N A T IO N A L T H E R M A L P O W E R P L A N T

BADARPUR THERM AL POWER

S TATION
Badarpur, New Delhi-110044

SUMMER TRAINING REPORT

TO STUDY VARIOUS OPERATIONS OF THERMAL POWER PLANT

SUBMITTED BY:

PULKIT KHANDURI
12109059
( Me 7 th
semester) NIT Jalandhar

PREFAC
E
I feel honored while pres enting this report of my work in BADARPUR THERM AL POWER
PLANT for the period of 6 weeks Indus trial training. This report has all the details about this
power plant and our training experiences . This report contains all the details of various s ections
of power plant and work performance.
I have tried to keep report as s imple as pos s ible and illus trative not leaving any information.
We als o took the help of NTPC res ources .

PULKIT KHANDURI

ACKNOWLEDGEME
NT
In this era of global energy we need a great balance between theoretical and practical
knowledge. In this res pect the vocational training is a great boon for the engineering as pirants .
It gives us a great chance to come in line with the actual problems going on in the indus tries
and getting a chance to work with the engineers and learn how to tackle every s ituation.
I am thankful to the s taff of the BTPS for their time and effort and their willingnes s in
s hearing there valuable experiences . I would like to my s incere thanks to M r. M an M ohan S ing
for giving me opportunity to learn with this es teemed organization. I would like expres s my deep
s ens e of gratitude to the operators and technician of thermal power plant (BM D, PAM , &
TM D) department for their guidance, continuous encouragement and valuable s ugges tion.

PULKIT
KHANDURI

Table of contents
Descripation
Introduction
Coal to electricity
Principle of combustion
Boiler drum
Air preheater
Basic of fans
Draft system
Pulverizer
Boiler fitting and mountings
Coal feeder
Water circulation system
Ash handling plant
Water treatment plant
Introduction Turbine and classification

NTPC LTD.
The year 1975 witnes s ed the birth of an organization that went on to achieve great feats in
performances in s ector that was until then, characterized largely by lack of inves tment, s evere s upply s hortages
and operational practices that made the commercial viability of the s ector uns us tainable. NTPC s ymbolized
hope of the country s uffering from crippling power black ours the Government of India, which was trying to
put an ailing economy back on tract and the world bank, which was s upporting the country in many
development initiatives . Thus , NTPC was created not only to redraw the power map of India but als o excel
in its performance and s et benchmarks for others to follow. It s ucceeded on both counts .
Today with an ins talled capacity of 43,019 M W, NTPC contributes one fourth of the nationals Power
generation, with only one fifth of Indias total ins talled capacity. An IS O 9001:2000 Certified company, it
is worlds 10th larges t power generation in the world, 3rd larges t in As ia. NTPC is firs t independent Power
Producer in the world. Als o it is 337th larges t company in the world
It is one of the larges t Indian companies in terms of market cap. The corporation recorded a
generation of 233.28 billion units in 2012-2013; through 17 coals bas ed, 7gas bas ed power plants , 7 s olar
bas ed plant s pread all over the country and als o has 7 plant in joint venture rated as of the s ixth bes t companies
to work for in India it has developed into a multi location and multi fuel company over the pas t three decades .

PLANTS DETAILS
The main plant equipment of thes e units was s upplied by M /S . BHEL. The boiler of s tage-1
(3X100M W) units is of CZECHOS OLOVAKIAN des ign and that of 210 M W units are of COM BUS TION
ENGINEERING des ign. The Turbo alternators , s upplied by M /S BHEL, are of RUS S IAN
deign and Control & Ins trumentation foe S tage-1 (3X95M W ) and S tage ll units are
mos tly of Rus s ian des ign and for S tage-lll are of KENT des ign and s upplied by M /S
ins trumentation Ltd., Kota.
Power is evacuated from BTPS by 10 circuits of 220KV network of Delhi through northern
grid. The coal s upply is through Railways from the linked mines of Bharat Coking Coal Ltd.
(BCCL ) and Central Coalfields Ltd. (CCL ) s ituated in Jharkhand. Water for cooling requirement
is receiving from Agra Irrigation Canal. The s tation is provided with cooling tower to operate on
clos ed cycle period during the mons oon period. The plant became operational on 26th July, 1973.
The trans fer of Badarpur Thermal power s tation built by the central electricity Authority,
for management by NTPC on April 1 1978 for the next ten years was an important landmark in the
his tory of the company. Badarpur threw up numerous challenges and opportunities . Though the
performance as

COAL TO ELECTRICITY
TRANSFORMATION OF
ENERGY COAL

BOILER

DIFFERENT LOADS

CHP OR COAL CYCLE

FROM JHARIA M INES
RAILWAY WAGON
BTPS WAGON TRIPPER
M AGNETIC S EPARATOR
CRUS HER HOUS E
COAL S TOCK
YARD RC BUNKER
RC FEEDER
BOWL M ILL
FURNACE

S TEAM TURBINE

GENERATOR

BASIC POWER PLANT CYCLE

The thermal (s team) power plant us es a dual (vapor + liquid) phas e cycle. It is a clos ed
cycle to enable the working fluid (water) to be us ed again and again. The cycle us ed is "Rankin
Cycle" modified to include s uperheating of s team, regenerative feed water heating and reheating
of s team.

On large turbines , it becomes economical to increas e the cycle efficiency by us ing reheat, which
is a way of partially overcoming temperature limitations . By returning partially expanded s team, to
a reheat, the average temperature at which heat is added, is increas ed and, by expanding this
reheated s team to the remaining s tages of the turbine, the exhaus t wetnes s is cons iderably les s
than it would otherwis e be convers ely, if the maximum tolerable wetnes s is allowed, the initial
pres s ure of the s team can be appreciably increas ed.
Coal to S team
Coal from the coal wagons is unloaded in the coal handling plant. This Coal is trans ported up to
the raw coal bunkers with the help of belt conveyors . Coal is trans ported to Bowl M ills by Coal
feeders the coal is pulverized in the Bowl M ill, where it is ground to a powder form. The mill
cons is ts of a round metallic table on which coal particles fall. This table is rotated with the help
of a motor. There are three large s teel rollers which are s paced 120" apart. When there is no coal,
thes e rollers does not rotate but when the coal is fed to the table it packs up between roller and
the table and this forces the rollers to

rotate. Coal is crus hed by the crus hing action between the rollers and rotating table. This crus hed
coal is taken away to the furnace through coal pipes with the help of hot and cold air mixture from
P.A. Fan.
Water from the boiler feed pump pas s es through economizer and reaches the boiler drum. Water
from the drum pas s es through down comers and goes to bottom ringleader. Water from the
bottom ring header is divided to althea four s ides of the furnace. Due to heat and- the dens ity
difference the water ris es up in the water wall tubes . "Wateris h partly converted to s team 'as it
ris es up in the furnace. This s team and water mixture is again taken to the boiler drum where the
s team is s eparated from water. Water follows the s ame path while the s team is s ent to s uper
heaters for s uperheating. The s uper heaters are located ins ide the furnace and the s team is
s uperheated (540"C) and finally it goes to turbine.
Steam to mechanical Power
From the boiler, a s team pipe conveys s team to the turbine through a s top valve (which can be
us ed to. s hut off s team in an emergency) and through control valves that automatically regulate
the s upply of s team to the turbine where it pas s es through a ring of s tationary blades fixed tithe
cylinder wall. Thes e act as nozzles and direct the s team into a s econd ring of moving blades
mounted on a dis c which rotates the blades and its pas s age of s ome heat energy is changed into
mechanical energy.

The turbine s haft us ually rotates at 3,000revolutions per minute. This s peed is determined
by the frequency of the electrical s ys tem us ed in this country and is the s peed at which a 2- pole
generator mus t be driven to generate alternating current at a frequency of 50 cycles per s econd.
BOILER MANTENANCE DEPARTMENT

Specifications

M ain boiler
Evaporation
F eed water tem perature
F eed water leaving
ec ono m izer
S TEAM
TEM PERATURE:
Drum
S uper heater outlet
Reheat inlet
Reheat outlet
S TEAM PRES S URE:
Drum des ign
Drum operating
S uper heater
outlet
Reheat inlet
Reheat outlet
FUEL: COAL
Fixed carbon
Volatile
matter
M ois ture
Grind ability
OIL:
Calorific value of fuel
oil
S ulphur content
M ois ture content
Flas h point

at 100%
load
700t/hr
247C
276
C
341C
540C
332C
540
C
158.20 kg/cm2
149.70 kg/cm2
137.00 kg/cm2
26.35 kg/cm2
24.50
kg/cm2
DES IGN
38%
26%
8%
50%
Hardgra
ve

WORS T
25%
25%
9%
45%
Hardgr
ave

10,000
kcal/kg
4.5% W/W
1.1% W/W
66

Feed water
cycle
DEAERATOR

CONDENSATE
CYCLE
FROM LOW PRES S URE TURBINE

BOILER FEED PUM P

CONDENS ER

H P HEATER1
H P HEATER2
H P HEATER3
FEED WATER LINE

HOT WELL

ECONOM IS ER

GLAND S TEAM COOLER

BOILER DRUM

CONDENATE PUM P
EJECTOR
LPH1

GS C2

DOWN COMERS

LPH2

UPRISERS

LPH3

BOILER DRUM

LHP4
DEAERATOR

Principles of Combustion
The primary function of oil and coal burning s ys tems the proces s of s team generation is to
provide controlled efficient convers ation of the chemical energy of the fuel into heat energy
which is then trans ferred to the heat abs orbing s urfaces of the s team generator. The combus tion
elements of a fuel cons is t of carbon, hydrogen and us ually a s mall amount of s culpture. When
combus tion is properly completed the exhaus t gas es will contain, carbon dioxide, water vapour,
s ulphur dioxide and a large volume of Nitrogen, Combus tion is brought about by combining carbon
and hydrogen or hydrocarbons with the oxygen in air. When carbon burns completely, it res ults in
the formation of a gas known as carbon dioxide. When carbon burns incompletely it forms carbon
monoxide.
The following factors in efficient combus tion are us ually referred to as "The three
Ts Time
It will take a definite time to heat the fuel to its ignition temperature and having ignited, it will
als o take time to bum. Cons equently s ufficient time mus t be allowed for complete combus tion of
the fuel to take place in the chamber.
TEMPERATURE
A fuel will not burn until it has reached its ignition temperature. The s peed at
which this Temperature will breach is increas ed by preheating the combus tion air. The
temperature of the flame of the burning fuel may vary with the quantity of air us ed. Too much
combus tion air will lower the flame temperature and may caus e uns table ignition.

TURBULENCE
Turbulence is introduced to achieve a rapid relative motion between the air and the
fuel particles . It is found that this produces a quick propagation of the flame and its
rapid s pread throughout the fuel/air mixture in the combus tion chamber. Combus tion
efficiency: It varies with individual different grades of fuel within each boiler. The idea to be
aimed at is the correct quantity of air together with good mixing of fuel and air to obtain the
maximum heat releas e.
M aximum combus tion efficiency depends on
Des ign of the boiler.
Fuel us ed.
S kill in obtaining combus tion with the minimum amount of exces s air

INTRODUCTION of furnace
Furnace is primary part of boiler where the chemical energy of fuel is converted to thermal
energy by combus tion. Furnace is des igned for efficient and complete combus tion. M ajor factors
that as s is t for efficient combus tion are amount of fuel ins ide the furnace and turbulence, which
caus es rapid mixing between fuel and air. In modern boilers , water-cooled furnaces are us ed.
TYPES OF FURNACE
P.F. FIRED DRY BOTTOM FURNACE:

gas temperature and hence les s s oot depos it ins uperheaters and reheaters .
SLAG TYPE FURNACE
Furnace of this type normally has two parts . Primary furnace is us ed for very high rate of
combus tion. Provis ion is to make molten s lag and crus h the granular form for eas y dis pos al. As
the as h has to flow from the primary furnace, coal having low melting temperature can only
be us ed. To obtain high temperature ins ide the primary s urface that will facilitate the eas y
flow of as h, very s mall but highly rated des ign is needed for primary furnace hence maintenance
is needed.

OIL FIRED BOILER FURNACE

Normally about 65% of furnace volume is enough for an oil-fired boiler as compared to
the corres ponding P.F. fired boiler. Oil-fired furnace is generally clos ed at the bottom, as there is
no need to remove s lag as in cas e of P.F. fired boiler. The bottom part will have s mall amount of
s lope to prevent film boiler building in the bottom tubes . If boiler has to des ign for both P.F. as
well as oil, the furnace has to be des igned for coal, as otherwis e higher heat loading with P.F.
will caus e s logging and high furnace exit gas temperature.

BOILER DRUM
Drum is of fus ion-welded des ign with welded hemi-s pherical dis hed ends . It is provided
with s tubs for welding all the connecting tubes i.e. down comers , ris ers , pipes , s aturated s team
outlet. The function of s team drum internals is to s eparate the water from the s team generated
in the furnace walls and to reduce the dis s olved s olid contents of the s team below the pres cribed
limit of 1 ppm and als o take care of the s udden change of s team demand for boiler.

The s econdary s tage of two oppos ed banks of clos ely s paced thin corrugated s heets , which direct
the s team and force the remaining entertained water agains t the corrugated plates . S ince the
velocity is relatively low this water does not get picked up again but rundown the plates and off
the s econd s tage of the two s team outlets . From the s econdary s eparators the s team flows
upwards to the s eries of s creen dryers , extending in layers acros s the length of the drum. Thes e
s creens perform the final s tage of s eparation.
Water walls
Water flows to the water walls from the boiler drum by natural circulation. The front and the
two s ide water walls cons titute the main evaporation s urface abs orbing the bulk of radiant heat of
the fuel burnt in the chamber. The front and rear walls are bent at the lower ends to form a
water-cooled s lag hopper. The upper part of the chamber is narrowed to achieve perfect mixing
of combus tion gas es . The water walls tubes are connected to headers at the top and bottom. The
rear water walls tubes at the top are grounded in four rows at a wider pitch forming the grid tubes .
REHEATER
Reheated is us ed to rais e the temperature of s team from which a part of energy
has been extracted in high- pres s ure turbine. This is another method of increas ing the
cycle efficiency. Reheating requires additional equipment I.e. Heating s urface connecting boiler
and turbine pipe s afety equipment like s afety valve, non-return valve, is olating valves , high
pres s ure feed pump, etc. Reheater is compos ed to two s ections namely front and rear pendant
s ection which is located above the furnace arch between water-cooled s creen wall tubes and rear
wall hanger tube.

SUPER HEATER
Whatever type of boiler is us ed, s team will leave the water at its s urface and pas s into the s team
s pace.

S team formed above the water s urface in a s hell boiler is always s aturated and cannot
become s uperheated in the boiler s hell, as it incons tantly in contact with the water s urface.
If s uperheated s team is required, the s aturated s team mus t pas s through a s uperheated. This is
s imply a heat exchanger where additional heat is added to the s aturated s team.
N water-tube boilers , the s uperheated may be an additional pendant s us pended in the
furnace area where the hot gas es will provide the degree of s uperheat required (s ee
Figure3.4.4). In other cas es , for example in CHP s chemes where the gas turbine exhaus t
gas es are relatively cool, a s eparately fireds uperheater may be needed to provide the additional
heat.

If accurate control of the degree of s uperheat is required, as would be the cas e if the s team is to
be us ed to drive turbines , then an attemperator (des uperheater) is fitted. This is advice ins talled
after the s uperheated, which injects water into the s uperheated s team to reduce its temperature.
ECONOMISER
The function of an economizer in a s team generating unit is to abs orb heat from the flue gas es
and add as a s ens ible heat to the feed-water before the water enters the evaporation circuit of the
boiler.
Earlier economizer were introduced mainly to recover the heat available in flue gas es that leaves
the boiler and provis ion of this addition heating s urface increas es the efficiency of s team
generators . In the modern boilers us ed for power generation feed-water heaters were us ed to
increas e the efficiency of turbine unit and feed-water temperature.
ECONOMISER

LOCATION AND MAINTENACE

It is us ual to locate economizer ahead of air heater. Counter flow arrangement is
normally s elected s o that heating s urface requirement is kept minimum for the s ame temperature
drop in flue gas . Water flow is from bottom to top s o that s team if any formed during the heat
trans fer can move along with water and the lock up s team which will caus e overheating and failure
of economizer tube.
M anholes and adequate s pacing between the banks of tubes are provided for ins pection
and maintenance works .
AIR PREHEATER
Air preheated abs orbs was te heat from the flue gas es and trans fers this heat to incoming
cold air, by means of continuous ly rotating heat trans fer element of s pecially formed metal
plates . Thous ands of thes e high efficiency elements are s paced and compactly arranged within
12 s ections . S loped compartments of a radically divided cylindrical s hell called the rotor. The
hous ing s urrounding the rotor is provided with duct connecting both the ends and is
adequately s caled by radial and circumferential s caling.
AIR PREHEATER CONSISTS OF
Connecting plates
Hous ing
Rotor
Heating s urface elements
Bearings
S ector plates and S ealing arrangement

S PECIFICATIONS
Number of air preheated per unit
Heater s ize
A p p r o x h e a t i n g s u r f a c
e
Rotor drive motor 15 H.P
S p e e d r e d u c t i o n r a t i o
A p p r o x o i l c a p a c i t y
S o l e n o i d V a l u e

2
27-VI-(T)-74
1cas
9 ing
0 0 0 m
2
110:1
13 Gallon
s 110 V, A.
C

e a c
h

BASICS OF FANS
The air we need for combus tion in the furnace and the flue gas that we mus t evacuate
would not pos s ible without us ing fans . A fan es capable of imparting energy to the air/gas in the
form of a boos t in pres s ure. We overcome the los s es through the s ys tem by means of this
pres s ure boos t. The boos t is dependent on dens ity for a given fan at a given s peed. The higher the
temperature, the lower is the boos t. Fan performance (M ax. capability) is repres ented as volumes .
Pres s ure boos t.
The bas ic information needed to s elect a fan is :
Air or Gas flow (Kg/hr).
Dens ity (function of temperature and pres s ure).
S ys tem, res is tance
(los s es ). Classification of
Fans
In boiler practice, we meet
the following types of fans .
Axial fans
Centrifugal (Radial) fans
In this type the movement of air or gas is parallel to its exit of rotation. Thes e fans are better
s uited to low res is tance applications .
The blade wheel whirls air centrifugally between each pair of blades and forces it out peripherally
at high velocity and high s tatic pres s ure. M ore air is s ucked in at the eye of the impeller. As the air
leaves the revolving blade tips , part of its velocity is converted into additional s tatic pres s ure by
s croll s haped hous ing.
AXIAL FAN

There are three types of

blades .

Backward curved
blades .
Forward curved blades .
Radial blades .

B efore a detailed s tudy of indus trial fans it is in the fitnes s of things to

unders tand the various draft s ys tems maintained by thos e fans .

The terms draft denotes the difference

between pres s ure exis ting in the furnace.

the atm os pheric pres s ure and the

Depending upon the draft us ed, we have

Natural Draft
Induced Draft
Forced Draft
Balanced Draft S ys tem

NATURAL DRAFT
In natural draft units the pres s ure differentials are obtained have c o ns truc ting
tall c him neys s o that vacuum is ' created in the furnace Due to s mall pres s ure difference, air is
admitted into the furnace
INDUCED DRAFT

In this s ys tem the air is adm itted to natural pres s ure differenc e and the flue g as es
of induc ed D raft fans and
are taken out by m eans
the under vac uum .
furnac e is m aintained
FORCED DRAFT

A s et of forced draft fans are made us e of for s upplying air to the furnace and s o the
furnace is pres s urized. The flue gas es are taken out due to the pres s ure difference between the
furnace and the atmos phere.
BALANCED DRAFT

Here a s et of Induced and Forced Draft Fans are

utilized furnace. Normally all the power s tations utilize this
draft s ys tem.

in
maintaining

a vacuuming
the

INDUSTRAIL
FAN

The induced Draft Fans are generally of Axial -Impuls e Type. Impeller nominal diameter is of
the order of 2500 mm.

The fan cons is ts of the following s ubas s emblies

S uction Chamber
Inlet Vane Control

Outlet Guide Vane As s embly

The outlet guides are fixed in between thec a e o f t h e d i f f u s e r a n d t h e c a s i n g . T

h e s e g u i d e v a n e s s e r v e t o direct the flow axially and to s tabilize the draft-flow
caus ed in the i m p e l l e r . T h e s e o u t l e t b l a d e s a r e r e m o v a b l e t y p e f r o
m o u t s i d e . During operation of the fan its elf thes e blades can be replaced one by one.
Periodically the outlet blades can be removed one at a time to find out the extent of wear
on the blade. If exces s ive wear is noticed the blade can be replaced by a new blade.
FD FAN
The fan, normally of the s ame
t y p e a s components :

ID Fa
n,

cons is
ts

of the
following

S ilencer
Inlet bend
Fan hous ing
Impeller with blades and s etting
mechanis m
Guide wheel cas ing with guide vanes and
diffus er.

The centrifugal and s etting forces of the blades are taken up by the blade bearings . The blade
s hafts are placed in combined radial and axial antifriction bearings which are s ealed off to the
outs ide. The angle of-incidence of the blades may be adjus ted during operation. The characteris tic
pres s ure volume curves of the fan may be changed in a large range without es s entially modifying
the efficiency. The fan can then be eas ily adapted to changing operating conditions . The rotor is
accommodated in cylindrical roller bearings and an inclined ball bearing at the drive s ide ads orbs
the axial thrus t. Lubrication and cooling thes e bearings is as s ured by a combined oil level and
circulating lubrication s ys tem.
PRIMARY AIR FAN
P.A. ran if flange mounted des ign, s ingle s tage s uction, NDFV type, backward curved bladed radial
fan operating on the principle of energy trans formation due to centrifugal forces . S ome amount
of the velocity energy is converted to pres s ure energy in the s piral cas ing. The fan is driven at a
cons tant s peed and the flow is controlled by varying the angle of the inlet vane control. The
S pecial feature of the fan is that is provided with inlet guide vane control with a pos itive and
precis e link mechanis m.

A pulverize is a mechanical device for the grinding of many different types of materials .
For example, they are us ed to pulverize coal for combus tion in the s team-generating furnaces of
fos s il fuel power plants .
.

Types of Pulverizes
Ball and Tube M ills
A ball mill is a pulverizer that cons is ts of a horizontal rotating cylinder, up to three
diameters in length, containing a charge of tumbling or cas cading s teel balls , pebbles , or rods .
A tube mill is a revolving cylinder of up to five diameters in length us ed for fine
pulverization of ore, rock, another s uch materials ; the material, mixed with water, is fed into the
chamber from one end, and pas s es out the other end as s lime.
Ring and Ball M ill
This type of mill cons is ts of two rings s eparated by a s eries of large balls . The
lower ring rotates , while the upper ring pres s es down on the balls via a s et of s pring and adjus ter
as s emblies . The material to be pulverized is introduced into the center or s ide of the
pulverizer (depending on the des ign) and is ground as the lower ring rotates caus ing the balls to
orbit between the upper and lower rings . The pulverized material is carried out of the mill by the
flow of air moving through it. The s ize of the pulverized particles releas ed from the grinding
s ection of the M illis determined by a clas s ifier s eparator.
M PS M ill
S imilar to the Ring and Ball M ill, this mill us es large "tires " to crus h the coal. Thes e are
us ually found in utility plants .
Bowl M ill
S imilar to the M PS mill, it als o us es tires to crus h coal. There are two types , a deep bowl
mill, and a s hallow bowl mill.

Advantage of pulverized coal

Efficient utilization of cheap and low grade coal
Flexibility to meet fluctuating load
Elevation of bending los er

BOILER FITTINGS AND MOUNTINGS

SAFETY VALVE
A
pres s ure
part of a
the s et
pres s ure

s afety valve is a valve mechanis m for the automatic releas e of a gas from a boiler,
ves s el, or other s ys tem when the pres s ure or temperature exceeds pres et limits . It is
bigger s et named Pres s ure (PS V) or Pres s ure Relief Valves (PRV). The other parts of
are named relief valves , s afety relief valves , pilot-operated s afety relief valves , low
s afety valves , vacuum pres s ure s afety valves .

FUNCTION AND DESIGN

BOILER STOP VALVES

A s team boiler mus t be fitted with a s top valve (als o known as a crown valve) which is olates
the s team boiler and its pres s ure from the proces s or plant. It is generally an angle pattern globe
valve of the s crew-down variety

The s top valve is not des igned as a throttling valve, and s hould be fully open or clos ed. It
s hould always be opened s lowly to prevent any s udden ris e in downs tream pres s ure and
as s ociated water hammer, and to help res trict the fall in boiler pres s ure and any pos s ible
as s ociated priming.
FEED WATER CHECK VALVES
The feed water check valve is ins talled in the boiler feed water line between the feed pump
and boiler. A boiler feed s top valve is fitted at the boiler s hell.

Boiler check
valve

The check valve includes a s pring equivalent to the head of water in the elevated feed
tank when there is no pres s ure in the boiler. This prevents the boiler being flooded by the s tatic
head from the boiler feed tank.
PRESSURE GAUGE
All boilers mus t be fitted with at leas t one pres s ure indicator. The us ual type is
a s imple pres s ure gauge cons tructed to BS 1780 Part 2 - Clas s One. The dial s hould be at
leas t 150 mm in diameter and of the Bourdon tube type, it s hould be marked to indicate the
normal working pres s ure and the maximum permis s ible working pres s ure / des ign pres s ure.
Pres s ure gauges are connected to the s team s pace of the boiler and us ually have a ring
type s iphon tube which fills with condens ed s team and protects the dial mechanis m from high
temperatures
Pres s ure gauges may be fitted to other pres s ure containers s uch as blow down
ves s els , and will us ually have s maller dials as s hown in Figure

GAUGE GLASSES AND FITTINGS

All s team boilers are fitted with at leas t one water level indicator, but thos e with a rating of 100
kW or more s hould be fitted with two indicators . The indicators are us ually referred to as gauge
glas s es complying with BS 3463.

GAUGE GLASS GUARDS

The gauge glas s guard s hould be kept clean. When the guard is being cleaned in place, or removed
for cleaning, the gauge s hould be temporarily s hut-off.
M ake s ure there is a s atis factory water level before s hutting off the gauge and take care not to
touch or knock the gauge glas s . After cleaning, and when the guard has been replaced, the gauge
s hould be tes ted and the cocks s et in the correct pos ition.
Coal Bunker
Thes e are in proces s s torage s ilos us ed for s toring crus hed coal from the coal handling
s ys tem. Generally, thes e are made up of welded s teel plates .' Normally, there are s ix s uch
bunkers s upplying coal of the corres ponding mills . Thes e are located on top of the mills s o as to
aid in gravity feeding of coal.

Coal Feeder
Each mill is provided with a drag link chain/ rotary/ gravimetric feeder to trans port raw coal from
the bunker to the inlet chute, leading to mill at a des ired rate.
Mills
There are s ix mill (25% capacity each), for every 200 .M W unit, located adjacent to the furnace at
'0' M level. Thes e mills pulverize coal to the des ired finenes s to be fed to the furnace for
combus tion.
Electros tatic precipitator
Thes e are generally two plate type located between boiler and the crr1imney. The
precipitator is arranged for horizontal gas flow and is cons tructed with welded s teel cas e

*********************************************************** *

WATER CIRCULATION SYSTEM

Theory of circulation
Water mus t flow through the heat abs orption s urface of the boiler in order that it is evaporated
into s team. In drum type units (natural and controlled circulation) the water is circulated from
the drum through the generating circuits and then back to the drum where the s team is s eparated
and directed to the s uper heater. The water leaves the drum through the down comer s at a
temperature s lightly below the s aturation temperature. The flow through the furnace wall is at
s aturation temperature. Heat abs orbed in water wall is latent heat of vaporization creating
admixture of s team and water. The ratio of the weight of the water tithe weight of the s team in
the mixture leaving the heat abs orption s urface is called

Types of boiler circulating system:

Natural circulation s ys tem
Controlled circulation s ys tem
Combines circulation s ys tem
Natural circulation system
Water delivered to s team generator from feed heater is at a temperature well below the
s aturation value corres ponding to that pres s ure. Entering firs t the economizer it is heated to about
30-40C below s aturation temperature. From economizer the water enters the drum and thus
joins the circulation s ys tem. Water entering the drum flows through the down comer and enters
ring heater at the bottom. In the water walls a part of the water is converted to s team and the
mixture flows back to the drum. In the drum, the s team is s eparated, and s ent to s uper heater for
s uper heating and then s ent to the high pres s ure turbine. Remaining water mixes with the
incoming water from the economizer and the cycle is repeated.
The circulation in this cas e takes place on the thermo-s iphon principle. The down comers
contain relatively cold water whereas the ris er tubes contain a s team water mixture. Circulation
takes place at s uch a rate that the driving force and the frictional res is tance in water walls are
balanced.
As the pres s ure increas es , the difference in dens ity between water and s team reduces .
Thus the hydros tatic head available will not be able to overcome the frictional res is tance
for a flow corres ponding to the minimum requirement of cooling of water wall tubes .

Controlled circulation system

Beyond 80 kg/cm of pres s ure, circulation is to be as s is ted with mechanical pumps to overcome
the frictional los s es . To regulate the flow through various tubes , orifice plates are us ed. This
s ys tem is applicable in the high s ub-critical regions (200 kg/cm).

Beyond the critical pres s ure, phas e trans formation is abs ent, and hence once through
s ys tem is adopted. However, it has been found that even at s uper critical pres s ure, it is
advantageous to recalculate the water through the furnace tubes and s implifies the s tart
up procedure. A typical operating pres s ure for s uch a s ys tem is 260 kg/cm.
ASH HANDLING PLANT
The as h produced in the boiler is trans ported to as h dump area by means of s luicing type hydraulic
as h handling s ys tem, which cons is ts of Bottom as h s ys tem, As h water s ys tem and As h s lurry
s ys tem.

BOTTOM ASH SYSTEM

In the bottom as h s ys tem the as h dis charged from the furnace bottom is collected
in two water compounded s craper through ins talled below bottom as h hoppers . The as h is
continuous ly trans ported by means of the s craper chain conveyor onto the res pective clinker
grinders which reduce the lump s izes to the required finenes s . The crus hed as h from the bottom
as h hopper from where the as h s lurry is further trans ported to operation, the bottom as h can is
dis charged directly into the s luice channel through the bifurcating chute bypas s the grinder.
The pos ition of the flap gate in the bifurcating chute bypas s es the grinder. The pos ition of
the flap gate in the bifurcating chute is to be manually changed.

The flus hing apparatus are provided under E.P. hoppers (40 Nos ), economizer hoppers (4
Nos ), air repeaters (2 Nos ), and s tack hoppers (4 Nos ), the fly as h gets mixed with flus hing
water and the res ulting s lurry drops into the as h s luice channel. Low pres s ure water is applied
through the nozzle directing tangentially to the s ection of pipe to create turbulence and proper
mixing of as h with water. For the maintenance of flus hing apparatus plate valve is provided
between apparatus and connecting tube.
Ash water system
High pres s ure water required for bottom as h hopper quenching nozzles , bottom as h hopper
s praying, clinker grinder s ealing s craper bars , cleaning nozzles , bottom as h hopper s eal
through flus hing, economizer hopper flus hing nozzles and s luicing trench jetting nozzles is
tapped from the high pres s ure water ring mainly provided in the plant area.
Low pres s ure water required for bottom as h hopper s eal through make up, s craper conveyor make
up, flus hing apparatus jetting nozzles for all fly as h hoppers excepting economizer hoppers , is
trapped from low pres s ure water rings mainly provided in the plant area.
Ash slurry system
Bottom as h and fly as h s lurry of the s ys temic s luiced up to as h pump along the channel with the
acid
of
high pres s ure water
locate
jets s uitable intervals
at
d
along
the
channe
l.

S lurry pump s uction line cons is ting of reducing elbow with drain valve, reducer and butterfly valve
and portion of s lurry pump delivery line cons is ting of butterfly valve, pipe & fitting has als o been
provided.

CHPH
(CONTROL S TRUCTURE PUM P HOUS E)
The control s ys tem has following pumps :Chlorine pump-2(for chlorination of water)
HP pump-6(for boiling of water)

LP pump-3(for EP pump hous e)

Fire pump-(in cas e of fire breakdown)
TWS pump-3(for s creening of water)
CRW pump-3(s upply water for water treatment)
This hous e is known as control hous e becaus e amount of water to be s upplied for
treatment is controlled from this hous e with the help of thes e pumps . Generally 2 CRW
pumps out of 3pumps remains open.s imilarly, 1 FS , 2 LP, 4 HP, 1 TWS pumps remain open. If
more water is needed then others pumps are opened
WATER TREATMENT PLANT
As the types of boiler are not alike their working pres s ure and operating conditions vary and s o do
the types and methods of water treatment. Water treatment plants us ed in thermal power
plants are des igned to proces s the raw water to water with very low in dis s olved s olids known as
"dematerialized water". No doubt, this plant has to be engineered very carefully keeping in view the
type of raw water to the thermal plant, its treatment cos ts and overall economic.

Actually, the type of demineralization proces s

chos en main factors :

for a power s tation depends on

three

The quality of the raw water.

The degree of de-ionization i.e. treated water quality
S electivity of res ins .
Water treatment proces s which is generally made up of two
s ections : Pretreatment s ection
Demineralization s ection
PRETREATMENT
SECTION
Pretreatment plant removes the s us pended s olids s uch as clay, s ilt, organic and inorganic
matter, plants another micros copic organis m. The turbidity may be taken as of two types of

coars ecomponents , s uch as s and, s ilt etc, can be removed from the water by s imple
s edimentation. Finer particles however, will not s ettle in any reas onable time and mus t be
flocculated to produce the large particles which are s ettling able. Long term ability to remain
s us pended in water is bas ically a function of both s ize and s pecific gravity. The s ettling rate
of the colloidal and finely divided (approximately 001 to 1 micron) s us pended matter is s o s low
that removing them from water by plain s edimentation is tank s having ordinary dimens ions is
impos s ible. S ettling velocity of finely divided and collide particles under gravity als o are s o
s mall that ordinary s edimentation is not pos s ible. It is neces s ary, therefore, to us e
procedures which agglomerate the s mall particles into larger aggregates , which have practical
s ettling velocities . The term Coagulation" and "flocculation" have been us ed indis criminately
To des cribe proces s of turbidity removal. "Coagulation" means to bring together the
s us pended particles . The proces s des cribes the effect produced by the addition of a chemical Al
(S P) g to colloidal dis pers ion res ulting in particle des tabilization by a reduction of force tending
to keep particles apart. Rapid mixing is important at this s tage to obtain. Uniform dis pers ion of
the chemical and to increas e opportunity for particles to particle contact. This operation
is done by flas h mixer in thec1ariflocculator. S econd s tage of formation of s ettle able
particles from des tabilized colloidal s ized particles is termed a flocculation". Here coagulated
particles grow in s ize by attaching to each other. In contras t to coagulation where the primary
force is electros tatic or intrins ic, "flocculation" occurs by chemical bridging. Flocculation is
obtained by gentle and prolonged mixing which converts the s ubmicros copic coagulated
particle into dis crete, vis ible & s us pended particles . At this s tage particles are large enough to
s ettle rapidly under the influence of gravity anomaly be removed.
If pretreatment of the water is not done efficiently then cons equences are as follows :
S i02 may es cape with water which will increas e the anion loading.
Organic matter may es cape which may caus e organic fouling in the anion exchanger
beds . In
the 'pre-treatment plant chlorine addition provis ion is normally made to combat organic
contamination.
Action loading may unneces s ary increas e due to addition of Ca(OH)2 in exces s of calculated
amount for rais ing the pH of the water for maximum floe formation and als o AKOrDgmayN
precipitate out. If les s than calculated amount of Ca (OH) 2 is added, proper pH flocculation
will not beobtained and s ilica es cape to demineralization s ection will occur, thereby increas ing
load on anion bed.
DEMINERALIZATION
This filter water is now us ed for dematerializing purpos e and is fed to cation exchanger
bed, butenroute being firs t dechlorinated, which is either done by pas s ing through activated
carbon filter or injecting along the flow of water, an equivalent amount of s odium
s ulphite through s ome s troke pumps . The res idual chlorine which is - maintained in
clarification plant to remove organic matter from raw water is now detrimental to action res in
and mus t be eliminated before its entry to this bed.
Normally, the typical s cheme of demineralization up to the .mark agains t average s urface
water is three bed s ys tems with a provis ion of removing gas eous carbon dioxide from water
before feeding to Anion Exchanger. Now, let us s ee, what happens actually in each bed when
water is pas s ed from one to another.

in s uch a way that thes e have the ability to, exchange one ion for another, hold it
temporarily in chemical combination and give it to a s trong electrolytic s olution. S uitable
treatment is als o given to them in s uch a way that a particular res in abs orbs only a
particular group of ions . Res ins , when abs orbing and releas ing cationic portion of dis s olved
s alts , is called cation, exchanger res in and when removing anionic portion is called anion
exchanger res in. Pres et trend is of employing 's trongly acidic cation exchanger res in and s trongly
bas ic anion exchanger res in in a DM Plant of modern thermal power s tation. We may s ee that
the chemically active group in a cationic res in is S Ox-H (normally repres ented by RH) and in
an anionic res in the active group is either tertiary amine or quaternary ammonium group
(normally the res in is repres ented by ROH). The reaction of exchange may be further repres ented
as below
Cation Res in
RH
+

NaKM gCa

(In the form of

s alts )
Anion Res in
ROH

RNaKCa

(Res in in H2CO3
form)

H2S O4

RS O4

H2S O4HCl HNO3

(Removed in degas s er
tower)

H2O

HCl ClHNO3 NO3M ineral acid Res ins in exhaus ted Obtain from cation form exchanger
The water from the ex-cation contains carbonic acid als o s ufficiently, which is very weak acid
difficult to be removed by s trongly bas ic anion res in and caus ing hindrance to remove s ilicate
ions from the bed. It is therefore a us ual practice to remove carbonic acid before it is led to anion
exchanger bed. The ex-cation water is trickled in fine s treams from top of a tall tower packed
with, ranching rings , and compres s ed air is pas s ed from the bottom. Carbonic acid breaks into
C03 and water mechanically (Henry's Law) with the carbon dioxide es caping into the
atmos phere. The water is accumulated in s uitable s torage tank below the tower, called
degas s ed water dump from where the s ame is led to anion exchanger bed, us ing acid res is tant
pump.
The ex-anion water is fed to the mixed bed exchanger containing both cationic res in and anionic
res in. This bed not only takes care of s odium s lip from cation but als o s ilica s lip from anion
exchanger very effectively. The final output from the mixed bed is Exira-ordinarily pure water
having les s than0.2/M ho conductivity 7.0 and s ilica content les s than 0.02 pm. Any deviation from
the above quality means that the res ins in mixed bed are exhaus ted and need regeneration,
regeneration of the mixed bed firs t calls for s uitable, back was hing and s ettling, s o that the two
types of res ins are s eparated from each other. Lighter anion res in ris es to the top and the heavier
cation res in s ettles to the bottom. Both the res ins are then regenerated s eparately with alkali and
acid, rins ed to the des ired value and air mixed, to mix the res in again thoroughly. It is then put to
final rins ing till the des ired quality is obtained.
It may be mentioned here that there are two types of s trongly bas ic anion exchanger. Type II
res ins are s lightly les s bas ic than type I, but have higher regeneration efficiency than type I.
Again as type II res ins are unable to remove s ilica effectively, type I res ins als o have to be us ed
for the purpos e. As s uch, the general condition s o far prevailing in India is to employ type I res in
in anion exchangers bed and type I res in in mixed bed (for the anionic portion).
It is als o a general convention to regenerate the above two res ins under through fare s ys tem i.e.

type II res in in anion exchanger bed. The content of utilizing the above res in and mode of
regeneration is now days being s witched over from the economy to a higher cos t s o as to have
more s tringent quality control of the final D.M .Water.
Internal Treatment
This final D.M effluent is then either led to hot well of the condens er directly as make up to
boilers , or being s tored in D.M . Water s torage tanks firs t and then pumped for makeup purpos e to
boiler feed.

As the D.M . Water has a good affinity to abs orb carbon dioxide and oxygen, and both are
extremely harmful to metal s urfaces for their des truction like corros ion, thes e have to be removed
before it is fed to boiler. This is being done in des ecrator. S till the res idual oxygen which is
remaining in the water is neutralized by a s uitable doze of hydrazine, at the point after
des ecrator. To have further minimum corros ion, the pH of feed water is to be maintained at
around 9.0 for which purpos e ammonia in s uitable doze is added to this make up water at a
point along with hydrazine as s tated above.
STEM TURBINE

OPERATING PRINICIPLES
A s team turbines two main parts are the cylinder and the rotor. As the s team pas s es
through the fixed blades or nozzles it expands and its velocity increas es . The high-velocity jet of
s team s trikes the firs t s et of moving blades . The kinetic energy of the s team changes into
mechanical energy, caus ing the s haft to rotate. The s team then enters the next s et of fixed
blades and s trikes the next row of moving blades .
As the s team flows through the turbine, its pres s ure and temperature decreas es ,
while its volume increas es . The decreas e in pres s ure and temperature occurs as the s team
trans mits .energy to the

s haft and performs work. After pas s ing through the las t turbine s tage, the s team exhaus ts into
the condens er or proces s s team s ys tem.

The kinetic energy of the s team changes into mechanical erringly through the impact (impuls e)
or reaction of the s team agains t the blades .
STEAM CYCLE
The thermal (s team) power plant us es a dual (vapour +liquid) phas e cycle. It is a clos ed cycle
to enable the working fluid (water) to be us ed again and again. The cycle us ed is "RankineCycle"
modified to include s uper heating of s team, regenerative feed water heating and reheating of
s team

On
to
us i
ove
ret
reh
whi
exp
re
exh
tha
if

large
turbines ,
it
becomes
economic increas e the cycle
efficiency by ng reheat, which is
a way of partially rcoming
temperature limitations . By urning
partially expanded s team to a eat,
the average temperature at ch
heat is added is increas ed and by
anding this reheated s team to
the maining s tages
of the
turbine, the aus t wetnes s is
cons iderably
les s n it would
otherwis
allowed, the initial pres s ure of the s team can be appreciably increas
ed e be convers ely, the
maximum tolerable wetnes s is
TURBINE CLASSIFICATION
Impulse Turbine:
In Impuls e Turbine s team expands in fixed nozzles . The high velocity s team from nozzles does
work on moving blades which caus es the s haft to rotate. The es s ential features of impuls e turbine
are that all pres s ure drops occur at nozzles and not on blades . A s imple impuls e turbine is
not very efficient becaus e it does not fully us e the velocity of the s team. M any impuls e
turbines are velocity compounded. This means they have two or more s ets of moving blades in

Reaction Turbine:
In this type of turbine pres s ure is reduced at both fixed& moving blades . Both fixed& moving
blades act as nozzles . Work done by the impuls e effect of s team due to revers als of direction of
high velocity s team. The expans ion of s team takes place on moving blades .
A reaction turbine us es the "kickback" force of the s team as it leaves the moving blades and
fixed blades have the s ame s hape and act like nozzles . Thus , s team expands , los es pres s ure and
increas es in velocity as it pas s es through both s ets of blades . All reaction turbines are
pres s ure-compounded turbines .
Compounding:
S everal problems occur if energy of s team is converted in s ingle s tep & s o compounding is
done. Following are the types of compounded turbine:
VELOCITY COMPOUND TURBINE
Like s imple turbine it has only one s et of nozzle &entire s team pres s ure drop takes place there.
The kinetic energy of s team fully on the nozzles is utilized in moving blades . The role of fixed
blades is to change the direction of s team jet & to guide it.
PRESSURE COMPOUNDED TURBINE
This is bas ically a no. of s ingle impuls e turbines in s eries or on the s ame s haft.
The exhaus t of firs t turbine enters the nozzle of the next turbine. Total pres s ure drop of s team
does not take on firs t nozzle ring but divided equally on all of them.

Pressure Velocity Compounded Turbine

It is jus t the combination of the two compounding has the advantages of allowing bigger
pres s ure drops in each s tage &s o fewer s tages are neces s ary. Here for given pres s ure drop the
turbine will be s horter length but diameter will be increas ed.

S team turbines may be clas s ified into different categories depending on their cons truction,
the proces s by which heat drop is achieved, the initial and final conditions of s team us ed
and their indus trial us age.

According to the direction of steam

flow
Axial turbines
Radial turbines
According to the number of
cylinder
S ingle - cylinder turbines .
Double- cylinder turbines .
Three-Cylinder turbines .
Four-Cylinder turbines
M ulti - Cylinder turbines
According to the steam conditions at inlet to turbines
Low-pres s ure turbines
M edium -pres s ure turbines
High-pres s ure
Turbines of very high pres s ures
Turbines of s upercritical
pres s ures According to their
usage in industry
Turbines with cons tant s peed of
rotation primarily us ed for driving
alternators .
S team turbines with variable s peed meant for driving turbo
blowers , air Circulators, pumps etc.
Turbines with variable s peed: Turbines of this type are us ually
employed in s teamers , s hips and railway locomotives (turbo
locomotives ) Main Turbine
The 210M W turbine is a tandem compounded type machine
compris ing of H.P. & I.P. cylinders . The
H.P. turbine compris es of 12 s tages the I.P. turbine has 11 s tages & the L.P. has four s tages of
double flow. The H.P. & I.P. turbine rotor are rigidly compounded & the I.P. & the I.P. rotor by
lens type s emi flexible coupling. All the three rotors are aligned on five bearings of which the

turbine. After expanding in the 12 s tages in the H.P. turbine the s team returned in the
boiler for reheating
The reheated s team from the boiler enter I.P. turbine via interceptor valves and control valves and
after expanding enters the L.P. turbine s tage via 2 numbers of cros s over pipes .
In the L.P. s tage the s team expands in axially oppos ite direction to counteract the trus t and enters
the condens er placed directly below the L.P. turbine. The cooling water flowing throughout the
condens er tubes condens es the s team a n d t h e condens ate collected in the hot well of the
condens er.
The condens ate collected is pumped by means of 3*50% duty condens ate pumps through L.P.
heaters to deaerator from where the boiler feed pump delivers the water to boiler through H.P.
heaters thus forming a clos ed cycle.
TURBINE CYCLE
Fres h s team from boiler is s upplied to the turbine through the emergency s top valve. From the
s top valves s team is s upplied to control valves s ituated on H.P. cylinders on the front bearing
end. After expans ion through 12 s tages at the H.P. cylinder s team flows back to boiler for
reheating and reheated s team from the boiler cover to the intermediate pres s ure turbine trough
two interceptor valves and four control valves mounted on the I.P.turbine.
After flowing trough I.P. turbine s team enters the middle part of the L.P. turbine through cros s
over pipes . In L.P. turbine the exhaus t s team condens es in the s urface condens ers welded
directly to the exhaus t part of L.P. turbine
The s election of extraction points and cold reheat pres s ure has been done with a view to achieve
the highes t efficiency. Thes e are two extractions from H.P. turbine, four from I.P. turbine and one
from L.P. turbine. S team at 1.10 to 1.03 g/s q cm Abs is s upplied for the gland s ealing. S team for
this purpos e is obtained from deaerator through a collection where pres s ure of s team is regulated.
From the condens er condens ate is pumped with the help of 3*50% capacity condens ate pumps
to deaerator through the low pres s ure regenerative equipments .
Feed water is pumped from deaerator to the boiler through the H.P. heaters by means of
3*50% capacity feed pumps connected before the H.P. heaters .
DES CRIPTION OF M AIN TURBINE
M AIN COM PONENTS OF TURBINE

EMERGENCY STOP
VALVE

S team from the boiler is s upplied to the turbine through two emergency s top valves . The
emergency s top valve operated by hydraulic s ervomotor s huts off s team s upply to the turbine
when the turbo s et is tripped. The emergency s top valves connected to the four control valves
through four flexible loop pipes of Chromium-M olybdenum-Vanadium s teel.
HP ROTOR

The H.P. rotor has dis cs integrally forged with the s hafts and is mechanical forming s ingle CrM o-V s teel forging. A s pecial proces s to prevent abnormal rotor deflection thermally
s tabilizes the rotor forging.
LP ROTOR

It cons is ts of s hrunk fit dis cs on a s haft. The s haft is a forging of Cr-M o-V s teel while the dis cs
are of high s trength Ni s teel forging.
The H.P. rotor is connected by rigid couplings whole the I.P. rotor and L.P. rotor are
connected by s emi-flexible lens typecoupling. The rotors are dynamically balanced to a very
precis e degree.
TURBINE BEARINGS

The three turbine rotors are s upported on fine bearings . The s econd bearing from pedes tal s ide
is a combined radial thrus t bearing while all others are journal bearings .
THRUST BEARINGS
It is M itchell type with bearing s urface dis tributed over a number of bearing s urfaces . They
are pivoted in hous ing on the s ide of I.P. rotor thrus t collar.

During operation on oil film is forced between pads and thrus t collar and there is
a no metal-to-metal contact. A s econd ring of pads on oppos ite s ide of thrus t collar takes the
axial thrus t as may occur under abnormal conditions .
LP HEATERS

Turbine is provided with non-controlled extractions which are utilized for heating the condens ate
from turbine bleeding s ys tem. There are four L.P. heaters . They are equipped with neces s ary
s afety valves in s team s pace level indicator for vis ual level indication of heated s team.
Condens ate pres s ure vaccum gauges are pres ent for meas urement of s team pres s ure.
Turbine has been provided with non-controlled extractions which are utilized for heating
the condens ate, from turbine bleed s team. There are 410w pres s ure heaters in which the
las t four extractions are us ed. L.P. Heater-1 has two parts LPH-1Aand LPH-1B located in the
upper parts of condens er A and condens er B res pectively. Thes e are of horizontal type
with s hell and tube cons truction. L.P.H. 2, 3 and 4 are of s imilar cons truction and they are
mounted in a row at 5M level. They are of vertical cons truction with bras s tubes the ends of which
are expanded into tube plate. The condens ate flows in the "U" tubes in four pas s es and extraction
s team was hes the outs ide of the tubes . Condens ate pas s es thru' thes e four L.P. heaters in
s ucces s ion. Thes e heaters are equipped with neces s ary s afety valves in the s team s pace level
indicator for vis ual level indication of heating s team condens ate pres s ure vacuum gauges for
meas urement of s team pres s ure etc.

GLAND STEAM
COOLER

Gland s team cooler has been provided to s uck and cool the air s team mixture from the gland
s eats . It employs a s mall ejector for which the working medium is s team of low parameters , which
can be taken either from the deaerator or auxiliary s ource. The pres s ure and temperature of this
s team s hould of this s team is retrieved to the fulles t pos s ible extent as the gland s team cooler is
als o interpos ed in the condens ate heating cycle thereby improving overall efficiency of the cycle.

TURBINE AUXILIARIE
CONDENS ATE PUM PS
The function of thes e pumps is to pumps out the condens ate to the des ecrator
through ejectors , gland s team cooler, and L.P. heaters . Thes e pumps have four s tages and s ince
the s uction is at a negative pres s ure, s pecial arrangements have been made for providing s ealing.
This pump is rated generally for 160m3 hr. at a pres s ure 13.2 Kg/cm2.
FEED WATER SYSTEM

The main equipments coming under this s ys tem are

Boiler Feed Pump: Three per unit of 50% capacity each located in the '0' meter level in the
TG
bay.
High Pres s ure Heaters : Normally three in number and are s ituated in the TG bay.
Drip Pumps : Generally two in number of 100% capacity each s ituated beneath the LP
heaters .
Turbine Lubricating Oil S ys tem: This cons is ts of M ain Oil Pump (M OP) S tarting Oil
Pump (S OP), AC s tandby oil pumps and emergency DC' oil pump and Jacking Oil Pump (JOP) (one
each per unit).

Objective of training
To gain maximum knowledge about the practical work.
To s ee employee the practical work
To s ee department of company and als o the work s ys tem of another
department
To unders tand the problem faced by the employees
To unders tand the relative working of the plant and its departments