1

KOTA SUPER THERMAL

POWER STATION
Summer Training Report
Water Treatment
Submitted to:
MR ASHEESH GOYAL
KOTA, RAJASTHAN

Submitted by: Mahesh Yogi (102113029)

CHEMICAL ENGINEERING DEPARTMENT
NATIONAL INSTITUTE OF TECHNOLOGY
TRICHY (TN), INDIA

Supervisors: Mr Asheesh Goyal

Start Date for Summer Training: 22th May, 2016
End Date for Summer Training: 06th July, 2016
Report Date: 06th July, 2016

CONTENTS
S NO
1
2
3
4
5
6
7
8

INDEX
Preface
Acknowledgement
Abstract
Introduction
Water Treatment
Principle
Control & Instrumentation
References

PAGE NO
2
3
4
5
7
8
15
16

PREFACE
This report documents the work done during the summer internship at THERMAL POWER
STATION KOTA, RAJASTHAN under the supervision of Mr Asheesh Goyal. The report
first shall give an overview of the tasks completed during the period of summer training with
technical details.
I have tried my best to keep report simple yet technically correct. I hope I succeed in my
attempt.
Mahesh Yogi

Acknowledgments
I am really grateful to have been given the opportunity to pursue my Industrial Training from
an esteemed company like K.S.T.P.S KOTA. In particular I am indebted to Mr Asheesh
Goyal for granting the permission for the perusal of the same.
On that account I would like to express my heartfelt gratitude to S.C. Madan and G.K. Rathi
to support me at each and every step of my training schedule.
Simply put, I could not have done this work without the lots of help I received cheerfully
from whole KSTPS KOTA. The work culture in THERMAL PLANT KOTA really
motivates. Everybody is such a friendly and cheerful companion here that work stress is
never comes in way.

ABSTRACT
Thermal Power Station is a Coal fired power station located in Kota district in the Indian
state of Rajasthan. It was established in 1983. It is located at the left bank of the CHAMBAL
River at the upstream of KOTA BAIRAJ
.
There are total seven units in Thermal Power Plant Kota for power generation.
First and second units are of 110 MW each. Third fourth and fifth units are of 210 MW. Six and
seven units of 195 MW.
Total generation capacity (110+110+210+210+210+195+195) =1240 MW

Beneficiary States- Uttar Pradesh, Rajasthan, Delhi.

At NTPC, we have undergone summer training at the end of 6th semester for a
period of 45 days starting from 26th May 2015. As per the schedule allotted to
me by Mr Asheesh Goyal Training Department KSTPS KOTA.
The report presents the tasks completed during summer training at KSTPS which
are listed below:
1. Layout
2. Water Treatment Plant
3. Control Room
This report gives a detailed account of my experience and observations during
the training period. The knowledge gained has been invaluable particularly, as it
relates a lot to the topics that we have learnt in our college.

IntroductionKota Super
Thermal Power
Station is the first
coal based
Electricity
Generating Power
Plant in Rajasthan.
At present the total
installed capacity
of KSTPS is
1240MW
Location
Kota Super Thermal Power Station is located on the left bank of river Chambal in
Rajasthans principal industrial city Kota. Infrastructural facilities like adequate water
availability in Kota Barrage throughout the year

Stag
e
I

Unit No.

Capacity(MW)

Synchronising Date

Cost(Rs.Crore)

110

17.1.1983

110

13.7.1983

210

25.9.1988

210

1.5.1989

III

210

26.3.1994

480

IV

195

31.7.2003

635

195

30.5 2009

880

II

143

480

TECHNICAL LAYOUT OF KSTPS

WATER TREATMENT PLANT

The principal problem is in high pressure boiler is to control corrosion and steam quality
Internal corrosion costs power station crores of rupees in repair without strict control impurities
in steam also form deposit over turbine blades and nozzles. The impurities present in water are
as follows:
1. Un-Dissolved and suspended solid materials
2. Dissolved slats and minerals
3. Dissolved gases
4. Other minerals (oil acid etc)
5. Turbidity & Sediment
6. Silica
7. Micro Biological
8. Sodium & Potassium Salt
9. Dissolved Sales Minerals
10. O2 Gas and CO2 Gas

D.M. Plant:
In this plant process water is fed from all these dissolved salts. Equipment for
demineralization cum softening plant is supplied and created by M/s Wanson (India) Ld. Pune.
This plant consists of two streams each stream with activated carbon filter, weak acid, acid
cation exchanger and mixed bed exchanger .The filter water to softening DM plant through 250
dia. Header from where a heater top off has been taken to softening plant. Two filtered water
line for meeting the pressure requirement in DM plant
Sodium Sulphate solution of required strength is dosed into different filtered water by
mean of dosing pump to neutralize chlorine prior to activated carbon filter. When water passed
an activated carbon filter will remove residual chlorine from water. Provision is made for back
washing the activated canon filter.
When pressure drop across filter exceeds a prescribed limit from the activated carbon
filter the works acid cation limit. The deception water the weak base anion exchanger unknit
water then enters degasified unit where fee co2 is scrubbed out of Water by upward counter
flow of low pr. Air flow through degasified lower and degassed water is pumped to strong base
exchanger (anion exchanger).
Arrangement for dosing ammonia solution inti demineralized water after mixed bed unit has
been provided P correction before water is taken in de-condensate transfer pump the DM water
to unit condenser as make up.

C.W. Plant

Circulating water pump house has pumps for condensing the steam for condenser. Five pumps
are used for condensing unit no 1 and 2 and after condensing this water is discharged back into
the river. Each pump has capacity of 8275 M3/Hr. and develop pressure about 1.94 Kg/Cm2 .
Three seal water pump are used for sealing circulating water pump shaft at pr 4.5 Kg./Cm2.
Two pump for unit 1 &2 with one stand by is used for supplying raw water to chlrorified
chemical dosing is tone between and chlorified water is taken through main line. From main
line water passes through filter bed to filter the water chlorified water is pumped to 42 m
elevation by two pumps of capacity M3/inch at discharged pressure of 6.9 Kg/cm2 At 42 m
deviation the water is stored in tank and used for cooling and returned back to river. Oil coolers
are situated on ground and there are no of trees for each unit.
B.C.W. Pump house:
Filter water after demineralization is used for bearing cooling from BCW pump house after
passing through strainer and heat exchanger it enters at 30-32C and leave exchanger at 38C. The
raw water used in ash handing plant and remaining quantity is stored in sumps of BCW Pump
House. From here the water is pumped to CW Pump by TWS (Travelling water screens) pumps
are run by motors of 90 KW and has a capacity of 240 Cum/hr/pump at pressure of 5 Kg/cm2
BCW here stand for water used for cooling oil used for cooling the bearing. In CW pump house
water is discharged from Nozzle and Impinged for traveling water screens for cleaning it.

How Coal Power Plants Produce Electricity

The conversion from coal to electricity takes place in three stages.
Stage 1
The first conversion of energy takes place in the boiler. Coal is burnt in the boiler furnace to
produce heat. Carbon in the coal and Oxygen in the air combine to produce Carbon Dioxide and
heat.
Stage 2
The second stage is the thermodynamic process.
1.
2.
3.
4.
5.

The heat from combustion of the coal boils water in the boiler to produce steam. In
modern power plant, boilers produce steam at a high pressure and temperature.
The steam is then piped to a turbine.
The high pressure steam impinges and expands across a number of sets of blades in the
turbine.
The impulse and the thrust created rotates the turbine.
The steam is then condensed and pumped back into the boiler to repeat the cycle.

Stage 3
In the third stage, rotation of the turbine rotates the generator rotor to produce electricity based
of Faradays Principle of electromagnetic induction

For all practical reasons the actual thermal efficiency will depend on

Pressure ratio
Turbine inlet temp.
Compressor inlet temp.
Efficiency of Compressor and Turbines.

Pump Performance

Pump shaft power (Ps)- Pump shaft power (Ps) is actual horsepower delivered to
the pump shaft.
Pump shaft power (Ps) = Hydraulic power Hp / pump efficiency () Pump25

Pump Efficiency ( Pump) = Hydraulic Power / Pump Shaft Power

Hydraulic power (Hp) = Q (m3/s) x Total head, hd - hs (m) x (kg/m3) x g (m/s2) /

1000
hd - Discharge Head

hs Suction Head,

- Density of the fluid

g-Acceleration due to gravity

Control & Instrumentation

WORK FLOWFIELD
MACHINE
INSTRUMENTS

CONTROL SYSTEM (DCS)

HUMAN
INTERFAACE

MEASUREMENT

Information purpose: To know the various parameters (e.g. pressure, temperature) at

various locations

Control purpose: To control drives (valves/ motor) operation based on parameters

value

Types of Measurement- There are two types of measurement, which is listed below:
1. Direct Measurementa. Pressure Gauge
b. Temperature Gauge
c. Thermometer
d. Direct Level Indicator
e. Rota-meter
2.

Indirect Measurement
a. Pressure Transmitter
b. Temperature Measurement through RTD/Thermocouple
c. Level Transmitter
d. Flow Transmitter

PRESSUREP=F/A

P=Pressure

A =Area

F=Force Exerted

Primary Sensor for Pressure Measurement1. Bourdon Tubes

a. Spiral Bourdon Tubes27

b. Helical Bourdon Tubes

c. C-Types Bourdon Tubes

2. Bellows
Bellows for Indication-

3. Diaphragms-

4. Manometer

5. Pressure Gauge

6. Pressure TransmitterCapacitance type pressure transmitter- Diaphragm acts a plate of capacitor which
moves w.r.t fixed plate causing change in capacitance which is converted &
amplified into a DC 4-20mA signal. This operates on two wire.

FLOW METERSPrinciple- The pressure drop across the meter is proportional to the square of the flow
rate. The flow rate is obtained by measuring the pressure differential and extracting the
square root.
Types of flow meter1. ORIFICE
2. VENTURI
3. NOZZLE
4. PITOT TUBE
Level Measurement 1. Direct measurement
2. Indirect measurement
Temperature Measurement1. TEMPERATURE GAUGE

2. THERMOCOUPLEThermocouple translate the temperature into Voltage which is then measured and processed
to compute numerical Value of temperature when two wires of dissimilar electrical properties
are joined together at both ends & one junctions is made hot & other junction is made cold,

small electrical current is produced proportional to the difference in the temperature seebeck
effect hot junction forms the sensor end.

4. RESISTANCE TEMPERATURE DETECTOR- R e s i s t a n c e of the sensor changes

as the temp changes.

Wired RTD-

COMPARISON THERMOCOUPLE & RTD

REFERENCE-

1. Training Manual KSTPS KOTA

2. Wikipedia of KSTPS KOTA
3. Study materials provided by KSTPS KOTA

THE END