VOCATIONAL TRAINING IN ARAVALI POWER COMPANY PRIVATE LIMITED (A joint venture of NTPC Ltd, HPGCL,IPGCL)

INDIRA GANDHI SUPER THERMAL POWER PROJECT

TITLE OF PROJECT- Preliminary study on thermal

power plant and detail study on coal handling plant DURATION 2 weeks
Concerned Coordinator- Sh. J P Rai (DGM Maintenance) Project report prepared by

Sh. ABIR MUKHERJEE

Thermal power plant

Simplified Diagram

Main Parts of a Thermal Power Plant

Boiler

Boiler
Boiler is a device for generating steam for power,processing or heating purposes.Boiler is designed to transmit heat from an external combustion source(usually fuel combustion to a fluid) contained with in boiler itself. In the boiler the water circulates in a controlled way, that is the flow in the downcomers is controlled by a pump called controlled circulation pump. There are different accessories in a boiler.These accessories are following1.boiler drum, 2.down comers, 3.water walls, 4.superheater, 5.burners, 6.ignitors. In this power plant water tube boiler is used.

Boiler drum

Boiler drum
The function of steam drum is to separate the water from the steam generated in the furnace walls and to reduce the dissolved solid contents of the steam to below the prescribed limit of 1 ppm. The drum is located on the upper front of boiler.

Feed water heater

Feed water heater

There are feed water heaters in the thermal power plant located by the side of turbine. These are generally vertical type and turbine bleed steam pipes are connected to them. There are two types of feed water heater, which are LP heater that is low pressure heater and HP heater that is high pressure heater. The exhaust steam which is drawn from HP turbine, at any intermediate pressure is passed through HP heater, and similarly , exhaust steam which is drawn from LP turbine at any intermediate pressure is passed through LP heater to complete the regeneration to increase the thermal efficiency of the plant.

Schematic of Deaerator

Deaerator
The presence of certain gasses, principally oxygen, carbon-di-oxide and ammonia, dissolved in water is generally considered harmful because of their corrosive attack on metals, particularly of internal corrosion in boilers, therefore the boiler feed water should be free as far as possible from all dissolved gasses especially oxygen. This is achieved by embodying into the boiler feed system a deaerator unit,whose function is to remove dissolved gases from the feed water by mechanical means

Schematic diagram of Steam turbine

Steam turbine
The steam turbine is one of the most important accessories of the thermal power plant. In any thermal power plant there are three type of steam turbines. Which are high pressure steam turbine, Intermediate pressure steam turbine, low pressure steam turbine. The high pressure turbine handles steam of pressure 200250 ksc, and temperature about 540 degree celcius. Exhaust steam of the high pressure turbine is passed through reheater, and after reheating it enters into intermediate pressure steam turbine, and then the exhaust steam of the intermediate pressure steam turbine enters into low pressure turbine, and then exhaust steam of the low pressure turbine enters to the condenser.

Mechanism of turbine
In the turbine there is a pin wheel ,the action of the flowing fluid causes the wheel to rotate. This part of the machine is called the 'Rotor'. In any turbine, the rotor is mounted on a shaft and consists of the 'Sails' or 'Paddles' which we will now refer to as 'Blades'. The blades are fitted into a wheel at an angle and are called 'Rotor Blades'. The wheel is then mounted on to the shaft. This arrangement of a single wheel is called 'one stage' or a 'Single Stage Rotor' and does not produce high power. For large processing and generation plants, very powerful turbines are needed for driving machines like compressors, large pumps or generators. In this case, 'Multi-Stage Turbines' are used. As stated earlier, the energy needed to drive these turbines, comes from high pressure, superheated steam. In order to get the steam to pass to the rotor blades, we need a means of directing the steam on to the blades. The piece of equipment used for this is called a Nozzle. As the steam leaves a nozzle, its pressure decreases and its velocity increases. This high velocity steam jet is directed at the rotor blades and, as in the pin-wheel, the rotor and shaft begins to rotate. As more and more steam is released on to the blades, the speed of rotation increases.

Condenser

condenser
There are two condensers entered to the two exhausters of the L.P turbine. These are surface type condensers with two pass arrangement. Cooling water pumped into each condenser by a vertical C.W pump through the inlet pipe. Water enters the inlet chamber of the front water box, passes horizontally through the brass tube to the water box at the other end, takes a turn, passes through the upper cluster of tubes and reaches the outlet chamber in front water box. From these ,cooling water leaves the condenser through the outlet pipe and discharge into the discharge duct.Steam exhausted from the L.P turbine washing the outside of the condenser tubes losses its latent heat to the cooling water and is connected with water in the steam side of the condenser. The condensate collects in the hot well, welded to the bottom of the condensers. Condensate pumpA condensate pump is a specific type of pump used to pump the condensate water

Cooling Tower

Cooling Tower
Cooling towers are heat removal devices used to transfer process waste heat to the atmosphere. Cooling towers may either use the evaporation of water to remove process heat and cool the working fluid to near the wet-bulb air temperature or, in the case of closed circuit dry cooling towers, rely solely on air to cool the working fluid to near the dry-bulb air temperature. Common applications include cooling the circulating water used in oil refineries, petrochemical and other chemical plants, thermal power stations. Cooling towers vary in size from small roof-top units to very large hyperboloid structures that can be up to 200 metres tall. In this power plant natural draft process is used to cool water. Warm, moist air naturally rises due to the density differential compared to the dry, cooler outside air. Warm moist air is less dense than drier air at the same pressure. This moist air buoyancy produces an upwards current of air through the
tower. Cooling water pump This pump helps to enter the hot water into the cooling tower. This pump handles large volume of water, that is 30000 m3/hr.

Schematic of superheater

Superheater
There are three stages of superheater besides the side walls and extended sidewalls. The first consists of horizontal superheater of convection mixed flow type with upper and lower banks located above economiser assembly in rear pass. The outlet temperature and pressure of the steam coming out from the superheater is 540c and 157 ksc respectively for H.P units.

Function of Reheater

Reheater
Power plant furnaces may have a reheater section containing tubes heated by hot flue gases outside the tubes. Exhaust steam from the high pressure turbine is passed through these heated tubes to collect more energy before driving the intermediate and then low pressure turbines. That is the function of reheater is to reheat the steam coming out from high pressure turbine to a temperature of 540c.

Function of Economiser

Economiser
The purpose of economiser is to preheat the boiler feed water before it is introduced into the steam drum by recovering heat from the flue gases leaving the boiler. The economiser is located in the boiler rear gas pass below the rear horizontal superheater. The economiser is continuous unfinned loop type and water flows in upward direction and gas in the downward direction.

Primary air fan

Primary air fan

The primary air fan supplies hot air to the coal mills to dry and convey pulverised coal to the burners.

Forced draft fan

Forced draft fan

The forced draft fan are designed for handling secondary air for the boiler. These fan s are located near P.A fan . This fan supplies air to the boiler.

Induced draft fan

Induced draft fan

There are two induced draft fans per boiler located between the Electrostatic precipitator and the chimney. These fans are used for sucking flue gas from furnace.

Function of Air preheater

Air preheater
The air preheater is a device which is used to recover the heat from the boiler flue gas which increases the thermal efficiency of the boiler by reducing the useful heat lost in the flue gas. As a consequence, the flue gases are also sent to the chimney at a lower temperature.

Electric Generator

Electric Generator
In electricity generation, an electric generator is a device that converts mechanical energy to electrical energy. A generator forces electric charge (usually carried by electrons) to flow through an external electrical circuit. In this plant the current which is created by the generator is 3-phase. The rotor of the generator is coupled with the shaft of the low pressure turbine. There is a exciter also which is used to control the generator's terminal voltage and the reactive component of the power developed by the generator.

Transformer

Transformer
The generator is connected to this transformer by means of isolated bus ducts. This transformer is used to step up the generating voltage. The transformer is generally provided with some cooling arrangement.

How Generated electricity reached customer

Water treatment plant

Water treatment plant

Water treatment plants used in thermal power plants are designed to process the raw water to a water with very low in dissolved solids known as demineralised water. No doubt, this plant has to be engineered very carefully keeping in view the type of raw water to the thermal plant, its treatment costs and overall economics. Actually , the type of demineralisation process chosen for a power station depends on three main factors: The quality of the raw water The degree of deionisation i.e. treated water quality Selectivity of resins.

Ash Handling System

Overburden Coal Seam

Surge Pile Pulverize (-150)

Electrostatic Precipitator Flue Gas Fly Ash

Boiler Flue Gas Fly Ash Bottom Ash

Fly Ash Smoke Stack

Bottom Ash

 Electrostatic precipitatorAn electrostatic precipitator (ESP), or electrostatic air cleaner is a particulate collection device that removes particles from a flowing gas (such as air) using the force of an induced electrostatic charge. Electrostatic precipitators are highly efficient filtration devices that minimally impede the flow of gases through the device, and can easily remove fine particulate matter such as dust and smoke from the air stream. These are generally two plate type located between boiler and the chimney. Fly ash collectionFly ash is captured and removed from the flue gas by electrostatic precipitators or fabric bag filters (or sometimes both) located at the outlet of the furnace and before the induced draft fan. The fly ash is periodically removed from the collection hoppers below the precipitators. Bottom ash collection and disposalAt the bottom of the furnace, there is a hopper for collection of bottom ash. This hopper is always filled with water to quench the ash and clinkers falling down from the furnace. Some arrangement is included to crush the clinkers and for conveying the crushed clinkers and bottom ash to a storage site.

Electrostatic precipitator

Chimney

Chimney
These are tall RCC structures. The height of these chimneys vary depending on the locations. Combustion product gases called flue gases are exhausted to the outside air through these chimney. Flue gases are produced when coal, oil is combusted in a power plant's steamgenerating boiler. Flue gas is usually composed of carbon dioxide (CO2) and water vapour as well as nitrogen and excess oxygen remaining from the intake combustion air. It also contains a small percentage of pollutants such as particulate matter, carbon monoxide, nitrogen oxides and sulphur oxides

COAL HANDLING PLANT

Introduction
The purpose of the Coal handling plant in a thermal power plant is to Process raw coal & insure against the irregular supply of coal which is dependent on many players in the Supply chain. The function of a CHP is to receive ,process, store, feed the Coal bunkers consistently over the entire life of the Power plant. Coal is received from mines in the form of lumps, the sizes varying from 100mm to 350mm, in two types of wagons through Rail; BOBR meaning Bogie Open Bottom Rapid discharge & BOXN meaning Bogie Open High Sided Side discharge Wagon. BOBR wagons are unloaded in Track Hoppers & BOXN Wagons are unloaded by Wagon tipplers. Coal is then supplied to the crusher house through Roller screens or Vibrating feeders to sieve the coal before feeding to the crusher; 20% of the coal that is received is already <20 mm size so this is separated & only larger lumps are fed to the Crusher. The crusher breaks the lumps to sizes <20 mm which is the input size to the coal Pulverisers.

Introduction
The crushed coal is fed to the conveyors in the crusher house through Belt feeders; Coal is either directly fed to the coal bunkers or to the Stacker / Reclaimers for stocking when the bunkers are full. The stacking is done to insulate the plant against the erratic supply of coal. CERC allows stocking of 1 months stock of coal for Pit head plants. In case of non receipt of wagons the coal from the stock pile is reclaimed through the Stacker / Reclaimers & fed to the coal Bunkers. To increase redundancy certain Plants also have Emergency reclaim Hoppers near the Crushed coal Stock pile where the dozers are used to feed coal to the bunkers when the Reclaimer is in breakdown condition. Coal is conveyed by means of conveyor Belts in the coal handling plant.

UNIT #1 500 MW PUMP HOUSE C C 9A TP 6 C 9B TP 7

UNIT #2 500 MW C 10A TP 8 C 10B

UNIT #3 500 MW C 11A C 11B

MCC 1C
C5 A/B ( 520)

TP 5

TP 9

TP 10
C 8 A/B (118)

TP 11

PUMP HOUSE A TP 14
PENT HOUSE

C 6 A/B (144)

C 7 A/B (107)

TP 3

TP 4

TP 13

TP 2
C3 A/B

STACKER RECLAIMER 2

TP 16
CONVEYOR 12B (720)

C 13 A/B

TP 12

TP 1

STACKER RECLAIMER 1

TP 15
CONVEYOR 12A (720)

MAIN CTRL ROOM HT SWGR MCC 1B CRUSHER HOUSE

CONVEYOR 2 A/B (415)

WT MCC 1A

PUMP HOUSE B PENT

HOUSE

ERA SCOPE
TP 19
CONVEYOR 15 A/B (103)

CONVEYOR 1 A/B (283)

TRF SCOPE

WT 3 & 4

TP 20
CONVEYOR 16 A/B (157)

TP 21

WT 1 & 2

TP 17

CONVEYOR 14 A/B (157)

TP 18

LAYOUT OF COAL HANDALING

Coal Flow Diagram -CHP

Main Equipments in CHP

Wagon Tippler Side Arm Charger Apron Feeder Conveyor System Transfer Points Vibrating Screen Feeder Crusher Shuttle Conveyor Stacker Cum Reclaimer Moving Head Assembly Travelling Tripper Auxiliary Systems

Miscellaneous equipments

Types of Wagons

GA Drawing of Wagon Tippler

Wagon Tippler

Wagons are Tippled by Wagon Tippler and the coal is feed to the hoppers.

Data Sheet of wagon tippler

Side arm charger

Side Arm Charger is required to position the wagons in the cradle of Wagon Tippler for Tippling Purpose.

Wagon Tippler with Side arm charger Datasheet

Apron Feeder

Front view of Apron Feeder

Apron Feeder

Apron Feeder receive the coal from hopper and it feeds the coal to belt feeder and subsequent conveyors

Different parts of Apron Feeder

Conveyor Systems

Coal is conveyed through Conveyor Systems from Wagon Tipplers to Bunkers.

Drawing of a Typical Conveyor

Main Parts of a Conveyor System

Pulleys Drive items Motor, Gear Box, Scoop Coupling Belt Idlers Frames for pulleys and drive items Counter Weight items

Conveyor Belting System

Conveyor Pulley

Conveyor Idlers

Drive items of a Conveyor

Drive consists of Motor, Gear Box and Scoop Coupling

Scoop coupling

Crusher House

Typical drawing of a Transfer Point

Vibrating Screen Feeder

It is working as a sieve. It feeds to bigger lumps to crusher and smaller lumps to shuttle conveyor.

Drawing of Vibrating Screen Feeder

Crusher

crusher

Shuttle conveyor

It is used to feed the coal in different chute positions. It moves upon rail.

Drawing of Shuttle conveyor

Stacker Cum Re-claimer

Different Parts of Stacker cum Re-claimer

It can stack the coal in the stack yard and it also reclaims the coal from yard when required

Drawing of Stacker cum Reclaimer

PAY LOADER

Moving head

Its function is to feed the coal in two location of chute

Drawing of Moving head

Drawing of Travelling Tripper

Travelling Tripper

Its function is to feed the coal in different location bunkers. It moves upon the structure mounted rail.

Auxiliary System
Auxiliary systems consists of the following items Cooling water system Service water system Drinking water system Dust suppression system Dust Extraction system Ventilation system

Pump house

Cooling water, Service water, Drinking water and Dust Suppression system is operated by Concerned Pump Houses

Pump house layout

Cooling Water System Layout

Dust Suppression

Dust Extraction System

It is situated near Crusher House. Its function is to extract the dust from concerned equipments.

Miscellaneous Equipments
ILMS Metal Detector Suspended Magnet Flap Gate with actuator Coal Sampling System RPG ROD Gate

Removal/Detection of Metal Particles

ILMS & Coal Sampling System

Coal sampling

Coal Trivia

Grades of coal

Thank you