SUSHIL LAMBA MECHANICAL ENGINEERING PART 2 IDD ROLL NO.

10406EN008 IIT (BHU) VARANASI

ACKNOWLEDGEMENT
With profound respect and gratitude, I take the opportunity to convey my thanks to complete the training here. I do extend my heartfelt thanks to Mr. Manmohan Singh for providing me this opportunity to be a part of this esteemed organization. I am extremely grateful to all the technical staff of BTPS / NTPC for their co-operation and guidance that has helped me a lot during the course of training. I have learnt a lot working under them and I will always be indebted of them for this value addition in me. I would also like to thank the training incharge of IIT (BHU) Varanasi and all the faculty members of Mechanical Engineering Department for their effort of constant cooperation, which have been a significant factor in the accomplishment of my industrial training.

CERTIFICATE

This is to certify that Sushil Lamba, student of Mechanical Engineering Dual Degree (IDD),Part 2, IIT (BHU) Varanasi, has successfully completed his training at National Thermal Power Station, Badarpur, New Delhi for 5 weeks from 28th May to 30th June 2012. He has completed the whole training as per the report submitted.

Training Incharge NTPC Badarpur, New Delhi

TRAINING AT BTPS
I was appointed to do 6 weeks training at this esteemed organization from 28th May to 7th July 2012. I was assigned to visit various division of the plant, which were: 1. Boiler Maintenance Department (BMD I/II/III)

2.

Plant Auxiliary Maintenance (PAM)

3.

Turbine Maintenance Department (TMD)

These 6 weeks training was a very educational adventure for me. It was really amazing to see the plant by yourself and learn how electricity, which is one of our daily requirements of life, is produced. This report has been made by my experience at BTPS. The material in this report has been gathered from my textbook, senior student reports and trainers manuals and power journals provided by training department. The specification and principles are as learned by me from the employees of each division of BTPS.
3

INDEX
S.No. 1. Contents BASIC STEPS OF ELECTRICITY GENERATION Page No. 05

2. 3.

BASIC POWER PLANT CYCLE BOILER MAINTAINANCE DEPARTMENT (BMD)

08 14

4.

PLANT AUXILIARY MAINTAINANCE (PAM)

19

5.

TURBINE MAINTAINANCE DEPARTMENT (TMD)

26

BASIC STEPS OF ELECTRICITY GENERATION

1. Coal to steam. 2. Steam to Mechanical Power. 3. Mechanical power to electrical power.

COAL TO STEAM Coal from the coal wagons is unloaded in the coal handling plant. This coal is transported up to the raw bunkers with the help of belt conveyors. Coal is transported to Bowl Mills by Coal Feeders. The coal is pulverized in the Bowl Mill, where it is ground to powder form. The mill consists of a round metallic table in which coal particles fall. This table is rotated with the help of a motor. There are
5

three large steel rollers, which are spaced 1200 apart. When there is no coal, these rollers do not rotate but when the coal is fed to the table it packs up between roller and table and thus forces the rollers to rotate. Coal is crushed by the crushing action between the rollers and the rotating table. This crushed coal is taken away to the furnace through the coal pipes with the help of hot and cold air mixture from P.A. Fan. P.A. Fan takes atmospheric air, a part of which is sent to the Air-Preheaters for heating while a part goes directly to the mill for temperature control. Atmospheric air from the F.D. Fan is heated in the air heaters and sent to the furnace as combustion air. Water from the boiler feed pump passes through the economizer and reaches the boiler drum. Water from the drum passes through down comers and goes to the bottom ring header. Water from the bottom ring header is divided to all the four sides of the furnace. Due to heat and density difference, the water rises up in the water wall tubes. Water is partly converted to steam as it rises up in the furnace. This steam and water mixture is again taken to the boiler drum where the steam is separated from the water. Water follows the same path while the steam is sent to the super heaters for superheating. The super heaters are located inside the furnace and the steam is superheated(5400 C) and finally it goes to the turbine. Flue gases from the furnace are extracted by induced draft fan, which maintains balance draft in the furnace with forced draft fan. These flue gases emit their heat energy to various super heaters in the pent house and finally through air preheaters and goes to electrostatic precipitators where the ash particles are extracted. Electrostatic Precipitator consists of metal plates, which are electrically charged. Ash particles are attracted on these plates, so that they do not pass through the chimney to pollute the atmosphere. Regular mechanical hammer blows cause the accumulation of ash to fall to the bottom of the precipitator where they are collected in a hopper for disposal.
6

STEAM TO MECHANICAL POWER

From the boiler, a steam pipe conveys steam to the turbine through a stop valve (which can be used to shut-off the steam in case of emergency) and through control valves that automatically regulate the supply of steam to the turbine. Stop valve and control valves are located in a steam chest and a governor, driven from the main turbine shaft, operates the control valves to regulate the amount of steam used( This depends upon the speed of the turbine and the amount of electricity required from the generator). Steam from the control valve enters the high pressure cylinder of the turbine, where it passes through a ring of stationary blades fixed to the cylinder wall. These act as nozzles and direct the steam into a second ring of moving blades mounted on a disc secured to the turbine shaft. The second ring turns the shafts as a result of a force of steam. The stationary and moving blades together constitute a stage of turbine and in practice many stages are necessary, so that the cylinder contains a number of tings of stationary blades with rings of moving blades arranged between them. The steam passes through each stage in turn until it reaches the end of the high-pressure cylinder and in its passage some of its heat energy is changed into mechanical energy. The steam leaving the high pressure cylinder goes back to the boiler for reheating and returns by a further pipe to the intermediate pressure cylinder. Here it passes through another series of stationary and moving blades. Finally the steam is taken to the low-pressure cylinders, each of which enters at the centre flowing outwards in opposite directions through the rows of turbine blades through an arrangement called the double-flow to the extremities of the cylinder. As the steam gives up its heat energy to drive the turbine, its temperature and pressure fall and it expands. Because of this expansion the blades are much larger and longer towards the low pressure ends of the turbine.

MECHANICAL POWER TO ELECTRICAL POWER

7

As the blades of the turbine rotate, the shaft of the generator, which is coupled to that of the turbine, also rotates. It results in rotation of the coil of the generator, which causes induced electricity to be produced.

BASIC POWER PLANT CYCLE

The thermal (steam) power plant uses a dual (vapour+liquid) phase cycle. It is a close cycle to enable the working fluid (water) to be used again and again. The cycle used is Rankine cycle modified to include superheating of steam, regenerative feed water heating and reheating.

On large turbines, it becomes economical to increase the cycle efficiency by using reheat, which is a way of partially overcoming temperature limitations. By returning partially expanded steam, to a reheat, the average temperature at which the heat is added, is increased and, by expanding this reheated steam to the remaining stages of the turbine, the exhaust wetness is considerably less than it would otherwise be conversely, if the maximum tolerable wetness is allowed. The initial pressure of the steam can be appreciably increased. Bleed steam extraction: For regenerative system, nos. of non-regulated extractions is taken from HP,IP turbine. Regenerative heating of the boiler feed water is widely used in modern power plants; the effect being to increase the average temperature at which heat is added to the cycle, thus improving efficiency. FACTORS AFFECTING THERMAL CYCLE EFFICIENCY Thermal cycle efficiency is affected by following: 1. Initial steam pressure.
9

2. 3.

Initial steam temperature. Whether reheat is used or not, and if used reheat pressure and temperature. Condenser pressure. Regenerative feed water heating.

4. 5.

RANKINE CYCLE
The Rankine cycle is a cycle that converts heat into work. The heat is supplied externally to a closed loop, which usually uses water. The Rankine cycle most closely describes the process by which steam-operated heat engines most commonly found in power generation plants generate power. The two most common heating processes used in these power plants are nuclear fission and the combustion of fossil fuels such as coal, natural gas, and oil. The Rankine cycle is sometimes referred to as a practical Carnot cycle because, when an efficient turbine is used, the TS diagram begins to resemble the Carnot cycle. The main difference is that heat addition (in the boiler) and rejection (in the condenser) are isobaric in the Rankine cycle and isothermal in the theoretical Carnot cycle. A pump is used to pressurize the working fluid received from the condenser as a liquid instead of as a gas. All of the energy in pumping the working fluid through the complete cycle is lost, as is most of the energy of vaporization of the working fluid in the boiler. This energy is lost to the cycle because the condensation that can take place in the turbine is limited to about 10% in order to minimize blade erosion; the vaporization energy is rejected from the cycle through the condenser. But pumping the working fluid through the cycle as a liquid requires a very small fraction of the energy needed to transport it as compared to compressing the working fluid as a gas in a compressor (as in the Carnot cycle). The efficiency of a Rankine cycle is usually limited by the working fluid. Without the pressure reaching super critical levels for the working fluid, the temperature
10

range the cycle can operate over is quite small: turbine entry temperatures are typically 565C (the creep limit of stainless steel) and condenser temperatures are around 30C. This gives a theoretical Carnot efficiency of about 63% compared with an actual efficiency of 42% for a modern coal-fired power station. This low turbine entry temperature (compared with a gas turbine) is why the Rankine cycle is often used as a bottoming cycle in combined-cycle gas turbine power stations. The working fluid in a Rankine cycle follows a closed loop and is reused constantly. The water vapor with entrained droplets often seen billowing from power stations is generated by the cooling systems (not from the closed-loop Rankine power cycle) and represents the waste heat energy (pumping and condensing) that could not be converted to useful work in the turbine. Note that cooling towers operate using the latent heat of vaporization of the cooling fluid. While many substances could be used in the Rankine cycle, water is usually the fluid of choice due to its favorable properties, such as nontoxic and nonreactive chemistry, abundance, and low cost, as well as its thermodynamic properties. One of the principal advantages the Rankine cycle holds over others is that during the compression stage relatively little work is required to drive the pump, the working fluid being in its liquid phase at this point. By condensing the fluid, the work required by the pump consumes only 1% to 3% of the turbine power and contributes to a much higher efficiency for a real cycle. The benefit of this is lost somewhat due to the lower heat addition temperature. Gas turbines, for instance, have turbine entry temperatures approaching 1500C. Nonetheless, the efficiencies of actual large steam cycles and large modern gas turbines are fairly well matched.

THE FOUR PROCESSES IN RANKINE CYCLE

11

There are four processes in the Rankine cycle. These states are identified by numbers (in brown) in the above Ts diagram. 1. 2. Process 1-2: The working fluid is pumped from low to high pressure. As the fluid is a liquid at this stage the pump requires little input energy. Process 2-3: The high pressure liquid enters a boiler where it is heated at constant pressure by an external heat source to become a dry saturated vapor. The input energy required can be easily calculated using mollier diagram or h-s chart or enthalpy-entropy chart also known as steam tables. Process 3-4: The dry saturated vapor expands through a turbine, generating power. This decreases the temperature and pressure of the vapor, and some condensation may occur. The output in this process can be easily calculated using the Enthalpy-entropy chart or the steam tables. Process 4-1: The wet vapor then enters a condenser where it is condensed at a constant temperature to become a saturated liquid.

3.

4.

In an ideal Rankine cycle the pump and turbine would be isentropic, i.e., the pump and turbine would generate no entropy and hence maximize the net work output. Processes 1-2 and 3-4 would be represented by vertical lines on the T-S diagram and more closely resemble that of the Carnot cycle. The Rankine cycle shown here prevents the vapor ending up in the superheat region after the
12

expansion in the turbine, [1] which reduces the energy removed by the condensers. Real rankine cycle (non-ideal) Rankine cycle with superheat

In a real power plant cycle (the name 'Rankine' cycle used only for the ideal cycle), the compression by the pump and the expansion in the turbine are not isentropic. In other words, these processes are non-reversible and entropy is increased during the two processes. This somewhat increases the power required by the pump and decreases the power generated by the turbine. In particular the efficiency of the steam turbine will be limited by water droplet formation. As the water condenses, water droplets hit the turbine blades at high speed causing pitting and erosion, gradually decreasing the life of turbine blades and efficiency of the turbine. The easiest way to overcome this problem is by superheating the steam. On the Ts diagram above, state 3 is above a two phase region of steam and water so after expansion the steam will be very wet. By superheating, state 3 will move to the right of the diagram and hence produce a drier steam after expansion. Rankine cycle with reheat

13

In this variation, two turbines work in series. The first accepts vapor from the boiler at high pressure. After the vapor has passed through the first turbine, it reenters the boiler and is reheated before passing through a second, lower pressure turbine. Among other advantages, this prevents the vapor from condensing during its expansion which can seriously damage the turbine blades, and improves the efficiency of the cycle, as more of the heat flow into the cycle occurs at higher temperature. Regenerative Rankine cycle The regenerative Rankine cycle is so named because after emerging from the condenser (possibly as a sub cooled liquid) the working fluid is heated by steam tapped from the hot portion of the cycle. On the diagram shown, the fluid at 2 is mixed with the fluid at 4 (both at the same pressure) to end up with the saturated liquid at 7. This is called "direct contact heating". The Regenerative Rankine cycle (with minor variants) is commonly used in real power stations. Another variation is where bleed steam from between turbine stages is sent to feedwater heaters to preheat the water on its way from the condenser to the boiler. These heaters do not mix the input steam and condensate, function as an ordinary tubular heat exchanger, and are named "closed feedwater heaters". The regenerative features here effectively raise the nominal cycle heat input temperature, by reducing the addition of heat from the boiler/fuel source at the relatively low feedwater temperatures that would exist without regenerative feedwater heating. This improves the efficiency of the cycle, as more of the heat flow into the cycle occurs at higher temperature.

14

1. BOILER MAINTAINENCE DEPARTMENT

BOILER AND ITS DESCRIPTION The boiler is a rectangular furnace about 50ft (15m) on a side and 130ft (40 m) tall. Its walls are made of a web of high pressure steel tubes about 2.3 inches in diameter. Pulverized coal is air blown into the furnace from fuel nozzles at the four corners and it rapidly burns forming a large fireball at the centre. The thermal radiation of the fireballs heats the water that circulates through the boiler tubes near the boiler perimeter. The water circulation rate in the boiler is three to four times the throughout and is typically driven by pumps. As the water in the boiler circulates it absorbs heat and changes into steam at 700 0F(370 0C) and 22.1 MPa. It is required from the water inside a drum at the top of the furnace. Boiler side of Badarpur Thermal Power station, New Delhi

15

The saturated steam is introduced into superheat pendant tubes that hang in the hottest part of the combustion gases as they exit the furnace. Here the steam is superheated to 1,000 F (540 C) to prepare it for the turbine. The steam generating boiler has to produce steam at the high purity, pressure and temperature required for the steam turbine that drives the electrical generator. A steam generator includes an economizer, a steam drum, and the furnace with its steam generating tubes and superheater coils. Necessary safety valves are located at suitable points to avoid excessive boiler pressure. The air and flue gas path equipment include: forced draft (FD) fan, Air Preheater (AP), boiler furnace, induced draft (ID) fan, fly ash collectors (electrostatic precipitator or baghouse) and the flue gas stack. For units over about 210 MW capacity, redundancy of key components is provided by installing duplicates of the forced and induced draft fans, air preheaters, and fly ash collectors. On some units of about 60 MW, two boilers per unit may instead be provided.

AUXILIARIES OF THE BOILER

16

1.

FURNACE
Furnace is primary part of boiler where the chemical energy of the fuel is converted to thermal energy by combustion. Furnace is designed for efficient and complete combustion. Major factors that assist for efficient combustion are amount of fuel inside the furnace and turbulence which causes rapid mixing between fuel and air.

2.

BOILER DRUM

Drum is of fusion-welded design with welded hemispherical dished ends. It is provided with stubs for welding all the connecting tubes, i.e. downcomers, risers, pipes, saturated steam outlet.

The risers discharge into steam a mixture of water, steam, foam and sludge. Steam must be separated from the mixture before it leaves the drum. The functions of a boiler drum are as following: 1. 2. 3. To store water and steam efficiently to meet varying load requirement. To aid in circulation. To separate vapour or steam from the water-steam mixture, discharged by the risers. To provide enough surface area for liquid- vapour disengagement. To maintain certain desired ppm in the drum water by phosphate injection and blowdown.

4. 5.

3. WATER WALLS
Water flows to the water walls from the boiler drum by natural circulation. The front and the two side water walls constitute the main evaporation surface, absorbing the bulk of radiant heat of the fuel burnt in the chamber.
17

The front and rear walls are bent at the lower ends to form a water-cooled slag hopper. The upper part of the chamber is narrowed to achieve perfect mixing of combustion gases. The water wall tubes are connected to headers at the top and bottom. The rear water tubes at the top are grounded in four rows at a wider pitch forming the grid tubes.

4. 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.

5. SUPERHEATER
Fossil fuel power plants can have a superheater and/or re-heater section in the steam generating furnace. In a fossil fuel plant, after the steam is conditioned by the drying equipment inside the steam drum, it is piped from the upper drum area into tubes inside an area of the furnace known as the superheater, which has an elaborate set up of tubing where the steam vapor picks up more energy from hot flue gases outside the tubing and its temperature is now superheated above the saturation temperature. The superheated steam is then piped through the main steam lines to the valves before the high pressure turbine. Nuclear-powered steam plants do not have such sections but produce steam at essentially saturated conditions. Experimental nuclear plants were equipped with fossil-fired super heaters in an attempt to improve overall plant operating cost.

6. ECONOMIZER
An economizer is a heat exchanger which raises the temperature of the feedwater leaving the highest pressure feedwater heater to about the saturation temperature corresponding to the boiler pressure. This is done by the hot flue gases exiting the last superheater or reheater at a temperature varying from 3700 C to 5400 C. By utilizing these gases in
18

heating feedwater, higher efficiency and better economy are achieved and hence the heat exchanger is called economizer. Economizer tubes are commonly 45-70 mm in outside diameter and are made in vertical coils of continuous tubes connected between inlet and outlet headers with each section formed into several horizontal paths connected by 1800 vertical bends. The coils are installed at a pitch of 45 to 50 mm spacing, which depends on the type of fuel and ash characteristics.

7. AIR PREHEATER
An air preheater (APH) is a general term to describe any device designed to heat air before another process (for example, combustion in a boiler) with the primary objective of increasing the thermal efficiency of the process. They may be used alone or to replace a recuperative heat system or to replace a steam coil.

The purpose of the air preheater is 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 flue gas stack (or chimney) at a lower temperature, allowing simplified design of the ducting and the flue gas stack. It also allows control over the temperature of gases leaving the stack (to meet emissions regulations, for example).

8. PULVERIZER

Pulverizer is a mechanical device for the grinding of many types of materials. For example, they are used to pulverize coal for combustion in the steam generating furnaces of the fossil fuel power plants.

19

TYPES OF PULVERIZERS

1.

BALL AND TUBE MILLS

A ball mill is a pulverizer that consists of a horizontal cylinder, up to three diameters in length, containing a charge of tumbling or cascading steel balls, pebbles or steel rods. A tube mill is a revolving cylinder f up to five diameters in length used for finer pulverization of ore, rock and other such materials, the materials mixed with water is fed into the chamber from one end, and passes out the other end as slime.

2.

BOWL MILL
It uses tires to crush coal. It is of two types; a deep bowl mill and the shallow mill.

3.
1.

PLANT AUXILIARY MAINTAINENCE (PAM)

ASH HANDLING PLANT

20

HYDRAULIC ASH HANDLING SYSTEM IS USED AT BADARPUR THERMAL POWER STATION

Boilers having pulverized coal have dry bottom furnaces. The large ash particles are collected under the furnace in a water filled ash hopper. Fly ash is collected in dust collectors with either an electrostatic precipitator or a bag house. A pulverized coal boiler generates approximately 80% fly ash and 20% bottom ash. Ash must be collected and transported from various points of the plants like economizer, air heater, and precipitator. Pyrites, which are rejects from the pulverizers, are disposed with the bottom ash system. Three major factors should be considered for ash disposal systems. 1. 2. Plant Site. Fuel source.
21

3.

Environmental regulation. Needs for water and land are important considerations for many ash handling systems. Ash quantities to be disposed depend on the kind of fuel source. Ash storage and disposal sites are guided by environmental regulations. The sluice conveyor system is the most widely used for bottom ash handling, while the hydraulic vacuum conveyor is the most frequently used for fly ash systems. Bottom ash and slag may be used as filling material for road construction. Fly ash can partly replace cement for making concrete. Bricks can be made with fly ash. These are durable and strong.

4.

WATER TREATMENT
As the types of boiler are not alike their working pressure and operating conditions vary and so do the types and methods of water treatment. Water treatment plants used in thermal power plants are designed to process the raw water to water with very low content of dissolved solids known as demineralized 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.

22

The type of demineralization process chosen for power station depends on three main factors: 1. 2. 3. The quality of the raw water. The degree of de-ionization i.e. treated water quality. Selectivity of resins.

Water treatment process is generally made up of two sections: a. Pretreatment section. b. Demineralization section. PRETREATMENT SECTION Pretreatment plant removes the suspended solids such as clay, silt, organic and inorganic matter, plants and other microscopic organism. The turbidity may be taken as two types of suspended solid in water; firstly, the separable solids and secondly the non-separable solids(colloids). The coarse components, such as sand, silt, etc. can be removed from the water by simple
23

sedimentation. Finer particles, however, will not settle in any reasonable time and must be flcculated to produce the large particles, which are settleable. Long term ability to remain suspended in water is basically a function of both size and specific gravity. DEMINERALIZATION This filter water is now used for demineralizing purpose and is fed to cation exchanger bed, butr enroute being first dechlorinated, which is either done by passing through activated carbon filter or injecting along the flow of water, an equivalent amount of sodium sulphite through some stroke pumps. The residual chlorine, which is maintained in clarification plant to remove organic maater from raw water, is now detrimental to action resin and must be eliminated before its entry to this bed. A DM plant generally consists of cation, anion and mixed bed exchangers. The final water from this process consists essentially of hydrogen iosn and hydroxide ions which is the chemical composition of pure water. The DM water, being very pure, becomes highly corrosive once it absorbs oxygen from the atmosphere because of its very high affinity for oxygen absorption. The capacity of the DM plant is dictated by the type and quantity of salts in the raw water input. However, some storage is essential as the DM plaant may be down for maintenance. Fot this purpose, a storage tank is installed from which the DM water is continuously withdrawn for boiler make-up. The storage tank for DM water is made from materials not affected by corrosive water, such as PVC. The piping and valves are generally of stainless stee. Sometimes, asteam blanketing arrangement or stainless steel doughnut float is provided on top of the water in the tank to avoid contact with atmospheric air.DM water make up is generally added at the steam space of the surface condenser(i.e. vacuum side). This arrangement not only sprays the water but also DM water gets deaerated, with the dissolved gases being removed by the ejector of the condeser itself.

24

4.
ID FAN

INDUSTRIAL FANS

The Induced Draft Fans are generally of Axial-Impulse Type, Impeller nominal diameter is of the order of 2500mm. The fan consists of the following subassemblies: 1. 2. 3. 4. Suction Chamber. Inlet Vane Control. Impeller. Outlet Guide Vane Assembly.

FD FAN The fan normally of the same type as ID Fan, consists of the following components: 1. 2. 3. 4. Silencer Inlet Bend. Fan Housing Impeller with blades and setting mechanism.

The centrifugal and setting forces of the blades are taken up by the blade bearings. The blade shafts are placed in combined radial and axial anti-friction bearings, ehich are sealed off to the outside. The angle of incidence of the blades
25

may be adjusted during operation. The characteristic pressure volume curves of the fan may be changed in a large range without essentially modifying the efficiency. The fan can then be easily adapted to changing operation conditions. The rotor is accomodated in cylindrical roller bearings and an inclined ball bearing at the drive side absorbs the axial thrust. Lubrication and cooling these is assured by a combined oil level and circulating lubrication system.

PA FAN PA Fan if flange-mounted design, single suction, NDFV type, backward curved blaede radial fan operating on the principle of energy transformation due to centrifugal forces. Some amount of the velocity energy is converted to pressure energy in the spiral casing. The fan is driven at a constant speed and varying the angle of the inlet vane controls the flow. The special feature of the fan is that is provided with inlet guide vane control with a positive and precise link mechanism. It is robust in construction for higher peripheral speed so as to have unit sizes. Fan can develop high pressures at low and medium volumes and can handle hot air laden with dust particles.

5.

COMPRESSOR HOUSE

Instrument air is rewuired for operating various dampers, burner tilting, devices, diaphragm valves, etc; in the 210 MW units. Station air meets the general requirement of the power station such as light oil atomizing air, for cleaning filters and for various maintenance works. The control air compresssors and station air compressors have been housed separately with separate receivers and supply headers and their tapping..

26

INSRUMENT AIR SYSTEM Control air compressors have been installed for supplying moisture free dry air required for instrument used. The output from the compressors is fed to air receivers via return valves. From the receiver air passed through the dryers to the main instrument airline, which runs along the boiler house and trubine house of 210 MW units. Adequate numbers of tapping have been provided all over the area. AIR-DRYING UNIT Air contains moisture which tends to condense, and causes trouble in operation of various devices by compreseed air. Therefore drying of air is accepted widely in case of instrument air. Air drying consists of dual absorption towers with embedded heaters for reactivation. The absoprtion towers are adequately filled with specially selected silica gel and activated alumina while one tower is drying the air. SERVICE AIR COMPRESSOR
27

The station air compressor is generally a slow speed horizontal double acting stage type and is arranged for belt drive. The cylinder heads nad barrel are enclosed in a jacket, which extends around the valve also. The intercooler is provided between the low and high pressure cylinder which cools the air between them and collect the moisture that condenses. Air from the L.P. cylinder enters at one end of the intercooler and goes to the opposite end where from it is discharged to the high pressure cylinder, cooling water flows through the nest of the tubes and cools the air.A safety valve is set at rated pressure. Two selected swithces one with positions atuo load/unload nad another with positions auto start/stop, non-stop have been provieded on the control panel of the compressor. In auto start/stop position the compressor will start.

6. TURBINE MAINTENANCE DEPARTMENT

A working fluid contains potential energy (pressure head) and kinetic energy (velocity head). The fluid may be compressible or incompressible. The types of turbines are: IMPULSE TURBINES change the direction of flow of a high velocity fluid or gas jet. The resulting impulse spins the turbine and leaves the fluid flow with diminished kinetic energy. There is no pressure change of the fluid or gas in the turbine blades (the moving blades), as in the case of a steam or gas turbine; the entire pressure drop takes place in the stationary blades (the nozzles). Before reaching the turbine, the fluid's pressure head is changed to velocity head by accelerating the fluid with a nozzle. Pelton wheels and de Laval turbines use this process exclusively. Impulse turbines do not require a pressure casement around the rotor since the fluid jet is created by the nozzle prior to reaching the blading on
28

the rotor. Newton's second law describes the transfer of energy for impulse turbines. REACTION TURBINES develop torque by reacting to the gas or fluid's pressure or mass. The pressure of the gas or fluid changes as it passes through the turbine rotor blades. A pressure casement is needed to contain the working fluid as it acts on the turbine stage(s) or the turbine must be fully immersed in the fluid flow (such as with wind turbines). The casing contains and directs the working fluid and, for water turbines, maintains the suction imparted by the draft tube. Francis turbines and most steam turbines use this concept. For compressible working fluids, multiple turbine stages are usually used to harness the expanding gas efficiently. Newton's third law describes the transfer of energy for reaction turbines. MAIN TURBINE The 210MW turbine is a cylinder tandem compounded type machine comprising of H.P., I.P. and L.P. cylinders. The H.P. turbine comprises of 12 stages, the I.P. has 11 stages and the L.P. has four stages of double flow. The H.P. and I.P. turbine rotor are rigidly compounded and the I.P. and L.P. rotor by lens type semi flexible coupling. All the 3 rotors are aligned on five bearings of which the bearing number is combined with thrust bearing. The main superheated steam branches off into two streams from the boiler and passes through the emergency stop valve and control valve before entering the governing wheel chamber of the H.P. turbine. After expanding in the 12 stages in the H.P. turbine then steam is returned in the boiler for reheating. The reheated steam from the boiler enters I.P. turbine via the interceptor valves and control valves and after expanding enters the L.P. stage via 2 numbers of cross over pipes. In the L.P. stage the steam expands in axially opposed direction to counteract the thrust and enters the condenser placed directly below the L.P. turbine. The
29

cooling water flow through the condenser tubes condenses the steam and the condensate collected in the hot well of the condenser. The condensate collected the pumped by means of 3x50% duty condensate pumps through L.P. heaters to deaerator from where the boiler feed pump delivers the water to the boiler through H.P. heaters thus forming a closed cycle. STEAM TURBINE A steam turbine is a mechanical device that extracts thermal energy from pressurized steam and converts it into useful mechanical work. From a mechanical point of view, the turbine is ideal, because the propelling force is applied directly to the rotating element of the machine and has not as in the reciprocating engine to be transmitted through a system of connecting links, which are necessary to transform a reciprocating motion into rotary motion. Here since the steam turbine possesses for its moving parts rotating elements only if the manufacture is good and machine is correctly designed, it ought to be free from out of balance forces. If the load in the turbine is kept constant the torque developed at the coupling is also constant. A generator at a steady load offers a constant torque. Therefore, a turbine is suitable for driving a generator, particularly as they are both high-speed machines. A further advantage of the turbine is the absence of internal lubrication. This means that the exhaust steam is not contaminated with oil vapour and can be condensed and fed back to the boilers without passing through the filters. It also means that turbine is considerable saving in lubricating oil when compared with a reciprocating steam engine of equal power. A final advantage of the steam turbine and a very important one is the fact that a turbine can develop many times the power compared to a reciprocating engine whether steam or oil. OPEARTING PRINCIPLES
30

A steam turbines two main parts are the cylinder and the rotor. The cylinder (stator) is a steel or cast iron housing usually divided at the horizontal centerline. Its halves are bolted together for easy access. The cylinder contains fixed blades, vanes and nozzles that direct steam into the moving blades carried by the rotor. Each fixed blade set is mounted in diaphragms located in front of each disc on the rotor, or directly in the casing. A disc and diaphragm pair a turbine stage. Steam turbines can have many stages. A rotor is rotating shaft that carries the moving blades on the outer edge of either discs or drums. The blades rotate as the rotor revolves. The rotor of a large steam turbine consists of large, intermediate and low pressure sections. In a multiple stage turbine, the steam at a high pressure and high temperature enters the first row of fixed blades or nozzles, it expands and its velocity increases. The high cvelocity jet of stream strikes the first set of moving blades. The kinetic energy of the steam changes into mechanical energy, causing the shaft to rotate. The steam that enters the next set of fixed blades strikes the next row of moving blades.

31