INDUSTRIAL TRAINING REPORT

A project report submitted as a part of industrial training done at Simhadri Super Thermal Power Project N.T.P.C Simhadri, Visakhapatnam From 5/5/2011-5/6/2011

By Burla Pradeep Nunela Sapthagiri Sai Ananth Nag Attota Gautham Sisti visweswara rao S.Ravi Teja of Department of Mechanical Engineering GITAM UNIVERSITY Beside Rushikonda,Visakhapatnam Andhra Pradesh Under the esteemed guidance of A.V.S.Pandarinath

AGM-MM,N.T.P.C-SIMHADRI

ACKNOWLEDGEMT
We express our deep gratitude to our Head Of Depatment Dr. S. Kamaluddin, Professor of department of Mechanical engineering, GITAM University, Visakhapatnam for rendering us guidance and valuable advice always. He has been a perennial source of inspiration and motivation from the inception to the completion of this Industrial training. We thank Mr. A.V.S.Pandarinath, AGM-MM who in spite of being extraordinary busy with his duties took time out to hear, guide and keep us in a correct path. We sincerely thank all the staff members of the department for giving us their heartfelt support in all the stages of Industrial training. In all humility and reverence, we express our profound sense of gratitude to all elders and professors who have willingly spared time, experience and knowledge to guide us in our Industrial training. Sisti Visweswara Rao(1210808254) Burla Pradeep (1210808212) Nunela Sapthagiri (1210808251) Sai Ananth Nag (1210808228) Attota Gautham (1210808201) S.Ravi Teja (1210808249)

CONTENTS:
1.INTRODUCTION 2.N.T.P.C SIMHADRI PLANT OVERVIEW 3.WORKING PROCESS 4.THERMAL POWER PLANT AND ITS EQUIPMENTS 5.COAL HANDLING PLANT 6.ASH HANDLING PLANT 7.ELECTROSTATIC PRECIPITATOR

1.

INTRODUCTION

1. THE EMERGING NEW FORCE ON INDIAS POWER HORIZON SETTING A NEW BENCHMARK
Crowning NTPCS superlative saga of power, Simhadri Thermal Power Project comes alive on the power map of the country with the synchronization of the first 500MW Unit. Racing against time in project implementation, the Simhadri Thermal Power Project has set a new benchmark for green-field project of this size and earned the distinction of being the only power project of this size and earned the distinction of being the only power project in the country to commission the 500MW unit in a record time of 39 months from the date of main plant order, a feat that will probably remain unsurpassed. Spread over an area of 3,384 acres near Paravada in Visakhapatnam District of Andhra Pradesh, the 1000MW Simhadri Thermal Power Project has two units of 500MW capacity each. The entire power generated from this station will be supplied to Andhra Pradesh. The erstwhile Andhra Pradesh State Electricity Board had signed a Power Purchase Agreement with NTPC on February 4, 1997. The Simhadri Power Project will provide a bountiful power to Andhra Pradesh, the land of myriad opportunities. World commissioning of the Simhadri Project is one step ahead in generation of reliable and quality power in large quantities from this

station will forever keep Andhra Pradesh forging ahead in the country as well as globally.

1.1

UNIQUE FEATURES SIMHADRI THERMAL POWER PROJECT HAS MANY FIRSTS

The Simhadri Power Project is the first coastal coal fired thermal power project of NTPC. The biggest intake well in the country has been installed inside the Bay of Bengal to draw sea water for use in CW system as make up water. Two natural draft cooling towers of 165 metre height each are the biggest in Asia and sixth biggest in world. First coal based project of NTPC from which entire power is allocated to the home state i.e. Andhra Pradesh. Simhadri project has created a new benchmark of excellence by commissioning the 500MW Unit in 39 months. Simhadri Thermal Power Project achieved the boiler light up of 500MW Unit in 351/2 months, which is a national record. The most modern project in India having the state of the art control and instrumentation system.

1.2

PROJECT LOCATION WHERE PAST GLORY TURNS INTO A POWERFUL FUTURE

Paravada mandal in Visakhapatnam District has the pride of being the location for Simhadri Thermal Power Project. The project is approximately 40km from Visakhapatnam City and is approachable by NH -5 via Elamanchili-Visakhapatnam road and further from Paravada to Vadacheepurupalli by road. The nearest railway station is Duvvada on the Howrah-Chennai main line.

1.3

GENESIS

DOWN MEMORY LANE

The Project name Simhadri comes from Simhachalam, the hill top temple of Lord Varaha Lakshminarasimha Swamy, which is 16km from Visakhapatnam. The project was originally conceived by the erstwhile Andhra Pradesh State Electricity Board, which submitted a feasibility report to the CEA in March 1994. Subsequently, the Government of Andhra Pradesh entrusted the project to NTPC. After completing the topographical survey, geotechnical investigation, demography and socio-economic surveys, NTPC obtained techno-economic clearance from the CEA in September 1996. The Public Investment Board of Government of India gave its approval in February 1997. The Cabinet Committee on Economic Affairs accorded approval for the project in July 1997.

1.4

A CHALLENGE TURNS INTO MEGA REALITY A DREAM COME TRUE

Setting up of the Simhadri Thermal Power Project, a fasttrack project has been a daunting task. A total of 3,384 acres of land has been acquired for construction of this project. A great deal of courage to take bold decision, transform concepts into real tasks, sound material, contractual, financial and man power management helped in commissioning the project well ahead of schedule. For achieving speedy implementation, NTPC adopted a unique packaging concept at the project. The entire works were executed under 13 packages as compared to earlier concept of 45 to 48 packages. The main plant turnkey contract was awarded to Bharat Heavy Electricals Ltd., in November 1998. The scope of the main plant turnkey contract includes design manufacturing, engineering, civil construction, erection, testing and commissioning. The massive task of installation of the project started with site levelling works on December 6, 1998. The site levelling involved massive earth filling to the tune of more than 82 lakh cubic metre, which was completed in 16 months against a schedule of 17

months. This is the first coastal-based green-field project, where additional works were required to be done due to massive earth filling and deeper foundations as well as preparing of structural designs that were suited for high wind zone and saline atmosphere to give protection for various structures, piping and equipment. The entire construction, erection and commissioning works have been executed ensuring quality and efficiency. As the works progressed, the project has set new bench marks in project implementation by achieving several major milestones well ahead of schedule. One of the major milestone achievements is Unit-1 boiler light upon November 6, 2001 in 351/2 months, which is a national record. The biggest intake well has been constructed offshore of the Bay of Bengal for drawing sea water for using in the CW system for condenser cooling as make up water. A 275-metre tall chimney, which has been built for wide dispersal of flue gases, is now towering over the area. Two natural draft cooling towers with a height of 165metres, which are the biggest in Asia and the sixth biggest in the world, have been constructed. Synchronization of the first 500MW Unit in a record time of 39 months is a challenge turned into mega reality through hard work, innovation, determination and courage in the face of odds for the entire NTPC team. Today, the project stands as a mammoth power complex.

1.5

PROJECT COST & FINANCING VALUE FOR MONEY

The Simhadri Thermal Power Project is being constructed at a cost of Rs3650.79crore. The project is being financed with debt equity ratio of 70:30 and it is funded to a large extent by Japanese bank for International Co-operation (JBIC) loan of 59,484 million Japanese yen comprising of three tranches (First tranche 19,817 million Japanese yen, second tranche 12,194 million Japanese yen and third tranche of 27,473 million Japanese yen) equivalent to Rs 2,225 crore and balance funds have been arranged by NTPC through internal resources and market borrowings.

1.6

COAL LINKAGE AND TRANSPORTATION FUEL SYSTEM

The primary fuel of coal for the project is being sourced from Talcher of Mahanadi Coalfields in Orissa. 5.79 million Tonnes of coal will be required annually for the project. The coal will be moved to the project site by the rail route from Talcher in Orissa through Talcher-Sambalpur-Titlagarh-VijayanagaramVisakhapatnam route. Construction of railway siding with associated rail line has already been completed well in advance. The first phase of railway siding of 21km length with the take off point at Duvvada Railway Station has been completed. The railway siding has an improved track structure. The project has also started receiving coal at the site from December 12, 2001 itself much before synchronization of the unit. Coal handling plant, coal conveyor system, coal mills etc., have been made ready to achieve coal firing immediately after synchronization. The second phase of the railway siding will be connected with the siding line of Visakhapatnam steel plant at Jaggayapalem, which is 5.6km from Duvvada.

1.7

SEA WATER FOR CW SYSTEM HARNESSING NATURES BOUNTRY

For the first time in the history of NTPC, sea water, which is available in abundance, is being used for cooling water requirements. A closed loop cycle cooling water system using sea water for make up water implemented at Simhadri. Sea water is drawn from an intake well pump house constructed at 700 metre. Offshore of Bay of Bengal. The intake well is located at Tikkavanipalem about 5km from the plant site. Two pumps with a capacity of 9100 cubic metres per hour (one working and one standby) to meet the make up water requirement for 2*500MW units have been installed. This is the biggest intake well in the country, which is constructed using the unique Caisson Well

sinking technology. A 700metres long approach jetty from the shore to intake well has been constructed to connect the pump house. Make-up water from the sea water intake pump shall be pumped to the desilting basin in the plant through two pipelines of 1300NB each and clear water from the de-silting basin will be further taken to CW pump house through intake channel by gravity. The most aspect of sea water pipes is that these pipes are protected from corrosion and degradation by coating with polyurethane. The requirement of sea water for make up would be 9100cubic metres per hour.

1.8

SWEET WATER REQUIREMENT THE VITAL ELEMENT

Sweet water requirement for the boilers and other plant equipment as well as drinking water shall be met from Yeleru main canal, which is about 11km from the main plant. Sweet water pump house has been constructed near Tadi village to pump fresh water from Yeleru canal. Sweet water will be drawn by gravity to the de-silting basin and into the pump house. As the Yeleru canal would be closed for carrying out the annual maintenance work, an in-plant reservoir equivalent to two months of sweet water requirement has been constructed in the plant area. The approximate fresh water requirement is 600 cubic meters per hour.

1.9 ASSOCIATED TRANSMISSION NETWORK REACHING OUT

Power will be evacuated from the station through 400kv double circuit lines of APTRANSCO. From the Simhadri Thermal Power Station power will be evacuated to Vizag pooling sub-station at Kalpaka, which is the biggest in Asia. Further it will be evacuated

through 400kv double circuit Vizag-Vemagiri-Nunna line of approximately 390km land 400kv double circuit Vizag-KhammamHyderabad line of approximately 590km.

1.10 PROJECT PROFILE

Approved capacity Location Project cost Source of finance Fuel Requirement Mode of Transportation Sweet Water Requirement Source Sea water Requirement Source Main Plant Turnkey package Evacuation : 1000MW (2*500MW) : Paravada Mandal, Visakhapatnam, A.P. : Rs 3,650.79 crore. : JBIC Loan and internal resources. : 5.04 Million Tonnes of coal per annum : By rail : 600 cubic metres per hour : Yeleru : 9,100 cubic metres per hour : Bay of Bengal : Awarded to BHEL on November 23rd, 1998. : Through 400kv system of APTRANSCO 400kv Double circuit Vizag-Vemagiri-Nunna line. 400kv Double circuit Vizag-Khammam line 400kv Double circuit Khammam-Hyderabad. 400kv Double circuit Vizag-Gajuwaka(PGCIL) Line.

Commissioning Schedule

: 500MW unit-1 March 2002 Synchronised on February 22, 2002 ahead of schedule.

3. WORKING
ELECTRICITY FROM COAL Coal from the coal wagons is unloaded with the help of wagon tipplers in the C.H.P. this coal is taken to the raw coal bunkers with the help of conveyor belts. Coal is then transported to bowl mills by coal feeders where it is pulverized and ground in the powered form. This crushed coal is taken away to the furnace through coal pipes with the help of hot and cold mixture P.A fan. This fan takes atmospheric air, a part of which is sent to pre heaters while a part goes to the mill for temperature control. Atmospheric air from F.D fan in the air heaters and sent to the furnace as combustion air. Water from boiler feed pump passes through economizer and reaches the boiler drum . Water from the drum passes through the down comers and goes to the bottom ring header. Water from the bottom ring header is divided to all the four sides of the furnace. Due to heat density difference the water rises up in the water wall tubes. This steam and water mixture is again taken to the boiler drum where the steam is sent to super heaters for super heating. The super heaters are located inside the furnace and the steam is super heated (540 degree Celsius) and finally it goes to the turbine. Fuel gases from the furnace are extracted from the

induced draft fan, which maintains balance draft in the furnace with F.D fan. These fuel gases heat energy to the various super heaters and finally through air pre heaters and goes to electrostatic precipitators where the ash particles are extracted. This ash is mixed with the water to from slurry is pumped to ash period. The steam from boiler is conveyed to turbine through the steam pipes and through stop valve and control valve that automatically regulate the supply of steam to the turbine. Stop valves and controls valves are located in steam chest and governor driven from main turbine shaft operates the control valves the amount used. Steam from controlled valves enter high pressure cylinder of turbines, where it passes through the ring of blades fixed to the cylinder wall. These act as nozzles and direct the steam into a second ring of moving blades mounted on the disc secured in the turbine shaft. The second ring turns the shaft as a result of force of steam. The stationary and moving blades together.

THERMAL POWER PLANT AND ITS EQUIPMENTS A Thermal Power Station comprises all of the equipment and a subsystem required to produce electricity by using a steam generating boiler fired with fossil fuels or befouls to drive an electrical generator. Some prefer to use the term ENERGY CENTER because such facilities convert forms of energy, like nuclear energy, gravitational potential energy or heat energy (derived from the combustion of fuel) into electrical energy. However, POWER PLANT is the most common term in the united state; While POWER STATION prevails in many Commonwealth countries and especially in the United Kingdom.

Such power stations are most usually constructed on a very large scale and designed for continuous operation. Typical diagram of a coal fired thermal power station 1. Cooling water pump 2. Three-phase transmission line 3. Step up transformer 4. Electrical Generator 5. Low pressure steam 6. Boiler feed water pump 7. Surface condenser 8. Intermediate pressure steam turbine 9. Steam control valve 10. High pressure steam turbine 11. Deaerator Feed water heater 12. Coal conveyor 13. Coal hopper 14. Coal pulverizer 15. boiler steam drum 16. Bottom ash hoper 17. Super heater 18. Forced draught(draft) fan 19. Reheater 20. Combustion air intake 21. Economizer 22. Air preheater 23. Precipitator 24. Induced draught(draft) fan 25. Fuel gas stack The description of some of the components written above is described as follows: 1. Cooling towers Cooling Towers are evaporative coolers used for cooling water or other working medium to near the ambivalent webbulb air temperature. Cooling tower use evaporation of water to reject heat from processes such as cooling the circulating water used in oil refineries, Chemical plants, power plants

and building cooling, for example. The tower vary in size from small roof-top units to very large hyperboloid structures that can be up to 200 meters tall and 100 meters in diameter, or rectangular structure that can be over 40 meters tall and 80 meters long. Smaller towers are normally factory built, while larger ones are constructed on site. The primary use of large , industrial cooling tower system is to remove the heat absorbed in the circulating cooling water systems used in power plants , petroleum refineries, petrochemical and chemical plants, natural gas processing plants and other industrial facilities . The absorbed heat is rejected to the atmosphere by the evaporation of some of the cooling water in mechanical forced-draft or induced draft towers or in natural draft hyperbolic shaped cooling towers as seen at most nuclear power plants. 2.Three phase transmission line Three phase electric power is a common method of electric power transmission. It is a type of polyphase system mainly used to power motors and many other devices. A Three phase system uses less conductor material to transmit electric power than equivalent single phase, two phase, or direct current system at the same voltage. In a three phase system, three circuits reach their instantaneous peak values at different times. Taking one conductor as the reference, the other two current are delayed in time by one-third and two-third of one cycle of the electrical current. This delay between phases has the effect of giving constant power transfer over each cycle of the current and also makes it possible to produce a rotating magnetic field in an electric motor. At the power station, an electric generator converts mechanical power into a set of electric currents, one from each electromagnetic coil or winding of the generator. The current are sinusoidal functions of time, all at the same frequency but offset in time to give different phases. In a three phase system the phases are spaced equally, giving a phase separation of one-third one cycle. Generators output at a voltage that ranges from hundreds of volts to 30,000

volts. At the power station, transformers: step-up this voltage to one more suitable for transmission. After numerous further conversions in the transmission and distribution network the power is finally transformed to the standard mains voltage (i.e. the household voltage). The power may already have been split into single phase at this point or it may still be three phase. Where the stepdown is 3 phase, the output of this transformer is usually star connected with the standard mains voltage being the phase-neutral voltage. Another system commonly seen in North America is to have a delta connected secondary with a center tap on one of the windings supplying the ground and neutral. This allows for 240 V three phase as well as three different single phase voltages( 120 V between two of the phases and neutral , 208 V between the third phase ( known as a wild leg) and neutral and 240 V between any two phase) to be available from the same supply. 3.Electrical generator An Electrical generator is a device that converts kinetic energy to electrical energy, generally using electromagnetic induction. The task of converting the electrical energy into mechanical energy is accomplished by using a motor. The source of mechanical energy may be a reciprocating or turbine steam engine, , water falling through the turbine are made in a variety of sizes ranging from small 1 hp (0.75 kW) units (rare) used as mechanical drives for pumps, compressors and other shaft driven equipment , to 2,000,000 hp(1,500,000 kW) turbines used to generate electricity. There are several classifications for modern steam turbines. Steam turbines are used in all of our major coal fired power stations to drive the generators or alternators, which produce electricity. The turbines themselves are driven by steam generated in Boilers or steam generators as they are sometimes called. Electrical power station use large stem turbines driving electric generators to produce most (about 86%) of the worlds electricity. These centralized stations are of two

types: fossil fuel power plants and nuclear power plants. The turbines used for electric power generation are most often directly coupled to their-generators .As the generators must rotate at constant synchronous speeds according to the frequency of the electric power system, the most common speeds are 3000 r/min for 50 Hz systems, and 3600 r/min for 60 Hz systems. Most large nuclear sets rotate at half those speeds, and have a 4-pole generator rather than the more common 2-pole one. Energy in the steam after it leaves the boiler is converted into rotational energy as it passes through the turbine. The turbine normally consists of several stage with each stages consisting of a stationary blade (or nozzle) and a rotating blade. Stationary blades convert the potential energy of the steam into kinetic energy into forces, caused by pressure drop, which results in the rotation of the turbine shaft. The turbine shaft is connected to a generator, which produces the electrical energy. 4.Boiler feed water pump A Boiler feed water pump is a specific type of pump used to pump water into a steam boiler. The water may be freshly supplied or retuning condensation of the steam produced by the boiler. These pumps are normally high pressure units that use suction from a condensate return system and can be of the centrifugal pump type or positive displacement type. Construction and operation Feed water pumps range in size up to many horsepower and the electric motor is usually separated from the pump body by some form of mechanical coupling. Large industrial condensate pumps may also serve as the feed water pump. In either case, to force the water into the boiler; the pump must generate sufficient pressure to overcome the steam pressure developed by the boiler. This is usually accomplished through the use of a centrifugal pump. Feed water pumps usually run intermittently and are

controlled by a float switch or other similar level-sensing device energizing the pump when it detects a lowered liquid level in the boiler is substantially increased. Some pumps contain a two-stage switch. As liquid lowers to the trigger point of the first stage, the pump is activated. I f the liquid continues to drop (perhaps because the pump has failed, its supply has been cut off or exhausted, or its discharge is blocked); the second stage will be triggered. This stage may switch off the boiler equipment (preventing the boiler from running dry and overheating), trigger an alarm, or both. 5. Steam-powered pumps Steam locomotives and the steam engines used on ships and stationary applications such as power plants also required feed water pumps. In this situation, though, the pump was often powered using a small steam engine that ran using the steam produced by the boiler. A means had to be provided, of course, to put the initial charge of water into the boiler(before steam power was available to operate the steam-powered feed water pump).the pump was often a positive displacement pump that had steam valves and cylinders at one end and feed water cylinders at the other end; no crankshaft was required. In thermal plants, the primary purpose of surface condenser is to condense the exhaust steam from a steam turbine to obtain maximum efficiency and also to convert the turbine exhaust steam into pure water so that it may be reused in the steam generator or boiler as boiler feed water. By condensing the exhaust steam of a turbine at a pressure below atmospheric pressure, the steam pressure drop between the inlet and exhaust of the turbine is increased, which increases the amount heat available for conversion to mechanical power. Most of the heat liberated due to condensation of the exhaust steam is carried away by the cooling medium (water or air) used by the surface condenser. 6. Control valves

Control valves are valves used within industrial plants and elsewhere to control operating conditions such as temperature,pressure,flow,and liquid Level by fully partially opening or closing in response to signals received from controllers that compares a set point to a process variable whose value is provided by sensors that monitor changes in such conditions. The opening or closing of control valves is done by means of electrical, hydraulic or pneumatic systems 7. Deaerator A Dearator is a device for air removal and used to remove dissolved gases (an alternate would be the use of water treatment chemicals) from boiler feed water to make it noncorrosive. A dearator typically includes a vertical domed deaeration section as the deaeration boiler feed water tank. A Steam generating boiler requires that the circulating steam, condensate, and feed water should be devoid of dissolved gases, particularly corrosive ones and dissolved or suspended solids. The gases will give rise to corrosion of the metal. The solids will deposit on the heating surfaces giving rise to localized heating and tube ruptures due to overheating. Under some conditions it may give to stress corrosion cracking. Deaerator level and pressure must be controlled by adjusting control valves- the level by regulating condensate flow and the pressure by regulating steam flow. If operated properly, most deaerator vendors will guarantee that oxygen in the deaerated water will not exceed 7 ppb by weight (0.005 cm3/L) 8. Feed water heater A Feed water heater is a power plant component used to pre-heat water delivered to a steam generating boiler. Preheating the feed water reduces the irreversible involved in steam generation and therefore improves the thermodynamic efficiency of the system.[4] This reduces

plant operating costs and also helps to avoid thermal shock to the boiler metal when the feed water is introduces back into the steam cycle. In a steam power (usually modeled as a modified Ranking cycle), feed water heaters allow the feed water to be brought up to the saturation temperature very gradually. This minimizes the inevitable irreversibilitys associated with heat transfer to the working fluid (water). A belt conveyor consists of two pulleys, with a continuous loop of material- the conveyor Belt that rotates about them. The pulleys are powered, moving the belt and the material on the belt forward. Conveyor belts are extensively used to transport industrial and agricultural material, such as grain, coal, ores etc.

9. Pulverizer A pulverizer is a device for grinding coal for combustion in a furnace in a fossil fuel power plant. 10. Boiler Steam Drum Steam Drums are a regular feature of water tube boilers. It is reservoir of water/steam at the top end of the water tubes in the water-tube boiler. They store the steam generated in the water tubes and act as a phase separator for the steam/water mixture. The difference in densities between hot and cold water helps in the accumulation of the hotterwater/and saturated steam into steam drum. Made from high-grade steel (probably stainless) and its working involves temperatures 390C and pressure well above 350psi (2.4MPa). The separated steam is drawn out from the top section of the drum. Saturated steam is drawn off the top of the drum. The steam will re-enter the furnace in through a super heater, while the saturated water at the bottom of steam drum flows down to the mud-drum /feed water drum by down comer tubes accessories include a safety valve,

water level indicator and fuse plug. A steam drum is used in the company of a mud-drum/feed water drum which is located at a lower level. So that it acts as a sump for the sludge or sediments which have a tendency to the bottom. 11. Super Heater A Super heater is a device in a steam engine that heats the steam generated by the boiler again increasing its thermal energy and decreasing the likelihood that it will condense inside the engine. Super heaters increase the efficiency of the steam engine, and were widely adopted. Steam which has been superheated is logically known as superheated steam; non-superheated steam is called saturated steam or wet steam; Super heaters were applied to steam locomotives in quantity from the early 20th century, to most steam vehicles, and so stationary steam engines including power stations. 12. Economizers Economizer, or in the UK economizer, are mechanical devices intended to reduce energy consumption, or to perform another useful function like preheating a fluid. The term economizer is used for other purposes as well. Boiler, power plant, and heating, ventilating and air conditioning. In boilers, economizer are heat exchange devices that heat fluids , usually water, up to but not normally beyond the boiling point of the fluid. Economizers are so named because they can make use of the enthalpy and improving the boilers efficiency. They are a device fitted to a boiler which saves energy by using the exhaust gases from the boiler to preheat the cold water used the fill it (the feed water). Modern day boilers, such as those in cold fired power stations, are still fitted with economizer which is decedents of Greens original design. In this context they are turbines before it is pumped to the boilers. A common application of economizer is steam power plants is to capture the waste hit from boiler stack gases (flue gas) and transfer thus it to the boiler feed water thus lowering the needed energy input , in

turn reducing the firing rates to accomplish the rated boiler output . Economizer lower stack temperatures which may cause condensation of acidic combustion gases and serious equipment corrosion damage if care is not taken in their design and material selection. 13. Air Preheater Air preheater is a general term to describe any device designed to heat air before another process (for example, combustion in a boiler). The purpose of the air preheater is to recover the heat from the boiler flue gas which increases the thermal efficiency of the boiler by reducing the useful heat lost in the fuel gas. As a consequence, the flue gases are also sent to the flue gas stack (or chimney) at a lower temperature allowing simplified design of the ducting and the flue gas stack. It also allows control over the temperature of gases leaving the stack. 14. Precipitator An Electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate device that removes particles from a flowing gas (such As air) using the force of an induced electrostatic charge. Electrostatic precipitators are highly efficient filtration devices, and can easily remove fine particulate matter such as dust and smoke from the air steam. ESPs continue to be excellent devices for control of many industrial particulate emissions, including smoke from electricity-generating utilities (coal and oil fired), salt cake collection from black liquor boilers in pump mills, and catalyst collection from fluidized bed catalytic crackers from several hundred thousand ACFM in the largest coal-fired boiler application. The original parallel plate-Weighted wire design (described above) has evolved as more efficient ( and robust) discharge electrode designs were developed, today focusing on rigid discharge electrodes to which many sharpened spikes are

attached , maximizing corona production. Transformer rectifier systems apply voltages of 50-100 Kilovolts at relatively high current densities. Modern controls minimize sparking and prevent arcing, avoiding damage to the components. Automatic rapping systems and hopper evacuation systems remove the collected particulate matter while on line allowing ESPs to stay in operation for years at a time. 15. Fuel gas stack A Fuel gas stack is a type of chimney, a vertical pipe, channel or similar structure through which combustion product gases called fuel gases are exhausted to the outside air. Fuel gases are produced when coal, oil, natural gas, wood or any other large combustion device. Fuel gas is usually composed of carbon dioxide (CO2) and water vapor as well as nitrogen and excess oxygen remaining from the intake combustion air. It also contains a small percentage of pollutants such as particulates matter, carbon mono oxide, nitrogen oxides and sulfur oxides. The flue gas stacks are often quite tall, up to 400 meters (1300 feet) or more, so as to disperse the exhaust pollutants over a greater aria and thereby reduce the concentration of the pollutants to the levels required by governmental environmental policies and regulations. When the fuel gases exhausted from stoves, ovens, fireplaces or other small sources within residential abodes, restaurants , hotels or other stacks are referred to as chimneys. 1. COAL HANDLING PLANT (C.H.P) Major Components 1. Wagon Tippler: - Wagons from the coal yard come to the tippler and are emptied here. The process is performed by a slip ring motor of rating: 55 KW, 415V, 1480 RPM. This

motor turns the wagon by 135 degrees and coal falls directly on the conveyor through vibrators. Tippler has raised lower system which enables is to switch off motor when required till is wagon back to its original position. It is titled by weight balancing principle. The motor lowers the hanging balancing weights, which in turn tilts the conveyor. Estimate of the weight of the conveyor is made through hydraulic weighing machine. 2. Conveyor: - There are 14 conveyors in the plant. They are numbered so that their function can be easily demarcated. Conveyors are made of rubber and more with a speed of 250-300m/min. Motors employed for conveyors has a capacity of 150 HP. Conveyors have a capacity of carrying coal at the rate of 400 tons per hour. Few conveyors are double belt, this is done for imp. Conveyors so that if a belt develops any problem the process is not stalled. The conveyor belt has a switch after every 25-30 m on both sides so stop the belt in case of emergency. The conveyors are 1m wide, 3 cm thick and made of chemically treated vulcanized rubber. The max angular elevation of conveyor is designed such as never to exceed half of the angle of response and comes out to be around 20 degrees. 3. Zero Speed Switch:-It is safety device for motors, i.e., if belt is not moving and the motor is on the motor may burn. So to protect this switch checks the speed of the belt and switches off the motor when speed is zero. 4. Metal Separators: - As the belt takes coal to the crusher, No metal pieces should go along with coal. To achieve this objective, we use metal separators. When coal is dropped to the crusher hoots, the separator drops metal pieces ahead of coal. It has a magnet and a belt and the belt is moving, the pieces are thrown away. The capacity of this device is around 50 kg. .The CHP is supposed to transfer 600 tons of coal/hr, but practically only 300-400 tons coal is transfer 5. Crusher: - Both the plants use TATA crushers powered by BHEL. Motors. The crusher is of ring type and motor ratings

are 400 HP, 606 KV. Crusher is designed to crush the pieces to 20 mm size i.e. practically considered as the optimum size of transfer via conveyor. 6. Rotatory Breaker: - OCHP employs mesh type of filters and allows particles of 20mm size to go directly to RC bunker, larger particles are sent to crushes. This leads to frequent clogging. NCHP uses a technique that crushes the larger of harder substance like metal impurities easing the load on the magnetic separators. MILLING SYSTEM 1. RC Bunker: - Raw coal is fed directly to these bunkers. These are 3 in no. per boiler. 4 & tons of coal are fed in 1 hr. the depth of bunkers is 10m. 2. RC Feeder: - It transports pre crust coal from raw coal bunker to mill. The quantity of raw coal fed in mill can be controlled by speed control of aviator drive controlling damper and aviator change. 3. Ball Mill: - The ball mill crushes the raw coal to a certain height and then allows it to fall down. Due to impact of ball on coal and attraction as per the particles move over each other as well as over the Armor lines, the coal gets crushed. Large particles are broken by impact and full grinding is done by attraction. The Drying and grinding option takes place simultaneously inside the mill. 4. Classifier:- It is an equipment which serves separation of fine pulverized coal particles medium from coarse medium. The pulverized coal along with the carrying medium strikes the impact plate through the lower part. Large particles are then transferred to the ball mill. 5. Cyclone Separators: - It separates the pulverized coal from carrying medium. The mixture of pulverized coal vapour caters the cyclone separators.

6. The Tturniket: - It serves to transport pulverized coal from cyclone separators to pulverized coal bunker or to worm conveyors. There are 4 turnikets per boiler. 7. Worm Conveyor: - It is equipment used to distribute the pulverized coal from bunker of one system to bunker of other system. It can be operated in both directions. 6. ASH HANDLING Ash handling refers to the method of collection, conveying, interim storage and load out of various types of ash residue left over from solid fuel combustion processes. The most common types of ash include bottom ash, bed ash, fly ash and ash clinkers resulting from the combustion of coal, wood and other solid fuels. Ash handling systems may employ pneumatic ash conveying or mechanical ash conveyors. A typical pneumatic ash handling system will employ vacuum pneumatic ash collection and ash conveying from several ash pick up stations-with delivery to an ash storage silo for interim holding prior to load out and transport. Pressurized pneumatic ash conveying may also be employed. Coarse ash material such as bottom ash is most often crushed in clinker grinders (crushers) prior to being transported in the ash conveyor system. Very finely sized fly ash often accounts for the major portion of the material conveyed in an ash handling system. It is collected from baghouse type dust collectors, electrostatic precipitators and other apparatus in the flue gas processing stream. Ash mixers (conditioners) and dry dustless telescopic

devices are used to prepare ash for transfer from the ash storage silo to transport vehicles. DIFFERENT TYPES OF ASH IN POWER PLANT The ash produced on the combustion of coal is collected by ESP. This ash is now required to be disposed off. This purpose of ash disposal is solved by Ash Handling Plant (AHP). There are basically 2 types of ash handling processes undertaken by AHP: Dry ash system Ash slurry system Dry ash system Ash slurry system Ash from boiler is transported to ash dump areas by means of sluicing type hydraulic system which consists of two types of systems: Bottom ash system Ash water system Bottom ash system In this system, the ash slag discharged from the furnace is collected in water impounded scraper installed below bottom ash hopper. The ash collected is transported to clinkers by chain conveyors. The clinker grinders churn ash which is then mixed with water to form slurry. Ash water system In this system, the ash collected in ESP hopper is passed to flushing system. Here low pressure water is applied through nozzle directing tangentially to the section of pipe to create turbulence and proper mixing of ash with water to form slurry. Slurry formed in above processes is transported to ashslurry sump. Here extra water is added to slurry if requiredand then is pumped to the dump area.

7. ELECTROSTATIC PRECIPITATOR

An electrostatic precipitator (ESP), or electrostatic air cleaner is a particulate collection device that removes particles from a flowing gas (such as air) using the force of an induced electrostatic charge. Electrostatic precipitators are highly efficient filtration devices that minimally impede the flow of gases through the device, and can easily remove fine particulate matter such as dust and smoke from the air stream.[1] In contrast to wet scrubbers which apply energy directly to the flowing fluid medium, an ESP applies energy only to the particulate matter being collected and therefore is very efficient in its consumption of energy (in the form of electricity). The most basic precipitator contains a row of thin vertical wires, and followed by a stack of large flat metal plates oriented vertically, with the plates typically spaced about 1 cm to 18 cm apart, depending on the application. The air or gas stream flows horizontally through the spaces between the wires, and then passes through the stack of plates. A negative voltage of several thousand volts is applied between wire and plate. If the applied voltage is high enough an electric (corona) discharge ionizes the gas around the electrodes. Negative ions flow to the plates and charge the gas-flow particles. The ionized particles, following the negative electric field created by the power supply, move to the grounded plates. Particles build up on the collection plates and form a layer. The layer does not collapse, thanks to electrostatic pressure (given from layer resistivity, electric field, and current flowing in the collected layer).