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TNEB Thermal Power Plant
TNEB Thermal Power Plant
REVENUE COLLECTION EFFICIENCY IS AT 99% TRANSMISSION AND DISTRIBUTION LOSS IS LOW AT 18% MAXIMUM WINDMILL CAPACITY 3456 MW (4TH PLACE IN THE WORLD, 1ST PLACE IN INDIA) INCIDENCE OF POWER THEFT IS VERY LOW PLANT LOAD FACTOR OF THERMAL STATIONS ARE VERY HIGH ONE OF THE FEW STATES, WHICH DO NOT HAVE POWER CUTS (courtesy:Power Line magazine, June-2007)
TNEB
POWERING TAMIL NADUS PROGRESS
Glorious Past Dynamic Present Promising Future Over 50 Years (1957 2007 ), Tamil Nadu Electricity Board has powered the State of Tamil Nadu to become one of the most progressive States in our country in socio economical aspects as well as in all the fronts (viz.,) Agriculture, Industrial Production and Service sectors. On this occasion of its GOLDEN JUBLEE on 1st July 2007, it reaffirms its, commitment for the sustained and fruitful services to the state of Tamil Nadu. (courtesy:Power Line magazine, June-2007)
INSTALLED CAPACITY IN MW
HYDRO 2174
THERMAL 2970
TOTAL 11185 MW
423
1 1 2
MW 4X30 70 60 64
MW 37 35 37
PURCHASE OF POWER
STATION NO OF EACH TOT YEAR UNITS UNIT MW MW MADRAS ATOMIC 2 235 470 1983 POWER STATION (KALPAKKAM ) NEYVELI TS-I NEYVELI TS-II NEYVELI TS I (EXPANSION) 6 3 7 2 50 100 210 210 300 300 1470 420 1962 1967 1986 2003
220
440
2000
Unit No
I II III IV
COAL HANDLING PLANT MAIN EQUIPMENTS WAGON TIPPLERS CONVEYORS PRIMARY CRUSHERS SECONDARY CRUSHERS COAL STOCK YARD STACKER CUM RECLAIMER MACHINES
COAL LINKAGE
Mettur TPS is getting its coal supply from Mahanadhi Coal fields, Orissa. Coal from Paradeep Port, Orissa is conveyed through ship to Ennore Port and from there by Rail to Mettur. 4 Nos. Wagon tipplers have been erected to tip the coal wagons. The coal is fed into the coal bunkers through mechanical conveyor system. There are two streams of coal conveyors with 1500 T/hr capacity each.
WAGON TIPPLER
PRIMARY CRUSHER
CAPACITY :1500 TPH OUTPUT PRODUCT SIZE :150 mm SCREEN DIA :4082mm MOTOR :260KW SCREEN PLATES :158 Nos LIFTING SHELVES :40 NOS SPECIAL BEAM RAIL :18 NOS SCREEN RPM :13 RPM
PRIMARY CRUSHER
SECONDARY CRUSHER
TYPE : RING TYPE GRANULATOR 2NOS IN ONE MACHINE CAPACITY : 850 MT/HR OUT PUT SIZE : < 25MM DRIVE : V BELT DRIVE WITH GUARD MOTOR : 1000 HP,1440 RPM CRUSHER ROTOR SPEED : 600 RPM CRUSHER RINGS : 32 Nos TOOTHED, 30 Nos PLAIN
The daily requirement of coal for the Station is 14000 T There is a coal yard with a space to stack 4.5 lakh tones of coal which is sufficient to meet one months requirement of all the 4 Boilers There are two stacker-cum-reclaimers machines in the yard to stack the crushed coal and to retrieve the coal to the bunkers whenever necessary.
BOWL MILL
Bowl Mill Type : XRP 803 with classifier X : Supply Frequency (50 cycles/sec) R : Founders Name (Raymond) P : Pressurized Mill 80 : Diameter of Bowl in Inches 3 : Number of rollers No of Mills/Boiler : 6 Nos Base Capacity : 39.68 T/Hr Mill Motor : 340 KW 6.6 KV 990 rpm
UTILITY BOILERS
Steam conditions used have been mainly sub-critical although a significant number of plants were built during 1960s and 1970s with super-critical steam conditions. From Non-RH Type, The Technology today has Advanced to Double Reheat Type. However, the Preference has Come Down Over The Years For Double Reheat. Operating pressures have also increased to above 300 atmospheres. To achieve better efficiencies. Boilers have been designed to take care of the deterioration in coal quality over the years resulting in bigger furnaces, large size pulverisers and large size auxiliaries.
INDUSTRIAL BOILERS
Unit sizes have grown in capacities from 10 t/h. to 300 t/h., pressure from 15 ata to 120 ata, temperatures from 200oc to 530oc, burning various types of fuels. Industrial boilers are designed with bi-drums or single drum depending on the pressure. For paper plants, unit size of chemical recovery boilers have increased to burn about 675 tons per day of dry solids from 140 tons/day of dry solids.
MAIN EQUIPMENTS
BOILER
The boilers of the Power Station were supplied by M/S B.H.E.L., Trichy. Main Parameters Capacity :700 T/Hr Temperature : 540C Pressure : 137 kg/cm2
BOILER
BOILER CIRCUITS
WATER AND STEAM CIRCUIT AIR AND FLUE GAS CIRCUIT COAL AND ASH CIRCUIT(Supporting fuel LDO & HFO) COOLING WATER CIRCUIT
RH attemperator
Drum
Uprisers 1 11 12
3L 10
D o w n C o m e r s
LTSH
9 W A T E R W A L L W A T E R W A L L 6
Economiser
EH I/L
4L 5 4R 8
EH O/L
Furnace
To SH / RH Attemperation
E C O R C
E2
E C O D R A I N
E1
LLCV
FLCV A
FLCV B
CIRCULATION RATIO =
TOTAL FEEDWATER FLOW THRO CIRCUIT TOTAL STEAM GENERATED IN THE CIRCUIT
STEAM GENERATOR
Steam Generator covers the whole unit, encompassing water wall tubes, super heaters, air heaters and economiser
ECONOMISER
Function: Absorbing the flue gas temperature to heat the feed water to its sensible heat. Arrangements:
Staggered (fin or plain tube) In-line (plain)
ECONOMISER BANKS
DRUM INTERNALS
Turbo separators (100 Nos.) Screen Dryers Economizers feed pipes (2 Nos.) Continuous Blow Down(CBD) collection pipe Emergency Blow Down(EBD) pipe Phosphate dosing pipes
DRUM
FLAME
Riser is a tube through which water & steam mixture pass from an upper water headers to drum.
SUPER HEATERS
Classified according to the position or heat received from flue gas:
- Positioning of Super heater: Mainly depends on steam parameters and the arrangements of evaporating tubes. - SH coil ends are welded to round-section headers. - SH tubes are bent into coils with a bending radius of not less than 1.9d. - Multi-pass coils are employed in high-pressure boilers. - With multi-pass coils, there may be not enough places on a header for welding the tube ends. Furthermore the header wall may be weakened. - Depending on the direction of flows of steam and gas SH may be parallel flow, counter flow or mixed flow. - A counter flow SH develops the highest temperature gradient between steam and gas, which makes it possible to diminish the heating surface area and metal used for fabrication.
RE-HEATER
Steam after expansion in HP turbine is heated to the rated temp 540 C at constant pressure. It consists of pendant assemblies and placed in medium temperature region. It consists of CRH, HRH lines, Desuperheating and safety valves.
FANS
A fan continuously moves mass of air, gas or vapour at the desired velocity by the action of its rotor. For achieving this objective there is a slight increase in the gas pressure across the fan rotor. However, the main aim of a fan is to move a gas without an appreciable increase in pressure.
PA FAN-SPECIFICATION
Type : NDV 22 TIEFSTACK ND Radial fan V Single suction simply supported fan 22 Nominal Diameter of Impeller in dm TIEFSTACK Type of impeller Capacity : 1250 KW Fan make : BHEL Flow : 70 m3 / s Speed : 1480 RPM Discharge Pr. : 1210 mmwc Regulation : Inlet Damper Control Direction : Clock wise from MNDE Bearings : Journal Bearings Lubrication : FDE - Forced lubrication : FNDE - Sump lubrication No. of fans : 2 Nos.in parallel
SPECIFICATION
TYPE : AN 18 e 6 AN - AXIAL NON PROFILED BLADES 18 - NOMINAL DIAMETER OF IMPELLER IN DM e6 - TYPE OF DIFFUSER Capacity : 1250 KW Flow Speed Regulation Direction Fan make Bearings Lubrication No. of fans : 132.2 m3 / s : 1480 RPM : Inlet Guide Vane Control : Counter Clock wise from MNDE : BHEL : Anti friction Bearings : Grease lubrication : 2 Nos.in parallel Discharge Pr. : 665 mmwc
INDUCED DRAFT FAN It induces the exhaust flue gas through chimney to atmosphere It controls the balanced draft system VARIABLE SPEED HYDRAULIC COUPLING It supports ID fan motor to overcome its initial torque It regulates the speed of ID fan as per unit load SPECIFICATION OF HYDRAULIC COUPLING Type : 1150 SVNL 21 18.5 T Working oil pr. - 16 bar Lub oil pr. - 0.3 to 0.6 bar Primary coupling - HBK 180 Secondary coupling - SBLK 180 Motor Speed - 740 rpm Full load slippage - 3.8 % Max output speed - 711 rpm
AIR POLLUTION
Life on earth, weather it is of human being, of animal, or of vegetation, is affected by air pollution. One of prime causes for the air pollution is mushroom growth of industries the developing and developed countries. Thermal power stations which burn coal as fuel and handle huge quantum of ash, may greatly pollute the environment, unless otherwise the particulate matter content in the flue gas is separated-out fully. In order to restrict the emission within the limits, thermal power stations are bound to upkeep there ash precipitator in good condition .
TYPES OF PRECIPITATOR
Mechanical type of precipitators Electrostatic precipitators ADVANTAGES OF ESP Low pressure drop in the flue gas stream, Less power consumption Easy control Sustained high collection efficiency Capacity to handle particles of all sizes Easy maintenance. BAPCON B : BHEL A : Advanced P : Precipitator CON : Controller
ELECTRON NAUTRALGAS MOL POSITIVE ION NEGATIVE ION DUST PARTICLE UNCHARGED DUST PARTICLE
FIELD CHARGING
While the electrons stream away from the discharge electrodes, the encounter with flue gas molecules and dust particles.When gas molecules receives electrons they are ionised with negative charge and migrate towards the positive electrode, they get collected over dust particles which obstruct their way. The dust particles go on collecting the ionised gas molecule and once it has accumulated sufficient negative charge, they are attracted by the positively charged collecting electrodes.
SPECIFICATION
NO. OF RECTIFIER NO. OF FIELDS NO. OF HOPPERS NO. OF COLLECTING ELECTRODES NO. OF EMMITING ELECTRODES NO. OF CRM MOTORS NO. OF ERM MOTORS : 24 Nos. / Boiler : 24 Fields / Boiler : 48 Nos. : 5292 / Boiler : 31104 / Boiler : 12 Nos./ Boiler : 24 Nos./ Boiler
SPECIFICATION
GAS FLOW RATE DUST CONCENTRATION TYPE OF PRECIPITATOR COLLECTION EFFICIENCY PRESSURE DROP VELOCITY OF GAS TREATMENT TIME POLUTION LIMIT : 363.1 m3 / s at 145 0 C : 51.18 g / Nm 3 :FAA-6X36-2X72125-2 : 99.64 % : 15 MMWC : 1.0025 m / s : 21.55 sec : 150 mg /Nm3
ASH DISPOSAL
A dyke has been constructed across the Perumpallam valley over an area of 1268 acres. The dyke consists of Upper Ash Dyke, Lower Ash Dyke and Two settling ponds in series. The ash slurry is pumped into the dyke.Ash settles down and the water flows into the primary pond and then to the secondary pond from where clear water is let into the river Cauveri. The effluent water is tested for very high degree of purity in accordance with the standards fixed by TNPCB.
HPT IPT
RE-HEATED STEAM TO IPT
LPTS GENERATOR
Steam to heater
STEAM
GENERATOR
CONDENSER
TURBINE
Main technical data: Rated output (measured at generator terminals) : 210 MW Rated main steam and reheat steam temperature : 535 C Rated main steam pressure : 130kgf/cm2 Max. Steam Flow(at valve wide open) : 670 tons/hr No. of heaters in regenerative feed water heating cycle : 8(including Deaerator) No. of extraction lines :7 Final feed water temperature : 242 C Overall length of Turbine : 20307 mm Overall width of Turbine : 8530 mm Total weight of Turbine : 560 Tons General :The steam turbine of BHEL make is a condensing type, tandem compound, three cylinder, horizontal, disc and diaphragm (impulse) type with nozzle governing. Turbine is coupled to directly driven A.C. Generator.
TURBINE
MAIN EQUIPMENTS OF TURBINE 1. Main Turbine. 2. Oil system. 3. Condenser 4. Cooling water system. 5. Hot well & Condensate system 6. HP Heaters & LP Heaters 7. Feed Water system
CONDENSER DETAILS
Condenser is located beneath the LPT. The used up steam from LPT is directly sent to condenser for condensing the steam to water. Cooling water received from CWPH is passed thro the cooling tubes to condense the steam. A Vacuum around 665 mmHg is maintained inside the condenser. The condensed water(condensate) is collected in the hotwell The condensate is pumped to De-aerator thro Low Pressure heaters (LPH) by CEP Loss in the system was make up at condenser.
CONDENSER (FRONT)
CONDENSER TUBES (7810 tubes on each side) PARTING PLANE AIR COOLING ZONE HOT WELL CEP
2000000
N U M B E R O F P U M P S E T S
1567317
1768052 1645329
1st 1951-56 2nd 1956-61 3rd 1961-66 4th 1969-74 5th 1974-78 6th 1980-85 7th 1985-90 8th 1992-97 9th 1997-02 10th 2002-07
1500000
1033556 1277501
1000000 500000 0
33440 117695
681205 256594
805616
10
PLAN PERIOD
MAIN EQUIPMENTS
GENERATOR Make M/S BHEL Voltage : 15.75 KV Capacity : 210 MW Coolant : Hydrogen gas
Neutral
HYDROGEN GAS COOLING SYSTEM ADVANTAGES OVER AIR The density is lowest of all gases and is of that of air
Lesser windage and friction loss due to less density Requires less fan power Increase in efficiency
GENERATOR
Though the installed capacity is more than the demand, actual generation is less due to i)Hydro Station are monsoon dependent and irrigation based ii)Statutory overhauling of Thermal & Hydro Units.
6908
6908
6090
6158
6578
6916
7120 5196
92-93 93-94 94-95 95-96 96-97 97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05 05-06
Installed Capacity ( MW) Sustained Peak Demand(MW)
3676
3948
4360
4424
4875
PLAN
4918
5580
7204
N U M B E R O F T R A N S F O R M E R S
2nd 1956-61 3rd 1961-66 4th 1969-74 5th 1974-78 6th 1980-85 7th 1985-90 8th 1992-97
10
PLAN PERIOD
METTUR THERMAL POWER STATION-A JOURNEY TO EXCELLENCE THE GOVT. OF INDIAS MERITORIOUS PRODUCTIVITY REWARDS & GOLDEN SHIELDS FOR THE OUTSTANDING PERFORMANCE
Sl.No 1. 2. 3. 4. 5. 6. 7. Year 1992-93 1993-94 1994-95 1995-96 1996-97 1997-98 1999-2K Reward Rs.15 Lakh & Certificate Bronze medal Bronze 10. Silver medal 11. Silver medal Bronze medal Silver medal 12. 13. 14. 2004-05 2005-06 2006-07 2003-04 2002-03 Sl.No 8. 9. Year 2000-01 2001-02 Reward
FIRST TO INTRODUCE RCC poles in LT and HT line work Power line carrier communication in grid operation Wireless communication system to attend to fuse-off calls in Chennai Complete rural electrification (courtesy:Power Line magazine, June-2007)
USEFUL POINTS TO IMPROVE YOUR QUALITY OF LIFE BE HONEST AND BE FRANK TO BE ABLE TO SPEAK THE TRUTH DO NOT EXPECT OTHERS TO DO WHAT YOU DO NOT WANT TO DO BE A WILLING STUDENT THROUGHOUT YOUR LIFE LEARN EVERY DAY IF YOU DONT KNOW, ASK DO NOT PROCRASTINATE
Er.R.GABRIEL GERMANS, M.E., F.I.E. Chief Engineer / Mettur Thermal Power Station TNEB / Mettur Dam-6