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A VOCATIONAL TRAINING REPORT

ON
DURGAPUR STEEL THERMAL POWER STATION
DAMODAR VALLEY CORPORATION

TRAINING PERIOD: 19/07/2022 TO 02/08/2022

DEPARTMENT OF MECHANICAL ENGINEERING

PREPARED AND SUBMITTED BY

STUDENTS OF MECHANICAL ENGINEERING DEPT ,
TECHNO MAIN SALT LAKE
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VOCATIONAL TRAINING BY STUDENTS OF MECHANICAL DEPT:-

1. SOUVIK CHATTARAJ
2. EVAN BOSE
3. SHUBHASHIS BAIDYA
4. PRITISH GANGULI
5. MRIGANKA HALDER
6. ARKAJYOTI DHAR
7. ABHIJEET KUMAR SINGH
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ACKNOWLEDGEMENT

The report has been prepared based on the vocational training undergone in a highly esteemed
organization of Eastern region, a pioneer in Generation Transmission & Distribution of power, one of
most technically advanced power plant in West Bengal, the Durgapur Steel Thermal Power Station
under Damodar Valley Corporation.

I would like to express my heartfelt gratitude to the authorities of Durgapur Steel Thermal Power
Station and Techno Main Salt Lake for providing me such an opportunity to undergo training in the
Thermal Power Plant of DVC, DSTPS.

I am also thankful to the Chief Engineer and project head, DSTPS and Joint Director (HR) for
providing me opportunity to carry out my vocational training in DSTPS. We are obliged to staff
members of DSTPS, DVC for the valuable information and time provided by them in their respective
fields. We are grateful for their co-operation during the period of my assignment.

Under The Guidance of :-

Training Co-ordinator (MECH) :- Sobhanlal Kirtaniya
Joint Secretary (HR):- Gopa Chakraborty
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Contents

 Introduction
 Durgapur Steel Thermal Power Station
 Introduction Of Water Treatment in Thermal Power Plant
 Cooling Towers
 Coal Handling Plant
 Steam Turbine
 Furnace and Boiler
 Electrostatic Precipitators
 Switchyard
 Electrical System Overview
 Ash Handling Plant
 DVC: Transmission and Distribution Network
 Conclusion
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 Introduction
Electricity generation is the process of generating electric power from
Sources of energy. Electricity is most often generated at a power station by electromechanical
generators, primarily driven by heat engines fueled by chemical combustion or nuclear fusion but also
by other means such as the kinetic energy flowing water and wind. There are many other technologies
that can be and are used to generate electricity such as solar photovoltaic and geothermal energy
power.

In Indian subcontinent the abundance of coal leads to establishment of thermal power stations and
governing bodies namely DVC, NTPC, TATA power acts as pioneers in the generation of electricity.

 Damodar Valley Corporation

The valley of the Damodar River was flood prone and the devastating flood of 1943, lead to the
formation of the high-powered "Damodar Flood Enquiry Committee" by the government of Bengal. The
committee recommended the formation of a body similar to the Tennessee Valley Authority. of the
United States. Subsequently, W.L. Voorduin, a senior engineer of TVA, was appointed to study the
problem. He suggested the multi-purpose development of the valley as a whole in 1944. Damodar
Valley Corporation was set up in 1948 as “the first multipurpose river valley project of independent
India.
DVC was formed with the central government and the governments of Bihar (later Jharkhand) and West
Bengal participating in it. The main aims of the corporation were flood control, irrigation, generation
and transmission of electricity, and year-round navigation. The corporation was also expected to
provide indirect support for the over-all development of the region. However, while Voorduin had
proposed the construction of eight dams, DVC built only four.
The first dam was built across the Barakar River at Tilaiya and inaugurated in 1953. The second dam,
Konar Dam, across the Konar River was inaugurated in 1955. The third dam across the Barakar River at
Maithon was inaugurated in 1957. The fourth dam across the Damodar at Panchet was inaugurated in
1959. Durgapur Barrage was built in 1955, with a 136.8 kilometers (85.0 mi) long left bank main canal
and an 88.5 kilometers (55.0 mi) long right bank main canal.
Command area: 24,235 km2 spread across the Damodar basin. Jharkhand: 2 districts fully (Dhanbad
and Bokaro) and parts of 9 districts (Hazaribagh, Koderma, Chatra, Ramgarh, Palamau, Ranchi,
Lohardaga, Giridih, and Dumka) West Bengal: 6 districts (Purba Bardhhaman, Paschim Bardhhaman,
Hooghly, Howrah, Bankura and Purulia)
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 Generations

Thermal Plants (Coal based)

Installed Capacity
Power Plant Name State
in MW
Mejia Thermal Power Station West Bengal 2,340
Raghunathpur Thermal Power
West Bengal 1,200
Station
Maithon Power Limited Jharkhand 1,050
Durgapur Steel Thermal Power
West Bengal 1,000
Station
Koderma Thermal Power Station Jharkhand 1,000
Chandrapura Thermal Power
Jharkhand 500
Station
Bokaro Thermal Power Station - A Jharkhand 500
BPSCL Power Plant Jharkhand 338
Total 7107

Hydel-Power Plants
Installed Capacity
Power Plant Name State
in MW
Panchet Dam Jharkhand 80
Maithon Dam Jharkhand 63.2
Tilaiya Dam Jharkhand 4
Total 147.2
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Durgapur Steel Thermal Power Station

Durgapur Steel Thermal Power Station also known as DSTPS is located at Andal which is a small town
located in the outskirts of Durgapur in Paschim Barddhaman District. It is one of the 4 Thermal Power
Stations of Damodar Valley Corporation in the state of West Bengal. The total power plant campus area
is surrounded by boundary walls and is basically divided into two major parts, first the Power Plant
area itself and the second is the Colony area for the residence and other facilities for DSTPS employees.
Technical Specification of DSTPS along with Specialities

Installed capacities -
 Total number of Units: - 2 x 500 MW with Brush less Type Generators
 Running Capacity: - 350 MW ( 1 x 140 + 1 x 240 MW)
 Coal linkage- Mines block in Jharkhand and Raniganj
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 SPECIALITIES OF DURGAPUR STEEL THERMAL POWER

PLANT:

 The plant is designed and engineered by both BHARAT HEAVY ELECTRICALS LIMITED and
Damodar Valley Corporation.
 Longer than 2KM Railway Tracks System for coal transport.
 Direct ignition of pulverized coal introduced for reduction in consumption of fuel oil vertical
bowl and roller type Mills for more mill rejects and less maintenance cost.
 Boiler of 88.8m height and four corner firing system for better combustion. All major and
hazardous systems like Steam Generation and Turbo Generation section are incorporated with
FSSS (Furnace Safety Supervisory System) for better safety.
 Other logic systems like EAST and ATRS are also incorporated.
 Water treatment plants along with two artificial water reservoir and two demineralization
plants loaded with PLC system.
 Chimney height up to 275M for less pollution.
 The plant is loaded with latest technology sensor, transducers and transmitters for more
accurate analyzing of various processes
 All the units are loaded with intelligent smart microprocessor-based systems known to be DCS
 systems provided by KELTRON, SIEMENS and MAX-DNA for process control.
 Station Service Transformers of 11KV step-down type are also available for better distribution
of
 power inside the plant for various requirements
 Switchyard with individual step-up generator transformers of ONAN/ANOF/AFOF cooling
 Transformers of 400K V.220KV for supply to national grid, along with other safety instruments.
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 Basic Need of a Thermal Power Plant

A thermal power station is a type of power station in which heat energy is converted to electrical
energy. In a steam-generating cycle heat is used to boil water in a large pressure vessel to produce high-
pressure steam, which drives a steam turbine connected to an electrical generator. The low-pressure
exhaust from the turbine enters a steam condenser where it is cooled to produce hot condensate which
is recycled to the heating process to generate more high-pressure steam. This is known as a Rankine
cycle.
The design of thermal power stations depends on the intended energy source: fossil fuel, nuclear and
geothermal power, solar energy, biofuels, and waste incineration are all used. Certain thermal power
stations are also designed to produce heat for industrial purposes; for district heating; or desalination
of water, in addition to generating electrical power.
Natural gas or oil fuel can also be burnt directly in a gas turbine connected to an electrical generator,
and to improve efficiency the hot exhaust gases are then used to boil water and produce more steam for
use in a steam generating cycle. This is known as combined cycle gas turbine plant.

 Overview of A Thermal Power Plant

Abstract: A Thermal Power Station is a station in which heat energy is converted continuously into
Electrical energy by rotation of a shaft. Here, working fluid is water which is in the liquid phase, and it is
convert into superheated steam by burning of fossil fuel (coal and oil). Energy released by the burning
of fuel is transferred to water which is inside the boiler to generate steam at high pressure and
temperature. Steam is passes through the turbine to produce shaft work. After it passes through the
turbine it is condensed in condenser and recycled to where it was heated. This cyclic process is known
is Rankine Cycle. The figure below illustrates the basic components of Thermal Power plant where
mechanical power of the turbine is utilized by the electric generator to produce electricity and
ultimately transmitted via transmission lines.
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1.Cooling tower. 2.Cooling water pump. 3.Transmission line(3-phase). 4.Unit transformer(3-

phase). 5.Electric generator(3-phase). 6.Low pressure turbine. 7.Condensate extraction pump. 8.
Condenser. 9. Intermediate pressure turbine. 10.Steam governor valve. 11.High pressure
turbine. 12.De-aerator. 13.Feed heater. 14.Coal conveyor. 15.Coal hopper. 16.Pulversied fuel
mill. 17.Boiler Drums. 18.Ash hopper. 19.Super heater. 20.Forced draught fan. 21.Re-heater. 22.
Air intake. 23.Economiser. 24.Air pre heater. 25.Precipitator. 26.Induced draught fan.
27.Chimney Stack.

 Site Requirement
The basic requirements thermal power plant is determined by the type, size and other specifications of
the plant. It is required to know the immediate capacity of the power plant after construction and the
extension of capacity in the future, to determine the area required for construction of the plant.
The basic things that are taken into consideration are as follows -
i. Station Building
ii. Coal Store
iii. Cooling Towers
iv. Switch Yard Compound
v. Surrounding Areas and Approaching
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 Introduction Of Water Treatment in Thermal Power Plant:

The main problem with boiler is to prevent corrosion and provide a good steam quality. Internal
corrosion can cost the plant huge financial losses. Without regulation of impurities in steam it may
deposit over turbine blade and nozzles.
FOR
COOLING
DAMODAR RIVER RESERVOIR CLARIFIER WATER
PORTABLE
WATER

DM EXCHANGER FOR DM
1.ACTIVATED CHARCOAL WATER &
FILTER PORTABLE GRAVITY
CONDENSATE 2.STRONG ACIDATION WATER FILTER BED
EXTRACTION CAHMBER
3.DEGASSER TANK
PUMP
4.STRONG BASE ANION
CHAMBER FOR DM
5.MIXED BED FILTER WATER
HOUSE

 Reservoir:
A reservoir is, most commonly, an enlarged natural or artificial lake or pond, or impoundment created
using a dam or lock to store water. In D.S.T.P.S the raw water is collected from DAMODAR RIVER, and
then the water is stored in two reservoirs for future use. The quantity of the water in two reservoirs is
in same level and same quantity.

 Clarifier:
Water from the reservoir is pumped into the clarifier. In this Clarifier solid sediments settle to the
bottom. The structure of the clarifier is quite simple with a central circular feed well through which
water is allowed to inlet and allowed to settle in tank. Then the topmost and the cleanest layer is
pumped into two different paths

 For cooling water

 For Dm water and portable water

The cooling water is pumped to the CW house and after that it is used for various purposes of cooling in
the plant.

Other line of water is going to the dm water plant and portable water system. Water which is going to
direct DM plant Is directed to gravity filter bed for further purification.
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 Gravity Filter Bed:

It is a simple water filter which is used for simple filtration of water. The water is released from the
pipes and released in the gravity filter bed. There the water is passed from some layers of sand, coal,
gravels, granules. All the impurities are structed in these layers. The water is now partially clean and
then that water is going in two paths
 For Portable water
 For DM water

Portable water is used for domestic uses in all the plant for drinking and other uses.

The DM water is going to the filter house for further filtration.

 Filter House:
In the filter house alum dosing is carried out (K 2SO4) which forms a scum and then removes the
colloidal particles from water. The plant maintains a steady level of alum froth just 2 feet above the inlet
pipe which acts as a trap for small froth to get trapped in it forms a layer which is periodically regulated
and waste water is send to ash pump house. The filtered water is sent for de-germination. De-
germination is done by adding chlorine which kills microbes present in water. The water is then
directed into the Dm exchanger house.

 DM Exchanger:
In the dm exchanger plant the whole demineralization process happens. This process is coordinated by some
complex steps.

 Activated Charcoal Filter [ACF Filter]

 Strong Acid Cation Chamber
 Degasser Tank
 Strong Base Anion Chamber
 Mixed Bed

Let discuss these processes briefly,

1) Activated Charcoal Filter [ACF Filter]:

Activated carbon filtration is a commonly used technology based on the adsorption of contaminants
onto the surface of a filter. This method is effective in removing certain organics such as unwanted taste
and odors, micro pollutant, chlorine, fluorine or radon from any kind of water. In this process all the
impurities are removed from that water.

2) Strong Acid Cation Chamber:

SAC resins can neutralize strong bases and convert neutral salts into their corresponding acids. These
resins are utilized in most softening and full demineralization applications. SAC resins derive their
functionality from sulfonic acid groups (HSO 3¯). When used in demineralization, SAC resins remove
nearly all raw water cations, replacing them with hydrogen ions. After Carbon filtration all the cations
from water like Na2+, Ca2+, Mg2+ were removed from the water and after that it is directed to the
Degasser tank.
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3) Degasser tank:
Degassing, also known as degasification, is the removal of dissolved gases from liquids, especially water
or aqueous solutions. There are numerous methods for removing gases from liquids. There is some
bicarbonate which is dissolved in water are released. In this process the bicarbonate elements are
broken into carbon dioxide and water.

4) Strong Base Anion:

Strong base anion (SBA) exchange resins are typically used for demineralization, DE alkalization, and
desalination, as well as removal of total organic carbon (TOC) or other organics depending on the type
of resin. They are available in multiple varieties, each of which offer a unique set of benefits and
constraints, but in general, SBA resins are strong enough to remove both strong and weak acids
including carbonic and silicic acid. Water flows through a zeolite softener and then an anion unit, which
replaces the carbonate, bicarbonate, sulfate, and nitrate ions with chloride ions. After that the water is
sent to the final process of mixed bed treatment.

Mixed bed resins or mixed bed ion exchange resins are mainly used in the water purification industry
for polishing process water to achieve demineralized water quality (such as after a reverse osmosis
system). Mixed bed as the name states consists of strong acid cation exchange and strong base anion
exchange resin, then the water goes to the storage tank. Then its send to condenser extraction pump,
afterwards it goes to the boiler after the whole boiler-turbine process as mention. The remaining used
steam from the turbine goes to the condenser (steam converted to water) and supplied to hot well then,
a part of condensed water is passes to CEP and another part of the condensed water passes to CPU.
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 NDCT (NATURAL DRAFT COOLING TOWER):

In DSTPS, the type of cooling tower used is NDCT. The natural draft cooling tower is an open, direct-
contact system. It works using a heat exchanger, allowing hot water from the system to
be cooled through direct contact with fresh air. To increase the heat transfer surface area (and optimize
the cooling process), hot water is sprayed from nozzles within the tower.  The hot water releases heat
after coming into direct contact with the fresh air, and some of the hot water is evaporated. Cold water
is collected at the bottom of the tower. 

AVGF (automatic valveless gravity filter)

A part of the cooling water is passed via AVGF. The main function of AVGF is to decrease the turbidity of
the cooling water.

CWPH (cooling water pump house)

Cooling water Pump House collects water from the AVGF and the cooling tower. Chlorine and Sulphuric
acid are dosed for degemination and pH balancing of the water. The main function of CWPH is to send
the cooling water to the condenser. Also, it sends cooling water to turbine, boilers and auxiliaries for
keeping the machineries cool.
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Coal Handling Plant

Coal is the prime fuel for a thermal plant. Hence adequate emphasis needs to be given for its proper
handling and storage. Also, it is equally important to have a sustained flow of this fuel to maintain
uninterrupted power generation. Generally, most of the thermal power plants use low grades of
bituminous coal. The coal handling plant in thermal power plant is to receive, process, store, feed the
coal bunkers consistently over entire life of the power plant.

Coal is transported to the power station rail or road from the mines. Coal is unloaded from wagons into
the track hopper. From the track hopper conveyor takes coal to crusher for crushing. Before the crusher
there is one set of magnetic separator and magnetic supply to remove magnetic materials. After
crusher, coal is taken by a system of conveyors to the bunker floor, also there is a provision for stacking
as well as reclaiming the crushed coal by means of a stacker-cum-reclaimer.

Before coal goes to bunkers one set of magnetic separator and pulley is provided on the conveyor to
remove magnetic materials like to be present in the coal being reclaimed from stacked coal yard. Belt
weighs are provided in the same conveyor as well as after crusher to know the coal flow to the bunker
and also to know the amount of stacked coal.

Layout of Coal Handling Plant

The coal handling plant at DSTPS consists of conveyors, crushers, screens, feeders, stacker cum
reclaimer, magnetic separator, paddle feeder, coal storage. All the equipment's are run in sequential
interlocked system from the main control desk at the coal handling plant room.

The coal after unloading from wagons and truck received will have number of boulders of higher size
and will damage the conveyor belts. Hence grid with 900 * 900 mm is provided, above which the higher
size coal will be broken manually to under size of 900 mm. Then paddle feeder takes the coal and drop
on the conveyor belts in certain predefined amount after interval of time to the crusher house.
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 IN LINE MAGNETIC SEPERATOR OR SUSPENDED MAGNET (SM)

The coal in from feeder passes through conveyor belts to In Line Magnetic Separator (ILMS). The In
Line Magnetic Separator (ILMS) is used for continuous and automatic extraction or discharge of
unwanted magnetic pieces (trap iron) from the point where coal is discharged from conveyor.

 ROLLING SCREEN
Rolling screens are suitable for separating fine, coarse and sticky coal. They are used for preliminary
screening and relief to crusher as well to ensure a clog free flow of coal It consists of roller bodies.

Roller Body/ Eccentric Discs- Roller body are equipped with curved triangular discs. Coal of different
sizes are passes through it, coal of size less than 20mm will be released directly to the conveyor. Coal of
size above 20mm are relived to the crusher. Roller body are mounted on bearings.

 CRUSHER
Ring granulator type crusher are used in coal handling plant for crushing coal to a size suitable at power
station prior to pulverization. The crushing action is performed when material is dropped through the
feed opening where it is struck, in midair by the multiple rings which are being driven round by the
multiple rings which are being driven round by the rotor discs in direction towards the breaker plate.
The rings are mounted on suspension bars. When the rotor is set in the motion centrifugal force brings
the ring out against material to be crushed. As material is fed to the machine the rings are forced back
towards the rotor center until bar is encountered by the ring internal surface and a forward driving
force is exerted. The material is broken and discharged through the cage bars or screen plates thus
easing the load and allowing the ring to move out until it is held again by suspension bar before
encountering the incoming feed once again.

Crusher diagram
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 Reversible belt feeder:

They are provided with full length impact idlers for absorbing the impact of falling material from
crusher. It is used for direct supply of crushed coal to bunkers and also to stacker cum reclaimer for
storage of coal at pile yard.

 Stacker cum reclaimer:

Stacking is process of storage of crushed coal are stored in a yard. This process is generally used when
boiler bunker level is full. Reclaiming process, the stored are reclaimed for sending to boiler bunkers.
This is used when boiler bunker is low. Both process (staking and reclaiming) is achieved by stacker
cum reclaimer.

 Bunker:
Plants like coal fired power plants, cement facilities and cogeneration industries employ coal bunkers to
store coal and coal mills to crush the raw material into fine particles (pulverized coal) before being
injected into the boiler. The process involves maintaining the level of boiler bunkers from the conveyor
belt the coal is discharged into bunkers.
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 Furnace:
Furnaces heat air and distribute the heated air through the house using ducts. Boilers heat water, and
provide either hot water or steam for heating. Steam is distributed via pipes to steam radiators, and hot
water can be distributed via baseboard radiators or radiant floor systems, or can heat air via a coil.
Steam boilers operate at a higher temperature than hot water boilers, and are inherently less efficient;
however, high-efficiency versions of all types of furnaces and boilers are currently available.

 Boiler system:
It is a closed vessel having diameter around 21882mm, inside temperature is around 1473k pressure
around 180 kg/cm^2.It is hanging by tiered or sling grader. It is just supported with the bottom hopper
and the gap between boiler and bottom hopper is 10mm. It is filled with water. This gap is provided
because of the expansion of boiler (Trap seal). There are four corners in a boiler and each corner
having 8 coal pipes which is coming from eight individual mills.

 Working principle of boiler:

In Boiler, demineralized water is converted to steam by addition of heat. The heat added by two
processes: sensible heat addition and latent heat addition. In sensible heat addition the heat will raise
the temperature of water and in latent heat addition the heat will change the phase of the system.

Thermodynamically, boiling is a process of heat addition to water at constant pressure and

temperature.
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 Boiler Mounting: These are the essential parts that defines the boiler’s performance. Main
components are
 Pressure Gauge: This gauge type is used to measure the pressure inside the
boiler which is fitted at the boiler’s front.
 Water level Indicator: It is used to check inside water level inside the boiler, fitted in front of
the boiler.
 Stop Valve: Used to control the flow of steam from the boiler to steam pipe.
 Safety Valve: This valve is fitted on the drum, which is used to prevent the boiler expansion.

Secondary Air Control Discharge Damper (SADC):

The secondary Air Damper control is to regulating the velocity and distribution of the secondary air in a
tangentially fired furnace to control its combustion and controlling the effective openings of a
secondary air nozzle as an orifice in regulation of the secondary air supplied to the nozzle to affect the
desired velocity and distribution of the secondary air from the nozzle.
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Important parts of Boiler and their functions:

1. Boiler feed pump: Boiler feed pumps are commonly centrifugal pump driven by constant
speed electric motor. It is used to supply pressurized feed water to the boilers. There are two types of
boiler feed pumps – 1) Turbine Driven Boiler Feed Pump (2 X TDBFP) , 2)Motor Driven Boiler
Feed Pump (1 x MDBFP). The water inventory at various operating loads. In small boilers feed pump
has the functions of both extracting the water from the condenser and feeding to the boiler itself and in
larger boiler the pumps are various.

Boiler feed pump

2.Drum: It is used for separation of steam and water mixture coming from the water wall tubes. It also
ensures that only steam goes with no part of water to turbine inlet and another function of drum is to
maintain the pH level of boiler water and dosing of Phosphate is also done in boiler.

3. Economizer: It is used to preheat water before it enters into the boiler drum. The economizer uses
the heat of flue gases to preheat the water. The flue gases coming out from boiler, first passes through
economizer and then to atmosphere. It also increases the efficiency of boiler.

4. Air preheater: Air preheater is use to preheat the pulverized coal. It is preheated by the exhaust
gases of boiler. The heated air also enters into the boiler. So, it also increases the efficiency of boiler.

5. Superheater: A superheater is a device which is used to convert Saturated steam or wet steam into
Superheated steam or dry steam. Superheated steam is used in steam turbines for electricity
generation.
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 Auxiliaries of steam boiler:

 Induced draft fan (ID fan):
Induced draft fan is normally located at the outlet between dust collector
and chimney. The fan takes hot flue gases from the boiler through dust collector and delivers it to the
chimney into the open atmosphere. Id fan creates negative pressure or suction to discharge the gases
out after combustion from the furnace. Since ID fans can handle hot flue gases, they have more
corrosion and erosion problems even when used with Electrostatic precipitators. The most common
type of fans used as ID fans are the backward inclined blade centrifugal fans.

 Forced draft fan (FD fan):

Forced Draft fans used in a power plant are  centrifugal fans, utilizing radial
airflow blading or variable pitch axial fans. Forced Draft Fans (FD) supply the air necessary for fuel combustion
by pushing air through the combustion air supply system and into furnace.  These fans are located at the inlet of
boiler to push high pressure fresh air into combustion chamber, where it mixes with the fuel to produce
positive pressure.

The key difference between a forced draft and an induced draft fan is, FD fan forces outside  air into the heating
system whereas ID fan draw flue gases from the system out into the atmosphere. Both FD fan and ID fan
operate in such a manner that it balances the air system in the boiler to make the combustion process efficient.

 Primary air fan (PA fan) or Exhauster fan:

Primary air fans or PA fans are high pressure fans, used in the boiler
power plants to supply the air for transportation of coal directly from the pulverizer to the furnace. PA fans give
positive pressure upstream of the coal pulverizer and handle relatively clean air.

In power plants PA fans supply air for conveying of the pulverized coal from coal mills to the furnace area.
These fans produce a pressure upstream the pulverizer, to push the coal and air mixture through pulverizer
into the furnace.

 Oil handling system:

Oil handling systems and oil pumps are basically used for lubrication and cooling purpose in
turbines. It mainly consists of 2 types of pumps :
1. GOP or MOP or Main Oil Pump
2. AOP or Auxiliary Oil Pump
 Coal mill or pulveriser:

Most efficient way of utilizing coal for steam generation is to burn it in pulverized
form. The coal is pulverized in coal mill or pulveriser to fineness such that 70-80% passes through a 200-
mess sieve. The factors that affect the operation of the mill or reduce the mill output are:

i. Moisture content of coal: More the moisture content in coal, lesser will be
the mill output and vice versa.
ii. Grindability of coal: Harder coal (which having hard groove index) reduces
mill output.
iii. Fineness of output: Higher fineness of coal output reduces mill capacity.
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iv. Wear of grinding element: More wear and tear of grinding elements
reduces the output from mill.

 Fuel oil handling system:

In Thermal Power Station Fuel Oil play a vital role. Oil burners besides initial lighting up are also used
to provide effective ignition of the coal to stabilize the flame. The burners can provide enough heat to
carry on boiler operation of the boilers for the initial starting period. It can provide 10-15% of the
maximum load. At load period or when it is desired to Run the Boilers at off load condition oil burners
are used.

Fuel oil used in Power stations are:

a. Heavy Furnace oil (H.F.O)

b. Light Diesel Oil (L.D.O)
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HIGH PRESSURE STEAM TURBINE

OR HPT
 Steam turbine:
The steam is one kind of medium in which heat energy is converted to mechanical work. The
construction of steam turbine is very simple. It consists of a rotor and a set of rotating blades which are
attached to a shaft and the shaft is placed in the middle of the rotor. An electric generator known
as steam turbine generator is connected to the rotor shaft. The turbine generator collects the
mechanical energy from the shaft and converts it into electrical energy. Steam turbine generator also
improves the turbine efficiency.

 TYPES OF STEAM TURBINE USED IN POWER PLANT

1. HIGH PRESSURE TURBINE OR HPT
2. INTERMEDIATE PRESSURE TURBINE OR IPT
3. LOW PRESSURE TURBINE OR LPT
 Working principle of Steam Turbine:
Working principle of steam turbine depends on the dynamic action of steam. A high-velocity steam is
coming from the nozzles and it strikes the rotating blades which are fitted on a disc mounted on a shaft.
This high-velocity steam produces dynamic pressure on the blades in which blades and shaft both start
to rotate in the same direction. Basically, in a steam turbine pressure energy of steam extracts and then
it converted into kinetic energy by allowing the steam to flow through the nozzles.

The conversion of kinetic energy does mechanical work to the rotor blades and the rotor is connected
to a steam turbine generator which acts as a mediator. Turbine generator collects mechanical energy
from the rotor and converts into electrical energy. Since the construction of steam turbine is simple, its
vibration is much less than the other engine for same rotating speed. Though different types of
governing system are used to improve turbine speed.

The High Pressure Turbine and Intermediate Pressure turbine is operational turbine is
operational with steam having temperature of about 813K but the for maximum efficiency no
reheating is done to the steam before entering to Low pressure Turbine, all the turbines are
operational on a common shaft which is supported by a GOP or MOP to avoid sagging of common
shaft.
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MS HRH
LINE CRH LINE LINE

BOILER HPT REHEATER IPT

BFP (TDBFP X2)

EONOMISER HPH (MDBFP X1) LPT

DEARATOR DEARATOR
STORAGE TANK
CONDENSOR

LPH DRAIN GSC HOT WELL

COOLER

CONDENSATE CYCLE (DM WATER)

USED ABBREVIATIONS

 MS LINE – MAIN STEAM LINE

 HPT- HIGH PRESSURE TURBINE
 CRH LINE – COLD RE HEAT LINE
 HRH LINE – HOT REHEAT LINE
 IPT – INTERMEDIATE PRESSURE TURBINE
 LPT – LOW PRESSURE TURBINE
 GSC – GLAND STEAM CONDENSOR
 LPH – LOW PRESSURE HEATER
 HPH – HIGH PRESSURE HEATER
 25 of 34

 Condenser:
In thermal power plants, the purpose of a condenser is to condense the exhaust steam from
a steam turbine to obtain maximum efficiency, and also to convert the turbine exhaust steam into water
(referred to as steam condensate) so that it may be reused in the steam boiler as boiler feed water. In
condenser there are many tubes which contains cooling water.

 CW Cycle:
After the clarification process of raw water, it is divided into two parts. One part goes or for DM Water
& Portable Water and another cooling water, in condenser many tubes are present which carries the
cooling water, after the steam passes through the condenser the cooling water absorbs heat from steam
and the steam get converted to water simultaneously the cooling water heats up. It gets sends to the
cooling tower, a part of the cooling tower water goes to the AVGF (automatic valveless gravity filter)
and another part goes for chemical treatment and then in CWPH (cooling water pump house), then it
goes to the condenser.
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 Electrostatic Precipitators
An electrostatic precipitator (ESP) is a filter device that removes fine particles, like dust and smoke,
from a flowing gas using the force of an induced electrostatic charge minimally impeding the flow of
gases through the unit.

In contrast to wet scrubbers, which apply energy directly to the flowing fluid medium, an ESP applies
energy only to the particulate matter being collected and therefore is very efficient in its consumption
of energy (in the form of electricity).

The electrostatic precipitator working principle is very simple. The unclean flue gas flowing through
the tube is supplied by two electrodes. The shape of the two electrodes mainly depends on the type of
precipitator employed like bars, plates, metal wires, etc. One of the plates is charged by a high negative
voltage, which causes particulates in the burn for getting a negative charge because they flow with this
plate. The next plate carries a high positive voltage equally, due to the fact that opposed charges attract.
The soot elements which are negatively charged are pulled in the direction of the positive electrode &
fix to it. Irregularly these two plates should be cleaned for eliminating the collected dust.

Most of the electrostatic precipitator’s works in the same method, and there are several dissimilarities
as well as types that work well for different amounts of pollution, shaped particles, and smoke

compositions.
 27 of 34

 Chimney
A chimney is a structure for venting hot flue gases or smoke from a boiler, stove, furnace or fireplace to
the outside atmosphere. The working of chimney is based on natural draft or stack effect. The hot air
being lighter rises to the top. The taller the chimney, more draught or draft is created. The height of
Thermal Power plant chimneys is dictated by the Air Pollution basis. As the Air pollution standards
have become stringent. The height of the chimney’s has increased – from 100m to 150m to 220m to
275m. In recent times, 275 m chimney has become a standard.

 Ash Disposal System

Depending upon the requirements of DVC, fly ash (dry) and wet ash may be collected from the ESP
hoppers.
 28 of 34

 Switchyard
It is a switching station which has the following credits:

a. Main link between Generating plant and Transmission system, which has a large influence on
the security of the supply.
b. Step-up and/or Step-down the voltage levels depending upon the Network Node.
c. Switching ON/OFF Reactive Power Control devices, which has effect on Quality of power

 Switchyard equipment's
Equipment's commonly found in switchyard:

1. Lightening arrestor
2. Current transformer
3. Voltage transformer
4. Power transformers / I.C.T.
5. Bus bar and clamp fittings
6. Support structure
7. Isolators
8. Circuit Breaker
9. Wave traps
10. Earthing switch
 29 of 34

 SWITCHYARD SPECIFICATION AT DSTPS

In switchyard there are two main bus which are always charged from Turbine Generating plant and
make a Transmission system to send the supply to all particular power grid. Power load is always
depended on demand of power grid. Two bus Reactors receive the current from Exciter and supply it
each Main Bus.

The specification of Main Bus (#1 & #2):

400 KV, 2500 A, 500Hz, 300 phase, 40 Ka for 1 sec

This specified current is supplied from Main Bus. The following power grids are:
1. DSTPS #1
2. FUTURE LINE #1
3. FUTURE LINE #2
4. 220KV SWYD (2)
 30 of 34

 Ash Handling Plant

 Overview of Ash Handling Plant:

DSTPS is a coal-based power station. A large quantity of ash is produced in the power plant using coal to
produce electricity. Handling of ash is a huge problem because ash along with the emitted gas is
poisonous for the environment. So proper handling of the ash and the emitted gases that results due to
combustion of coal is very important.

Two types of ash is produced, fly and wet ash. Fly ash is around 85% and wet ash is around 15%.
After combustion of coal flue gas (ash mixed with toxic gases) are produced. The temperature of flue
gas is very high. To increase the thermal efficiency of the boiler plant, the heat from the flue gas is
utilized by Economizer that further heats the steam that is produced by the boiler.

Further the flue gas is passed through Air Preheater (APH) that absorbs heat and sends the heat to
the coal to remove moisture before the coal is combusted in the boiler. And then the flue gas is passed
to Electrostatic Precipitator (ESP) for its purification before emitting the gas into the environment via
chimney. Wet ash is collected from Bottom ash hopper and Eco Hopper. Fly ash is collected from APH
hopper and ESP hopper.

Ash handling plant is controlled by 3 parts -

1. Vacuum pump house

2. Ash water pump house

3. Ash disposal pump house

 VACCUM PUMP HOUSE

Power plants utilizing fossil fuels, coal and waste biomass materials emit sulfur and other poisonous
gases. Vacuum pumps are used to provide a vacuum filtering on flue gas desulphurization system
before the gases are emitted through the stack.
 31 of 34

 ASH WATER PUMP HOUSE

Bottom-ash high-pressure water supply pumps are used to extract bottom ash from the
furnace/economizer. When the bottom-ash handling system deploys jet pumps, HP pumps operate
sequentially and in on-off mode, supplying to the jet pumps, hopper flushing, seal trough and gate
housing flushing, etc.

Bottom-ash low-pressure water supply pumps are used for systems with jet pumps for refractory
cooling, hopper cooling water to maintain hopper water temperature at 60°C, make up/fill of hopper
water, seal trough, slurry sump, etc.

 ASH DISPOSAL PUMP HOUSE

Slurry formed due to mixing of water and ash is transported to ash disposal area by using two systems:
High concentration ash slurry disposal system – Slurry pump is used to transport ash slurry to ash
disposal area via ash slurry transportation pipes.

Why Ash Handling System is required?

In Thermal Power Plant's coal is generally used as fuel and hence the ash is produced as the by-product

of Combustion. Ash generated in power plant is about 30-40% of total cost consumption and hence the

system is required to handle Ash for its proper utilization or disposal.

 Volume of ash and properties

The ash handling system handles the ash by bottom ash handling system, coarse a handling system, fly
ash handling system, ash disposal system up to the disposal area and water recovery system from ash
pond and Bottom ash overflow.

Description is as follow.

 Bottom Ash Handling System

Bottom ash resulting from the combustion of coal in the boiler shall fall in the over ground, refractory
lined water impounded, maintained level, double V-Section type W type steel fabricated bottom ash
hopper having a hold up volume to store bottom ash and economizer ash of maximum allowable
condition with the rate specified. The slutty formed shall be transported to slurry sump through pipes.

 Air Pre Heater ash handling system

Ash generated from API hoppers shall be evacuated once in a shift by vacuum conveying system
connected with the ESP hopper vacuum conveying system

 Fly Ash Handling System

Fly ash is considered to be collected in ESP Hoppers. Fly ashes from ESP hoppers, extracted by Vacuum
Pumps, fly up to Intermediate Surge Hopper cum Bag Filter for further Dry Conveying to fly ash silo.
Under each surge hopper ash vessels shall be connected with Oil free screw compressor for conveying
 32 of 34

the fly ash from intermediate Surge Hopper to silo. Total fly ash generated from each unit will be
conveyed through streams operating simultaneously and in parallel.

 Ash Slurry Disposal System Bottom

Ash starry, Fly ash slurry and the Coarse Ash starry shall be pumped from the common ash slurry pump
up to the dyke area which is located at a distance from slurry pump house.

 Advantages:
I. Commercial utilization of ash in -
a. Cement additives
b. Bricks plants
c. Road making
II. Saving of water-a precious commodity.
III. Energy Efficient
IV. High liability
V. Long Plant Life
VI. Least maintenance
VII. Environment Concern
 33 of 34

 Electrical System Overview

Electrical system of a thermal power plant basically consists of the following parts -
i. Generator
ii. Switchyard
iii. Power distribution system

GENERATOR

 20kv GENERATED VOLTAGE

 400KV BUSBAR VOLTAGE
 11KV AND 3.3 FOR MANY TYPES OF HIGH VOLTAGE DRIVES IN POWER STATION
 415KV FOR DIFFERENT LOW VOLTAGE DRIVE AND ALL SORTS OF COMMON APPLICATION

 DC POWER FLOW

In DSTPS only 220v dc is used for all type of circuit breaker/switchgear and drive.
 34 of 34

CONCLUSION

As an undergraduate student of TECHNO MAIN SALTLAKE we would like to say that this training
program is an excellent opportunity for us to get to the ground level and experience the things that we
would have never gained through going straight into a job. We are grateful to TECHNO MAIN
SALTLAKE and DVC DURGAPUR STEEL THERMAL POWER STATION for giving us the wonderful
opportunity. The main objective of this industrial training is to provide an opportunity to
undergraduate to identify, observe and practice how engineering is applicable in real industry. It is not
only to get experience on technical practices but also to observe management practices and to interact
with fellow workers.it is easy to work with sophisticated machines, but not with people. The only
chance that an undergraduate has to have this experience is the industrial training period. We feel we
got the maximum out of the experience. Also, we learnt the way of work in an organization, the
importance of being punctual, the importance of maximum commitment, and the importance of team
spirit. The training program having several destinations was a lot more useful than staying at one place
throughout the whole three week from 19/07/2022 to 02/08/2022. It was an advantage for us to be
in the Mechanical operation dept where We have boosted up our skills and abilities. The conclusion
that we can make is that DVC DURGAPUR STEEL THERMAL POWER STATION is the right place for
students to do their industrial training .