TUTICORIN THERMAL POWER STATION, TNEB

IN-PLANT TRAINING REPORT (JUNE 2016)

(OVERVIEW OF POWER PLANT)

SUBMITTED
BY
JABIN J (15230001)

SUBMITTED
TO
MATHEVAN PILLAI

ABOUT TTPS

TTPS is situated near the new port of Tuticorin on the sea shore of bay of
Bengal and spread over an area of 160 hectares.
TTPS has a total installed capacity of 1050 MW comprising 5 units of
210 MW each.
The station was erected in III stages.
The first stage consists of units I & II of 210 MW each at a total cost of
Rs. 178 crores.
The second stage consists of 210 MW unit III of Rs.89 crores.
The third stage consists of units IV & V of 210 MW each at a total cost
of Rs. 804 crores.
The units are all coal based.
Coal is transported by sea through ships from Haldipa, Paradeep, Vizag
ports to TTPS.
Generation and plant load factor (PLF) for year 2010-11 is 7113.696 MU
and 77.33% respectively.

 TTPS has received cash awards

along with shields, Medals &

Certificates from the Govt of India for higher Productivity, Reduction

in Auxiliary Consumption, Reduction in fuel Oil Consumption when
the cash incentive reward scheme by the Govt. of India was in force.
TTPS has received Gold shield under Government of India meritorious
productivity Reward scheme for 4 years consecutively during

2000-

2001, 2001-02, 2002-03 & 2003-04 for peak hour generation.

Under the modified comprehensive Performance award scheme by the
Govt. of India, TTPS has been awarded Bronze shied for the year 200405.
COMISSIONING DETAILS

UNITS

Capacity(M.W)

Date of
Commissioning

210

09/07/1979

II

210

17/12/1980

III

210

16/04/1982

IV

210

11/02/1992

210

31/03/1991

210 MW - PLANT LAYOUOT

1. 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 either drives an electrical

generator or does some other work, like ship propulsion. 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. The greatest variation in the design of thermal power stations is due to the
different fuel sources. In thermal power stations, mechanical power is produced by a heat
engine that transforms thermal energy, often from combustion of a fuel, into rotational
energy. Most thermal power stations produce steam, and these are sometimes called steam
power stations. not all thermal energy can be transformed into mechanical power, according
to the second law of thermodynamics. Therefore, there is always heat lost to the environment.
If this loss is employed as useful heat, for industrial processes or district heating, the power
plant is referred to as a cogeneration power plant or CHP (combined heat-and-power) plant.
In countries where district heating is common, there are dedicated heat plants called heat-only
boiler stations. An important class of power stations in the Middle East uses by-product heat
for the desalination of water. There are number of methods by which electricity can be
produced, but most common method of production of electrical energy is to rotate a
conductor in a magnetic field continuously cutting of magnetic lines will cause E.M.F. to be
generated at the ends of conductor. If these terminals are connected through load then
electricity will start flowing through that conductor. Now let us see what we are doing in
Thermal Power Station for the purpose of production of Electricity. Actually speaking we are
doing conversion of energies from form to another form, and our ultimate aim is to get
Electrical energy. For this purpose the rotation movement is required to rotate the magnetic
field so that it may cut the stationery conductors of the machine. To be more precise this
rotational or mechanical energy is derived from a machine to which we call Turbine which is
actually capable enough to convert heat energy to rotational energy. For obtaining heat energy
we have to make use of the chemical energy, to which we call fossil fuel i.e. coal, oil, gas etc.
This is achieved in a plant to which we call furnace or sometimes Boiler. For transportation of
heat energy from furnace to turbine inlet, we require a medium and we have chosen water as
media. This water is converted into steam in furnace. Quality of steam is always monitored
properly process of Electrical generation. So we see that the rotational movement required to
rotate the magnetic field of the electric generator is produced by the steam turbine. The power
to the steam turbine is given by steam generator in the form of high pressure and high
temperature steam. The steam after doing work on the turbine shaft is condensed and
condensate is pumped back into Boiler as high pressure and low temperature water, by means
of Boiler feed pump.

2. VARIOUS OPERATION CYCLES

2.1 Coal Cycle

The simplest of the above four cycles is the coal cycle. In this cycle as explained
earlier crushed coal of about 20mm is transported by conveyor belts to the coal mill
bunkers. From here the coal goes to coal mills through raw coal feeders. In the coal mills
the coal is further pulverized (crushed) to powder form. The temperature of the coal mills
are maintained at 180-200 degree centigrade by a suitable mixture of hot & cold air. The air
comes from Primary Air fans (P.A FANS) which are 2 in Nos. - A&B. The outlet duct after
combining gets divided into two. One duct goes to the Air Heaters (A.H- A&B) where
primary air is heated by the hot flue gases in a Heat Exchanger. This duct provides hot air
& the other one provides cold primary air. A suitable mixture of this hot & cold air is fed to
the coal mills to maintain their temperature. This is done to remove moisture of coal. More
over this primary air is also used for transportation of powdered coal from coal mills to the
four corners of the boiler by a set of four pipes. There are six coal mills A, B, C, D, E&F
and their outlets in the Boiler are at different elevations. The high Temperature of the
primary air does not allow the air coal mixture to choke the duct from mill to boilers. A
portion of the primary air is further pumped to high pressure and is known as seal air. It is
used to protect certain parts of mills like bearings etc. where powered coal may pose
certain problems in the functioning of the mill. When the air coal mixture enters the boiler
it catches fire in the firing zone and some ash along with clinkers settles down. This is
removed periodically by mixing it with water to make slurry.

2.2 Oil Cycle

In the oil cycle the oil is pumped and enters the boiler from four corners at three
elevations. Oil guns are used which sprays the oil in atomized form along with steam so
that it catches fire instantly. At each elevation and each corner there are separate igniters
which ignite the fuel oil. There are flame sensors which sense the flame and send the
information to the control room.

2.3 Air & Flue Gas Cycle

For the proper combustion to take place in the boiler right amount of Oxygen or
air is needed in the boiler. The air is provided to the furnace in two ways - Primary Air &

Secondary Air. Primary air is provided by P.A. fans and enters the boiler along with
powdered coal from the mills. While the secondary air is pumped through Forced Draft
fans better known as F.D Fans which are also two in numbers A&B. The outlet of F.D fans
combine and are again divided into two which goes to Steam coiled Air pre heaters
(S.C.A.P.H) A&B where its temperature is raised by utilizing the heat of waste steam. Then
it goes to Air Pre heater-A&B where secondary air is heated further utilizing the heat of
flue gases. The temperature of air is raised to improve the efficiency of the unit & for
proper combustion in the furnace. Then this air is fed to the furnace.
From the combustion chamber the fuel gases travel to the upper portion of the boiler
and give a portion of heat to the Platen Super Heater. Further up it comes in contact with the
Reheater and heats the steam which is inside the tubes of reheater. Then it travels horizontally
and comes in contact with Final Super Heater. After imparting the heat to the steam in super
heater flue gases go downward to the Economizer to heat the cold water pumped by the
Boiler Feed Pumps (B.F.P.) these all are enclosed in the furnace. After leaving the furnace the
fuel gases go to the Air Heaters where more heat of the flue gases is extracted to heat primary
and secondary air. Then it goes to the Electrostatic Precipitators (E.S.P.) Stage A&B where
the suspended ash from the flue gases is removed by passing the fuel gas between charged
plates. Then comes the induced draft fan (I.D Fan) which sucks air from E.S.P. and releases it
to the atmosphere through chimney. The pressure inside the boiler is kept suitably below the
atmospheric pressure with the help of 1.0. Fans so that the flame does not spread out of the
openings of boiler and cause explosion. Further very low pressure in the boiler is also not
desirable because it will lead to the quenching of flame.

2.4 Steam Water Cycle

The most complex of all the cycles is the steam & water cycle. Steam is the
working substance in the turbines in all the thermal and nuclear power plants. As there is
very high temperature and pressure inside the boiler, initially water has to be pumped to a
very high pressure. Water has also to be heated to a suitably high temperature before
putting it inside the boiler so that cold water does not cause any problem. Initially cold
water is slightly heated in low pressure heaters. Then it is pumped to a very high pressure
of about 200 Kg/Cm2 by boiler feed pumps A & B. After this it is further heated in high
pressure heaters by taking the heat from the high pressure steam coming from various
auxiliaries and / or turbines. Then this water goes to the economizer where its temperature
is further raised by the flue gases.
This hot water then goes to the boiler drum. In the boiler drum there is very high
temperature and pressure. It contains a saturated mixture of boiling water and steam which
are in equilibrium. The water level in the boiler is maintained between certain limit. From

here relatively cold water goes down to the water header situated at the bottom, due to
difference in density. Then this cold water rises gradually in the tubes of the boiler on being
heated. The tubes are in the form of water walls. These tubes combine at the top in the hot
water header. From here the hot water and steam mixture comes back to the boiler drum
completing the small loop.
From the boiler drum hot steam goes to platen super heater situated in the upper portion
of the boiler. Here the temperature of the steam is increased. Then it goes to final super
heater. Here its temperature is further increased.
The turbine is a three cylinder machine with high pressure (H.P), intermediate
pressure (I.P) & low pressure (L.P) casings taking efficiency into account the .The turbine
speed is controlled by hydro dynamic governing system. The three turbines are on the same
shaft which is coupled with generator. The generator is equipped with D.C excitation system.
The steam from the final super heater comes by main steam line to the H.P turbine. After
doing work in the H.P turbine its temperature is reduced. It is sent back to the boiler by cold
reheat line to the re-heater. Here its temperature is increased and is sent to the I.P turbine
through hot reheat line. After doing work in the I.P turbine steam directly enters L.P turbine.
The pressure of L.P turbine is maintained very low in order to reduce the
condensation point of steam. The outlet of L.P turbine is connected with condenser. In the
condenser, arrangement is made to cool the steam to water. This is done by using cold water
which is made to flow in tubes. This secondary water which is not very pure gains heat from
steam & becomes hot. This secondary water is sent to the cooling towers to cool it down so
that it may be reused for cooling. The water thus formed in the condenser is sucked by
condensate water pumps (C.W. PUMPS) and is sent to de-aerator. A suitable water level is
maintained in the hot well of condenser.
Water or steam leakages from the system are compensated by the make up water, line
from storage tanks which are connected to the condenser. The pressure in side condenser is
automatically maintained less then atmospheric pressure and large volume of steam condense
here to form small volume of water. In the de-aerator the water is sprayed to small droplets &
the air dissolved in it is removed so that it may not cause trouble at high temperatures in the
Boiler. Moreover, the water level which is maintained constant in the de-aerator also acts as a
constant water head for the boiler feed pumps. Water from de-aerator goes to the Boiler feed
pumps after the heated by L.P. Heaters. Thus the water cycle in the boiler is completed and
water is ready for another new cycle. This is a continuous and repetitive process.

OVERVIEW OF BOILER