INDUSTRIAL VISIT

(AT 2X500 MW BHUSAVAL THERMAL POWER PLANT) UNDER

VISIT BY: MAYUR BHAGWAN VANJARI

STUDENTS OF: TRIMURTI INSTITUTE OF TECHNOLOG JALGAON, MAHARASHTRA.

ABSTRACT
This report is based on our observations during our visit to the Bhusaval Thermal Power Plant (2X500 MW). Nowadays various modifications have been done in the conventional method of generation in order to increase the efficiency of the plant. So all the new and recent technologies have been used in this plant and all such new machines and technologies were observed and studied.

INTRODUCTION
In a thermal power plant, thermal energy generated after burning coal is converted into the electrical energy. Steam generated in the boiler is introduced into the turbine, which rotates the turbine blades at particular speed and hence drives the generator to produce electricity. The main fuel used for producing steam is coal. After we drive the generator on, the magnetic flux is generated in the rotor winding, which is cut by the stator winding and current is induced in the stator winding. This is the basic principal of generation of the electricity but various factors have to be taken into consideration for the efficient generation. Hence it includes various systems and cycles such as turbine cycle, ash handling system, coal handling system etc. so this report contains a study of all the systems and all analysis are reported in brief.

UNIT OVERVIEW
For generating power, all the systems of the power plant need to work in synchronised manner. In power plant, there are various systems which work separately, but these are interconnected for generation purposes which are as follows. 1. 2. 3. 4. 5. 6. Boiler and ESP Turbine section Coal handling plant Ash handling plant Oil handling plant Other supporting systems such as i. Air conditioning system ii. Ventilation system iii. EOT cranes, transformers etc.

There are in all 8 coal mills in this 1000 MW project out of which 6 mills are work for each of 500 MW unit. The mills are used for crushing the coal into fine powders. This fine powdered coal is taken to the furnace where it is burned. This heat energy so produced is used to produce steam into the boiler, which is used to drive the turbine blades and connected to the exciter to generate the electricity. Three types of turbines are used namely High Pressure Turbines (HPT), Intermediate Pressure Turbines (IPT) and Low Pressure Turbines (LPT). The steam generated is firstly passes to the HPT and the steam coming out is taken back to the furnace and reheated and then given to the IPT. The steam through the IPT is given directly to the LPT. After the steam is used to drive the turbine blades, it needs to be condensed. The steam is taken to the condenser for the condensation. The resulting liquid is taken to the low pressure heater (LPH) for heating. Then this is taken to the Deaerator, where the air and the water are separated. Then the water is taken to the High Pressure Heater for heating.

BOILER
The steam required to drive the turbine is generated in the boiler. Water tube boiler is used in this power plant. The coal in the powdered is taken from the mills. There are 8 mills, 4 on the either side of the boiler. The coal is feeded from the 4 corners of the boiler. Initially some temperature is required to burn the coal. So firstly the combustion in the boiler is carried out using LDO (Light Diesel Oil). Then this heat is used in the combustion of HFO (Heavy Furnace oil). Using this combustion process a sufficient heat conditions are achieved for the burning of the coal. The height of the boiler used in this plant is 80 meters. Many number of water tubes are present around the furnace. The combustion of the coal in the furnace generates sufficient heat to convert steam into the water. There are three steam lines through the boiler, a main steam line and the other 2 through the HT turbine (for super heating purpose). At the 8 meter height, a ring header is present to supply water to the boiler tubes.

ELECTROSTATIC PRECIPITOR
This part comes into picture for handling of ash coming out from boiler section after combustion of coal. It is based on electrostatic phenomenon. The ash coming out of furnace contains many ions. Ionisation is done to extract this ash. This portion consists of series of positively charged plates and negatively charged coils placed alternately. Ash gets stick to the plates. These plates are vibrated using hammers which are coupled to the shaft of rapper motor. As soon as the plates are hammered, due to vibration, ash falls down and gets accumulate in hopper. Hopper looks like a funnel which is provided with heater at its bottom to keep ash temperature favourable (120 ). Air is also blown into the hopper through pipes for easier flow of ash down to vacuum container. After that ash stored in buffer hopper and is transported to silo through pipes. Pressurised air is used to make the transportation. From silo sufficient amount of water is mixed with the ash to form the slurry. This slurry is transported out of the plant to the ash bund. This ash is further utilised for cement and brick manufacturing. On the other hand smoke and various gases are sent into air through chimney. ID fan (induced draft) is used for this operation. Induced draft fan sucks the smoke and gases from the hopper and sends them into air. The chimney is structured with the height of 275m.

TURBINE CYCLE
There are three turbines present in this power plant namely High Pressure Turbines (HPT), Low Pressure Turbines (LPT), Intermediate Pressure Turbines (IPT). HPT is placed first followed by the IPT and LPT. The place where all the turbines are place is called as the Turbine generator building. To all these turbines a generator is connected to generate the electricity. The turbines are placed at the 17 meter height. Between 0 meter and 17 meter all the machineries and equipments are placed required to condense the generated steam. The turbines are initially driven using the oil before the steam is passed and the machineries required for this oil (mainly oil tank, pump etc.) are kept at the 0 meter height. This oil is used to lubricate the shaft. The steam is initially to the HTP. Then the heat coming through the HTP is taken back to the furnace for reheating before it is given to the ITP. Then this steam is given to the LTP directly. The resulting steam is taken back to the condenser. The steam required to drive the turbines should not be acidic for it does not damage the turbine blades. The pH levels are checked whether the steam is of the appropriate quality or not.

OIL HANDLING PLANT

In oil handling plant, oil handled are LDO (Light diesel oil) and HFO (high furnace oil). These oils are stored in cans of volume 2000 kl. There are two cans for HFO and single for LDO. LDO has light viscosity and burns very easily, while HFO is high viscous and takes time for combustion. Pressure, transmission, temperature and withdrawing oil from containers of train is controlled by control room. LDO is costly as compared to HFO. Initially LDO is used for combustion. The reason behind this is LDO burns easily. Then HFO is used and then finally coal.

COAL HANDLING PLANT

Wagon tipplers are used to collect the coal from the wagon of the train. Wagon tippler rotates the wagon 180 and coal is collected in the container. Then coal is transported to the bunker through the belt which has an inclination of 15 and taken to the height of 60m of the bunker. There are crushers in between coal extraction point and bunkers. The operation of crusher is to divide the carrier belt into two ways one goes to unit 4 and another to unit 5. Since during extraction of coal from wagons there forms huge amount of dust, these dust is removed using air ducts provided all over the carrier belt section. When carrier reaches above the bunker a machine is used to withdraw coal into different bunkers. Each bunker has capacity of 800 tons.

PLANT CONTROL ROOM

All the major parameters of every section of plant are controlled from Plant control room. PCR consists of two sections, one is operation and other is control and instrumentation room. PCR involves microprocessor based systems in which plant parameters are controlled automatically or manually on computer by operator. Using designed software, all essential controls are given on computer screen. It can be controlled by the operator operating particular section on computer screen seating in operational room in PCR section. For example, if there is increase in humidity in steam, it will be displayed on computer screen this is done using sensors. To control the humidity temperature of air is increased all over from PCR. Similarly, all operations can be controlled using PCR such as, working of motor etc. PCR is basically electronic system involving PLC and SCADA using microprocessors and microcontrollers.

GENERATOR
Basic principle: Generator is the synchronous machine which converts mechanical energy into electrical energy by the principle of electromechanical energy conversion. It consists of stator core, stator winding, rotor, rotor core and yoke. 500 MW GENERATORS Generator used in this power station is 500 mw capacity turbogenerator. It is called turbogenerator because it is driven mechanically by steam turbine. Controlled dc excitation is given to rotor winding. Dc excitation is controlled by automatic voltage convertor. Brushless excitation system is used which consist of pilot exciter, main exciter and rolling diode arrangement. An EMF is induced in the stator winding by action of flux cutting. This induced EMF is nothing but three phase voltage across generator which is 21 KV in this case. Supply frequency is controlled by steam input to the turbine.

GENERATOR TRANSFORMER
Transformer is electrostatic device which transforms electrical energy from supply end to load end with change in voltage level keeping frequency constant. A simple transformer consists of two windings having mutual inductance on a common magnetic core which carries flux. In this power station three single phase generator transformers are used which step up the generator voltage from 21kV to 400kV for transmission purpose. Advantage of stepping up the generator voltage is to reduce transmission losses. In overhead conductors each single phase unit is having capacity of 200 MVA, and a coil is used for cooling i.e. OFAF cooling is used. Primary side of transformer is connected in delta and secondary winding is connected in star.

SWITCH YARD
The switch yard of the power plant is for the transmission purpose of the generated power. All the power is supplied to the switch yard in bulk which then supplies it to the various sub stations. Basically a transmission of 400 KV is to be stepped down for transmission and provided to the consumers. 400 KV is supplied to some of the large consumers like big industries, then some large consumers demand 220 KV or 132 KV supply and 11 KV or 22KV is to be supplied at various levels. At the domestic levels the generated voltage needs to be stepped down to 400 V. all this lines of transmission pass through the switch yard. At the stage of plant erection, ate auxiliaries need a supply. This transmission of power to the plant from other stations is taken care by the switch yard. The power from the other stations comes to the switch yard through bus bars and is stepped down to 11 kV for the plant use by station transformers. The switch yard mainly consists of the transmission lines, isolators, breakers, current transformers, potential transformers. Isolators are used to de-energize the electrical circuits for the maintenance purpose. A circuit breaker is an automatically operated switch designed to protect the electrical circuit from damage due to overload and short circuit. CT and PT are used basically for the measurement purposes. When the power is generated, the plant auxiliaries are run on this generated power. That means the plant uses its own power to run its auxiliaries. Unit auxiliary transformer is used for this purpose. The unit auxiliary transformer is a power transformer that provides power to the station auxiliaries during normal operation. This transformer is connected directly to the main generator and as such will provide the cheapest power for the station use since any power from the transmission lines has losses associated with it due to the line losses and transformer losses from whatever step up transformer provided that power. These unit auxiliary transformer is a three winding transformer having one primary winding rated 22 kV and two secondary windings rated 6.6 kV and 4.2 kV. This allows the transformer to power two different voltage level buses in the plant .This transformers take the power generated in the plant, step it down and supply it to the auxiliaries that need to run the power plant.

The UATs secondary windings are connected to the non -segregated phase bus duct. This bus work conveys the power to the different medium voltage switch gears located in the plant. Switch gear is the collective term used all the equipment used for protection, measurement and controlling electric power. In this plant design there are two sets of switch gear buses rated at 6.6 kV and 4.2 kV. Each 6.6kV bus can be energised by the UAT. The same is true for 4.2 kV switch gear.