A Report on In plant Training at

18MW Power House

Of

The Singareni Collieries

Company Limited
RG-1, A.P.

From 06-12-2009 to 22-12-2009

By
CH.RAMAKRISHNA
3rd year B-Tech
R.NO.05611A0227
Electrical & Electronics Engineering
J.N.T.U.H.

INDEX

Sl. No
1
2
3
4
5
6

Topic:

Page
No:

Acknowledgement

Introduction
History
Power Production
process
Description of Individual
key components

2
3
4
9
16

Details of Main Machinery

7
8

Water Flow Chart of P.H

DM Plant Layout

9
10

18
19
20

Layout diagram of power

house

21

Power Generation
Chart

Acknowledgement
I
am
heartily
thankful
to
Sri.
P.V.Satyanandam (AGM PH RG-1), Raja Rao,

Sudhakar Reddy, Laxman Rao whose

encouragement, guidance and support from
the initial to the final level enabled me to
develop an understanding of the subject.
Lastly, I offer my regard to all of those who
supported me in any respect during the
period of my Training.

Introduction
A Thermal Power Station is a power plant in which the prime
mover is steam driven. Water is heated, turns into steam and
spins a steam turbine which drives an electrical generator. After
it passes through the turbine, the steam is condensed in a
condenser and recycled to where it was heated; this is known
as a Rankine cycle. Power plants burning coal, oil, or natural
gas are often referred to collectively as Fossil fuel plants.
Commercial electric utility power stations are most usually
constructed on a very large scale and designed for continuous
operation. Electric power plants typically use three-phase or
individual-phase electrical generators to produce alternating
current (AC) electric power at a frequency of 50 Hz or 60 Hz

Fig1.A Rankine cycle with a two-stage steam turbine and a

single feed water heater.
Here at Ramagundam the Power House is a Coal-fired
Thermal Power Plant with an output of 18 MW utilizing four
Rumanian boilers and a FBC boiler coupled with three
Generators i.e. generating 6 MW each.

History
Coal Production started in Singarani during the year
1889. Till 1910 the production of coal was manually
done with tools like crow bars, axe etc.

During the year 1910, power driven haulers were

introduced. At that time the power was seen in the
Nizams house and Singareni officers houses.
During the year 1924, 1st captive power station under
British administration at Yellandu with 4MW unit was
commissioned by Singareni Collieries Company.
During the year 1965-68 the fifth captive power station
plant of Singareni Collieries Company was started at
Ramagundam with 18 MW capacity.

Coal-fired Thermal Power Station:

Power production process:

Coal is stocked in
the coal yard. Required coal is drawn from the ground level
bunkers to crusher. Coal is conveyed from an external stack
and ground to a very fine powder by large metal spheres in the
pulverized fuel mill. There it is mixed with preheated air driven
by the forced draught fan. The hot air-fuel mixture is forced at
high pressure into the boiler where it rapidly ignites. Water of a
high purity from the dearator flows vertically up the tube-lined
walls of the boiler, where it turns into steam as it passes
through the economizer. The water temperature at economizer
outlet is 250C and from economizer water is passed to the
boiler drum, where steam is separated from any remaining
water & any escaped scale forming salts are traped here due to
chemical feeding in the drum and the trapped salts are let out
through blow downs.
Now the water from the mud drum enters into down comers
then to side water walls where the temperature will rise to
300C. Then the water passes into Bottom drum and finally
enters into super heater zone of boiler where the steam
temperature will be 430C - 450C.
This super heater steam is connected to turbine through
common steam range pipelines. Super heater steam i.e. 430C450C with 40Kg pressure from boiler enters into Turbine
through throttle valve and nozzle plate where it gets converted

into high velocity and drives the turbine rotor. Due to hitting of
steam at higher velocity, the turbine shaft rotates at 3000rpm.
At the entry of steam i.e. H.P side of the turbine blades are of
smaller dia and as the steam travels L.P side the turbine blades
are larger in dia and as the steam travels from H.P side of the
turbine the pressure of the steam comes to -1kg and it gets
condensed. Condensed steam passes into the condenser.
Turbine rotor is in turn connected with Generator rotor.
Generator has internally a number of coils surrounded and
Generator rotor when rotates Electro Magnetic field is
developed and thus emf is induced in the stator windings of the
alternator. The Generator voltage is 11kV 3 phase 50Hz AC.
The 11Kv power generated is stepped up to 33 kV in the
substation and fed to mines through different feeders. However
11/33kV is further stepped down to 3.3KV and power is fed to
colonies.

Bottom of turbine is fitted with Condenser. Internally

condenser is fitted with 4000 admiralty brass tubes of 17mm.
Through these brass tubes cool circulating water of cooling
tower is passed. Surrounding these tubes the condensate
steam from turbine is passed. The steam gets condensed with
the contact of cold water flowing through brass tubes of
circulating water. The condensed steam is extracted through
condensate extraction pumps and sent to dearator. This water
from dearator goes to boilers. At the boiler steam is generated.
Generated steam is fed to turbine. From turbine the steam gets
condensed at the condenser. From condenser the condensed
water again goes to dearator. This is one circulation of water.
The water from D.M plant is fed to dearator only about 23 %
as make up to substitute losses due to leakage, boiler blow
downs, floating of safety valves etc.

Each condenser has two circulating water pumps. The

suction of C.W pumps is connected to cold water channel. The
delivery of C.W pumps is connected to condenser. This cold
water enters into condenser and after heat transmission due to
hot condensate water, the cold water of cooling tower gets
heated and hot condensate gets cooled. The hot water outlet of
condenser is sent to Cooling tower through hot water line.
The hot water at cooling tower is let into hot water channel and
from it through pipes enters into cooling towers. Each pipe is
connected with no of nozzles. The hot water is sprayed through
these nozzles on to the fills; each cell of cooling tower has fans
which when operates, induced draught is created. Air at
<180C enter in opposite direction. Water gets sprinkled and
falls down into the cooling tower basin. Thus hot water gets
contacted with cool air and hot water gets cooled and hot
vapors escapes into the atmosphere. C.T fans suck the cold air
in opposite direction. This cool water from cooing tower basin is
connected to cold water channel. This cool water from cold
water channel enters into condenser. After heat transmission
when it gets heated it is sent to C.T for cooling and thus this
circulating water cycle is of continuous process.

Coal feeding:

Slack coal from mines is the main raw

material required for power house. Coal size fed to Rumanian
boiler is 25mm as these boilers have coal mills, and the coal
fed to F.B.C boiler is 6mm size. Thus the coal of different sizes
i.e. 6mm and above is fed through one conveyor level belt to
top side of the boiler house where coal storage bunkers are
located. The coal is filled in each bunker through coal delivery
trolley at the end of level belt.

Rumanian Boiler:

The steam boiler with 42Kg f/cm2,

450C temperature of the super heated steam, burning
pulverized coal, is a Radiant heat type water tube boiler. A total
of 4 Rumanian boilers are being used.

Coal feeding to Pulverized boilers: From coal bunkers

the boilers are connected by coal feeders. Through coal feeders
the coal enters into coal mills. At coal mills the coal gets
pulverized in to powder form. This coal powder is lifted to
furnace zone of boiler by Force Draft fans. In the Fire zone the

coal powder catches fire and due to this fire the temperature of
the inside of the boiler rises. Consequently temperature raises
and steam is produced. The fire zone of boiler internally is
surrounded by water wall tubes and when this fire gets in
contact with the boiler tubes in which water is flowing, the heat
transmission takes place and due to which the temperature of
water and raises and steam is produced. As Induced Draft fan
induces air, vacuum is created in boiler. After the coal is burnt
the hot flue gases passes through economizer zone and multi
cyclones, Electrostatic precipitator in turn connected to
chimney. The burnt coal ash is trapped in multi cyclones. The
trapped or collected ash is mixed with water and forms ash
slurry which is disposed into ash ponds through open channel
by gravity. The ash water is subjected for settlement at ash
pond. After settlement of ash the water passes through filter
media present at ash pond and the filtered and cleat water
after flowing through ground channel let out to river Godaveri.
Some of the bottom ash collected at coal mills is manually
transported to ash storage area.

Fluidized bed combustion:

has emerged as a
viable alternative and has significant advantages over
conventional firing system and offers multiple benefits
compact boiler design, fuel flexibility, higher combustion
efficiency and reduced emission of noxious pollutants such as
SOx and NOx
When an evenly distributed air or gas is passed up ward
through a finely divided bed of solid particles such as sand
supported on a fine mesh, the particles are undisturbed at low
velocity. As air velocity is gradually increased, a stage is
reached when the individual particles are suspended in the air
stream. Further, increase in velocity gives rise to bubble
formation, vigorous turbulence and rapid mixing and the bed is
said to be fluidized.

If the
sand in a fluidized state is heated to the ignition temperature of
the coal and the coal is injected continuously in to the bed, the
coal will burn rapidly, and the bed attains a uniform
temperature due to effective mixing. Proper air distribution is
vital for maintaining uniform fluidisation across the bed.). Ash is
disposed by dry and wet ash disposal systems.

Coal feeding to FBC Boiler: The size of the coal fed to

FBC boiler is <6mm. from coal bunkers the 6mm coal is fed to
boilers through Pocket feeders. Coal feeders are connected to
boiler compartments where coal is added to the bed material
which is fluidized due to air blown by Primary air fan.

Description of Individual Components:

Steam Generator
In fossil-fueled power plants, steam generator refers to a
furnace that burns the fossil fuel to boil water to generate
steam. In the nuclear plant field, steam generator refers to a
specific type of large heat exchanger used in a pressurized
water reactor (PWR) to thermally connect the primary (reactor
plant) and secondary (steam plant) systems, which of course is
used to generate steam. In a nuclear reactor called a boiling
water reactor (BWR), water is boiled to generate steam directly
in the reactor itself and there are no units called steam
generators. In some industrial settings, there can also be
steam-producing heat exchangers called heat recovery steam
generators (HRSG) which utilize heat from some industrial
process. The steam generating boiler has to produce steam at
the high purity, pressure and temperature required for the
steam turbine that drives the electrical generator. A fossil fuel
steam generator includes an economizer, a steam drum, and
the furnace with its steam generating tubes and superheater
coils. Necessary safety valves are located at suitable points to
avoid excessive boiler pressure. The air and flue gas path
equipment include: forced draft (FD) fan, air preheater (APH),
boiler furnace, induced draft (ID) fan, fly ash collectors
(electrostatic precipitator or baghouse) and the flue gas stack.

Boiler furnace and steam drum:

Once water inside the boiler or steam generator, the process of
adding the latent heat of vaporization or enthalpy is underway.

The boiler transfers energy to the water by the chemical

reaction of burning some type of fuel.
The water enters the boiler through a section in the convection
pass called the economizer. From the economizer it passes to
the steam drum. Once the water enters the steam drum it goes
down the downcomers to the lower inlet waterwall headers.
From the inlet headers the water rises through the waterwalls
and is eventually turned into steam due to the heat being
generated by the burners located on the front and rear
waterwalls (typically). As the water is turned into steam/vapor
in the waterwalls, the steam/vapor once again enters the steam
drum. The steam/vapor is passed through a series of steam and
water separators and then dryers inside the steam drum. The
steam separators and dryers remove water droplets from the
steam and the cycle through the waterwalls is repeated. This
process is known as natural circulation.
The boiler furnace auxiliary equipment includes coal feed
nozzles and igniter guns, soot blowers, water lancing and
observation ports (in the furnace walls) for observation of the
furnace interior. Furnace explosions due to any accumulation of
combustible gases after a trip-out are avoided by flushing out
such gases from the combustion zone before igniting the coal.
The steam drum (as well as the superheater coils and headers)
have air vents and drains needed for initial startup. The steam
drum has internal devices that removes moisture from the wet
steam entering the drum from the steam generating tubes. The
dry steam then flows into the superheater coils.

Superheater:
Fossil fuel power plants can have a superheater and/or reheater
section in the steam generating furnace. Nuclear-powered
steam plants do not have such sections but produce steam at
essentially saturated conditions. In a fossil fuel plant, after the
steam is conditioned by the drying equipment inside the steam
drum, it is piped from the upper drum area into tubes inside an
area of the furnace known as the superheater, which has an
elaborate set up of tubing where the steam vapor picks up
more energy from hot flue gases outside the tubing and its

temperature is now superheated above the saturation

temperature. The superheated steam is then piped through the
main steam lines to the valves before the high pressure
turbine.

Reheater:
Power plant furnaces may have a reheater section containing
tubes heated by hot flue gases outside the tubes. Exhaust
steam from the high pressure turbine is rerouted to go inside
the reheater tubes to pickup more energy to go drive
intermediate or lower pressure turbines. This is what is called
as thermal power.
Fuel preparation system
In coal-fired power stations, the raw feed coal from the coal
storage area is first crushed into small pieces and then
conveyed to the coal feed hoppers at the boilers. The coal is
next pulverized into a very fine powder. The pulverizers may be
ball mills, rotating drum grinders, or other types of grinders.
Some power stations burn fuel oil rather than coal. The oil must
kept warm (above its pour point) in the fuel oil storage tanks to
prevent the oil from congealing and becoming unpumpable.
The oil is usually heated to about 100 C before being pumped
through the furnace fuel oil spray nozzles.
Boilers in some power stations use processed natural gas as
their main fuel. Other power stations may use processed
natural gas as auxiliary fuel in the event that their main fuel
supply (coal or oil) is interrupted. In such cases, separate gas
burners are provided on the boiler furnaces.

Air path:
External fans are provided to give sufficient air for combustion.
The forced draft fan takes air from the atmosphere and, first
warming it in the air preheater for better combustion, injects it
via the air nozzles on the furnace wall.

The induced draft fan assists the FD fan by drawing out

combustible gases from the furnace, maintaining a slightly
negative pressure in the furnace to avoid backfiring through
any opening

Auxiliary systems
Fly ash collection:
Fly ash is captured and removed from the flue gas by
electrostatic precipitators or fabric bag filters (or sometimes
both) located at the outlet of the furnace and before the
induced draft fan. The fly ash is periodically removed from the
collection hoppers below the precipitators or bag filters.
Generally, the fly ash is pneumatically transported to storage
silos for subsequent transport by trucks or railroad cars.

Bottom ash collection and disposal:

At the bottom of the furnace, there is a hopper for collection of
bottom ash. This hopper is always filled with water to quench
the ash and clinkers falling down from the furnace. Some
arrangement is included to crush the clinkers and for conveying
the crushed clinkers and bottom ash to a storage site.asa

Boiler make-up water treatment plant and

storage:
Since there is continuous withdrawal of steam and continuous
return of condensate to the boiler, losses due to blowdown and
leakages have to be made up to maintain a desired water level
in the boiler steam drum. For this, continuous make-up water is
added to the boiler water system. Impurities in the raw water
input to the plant generally consist of calcium and magnesium
salts which impart hardness to the water. Hardness in the
make-up water to the boiler will form deposits on the tube
water surfaces which will lead to overheating and failure of the
tubes. Thus, the salts have to be removed from the water, and
that is done by a water demineralising treatment plant
(DM). A DM plant generally consists of cation, anion, and mixed
bed exchangers. Any ions in the final water from this process

consist essentially of hydrogen ions and hydroxide ions, which

recombine to form pure water. Very pure DM water becomes
highly corrosive once it absorbs oxygen from the atmosphere
because of its very high affinity for oxygen.

Steam turbine-driven electric

generator:
The steam turbine-driven generators have auxiliary systems
enabling them to work satisfactorily and safely. The steam
turbine generator being rotating equipment generally has a
heavy, large diameter shaft. The shaft therefore requires not
only supports but also has to be kept in position while running.
To minimise the frictional resistance to the rotation, the shaft
has a number of bearings. The bearing shells, in which the shaft
rotates, are lined with a low friction material like Babbitt metal.
Oil lubrication is provided to further reduce the friction between
shaft and bearing surface and to limit the heat generated.

Condenser:
The surface condenser is a shell and tube heat exchanger in
which cooling water is circulated through the tubes. [2][6][7][8] The
exhaust steam from the low pressure turbine enters the shell
where it is cooled and converted to condensate (water) by
flowing over the tubes as shown in the adjacent diagram. Such
condensers use steam ejectors or rotary motor-driven
exhausters for continuous removal of air and gases from the
steam side to maintain vacuum.

Fig.Diagram of a typical water-cooled surface condenser.

Deaerator:
A steam generating boiler requires that the boiler feed water
should be devoid of air and other dissolved gases, particularly
corrosive ones, in order to avoid corrosion of the metal.

Fig.Diagram of boiler feed water deaerator (with vertical,

domed aeration section and horizontal water storage section
Generally, power stations use a deaerator to provide for the
removal of air and other dissolved gases from the boiler
feedwater. A deaerator typically includes a vertical, domed
deaeration section mounted on top of a horizontal cylindrical
vessel which serves as the deaerated boiler feedwater storage
tank.

Cooling towers: are heat removal devices used to

transfer process waste heat to the atmosphere. Cooling towers
may either use the evaporation of water to remove process

heat and cool the working fluid to near the wet-bulb air
temperature or rely solely on air to cool the working fluid to
near the dry-bulb air temperature. Here the Cooling tower type
is a induced Draught counter flow type.

Counterflow:
In a counter flow design the air flow is directly opposite to the
water flow (see diagram below). Air flow first enters an open
area beneath the fill media and is then drawn up vertically. The
water is sprayed through pressurized nozzles and flows
downward through the fill, opposite to the air flow.

Details of Main Machinery/Equipments

Installed Capacity = 18 MW
Supplier = Industrial Export, Bucuresti, Rumania
Boiler- Five boilers rated as follows:
Pressure=36Kg/sq.cm(at super heater outlet)

 Working Pressure=42Kg/sq.cm
Temperature=450C
Capacity(pulverized
capacity)

boiler)=24t/hr(max

continuous

Capacity(FBC boiler)=36t/hr
Feed water temperature=100C
Efficiency=80% at max continuous o/p
Coal pulverizing mills-(2 per boiler)
Max. Capacity of mill=3 t/hr
Speed=750 rpm
Electric motor=80kW
Furnace Coal consumption at max. Continuous o/p=4 t/hr
Flue gas temperature at air pre heater outlet=180C
Feed Pumps (5 units, 2 standby),Q =45m3/hr
D.M water pumps(2units, 1 standby),Q=15m3/hr
Turbo Groups Max. Continuous o/p at generator terminals=6 MW
Rated velocity=3000rpm
Live steam temperature at the main valve inlet=435C
Pressure=35Kg/cm2
Max. Live steam consumption at rated parameters=32t/hr
Cooling Water pumps (6 Nos.),Q =1250m3/hr
Generator-

 Apparent power=7500 KVA

Power at terminals=6300KW
Velocity=3000rpm
Phase voltage=11KV
Phase factor Cos =0.8
Phase current=394 A
Frequency=50 Hz
Crusher 75KW, 100 TPH (coal crusher)
Cooling Tower (Axial induced air fan):
Air flow: 130m3/hr
Motor = 28KW
Speed = 1500/750 rpm.

Conclusion:
My training here in the 18 MW power house has given me a lot
of practical experience about how a Thermal power plants
operates the mechanism involved and the real life problems
and challenges faced during its operation and maintenance.
This plant is one of the oldest of its kind and is still functional at
its full capacity and it was a wonderful experience for me to

work here. Im sure the knowledge Ive gained here will be of

great importance in my life.