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Thermal Power Plant
Thermal Power Plant
Thermal Power Plant
Basic Layout
THERMAL POWER STATION
– An impulse turbine has fixed nozzles that orient the steam flow
into high speed jets. These jets contain significant kinetic
energy, which the rotor blades, shaped like buckets, convert into
shaft rotation as the steam jet changes direction. A pressure
drop occurs across only the stationary blades, with a net
increase in steam velocity across the stage.
– As the steam flows through the nozzle its pressure falls from
steam chest pressure to condenser pressure (or atmosphere
pressure). Due to this relatively higher ratio of expansion of
steam in the nozzle the steam leaves the nozzle with a very high
velocity. The steam leaving the moving blades is a large portion
of the maximum velocity of the steam when leaving the nozzle.
The loss of energy due to this higher exit velocity is commonly
called the "carry over velocity" or "leaving loss".
Reaction Turbines
– In the reaction turbine, the rotor blades themselves
are arranged to form convergent nozzles. This type of
turbine makes use of the reaction force produced as
the steam accelerates through the nozzles formed by
the rotor. Steam is directed onto the rotor by the fixed
vanes of the stator. It leaves the stator as a jet that
fills the entire circumference of the rotor. The steam
then changes direction and increases its speed
relative to the speed of the blades. A pressure drop
occurs across both the stator and the rotor, with
steam accelerating through the stator and
decelerating through the rotor, with no net change in
steam velocity across the stage but with a decrease in
both pressure and temperature, reflecting the work
performed in the driving of the rotor.
Steam Condenser
• Surface condenser is the commonly used term for a
water cooled shell and tube heat exchanger installed on
the exhaust steam from a steam turbine in thermal
power stations. These condensers are heat exchangers
which convert steam from its gaseous to its liquid state
at a pressure below atmospheric pressure. Where
cooling water is in short supply, an air-cooled condenser
is often used. An air-cooled condenser is however
significantly more expensive and cannot achieve as low
a steam turbine exhaust pressure as a surface
condenser
Alternator
• An alternator is an electromechanical device that
converts mechanical energy to alternating current
electrical energy. Most alternators use a rotating
magnetic field but linear alternators are occasionally
used. In principle, any AC electrical generator can be
called an alternator, but usually the word refers to small
rotating machines driven by automotive and other
internal combustion engines
Principle of operation
• Alternators generate electricity by the same principle as DC generators,
namely, when the magnetic field around a conductor changes, a current is
induced in the conductor. Typically, a rotating magnet called the rotor turns
within a stationary set of conductors wound in coils on an iron core, called
the stator. The field cuts across the conductors, generating an electrical
current, as the mechanical input causes the rotor to turn.
• The rotating magnetic field induces an AC voltage in the stator windings.
Often there are three sets of stator windings, physically offset so that the
rotating magnetic field produces three phase currents, displaced by one-
third of a period with respect to each other.
• The rotor magnetic field may be produced by induction (in a "brushless"
alternator), by permanent magnets (in very small machines), or by a rotor
winding energized with direct current through slip rings and brushes. The
rotor magnetic field may even be provided by stationary field winding, with
moving poles in the rotor. Automotive alternators invariably use a rotor
winding, which allows control of the alternator generated voltage by varying
the current in the rotor field winding. Permanent magnet machines avoid the
loss due to magnetizing current in the rotor, but are restricted in size, owing
to the cost of the magnet material. Since the permanent magnet field is
constant, the terminal voltage varies directly with the speed of the
generator. Brushless AC generators are usually larger machines than those
used in automotive applications.and the large alternators in power station
which are driven by steam turbine are called turbo alternators
Poles verses RPM Poles RPM at
50Hz
• The output frequency of an
2 3000
alternator depends on the 4 1500
number of poles and the
rotational speed. The speed 6 1000
corresponding to a particular
frequency is called the 8 750
synchronous speed for that
frequency. This table gives
10 600
some examples: 12 500
14 428.6
16 375
18 333.3
20 300
CLZS Parameters
• Captive Power Plant in Chanderiya consists of 3
units (2X77 MW + 1X80 MW).
• All three units are supplied by BHEL,
Hyderabad.
• While supplying uninterrupted and reliable power
to Chanderiya Lead Zinc Smelter, the CPP has
been additionally wheeling power to its Agucha,
Debari and Dariba units of Hindustan Zinc
Limited.
• Recently sale of power has also been initiated
with both RSEB and power exchange.
• In the Financial year 2008-’09,the 234 MW CPP the
operating parameters for U1,2,3 were PLF (100.2%,
93.4% and 95.0 % respectively), Availability
(98.5%,97.3% and 88.9% respectively), Auxiliary
consumption(8.93%,9.35% and 9.53% respectively.
• With a vision to reduce Cost of generation, usage of
Indian Coal has been increased.
• The Plant is actually designed for pulverized fuel with
coal imported from Indonesia and South Africa having
10% moisture,12% ash,55% fixed carbon,23% volatile
matter and 6000Kcal/Kg.
• In comparison to pure imported coal being used earlier,
blending of around 40 % Indian coal was started thereby
reducing the cost of coal significantly.
• Day-to-Day operational and maintenance
hurdles were faced as per an action plan and
overcome.
• Usage of linkage coal, which has a potential to
reduce coal cost by around Rs.1200/MT has
been started.
• Chanderiya CPP has upheld highest standard of
Environmental consciousness by discharging
minimum effluents, both gaseous and liquid, into
the atmosphere.
• The SPM, SOX, NOx and other gaseous
effluents have been maintained well below the
pre-defined norms set by the governing bodies.
AWARDS
• The Captive Power Plant of Hindustan Zinc Limited won Asian
Power Plant of the year and Best Emission reductions project in
Asia in the year 2006-07
• CPP, HZL was proud to receive awards in two categories from
the “Confederation of Indian Industry” at “National Competition
for Excellence in Water Management”. The Categories in which
CPP, HZL excelled were Innovative Case Study and Water
Efficient Unit.
• Operation and Maintenance of CPP has been outsourced to KPS
(Korea Plant Engineering & Services).
• KPS has deputed around 10 Korean persons who are stationed
in Chanderiya. They hold managerial positions of various
technical and non-technical departments.
• They have also recruited specialized/experienced Operation and
maintenance personnel who look after the operation and
maintenance part of the CPP.)
CPP CONTROL ROOM
OPERATIONAL BOILER PARAMETERS
1. Furnace Draft
2. Oxygen at APH inlet
3. Feed water flow
4. Steam flow
5. Air flow
6. Coal flow
7. Oil flow
8. Deaerator level
9. Drum level
10. MS Temperature
11. MS Pressure
BOILER TRIPPINGS
• Boiler trips on M. F. T.
• Drum level Very Low : -375mmwc
• Drum level Very high : -25mmwc
• Furnace draft very High : 150mmwc :
• Loss of I.D. Fans
• Loss of F. D. Fans
• Loss of P. A. Fans
• Furnace Slagging
• High Super-heater temperature : >540 deg. C
• Low super-heater temperature : 480 deg.C
• Ignitor fails to ignite
• Mill trip
• Flame instability : (Flame failure)
• Water wall tube failure
• Economizer Tube Failure
• Super-heater tube failure