A

TRAINING REPORT

Submitted in partial fulfillment of the requirement for the Degree of

Bachelor of Engineering
In
DEPARTMENT OF ELECTRONICS AND COMMUNICATION ENGG.
Submitted to
RAJIV GANDHI PROUDYOGIKI VISHWAVIDYLAYA,
BHOPAL (M.P)

SUBMITTED BY

ABHIJEET KUMAR
(0176EC151001)

Under The Guidance

Rajdeep Shrivastava

DEPARTMENT OF ELECTRONICS AND COMMUNICATION ENGINEERING

LAKSHMI NARAIN COLLEGE OF TECHNOLOGY & EXCELLENCE
BHOPAL
SESSION: 2015-19
 Declaration

I ABHIJEET KUMAR, Hereby declare that this training work has been
carried out by me under the guidance & supervision of NTPC, KAHALGAON
This training work is submitted to DEPARTMENT OF ELECTRONICS AND
COMMUNICATION ENGINEERING during the academic year 2015-19.

ABHIJEET KUMAR
(0176EC151001)

PLACE: BHOPAL

DATE: …. /…. /……

 ACKNOWLEDGEMENT

The completion of the vocational training has been possible with

continued & dedicated efforts & guidance of NTPC, KAHALGAON staff
members of Public Work Department. I acknowledge our gratitude to all
of them.

I also express our sincere thanks to NTPC, KAHALGAON guidance of

Training Department for his encouragement & providing all the facilities
in the department. Who helped me directly or indirectly in completion of
the training?

ABHIJEET KUMAR
(0176EC151001)
 CONTENTS

TOPIC PAGE NO.

1. CHAPTER 1 ABOUT N.T.P.C

(NATIONAL THERMAL POWER CORPORATION)
1.1INTRODUCTION
1.2POWER GENERATION
1.3 INSTALLED CAPACITY
1.4NTPC POWER STATIONS IN INDIA
2. ABOUT B.T.P.S
(BADARPUR THERMAL POWER STATION)
2.1 INTRODUCTION
2.2 BASIC POWER PLANT

3. ABOUT PAM
(PLANT AUXILIARY MAINTENANCE DEPARTMENT)
3.1 THEORY OF CIRCULATION OF WATER
3.2 ASH HANDLING PLANT.
3.3 CSP HOUSE
3.4 WATER TREATMENT PLANT
4. ABOUT TMD
(TURBINE MAINTENANCE DEPARTMENT)
4.1 STEAM TURBINE THEORY
4.2 STEAM CYCLE
4.3 TURBINE CLASSIFICATION
4.4 TURBINE CYCLE
4.5 DESCRIPTION OF MAIN TURBINE
4.6 TURBINE AUXILLIARIES AND THEIR ARRANGEMENT
TABLE OF FIQURES
Figure 2-1 BTP 9
Figure 2-2 components of a coal fired thermal plant 11
Figure 2-3 boiler maintenance department 11
Figure 3-1 boiler maintenance department 12
Figure 3-2 Schematic diagram of typical coal-fired power plant steam generator 13
Figure 3-3 furnance 17
Figure 3-4 boiler drum 17
Figure 3-5 super heater 19
Figure 3-6ECONOMIZER 20
Figure 3-7 air preheater 22
Figure 3-8 axial fans 23
Figure 3-9 Centrifugal Fan 24
Figure 3-10 ID FAN LUBE OIL SYSTEM 26
Figure 3-11 FD FAN LUB OIL SYSTEM 27
Figure 3-12 PA FAN LUBE OIL SYSTEM 28
Figure 3-13PULVERIZER 29
Figure 3-14 ELECTROSTATIC PRECIPITATOR
Figure 4-1 boiler circulating system 35
Figure 4-2 NATURAL CIRCULATION SYSTEM 36
Figure 4-3 COMBINED CIRCULATION SYSTEM 37
Figure 4-4 COMPRESSOR HOUSE 39
Figure 4-5 D.M.TANK 43
Figure 4-6 cooling tower 44
Figure 4-7 CROSS-FLOW COOLING 45
Figure 4-8 COUNTER-FLOW COOLING 45
Figure 5-1 STEAM TURBINE 48
Figure 5-2 steam cycle 49
Figure 5-3 impulse and reaction turbine 50
Figure 5-4 VELOCITY COMPOUNDED TURBINE 51
Figure 5-5 curtis stage 52
Figure 5-6 PRESSURE COMPOUNDED TURBINE 53
Figure 5-7 Pressure-Compounded Impulse Turbine 53
Figure 5-8 Three stages of reaction turbine indicating pressure and velocity distribution 54
Figure 5-9 The velocity diagram of reaction blading 55
Figure 5-10 Velocity diagram for maximum efficiency 56
Figure 5-11 Different stage of a steam turbine 57
Figure 5-12 MAIN TURBINE 59
Figure 5-13 TURBINE CYCLE 60
Figure 5-14L.P ROTOR…………………………………………………………………62
Figure 5-15TURBINE BEARINGS 63
Figure 5-16THRUST BEARINGS 63
Figure 5-17 L.P. HEATERS 64
Figure 5-18 Gate Valve 67
Figure 5-19 Regulating Valve 67
Figure 5-20 Non-Return Valve 67
Figure 5-21 Safety Valve 67

LIST OF TABLE
Table 1-1 installed capacity 7
Table 1-2 GAS BASED 7
Table 1-3 COAL BASED: 7
Table 2-1 BTP capacity 9
Table 3-1 Indian Bituminous Coal 14
Table 3-2INDUSTRIAL FANS 26
 CHAPTER 1: ABOUT OF NTPC

1.1 INTRODUCTION

The year 1975 witnessed the birth of an organization that went on to achieve great feats in
performance in a sector that was then, characterized largely by lack of investment, severe supply
shortages and operational practices that mad the commercial viability of the sector unsustainable.
NTPC symbolized hop of the country suffering from crippling power black-outs, the
Government of India, which was trying to pull an ailing, economy back on the track and he
World Bank, which was supporting the country in many development initiatives. Thus, NTPC
was created not only o redraw the power map of India but also excel in is performance and se
benchmarks for others to follow. It succeeded on both counts.
Today with an installed capacity of 39,174 MW, NTPC contributes one fourth of the Nations
Power generation, with only one fifth of India total installed capacity. An ISO 9001:2000
Certified company, it is world world`s 10th largest power generation in the world, 3rd largest in
the Asia. NTPC is #1 independent Power Producer (IPP) IN THE WORLD. Also it is 384th
largest company in he world (FORBES 2011).
It is one of the largest Indian companies in terms of market cap. The corporation recorded a
generation of 222.07 billion unit(BUS) IN 2011-2012; through 16 coal based and 7 gas based
power plant spread all over the country and also has 07 plants in joint venture. Rated as one of
the best company to work for in India, it has developed into a multi-location and multi-fuel
company over the past three decades.
501.8852 billion (US$10.01 billion)(2009–10) Revenue

1.2 POWER GENERATION

Presently, NTPC generates power from Coal and Gas. With an installed capacity of 39,174
MW, NTPC is the largest power generating major in the country. It has also diversified into
hydro power, coal mining, power equipment manufacturing, oil and gas exploration, power
trading and distribution. With an increasing presence in the power value chain, NTPC is well on
its way to becoming an “Integrating Power Major.”

1.3 INSTALLD CAPACITY

 Be it the generating capacity or plant performance or operational efficiency, NTPC’s
Installed Capacity and performance depicts the company’s outstanding performance across a
number of parameters.

Table 1-1 installed capacity

CAPACITY(MW) NO. OF PLANTS N T P C O W N E D
3 0 , 8 5 5 1 6 C O A L
3 , 9 5 5 7 GAS/LIQUID FUEL
3 4 , 8 1 0 23 T O T A L
O W N E D B Y J V s
4 , 3 6 4 7 COAL AND GAS
3 9 , 1 7 4 3 0 T O T A L

1.3 POWER STATIONS IN INDIA

Table 1-2GAS BASED

INST. CAPACITY(MW) S T A T E P R O J E C T SR. NO.
4 1 3 RAJASTAN N T P C A N T A 1 .
6 5 2 U P NTPC AURAIYA 2 .
6 4 5 GUJARAT N T P C K A W A S 3 .
8 1 7 U P N T P C D A D R I 4 .
6 4 8 GUJARAT NTPC JHANOR 5 .
3 5 0 KERALA NTPC KAYAMKULAM 6 .
4 3 0 HARYANA NTPC FARIDABA D 7 .
3 9 5 5 TOTAL

Table 1-3COAL BASED:

INST. CAPACITY S T A T E P R O J E C T SR. NO.
2 0 0 0 UTTARPRADESH SINGRAULI SUPER THERMAL POWER STATION 1 .
2,600 N T P C K O R B A 2 . ,
CHHATTISGARH

2 , 6 0 0 ANDHRA PRADESH N T P C R A M A G U N D A M 3 .
2 , 1 0 0 WEST BENGAL FARAKKA SUPER THERMAL POWER STATION 4 .
3 , 7 6 0 MADHYA PRADESH N T P C V IN D H Y A C H A L 5 .
2 , 5 0 0 UTTAR PRADESH RIHAND THERMAL POWER STATION 6 .
2 . 3 4 0 B I H A R KAHALGAON SUPER THERMAL POWER STATION 7 .
1 , 8 2 0 UTTAR PRADESH N T P C D A D R I 8 .
3 , 0 0 0 O R I S S A NTPC TALCHER KANIHA 9 .
1 , 0 5 0 UTTAR PRADESH FEROZE GANDHI UNCHAHAR THERMAL POWER PLANT 1 0 .
4 6 0 O R I S S A TALCHER THERMAL POWER STATION 1 1 .
1 , 5 0 0 ANDHRA PRADESH SIMHADRI SUPER THERMAL POWER PLANT 1 2 .
4 4 0 UTTAR PRADESH TANDA THERMAL POWER PLANT 1 3 .
7 0 5 D E L H I BADARPUR THERMAL POWER PLANT 1 4 .
2 , 9 8 0 CHHATTISGARH SIPAT THERMAL POWER PLANT 1 5 .
7 5 0 A S S A M NTPC BONGAIGAON (COMMISSIONING 2013 ONWARDS ) 1 6 .
1 , 0 0 0 MAHARASHTRA NTPC MOUDA (1 UNIT 500 MW IS COMMISSIONED IN APRIL 2012 ) 1 7 .
5 0 0 UTTAR PRADESH RIHAND THERMAL POWER STATION (ERECTION PHASE) 1 8 .
3 , 3 0 0 B I H A R NTPC BARH (COMMISSIONING 2013 ONWARDS ) 1 9 .
3 1 ,99 5 TOTAL
 CHAPTER 2: ABOUT BTPS

2.1 INTRODUCTION

The Badarpur Thermal Power Plant has an installed capacity of 705 MW. The main plant
equipment was supplied by M/S. BHEL. The boiler ofStage-1 (3×95)MW units are of
CZECHOSOLOVAKIAN design and thatof 210 MW units are of COMBUSTION
ENGINEERING design. The Turbo-alternators, supplied by M/S BHEL, are of RUSSIAN
design and Control and Instrumentation for Stage-1 (3×95) and Stage-2 units are mostly of
RUSSIAN design and for Stage-3 are of KENT design and supplies by M/S Instrumentation
Ltd., KOTA.

Table 2-1 BTP capacity

STATUS DATE OF COMMISSIONING INT. CAPACITY(MW0 UNIT NUMBER STAGE

Running J u l y , 1 9 7 3 9 5 1 Fi rs t
Running A u g u s t , 1 9 7 4 9 5 2 Fi rs t
Running M a r c h , 1 9 7 5 9 5 3 Fi rs t
Running December, 197 8 2 1 0 4 S econ d
Running December, 198 1 2 1 0 5 S econ d
 Figure 2-1 BTP

2.2 BASIC THERMAL POWER PLANT

In thermal generating plants, fuel is converted into thermal energy to heat water, making steam.
The steam turns an engine (turbine), creating mechanical energy to run a generator. Magnets turn
inside the generator, producing electric energy.
Coal, oil and gas are used to make thermal electricity. They all work basically the same way
(with a few exceptions: for example, in an oil- or gas-fired plant, fuel is piped to the boiler).
1. Coal supply — After haulers drop off the coal, a set of crushers and conveyors prepare
and deliver the coal to the power plant. When the plant needs coal, coal “hoppers” crush
coal to a few inches in size and conveyor belts bring the coal inside.
2. Coal pulveriser —the belts dump coal into a huge bin (pulveriser), which reduces the coal
to a fine powder. Hot air from nearby fans blows the powdered coal into huge furnaces
(boilers).
3. Boiler — The boiler walls are lined with many kilometres of pipe filled with water. As
soon as the coal enters the boiler, it instantly catches fire and burns with high intensity (the
temperatures inside the furnace may climb to 1,300° C). This heat quickly boils the water
inside the pipes, changing it into steam.
4. Precipitators and stack — As the coal burns, it produces emissions (carbon dioxide,
sulphur dioxide and nitrogen oxides) and ash.The gases, together with the lighter ash (fly
ash), are vented from the boiler up the stack. Huge air filters called electrostatic
precipitators remove nearly all the fly ash before it is released into the atmosphere. The
heavier ash (bottom ash) collects in the bottom of the boilers and is removed.
5. Turbine and generator — Meanwhile, steam moves at high speed to the turbines,
massive drums with hundreds of blades turned at an angle, like the blades of a fan. As jets
of high-pressure steam emerge from the pipes, they propel the blades, causing the turbine
to spin rapidly. A metal shaft connects the turbine to a generator. As the turbine turns, it
causes an electro-magnet to turn inside coils of wire in the generator. The spinning magnet
puts electrons in motion inside the wires, creating electricity.
6. Condensers and cooling water system — Next, the steam exits the turbines and passes
over cool tubes in the condenser. The condensers capture the used steam and transform it
back to water. The cooled water is then pumped back to the boiler to repeat the heating
process. At the same time, water is piped from a reservoir or river to keep the condensers
constantly cool. This cooling water, now warm from the heat exchange in the condensers,
is released from the plant.
7. Water purification — To reduce corrosion, plants purify water for use in the boiler tubes.
Wastewater is also treated and pumped out to holding ponds.
8. Ash systems — Ash is removed from the plant and hauled to disposal sites or ash lagoons.
Ash is also sold for use in manufacturing cement.
9. Transformer and transmission lines — transformers increase the voltage of the
electricity generated. Transmission lines then carry the electricity at high voltages from the
plant to substations in cities and towns.

Figure 2-2 components of a coal fired thermal plant

Figure 2-3 boiler maintenance department
 CHAPTER 3 PLANT
AUXILIARY MAINTENANCE DEPARTMENT
3.1 WATER CIRCULATION SYSTEM

THEORY OF CIRCULATION

Water must flow through the heat absorptionsurface of the boiler in order that it is evaporated
into steam. Indrum type units (natural and controlled circulation) the water iscirculated from the
drum through the generating circuits and then back to the drum where the steam is separated and
directed to thesuper heater. The water leaves the drum through the down comersat a temperature
slightly below the saturation temperature. Theflow through the furnace wall is at saturation
temperature. Heatabsorbed in water wall is latent heat of vaporization creating amixture of steam
and water. The ratio of the weight of the water tothe weight of the steam in the mixture leaving
the heat absorptionsurface is called

Figure 4-1boiler circulating system

Types of boiler circulating system:

•Natural circulation system
•Controlled circulation system
•Combines circulation system

NATURAL CIRCULATION SYSTEM

Water delivered to steam generator fromfeed heater is at a temperaturewell below the saturation
valuecorresponding to that pressure. Entering first the economizer it isheated to about 30-
40˚C below saturation temperature. Fromeconomizer the water enters the drum and thus joins the
circulationsystem. Water entering the drum flows through the down comer and enters ring heater at
the bottom. In the water walls a part of thewater is converted to steam and the mixture flows back to
thedrum. In the drum, the steam is separated, and sent to
superheater for super heating and then sent to the high pressure turbine.Remaining water mixes w
ith the incoming water from theeconomizer and the cycle is repeated.The circulation in this case
takes place onthe thermo-siphon principle. The down comers contain relativelycold water
whereas the riser tubes contain a steam water mixture.Circulation takes place at such a rate that
the driving force and thefrictional resistance in water walls are balanced.
As the pressure increases, the difference in density between water and steam reduces. Thus the
hydrostatic head available will not beable to overcome the frictional resistance for a flow
correspondingto the minimum requirement of cooling of water wall tubes.Therefore

Figure 4-2NATURAL CIRCULATION SYSTEM

natural circulation is limited to the boiler with drumoperating pressure around 175 kg/cm².

CONTROLLED CIRCULATION SYSTEM

Beyond 80 kg/cm² of pressure, circulationis to be assisted with mechanical pumps to

overcome the frictionallosses. To regulate the flow through various tubes, orifice platesare used.
This system is applicable in the high sub-critical regions(200 kg/cm²).

COMBINED CIRCULATION SYSTEM

Beyond the critical pressure,

phasetransformation is absent, and hence once through system isadopted. However, it has been found that
even at super critical pressure, it is advantageous to recirculation the water
throughthefurnace tubes and simplifies the start up procedure. A typicaloperating pressure for such a
system is 260 kg/cm².

Figure 4-3COMBINED CIRCULATION SYSTEM

3.2 ASH HANDLING PLANT

The ash produced in the boiler is transportedto ash dump area by means of sluicing type
hydraulic ash handlingsystem, which consists of Bottom ash system, Ash water systemand Ash
slurry system.

Bottom ash system

In the bottom ash system the

ashdischarged from the furnace bottom is collected in two water compounded scraper through installed
below bottom ash hoppers.The ash is continuously transported by means of the scraper
chainconveyoronto the respective clinker grinders which reduce thelump sizes to the required fineness.
The crushed ash from the bottom ash hopper from where the ash slurry is further transportedto operation,
the bottom ash can be discharged directly into thesluice channel through the bifurcating chute bypass the
grinder.The position of the flap gate in the bifurcating chute bypasses thegrinder. The position of the flap
gate in the bifurcating chute is to be manually changed.

Fly ash system

The flushing apparatus are provided under E.P. hoppers, economizer hoppers, air preheaters,
and stack hoppers. The fly ash getsmixed with flushing water and the resulting slurry drops into
theash sluice channel. Low
pressure water is applied through thenozzle directing tangentially to the section of pipe to createturbulenc
e and proper mixing of ash with water. For themaintenance of flushing apparatus plate valve is provided
betweenapparatus and connecting tube.

Ash water system

 High pressure water required for bottom ashhopper quenching nozzles, bottom ash hopper spraying,
clinker grinder sealing scraper bars, cleaning nozzles, bottom ash
hopper seal through flushing, economizer hopper flushing nozzles andsluicing trench jetting nozzles is
tapped from the high pressurewater ring mainly provided in the plant area.Low pressure water required
for bottom ashhopper seal through make up, scraper conveyor make up,
flushingapparatus jetting nozzles for all fly ash hoppers exceptingeconomizer hoppers, is trapped from lo
w pressure water ringsmainly provided in the plant area.

Ash slurry system

Bottom ash and fly ash slurry of the systemis sluiced up to ash pump along the channel with
the acid of high pressure water jets located at suitable intervals along the channel.
Slurry pump suction line consisting of reducing elbow with
drainvalve, reducer and butterfly valve and portion of slurry pumpdelivery line consisting of
butterfly valve, pipe & fitting has also been provided.

3.3 CSPH(CONTROL STRUCTURE PUMP HOUSE)

The control system has following pumps:-

•Chlorine pump-2(for chlorination of water)
•HP pump-6(for boiling of water)
•LP pump-3(for EP pump house)
•Fire pump-(incase of fire breakdown)
•TWS pump-3(for screening of water)
•CRW pump-3(supply water for water treatment)
This house is known as control house because amount of water to be supplied for treatment is
controlled from this house with thehelp of these pumps. Generally 2 CRW pumps out of 3pumpsremains
opensimilarly, 1 F ,2 LP,4 HP,1 TWS pumps remainsopen. If more water is needed then others pumps
are opened.

3.4 COMPRESSOR HOUSE

An air compressor is anything that increases the amount of air that is contained within a
particular space. By packing in the air, the air pressure is increased. This creates a force that is
useful for a variety of purposes, such as industrial, manufacturing, commercial and personal
purposes. Stages
Another way to group air compressors is by the number of stages they have. A two-
stage aircompressor usually is used for heavy-duty use and offers a higher level of compression
than smaller, single-stage air compressors. Two-stage air compressors can store air for future use
and are more energy efficient because they produce more air per unit of horsepower than single-
stage compressors. Also, less heat is generated in a two-stage compressor, which means that
wear on the unit is reduced. Portable electric air compressors also are available for light-duty
applications.

Figure 4-4COMPRESSOR HOUSE

3.5 WATER TREATMENT PLANT

As the types of boiler are not alike their working pressure and operating conditions vary and
so do the typesand methods of water treatment. Water treatment plants used inthermal power plants are
designed to process the raw water to water with very lowin dissolved solids known as
"dematerializedwater". No doubt, this plant has to be engineered very carefullykeeping in view
the type of raw water to the thermal plant, itstreatment costs and overall economics

Actually, the type of demineralization processchosen for a power station depends on three
main factors:
•The quality of the raw water.
•The degree of de-ionization i.e. treated water quality
•Selectivity of resins.
Water treatment process which is generally made up of two sections:
•Pre-treatment section
•Demineralization section

Pre-treatment section
Pretreatment plant removes the suspendedsolids such as clay, silt, organic and inorganic
matter, plants andother microscopic organism. The turbidity may be taken as of twotypes of
suspended solids in water. Firstly,the separable solids and
secondly the non separable solids (colloids). The coarsecomponents, such as sand, silt etc, can be
removed from the water by simple sedimentation. Finer particles however, will not settle inany
reasonable time and must be flocculated to produce the
large particles which are settling able. Long term ability to remainsuspended in water is basically
a function of both size and
specificgravity. The settling rate of the colloidal and finely divided(approximately 001 to 1
micron) suspended matter is so slow thatremoving them from water by plain sedimentation is
tank shavingordinary dimensions is impossible. Settling velocity of finelydivided and collide
particles under gravity also are so small thatordinary sedimentation is not possible. It is
necessary, therefore, touse procedures which agglomerate the small particles into
larger aggregates, which have practical settling velocities. The term"Coagulation" and
"flocculation" have been used indiscriminatelyto describe process of turbidity removal.
"Coagulation" means to bring together the suspended particles. The process describes theeffect
produced by the addition of a chemical Al (SP) g to
acolloidal dispersion resulting in particle destabilization by areduction of force tending to keep
particles apart. Rapid mixing
isimportant at this stage to obtain. Uniform dispersion of thechemical and to increase opportunity
for particles to particlecontact. This operation is done by flash mixer in thec1ariflocculator.
Second stage of formation of settle able
particlesfrom destabilized colloidal sized particles is termed a"flocculation". Here coagulated
particles grow in size by attachingto each other. In contrast to coagulation where the primary
force iselectrostatic or intrinsic, "flocculation" occurs by chemical bridging. Flocculation is
obtained by gentle and prolonged
mixingwhich converts the submicroscopic coagulated particle intodiscrete, visible & suspended
particles. At this stage particles
arelarge enough to settle rapidly under the influence of gravityanomaly be removed
If pre-treatment of the water is not done efficiently thenconsequences are as follows:
•Si02 may escape with water which will increase the anion loading.
•Organic matter may escape which may cause organic
foulingin the anion exchanger beds. In the 'pre-treatment plant chlorine
addition provision is normally made to combat organic contamination.
•Cation loading may unnecessary increase due to addition of Ca (OH)2 in excess of
calculated amount for raising the pH of the water for maximum floe formation and also
AKOrDgmay precipitate out. If less than calculated amount of Ca
(OH)2 is added, proper pH flocculation will not be obtained and silica escape to demineralization
section will occur, thereby increasing load on anion bed.
 CHAPTER 4
. TURBINE MAINTENANCE DEPARTMENT
4.1 STEAM TURBINE THEORY

Figure 5-1STEAM TURBINE

OPERATING PRINCIPLES

A steam turbines two main parts are the cylinder andthe rotor.As the steam passes through
the fixed blades or nozzles itexpands and its velocity increases. The high-velocity jet of
steamstrikes the first set of moving blades. The kinetic energy of thesteam changes into
mechanical energy, causing the shaft to rotate.The steam then enters the next set of fixed blades
and strikes thenext row of moving blades.As the steam flows through the turbine, its pressure
andtemperature decreases, while its volume increases. The decrease in pressure and temperature
occurs as the steam transmits .energy tothe shaft and performs work. After passing through the
last turbinestage, the steam exhausts into the condenser or process steamsystem.
The kinetic energy of the steam changes intomechanical erringly through the impact
(impulse) or reaction of thesteam against the blades.

4.2 STEAM CYCLE

The thermal (steam) power plant uses a dual (vapour +liquid) phase cycle. It is a closed cycle
to enable the working fluid(water) to be used again and again. The cycle used is "RankineCycle"
modified to include super heating of steam, regenerativefeed water heating and reheating of
steam.
On large turbines, it becomes economic to increase
thecycle efficiency by using reheat, which is a way of partiallyovercoming temperature limitatio
ns. By returning partiallyexpanded steam to a reheat, the average temperature at which heatis
added is increased and by expanding this reheated steam to
theremaining stages of the turbine, the exhaust wetness isconsiderably less than it would
otherwise be conversely, if themaximum tolerable wetness is allowed, the initial pressure of
thesteam can be appreciably increased.
 Figure 5-2 steam cycle

4.3 TURBINE CLASSIFICATION

Impulse Turbine:In Impulse Turbine steam expands in fixed nozzles.The high velocity
steam from nozzles does work on moving bladeswhich causes the shaft to rotate. The essential
features of impulseturbine are that all pressure drops occur at nozzles and not on blades.A simple
impulse turbine is not very efficient because it doesnot fully use the velocity of the steam. Many
impulse turbines arevelocity compounded. This means they have two or more sets of moving
blades in each stage.
Reaction Turbine:In this type of turbine pressure is reduced at both
fixed& moving blades. Both fixed& moving blades act as nozzles. Work done by the impulse
effect of steam due to reversals of direction of high velocity steam. The expansion of steam
takes place on moving blades.A reaction turbine uses the "kickback" force of thesteam as it
leaves the moving blades and fixed blades have
thesame shape and act like nozzles. Thus, steam expands, loses pressure and increases in velocity
as it passes through both sets of blades. All reaction turbines are pressure-compounded turbines.
 Figure 5-3 impulse and reaction turbine

COMPOUNDING:

Several problems occur if energy of steam is convertedin single step & so compounding is
done. Following are the typesof compounded turbine:

• VELOCITY COMPOUNDED TURBINE

The velocity-compounded impulse turbine was first proposed by C.G. Curtis to solve the
problems of a single-stage impulse turbine for use with high pressure and temperature steam.
The Curtis stage turbine, as it came to be called, is composed of one stage of nozzles as the
single-stage turbine, followed by two rows of moving blades instead of one. These two rows are
separated by one row of fixed blades attached to the turbine stator, which has the function of
redirecting the steam leaving the first row of moving blades to the second row of moving blades.
A Curtis stage impulse turbine is shown in Fig. 23.1 with schematic pressure and absolute steam-
velocity changes through the stage. In the Curtis stage, the total enthalpy drop and hence
pressure drop occur in the nozzles so that the pressure remains constant in all three rows of
blades.
 F i g u r e 5 - 4 V E L O C I T Y C O M P O U N D E D T U R B I N E

Velocity is absorbed in two stages. In fixed (static) blade passage both pressure and velocity
remain constant. Fixed blades are also called guide vanes. Velocity compounded stage is also
called Curtis stage. The velocity diagram of the velocity-compound Impulse turbine is shown in
Figure
 Figure 5-5curtis stage

The fixed blades are used to guide the outlet steam/gas from the previous stage in such a
manner so as to smooth entry at the next stage is ensured.K, the blade velocity coefficient may
be different in each row of blades

Work done =

End thrust =

The optimum velocity ratio will depend on number of stages and is given by
• Work is not uniformly distributed (1st >2nd)
• The first stage in a large (power plant) turbine is velocity or pressure compounded impulse
stage.

•PRESSURE COMPOUNDED TURBINE

This is basically a no. of single impulse turbines inseries or on the same shaft.The exhaust of
first turbine enters the nozzle of the next turbine.Total pressure drop of steam does not take on
first nozzle ring butdivided equally on all of them.
 Figure 5-6PRESSURE COMPOUNDED TURBINE

To alleviate the problem of high blade velocity in the single-stage impulse turbine, the total
enthalpy drop through the nozzles of that turbine are simply divided up, essentially in an equal
manner, among many single-stage impulse turbines in series. Such a turbine is called
a Rateauturbine , after its inventor. Thus the inlet steam velocities to each stage are essentially
equal and due to a reduced Δh.

Figure 5-7Pressure-Compounded Impulse Turbine

Pressure drop - takes place in more than one row of nozzles and the increase in kinetic
energy after each nozzle is held within limits. Usually convergent nozzles are used

We can write
 where is carry over coefficient

REACTION TURBINE

A reaction turbine, therefore, is one that is constructed of rows of fixed and rows of moving
blades. The fixed blades act as nozzles. The moving blades move as a result of the impulse of
steam received (caused by change in momentum) and also as a result of expansion and
acceleration of the steam relative to them. In other words, they also act as nozzles. The enthalpy
drop per stage of one row fixed and one row moving blades is divided among them, often
equally. Thus a blade with a 50 percent degree of reaction, or a 50 percent reaction stage, is one
in which half the enthalpy drop of the stage occurs in the fixed blades and half in the moving
blades. The pressure drops will not be equal, however. They are greater for the fixed blades and
greater for the high-pressure than the low-pressure stages.The moving blades of a reaction
turbine are easily distinguishable from those of an impulse turbine in that they are not
symmetrical and, because they act partly as nozzles, have a shape similar to that of the fixed
blades, although curved in the opposite direction. The schematic pressure line shows that
pressure continuously drops through all rows of blades, fixed and moving. The absolute steam
velocity changes within each stage as shown and repeats from stage to stage. Figure shows a
typical velocity diagram for the reaction stage.

Figure 5-8Three stages of reaction turbine indicating pressure and velocity distribution
Pressure and enthalpy drop both in the fixed blade or stator and in the moving blade
or Rotor

Degree of Reaction =
 or,
A very widely used design has half degree of reaction or 50% reaction and this is known as
Parson's Turbine. This consists of symmetrical stator and rotor blades.

Figure 5-9The velocity diagram of reaction blading

The velocity triangles are symmetrical and we have

Energy input per stage (unit mass flow per second)

From the inlet velocity triangle we have,

Work done (for unit mass flow per second)

Therefore, the Blade efficiency

 Put then

For the maximum efficiency and we get

from which finally it yields

Figure 5-10Velocity diagram for maximum efficiency

Absolute velocity of the outlet at this stage is axial. In this case, the energy transfer

can be found out by putting the value of in the expression for blade
efficiency

is greater in reaction turbine. Energy input per stage is less, so there are more number of
stages.
Stage Efficiency and Reheat factor
The Thermodynamic effect on the turbine efficiency can be best understood by considering a
number of stages between two stages 1 and 2 as shown in Figure
 F i g u r e 5 - 1 1 D i f f er e n t s t a g e o f a s t e a m t u r b i n e

The total expansion is divided into four stages of the same efficiency and pressure
ratio.

The overall efficiency of expansion is . The actual work during the expansion from 1 to 2
is

or,

Reheat factor (R.F.)=

or,

R.F is 1.03 to 1.04

If remains same for all the stages or is the mean stage efficiency.
 or,

We can see:

This makes the overall efficiency of the turbine greater than the individual stage
efficiency.The effect depicted due to the thermodynamic effect called "reheat". This does not
imply any heat transfer to the stages from outside. It is merely the reappearance of stage losses
an increased enthalpy during the constant pressure heating (or reheating) processes AX, BY, CZ
and D2.

•PRESSURE VELOCITY COMPOUNDED TURBINE

It is just the combination of the two compounding hasthe advantages of allowing bigger
pressure drops in each stage &so fewer stages are necessary. Here for given pressure drop
theturbine will be shorter length but diameter will be increased.

STEAM TURBINES MAY BE CLASSIFIED INTO DIFFERENT CATEGORIESDEP

ENDING ON THEIR CONSTRUCTION, THE PROCESS BY WHICH HEAT DROP IS
ACHIEVED, THE INITIAL AND FINAL CONDITIONS OF STEAM USED AND THEIR
INDUSTRIAL USAGE
.
According to the direction of steam flow
•Axial turbines
•Radial turbines
According to the number of cylinder
•Single - cylinder turbines.
•Double- cylinder turbines.
•Three-Cylinder turbines.
•Four-Cylinder turbines.
•Multi - Cylinder turbines
According to the steam conditions at inlet toturbines
•Low-pressure turbines
•Medium -pressure turbines
•High-pressure
•Turbines of very high pressures
•Turbines of supercritical pressures
According to their usage in industry
•Turbines with constant speed of rotation primarily used for driving alternators.
•Steam turbines with variable speed meant for driving turbo blowers, air circulators, pumps
etc.
•Turbines with variable speed: Turbines of this type are usually
•employed in steamers, ships and railway locomotives (turbolocomotives)

MAIN TURBINE

Figure 5-12MAIN TURBINE

The 210MW turbine is a tandem compounded typemachine comprising of H.P. & I.P.
cylinders. The H.P. turbinecomprises of 12 stages the I.P. turbine has 11 stages & the L.P.
hasfour stages of double flow. The H.P. & I.P. turbine rotor are rigidlycompounded & the I.P. &
the I.P. rotor by lens type semi flexiblecoupling. All the three rotors are aligned on five bearings
of whichthe bearing no.2 is combined with thrust bearing.The main superheated steam branches
off into twostreams from the boiler and passes through the emergency
stopvalve and control valve before entering, the governing wheelchamber of the H.P. turbine.
After expanding in the 12 stages inthe H.P. turbine the steam returned in the boiler for reheating.
The reheated steam from the boiler enter I.P. turbine viainterceptor valves and control valves
and after expanding entersthe L.P. turbine stage via 2 numbers of cross over pipes.In the L.P.
stage the steam expands in axially oppositedirection to counteract the trust and enters the
condenser
placeddirectly below the L.P. turbine. The cooling water flowingthroughout the condenser tubes
condenses the steam and thecondensate collected in the hot well of the condenser.Thecondensate
collected is pumped by means of 3*50% duty condensate pumps through L.P. heaters
todeaerator from where the boiler feed pump delivers the water to boiler through H.P. heaters thu
s forming a closed cycle.

4.4 TURBINE CYCLE

 Fresh steam from boiler is supplied to the turbinethrough the emergency stop valve. From the
stop valves steam issupplied to control valves situated on H.P. cylinders on the front bearing end.
After expansion through 12 stages at the H.P. cylinder steam flows back to boiler for reheating
and reheated steam from
the boiler cover to the intermediate pressure turbine trough twointerceptor valves and four
control valves mounted on the I.P.turbine.After flowing trough I.P. turbine steam enters the
middle part of the L.P. turbine through cross over pipes. In L.P. turbine theexhaust steam
condenses in the surface condensers welded directlyto the exhaust part of L.P. turbine. The
selection of extraction points and cold reheat pressurehas been done with a view to achieve the
highest efficiency. Theseare two extractions from H.P. turbine, four from I.P. turbine andone
from L.P. turbine. Steam at 1.10 to 1.03 g/sq cm Abs issupplied for the gland sealing. Steam for
this purpose is obtainedfrom deaerator through a collection where pressure of steam
isregulated.From the condenser condensate is pumped with the helpof 3*50% capacity
condensate pumps to deaerator through the low pressure regenerative equipments.

Figure 5-13TURBINE CYCLE

Feed water is pumped from deaerator to the boiler through the H.P. heaters by means of 3*50%
capacity feed pumpsconnected before the H.P. heaters.
 4.5 DESCRIPTION OF MAIN TURBINE

SPECIFICATION:
TURBINE MAIN DATA
Rated Power 210MW
Rated Speed 3000 rpmRated Steam(Pressure) before ESV 130 Kg`/cm2abs
Rated Steam Temp. Before ESV 5350C
Rated Steam pressure Before IV 27 Kg/cm2Abs
RatedSteam temp. Before IV 5350C
Rated Steam Flow 670 T/Hr
HPT Exhaust Pressure 27 Kg/cm2
HPT Exhaust Temperature 3270C
Rated circulating water quantity 27000 m3
through condenser
Condenser back pressure 0.09 Kg/cm2
Critical Speed 1585,1881,2017&2489
Rated condenser cooling water inlet 240C to 330C
Temperature
Rated condenser cooling water 1.0 to 1 Kg/cm2
PressureType of governing Hydro mechanicalNozzle type
governingType of turbine condensing, tandem compoundThree cylinder,
HorizontalNos. of bearing 5 Nos.( for turbine side only &HPC front bearingis combined thrust &
journal bearingBarring gear 3.4rpm, ac motor of 30kw, 730rpm, 50c/s,415v, 220:1
RatioLocation of anchor point of At the middle foundation frame of frontthe turbine exhaust part
of the L.P. Cylinder

CONSTRUCTIONAL DETAILS:
H.P. CYLINDER: 12 stages (1stis governing stage) each stageConsists of a diaphragm &a set
of movingBlades connected on a disc.
BODY: In two valves made of Creep Resistance(Cr-Mo-V) steel
STUDS & NUTS: High Creep Resistance (Cr-Mo-V) steelForgings
NOZZLE & STEAM CHEST:4 Nos (2 on Top & 2 on sides) madeof High Creep resisting
(Cr-Mo-V)Steel casting
I .P. CYLINDER: 11 stages
BODY:2 parts (a ) Pressure part made of Creep Resisting (Cr-Mo-V) steel

MAIN COMPONENTS OF TURBINE:

EMERGENCY STOP VALVE
Steam from the boiler is supplied to the turbine throughtwo emergency stop valves. The
emergency stop valve operated byhydraulic servomotor shuts off steam supply to the turbine
whenthe turbo set is tripped. The emergency stop valves connected
tothe four control valves through four flexible loop pipes of Chromium-Molybdenum-Vanadium
steel.
 H.P. CYLINDER
It is made of creep resisting Cr-Mo-V steel castingmade of two halves joined at the
horizontal plane.
The horizontal joint is secured with the help of studsand nuts made of high creep resisting
Cr-Mo-V steel forgings.
Toensure H.P. tightness the studs are tightened by heat to a predetermined temperature with the
help of electric heater.
H.P. ROTOR

The H.P. rotor has discs integrally forged with the shaftsand is mechanical forming single Cr-
Mo-V steel forging. A special process to prevent abnormal rotor deflection thermally
stabilizesthe rotor forging.

➢ L.P. ROTOR
It consists of shrunk fit discs on a shaft. The shaft is aforging of Cr-Mo-V steelwhile the discs
are of high strength Nisteel forging.The H.P. rotor is connected by rigid couplings whole the I.P
rotor and L.P. rotor are connected by semi-flexible lens typecoupling. The rotors are dynamically
balanced to a very precisedegree.
 Figure 5-14 L.P. ROTOR

➢ TURBINE BEARINGS
The three turbine rotors are supported on fine bearings.The second bearing from pedestal
side is a combined radial thrust bearing while all others are journal bearings.

Figure 5-15TURBINE BEARINGS

➢ THRUST BEARINGS
 It is Mitchell type with bearing surface distributed over a number of bearing surfaces. They
are pivoted in housing on theside of I.P. rotor thrust collar.During operation on oil film is forced
between padsand thrust collar and there is a no metal-to-metal contact. A secondring of pads on
opposite side of thrust collar takes the axial thrustas may occur under abnormal conditions.

Figure 5-16THRUST BEARINGS

➢ L.P. HEATERS
Turbine is provided with non-controlled
extractionswhichare utilized for heating the condensate from turbine bleedingsystem. There are f
our L.P. heaters. They are equipped withnecessary safety valves in steam space level indicator
for visual
Mauges are present for measurement of steam pressure.
 Figure 5-17L.P. HEATERS

➢ GLAND STEAM COOLER

Gland steam cooler has been provided to suck and coolthe air steam mixture from the gland
seats. It employs a smallejector for which the working medium is steam of low parameters,which
can be taken either from the deaerator or auxiliary source.The pressure and temperature of this
steam should of this steam isretrieved to the fullest possible extent as the gland steam cooler
isalso interposed in the condensate heating cycle thereby
improvingoverall efficiency of the cycle.

➢ CONDENSATE PUMPS

The function of these pumps is to pumps out thecondensate to the desecrator through
ejectors, gland steam cooler,and L.P. heaters. These pumps have four stages and since thesuction
is at a negative pressure, special arrangements
havebeenmade for providing sealing. This pump is rated generally for 160m3 hr. at a pressure
13.2 Kg/cm2.

Feed Water System

The main equipments coming under this system are:

 •Boiler Feed Pump: Three per unit of 50% capacity eachlocated in the '0' meter level in the TG
bay.
•High Pressure Heaters: Normally three in number and aresituated in the TG bay.
•Drip Pumps: Generally two in number of 100% capacity eachsituated beneath the LP heaters.
•Turbine Lubricating Oil System: This consists of Main OilPump (MOP) Starting Oil Pump
(SOP), AC standby oil pumpsand emergency DC' oil pump and Jacking Oil Pump (JOP) (oneeach per
unit).

BOILER FEED PUMPS

Boiler feed pump is used to feed water to steam generator boiler drum at desired pressure and
temperature. Boiler feed pump extract water from de-aerator and feed it to the boiler drum via
H.P heaters and economizer. It works with the steam extraction from Intermediate Pressure (I.P.)
turbine exhaust
This pump is horizontal and of barrel design driven byan Electric motor through a hydraulic
coupling. All the bearings of pump and motor are forced lubricated by a suitable oil
lubricatingsystem with adequate protection to trip the pump if the lubricationoil pressure falls
below a preset value.The high-pressure boiler feed pump is very
expensivemachine which calls for a very careful operation and skilledmaintenance. The safety in
operation and efficiency of the feed pump depends largely on the reliable operation and
maintenance.Operating staff must be able to find out the causes of defect at thevery beginning which can
be easily removed without endangeringtheoperator of the power plant and also without the
expensivedismantling of the high pressure feed pump.The feed pump consists of pump barrel,
into which ismounted the inside stator together with rotor. The hydraulic part
isenclosed by the high pressure cover along with the balancingdevice. The suction side of the barrel and
the space in the high pressure cover behind the balancing device are enclosed by the low pressure covers
along with the stuffing box casings. The
bracketsof the radial bearing of the suction side and radial and thrust bearing of the discharge side are
fixed to the low pressure covers.The entire pumps are mounted on a foundation frame. Thehydraulic
coupling and two claws coupling with coupling guardsare also delivered along with the pump. Water
cooling and oillubricating are provided with their accessories.

TURBINE DRIVEN BOILER FEED PUMP

The single cylinder turbine is of the axial flow type.The live steam flows through the emergency
stop valve and thenthrough the main Control Valves 5 nos. (Nozzle governing). Thesevalves
regulate the steam supply through the turbine in accordancewith load requirements. The control
valves are cylinder mounted on the turbine casing.The journal bearings supporting the turbine
shaft arearranged in the two bearing blocks. The front end -bearing block also houses the thrust
bearing, which locates the turbine shaft andtakes up "the axial forces”.There are 14 stages of
reaction balding. The actuated by a lift bar which is raised or lowered via a lever system by the
relay balancing piston is provided at the. Steam admission side to compensate theaxial thrust to
the maximum extent. Since the axial thrust varieswith the load, the residual thrust is taken up by
the thrust bearing.The leak off from the balancing piston is connected back to theturbine after 9th
stage.The turbine is provided with hydraulic andelectro-hydraulic governing system. A primary
oil pump is used asa speed sensor for hydraulic governing and shall Probes are used asa speed
sensor for electro hydraulic governing.Whenever steam is drawn from the cold reheat line
or auxiliary supply, steam flow is controlled by auxiliary controlvalve. During this period the
main control valves (4 nos.) willremain fully opened and the bypass valve across it will
remainclosed. (Bypass remains closed fora short period when change,over from IP steam to CRH
takes place).The steam exhaust for the BFP- Turbine is connected tothe main condenser and the
turbine glands are sealed by glandsteam.

HIGH PRESSURE HEATERS

These are regenerative feed water heaters operating

athigh pressure and located by the side of turbine. These aregenerally vertical type and turbine bleed
steam pipes are connectedto them.HP heaters are connected in series on feed watersideand by such
arrangement, the feed water, after feed pump entersthe HP heaters. The steam is supplied to these heaters
form the bleed point of the turbine through motor operated valves.Theseheaters have a group bypass
protection on the feed waterside.In the event f tube rupture in any of the HPH and the level of
thecondensate rising to dangerous level, the group protection
devicediverts automatically the feed water directly to boiler, thus bypassing all the 3 H.P. heaters.
Following fittings are generally provided on the HP heaters
•Gauge glass for indicating the drain level.
•Pressure gauge with three way cock.
•Air Vent cock.
•Safety valve shell side.
•Seal pot.
•Isolating valves.
•High level alarm switch.

SPEED GOVERNOR

It is directly coupled to the turbine rotor

throughcoupling and has been designed to maintain automatically thespeed of the turbo set. It
is located with the front pedestals.

LOAD LIMITER

Turbine is equipped with the load limiter used in specialcases to limit the opening of valves
by speed governor.

PURPOSE:

To limit the load rising beyond the set point, can bevaried over the entire load range.
TURBINE OIL LUBRICATING SYSTEM
 This consists of main oil pump, starting oil pump emergencyD.C. oil pump and each per unit.

5.1TYPES OF VALVES USED AND MAINTAINED IN TMD

Figure 5-18Gate Valve

Figure 5-19Regulating Valve

Figure 5-20Non-Return Valve

Figure 5-21Safety Valve
Valves are made of cast iron, cast steel, carbon steel,alloy steel.
● Cast iron valves: 0-150 0C temperature (used for water lines).
● Carbon steel valves: 150-4250C temperature (used for water/steam lines).
● Alloy steel valves: 425-5350C (used for steam lines)