Beruflich Dokumente
Kultur Dokumente
(18-06-2015 TO 11-07-2015)
ACKNOWLEDGEMENT
The Training opportunity I had with KOLAGHAT THERMAL POWER PLANT
(WBPDCL) was a great chance for learning and professional development.
Therefore, I consider myself as a very lucky individual as I was provided
with an opportunity to be a part of it. I am also grateful for having a
chance to meet so many wonderful people and professionals who led me
though this internship period. Bearing in mind previous I am using this
opportunity to express my deepest gratitude and special thanks to the GM
of KTPS MR. TAPAS KUMAR PATRA who in spite of being extraordinarily
busy with her/his duties, took time out to hear, guide and keep me on the
correct path and allowing me to carry out my project at their esteemed
organization and extending during the training. I express my deepest
thanks to Mrs Susmita Basak, HR manager KTPS for taking part in useful
decision & giving necessary advices and guidance and arranged all
facilities to make life easier. I choose this moment to acknowledge his/her
contribution gratefully. I will also thank my teammates Madhumainty
,Debtanu, Aindrila, Lucy ,Moumita for their support in this whole training.
CONTENT
1. INTRODUCTION OF A THERMAL POWER PLANT
1.1
1.2
1.3
1.4
1.5
1.6
1.7
PAGE NO
2. BOILERS
3.1 Definition of boiler
3.1.1 Function
3.1.2 Working
3.1.3 Quality
3.2 Types of boiler
3.3 Boiler systems
3.4 working of water tube boiler in tps
3.5 Boiler drum
3.6 Steam flow
2
3. STEAM TURBINE
3.1 Definition of steam turbine
3.2 Type of steam flow
3.3 Type of steam turbine
3.4 Cylinder arrangement in steam turbine
3.5 Turbine losses
3.6 General layout of a steam turbine in a power plant
3.7
Steam turbine Equipment & Related Auxiliaries
3.7.1 Turbine rotor
3.7.2 Turbine Casing
3.7.3 Turbine coupling
3.7.4 Turbine bearings
3.7.5 Turbine sealing system
3.8 Turbine supervisory instrument& system control
3.9 Turbine governing system
4. CONDENSER
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
Definition of condenser
Working of a condenser
Condenser in power cycle
Condenser associative equipment
Condenser tube cleaning
Water usages in thermal power plant
A brief idea of a CW system
Cooling water and ACW System
HANDLING PLANT
1.3
UNIT NO
INSTALLED
DATE OF
CAPACITY(MW
COMMISSIONIN
210
SEPT-1990
5
STATUS
OP
located in river Rupnarayan. There is also a acw pump for machine cooling
of 2500
/hr capacity
Advantages: 1) Economical for low initial cost other than any generating
plant.
2) Land required less than hydro power plant.
3) Since coal is main fuel & its cost is quite cheap than petrol/diesel so
generation cost is economical.
4) There are easier maintenance.
5) Thermal power plant can be installed in any location where
transportation & bulk of water are available.
3. BOILER:
3.1 Definition of Boiler: Boiler is a closed vessel in which
the under pressure is transformed into steam by the application of heat.
3.1.1 FUNCTION: The function of Boiler is to transfer the heat
to the water in the efficient manner .
3.1.2 WORKING: The chemical energy converted into the
heat energy by the combustion process is absorbed by the boiler.
3.1.3 QUALITY: A boiler must be designed to absorbed the
maximum amount of heat release in the process combustion.
3.2. TYPES OF BOILER:
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3.5. BOILER DRUM & FURNACE: The boiler enclosures are in two parts,
the furnace or radiant zone and the rear pass or convection zone. The four
sides of the furnace have membrane type water cooled walls. A division
wall is provided on the centre line of the furnace extending the full depth
expect for gaps between division wall tubes & front/rear walls and in the
centre.
The single drum at the bottom and three drums on the top were
connected through a network of tubes which were welded to the drums
above and the single drum below. The rational demand of steam in terms
of capacity, pressure and temperature resulted in bi drums and single
drum boilers.
The separated steam is drawn out from the top section of the drum and
distributed for process. Further heating of the saturated steam will make
superheated steam normally used to drive a steam turbine. Saturated
steam is drawn off the top of the drum and re-enters the furnace in
through a super heater. The steam and water mixture enters the steam
drum through riser tubes; drum internals consisting of demister separate
the water droplets from the steam producing dry steam. The saturated
water at the bottom of the steam drum flows down through the down
comer pipe, normally unheated, to headers and water drum. Its
accessories include a safety valve, water-level indicator and level
controller. Feed-water of boiler is also fed to the steam drum through a
feed pipe extending inside the drum, along the length of the steam drum.
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3.8 WATER TUBES : These are also essential for Feed Water and Steam
Circuit of Boiler Water tubes are bent or straight hollow tubes through
which steam water mixture circulates. There are two types of water tubes,
viz. down-comer and riser. This down comer, riser assembly is also known
as Evaporator (or boiler proper). In the evaporator actual state change
from water to steam occurs. In the T-S diagram beside, the zone of
evaporator is illustrated. Qeva is the heat absorbed by evaporator. It is
mainly the latent heat of vaporization of water.
Down-comers are the water tubes through which water comes down from
steam drum to mud drum (see fig.). No vapour bubble should flow along
with saturated water from the drum to the down comers. This will reduce
the density difference and the pressure head for natural circulation.
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350
Primary
superhete
Platron
superheat
er
450
Final
superheater
540
3.9 REHEATER: After expanding through the high pressure turbine the
exhaust steam is returned to the boiler at 360C and 42 bar pressure for
reheating before being used in the intermediate pressure turbine.
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DEARATOR: The lower portion of dearator acts a surge vessel for the
boiler fed pump . The working part of deaerator is the smallest vertical
section on top of the surge vessel.
This particular temp corresponds to the boiling point of water. Then it can
be said deacontrols pressure.
4. STEAM TURBINE:
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blade=
2 UVw
V 12
& stage=
U Vw
H
eff=blade* stage
Reaction Turbine: In the reaction turbine, the rotor blades themselves are
arranged to form convergent nozzles. This type of turbine makes use of
the reaction force produced as the steam accelerates through the nozzles
formed by the rotor. Steam is directed onto the rotor by the fixed vanes of
the stator. It leaves the stator as a jet that fills the entire circumference of
19
Figure 1
Figure 2
Basically the second arrangement is quite useful for the TPS and
in KTPS also they used such a kind of arrangement for
generation.
4.4 TURBINE LOSSES:
1.ADMISSION LOSSES :i n practice the flow of steam through nozzle is
not isentropic, but accompanied with losses which decrease the kinetic
energy of steam coming out of the nozzle.
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21
4.7.3 TURBINE BLADES: Turbine blades are of two basic types, blades and
nozzles. Blades move entirely due to the impact of steam on them and
their profiles do not converge. This results in a steam velocity drop and
essentially no pressure drop as steam moves through the blades. A
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STEAM CONTROL:
MAIN STEAM STOP VALVE: The Main steam stop valve is located in the
main steam piping between the boiler and the outlet piping to turbine
casing the main stop valve has one inlet and two identical outlet pipe
connections.
The primary work function of main steam stop valve is to quickly shut off
the steam flow.
THE CONTROL VALVE : the control valve are arranged into an upper and
lower valve group with each mounted on common chest which is an
integral part of the upper and lower turbine outer shells .
CV admits steam from value chest of its group to individual nozzle box.
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5. CONDENSER:
5.1 Definition of condenser:
Steam condenser is a device in which
the exhaust steam from steam turbine is condensed by means of
cooling water. The main purpose of a steam condenser in turbine is to
maintain a low back pressure on the exhaust side of the steam turbine.
After releasing from nozzles, the steam has to expand to a great extent
for converting available energy into it to usable mechanical work. So, if
the steam after doing its, work, does not get condensed, it will not give
required space to other steam behind it, to expand to its required
volume.
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5.6 A BRIEF IDEA OF CW SYSTEM: At full load operation of the unit ,about
480 T/hr of steam is exhausted into two surface condenser . About
27000T/hr of cooling water is required for condensing this exhaust steam .
The cooling water is required for condensing this exhaust steam . the
cooling water is supplied by three nos of 33% capacity vertical mixed flow
pump of 9000T/hr. capacity each .
18 nos of circulating pumps of all six units are located in the common C.W
pump House and take suction from the common C.W basin . Each C.W
pump is provided with separate suction from the common C.W basin .
Each c.w pump is provided with separate suction bay with isolating gate .
All the pump discharge into the common 2.2 m dia C.W header supplying
to to the twin condenser. the normal inlet and outlet of the condenser. The
normal inlet and outlet of the condenser are through the bottom and top
respectively. In inlet and out let there are motor operated butterfly valves.
The hot water outlet from the condenser, discharging into 2.2 m dia . Pipe
taken to cooling water tower provided for each unit of 32000 T/h
capacities. The cooling tower is induced draft, cross flow type consisting of
8 nos cells. The water enter the distributing header at tower top ,flows
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the heat exchanger and the water used here is basically DM water.
6. COAL HANDLING PLANT :
6.1 DEFINATION OF COAL HANDLING PLANT: CHP (C- Coal, H- Handling, PPlant)
This properly handles the coal from its receipt to transferring it to bunkers.
OBJECTIVE OF COAL HANDLING PLANT:
1. To supply the quanta of processed coal to bunkers of Coal mills for
Boiler operation.
2. To stack the coal to coal yard.
6.2 GENERAL LAYOUT OF CHP:
1.roadway
2.railway
3.ropeway
WAGON TIPPLERS: wagon tipplers are basically two types described
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R a k
e
s h u
n ti
n g
fo r
p la
ce
m e A i
n t
r
a t
R e
T /H
le
,
W T a s
M E
C H
E D
A /
K O
L A
G H
AT
S ta
t io
n
S e
L o a
cu
d
r
it
P la
ce
y
m e G a
n t
te
b y
R a il
w a
y
A t
K T P
S
Ya r
d
K T P S
E n g in e
a tta c h m e
n t
35
3. RECLAIMING PROCESS: the crushed coal from the stock pile can also be
reclaimed through the hoppers over the conveyor -7A,7B,7C and 7D .
these hoppers are equipped with rack and pinion gates. Coal from yard -2
is fed in the hoppers of vibrators No-17, 18,19,20,21,22,23,24 by dozer. In
the same way dozer feeding is done from yard no-3.
A basic cycle for reclaiming process:
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.
5.Metal detector: This will detect the presence of any ferrous and
non-ferrous metal in the coal and sends a singnal to a relay which closes
to seize the movement of belt until the metal is removed . It basically
consists of a transmitter and receiver.
6. Belt weightier: it is used to keep account of the tension on the belt
carryimg coal and is moves accordingly to release tension on the belt.
7. Reclaim Hoppers: Reclamation is a process of taking coal from the
dead storage for preparation or fur their feeding to reclaiming hoppers.
This is accomplished by the belt conveyors.
8. Conveyor Belts :
10.Pulleys : These are heavy cast iron ,driving pulleys are faced with ferodo or
similer frictional materials .
Proximate analysis
Ultimate analysis
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7.5 Ash slurry disposal system: Bottom Ash slurry, Fly ash slurry and
the Coarse Ash slurry shall be pumped from the common ash slurry
sump up to the dyke area which is located at a distance from Slurry
pump house.
Pre-treatment plant
Demineralization plant
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STRONG ACID CATION (SAC): SAC resins can neutralize strong bases and
convert neutral salts into their corresponding acids. SAC resins derive their
functionality from sulfonic acid groups (HSO3). When used in
demineralization, SAC resins remove nearly all raw water cations,
replacing them with hydrogen ions.
DEGASIFIER: In water demineralization, a degasifier, or degasser, is often
used to remove dissolved carbon dioxide after cation exchange. The most
common degassers are of the so-called forced draft or atmospheric type.
Aft
er cation exchange, the bicarbonate and carbonate (if any) ions are
converted to carbonic acid, or carbon dioxide. CO2 is soluble in water, but
it tends to escape into the air, much as it does in a glass of Cold drink
when you stir it. Using a degasser to remove CO2 reduces the ionic load on
the strong base anion resin, and the consumption of caustic soda is thus
lower.
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Stator
Rotor
Excitation system
Cooling system
Sealing system
Protections
Stator: The stator is the outer stationary part of the machine, which
consists of. The outer cylindrical frame called yoke, which is made either
of welded sheets steel,
Cast iron. The magnetic path, which comprises a set of slotted steel
laminations called stator core pressed into the cylindrical space inside the
outer frame. The magnetic path is l laminated to reduce eddy currents,
reducing losses and heating. CRGO laminations of0.5 mm thickness are
used to reduce the iron losses. A set of insulated electrical windings are
placed inside the slots of the laminated stator.
The cross-sectional area of these windings must be large enough for the
power rating of the machine. For a 3-phase generator, 3 sets of windings
are required, one for each phase connected in star. Fig. 1 shows one stator
lamination of a synchronous generator. In case of generators where the
diameter is too large stator lamination cannot be punched in on circular
piece. In such cases the laminations are punched in segments. A number
of segments are assembled together to form one circular laminations. All
the laminations are insulated from each other by a thin layer of varnish.
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ROTOR: In case of turbo alternator the rotors are manufactured form solid
steel forging. The rotor is slotted to accommodate the field winding.
Normally two third of the rotor periphery is slotted to accommodate the
winding and the remaining one third unspotted portion acts as the pole.
Rectangular slots with tapering teeth are milled in the rotor. Generally
rectangular aluminium or copper strips are employed
For filed windings. The field windings and the overhangs of the field
windings are secured in place by steel retaining rings to protect against
high centrifugal forces. Hard composition insulation materials are used in
the slots which can with stand high forces, stresses and temperatures.
Perfect balancing of the rotor is done for such type of rotors. Damper
windings are provided in the pole faces of salient pole alternators. Damper
windings are nothing but the copper or aluminium bars housed in the slots
of the pole faces. The ends of the damper bars are short circuited at the
ends by short circuiting rings similar to end rings as in the case of squirrel
cage rotors. These damper windings are serving the function of providing
mechanical balance; provide damping effect, reduce the effect of over
voltages and damp out hunting in case of alternators. In case of
synchronous motors they act as rotor bars and help in self-starting of the
motor.
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Rotor windings and retaining rings: The rotor carries the field windings.
Silver bearing copper (containing 0.03) is used for the windings with mica
as the insulation between conductors. A mechanically Strong insulator
Such As micanite, is used for lining the slots. Later designs of winding
flange rotor incorporate combinations of hollow conductors with slots of
holes arranged to provide for circulation of the cooling gas through the
actual conductors. When rotating at high speed, centrifugal force tries to
lift the winding out of the slots are contained by duralumin wages.
Rotor Balancing: The final rotor is an end product of several machining
operations, however due to inaccuracies in the machining operations,
certain unbalance is likely to be introduced in the rotor. It is therefore,
necessary that when completed ,the rotor must be tasted for mechanical
balance. Which means that a check is made to see if it will run up to
normal speed without vibrations. If the residual unbalance is of larger
balance weights. Arrangements are therefore, made in all designs to fix
adjustable balance weights at each of the rotor.
Slip ring and Brush gear assembly: The slip ring assembly is made of alloy
steel and insulating material. It must safety withstand the stresses due to
centrifugal forces .Both the rings are mounted on a single common steel
bush,. Which has an insulating jacket premoduled on it.The complete bush
with slip rings, is shrunk on the rotor shaft? The slip rings are provided
with inclined holes for slip rings, is shrunk on the rotor shaft. The slip rings
are provided with inclined holes for self-ventilations
Brush gear is provided on the extended part of the bearing pedestal pond
the excitation side. Brush holders are fixed on brass ring, made in such a
way as to provide staggering of the brushes along with slip ring.
Generator Cooling System :
I.
Hydrogen Cooling :
Minimize drag - windage
Maximize generator output
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III.
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Generator Protection:
Under Electrical Protection a generator is subjected to electrical traces
imposed on the insulation of the machine, mechanical forces acting on the
various parts of the machine, and temperature rises. These are the main
factors which make protection necessary for the generator or alternator.
Even when properly used, a machine in its perfect running condition does
not only maintain its specified rated performance for many years, but it
does also repeatedly withstand certain excess of over load. Hence,
preventive measures must be taken against overloads and abnormal
conditions of the machine so that it can serve safely. Despite of sound,
efficient design, construction, operation, and preventive means of
protection, the risk of that fault cannot be completely eliminated from any
machine. The devices used in generator protection, ensure the fault,
made dead as quickly as possible. An electrical generator can be
subjected to either internal fault or external fault or both. The generators
are normally connected to an electrical power system, hence any fault
occurred in the power system should also be cleared from the generator
as soon as possible otherwise it may create permanent damage in the
generator. The number and variety of faults occur in generator, are huge.
That is why generator or alternator is protected with several protective
schemes. The generator protection is of both discriminative and nondiscriminative type. Great care is to be taken in coordinating the systems
used and the settings adopted, so that the sensitive, selective and
discriminative generator protection scheme is achieved.
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2.
3.
Instantaneous relays.
Differential.
2.
Unbalance.
3.
Neutral displacement.
4.
Directional.
5.
6.
Over fluxing.
7.
Distance schemes.
8.
9.
includes
circuit
breaker,
current
transformer,
voltage
53
through
gear
lever
arrangement
with
the
operating
2.
3.
54
2.
Indoor breaker.
2.
3.
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CABLES: Cables are used for the interconnection. Two types of cables are
used. Power cable and control cable.
1. Power cables (which is used to connect the motor to panel component
and panel to main supply)
2. Control cables (which is used to connect the control circuits)
BUS BAR: Incoming supply is connected to bus bar and distributed from
bus bar. It is normally made by Aluminium.
MCB (Miniature Circuit Breakers): MCB is a protecting device. It is used
before the feeder. This should be selected according to the capacity of the
feeder.
MCCB (Mould Case Circuit Breaker): In most of the cases the MCCB used
as an incomer for higher capacity feeders for better protection.
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SELECTOR SWITCH: Selector is switch is used for ON/OFF purpose and for
selecting the mode of operation like auto/manual.
Starters: are used for starting the motors safely. Mainly two types of
starters are there. DOL starters and Start to delta. Dol starter is enough
for the motors with power less than 10 hp.
OVER LOAD RELAY: Over load relay is for the protection of motor from the
over load. It senses the load current and trips if it exceeds the limit.
Current limit has to be set manually. It should be 80% of the full load
current.
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COMPONENTS IN SWITCHYARD:
Lightening arresters
Current Transformer (C.T.)
Potential Transformer (P.T.)
Line isolator with Earthing switch
SF6 Circuit breaker with starting
resistance
Bus isolator
3 phase reactor
Wave trap
Power transformers
Cables trench & tray
Firefighting facility
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Pantograph type
bus isolators
The line isolators are used to isolate the line (after the operation of
opening C.B.) under maintenance from the healthy system which
otherwise may get resulted in L-G fault.
The bus isolators are used to isolate the bus under maintenance.
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Cables trench & tray: The cables that collect the communication signals
from instrument transformers, circuit breakers, isolators, wave traps
etc. are made to run in cable trench towards the control room.
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