p1. INTRODUCTION The word power is attractive to any one in this world of today.

Everybody is after power where it is Money power, Electrical power and Political power. Out of these we can electric power is the power, which affects the masses not individual alone. Today the standard of life and industrial development so largely on the use of power that the amount of use power per capita in any country is an index of the material and industrial development in that country and the standard of civilization that has been attained in it. In olden days man had to rely for power on his own physical strength and those of his tamed cattle and animals. Today man has discovered and development many sources of electric power for his industrial and cultural development. The sources of power can be divided into two major groups: Conventional Methods Non Conventional Methods The major share of electric power generation is through Conventional Method as for. CONVENTIONAL METHOD: 1. Coal based thermal power project 2. Hydro power project 3. Nuclear power project 4. Gas turbine based power project 5. Oil based power project In India out of 84500 M.W. of installed power generation units 50000M.W. is through coal based thermal power plants. 31220 M.W. is from Hydro power plants. 2005 M.W. from Nuclear and 1280 M.W. is from Gas based power plants. NON CONVENTIONAL METHODS: 1. Wind generator 2. Solar power 3. Sea bed

The major source of power generation in India as well as abroad is coal based thermal projects. Despite immense electric installation of recent years, thermal power still today play a vital role and occupies a position of prime importance. There are thermal projects of different ratings that are from 30 M.W. to 500 M.W. In this also 200/210 M.W. units i.e. 119 such have been commissioned in India contribute a major share of thermal generation. Even in the near future, traveling in the planets with the help of rockets propelled by thermal power is not at all a dream or fantasy.

GURU NANAK DEV THERMAL PLANT is situated in Bathinda (Punjab)

on Bathinda-Malout Road. The foundation stone of this prestigious Thermal Plant, comprising of four units of 110 MW each was laid on 19th November, 1969, the quincentenary year of the birth of the great Guru Nanak Dev Ji from whom it gets its present name. This project was completed in two phases at a total cost of about Rs 115 crore. The first unit was commissioned in September, 1974 and the others were subsequently commissioned in September, 1975, March, 1978 and last one in January, 1979. The commissioning of these units not only helped bridge the gap between supply and demand in Punjab but also solved the chronic problem of low voltage prevailing in the Malwa region. Each unit of GNDTP, Bathinda, when operated at full capacity is capable of generating 26.4 lac units of electricity a day. The coal consumption is about 1500 to 1600 MT per unit depending upon the quality of coal. The total daily coal requirement is about 6500 M.T.( about two rakes of 58 wagons each) when all the four units are in operation. The coal supplies are being received from Jharkhand /Madhya Pradesh which are more than 1500 KMs from this Power Station.This power plant has been performing exceeding well over the years. The actual Plant Load Factor during 2004-05 on three unit basis (unit-2 is under R&M) is about 70% which is among the highest achieved in the country for 110 MW units. Conservation of fuel oil in the context of power generation has become a way of working at this power station. As in the previous years, GNDTP has
2

further brought economy in fuel oil consumption during the year 2004-05 in which fuel oil consumption is as low as 1.46 ml/kwh. This consumption level is lowest in the country amongst power stations having similar capacity units. Due to better performance the plant has won a number of National Awards from Govt. of India.It is a matter of pride that all the four units have successfully completed Silver Jubilee (25 Years) of their operation. At the same time all the units have outlived their designed life. Hence, Residual Life Assessment study of the units have been got carried out through M/S CPRI, Bangalore. All these units have clocked more than 1, 65,000 running hours against designed life of 1, 00,000 hours. Accordingly, extensive Renovation & Modernization based on Residual Life Assessment (RLA) study of all the four units has been planned to be executed in a phased manner to restore rated capacity of 110 MW in respect of unit-1&2 and enhanced capacity of 120 MW for unit-3&4 , increase efficiency, reduce auxiliary consumption and extend useful life of the plant by another 15-20 years. Work Orders amounting to Rs. 183 crores for major R&M of Boiler furnaces, rotating machinery, H.P. turbine, Instrumentation & Control systems, D.M. Plant, ash handling plant etc. have been placed on M/s NASL, New Delhi for units I & II. The total cost of this project is Rs. 229 crores . Loan for this R&M work has been arranged from M/S PFC, New Delhi. The work also includes updating of Electrostatic Precipitators to bring down SPM (Suspended particulate matter) level below 90 mg/NM3 to reduce pollution in the area. However to bring down the pollution level till R&M is completed, Ammonia flue gas conditioning system has been installed and SPM level as prescribed by the Pollution Control Board has been achieved on these units. Generating capacity of unit-III & IV is proposed to be enhanced to 120 MW from existing 110 MW after replacement of all the three turbine rotors. The Plant Load Factor of each unit and station as a whole will improve to more than 80% on completion of R & M works of the units.

The basic requirements are: Fuel (coal) Boiler Steam turbine Generator Ash handling system Unit auxiliaries

1.1 MAIN FEATURES The main features of the Thermal Plant are as given below.

1)

Location Main Features

Bathinda (Punjab) Highest Generation achievement in 2000-01 (2793.67MU) Highest PLF in March 1987 (88.14%)

2)

Lowest Ever yearly aux. consumption 2002-03 (9.32% without T&E Losses) Lowest DM Water make up in 2004-05 (2.02%) Lowest Oil Consumption in 2002-03 (1.35ml/Kwh) No. of Power House No. of Unit Total generating capacity Source of water supply Fuel Used

3)

ONE

4)

FOUR

5)

4 x 110 MW = 440 MW

6)

Canal water

7)

Primary Fuel: Bituminous coal with calorific value

4

3500-4500 kcal/kg Secondary Fuel: Fuel oil/L.D.O.HPS/FO with calorific value of 9000 to 10,000 K.Cal / liter. 8) Turbine Three casing type impulse turbines 110 MW capacity with 3000 rpm, 29 stages with exhaust pressure 0.08 kg/sq. cm 9) Generator BHEL make three phase synchronous type 110 MW,11000 V with H2 cooling and DC/Static exciter ( 2 units with Static Exciter & 2 units with separate DC exciter) 10) Commissioning U-1 = 22.9.74 U-2 = 19.9.75 U-3 = 29.3.78 U-4 = 31.1.79 Date of commissioning after R&M : U-1 = 01.01.2006 U-2 = 15.04.2007 115 crores(Original),R&M Cost for U#1 & U#2=229 Crore Rs.2.20 (2006-07)

11)

Cost of Project

12)

Cost per unit Total energy

13)

contribution annually

2359.18 MUs (2005-06) ,2221.12 MUs (2006-07)

(Table 1.1)

1.2 SITE SELECTION The selection of site for Thermal Power Plant is more difficult compared to Hydro Power Plant, as it involves number of factors to be considered for its

economic justification. The following consideration should be examined in detail before selection of the site for the Plant. The location for plant should be made with full consideration not only of the trends in the development and location but also the availability and location of the cheapest source of primary energy: Availability of fuel Ash disposal facilities Space requirement Nature of land Availability of labor Transport facilities Public society problems Development of Backward Area

1.3 LANDMARK ACHIEVED G.N.D.T.P. won an award of Rs. 3.16 crores from Govt. of India for better performance in 1983-84. It achieved a rare distinction of scoring hart Rick by winning meritorious productivity awards of Govt. of India, Ministry of Energy

for year 1987, 1988 and 1989 due to its better performance. It again won meritorious productivity awards during the year 1992-1993 and 1993-94 and

has become entitled for the year 1996-1997 for better performance. It also won awards for reduction in fuel oil consumption under Govt. of India incentive scheme years from 1992-1993 (awards money for 1992, 1993 and 1994 already released for 1995, 1996 and 1997 under the consideration of Govt. of India). G.N.D.T.P. had achieved a generation of 2724240 LUs (at a PLf of 70%) and registering an oil consumption as low as 1.76ml/kwh during the year 1993-94 has broken all previous records of performance since the inception of plant.

1.4 CONTRIBUTION OF THE PLANT Guru Nanak Dev Thermal Plant, Bathinda, in addition to indirect contribution in various facts of state economy, is also responsible for: Narrowing the gap between power demand and power availability of the state. Providing employment potentials to thousands of workers. Covering the backward surrounding area into fully developed Industrial Township. Providing additional relief to agricultural pumping sets to meet the irrigation needs for enhancing the agriculture production. Reliability and improvement in continuity of supply and system voltage. Achieving cent percent rural electrification of the state.

1.5 HISTORY OF THERMAL POWER PRODUCTION Although electric power generation in India on a commercial basis is almost a century old, substantial power development efforts began only after independence. At the launch of the First Five-Year plan in 1951, power generation was recognized as a major input for the country's economic development and was accorded high priority. Power sector outlays have been among the highest in successive five-Year Plans ever since. The first two Plans focused on hydro power (as component of multi-purpose projects). Subsequent plans emphasized on rapid installations of thermal power stations. As a result of Plan efforts, India's installed power generation capacity grew to 16,664 MW in 1974. However, assessment of the planned growth since 1951 indicated that with the uneven distribution of resources, power development with only States as spatial units, would result in large inter-state imbalances. This, and the need for quicker and greater capacity addition, led the Government of India to assume a leading role in large scale power generation as a matter of policy and, through an amendment of the Electricity (Supply) Act, National Thermal Power Corporation Ltd. (NTPC) and National Hydroelectric Power Corporation Ltd. (NHPC) were
7

set up in the central sector to supplement the efforts of the States. Consequently, total installed capacity of power utilities has increased from 1,362 MW in 1947 to 104918 MW in March, 2002. Electricity generation, which was only about 4.1 billion units in 1947, has risen to 515 billion units in 2001-02.

1.6 WORKING OF THERMAL PLANT The various organs combine together and made a human body. Every organ of human being has a defined role to play e.g. eye to see, hand to work, mind to process etc. these activity of the body similarly all major and auxiliary systems of a thermal power plant which function together and produce electricity. Coal received from collieries in the rail wagon is mechanically unloaded by Wagon Tippler and carried by belt Conveyor System Boiler Raw Coal Bunkers after crushing in the coal crusher. The crushed coal when not required for Raw Coal Bunker is carried to the coal storage area through belt conveyor. The raw coal feeder regulates the quantity of coal from coal bunker to the coal mill, where the coal is pulverized to a fine powder. The pulverized coal is then sucked by the vapors fan and finally stored in pulverized coal bunkers. The pulverized coal is then pushed to boiler furnace with the help of hot air steam supplied by primary air fan. The coal being in pulverized state gets burnt immediately in the boiler furnace, which is comprised of water tube wall all around through which water circulates. The water gets converted into steam by heat released by the combustion of fuel in the furnace. The air required for the combustion if coal is supplied by forced draught fan. This air is however heated by the outgoing flue gases in the air heaters before entering the furnace. The products of combustion in the furnace are the flue gases and the ash. About 20% of the ash falls in the bottom ash hopper of the boiler and is periodically removed mechanically. The remaining ash carried by the flue gases, is separated in the electrostatic precipitators and further disposed off in the ash damping area. The cleaner flue gases are let off to atmosphere through the chimney by induced draught fan. The chemically treated water running through the water walls of boiler furnace gets
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evaporated at high temperature into steam by absorption of furnace heat. The steam is further heated in the super heater. The dry steam at high temperature is then led to the turbine comprising of three cylinders. The thermal energy of this steam is utilized in turbine for rotating its shaft at high speed. The steam discharged from high

(Fig 1.a)

pressure (H.P.) turbine is returned to boiler reheated for heating it once again before passing it into the medium pressure (M.P.) turbine. The steam is then let to the coupled to turbine shaft is the rotor of the generator, which produces
9

electricity. The power from the generator is pumped into power grid system through the generator transformer by stepping up the voltage. The steam after doing the useful work in turbine is condensed to water in the condenser for recycling in the boiler. The water is pumped to desecrator from the condenser by the condensate extraction pumps after being heated in the low pressure heater (L.P.H) from the desecrator, a hot water storage tank. The boiler feed pump discharge feed water to boiler at the economizer by the hot flue gases leaving the boiler, before entering the boiler drum to which the water walls and super heater of boiler are connected. The condenser is having a large number of brass tubes through which the cold water is circulated continuously for condensing the steam passing out sides the surface of the brass tubes, which has discharged down by circulating it through the cooling tower shell. The natural draught of cold air is created in the cooling tower, cools the water fall in the sump and is then recirculated by circulating water pumps to the condenser.

1.7 AIR COMPRESSOR A machine providing air at high pressure is known as air compressor. The air compressor is driven by some prime mover. The object of all the compressors is to raise the pressure of the air with the expenditure of energy. Air is taken into the compressor from the atmosphere through an air cleaner. The air is compressed and delivered to the storage tank. The compressed air from the storage tank may be taken by means of pipes to any point where so ever the supply of the compressed air is required.
ATMOSPHERIC AIR

HEAT SOURCE

COMPRESSED AIR

PRIME MOVER

COMPRESSOR

HEAT SINK
HEAT LOSES TO COOLANT

(Fig 1.b)

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GENERAL ARRANGEMENT OF COMPRESSOR The compressor receives energy from the prime mover. The compressor for its operation absorbs some part of this energy. Out of the remaining, some part is lost to the coolant and rest is maintained within the compressed air. USES OF COMPRESSED AIR: The compressed air may be used in the different fields, which are given below: 1. It is used for operate the opening valves and closing of feed gates of chutes. 2. It is used in mines to operate pneumatic appliances such as drills, motor generators, pumps etc. 3. It is used to operate pneumatic lifts and elevators. 4. It is used in foundry for sand blasting. 5. It is used for operate the tools used for chipping and riveting etc. 6. It is used to produce air blast. 7. It is used to atomize the perfumes etc. by means of sprayers. 8. It is used in painting spray guns. 9. It is used in spray gun for killing insects etc. 10.It is used in air breaks.

1.7.1 CLASSIFICATION OF COMPRESSORS: The compressor may be grouped into two categories- Reciprocating and Rotary. Besides this the compressors may be classified as follow: 1. ACCORDING TO THE OPERATION a) Single acting b) Double acting 2. ACCORDING TO DESIGN a) Reciprocating b) Rotary
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3.

ACCORDING TO NO. OF CYLINDERS a) Single cylinder b) Multi cylinder

4.

ACCORDING TO NO. STAGES a) Single stage b) Double stage c) Multi stage

5.

ACCORDING TO PRESSURE LIMIT a) Low pressure b) Medium pressure c) High pressure

6.

ACCORDING TO THE METHOD OF COOLING a) Air cooled b) Water cooled

7.

ACCORDING TO INSTALLATION a) Portable b) Fixed

RECIPROCATING AIR COMPRESSOR: The reciprocating air compressor essentially consists of a piston and cylinder a simple type of positive displacement compressor from which the delivery is intermittent. The piston reciprocates in the cylinder. The cranck shaft through the connecting rod drives it. There are two valves mounted on the head of cylinder. These valves are inlet and delivery valves. Both the valves usually operate as a result of pressure difference across them. OPERATION: During the downward movement of the piston the residual compressed air is clearance volume will expend. When the pressure inside the cylinder falls below the outside pressure, the inlet valve will lift off from its seat. Air from the out side is admitted into the cylinder through the inlet valve, during the downward
12

movement of piston. This is known as induction stroke of the piston. During this stroke the delivery remains closed. After the completion of induction stroke the piston starts moving in the upward direction. The inlet valve will be closed as the pressure inside the cylinder increases with the upward movement of the piston now both the valves are closed so the air entrapped in the cylinder is compressed to high pressure .the delivery valve is lifted up as soon as inside the air pressure in the delivery chamber. The compressed air is now delivered during the remaining upward movement of the piston this stroke of piston is known as compression stroke. At the end of this stroke, the piston again starts moving in the downward direction, for its induction stroke. The delivery valve closes and the inlet valve opens. Thus the cycle is repeated. The compressed air is stored in a storage tank from which it may be taken out according to requirement.

PRINCIPLE AND WORKING OF DOUBLE STAGE DOUBLE ACTING COMPRESSOR: In double stage double acting compressor two cylinders are positioned on either side of crank case facing each other being driven by same crank shaft with the two cranks at 180 degree, the reciprocating mechanism in the two cylinders will always have movements exactly opposed to each other thus imparting perfect dynamic balance into the system. The balanced opposed piston compressors are either single stage design where input pressure for both the cylinders are same P1 and so also the output pressure P2 or two stage design where the output of low pressure cylinder will be the input for high pressure cylinder. The output pressure of two-stage compressor P3 will be higher than that of a corresponding single stage compressor. The compressor crankshaft can be made to drive a number of pairs of such cylinders to give a multi bank compressor for higher output usually low pressure compressors are belt driven or directly coupled type. Sometimes it may not be possible to get a very high pressure of air in a single cylinder, and then double stage compressor is employed.
13

WATER ATMOSPHERIC AIR

COMPRESSED AIR DELIVERY

INTER COOLER R E C E I V E R H.P. CYLINDER

L.P. CYLINDER

(Fig 1.c)

DOUBLE STAGE COMPRESSOR The atmospheric air is first compressed in a cylinder. During compression air become hot to some extent It is cooled down to its initial temperature by passing it through the heat exchanger which is known as inter cooler. The cooled air from the intercooler is supplied to the second cylinder where it further compressed to desired pressure. The first cylinder is known as low-pressure cylinder and it is first stage of compression. The second stage receive the compressed air through the intercooler is known as high-pressure cylinder and it is second stage of compression. The dimensions of the H.P. cylinder is smaller than that of L.P. cylinder because the volume of air is decreased when it is compressed. The intercooler saves some amount of work required during the second stage of compression. The L.P. and H.P. cylinders are coupled and are driven by same prime mover. After H.P. it goes into heaters where it dries silica gel is used in heaters.

14

1.8

COAL HANDLING PLANT

(Fig 1.d) In G.N.D.T.P, the main fuel is COAL. It is burnt to get the thermal energy, which is used to convert water into steam. This energy is released by the combustion of certain chemicals (e.g. carbon, hydrogen etc.) present in coal with oxygen. The various types of fuels in steam thermal plants used are: solid fuels (coal, coke), liquid fuel (petrol, diesel), gas fuel (natural gas, biogas). In steam thermal plants, the selection of a particular type of fuel is a problem of economics. However in G.N.D.T.P, coal is used.

In coal handling plant, the coal is transferred from the coal storage site to the bunkers (capacity of bunker is 500MT) through conveyors belt connected from one place to other place. Firstly, the coal from the wagon is unloaded through wagon tippler and then the coal is transferred to the crusher house and finally the crushed coal is stored at the coal storage site.

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1.8.1 COAL AND ITS SELECTION Coal is a general term that encompasses large organic minerals with widely differing compositions and properties, although all are essentially rich in amorphous elemental carbon. The main types of coal are: 1. Peat 2. Lignite 3. Sub-bituminous 4. Bituminous 5. Semi- bituminous 6. Anthracite 7. Super-anthracite. The primary fuels, which are burned to release heat and generate steam in boilers, are the fossil fuels in the form of coal, oil and natural gas. Coal is the principal energy source because of its large deposits and availability. Coal originated from vegetable matter, which grew millions of year ago. Peat contains up to 90% moisture and is not attractive as a utility fuel. Rank is a measure of carbon content in coal. Lignite is considered to be low rank and anthracite to highest rank. The coal is transported in the rail wagons from collieries to the plant site. A rake of train means to 58 wagon. And capacity of each wagon is 60MT.At the plant site, the coal is unloaded mechanically by means of wagon tipplers. Tippling it in the coal hopper form where the coal is carried by belt conveyor to the crusher house empties the loaded wagon. The coal is sent by one or more of these companies by railway transportation. In plant, the properties of coal are examined by chemical methods. Main methods are:

1. Proximate analysis 2. Ultimate analysis.

16

Proximate analysis gives the principal characteristics of the coal, whereas ultimate analysis gives its chemical composition. On the basis of the properties of coal studied, coal is ranked as per standards maintained. Then payment of coal is done on the basis of rank observed by the Punjab State Electricity Board to the concerned companies.

The coal should have the following properties:

1. LOW MOISTURE CONTENT 2. LOW ASH CONTENT 3. LOW VOLATILE MATTER 4. LOW SULPHUR CONTENT 5. LOW HYDROGEN 6. HIGH CARBON CONTENT.

1.8.2 COAL SAMPLING The coal testing starts from coal sampling. In coal sampling a standard technique to take samples of coal suggested by P.S.E.B. is followed. In this technique, there is a set of 75 lists of 15 wagon numbers chosen randomly. A list is taken. Then in those wagon nos. the coal sample of weighing about 1 kg is taken. This amount is taken from 1meter depth of wagon. Thus we collect 15 kg of coal. Then this coal is mixed well. Now the coal is divided into four parts. Two parts are randomly rejected The other two parts are mixed and again divided in four parts. From which two are rejected. This procedure continues till we get 2 kg of coal. Then it is crushed and is sent to coal testing room.
17

1.8.3 COAL TESTING AND GRADING Here the properties of coal are examined by applying the chemical tests. The following tests are done on coal sample.

1. Proximate analysis 2. Ultimate analysis.

Proximate analysis gives the principal characteristics of the coal, whereas ultimate analysis gives its chemical composition. On the basis of the properties of coal studied, coal is ranked as per standards maintained.

From Proximate analysis, we get the following data: PERCENTAGE OF MOISTURE CONTENT PERCENTAGE OF ASH CONTENT PERCENTAGE OF VOLATILE MATTER PERCENTAGE OF CARBON CONTENT.

From the Ultimate analysis, we get the following data: percentage of sulphur content percentage of hydrogen content Percentage of ash content.

After getting the above information, the grading of coal is done. It is done by studying the features like ash content sulhur content Calorific value.

On the basis of grade of coal, the payment is done to the relative Coal Company by P.S.E.B.

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1.8.4 COAL HANDLING

(Fig 1.e)

Coal handling is done mechanically instead of manually, due to following reasons:

1. Large quantity of Coal has to be handled everyday, 2. Reliability of mechanical devices, 3. Mechanical handling is cheaper one, 4. Unloading of Coal from rail wagons is difficult and time consuming by manual handling, MAJOR PARTS

The main parts are divided into two parts:

1.General Working Parts, 2.Emergency Working Parts.

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General Working Parts are: 1. Wagon Tippler 2. Junction Tower 3. Primary crusher 4. Secondary crusher 5. Bunkers 6. Conveyer System

Emergency Working Parts are: 1. Stacker cum Reclaimer 2. Manual Handling Hopper 3. Emergency Reclaimer Hopper

Also there are spare General Working Parts i.e. each General Working Part has duplicate of its own. If one part is under breakdown, the other can be used at that time.

1.8.5 PLANT ORGANISATION STRUCTURE

Coal Handling Plant has been divided into two departments: 1. Mechanical Department

a. Operation Department b. Control Department c. Maintenance Department

2. Electrical Department

a. Wiring and Lighting Maintenance Department b. Electrical Equipment Maintenance Department

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PARTS DESCRIPTION

WAGON TIPPLER

(Fig 1.f)

It is an Unloading Device used in plant to unload COAL from rail wagons. There are two no of WT. One is kept under maintenance and other is working. The effective unloading output is designed for:

Useful load Wagon tare weight Total weight

55 tons 25 to 30 tons 80 to 90 tons.

(Table 1.2)

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TYPES OF WAGONS TO BE HANDLED TYPE WEIGHT O OZ BOX BOZ 14428*2955*2836 14740*3166*3040 13730*3075*3160 13192*2950*3150 33 40 82 80 MAXIMUM DIMENSIONS GROSS

(Table 1.3)

TECHANICAL DATA OF WAGON TIPPLER The tippler drive unit consists of: the electric motor the connection coupling with brake arranged between motor and gearbox the spur wheel gearbox the coupling shaft with 480 dia. Pinions Toothed rims diameter 8470mm connected to the end shields by screws. Base frame Flexible couplings The main function of tippler drive unit is to tilt the end Frame

The tippler platform is rated for 120-ton weight maximum. Total weight to be unloaded Maximum tilting angle Tipping cycle time Tipping cycle/hour max Tipping cycle/hour guaranteed Circumferential speed Gearbox ratio
(Table 1.5) 22

105 tons 155 deg. 175 sec(app) 20 16 0.27m/s 1:140

The main components are: 1 end shield with gear teeth 2 Counterweights 3 Main Hydraulic Cylinder 4 Main Bearing and main Shaft 5 Drive pinion 6 Line Shaft 7 Upper Holding Beam 8 Cross arm Cylinder 9 Side Arm 10 Wagon Fixture 11 Tippler Platform 12 Side Arm Charger 13 Chock Beam 14 Hopper 15 Drive 16 Operator Cabin

Main parts are described below:-

Tippler drive Unit: The drive unit consists of the following components: a. b. c. d. e. f. g. h. Base Frame Eddy Current Brake Slip ring motor Spur Gear Unit Flexible Couplings Drum Brake Drive pinions for Rotating End Shields Line Shaft and set of Bearings and Bearing Housings
23

End Shield: The 8520mm-dia.end shield is in a sector form weighs about 9 tons and (without counterweights) is fabricated out of plate works. This is roughly of semicircular shape and rotates on main Pedestal bearing supported on the R.C.C. Pedestals. End Shield is having tooth rim on its periphery; these teeth are driven through a pinion mounted on the line shaft. When End shield gets its motion through pinion it moves the table and the wagon placed on it along it. The end Shield is having Counter Weight, which designed to balance part of the Wagon and the platform. Platform: Platform approx. 19.7m long is a plate fabricated structure weighing about 10 tons, a bridge shaped structure carrying a section of the rail track, bearing eye centering device and the rollers. It has sufficient length to accommodate all types of wagons listed above, including O and OZ in pairs. The platform rests on civil foundation via a centering device. Upper Holding Beam: This is a18.2m long, 7.5 ton structural work made out of heavy plate work, and connected at the Side Arms which are supported on the main bearings. The Upper Holding Beam gets its forward motion through a pair of main Hydraulic Cylinder and gets clamped with the Wagon fixtures (PAWS). This also supports the weight of the Wagon during tipping and prevents from falling from the platform. Chock Beam: Chock beam is fabricated out of plate work and weighs about

13.5 tons. At the start of tipping operation when the table along with wagon tilts about the cantilever arm pin. The wagon rests on its side on the chock beam. To avoid damage to wagon the chock beam is lined with thick rubber, which absorbs any impact due to wagon resting. Side Arm Charger (S.A.C.): The Side Arm Charger moves the selected portion of the train rake to a position of readiness. Further it moves the Wagon to be unloaded on the Tippler table. After the Wagon has been unloaded S.A.C. helps in ejecting the empty Wagon from the Tippler table.

24

TECHANICAL DATA: No of Wagons that can be pulled Weight of loaded Wagon Travel Speed forward Backward Max. Pulling force Required pulling force Pinion diameter of planetary gearbox Speed of hydra. Motor Speed of planetary gearbox 24 90 0.5 m/sec 1.0 m/sec 200kN 170kN 280mm 1600/3200 rpm forward 34,104 rpm Backward 62,208 rpm

(Table 1.6)

MAJOR PARTS: The travel drive is achieved Electro-hydraulically via pinion and toothed rack. The travel drive consists of 2 complete drive units to be vertically arranged on the drive frame, their pinion mesh with the toothed rack fixed at the substructure. Each drive unit is combined with a hydraulic motor, planetary gearbox and toothed pinion, whereas one drive unit is equipped with a brake. Lifting and lowering of the holding arm as well as hydraulic cylinders achieve coupling and uncoupling of the wagons at its beam end. Hydraulic buffers to be arranged with in the area of the holding beam of he wagons as is compensate shocks, which occur with the shifting of the wagons due to acceleration or deceleration. The total length of travel of the S.A.C. is controlled by a set of Magnetic Switches. An over travel limit Switch is set by he back-up Heavy duty Mechanical Switches. The moving parts are provided with grease Lubrication system.
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JUNCTION TOWER:

It is a structure used to divert the conveyor system at 90

deg. There are junction towers installed in coal plant. The main parts of a junction tower are: Motor drive Sector gates Chute Dust suction system

The main purposes of Junction Tower are: To divert the conveyor system at 90 deg To make the connections between two conveyors With the help of Junction Tower, we have many optional ways of carrying coal.

PULVERIZED COAL: The coal available is not in suitable form it is present in pieces of average size 50 to 100 mm. These pieces cannot be used in Furnace directly. The reason is that its surface area is not so enough to combust it fully and properly. As surface area of coal increases, it catches fire very easily and soon. The main advantages of using pulverized are given below:

Surface area is increased, hence combustion is completed. Coal is dried effectively No/reduced clinkers formed Efficiency increases as complete combustion. Easy transportation of coal into furnace.

26

Hence we have to convert the pieces of coal into pulverized coal to take the advantages of it.Two types of crushers has been used to convert the bigger coal pieces into smaller ones. Then these pieces are converted into pulverized (powder) form with the help of mills (known as PULVERIZER). These crushers and mills are:

1 PRIMARY CRUSHER 2 SECONDARY CRUSHER 3 BOWL MILLS.

Name of equipment

Type

No.

Primary Crusher

Rotary crusher

Secondary Crusher

Ring granulator

Pulverizer

Bowl mill

6 (for each unit)

(Table 1.7)

PRIMARY CRUSHER: It is a type of crusher used to break the bigger pieces into smaller ones. There are TWO Primary Crushers PC A and PC B. The purpose of having two is to have uninterrupted crushing of coal. Suppose one P.C. breaks down during crushing, then at the same time the other is started. Meanwhile the first one is undergone repair and maintenance, thus making it ready for further operation. When one is working the other is kept always ready for meeting emergencies. These are used shift by shift. One is working in day sift and remains at maintenance and is ready for working in next shift.

27

Main parts of it are:

1. 2. 3. 4.

CASING PERFORATED CYLINDER LIFTER SHELVES MOTOR DRIVE SYSTEM

PURPOSE OF PC: The main purposes are: To break the bigger pieces into smaller ones To reject the foreign particles and the coal pieces which do not break in PC.

WORKING OF PRIMARY CRUSHER:

This crusher s composed of a large

cylinder. It consists of a large no of holes on its surface area. The diameter of these holes has been varied along the periphery. Some initial rows have the holes of dia 25cm, next ones have the hole dia of 20 mm, and others have hole dia 15mm. On the inner periphery of cylinder lifting shelves are attached. The cylinder rotates at a small speed of 20rev per min. The cylinder receives the coal feed at motor drive side. The smaller pieces (Dai <25mm) directly falls from holes. The lifting shelves lift the bigger ones. When shelves go on top, the coal pieces falls down and break and pass through the holes. This procedure continues until the pieces are broken down. Although there are some pieces, those do not break, are lifted by shelves ad are thrown in rejection duct.

SECONDARY CRUSHER:

In this crusher, the coal pieces coming from P.C.

are further crushed. The size of coal pieces is reduced from 25mm to 10-15mm. Like P.C., there are two no of S.C. SC A and SC B. The type of S.C. is RING GRANULATOR. The purpose of having two is to have uninterrupted crushing of coal. Suppose one S.C. breaks down during crushing, then at the same time the

28

other is started. Meanwhile the first one is undergone repair and maintenance, thus making it ready for further operation. When one is working the other is kept always ready for meeting emergencies. These are used shift by shift. One is working in day sift and remains at maintenance and is ready for working in next shift. Main parts of it are:

1. HAMMERS (LOOSE RINGS ) 2. VIBERATING SCREEN 3. SCREEN BAR( PERFORATED PLATES ) 4. MOTOR DRIVE SYSTEM 5. SHAFT 6. PRESSURE PLATES

WORKING OF SC:

The coal coming from Primary Crusher is fed in

VIBERATING SCREEN. The Vibrating Screen separates the fine coal dust particles from the coal pieces. The coal dust falls down. The coal pieces are allowed to fall in casing of SC. Here the main Shaft is rotated at a normal speed of 100-130 rpm. On this shaft, hammers are mounted. These are the loose rings made of cast iron. Here are five sets of loose ring rod. On each rod there are 15 loose rings. As shaft rotates, the hammers, due to Centrifugal forces, tend to come outside. The coal pieces now come between two surfaces. One is of hammers and other is of pressure plate. As there is very small gap (of 10mm) between two surfaces, the coal is broken. Now this crushed coal is fallen down on the conveyors and is sent further.

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STACKER CUM RECLAIMER:

It is a huge structure used to store the coal

when not needed and reclaim it when required. Sometimes there is no need of coal in bunkers. But the is a rake of coal. To avoid railways penalty and to have a stock of coal in emergencies (like no coal is coming), the coal is stored with the help of STACKER. When there is need of coal in bunkers and no fresh coal is coming, the stored coal is conveyed to the bunkers with the same structure. That is why it is called STACKER CUM RECLAIMER. The purpose of having two is to have uninterrupted crushing of coal. Suppose one S.C. breaks down during crushing, then at the same time the other is started. Meanwhile the first one is undergone repair and maintenance, thus making it ready for further operation. When one is working the other is kept always ready for meeting emergencies. These are used shift by shift.

1.8.6 EMERGENCY OPERATION SYSTEMS

The emergency means that at any time any part can be stop working and system can be come to at halt. Any type of breakdown may occur which can stop the work along with huge damage. In order to avoid interrpution in work operation, the emergency operation systems are provided. The main emergency operation systems are: MANUAL HANDLING HOPPER EMERGENCY RECLAIMER HOPPER CONVEYOR SYSTEM HAS BEEN DOUBLED.

EVERY PART HAS BEEN DOUBLED.

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1.9 WATER TREATMENT PLANT The water is required for two purposes at GURU NANAK DEV THERMAL POWER PLANT:1) For Boiler feed makeup taken from D.M. plant 2) A. Cooling tower makeup B. Portable water C. Service water and other requirement D. For fire protections Total hourly requirement of 1 unit of 110MW is nearly 1200 m/hr. 1.9.1 SOURCE OF RAW WATER:- The source of raw water for the plant is Sirhind canal or river water. It contains impurities like Calcium, Magnesium salts, Silica suspended solids and minerals to a 300-500 ppm during monsoon period and a normal supply has 200-300 ppm. Hardness of water indicates calcium and magnesium salts present in water. Bicarbonates and carbonates of these salts constitute temporary hardness sulphates, nitrates chlorides etc. constitute permanent hardness. These cause scale formation in boiler. To avoid the deposition of scale on metal surfaces, corrosion of boiler tube metal etc. difficulties, water treatment process is used. This knows the impurities of water as External water treatment Internal water treatment

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1.9.2 External Water Treatment comprises of: a) b) c) d) a) Chlorination. Bacteria and other living organisms results in the formation of algae on the surface of tanks, pipes and other equipments. Addition of oxidizing agents such as chlorine & bleaching powder destroy the bacteria or any other micro organisms. At present, chlorine dosing is done at Intake. Pump House and at both CW Pump House with Gas Chlorinator of vacuum type at the rate of 10 Kg/Hr. Chlorination. Sedimentation & Clarification. Filtration. Demineralization.

b) Sedimentation & Clarification The suspended impurities in water are removed by sedimentation and clarification. When the river or cannel water is allowed to stand for sometime in a big tank or reservoir most of the suspended material settles down. The process of clarification is done in clarifier and is accelerated by adding coagulant such as alum (aluminium and ferrous sulphate) or Sodium Aluminate. These results in the formation of precipitate of aluminium hydroxide, which tends to agglomerate colloidal,Organic and suspended impurities in water. The precipitates so formed settles at the bottom of clarifier. These are removed by operating desludging valve. Al2(SO4)3 + 3Ca(HCO3)2 3CaSO4 + 2Al(OH)3 +CO2. Impurities not removed in this process are removed by filteration. At present, we have 4 clarifiers with a clarifying capacity of 1200 MT/Hr each to reduce turbidity upto 20ppm. c) Filtration It is the process of passing of liquid containing suspended matter through a suitable porous material (Filtering Medium) to effectively remove the suspended
32

matter in the liquid. For the process of filtration there are 3 pressure filters in each D.M.Plant having a capacity of 27 M3/Hr each. Turbidity of filtered water from pressure filters is not greater than 2 ppm. Filter media commonly employed are graded and washed sand of effective size of 0.35 mm to 0.5 mm resting on supporting under bed of crushed gravel and pebbles of four varying size with coarsest size at the bottom of the bed. d) Demineralization (Removal of dissolved impurities) The development of modern high-pressure boilers has been accompanied by serious problems connected with the formation of scale, corrosion etc.The principle scale forming and hardness producing substances found in natural water are the soluble salts of calcium and magnesium. The most common are bicarbonates Ca(HCO3)2, Mg(HCO3)2.The sulphate CaSO4,MgSO4. The chlorides CaCl2, Mg/Cl2 and sometimes nitrates are also present. The processes which are used for water softening are: 1. Boiling (For removing temporary hardness only). 2. Lime Soda Treatment. 3. Base Exchanger Zeolite process. 4. Ion Exchange.

ION EXCHANGE The demineralization of water at GNDTP, BATHINDA is done by ion exchange process. There are two D.M. Plants each having capacity 900 MT/day design for 5% station make up. The ion exchange process is used in removing all the above scale forming constituents. This is the most modern and latest method. The ion exchange is the process in which there are irreversible interchanges of ions of like sign between a solution and an insoluble solid. In this process the cations in water are exchanged with H+ ions of cations resins and anions are exchanged with OHions of anion resins.

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RESIN Resin consists of a giant organic molecule arranged in the form of porus framework, having replaceable H+ions attached to it in case of cations resin and replaceable OH-ions in case of anion resins. The demineralization process consists of 3 units in series, one is called Cation Exchange Unit and the other is called Anion Exchange Unit. Mixed bed unit follows this. 1. Cation Exchange Unit This exchanger removes all the cations such as Sodium (Na+), Potassium (K+), Calcium (Ca++), Magnesium(Mg++)etc. When the water passes through cations resin the functional hydrogen ion are replaced by the cations with the formation of respective acid. The equation is represented as: (a) R'H+ + Ca (HCO3)2 R'Ca+ + H2CO3 (b) R'H+ + CaSO 4 (c) R'H+ + NaCl R'Ca+ + H2SO4 R'Na + HCl

When the resin gets exhausted, it needs regeneration (i.e. reconversion of resin into the operating form) for cation exchange units mineral acid such as hydrochloric acid is used for regeneration e) RCa 2. Degasser Unit The treatment water is passed through degasser unit, since it has large amount of CO2 and here the CO2 is removed. This reduces load on the anion exchanger. The treatment water from cation exchanger is sprayed from the top of the degasser tower. The degasser tower is packed with rasching, rings and air flowing arrangement is provided from bottom to top with air outlet at the top. Air which is being pushed from the bottom comes in contact with water droplets & finally, CO2 is removed in sufficient amount & is ejected out by air draft. a) H2CO3 H2O + CO2 + 2HCl 2RH+ + CaCl2

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3. Anion Exchanger Units This unit removes all the anions such as Sulphates, Chlorides, Nitrates, SiO2 and residual CO2from degasser. When the water passes through anion exchange resin, all the anions are exchanged with functional OH- group of the resin. 1) R+OH' 2) R+OH' + + HCl RCl + RSiO3 H2O + H2O

H2SIO4

After sometimes when it gets exhausted, it needs regeneration. It is regenerated with 5% NaOH 3) R+Cl' + NaOH ROH + NaCl

(Exhausted Resin) 4. Mixed Bed

(Regenerated to Drain Resin)

Mixed bed contains both the cations and anion resins. Any cation or anion which has slipped from the cation exchanger and anion exchanger are removed here in the mix bed unit. After mixes bed treated water is quit suitable for use in boiler. PH = 6.8 to 7.2

Conductivity = SiO2 Others = =

1.0 micromhos/cm < 0.02 ppm. NIL

1.9.3 Internal Water Treatment When after standard treatment it is necessary to further condition the boiler feed water because D.M. Water dissolves CO2 andO2 in the storage tanks and becomes slightly acidic and corrosive in character. This is treatment at various stages of feed water is called internal water treatment. Internal Water Treatment is required by chemical dosing to combat the following: (a) Corrosion. (b) Scaling (c) Pitting
35

(d) Foaming (e) Caustic Embrittlement. (a) Corrosion Corrosion is the gradual destruction of metal by chemical or electro chemical reaction of metal with the surrounding medium. Corrosion begins at the surface and gradually penetrates into the metal. It also changes the mechanical and physical properties of material. (b) Scaling Once in boiler the water is heated to saturation. The temperature thus evaporates at the point of contact with heated tube surface. The impurities are left in boiler water whose concentration thereby increases. The impurities to deposit on the tube surface a scale. Scaling may take place in boiler drum, water walls heater and feed water piping. It reduces the flow requiring an increase in pressure to maintain water delivery and more fuel consumption. Then this condition occurs tube failure due to overheating, blistering and rupturing may be expected. (c) Pitting When minute holes are created on metal surface by oxidation it is know as pitting. This type of corrosion is caused by dissolved oxygen in water. The residual oxygen is removed by treatment with hydrazine. (d) Foaming Foaming priming and carry over are closely associated terms production of stable foam over the surface of water is called foaming. Too high concentration of dissolved salts is the cause of foaming. (e) Caustic Embrittlement The tendency of caustic (Sodium Hydroxide) to concentrate in drum seals, under rivets or at rolled tube joints injuring the metal is called caustic embrittlement. Foaming, priming, carryover, caustic embrittlement can be controlled by maintain proper alkalinity, operating blow down and maintaining proper drum level i.e. 30 to 60 mm.
36

CHEMICAL DOZING FOR INTERNAL TREATMENT OF WATER To take care of scaling and corrosion following chemical dosing is done to neutralize effect of CO2, O2 Calcium Magnesium, Salts and silica etc. (1) Morrholine dozing. (2) Hydrazine dozing. (3) Phosphate dozing. (1) Morrholine dozing

This dozing is done to increase the pH of the feed water and remove any in the system 2C4H9ON + 2CO2 2C4H9CO3 + N2

The pH of the feed and steam cycle is maintained between 8.4 to 8.8 to minimize corrosion, it is dozed at the discharge of condensate extraction pump. (2) Hydrazine dozing

It is a powerful reducing agent which reacts with dissolved oxygen under boiler water condition to produce water and nitrogen only as follows. N2H4 + O2 2H2O2 + N2

Hydrazine also reduces non-protective iron oxide to protective magnetite.

(3)

Phosphate dozing

It is done with two aims: a. Any hardness (salts of Ca and Mg) entering the boiler is likely to form scale in boiler. The addition of phosphate prevents this. The phosphate reacts with calcium and magnesium to form sludge, which can be removed by blow down. In this way, Ca and Mg scales are completely removed from the boiler drum. b. T.S.P. maintains proper pH of the boiler water. T.S.P. on hydrolysis with boiler water liberates NaOH with the reaction. Na3PO4 + H2O
37

Na2HPO4

NaOH

1.9.4 RAW WATER AND CIRCULATING WATER SYSTEM:-

RAW WATER:- The total water requirements for running of the units are supplied by the intake pump house in the raw water form. The raw water is taken from Sirhind canal near the plant area and stored in the storage ponds. There are separate ponds for units. The ponds act as a water reservoirs since the canal runs dry once in a month for 7 days. Normal season has a normal supply of water. In order to destroy algae and bacteria in water chlorination is done intermittently at the suction of intake pumps. In the intake pump house which is common for stage-1,2 there are six number of pumps, one pump for each unit and two acts as standby. Particulars of pumps:Capacity of each pump Total head Suction pressure Motor 1200 m3/hr. 8 MWC 0.3-0.46 kg/cm2 415 Volts, 45 kW
(Table 1.8)

These pumps take suction and pump the raw water to the clarifier.

CLARIFIER:The basic purpose of clarifier is to remove or to precipitate out the undissolved impurities present in raw water which coagulates by putting alum and settles down at the bottom in the form of sludge which is further removed with the help of valves provided for this purpose. The quantity of alum is regulated depending upon the raw water. There are four clarifiers for four units. The raw water from intake pump house comes into the clarifiers. Each clarifier is capable of clarifying raw water at the rate of 1200 m3/hr. The size of clarifier is 34.74 meters in diameter and 3.7 meters in depth. It has a floculator of 12 meters diameter. The water in floculator is stirred by a motor operated stirrer. The water

38

from clarifier is transferred to the clear well of 1200 m3. The clarifier water from the clear water well is utilized for the different purposes as: For D.M. plant i.e. D.M. water is to be used in the boiler or for boiler make up in the hot well through D.M. transfer pumps. For fire fighting. For servicing in the plant. For drinking/portable purposes. For makeup of the circulating water in the circulating water sump.

CIRCULATING WATER:There are two C.W. pump houses, one for unit-1,2 (stage-1) and other for unit-3,4 (stage-2). In each C.W. pump house there are five number of pumps for circulating water, two pumps for each unit having 50% capacity and pump is stand by for both units. The particulars of C.W. pumps for unit 1,2 are:Manufacturer Type of pump : : M/s Johnson Pumps Ltd. Calcutta Wet pit, mixed flow, vertical directly coupled

with an electrical motor drive. Pump Bearing lubrication Design capacity Motor : : : Forced fresh water from external source. 8600 m3/hr. 800 kW, 6.6 kV, 50Hz, AC Induction motor of BHEL, Haridwar.

The required cooling and sealing for the circulating pump is done with the help of water pump. which circulates the water through bearing and periphery for sealing of circulating water pump. the details are:-

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PUMP Make Bestand Company Speed No. of stages No. of pumps

(Table 1.9)

2900 rpm 2 3 for each

MOTOR Make Power Voltage

(Table 1.10)

Kirloskar 12.5 HP 440 Volts

PARTICULARS OF C.W. PUMPS UNIT 3 AND 4:Manufacturers Type Capacity Lubrication Discharge pressure Motor : Flow more Pvt. Ltd., New Delhi : Mixed flow, vertical : 8600 m3/hr. : : : Forced external water lubrication 2 kg/cm2 (approx.) 1000 HP, 6kV, BHEL
(Table 1.11)

The pumps are of vertical type and suction from the C.W. pump and the discharge of each pump is connected to a common discharge header from where the water enters in a cold water tunnel which is further distributed for various
40

purposes mainly in the condenser. This water in the condenser tubes takes the heat of the steam and gets heated up. The outlet of the condenser is sent to the cooling tower through another hot water tunnel. Where the hot circulating water is cooled down by 10C by the natural draught of air, capacity of each cooling tower is 18000 m3/hr. The water falling at the height of about 10.5 meters from the cooling tower is collected in the sump, which further overflows, to the CW sump. The make of the CW is added to the sump as required. There are three numbers of seal water pumps for sealing of the glands of the CW pumps for stage C. The suction of these pumps are taken from the concerned sumps. One direct seal water line is taken from the overhead service tank which serves in case of failure. 1.9.5 COOLING WATER SYSTEM:1) For Condensers:- Approximately 15000 m3/hr. of CW water is required for condensing steam at fuel load per unit. The water is tapped from cold water tunnel and after condensing steam in the condensers, hot water enters the hot water tunnel and then leads to cooling tower. 2) For Hydrogen Coolers:- The water for the hydrogen cooler is taken from the cold water tunnel, there are two hydrogen cooler booster pumps for each unit. One works at a time and second remains standby. The discharge of H2 coolers is mainly connected to the hot water tunnel but during startup it can be sent to blow down sump for ash disposal. 3) Turbine Lubrication Oil Coolers:- There are six number of turbine lubrication oil coolers for each unit, the cooling water tunnel is taken for inlet and outlet is connected to hot water tunnel. 4) Bearing Cooling Water System:- There are three number of BCW pumps for each unit which supplies cooling water to various boilers and turbine auxiliaries of the unit at the required pressure. The pumps take suction from the line taken from the cold water tunnels and outlet goes to the blow down sump of ash disposal.
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1.10 BOILER

A boiler is a combination of systems and equipment in which the chemical energy of fossil fuels is converted into thermal energy, which is then transferred to a working fluid (water) so as to convert it into steam at high pressure and temperature. This high pressure and temperature steam is then used for the development of power in a turbine.

(Fig 1.g)

It is the main portion part of STEAM GENERATOR. It is an assembly of a large no. Of vertical riser tubes embedded in refractory walls. There are two boilers one for each unit. The type of the boiler is NATURAL CIRCULATION, RADIENT SINGLE REHEAT boiler. The four refractory walls make a closed box called FURNACE. The walls are given special names. These are:

1. 2. 3. 4.

RIGHT WALL consisting 130 TUBES. LEFT WALL consisting 130 TUBES. FRONT WALL consisting 181 TUBES. REAR WALL consisting 181 TUBES.

On the right and left wall, the WIND BOXES are installed. At the joint of two walls a FURNACE CORNER is installed. Thus there are Four Furnace Corners.

42

The water tubes cool the walls by absorbing the heat and transferring it to the water running in them. The tubes are embedded in refractory walls very close (the gap between two tubes is 10mm). The inner diameter of the tube is 63.5mm.

JUSTIFICATION OF THE BOILER TYPE: The type of the boiler is WATER TUBE, NATURAL CIRCULATION, RADIENT SINGLE REHEAT boiler. The meaning of each word has been explained below:

WATER TUBE: tubes.

It means the water runs in the tubes and the fire is outside the

NATURAL CIRCULATION: The CIRCULATION word means how the water is risen in the walls. We know that to rise the water upwards we have to supply some external power e.g. some pump system. But here a law does this work naturally. The saturated water collected at the bottom known as RING HEADER. The water rises from it in riser pipes naturally. There is a TWO PHASE MIXTURE of WATER and STEAM in risers. There is a DIFFERENCE BETWEEN the DENSITIES of the MIXTURE and SATURATED WATER in Ring Header. Also there is a STATIC HEAD. Due to the result of both factors there is NATURAL CIRCULATION operates in boiler. RADIENT TYPE: As the name implies, the heat is transferred from combustion gas to the water walls by RADIATION. The heat is then CODUCTED to water tubes and through the thickness of tubes. Then is CONVECTED to the TWO PHASED MIXTURE.

SINGLE REHEAT :

It implies that the steam is reheated only once. When

the steam goes to HP Turbine, its temperature decreases from 540 deg to 343 deg. It is then send to reheater to increase the temp to again 540 deg.

43

1.10.1 ESSENTIALS OF A GOOD BOILER

1. It should be absolutely reliable and capable of raising maximum amount of steam for minimum fuel consumption, attention, initial cost and maintenance charges. 2. It should be light in weight and should occupy small space. 3. It should be capable of quick starting and meeting rapidly large variation of load demands. 4. The water surface and the tube should be so arranged so as to avoid priming. 5. The tubes should not accumulate soot or water deposits. 6.The refractory material should be as little as possible, but sufficient to secure easy ignition and smokeless combustion of the fuel on reduced load. The boiler site comprises with the following auxiliaries required to run the boiler: COAL BUNKERS The coalbunker is a large hopper containing crushed coal coming from the coal storage plant. Its capacity is 1000MT i.e. it can store the coal of 1000MT. There are six coalbunkers out of which one remains stand by according to the schedule of working of the machine. There is a level indicator for knowing the amount of coal in the bunker. From the bunker, the coal comes into the coal mill through the RC feeder. The RC feeder gives an indication of how much coal is in the coal mill. It has a belt that is being rotated with a motor at a constant known speed. Coal/Bowl Mills There are six coal mills out of which one acts as stand by as according to the schedule of operating a machine. The coal mill is also called the bowl mill, because it contains the bowl. The bowl is rotated with a shaft connecting with an asynchronous 3-phase motor through gearbox. The function of gearbox is to reduce the speed of the motor, because the speed of the motor is 930rpm and it is required to rotate the mill at 500RPM. From the coal mill, the four pipes going
44

outward to the each corners of the boiler. There are total 6*4=24 pipes and each corner of the boiler gets six pipes of coal. The function of coal mill is to grind the coal in the pulverized form. The air pressure from the P.A. fan is taken to blow the pulverized coal in the boiler at its combustion chamber. P.A. Fan P.A.Fan 3-Phase Induction Machine Output Voltage Current Speed Power factor
(Table 1.12)

motor 1250KW 6.6KV 131.A 1493RPM

88.00%

The full form of P.A. fan is primary air fan. It sucks the air from the atmosphere. And force it towards coal mills. The P.A fan produces cold air. This air is passed through air preheated. Here it converts into hot air, called primary air. This air dries the pulverized coal and removes the moisture contents as well. There are two P.A. fans per unit.

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F.D. Fan: F.D.Fan 3-Phase Induction Machine Output Voltage Current Speed motor 750KW 6.6KV 66A 1490RPM
(Table 1.13)

The F.D. fan sucks air from the atmosphere and force it to the boiler. The air firstly passes through the air preheater From here it converts into the secondary air. At the starting of the boiler, F.D fan is on firstly for 10minutes. After this I.D fan and then P.A. fan are on.

There are two F.D. fans per unit. I.D. Fan: I.D.Fan 3-Phase Induction Machine Output Voltage Current Speed
(Table 1.14)

motor 1300KW 6.6KV 131.A 993RPM

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To recover the heat of combustion gases, the flue gas is forced to flow through economizer,superheated,reheater, air preheater etc, This is done by I.D.fan. I.D.fan is on after the F.D. fan for maintaining the pressure below a critical value in the boiler. If I.D. fan is not on, then the air pressure in the boiler may exceed the limit, result in the damage of boiler walls. I.D. Fan extracts the flue gases from the boiler in such a way that flue gases come in contact with superheated, reheater, air preheater and economizer etc, From boiler to chimney, there are hoppers and ESPs to remove the fly ash. There are three I.D. fans, out of which one serves as stand by.

1.10.2 TECHNICAL DESCRIPTION OF BOILER The boiler is a single drum unit with natural circulation, with dry bottom furnace, outdoor type. The boiler is designed to supply steam to the turbo set of 210-mw rating. SUPPORTING STRUTURE, GALLERIES & STAIRCASE The supporting structure serves for arranging and suspending the water wall system, steam super heater, reheater, economizer, air heater, galleries, brickwork and sheet steel casing. The entire steel structure is so designed to permit undisturbed expansion of individual boiler parts and also to avoid any damage to the boiler or brickwork setting due to thermal influences. The supporting structure is designed strong enough with reference to the outdoor design of the boilers. Boilers comprises of following things: Boiler Drum It is made of alloy steel plate of 97mmnominal thickness and has an outside diameter of 1800mm.The boiler drum level is 60mm. Economizer An economizer is a heat exchanger, which raises the temperature of the feed water leaving the H.P. Heaters to about the saturation temperature corresponding to the boiler pressure. The hot flue gases exiting the super-heater at a temperature
47

varying from 370 to 540 degree centigrade do this. The economizer with a heating surface of 4930M2 is made of seamless steel tubular loops. Air preheater The use of air preheater is more economical with pluralized fuel boilers because of temperature of flue gases going out is sufficiently large and high air temperature is always desirable for better combustion. The tubular air heaters having a total heating surface of 21690M2 are made of tubular tubes of outside diameter 40mm. Super-heater The super-heater is a heat exanchanger in which heat is transferred to the saturated steam to increase its temperature. It raises overall cycle efficiency. The steam superheated has a total heating surface of 3782M2. Reheater The use of reheater is same as that of super-heater. The steam reheater having a total heating surface of 3366M2 are made of pendant and horizontal tubular loops. Pulverized coal burner Tilting type pulverized coal burners are arranged in the four corners of the combustion chamber. In each corners there are six blowing pulverized coal primary air mixture into the furnace. The pulverized coal is supplied to the burners through pipes. Auxiliaries for running the boiler: Soot blowers During boiler operation, the heating surfaces become coated with products of combustion i.e. dusts, soot, cinder and fly ash. This phenomenon is especially present in the coal fired water tubes boiler. The effect of these deposits is to reduce the heat transfer. Therefore, for the efficient working of the boiler the regular cleaning of these deposits is very essential. This is achieved by means of soot blower, which use super-heated steam for blowing of the deposits from the external heating surface of boiler, superheated, economizer and air preheater.
48

Fire Guns There are total twelve fire guns. Each corner of the boiler gets one fire gun. There are three floors at which the coal, air and oil are introduced in the combustion chamber of the boiler.The fire gun is also called the oil gun. At AB stage the oil gun has LOP with air and HOP with steam guns. The remaining guns at CD and EF are only LOP with air gun. The function of the oil gun is to ignite the furnace in starting of the boiler.

Deaerator The function of the deaerating header is to remove dissolved noncondensable gases and to heat boiler feed water. A deaerating header consists of a pressure vessel in which water and steam are mixed in a controlled manner. When this occurs water temperature rise, and all non-condensable dissolved gases are liberated. A deaerator header is the watch dog of a boiler as it protects the feed pump piping boilers and any other piece of equipment that is in the boiler feed and return cycle from the effect of corrosive gases that is oxygen and CO 2 to a level where are no longer a corrosion factors.

1.10.3 FURNACE Furnace is the primary part of boiler where the chemical energy available in the fuel is converted to thermal energy by combustion. Furnace is designed for efficient and complete combustion. Major factors inside the furnace, temperature inside the furnace, and turbulence, which causes rapid mixing between fuel and air. Bharat Heavy Electricals limited has developed the modern water-cooled furnace. At the present time water cooled furnaces are supplied on every type and size of boiler. Water cooled furnace has the following advantages: a) In furnace not only combustion but also heat transfer is taking place simultaneously.
49

b) The maintenance work involved in replacing the fire bricks (which is otherwise necessary) is practically eliminated. c) Due to heat transfer in the furnace the fuel gas leaving the furnace is reduced to the acceptable level to the superheating surface. d) Higher heat lading in the furnace is possible as heat transfer is simultaneously removing heat. And have total economy in surfacing. The furnace hopper outlet section is provided with an opening of approx 1100 mm depth, for the fuel width of the furnace. On each side wall, in the furnace hopper area, one water cooled access door (oval in shape of size 406*457 mm is provided. These openings are provided for taking maintenance of the furnace.

1.11 ELECTROSTATIC PRECIPITATOR

(Fig 1.h)

Dust extractions from industrial gases become a necessity for environmental reasons. Most of the plants in India use coal as fuel for generating steam. The exhaust gases contain large amount of smoke and dust, which are being emitted into atmosphere. This poses a real threat to the mankind as a health hazards. Hence it has become necessary to free the exhaust gases from smoke and dust.

50

1.11.1 Need of New Electrostatic Precipitator The electrostatic precipitators installed at GNDTP units are designed to give an emission level of 789 mg/NM3 for a coal having an ash content of not more than 30%. However on actual testing it has been found that emission level from ESPs was about 3.0 mg/M3. The high level of emission is due to the fact that coals burnt in the boiler have much higher ash content than what boilers are designed for. The pollution control board of Punjab Govt. has specified an emission level of 380 mg/M3 from chimney. In order to achieve this new emission level additional ESPs have been installed at GNDTP Bathinda.

1.11.2 Working Principle The Electrostatic precipitator utilizes electrostatic forces to separate the dust particle form the gas to be cleaned. The gas is conducted to a chamber containing Curtains of vertical steel plates. These curtains divide the chamber into a number of parallel gas passages. The frames are linked to each other to form a rigid framework. The entire framework is held in place by four supports insulators, which insulates it electrically from all parts, which are grounded. A high voltage DC is applied between the framework and the ground thereby creating a strong electrical field between the wires in the framework and the steel curtains. The electrical field becomes strongest near the surface of the wire, so strong that an electrical discharges. The Corona discharge is developed along the wires. The gas is ionized in the corona discharge and large quantities of positive and negative ions are formed. The positive wires are immediately attracted towards the negative wires by strength of the field induced. The negative ions however have to travel the entire space between the electrodes to reach the positive curtains. On routes towards the steel curtains the ions collide with each other and get charged and also this charge is transferred to the particles in the gas. The particles thereby become electrically charged and also begin to travel in the same direction as the ions towards the steel curtains. The electrical force on each particle becomes much greater than gravitational force. The speed
51

of migration towards the steel curtains is therefore much greater than the speed of sedimentation in free fall.

(Fig 1.i)

General Description There various parts of the precipitators are divided into two groups: 1. Mechanical system comprising of casing, hoppers, gas distribution system, collecting and emitting systems, rapping mechanism, stairway and galleries. 2. Electrical system comprising of transformer rectifier units with Electronic Controller, Auxiliary Control Panels, Safety Interlocks and Field Equipment Devices.

52

Precipitator Casing The precipitator casing is an all welded pre-fabricated wall and roof panels. The casing is provided with inspection doors for entry into the chamber at each field. The doors are of heavy construction with machined surface to ensure a gas tight seal.

(Fig 1.j)

The roof carries the precipitators internals, insulator housings, transformers etc. The casing rests on roller a support which allows for free thermal expansion of the casing during operating conditions. Galleries and stairway are provided on the sides of the casing in easy access to rapping motors, inspection doors, transformers etc. walkways are provided inside EP between fields for inspection and maintenance. The dust is collected in large quantities on the curtains, the collected electrodes. Due to periodic rapping, the dust falls into the hopper.

53

1) Hoppers The hoppers are sized to hold the ash for 8 hrs. collection. Buffer plates are provided in each hopper to avoid gas leakage. Inspection door is provided on the one side of hoper wall. Thermostatically controlled heating elements are arranged at the bottom portion of the hopper to ensure free flow of ash.

(Fig 1.k)

2) Gas Distribution System The good performance of the precipitators depends on the event distribution of gas over the entire cross-section of the field. As the gas expands ten-fold while entering the precipitator, guide vanes, splitters and screens are provided in the inlet funnel to distribute the flue gas evenly over the entire cross section of the EP. 3) Collecting Electrode system The collecting plates are made of 1.6 mm cold rolled mild steel plate and shaped in piece by roll forming. The collecting plates and shaped in one piece by roll forming. The collecting electrode has unique profile with a special configuration on its longitudinal edges. This profile is designed to give rigidity and to contain the dust in quiescent zone free from re-entertainment; collecting plates are provided with hooks at their top edge for suspension. The hooks engage in slot of the supporting angle. All the collecting plates in arrow are held in position by a shock bar at the bottom. The shock bars are spaced by guides.
54

4)

Emitting Electrode system

The most essential part of precipitators is emitting electrode system. Four insulators support this, the frames for holding the emitting electrodes are located centrally between collecting electrodes curtains. The entire discharge frames are welded to form a rigid box like structure. The emitting electrodes are kept between the frames. 5) Rapping System

Rapping mechanism is provided for collecting and emitting electrodes. Geared motors drive the rapping mechanism. The rapping system employs tumbling hammers, which are mounted on a horizontal shaft. As the shaft rotates slowly the hammers tumble on the shock bar/shock, which transmits blow to the electrodes. One complete revolution of the rapping shaft will clean the entire field. The rapper programmer decided the frequency of rapping. The tumbling hammers disposition and the periodicity of the rapping are selected in such a way that less than 2% of the collecting area is rapped one time. This avoids reentertainment of dust and puffing at the stock outlet.

(Fig 1.L)

The rapping shaft of emitting electrodes system is electrical isolated from the geared motor driven by a shaft insulator. The space around the shaft insulator is continuously heated to avoid condensation.

55

(Fig 1.m)

Following are the Modules for the Outgoing Feeders 1. Hopper heater for each field 2. Support insulator heaters. 3. Shaft insulator heaters. 4. Collecting electrode-rapping motor for each field. 5. Emitting electrode rapping motor for each filed.

1.11.3 ELECTRICAL SYSTEM High Voltage Transformer Rectifier (HVR) with Electronic Controlled (EC) The rectifier supplies the power for as particle charging and collection. The basic function of the EC is to feed the precipitator with maximum power input under constant current regulation should there be any flash between collecting and emitting electrodes, the EC will sense the flash and quickly react by bringing the input period voltage to zero and blocking it for a specific period. After the ionized gases are cleaned and the dielectric strength restored, the control will quickly bring back the power to a present value and raise it to the original nonsparking level. Thus the EC ensure the electrical disturbance within precipitator. Regulated AC power from EC is fed to the primary of the transformer, which is stepped up and rectified to give a full wave power output. The transformer is mounted on roof of the precipitator while the EC is located in an air conditional room.
56

Auxiliary Control Panel (ACP) The ACP houses the power and circuits required for energizing rapping motor and heating elements of the precipitator. ACP controls each gas path. The complete ACP is of modular type with individual module for each feeder. Each module houses the power and control circuit with meters. Push buttons, witches and indicating lamps are mounted on the door of the compartments.

Flue Gas Velocity (Flow) If the flue gas velocity is more than desired, the treatment time in the fields will reduce. It will cause poor performance of EPs. Percentage oxygen on higher side is an indication of excess flow of the flue gases. Efforts should be made to bring percentage oxygen near to 6% at boiler outlet. Proper flue gas flow can be achieved by plugging air leakages into the boiler. The ducts and the EPs and also by regulating primary air and secondary air required for proper combustion in the furnace.

Maximizing the Performance OF ESP The performance of the ESP is influenced by a number of factors many of which may be controllable. It should be the aim of every operator to maximize the performance by judiciously adjusting the controllable variables.

Cleaning Of Electrodes The performance of the ESP depends on the amount of electrical power absorbed by the system. The highest collection efficiency is achieved when maximum possible electric power for a given set of operating conditions is utilized on the fields. Too thick a dust layer on the collecting plates will lead to drop in the effective voltage, which consequently reduces the collection efficiency. It also leads to unstable to unstable operating conditions. Therefore the rapping system of collecting and emitting electrodes should be kept in perfectly working condition. All the rapping motors have been programmed to achieve the optimum efficiency.
57

Spark Rate The operating voltage and current keep changing with operating conditions. The secondary current of HVRs have been set just below the spark level, so that only few sparks occur during an hour. Spark rate between 5 to 10 sparks per minute is the most favorable limit, as per the practical experience. Too high flash over will not only result in reduction in useful power and interruption of precipitation process but will cause snapping of emitting electrodes due to electrical erosion.

How to Control the Spark Rate ? One number s-pot and one number t-pot have been provided on the front of each electronic controller. The s-pot controls the drop rate of rise of field current after the spark is over. The operator can control the rate of spark by adjusting these two pots manually. Both the pots if turned anticlockwise will cause increase in spark rate.

Ash Hopper Evacuation Improper/incomplete hopper evacuation is a major cause for the precipitator malfunction. If the hoppers are not emptied regularly, the dust will build up to the high tension emitting system causing shot circuiting. Also the dust can push the internals up causing misalignment of the electrodes. Though the hoppers have been designed for a storage capacity of 8 hours, under MCR conditions, this provision should be used in case of emergency. Normally, the hopper should not be regarded as storage as storage as storage space for the collected ash.

Oil combustion The combustion of oil used during start up or for stabilization of the flames can have an important impact on precipitator operation. Un burnt oil, if passed into ESP can deposit on the emitting and collecting electrodes and deteriorates the electrical condition i.e. reduce the precipitators operating voltage due to high electrical resistivity and consequently the ESPs performance is affected
58

adversely. The precipitator performance remains poor until the oil vaporizes and the ash layer gets rapped off, which usually takes along time. Air Conditioning of the ESPs Control Room The ESPs control room houses sophisticated electronic controller. The operation of these controllers directly reflects on precipitator performance. In order to ensure that the controllers are in proper working conditions, it is essential to maintain a dust free atmosphere with controlled ambient conditions. Therefore, the air conditioners should be kept in proper working conditions.

GENERAL DISCRIPTION OF ELECTRONIC CONTROLLER The EC-HVR is the High voltage DC power supply equipment for the electrostatic precipitator used for extracting fly ash from the exhaust gases. The equipment is supplied in two parts: 1. The High Voltage Transformer Rectifier (HVR). 2. The Electronic Controller (EC). The transformer rectifier unit (HVR) consists of an oil immersed step up transformer ac reactor, high voltage, high frequency choke, measuring and protection components. The electronic controller (EC) contains the anti parallelconnected thyristors pair for controlling the input voltage to the transformer rectifier unit & necessary control circuit. The complete equipment is designed to provide a continuously adjustable dc output voltage up to 70 KV peak across the precipitator electrode. The controls are arranged i.e. the unit operate as constant current source adjustable up to an average current of 800 mA max. Occurrence of spark at the electrodes is sensed & made to block the output voltage for a specific period & the voltage is built up again in a specified manner to provide optimum operational efficiency of the precipitator. Principle of Operation Controlling the voltage on the primary of the transformer controls the output voltage & current at high voltage DC terminals. The voltage control is achieved by two thyristors connected in anti-parallel configuration. In normal operation, the output of the thyristors is controlled by the gate pulse circuit, which in turn
59

gets its control signal from the current regular output. The output of current regulator adjusts itself i.e. the actual current is maintained equal to set reference value. In case of a spark detection unit detects the same. Wide ranges of adjustment are provided for selecting blocking period & range of S & T control to make equipment suitable to different operating conditions. Persistent low voltage at the primary of transformer or the persistent excess current on primary side that may occur to short-circuiting initiates tripping of equipment.

TECHNICAL DATA OF ELECTROSTATIC PRECIPITATOR Design Conditions Unit-1,3,4 200m3/sec 1450 C 38.9 gms/Nm3 One 2 5

1. Gas flow rate 2. Temperature 3. Dust concentration 4. Number of precipitator 5. Number of gas path per boiler 6. No. of fields in series in each gas pass

(Table 1.15)

COLLECTING ELECTRODE

1. Total No. of collecting plates 2. Nominal height of collecting plate

60

2480 12.5 m

3. Nominal Length of collecting plate

400 mm

(Table 1.16)

EMITTING ELECTRODES

1. Type 2. Size 3. No. of electrodes in each field 4. Plate/Wire spacing.

Spiral

2.7mm 1440 150 mm

(Table 1.17)

RAPPERS FOR COLLECTING ELECTRODES

1. No. & type of rapper 2. Frequency of Rap 3. Drive

One drop hammer per row of collecting electrodes surface area 90 m2 Varying from 12 raps/hr at the inlet field to 1 rap/hr at exist. Geared electric motor controlled by synch. Programmer.

4. Location

At the bottom of collecting system.

(Table 1.18)

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RAPPERS FOR EMMITING ELECTRODES 1.No. and type of rappers Approx. one drop hammers/two rows of electrodes. 2. Frequency of Rap 10 raps/hour.

3. Driver

Geared Electric Motor controlled by Synch. Programmer. On the side of emitting frame

(Table 1.19)

HOPPERS

1. Type

Pyramidal

2 .No of Hoppers

20

3. Capacity

8 hour storage

(Table 1.20)

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MOTORS RAPPING OF EMMITING ELECTODE

1. Quantity

10 Nos.

2. Rating

Geared Motor 0.33hp/2.5 rpm at 3-phase 415 V, 50 Hz

3. Location

On the top EP

(Table 1.21)

RAPPING OF COLLECTING ELECTODE

1. Quantity 2. Rating

10 Nos. Geared Motor, 33hp/2.5 rpm at 3- Phase 415 V 50 Hz.

3. Location On the top EP

(Table 1.22)

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ELECTRICAL ITEM

RECTIFIERS

1. Rectifier Rating

70 KV (peak),800 MA (Mean)

2. Number/Boiler

10

3. Type

Silicon Diode Full Wave, Bridge connection

4. Location

Mounted on the top of precipitator

(Table 1.23)

RECTIFIER CONTROL PANEL

1. Type of Control

Thyristor

2. Location

In the Control Room

(Table 1.24)

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1.12 ASH HANDLING SYSTEM Operation & maintenance features of ash handling system, for the said power station, is being executed by M/S.DC industrial plant services Ltd., (DCIPS), Calcutta. The ash handling system is furnished with necessary in- built facilities and devices for removal of ash. Generated in boiler furnace on combustion of coal, to a distant location. Bottom ash formed in lumps falls down into a water impounded furnace hopper, namely Bottom ash hopper, directly beneath the furnace. The ash is cooled and stored therein and is hydraulically removed in slurry state from the hopper into an in-plant slurry sump followed by further transportation to a remote ash pond. Fly ash which is extremely fine in nature and shares the major amount of the total generation is also carried by the flue gas and is collected, in steps, in economizer hopper, Air heater hoppers, ESP Hoppers and Stack hopper on the flue gas path. Out of the total quantity of fly ash, the major amount is separated from the flue gas in ESP and is collected in corresponding ESP hoppers. The fly ash thus collected in various hoppers is disposed in dry state to silo. The dry disposal is achieved by collecting the ash in dry form in station silos and further unloading it on road trucks for conveying it away for necessary commercial utilization. In the case of wet disposal how ever, the fly ash in the form of slurry is received into the in-plant slurry sump followed by final disposal to remote ash pond. Necessary slurry pumping facilities are in that system for disposal of bottom ash, and fly ash slurry under wet state disposal i.e. slurry disposal from silos) from the in plant slurry sump to remote ash pond. Necessary water supply arrangements through pumps are also induced in the system to cater to water requirement at various consumption points during system operation.

65

(Fig 1.n)

1.12.1 BOTTOM ASH HANDLING SYSTEM Bottom ash, generated in lumps in the boiler furnace for each unit, falls down into respective water impounded and self supported bottom ash hopper installed directly beneath the furnace. The bottom ash hopper so of adequate capacity to provide, effective storage if ash and is continuously supplied with make up water to cool the ash from furnace temperature down to a substantially lower temperature permissible inside the hopper. The bottom ash hopper belongs to a w-type configuration with a common rectangular section at the upper part and two integral V-Section at the lower part of the hopper. Each V-Sections is furnished with two (2) sets of ash discharge equipment consisting of feed gate, double roll clinker grinder, feed sump and jet pump installed one after another in above sequence. Out of two gats of ash discharge equipment for each v Section, one is normally utilized for cleaning of ash and the other stand by. During ash cleaning operation, the bottom ash mixed with water, is allowed to get discharge from the hopper by opening the feed gate. The mixer is further diluted by high-pressure spray water from dilution water by and thick bottom ash slurry in turn is fed directly into the crusher located below the feed gate. Big clinkers of bottom ash are fragmented in the crusher into smaller sizes convenient for pipeline Transportation and are fed into the jet pump. The jet
66

pump is hydraulically operated by means of High pressure water supply and conveys the input ash in the form of slurry to the in plant ash slurry sump. Bottom ash cleaning operation for each unit is carried out at least once in every shift from respective local panel, designated as Bottom Ash System Panel .

1.12.2 FLY ASH SYSTEM Fly ash system utilizes pressure-conveying principal for onward transportation of fly ash from fly ash hopper to station silos. There are two type of ash disposal.

1. Dry Ash Disposal 2. Wet Ash Disposal In Dry Ash Disposal, some of Fly Ash is sent to the cement factory and remaining fly ash is disposed in Wet Ash Disposal way. In Wet Ash Disposal, Fly Ash is mixed with high-pressure water and produce ash slurry is discharge to ash slurry sump and from there to ash pond for disposal. Ash pond has length of 1.5 K.M, Breadth of 500 M and depth of 10M.

NEED OF WET ASH DISPOSAL Since, the hopper capacity is 500 T, and the rate of Fly Ash is 100 T /H .It is difficult to store dry ash because of short capacity of silo.

1.13

TURBO-GENERATOR (T.G.)

The generator is directly coupled to the turbine shaft, converts mechanical energy of turbine shaft into electrical energy. It consists of two electrical windings. One is mounted on the turbine shaft, rotating with it, and is called the rotor. The other is arranged as a shroud around the rotor, fixed to the floor, and is called stator. The relative motion of rotor and stator generates the electricity. The generator, which is hydrogen, cooled produces electricity at 15,750Volt. The T-G is two pole type with cylindrical rotor (Non -Salient Pole type) using direct water cooling of stator winding, including phases connecting bus bar,
67

terminal bushing and direct hydrogen cooling of rotor winding. The stator frame is of pressure resistant and gas tight construction with 4 horizontal coolers in the frame itself forming part of ventilation and closed cooling circuit. GENERATOR CAPABILITY The generator is capable of delivering 247MVA continuously at 15.75KV terminal voltage, 9050 Amps stator current and 3.5Kg/Cm2 hydrogen pressure with cold gas temperature not exceeding 44degrree Celsius and distillate temperature at inlet of stator winding not exceeding 45 degree celicsus. Output of the generator at the various lagging and leading power factors at rated hydrogen pressure are as per the generator capability curve given. Characteristics (O.C.C, S.C.C) and v-curves of the generator are shown on the diagrams. HYDROGEN COOLER: The turbo-generator has been provided with four Nos. gas coolers mounted longitudinally in side stator body for cooling of hot gas, thus taking away the heat looses generated by rotor winding, stator core and wind age losses. The gas cooler is a shell and tube heat exchanger consisting of cooling tubes with coiled copper wire around them to increase the surface area of cooling. Cooling water flows through the tubes while hydrogen flowing across coolers comes into contact with external surface of cooling tubes. Heat removed from hydrogen is dissipated through cooling water. AUXILIARIES SEAL OIL SUPPLY SYSTEM The shaft seals are supplied with seal oil from a separate circuit, which consists to the following principal component Vacuum Tank, AC seal oil pumps 1&2, DC seal oil pump, Vacuum pump, oil coolers, and Seal oil filters, Intermediate oil tank. A vacuum tank pump keeps the seal oil in the vacuum tank under vacuum and largely extracts the gas absorbed by the oil while passing through the hydrogen and air atmospheres. The seal oil is drawn from the vacuum tank and delivered to
68

the shaft seals via a cooler and filter. In the event of a failure of seal oil pump1. Seal oil pump 2. Automatically takes over the seal oil supply. Upon failure of seal oil pump2, the standby DC seal oil pump is automatically takes over the oil supply to the shaft seals. GAS SUPPLY SYSTEM The gas system has the following functions: To provide means for safely putting H2 into or taking it out of the machine. To maintain gas pressure in the machine at the desired value. To indicate to the operator at all tomes the condition of gas in the machine, its pressure and purity. To dry the gas in the machine and remove any water vapour which may get into it from the seal oil. The gas system essentially comprises the following equipments H2 and CO2 cylinders Pressure reducers CO2 vaporizer Gas drier Humidity Monitors Purity measuring instruments. Hydrogen is admitted to the generator through a perforated pipe header extending along the length of the casing at the top. To prevent formation of an explosive mixture in the generator casing during filling and removing the hydrogen. The air or hydrogen in the casing is first removed with carbon dioxide respectively. The latter is introduced through CO2 feed pipe, and the air or hydrogen in the casing is discharged to atmosphere through the hydrogen feed line. The hydrogen driers, services to dry the gas inside the generator.

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1.13.1 STATOR WATER COOLING SYSTEM The water for cooling the stator winding, phase connection and bushing is circulated in a closed circuit. To ensure uninterrupted generator operation 100% capacity pumps sets are provided. In the event of a failure of one pump the standby pump is immediately cut in by automatic starting equipment. The stator water supply system essentially comprise the following components: Expansion Tank Stator Water Pump A&B Stator Water Cooler A&B Stator Water Filter A&B The operating pump draws the water from the expansion tank. The water after passing through water coolers, filters enter the winding and returns back to the expansion tank. 1.13.2 START UP OF GENERATOR Prior to start up, it should be ascertained that the following auxiliaries are in operation and will continue to remain in service. Seal oil system Gas System Stator water system Secondary cooling water system Prior to startup, all the connections should be rechecked. This applies to the piping as well as to cabling. When checking the cabling, special attention should be paid to testing the metering and signal cables. All alarm systems should be checked. All temperature measuring points should also be checked . This applies to the local as well as remote reading thermometers.

70

1.13.3 SHUT DOWN OF GENERATOR When shutting down the generator all excitation should be removed by the time speed reaches to 2000rpm. If this is not done the field winding temperature will rise to lack ventilation since rate of gas circulation is proportional to speed.

1.14 TURBINE FUNCTION OF TURBINE The steam turbine is a prime mover that converts the stored mechanical energy in steam into the rotational mechanical energy. The thermal energy of the steam delivered to the turbine is converted into the kinetic energy of the steam flow through steam nozzles. The function of a steam nozzle is to convert the heat energy of the steam into the kinetic energy. Its chief use is to produce a high velocity jet of steam, which is used to drive a steam turbine. This is achieved by allowing the steam to expand from a region of high pressure at the inlet to a region of low pressure at the outlet. The jets of high velocity steam are then directed on to a ring of blades, which are free to rotate. These moving blades are fixed to the rim of a revolving wheel. Between each row of moving blades, there is a ring of fixed blades. These stationary blades are fixed to the turbine casing and they face the opposite direction to the moving blades. The function of fixed blades is only to receive the steam jet coming out of the moving blade ring and to divert it on to the next ring of moving blades by changing its direction.

GENERAL DESCRIPTION: There are two live steam lines connecting the boiler to the turbine. There are to cold reheat and two hot reheat lines connecting the repeater and the turbine. In each of the two live steam lines, one electrically operated isolating valve, one water separator and one quick closing stop valve are mounted. In each of the cold reheat lines a non-return flap valve, controlled by quick closing oil is provided.
71

Both the hot reheat lines are provided with water separators just before the interceptor valves. 1.14.1 CONSTRUCTION The turbine is a tandem compound machine with HP, IP and LP parts. The HP part is a single-flow cylinder and the IP and LP parts are double flow cylinder. Rigid coupling connects the individual turbine rotors and the generator rotor. Hp Turbine, Barrel Type Casing The outer casing of the HP turbine is of the barrel type and has neither an axial nor a radial flange. The barrel type casing permits flexibility of operation in the form of short start-up times and a high rate of change of load even at high initial steam conditions. IP Turbine The IP parts are of double flow construction. Attached in the axially split outer casing is an inner casing supported cinematically and taking the guide blades. The arrangement of an inner casing confines the high steam inlet conditions to the admission branch of the casing, while the joint of the outer casing is only subjected tom the lower pressure and lower temperature at the exhaust of the inner casing. LP Turbine The casing of the double-flow LP cylinders is of three-shell design. The shells are axially split and of rigid welded construction. The inner shell taking the first rows of guide blades is attached cinematically in the middle shell. BALDING The entire turbine is provided with reaction balding. The moving blades of the HP and IP parts and the front row of the LP part with T-roots and shrouding are milled from the solid. The last stages of the LP part consist of twisted, drop forged moving blades.

72

CONSTRUCTION Three Cylinders reheat condensing turbine 1. Single flow HP turbine wit 25 reaction stages 2. Double flow IP turbines with 20 reaction stages per flow 3. Double flow LP turbines with 8 reaction stages per flow TURBINE SITE CONTAINS THE FOLLOWING MAIN MACHINES: 1. Boiler feed Pump BFP 3-Phase Induction Machine Output Voltage Current Speed Power factor Connection Rotor type Efficiency Weight motor 4000KW 6.6KV 410A 1493RPM 89.00% Star SQ. Cage 96% 19700Kg
(Table 1.25)

The 210MW turbo set is provided with the three boilers feed pumps, each for 100% of the total quantity. This pump feeds feed water to the boiler. This is the largest auxiliary of the unit with 100% capacity which takes suction of feed water from the deaerator and supplies to the boiler drum after preheating the same in the H.P. heaters 1&2 and economizer. The delivery capacity of B.F.P is 445T/Hr.to meet the boiler requirement corresponding t the various load. The following table gives the rating of the motor connecting in the pump.

73

2. Condensate Extraction Pump

CEP Machine Output Voltage Current Speed Power factor Connection Rotor type Efficiency Weight 3-Phase Induction motor 600KW 6.6KV 63.5A 1484RPM 88.00% Star SQ. Cage 94% 5880Kg

(Table 1.26)

The steam after working in three casing of turbine is condensed in the two surface condenser in each unit installed just below the L.P.exhaust. The condensate is collected in the bottom portion of each condenser so to call hot well pumps from where it is pumped up to the deaerator by the condensate extraction pumps through the L.P. heaters. There are two CEP, out of which one remains as stand by. 1.15 SWITCH GEAR The apparatus including its associated auxiliaries employed for switching, controlling and protecting the electrical circuits and equipments is known as switchgear. A tumbler switch, which is an ordinary fuse, is the simplest form of switchgear and is generally used to control and protect the domestic and commercial
74

appliances and equipments. For high rating circuits, a high rupturing capacity (H.R.C.) fuse in conduction with switch may serve the purpose. However, such switchgear cannot be applied on power system operating at high voltages, i.e. more than 11 KV because of the following reasons: 1. When fuse blows, it takes sometime to replace it and consequently there is interruption of power supply. 2. On high voltage system, a fuse cannot successfully interrupt large fault currents. 3. When fault occurs, fault takes sometime to blow. During this time the costly equipments e.g. generators, transformers etc. may be damaged. Therefore in order to protect lines, generators, transformers and other electrical equipments from damage, an automatic protective device or switchgear are required. Automatic protective switchgear mainly consists of the relays and circuit breakers. A circuit breaker is switchgear, which can be open or close the circuit after an operation. Therefore, a circuit breaker is rather preferred even in the instance when a fuse is adequate. Switch It makes and breaks the circuit under full load or no load condition but cannot be operated under fault conditions. It is generally operated manually. Isolator It is only operated under no load conditions. Its main purpose is to isolate a portion of the circuit from the other. Isolators are generally place on the both sides of a circuit breaker from the other in order to make repairs and maintenance on the circuit breaker without any danger. There are two types of isolators: Types of Isolators Single pole Isolator Double pole Isolator Fuses
75

A fuse is short piece of metal, insert in series with the circuit, which melt excessive current flows through it and thus breaks the circuit. The material used for the fuse element should possess the following properties: Low melting point. High conductivity. Free from oxidation. The common materials used for the fuse element are copper, tin-lead alloy (tin 63% and lead 37%, silver, aluminum etc.)A fuse is connected in series with the circuit to be protected and carries the load current without overheating under normal conditions. However when an abnormal condition occurs, excessive current flows through it. This raises the temperature, which melt the fuse element and open the circuit. This protects the machine or apparatus from the damage, which can be used by excessive currents. Circuit Breakers Circuit breaker is on/off switch operating in an electric circuit in normal as well as abnormal operating conditions. While making or breaking contact there is a transition stage of arcing between contacts which is governed by electric discharge between the contacts at instant of separation, thus current continuous in the circuit till discharge appears. The study of this phenomenon is very important for design and operational characteristics of C.B.

1.15.1 Functions of Switchgear Under different conditions CB is subjected to varying stresses as current varies from few amp due to no load current of T/F up to many K amp heaviest short circuit current and varying circuit impedance. CB not only interrupts, but also closes the circuit. If breaker closes during short circuit it causes some trouble because then the voltage break down that bridges the contact gap produces high current arc which melt the contact before closer such situations is not desirable as
76

breaker may not reopen. Often automatic re-closing is required because usually fault is of temporary nature. About 20% of the short circuit current persists however immediately after re-closing the breaker has to re-interrupt the short circuit current. This is main function specially if there are extremely high currents, which would result in the contact wear and tear. The main function, which CB has in addition to satisfy the rated breaking capacity and rated making and breaking times are: Short Circuit interruption. Interruption of small induction currents. Capacitor Switching. Asynchronous Switching. Interruption of Shot Line Faults. Operating Principle of Circuit Breaker A circuit breaker is a device which: Makes or Breaks a circuit either manually or by remote contact under normal (full load) conditions. Breaks a circuit manually or by remote control under abnormal conditions. Breaks a circuit automatically under abnormal conditions i.e. fault conditions. Thus circuit breaker is just a switch, which can be operated under normal and abnormal conditions both manually and automatically. To perform the above operation a circuit breaker essentially consists of fixed and moving contacts, called electrodes. When fault occurs on the power system, the trip coil of the circuit breaker is energized, which pulls apart the moving contacts from the fixed contacts as shown in fig thus opens the circuit. When the moving contacts are separated from the fixed contacts, an arc is struck between them. The production of arc not only delays the current interruption process but also generates enormous heat which may cause damage to the equipments of the

77

power system or the breaker itself. Therefore every effort is made to extinguish the arc produced in the circuit breaker as quickly as possible.

RELAYS Relay is a device that detects the fault mostly in the high voltage circuits and initiates the operation of the circuit breaker to isolate the defective section from the rest of the circuit. Whenever fault occurs on the power system, the relay detects that fault and closes the trip coil circuit. This results in the opening of the circuit breaker, which disconnects the faulty circuit. Thus the relay ensures the safety of the circuit equipment from damage, which the fault may cause.

Switch Gear supplied to G.N.D.T.P. BATHINDA In 6.6/0.415 KV switchgear we have two unit transformer and one station T/f that after stepping down the voltage, fed it to two 6.6 KV unit buses and to station bus. Various feeders are connected to 6.6 KV buses and in order to avoid complete shutdown, supply is maintained by drawing supply from station bus, to 3B & 4B bus. Supply from 3A bus is stepped down to 415 V by 1000 KVA SWGR T/F 1 & fed to 415 V bus. As same in 4B bus. In case of tripping standby bus used. Various feeders are connected to these buses. We generate electricity at 11 KV & step-down to 7 KV by UAT. Rating of UAT T/F is 15 MVA & station T/f is 225 MVA, 11/7 KV.

CIRCUIT BREAKER USED IN INDOOR SWITCHGEAR Mainly two types of CBs are used in switchgear according to the requirement 1. 6.6KV MOCBs 2. 415 V ACBs Minimum Oil CB (6.6 KV)

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It is provided for each motor feeder of rating 6.6 KV and as incoming breaker for 6.6 KV bus. In these CBs arc is quenched in arcing chamber with minimum quantity of oil.

SPECIFICATIONS OF MOCB OF MOTOR FEEDER Rated Voltage Rated current Breaking Current Breaking Capacity Making Capacity Short Time Current Capacity 6.6 KV, 50 Hz, 3-pole 1250 Amperes 34.7 KA (Sym)-378 (Asym) 395 MVA 88 Peaks KA 34.7 KA for 1 Sec

MOCB uses solid material for insulating purposes and use just minimum oil for arc quenching. The arc-interruption device is enclosed in a tank of insulating material, which is a line voltage in normal operation. Thus are also known as live tank breathers. Various protections relay are used in conjunction with MOCBs according to requirement of connected equipment are Over current relay Instantaneous relay Locked rotor relay Unbalanced protection relay Earth fault protection relay Under voltage relay 415V ACBs In these CBs air at atmospheric pressure is used for quenching the arc. Specifications of ACBs Rated Voltage Rated Current Rated Making Capacity
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660 V (AC) 1600 Amperes 95 KA (PEAK)

Rated Breaking Capacity Max. Switching Frequency/hour Opening Time Total Opening Time Included Arcing Time Closing Time

45 KA (rms) 15 make/break open 20msec

30.35 msec 500 msec

This CB is provided with Three Main Protection Trips 1. Thermal Delayed Over Current Trip This consists of three bimetal strips, each headed by a current T/F, which is slid on to the appropriate phase conductor. Tuning the calibrated knob vary the setting. A temp, compensating strip is also used which makes the tripping time largely independent of ambient temperature. 2. Instantaneous Over Current Trip This is fitted in contact assemblies. The U shaped magnet cores with associated armature are mounted on the conductor and energized by breaker current. 3. Under Voltage Trip It open the breaker instantly if the auxiliary as main voltage drop to 50% of the rated coil voltage.

VARIOUS REQUIREMENTS OF CB USED IN S/G a. All the CB should be three-pole and there should be suitable for remote/local electrical operation and manual operation also. b. The CB should be suitable for the operation on 220 V dc auxiliary control supply. c. The CB is required to drive motors and also be suitable for incoming from LT T/F. d. The closing Of CB should be direct motor drive type as stored energy type. e. The CB should be provided with manual closing and tripping device also. f. The CB should also be provided with shunt tripping coil suitable for 220 V. g. CB should have mechanical indication for ON/OFF position.
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h. CB should be provided with the device, which does not allow closed breaker reached in as reached out i. The CBs should be suitable for locking, test & service position & it should also be suitable for electrical/mechanical operation in both testing service position. Bus Bars (6.6 KV/415 V) This term is used for main bar on conductor carrying electric current through which many connections are made for connecting switches and the equipments like bus bar made of Aluminum because it has higher conductivity, corrosion resistant and lower cost as compared to copper Switch Gear 6.6 KV Circuit Breakers Rupturing Capacity Current Rating Switch Gear Circuit Breakers Current Rating 1.16 SWITCH YARD The electricity generated at 11KV by the turbo-generation sets is stepped up by power transformers to132 KV in case of stage-1 and to 220 KV in case of stage-2 for further transmission through 7, 220 KV and 15, 132 KV air blast circuit breakers along with their associated protective systems. The major equipments installed at G.N.D.T.P. sub-stations are: Transformers Circuit Breakers Isolators Bus-Bars Lightening Arrestors Current Transformers Indicating Lamps
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Minimum Oil Type 350 MVA 1250 Amperes 415 V Air Type 0.8Amperes

1.16.1 CLASSIFICATION According to design Sub-Stations are classified as: Indoor Sub-Station It is installed with in the building of the sub-station and hence the named Indoor Sub-Stations. Such s/s are usually designed for 11 KV but can be constructed for 33 KV or 66 KV, if the surrounding atmosphere is containing impurities such as snow, heavy rainfall, dense fog, dust etc, which may damage the equipments. Outdoor Sub-station In this type the apparatus of the s/s is installed in the open and hence the name outdoor s/s. such s/s can be designed to handle low, high, extra high voltage. The outdoor s/s may be further classified as: Pole Mounted S/S Foundation Mounted S/S.

Sub-Station Equipments Following are the important equipments/apparatus employed at sub-stations: Transformers It is static device or machine, which is isolated, input voltage from the output voltage at the same frequency. It is used to step up or step down the voltage. Power Transformers These are provided for stepping up the generation voltage. For units 1 & 2 the

power transformer step up the voltage from 11 KV to 132 KV and for units 3 & 4 the power transformers step up the voltage from 11 KV to 220 KV. All the four transformers have a rated capacity of 125 MVA each.

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(Fig 1.o)

Auto Transformer The auto transformers are used to balance the load between the 132 KV bus bars and the 220 KV bus bars. The auto transformers have a capacity of 100 MVA each.

(Fig 1.p)

Unit Auxiliary Transformer There is one unit of auxiliary transformer provided on each unit to step down the voltage from 11 KV to 6.6 KV which is require for major plant auxiliaries. These transformers have a capacity of 15 MVA each.

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(Fig 1.q)

Station Transformers Two Nos station transformers one for each unit are provided to step down the voltage from 132 KV to 6.6 KV. These transformers have capacity of 22.5 MVA. They serve as the standby source of supply to auxiliaries.

(Fig 1.r)

Circuit Breakers It is device, which makes and breaks the circuit under no load, full load or fault conditions. It can be operated manually under normal conditions and
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automatically under abnormal conditions with the help of relays. These are installed to perform the following duties: To carry full load current continuously. To open and close the circuit on no load. To make and break the normal operating current. To make and break the short circuit current. At G.N.D.T.P. switch yard air blast circuit breakers are employed instead of oil circuit breakers due to following reasons: There is no risk of fire hazard and explosion. Due to less arc energy in it as compared to that in oil circuit breakers burning contact is less.

Axial-Blast Air Circuit Breakers A schematic arrangement of an axial-blast air circuit breaker is as shown in figure. The arcing potions of the fixed and moving contacts are coated with silver tungsten alloy. The moving contacts are coated to a piston and shaft of the contact is guided by guide spring. Opening the lower air valve closes the circuit breaker and under normal conditions the valve remains open. Whenever a fault occurs, the upper valve is opened and the lower valve is closed by the mechanism not shown in figure. Air enters the upper vessel at a high pressure, which separates the moving contacts from the fixed. An arc is struck between the contacts, which is extinguished by the axial blast of cold air and current is interrupted. Once the arc is extinguished, the upper valve is closed and the lower valve is opened to close the circuit. SF6 Circuit Breakers: - Sulpher hexafluoride CB is shown in fig. In this the movable cylinder is coupled with the moving contacts, whereas the piston is fixed. When fault occurs the moving contacts is separated from the fixed contact. Since the movable cylinder is attached with the moving contacts, it moves against the fixed piston. Thus the gas filled in the cylinder is compressed and released through the nozzle as shown in fig.
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The gas moves along the arc and reduces its diameter by axial convection and radial

(Fig 1.s)

dissipation. At zero current, the diameter becomes too small and the arc gets extinguished. The gas is not exhausted to the atmosphere; it is rather again used for arc extinction. Advantages They are smaller in size because of high dielectric strength of SF6 gas. No danger of or explosion. They require minimum maintenance. Since same gas is recycled, a small quantity of SF6 gas is required for long run. They give silent operation; they do not make any sound like A.C.B. during operation. It requires less maintenance. Isolators One of the cardinal measures for ensuring full safety in carrying out work on piece of equipment in electrical installation is to disconnect reliably the unit or section on which the work is to be performed from all other live parts of the
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installation. To guard against mistake it is necessary that an apparatus,

which

make visible break in the circuit, should do this. Such an apparatus is the isolator. Isolators do not have the arc control devices and therefore cannot be used to interrupt current at which an arc will be drawn across the contacts. The open arc that would be drawn in such a case is very dangerous in that it will not only damage or destroy the isolator and the equipments surrounding it, but will also as a rule will cause Flash Over between phases, in other words results is short circuit in the installation. This is why isolators are used only for disconnecting and connecting parts or units after de-energizing them by opening their circuit with respective circuit breakers. It is operated only at no load. These are generally placed on the both the sides of a circuit breaker in order to make repair and maintenance on the circuit breaker without any danger.

(Fig 1.t)

Bus Bars Bus bar is the term used for the main bar of the conductor carrying an electric current to which many connecting switches and other equipments in various arrangements. At G.N.D.T.P. there are 2 Nos of 132 KV bus bars and 220 KV
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bus bars. These bus bars are made up of aluminum. Two number bus couplers connect the 132 KV bus bars and 220 KV bus bars with each other. Lightening Arrestors These are the arc apparatus devices designed to protect insulators of power lines and electrical installations from lightening surges by diverting surge to earth and instantly restoring the circuit insulation to its normal strength with respect to earth. These are connected between earth and line.

(Fig 1.u)

Current Transformer These are the instrument transformers. The secondary winding of the C.T. is connected to the instruments placed on the panel boards. The secondary winding is also connected to various relays for their operations.

(Fig 1.v)

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Insulators Generally suspension and strain insulators are employed at the sub-station. They provide insulation between the conductors and the earth sheet towers. Wave Traps These are used in carrier communication circuits and are mounted on the lines.

(Fig 1.w)

EARTHING Earthing Process of connecting metallic bodies of all the electrical apparatus and equipment to the huge mass of the earth by a wire of negligible resistance is called earthing.When a body is earthed, it is basically connected to the huge mass of earth by a wire having negligible resistance. Thus, the body attains zero potential i.e., potential of earth. This ensures that whenever a live conductor comes in contact with the outer body, the charge is released to the earth immediately. The meaning of the term Earthing or Grounding is to connect the electrical equipment to earth i.e., to connect the apparatus with a water pipe or to an artificial earth electrode through a conductor having negligible resistance. When a body is earthed, it is said to have zero potential and thus will avoid shock to the operator. According to Indian Electricity Rules, the means connection with general mass of earth in such a manner so as to ensure at all times an immediate discharge of energy without danger.
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Chapter No.2
2.Introduction To project Touring and Study of the various plant cells and their respective working (Fig. 2.a) INDUSTRIAL PROJECTS
INDUSTRIES, HOUSEHOLD COMMERCIAL SUPPLIES

MAJOR PROJECTS

MINOR PROJECTS

GENERATION BASED

Designing The Drum Level Controller Software Study Of The Plant Working (UCBS / Cells)

ENVIRONMENTAL STUDY MANAGEMENT

Auto ESP Design For The Air Pollution Control Rain Water Harvesting

(fig 2.a)

Study Of The Management Subjects Such Human Resource And Plant Management. Waste (Coal Ash) Management

2.1 GENERATION/ PRODUCTION BASED PROJECT

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Project Objective: Touring various plant cells To study the various plant sectors and understanding the working of the plant Dm plant and cooling towers Coal plant Boiler and furnace section ESP units Turbine / Generation sector Power distribution sector

2.1.1 Designing the Drum Level Control

To always maintain an optimum water level in the drum (refers to the BOILER DRUM which is used for the generation of high pressure steam in the boiler plant) for the efficient working of the boiler and the turbine section, this in turn results in the effective generation of electricity. The project aims at providing a security cover to the drum if accidentally the critical conditions are met. The project aims at developing: Flow control diagrams Designing the control structure for the drum Visiting the site (installation plans) Identifying design parameters and the ambient conditions

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Drum Level Controller

MAIN STEAM SUPERHEATERS HIGH PRESSURE TURBINE

DRUM SECTION O-LEVEL BOILING WATER COILED WATER PIPES

REHEATERS

MEDIUM PRESSURE TURBINE

REHEATERS

FURNACE ZONE

LOW PRESSURE TURBINE

CONDENSER

CONTROLLER
FEED FLOW

CONDENSER EXTRACTION PUMP

BOILER FEED PUMP

DEAERATOR

(Fig 2.b)

Color Coding

1. 2. 3. 4. 5.

RED GREEN BLUE ORANGE GREY

Control Inputs & Outputs Steam Flow Path Water Flow Furnace/ Coal Firing Zone Turbine Shaft Coupling
(Table 2.1) 92

2.2 ENVIRONMENTAL STUDY BASED PROJECTS

2.2.1 Project Objective: Environmental studies aims at infusing a strong feeling of Love & Concern towards the nature. It teaches the trainee the importance of protecting the environment and urges to implement the eco- friendly methods for the power industry. 1. Coal Waste Management i. Highlighting the problem ii. Working for the Remedial solution 2. Rain Water Harvesting i. Concept ii. Design issues iii. Finding out the potential site for the project implementation. 2.2.2 Waste Management Since the Thermal Plant works on the Coal Consumption for the generation of power electricity, thus the burning of coal leads to the emission of many harmful gases such as carbon dioxide, carbon monoxide, sulphur dioxide and nitrous compounds. The emission of such gases in the atmosphere leads to the air pollution of the adjoining city and the localities. The smoke from the chimney is often accompanied by the fly ash content which is not only harmful for the living beings but is also a poison for the agricultural land nearby.

This waste from the coal burning has always been the major issue for the organization. The plant earlier dumped the fly ash and the slurry (coal ash + water) in the adjoining barren land which resulted in the pollution of the underground water. The land became totally useless and the slurry after drying was carried away by the blowing winds in the nearby surroundings thus polluting both the atmosphere and hampering the agricultural production.
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ESP DESIGN ISSUES

High voltage Supply

Electrostatic Precipitator Flue Gases

Ammonia Dosing

Exhaust Free from Fly Ash

Boiler And Furnace Zone

Waste
Dry Ash And Slurry

(fig 2.c)

2.2.3 Rain Water Harvesting General Introduction: Rain water harvesting is one of the methods of water conservation. The rain water is collected in small pits which are in turn connected with a big water reservoir. So the rain water keeps on accumulating in the reservoir which can be harnessed for any suitable purpose at any instant of time.

Since this belt of Punjab receives very scanty rainfall. Still when it showers, it becomes a major drainage problem. Effort has been taken to club the drainage pipes from the roof-tops to a common collector zone. Thus the rain water is progressively collected in the reservoir for the future use.

2.3 RESOURCE MANAGEMENT BASED PROJECT

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2.3.1 Project Objective: Resource management always plays an important role in the effective working of any organization. This project aims at making the trainee aware of the following:
Human resource management Employee demands Plant employee relationship Resources management (Coal /Fuel management) Safety issues

Coal Management deals with the concept of effective usage of coal. Coal being one of the valuable non- renewable resources must be efficiently used. Now a day coal is not a cheaper commodity, due to limited stock available within the country domain. The coal reservoirs are depleting at a much faster pace due to rapid usage and dependency.

For the efficient use of the coal, the coal is used with the at most care and management. This flow chart depicts the coal chain in the plant. Some of the key factors leading the coal management are stated as:

Key Factors: Certain minimum stock should always be available for efficient working of the plant. Since quality and quantity are closely related, so the amount of the coal required highly depends upon the quality of the coal in use. Low ash content coal is the major demand of any coal based industry.

FLOW CHART ON COAL PROCESSING

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Start

Coal is mechanically unloaded from the rail wagons using tipplers Monitor the status of the coal

Is coal Fine grated?

No

Coal is shifter to the crusher house on magnetic conveyor belt

Yes Fine grated coal is stored in boiler raw coal bunkers Raw coal chain feeder feeds the coal mill Powdered coal is finally stored in the pulverized bunkers Grated coal heap Surplus Coal storage

At last the powdered coal is carried with a stream of hot air to the furnace for ignition

Stop

(Fig 2.d)

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Abstract
Fossil fuel such as coal are concentrated form of energy and produce cheap thermal energy. India being rich in Coal reserves which are predicted to last for 200 years has set up Thermal Plant in most of states. The capital investment and gestation period are less in conducting thermal pants. However the major drawbacks is that these Power Plant generates environmental pollution like Air, Water, Noise and Solid waste but by taking suitable corrective measures the Thermal Plants can be made eco-friendly and efficient. Secondly, it is being noted that all the units are being working automatically by the Engineers through the Control Room Unit that is UCBS. In order to operate the plant one should have the proper knowledge of each unit thoroughly.

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