Steamthermalpowerplantpanki 121107093655 Phpapp01

Dr. B. R.
Ambedkar
National Institute of Technology, Jalandhar
Report on
Summer Training
[16
th
June to 28
th
July 2012]
Study of Electricity
Generation Through
Steam at PTPS

Ranjeet Kumar
Industrial & Production
Engineering
09113039
ranjeetnitj@gmail.com
N.I.T Jalandhar

Power Consumption In India
The energy sector holds the key in accelerating the economic
growth of India. The energy demands for developing country like
India keep on continuously growing. Energy is a driving force
behind rapid economic growth of the country. India ranks tenth in
the world in total energy consumption. It is first requirement of
energy to accelerate the development of the sector to meet its
growth aspirations.
The pattern of energy production put coal and oil again on
top. These account for 65% of the entire generation. Renewable
energy ranks bottom of the total production just before the
Nuclear energy. The distribution of energy resource like hydro
power is skewed towards North-eastern states of the country as 70
% of the total hydro potential is located in the Northern and
North-eastern region.

Figure of Power Consumption
Panki Thermal Power Station(PTPS),
Kanpur[U.P]
Panki Thermal Power Station is a Electricity Generation Station where
Electricity Generated through the steam operation on Turbine & Steam is
Generated by Coal Firing so it is a Typical Coal fired Electricity Generation
Station.
It is Located about 16 Kms Away from Kanpur Railway Station ,was
Started with two units(1
st
& 2
nd
) of 32 MW each.it was established in 1968.
After Generating Power for about 28-29 years,2*32 MW units had
completed their Rated Life So they were closed on 30
th
November 1995 &
18
th
April 1997 respectively.
So In 1976-77 ,Two Units (3
rd
& 4
th
of 2*110 MW each) Manufactured
,Installed Bharat Heavy Electronics Ltd. These units were established in
1976 & 1977 respectively.
Unit 3
rd
& 4
th
have been derated to 105 MW each by the Central
Electricity Authority(C.E.A) on 11
th
January 1990.
So Presently there are two units (3
rd
& 4
th
of 105 MW each) working at PTPS.

by ranjeetnitj@gmail.com (N.I.T Jalandhar)
About Steam Thermal Power Station
Process:-
A steam power plant is a power plant in which prime mover
is steam driven. Water is heated ,turns into steam and spins a
steam turbine(Impulse & reaction), which drives an
electrical generator. When the turbine turns, electricity is
generated and given as output by the generator, which is
then supplied to the consumers through high-voltage power
lines.

Process Diagram at Steam Power Plant
Fossil Fuel Power Station
Previously we discussed that steam is prime driven object in steam
power plant so in the case we needed steam for power generation ;so
this steam is generated by boiling the water in boiler & this boiling is
done by burning of Fuel.
FOSSIL FUEL POWER STAION:-
a fossil fuel power station is a power station that burns fossil fuels such as
coal ,natural gas or petroleum (oil) to produce electricity.

Chemical Energy Heat Energy Mechanical Electrical


Fuel+oil

Furnace Turbine Generator
Coal fired Steam Power Plant
Coal Fired Power Station:-
A coal Fired power station is that type of Fossil Fuel power station in
which coal is used as a Fuel. In the Steam Power Plant There is a
Separate Unit for Coal Handling System.
There are basically Five main units of a thermal power plant:
1. Coal Handling Plant (C.H.P)
2. Water Treatment Plant (W.T.P)
3. Boiler Maintenance Division (B.M.D)
4. Turbine Maintenance Division (T.M.D)
5. Generator

Coal Handling Plant
-:COAL HANDLING & DELIVERING SYSTEM:-
In a coal Based Thermal Power Plant , the initial process in the power
generation is Coal Handling so in this article I will Discuss the overall
Process Carried out a coal handling plant in a coal based thermal
power generating station.
The huge amount of coal is usually supplied through railways. A
railway siding line is taken into the power station and the coal is
delivered in the storage yard. The coal is unloaded from the point of
delivery by means of wagon tippler. It is rack and pinion type. The coal is
taken from the unloading site to dead storage by belt conveyors. The
belt deliver the coal to 0 meter level & further moves to transfer point.
The transfer points are used to transfer coal to the next belt. The belt
elevates the coal to breaker house. It consists of a rotary machine,
which rotates the coal and separates the light dust from it through the
action of gravity and transfer this dust to reject bin house through belt.
The belt further elevates the coal to the transfer point and it reaches the crusher
through belt. In the crusher a high-speed 3-phase induction motor is used to
crush the coal to a size of 50mm so as to be suitable for milling system. Coal rises
from crusher house and reaches the dead storage by passing through transfer
point.
Equipment used in a coal handling plant
1. Pull cord switch
Pull cord switch also known as Rope Operated Emergency Switch is used as safety
switch to stop the conveyor belt in case of an emergency by pulling the Rope. Pull
cord switch is mounted on the walkway side of the conveyor belt, Preferably at
about every 30 meters. when the rope is pulls from any side, the switch gets
operated. Unless and until the handle is reset manually position, the switch remains
in operated condition. NC contacts of all pull cord switches are wired in series and
further connected to PLC. when any switch along the belt operates, the contact
opens and conveyor is stopped.

Auxiliaries Of Coal Handling Plant
Figure of Pull cord switch & Belt weightier
2. Vibrating feeder
The coal stored in a huge hub is collected on the belt through vibrations
created by the vibrating feeder.
3. Flap gates
These are used to channelize the route of coal through another belt in case
the former is broken or unhealthy. The flap gates open let the coal pass and
if closed stop its movement.
4. Magnetic separator
these are used to separate the ferrous impurities from the coal.
5. Metal detector
These are detect the presence of any ferrous and non-ferrous metal in the
coal and sends a signal to a relay which closes to seize the movement of
belt until the metal is removed. It basically consists of a transmitter and a
receiver.
The transmitter consists of a high frequency oscillator, which produces a.
oscillations of 1500 Hz at 15V. The receiver receives this frequency signal.
If there is any presence of metal in the coal. Then this frequency is
disturbed and a tripping signal is send to relay to stop the conveyor belt
6. Belt weightier
It is used to keep an account of the tension & support on the belt
carrying coal and is moves accordingly to release tension on the belt.
7. Reclaim hopper
Reclamation is a process of taking coal from the dead storage for
preparation or further feeding to reclaim hoppers. This is accomplished
by belt conveyors
Reclaim Hopper
Steam Generation Process from Coal
STEAM GENERATION FROM COAL:-
1. Tipplers
Coal from the coal wagons is unloaded in the coal handling plant. This
unloading is done by the Tipplers. This coal is transported up to the raw
coal bunkers with the help of conveyor belts.
2.Coal Crushing
Although coal can be burned in solid form on grates, it is more usual to
break it up before feeding it to the combustion chamber. The treatment
depends on the nature of the coal. Some coals lend themselves to being
ground down to a very fine powder (called pulverized fuel (PF)) which is
then carried to the burners by a stream of air. Other coals are fed to
impact mills(Formally called Milling System) which use flails or hammers to
break up the material before it is propelled to the burners by an air stream.
The type of mill to be used on a particular plant will be determined by the
process
Preparation of Fuel
engineers and it is the task of the control engineer to provide a system which
is appropriate. To do this it is necessary to have some understanding of how
the relevant type of mill operates.
Various types of pulverized-fuel mill will be encountered, but two are
most commonly used:
The Pressurized or vertical-spindle ball mill
horizontal-tube mill
AT PTPS Vertical spindle ball mill is used.
Vertical-spindle ball mills
Figure shows the operating principle of a typical ball mill, such as the
Babcock 'E' mill. In this device, the coal that is discharged from the
storage hoppers is fed down a central chute onto a table where it is crushed
by the crushing actions between the rollers and rotating tables rotating steel
balls. Air is blown into the crushed coal and carries it, via

Preparation of Fuel
adjustable classifier blades, to the PF
pipes that transport it to the
burners. The air that carries the fine
particles of coal to the burners is
supplied from a fan called a 'primary-
air fan'. This delivers air to the mill,
which
therefore operates under a pressure
which is slightly positive with respect
to the atmosphere outside. Because
of this and because of its other
constructional
features, this type of mill is properly
called a 'vertical-spindle,
pressurized ball mill'.

Air supply systems for Ball mills
As stated above, the crushed coal in a pressurized ball mill is propelled to
the burners by a stream of warm air for proper drying & obtaining a particular
temperature of coal. Figure shows the arrangement
for doing this: cool air and heated air are mixed to achieve the desired temperature.
Primary Air FAN System for Ball Mill
Fuel Burning
3.Grate- It is the platform in Furnace upon which Fuel is Burnt & it is made of
Cast Iron Bars.The Bars are so arranged that air may pass on to the Fuel for
combustion.The area of the grate on which the fire rests in a coal or wood
fired boiler is called Grate surface.
4. Furnaces
It is a chamber formed by the space above the grate & below the boiler
shell,in which combustion takes place. It is also called a fire Box.
This crushed coal is taken away to the furnace through coal pipes with the
help of hot and cold air mixture from P.A Fan. P.A Fan takes atmospheric air,
a part of which is sent to Air pre-heaters for heating while a part goes
directly to the
mill for temperature control. Atmospheric air from F.D Fan is heated in the air
heaters and sent to the furnace as combustion air.
F.D(Force draught) Fan:-Force Draught Fan is main auxiliary of Furnace
which Provides Oxygen for Proper Combustioning of Fuel.It Takes Suction
From Environment. It is an Axial Flow Fan.

Oil Handling System
-:Oil Handling Plant:-
In Thermal Power Station Fuel Oil play a vital role.Oil burners besides initial
lighting up are also used to provide effective ignition of the coal
associated with P.F Burners and to stabilize the flame .The Burners can
provide enough heat to carry on boiling operation of the boilers for the
initial starting period. It can Provide 10-15% of the maximum load. At
Lean Period or when it is desired to Run the Boilers at OFF Load Condition
oil Burners are used.
Fuel oil used in Power Stations Are:-
# Heavy Furnace Oil (H.F.O)
# Light Diesel Oil (L.D.O)
# High Speed Diesel Oil (H.S.D)
# Low Sulphur High Stock Oil (L.S.H.S)
At Panki Thermal Power Station L.D.O is used as Fuel Oil
The Water Treatment plant is required at the water from canal cant be directly Used in
Boiler for Thermal Electricity Generator water is converted into steam at High Pressure &
It is allowed to force Turbine Rotated and the electricity is Generated. Therefore water is
the basic requirement to the thermal Power plant. Generally in the Thermal Power Plant
Is Employed to Refine the Water.
Necessity of Water Treatment:-
Natural Water Contains Solid,Liquid & Gasseous Impurities and Therefore this water cant
Be used for Generation of Steam in the Boiler ,The different Effect introduced due to use
Of Unrated Water in the boiler.So the water impurities should be removed before its used
as a stream.The following procedure is used in WTP for minimizing the hardness &
removing the impurities:-
Flocculate Plant:-
Here Alum is added is added to water to Precipitate
Dust Particles In Water.Aluminium in Alum
neutralizes Charge Dust Particle & this gives Result
to a heavy Complex Compound Which is settled

Water Treatment Plant (W.T.P)
Auxiliaries of W.T.P
down. Bleaching Powder & limestone along with chloride is also added
in this flocculation Tank to remove temporary hardness & chloride also
removes Bacteria & Organic matter.
This is Called flocculate plant because ,all the mixing and
processing is done In flocculation plant where flocculation Mechanism is
also happens.
Sand Filter-
These Stages of sand filter are putt across the flow so as to remove other
Suspended Particle, If any.
Activated Carbon filter-
This Filter is employed for removal of Bacteria and organic material. Here
anthracite(Coal) is uses for Filter.

Auxiliaries of W.T.P
Cation Exchanger-
At this stage ions are observed by ion exchnanger method,HCl and
negative resin are principle ingredient of this chemical filter
Anion Exchanger:-
Here Negative Ions are observed by Carefully Formulated by positive
resin.
Mixed Bed Exchanger:-
Here Remaining a negative ion is removed that is extracted through
resin.
The D.M(De mineralized) water is now ready which has some properties-
Conductivity-0.03 to 0.5 (micro/cm2)
PH-6.5
Hardness-NIL
Diagram of W.T.P at PTPS
Boiler:-
Boiler is an apparatus to produce Steam. Thermal energy Released by
Combustion of Fuel is Transferred to water ,Which Vaporizes and gets
converted water into steam at the desired temperature and pressure.It is
about 52 meter from the ground level.About its Design The boiler is a
rectangular furnace about 50 ft (15 m) on aside and 130 ft (40 m) tall. Its
walls are made of a web of high pressure steel tubes about 2.3 inches
(60 mm) in diameter. Pulverized coal is air-blown into the furnace from
fuel nozzles at the four corners and it rapidly burns, Forming
a large fireball at the center. The thermal radiation of the fireball heats
the water that circulates through the boiler tubes near the boiler
perimeter. The water circulation rate in the boiler is three to four times
the throughput and is typically driven by pumps. As the water in the
boiler circulates it absorbs heat and changes into steam at 700
0
F
(370
0
C)and 3,200psi (22.1MPa). It is separated from the water inside a
drum at the top of the furnace. The saturated steam is introduced into
superheat pendant.
Boiler Maintenance Division (B.M.D)
B.M.D & Its Supporting Auxiliaries
tubes that hang in the hottest part of the combustion gases as they exit the
furnace. Here the steam is superheated to 1,000F (540 C) to prepare it for
the turbine. 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. The generator includes the
economizer,
The Boiler Shell
Setting
Grate
The furnace with its steam generating tubes
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 bag house) and The
flue gas stack.
The Steam produced is used for Producing Mechanical work by
expanding it in steam engine or steam turbine.
According the Process Boiler is of two type-
1.Water Tube Boiler-In water Tube boilers,Water cIrculates through the
tubes and hot products of Combustion Flow over These tubes.
2.Fire Tube Boiler In this fire flows in the tubes & tubes is surrounded by
water,Fire tube boilers have low Initial cost in compare to Water Tube
Boiler.
At PTPS Water Tube Boilers Are Used.
Boilers are also called Steam Generator

Boiler
Boiler Shell or Boiler Drum:-The Shell or drum Consist of one or more Steel
Plates bent Into Cylinderical Form land Riveted or welded together.The shell
end are closed with the end plates.Its second or down plate made more
thicker than upper because all load applied on this.It is the main drum
which Received D.M Water from Boiler Feed Pump Passing through High
Pressure Heater & Economizer at a operating Pressure of 183kg/cm2 From
Boiler Drum.The Water Runs through the tubes.These Tubes are known as
down comers.
Setting- The Primary Function of setting is to continue Heat to the Boiler by
the Passes of gases taking From FD Fan .It is made from Brickwork.
Grate- It is the platform in Furnace upon which Fuel is Burnt & it is made of
Cast Iron Bars.The Bars are so arranged that air may pass on to the Fuel for
combustion.The area of the grate on which the fire rests in a coal or wood
fired boiler is called Grate surface.
Furnaces-It is a chamber formed by the space above the grate & below
the

External View of Boiler at PTPS
boiler shell,in which combustion takes place. It is also called a fire Box.

Mountings-The Items Such as Stop Valve ,Safety valve, Water level Gauges,
Fusible Plug,Blow off cock ,Pressure Gauges,Water level Indicator etc. are
the mountings and a boiler cant work safely without these.
Path away Accessories or Integral Part of Boilers:-
Economizer:-Economizer is an important boiler accessory.The work of
Economizer is preheating of Feed water of boiler and to less Fuel
consumption Furnace. Preheating of feed Water is done by Flue Gases
which is comes from after burning of Fuel in the Combustion Chamber.
The Temperature of Feed Water at inlet of economizer is in Range of 160-
180
0
C
And after Leaving it,It becomes 210
0
C.It is located in Rear Side of Boiler.
Rotating Air Pre Heater:- The Purpose of Air Preheater is to Recover heat
of the Flue Gases Which is at a Considerably High as PA Fans
Temperature. It Rotates at the Speed of 176 rpm. The Heat of the flue
gases is absorbed by Heating Surface of air pre heaters and then transfer
to the cool air coming From P.A Fans.
LPH(Low Pressure Heater):-it takes Extraction from Turbine & gives
these Extraction to Condensate Water Cycle for PreHeating of this
water.It is Situated at 4meter level on Turbine Side.
HPH(High Pressure Heater):- Its work same as LPH to Preheat of Feed
water by bleeding of Turbine.
Dearator:-Work of Dearator is to Dearate of Water means to Remove
Dissolve Gases from DM water & to Give Proper Suction To Boiler Feed
Pump.It is Situated at 27meter level in Boiler side.
Boiler Feed Pump:-Its work is to take suction from dearator and give
it to Boiler Drum on High Pressure(183Kg/cm2).Cycle of Dearator to
boiler drum is called Feed Water Cycle.It is situated at 0 meter level
on Turbine side.
F.D(Force draught) Fan:-Force Draught Fan is main auxiliary of
Furnace which Provides Oxygen for Proper Combustioning of Fuel. It
Takes Suction From Environment. It is an Axial Flow Fan.
ID fan(Induced Draft Fan):-basically pulls out flue gas from the furnace
of boiler. It is located between dust precipitators(ESPs) and Chimney.
Obviously it handles hot air/dust. Whereas, FD fan(Forced Draft
Fan)supplies the required air into the furnace for combustion of fuel. It
handles air at normal temperature. The capacity/power rating of ID fan
will be more than that of FD fan.
Chimney:-When Coal burns in Furnace then Produce Smoke, Flew
Gases which content NO,SO2,CO,C etc. that ash is send in to Electro
Static precipitation and ash comes out with water but some Ash is
sucked by I.D fan which send into chimney with the smoke so the some
which is passing through Chimney is Black.
Super Heater:-The Function of a super heater is to Increase the
Temperature of Steam above Its Saturation point.The Super heater is very
important accessory of a Boiler & used in both in Fire Tube & Water Tube
Boiler.
Turbine Maintenance Division(T.M.D)
Steam Turbine
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.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 stages with each stage consisting of a stationary blade (or nozzle)
and a rotating blade. Stationary blades convert the potential
energy of the steam (temperature and pressure) into kinetic energy (velocity)
And direct the flow onto the rotating blades. The rotating blades convert the 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. The rotational speed is 3000 rpm for
Indian System (50 Hz)systems and 3600 for American (60 Hz) systems.

T.M.D
In a typical larger power stations, the steam turbines are split into three
separate stages, the first being the High Pressure (HP), the second the
Intermediate Pressure (IP) and the third the Low Pressure (LP) stage, where
high, intermediate and low describe the pressure of the steam.
After the steam
has passed through the HP stage, it is returned to the boiler to be re-heated
to its original temperature although the pressure remains greatly
reduced. The reheated steam then passes through the IP stage and finally
to the LP stage of the turbine.
A distinction is made between "impulse" and "reaction turbine designs
based on the relative pressure drop across the stage. There are two
measures for pressure drop, the pressure ratio and the percent reaction.
Pressure ratio is the pressure at the stage exit divided by the pressure at the
stage entrance. Reaction is the percentage is entropic enthalpy drop
across the rotating blade or bucket compared to the total stage enthalpy
drop. Some manufacturers utilize percent pressure drop across stage to
define reaction.
Steam Properties
At High Pressure (H.P) Turbine:-
Entrance Pressure-535
0
C-540
0
C
Entrance Temperature-130Kg/cm
2
Exit Pressure - 26Kg/cm
2
Exit Temperature-340
0
C
At Intermediate Pressure(I.P) Turbine:-
Entrance Pressure-24Kg/cm
2
Entrance Temperature-535
0
C
Exit Pressure-1.02 Kg/cm
2

Exit Temperature-140
0
C

Steam Turbine
Generator

Generator:-
An electric Generator is a machine which converts Mechanical Energy
(or Power) into Electrical Energy. This Energy Conversion is based on the
principle of the production of dynamically induced e.m.f is Produced in
it according to faradays law, Whenever a conductor is moving in a
magnetic Field then it cuts Magnetic Flux and there were an
E.M.F(Electro magnetic Force) Produced ,which is Called Induced
E.M.F.
e=N*d/dt
Overall Process
Thank You !

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