & I group.
These are DAS (Data Acquisition System), ACS (Analog Control
System), FSSS (Furnace Safeguard Supervisory System), and other
relays governing numerous activities. Last but not the least is the
switching and transmission methods used here. The generated
power cannot be transmitted as such. It is stepped up to 132 KVA
or 400 KVA then passed through a series of three switches an
isolator, a circuit breaker and an isolator. Three phase system is used
for the power transmission. Each generator has its own switchyard
and transmission arrangement.

14
 2. COAL HANDLING PLANT (CHP)

2.1 INTRODUCTION

Every thermal power plant is based on steam produced on the

expanse of heat energy produced on combustion of fuel. Coal is
categorized as follows depending upon fixed carbon, volatile
matter and moisture content:
 Anthracite having 86% fixed carbon
 Bituminous having 46 to 86% fixed carbon
 Lignite having 30% fixed carbon
 Peat having 5 to 10% fixed carbon

Coal from mines is transported to CHP in railway wagons. It is

unloaded in track hoppers. Each project requires transportation of
large quantity of coal mines to the power station site. Each project
is established near coal mine which meets the coal requirements for
the span of its entire operational life. For the purpose each plant has
Merry Go-Round (MGR) rail transportation system. The loading
operation of the coal rake takes place while it is moving under the
silo at a present speed of 0.8 Km/hr. the loading time for each wagon
is one minute. For unloading of coal from the wagons an
underground track hopper is provided at the power station.

The term coal handling plant means to store and to handle the coal
which is transported by the train and convey to the bunkers with the
help of belt conveyers. Through the bunkers coal is transferred to
the coal mill and drifted to the furnace. The coal handling plant
includes wagon tippler, conveyer belt, crusher house, stacker &
reclaimer, bunkers & coal mill.

COAL SUPPLY IN KaTPP: -Ministry of coal, Govt. of India has

allotted Paras east and Kanta basin coal blocks to RVUN in
Chhattisgarh state.

15
 2.2 STAGES OF COAL HANDLING PLANT

1. WAGON TIPPLER-The term Wagon Tippler contains two

words WAGON & TIPPLER. Wagon means the compartment
of train which is just like a container which is used to carry the
coal from mines to generating stations & the word Tippler
means a machine, which is used to unload the wagon into the
hopper. Hopper is just like a vessel which is made of concrete
& it is covered with a thick iron net on its top. Here big size coal
pieces are hammered by the labors to dispose it into the hopper.

Capacity 90 tones
Types of Tipplers 1.Weighing type,
2.Non weighing type
Drive unit Motor 37.3 KW
Angle of Tip 30 to 35
Wire Ropes 1.Hoisting Ropes,
2.Counter Weight Ropes
Operating Cycle 10 wagons/Hour on 1 wagon
Tippler
Time consumes for one cycle 6 minutes

2. FEEDER- It is used to control the supply of crushed coal to

the mill depending upon load condition. It is installed under
wagon tippler and hopper. In KaTPP there are 4 unbalanced
Motor Vibrating Feeder installed in unit 1st.
3. CHRUSHER/RING GRANULATOR-In ring granulator the
material is fed in to the crushing chamber and is crushed by the
rind hammers with impact and rolling action across the feed,
with concentrated pressure. This cracks the coal producing a
granulator product with a minimum of fines up to 20 mm
square.

16
 Capacity 500 Tonnes/hr.
Machine Weight 30 Tonnes
Motor 500 Tonnes/hr.
Max Feed Rate 720 r.p.m
Rotor Speed 550 H. P
Phase 606 Kv
Volts 3 Phase motor

4. CONVEYORS-Conveyor belt is used to send the coal from

coal storage yard and also used to send crushed coal from store
to mill bunkers. The carrying capacity of conveyors belt is 750
tonnes/hrs. that are installed in KaTPP.

PARTS OF CONVEYORS

1) Flap Gate-it provide under coal transfer chutes for

replacements of crusher/conveyors.
2) Deflector Plate-Deflector plates are installed in the chutes
coming on conveyors to keep the coal direction in the center
of the conveyors.
3) Skirt board and Skirt Rubber-These are provided on tail
end chutes to avoid spillages of coal from Conveyors.
4) Stone picker-Stone picker picks the stones from the running
belt manually.
5) Metal Detactor-Electromagnets are provided on conveyors
to avoid and to save crusher parts and entry of iron pieces in
crusher. It also stops the entry of iron pieces in coal bunker to
save damage of coal mills.
6) Guide Idlers-These idlers help to train/guide the conveyors.
7) Return Idlers-These idlers carries the conveyors belts in
return side.
8) R.T.I (Return Training Idler)-These idlers are provided on
return side to guide the conveyors.

17
9) Impact Idler-These Rubber idlers are provided under chutes
through which coal falls on conveyors.
10) Carrying Idlers-These are installed to run the conveyor.

 BUNKERS-Bunkers are fabricated to store the coal before

sending to coal mills. Coal is fed in the bunkers with the help
of tripper trolleys installed at 37 m height for unit 1st and
2nd. These are 20 bunkers for unit 1st and 2nd. Capacity of a
bunker=500 tonne/bunker.
 COAL BUNKERS-These are in process storage used for
storing crushed coal from the handling system. Generally,
these are made up of the welded steel plates with vibrating
arrangement of the outlet to avoid chocking of coal, normally
there are six bunker supply coal to the corresponding mills.
These are located on the top of mills so as to add gravity
feeding of coal.
 RECLAIM YARD-After filing the coal bunkers extra coal is
taken to reclaim yard after crushing of coal to storage.
 COAL CIRCULATION-Coal is transported from the coal
mine with the help of train. Train wagons are emptied with
the help of wagon tipplers and sent to the crusher for
crushing. From coal crusher it goes to the bunker through
conveyor belt and from coal bunker it moves to R.C feeder
feeds coal to the coal mill, where the coal is ground in to
powder from.

18
Fig: - COAL HANDLING LAYOUT

19
3. IMPORTANT PARTS OF THERMAL POWER PLANT

3.1 BOILER

Boiler can simply define as the device where any liquid is boiled or
Boiler may be defined as a device that is used to transfer heat
energy being produced by burning of fuel to liquid, generally
water, contended in it to cause its vaporization. Boiler, in simple
terms, can be called “Steam Generator”.
In simple way, boiler is a device used for producing steam. There
are two types of boilers.
a) Fire tube boiler
b) Water tube boiler

Here, boiler used is of water type. In the boiler, heat energy

transfer takes place through tube walls and drum. The gases lose
their heat to water in the boiler or superheated. The escape heat is
used to heat the water through economizer.
ID and FD fans are used to produce artificial draught. The fuel oil
is used to ignite the boiler and pulverized coal is lifted from the
coal mills by PA fans.

WATER TUBE BOILER USED IN KaTPP WITH 97M HIGHT

Various motors use in boiler are different rating and parameters

32KW ,15KW ,11KW, & 3.3KW Parameter in 15KW motor

20
 Manufacturing Made in China
Motor rating 15 KW
Rated voltage 970 r.p.m
Speed 416 V
Rated current 28.4 A
Impedance voltage 80.0 %
Oil weight 20 Kg
Core+ winding weight 224 Kg
Temp rise 50-55 deg cel.
Total weight 600 Kg

Fig: - Water tube boiler

21
BOILER AUXILIARIES-Efficiency of a system is of most
concerned. Thus, it is very important to maintain a system as
efficient as possible. So, Boiler auxiliaries help in improving
boiler’s efficiency. Following are the important auxiliaries used

 ECONOMISER: Its purpose is to preheat feed water before

it is introduced into boiler drum by recovering heat from flue
gases leaving the furnace.
 SUPER HEATER: It increase the temperature of steam to
super-heated region.
 REHEATER: It is used for heat addition and increase the
temperature of steam coming from high pressure turbine to
540 deg.
 DRAFT FANS: They handle the supply of air and the
pressure of furnace. BOILER MOUNTINGS-These are used
for the safe operation of boiler. Some examples of mountings
used are water level indicator in drum, furnace temperature
probe, reheat release valve, pressure gauges indicating steam
pressure etc.

22
 3.2 TURBINE

A turbine is a machine that transforms rotational energy from a

fluid that is picked up by a rotor system into usable work or energy.
Turbines achieve this either through mechanical gearing or
electromagnetic induction to produce electricity.
When working substance is steam it is called ‘Steam Turbine’

 PRINCIPLE-Working of the steam turbine depends wholly

upon the dynamic action of steam. The steam is caused to fall
with pressure in a passage of nozzle, due to this fall in
pressure, a whole amount of heat energy is converted into
mechanical energy & steam is set moving with the reactor
velocity. The rapidly moving particle of steam enter the
moving part of turbine and here suffers a change in the
direction of motion which gives rise to change of momentum
and therefore to a force. This constitutes a driving force to a
turbine.

The passage of them/through the moving part of the turbine

commonly called the blade, may take place in such a manner that
the pressure at the outlet sides of the blade is equal to that of the
inlet side. Such a turbine is broadly termed as outlet turbine or
Impulse type
On the other hand, the pressure of the steam at outlet from the
moving blade may be less than that at type inlet side of the blade.
The drop of pressure suffered by the steam during its flow through
the moving blades causes a further generation of kinetic energy
within the blades and adds to the propelling force which is applied
to the turbine rotor, such a turbine is broadly termed as Reaction
Turbine. Here in Kalisindh Thermal Power Project N600-
16.7/587/537, Re-Het, Three Casing, Four Exhaust, Tandem
Compound Condenser Type Turbine Used. The turbine is of
tandem compound design with separate High Pressure (HP),

23
Intermediate Pressure (IP) and Low Pressure (LP) cylinders. The
HP turbine is of Single Flow type while IP and LP turbines are of
Double Flow type. The turbine is condensing type with single
reheat. It is basically engineered on reaction principle with throttle
governing. The stages are arranged in HP, IP AND LP turbines
driving alternating current full capacity turbo generator. The
readily designed HP, IP and LP turbines are combined and sized to
required power output, steam parameters and cycle configuration
to give most economical turbine set. The design and constructional
feature have proved their reliability in service and ensure trouble
free operation over long operating periods and at the same time
ensuring high thermal efficiencies

24
 TURBINE SPECIFICATION

Rated output with extraction flow 600 MW

Speed 3000 r.p.m
Main steam throttle flow at HP Inlet 1848.5 TPH
Main steam pressure to HP turbine 167 kg/sq.cm
inlet
Main steam temp. to HP turbine inlet 538 deg.cel
Re-heater steam flow at IP inlet 1587.942 TPH
Re-heater steam temp. at IP inlet 538 deg.cel
Steam pressure at LP inlet 35.12 kg/sq.cm
Steam flow at LP inlet 1353.7 TPH
Rotation Direction (view from turbine) anticlock wise
Number of stages 42
High pressure turbine 1 governing and 8 pressure
a) Intermediate pressure 5 pressure stage
b) Low pressure turbine 28 pressure stage
c) Governing system
Inlet steam flow governing type Nozzle + throttle
Rated exhaust pressure 0.09 kg/sq.cm
Type of bearing turbine 6 journal +1 thrust
Turbine allowable frequency 47.5 to 51.5 Hz
Turning gear rotation speed 1.5 r.p.m
1st critical speed of HP & LP rotor 1722 r.p.m
1st critical speed of LP-A rotor 1839 r.p.m
1st critical speed of LP-b rotor 1903 r.p.m
Heat regenerative extraction system 3 HP heater +1 deaerator +4 LP
heater
Final feed water temperature 274.9 deg.cel
Maximum bearing vibration 0.076 m
Maximum allowable exhaust temp. 80 deg.cel
Colling water design flow at condenser 70200 TPH

25
 3.3 GENERATOR

Generator is the important part of thermal power plant. It is device

which convert the mechanical energy into electrical energy.
Generator is driven by coupled steam turbine at a speed of 3000
r.p.m. due to rotation at high speed it gets heat. So, there is cooling
construction enclosing the winding core of the generator. So that
during the operation is being in normal temperature.
In KaTPP, each of the 2 units have been provided with 3-phase turbo
generator rated output 706MVA, 18.525KA, 22KV, 0.85 lagging
p.f., 984 rpm and 50 cycles/sec. The generator has closed loop of
hydrogen gas system for cooling of the stator and rotor at a pressure
of 4.5kg/sq-cm(g)

26
GENERATOR SPECIFICATION FOR UNIT I AND II: -

Make CQ GEARBOX China

Type QFSN
Apparent output 706 MVA
Active output 600 MW
Power factor 0.85 lagging
Rated voltage 22 KV
Rated current 18525 Amp
Rated speed Rated speed
Frequency 50 Hz
Phase connections Double gen. star
Cooling mode H20-H2-H2
Rated H2 pressure 4.5 Kg/sq-cm
Terminal in generator 6

DIESEL GENERATOR SET

It is used to emergency purpose to supply auxiliary system of

power plant.3 Set Diesel generator are use in which one is standby.
parameters of generator are as

Make BY STAMFOARD
MAHARASTRA
INDIA
Rating 1900 KVA
Speed 1500 R.P.M
Rated Current 2643.37 A
Rated Temp Rated Temp
AMPS 3.6 A

27
 3.4 CONDENSER
In condenser, the water passes through various tubes and steam
passes through a chamber containing a large number of water tubes
(about 20000)
The steam gets converted into water droplets, when steam comes in
contact with water tubes. The condensate is used again in boiler as
it is dematerialized water and 5-6 heats the water, which was in
tubes, during the process of condensation. This water is sent to
cooling tower.
Condenser is installed below the LP exhaust. The condenser is of
surface type made of fabricated construction in single shell. The
tube is of divided type double pass arrangement, having two
independent cooling water inlet, outlet and reverse and water boxes.
This arrangement facilitates the operation of one half of condenser
when the other half is under maintenance. The condenser is provided
with integral air-cooling zone at the center from where air and non-
condensable gases are continuously drawn out with the help of
mechanical vacuum pump.
 Area of condenser = 9655 sq m
 Cooling water flow rate = 2400 cubic m/Hr

28
 3.5 COOLING TOWER

It is a structure of height 202 m (tallest in the world) designed to

cool the water (coming from condenser) by natural draught. The
cross-sectional area is less at the center just to create low pressure
so that ate air can lift up due to natural draught and can carry heat
from spherical drops. The upper portion is also diverging for
increasing the efficiency of cooling tower. Hence it is named as
natural draught cooling tower
In KaTPP two natural draught cooling towers (2 NDCT) is present
with height 202 m each for each unit.

Fig-Cooling Tower

29
 3.6 WATER TREATMENT PLANT

As everyone know that the cost of any thermal power plant is cores
of rupees. So major problem of any thermal power plant is that how
to prevent the corrosion. The water available can’t be used in boilers
as such. The objective of water treatment plant is to produce the
boiler feed water so that there shall be.
 No scale formation
 No corrosion
 No priming or forming problems

Water used in thermal power plant is called ‘Dematerialized

Water’ or DM Water

4. ESP AND AHP SYSTEM

4.1 ELECTROSTATIC PRECIPITATOR (ESP)

Electrostatic Precipitator (ESP) is equipment, which utilizes an

intense electric force to separate the suspended particle from the
gases. In India coal is widely used to generate power. The exhaust
gases are emitted directly into the atmosphere, it will cause great
environmental problems. So, it is necessary to extract this dust and
smoke before emitted the exhaust gases into atmosphere. There are
various methods of extracting dust but electrostatic precipitator is
the most widely used. It involves electric changing of suspended
particle, collection of charge particles and removal of charge
particles from collecting electrode. Its various other advantages are
as follows:

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  It has high efficiency i.e., about 99%
 Ability to treat large volume of gases at high temperature
 Ability to cope with the corrosive atmosphere.
 It offers low resistance to the flow of gases.
 It requires less maintenance.

WORKING PRINCIPLE- The electrostatic precipitator utilizes

electrostatic forces to separate dust particles from the gases to be
cleaned. The gas is passed through a chamber, which contains steel
plates (vertical) curtains. Theses steel curtains divide the chamber
into number of parallel paths. The framework is held in place by
four insulators, which insulate it electrically from all parts, which
are grounded. A high voltage direct current is connected between
the framework and the ground, thereby creating strong electric field
between the wires in the framework curtains.
Strong electric field develops near the surface of the wire creates
Corona Discharge along the wire. Thus, ionized gas produces +ve
and –ve ions. In the chamber plates are positively charged whereas
the wire is negatively charged. Positive ions are attracted towards
the wire whereas the negative ions are attracted towards the plates.
On their way towards the curtains negative ions strike the dust
particle and make them negatively charged. Thus, is collected on the
steel curtains

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The whole ESP is divided into two parts-
 Mechanical System
 Electrical System

Here we will discuss only Mechanical System (i.e. Precipitator

Casing, Emitting and Collecting System and Hopper)

Precipitator Casing-Precipitator Casing is made of 6mm mild steel

plates with required stiffness. The precipitator casing is all welded
construction comprising of pre-fabricated walls and proof-panels.
The roof carries the precipitator internals, insulator housing,
transformer etc. Both emitting and collecting systems are hung from
the top of the casing.

Emitting and Collecting System- Emitting System is the most

important part of ESP. Emitting system consists of rigid emitting
frame suspended from four points on the top of rigid emitting

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electrodes in the form of open spiral. The four suspension points are
supported on support insulators to give electrical insulation to the
emitting frame. The frame is designed to take up the retention forces
of the emitting electrode. The emitting electrode consists of hard
drawn spiral wires and are fastened with hooks to the discharge
frame. Collecting system mainly consists of collecting suspension
frame, collection electrodes and shock bars. Collecting electrode are
made of 1.6 mm thick Mild Steel sheets formed in ‘G’ Profile of
400mm width. Hook and guide are welded on one end and shock
iron on the dipped in rust preventive oil tank. Collecting electrodes
bundles are properly bundled in order to avoid any damage to
electrode.

Hoppers- Hoppers are seized to hold the ash for 8-hour collection
and is provided under the casing of ESP. It is of Pyramidal Shape
and is 56 in number. It is preferred to evacuate the hoppers at the
earliest as long storage of dust in hopper leads to clogging of hopper.
Also, at the bottom of hopper electrical heating is provided to avoid
any condensation, which could also lead to clogging of hopper.
Baffle plates are provided in each hopper to avoid gas leakage

RAPPING MECAHISM FOR COLLECTING SYSTEM-

During electrostatic precipitation a fraction of dust will be collected
on the discharge on the discharge electrodes and the corona will be
suppressed as the dust layer grows. So rapping is done in order to
remove this dust by hammering the electrodes. As the shaft rotates
the hammer tumbles on to the shock bar that transmits the blow to
the electrode. The whole rapping mechanism is mounted on a single
shaft, which is collection of ash on the collecting electrode.

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 4.2 ASH HANDLING PLANT (AHP)

The ash produced on the combustion of coal is collected by ESP.

This ash is now required to disposed off. This purpose of ash
disposal is solved by Ash Handling Plant (AHP). There are basically
two types of ash handling process undertaken by AHP
 Dry Ash System
 Ash Slurry System

DRY ASH SYSTEM- Dry ash is required in cement factories as it

can be directly added to cement. Hence the dry ash collected in the
ESP hopper is directly disposed to silos using pressure pumps. The
dry ash from these silos is transported to the required destination

ASH SLURRY SYSTEM- Ash from boiler is transported to ash

dump areas by means of sluicing type hydraulic system which
consists of two types of system-
 Bottom Ash System
 Ash Water System

BOTTOM ASH SYSTEM- In this system, the ash slag discharged

from the furnace is collected in water impounded scraper installed
below bottom ash hopper. The ash collected is transported to
clinkers by chain conveyors. The clinker grinders churn ash which
is then mixed with water to form slurry.

ASH WATER SYSTEM-In this system, the ash collected in ESP

hopper is passed to flushing system. Here low-pressure water is
applied through nozzle directing tangentially to the section of pipe
to create turbulence and proper mixing of ash with water to form
slurry. Slurry formed in above processes is transported to ash slurry
sump. Here extra water is added to slurry if required and then is
pumped to the dump area

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FLY ASH SYSTEM-Even though ESP is very efficient, there is
still some ash, about 0.2%, left in flue gases. It is disposed to the
atmosphere along with flue gases through chimney

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5. CONTROLLING, SWITCHING AND TRANSMISSION

5.1 CONTROL AND INSTRUMENTATION SYSTEM

Control and Instrumentation (C & I) systems are provided to enable

the power station to be operated in a safe and efficient manner while
responding to the demands of the national grid system. These
demands have to be met without violating the safety or operational
constraints of the plants. For example, metallurgical limitations are
important as they set limits on the maximum permissible boiler
metal temperature and the chemical constituents of the Feed water.
The control and Instrumentation system provides the means of the
manual and automatic control of plant operating conditions to
maintain an adequate margin from the safety and operational
constraints. Monitor these margins and the plant conditions, and
provide immediate indications and permanent records. Draw the
attention of the operator by an alarm system to any unacceptable
reduction in the margins. Shut down the plant if the operating
constraints are violated.

5.2 SWITCHING AND TRANSMISSION

The electricity is usually produced in the stator winding of the large

modern generators at about 25,000 volts and is fed through terminal
connections to one side of a generator transformer that steps up the
voltage 132000, 220000 or 400000 volts. From here conductors
carry it to a series of three switches comprising an isolator, a circuit
breaker and another isolator. The circuit breaker, which is a heavy-
duty switch capable of operating in a fraction of a second, is used to
switch off the current flowing to the transmission lines. Once the
current has been interrupted the isolators can be opened. These
isolate the circuit breaker from all outside electrical sources.

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From the circuit breaker the current is taken to the bus bars-
conductors, which run the length of the switching compound and
then to another circuit breaker with its associated isolates before
feeding to the grid.
Three wires are used in a ‘three=phase’ system for large power
transmission. The center of the power station is the control room.
Here engineers monitor the output of electricity, supervising and
controlling the operation of the generation plant and high voltage
switch gear and directing power to the grid system as required.

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 6. EFFICIENCY AND CONCLUSION

6.1 EFFICIENCY

Efficiency is defined as the ratio of output to input. Efficiency of

any thermal power plant can be divided into four parts
 Cycle Efficiency
 Boiler Efficiency
 Generator Efficiency
 Turbine Efficiency

Efficiency of thermal power plant is defined as in the term of overall
efficiency i.e., overall efficiency = cycle x boiler x generator x
turbine efficiency

CYCLE EFFICIENCY- Cycle efficiency is defined as the ration

of energy available for conversion in work to the heat supplied to
the boiler.

BOILER EFFICIENCY- Efficiency of boiler depends upon the

following factors: a) Dry flue gas loss: Increase by excess air in
boiler. b) Wet flue gas loss: Moisture in coal. c) Moisture in
combustion loss: Hydrogen loss.

GENERATOR EFFICIENCY- Efficiency of generator is about

98% also its efficiency depends upon: a) Copper and iron loss b)
Windage losses

TURBINE EFFICIENCY-It means the efficiency of steam turbine

in converting the heat energy made available in the cycle into actual
mechanical work.

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 6.2 CONCLUSION

This is my first practical training in which I learned lot of things and

seen lot of huge machine-like Turbine, Boiler, Generator, cooling
tower and many other things. The architecture of the power plant,
the way various units are linked and the way working of whole plant
is controlled make the student realize that engineering is not just
learning the structure description and working of various machine
but the great part is of planning proper and management.

7.REFERENCE

 www.rvunl.com
 www.googleindia.com
 Generation of electrical power By B. R. Gupta, S CHAND
PUBLICATION

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Thank You

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