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ELECTRICAL AND ELECTRONICS ENGINEERING DEPARTMENT

SIKKIM MANIPAL INSTITUTE 0F TECHNOLOGY
MAJITAR, RANGPO, EAST SIKKKIM-737136

PRESENTATION
ON
COAL TO POWER
Presented by:Baibhav saha
Ashish Prasad
Debdarshan Panda

IN THIS PRESENTATION
INTRODUCTION
THERMAL POWER PLANT OVERVIEW
ELECTRICAL EQUIPMENTS AND
CONCEPTS
SLD AND FLOW CYCLES
SITE SELECTION FOR THERMAL
POWER PLANT

INTRODUCTION
India is one of the worlds largest consumer of
energy
Conventional sources: Thermal, Hydro and
Nuclear.
Non- conventional: Wind, solar, Geothermal, tidal.
Installed capacity 1,61,352MW
Thermal = 95151.74MW
Nuclear = 4,120MW
Hydro = 36877.76MW
solar = 1324.41MW

Annual power production 680 billion KWH

Break up of Power

Thermal Power Plants 75%

Hydro Electric Power Plants - 20%
Nuclear Power Plants - 4%
Solar power plants 1%
Installed wind power Generation
9655MW
30% to 40% of electrical power is lost
in transmission and distribution

OPERATIONAL FEATURES
INSIDE THE POWER PLANT

SIMPLE STEPS FOR ELECTRICITY GENERATION:

Pollutan
ts

Coa
l
Hea
t

Turbine
Torque

Super
Heated
Steam
ASH

Heat
Loss In
Condens
er

Mech.
Energy
Loss

Los
s
Chemical
Energy

Thermal
Energy

Kinetic
Energy

Electrical
Energy

Alternating
current in Stator
Elet.
Energy
Loss

Operations In Thermal Power

Station
Step wise operations in a
thermal power plant are as
follows:Coal is used as a fuel to
boil the water.
Water is boiled to form
pressurized steam.
Pressurized steam is the
force that cause the turbine
to rotate at a very high
speed.
Low pressure steam after
pushing through the
turbine ,its going into the
condenser.
Condenser the place
where the steam is
condensed back it its liquid
form .Then the
process is

Coal

ESP

Coal
Storage

Air
Pre-heater

Chi
mn
ey

Coal Handling
Plant

Air
Economizer

Ash Handling
Plant

Turbine

Boiler

Super
Heater

Generat
or

Ash
Storage

Ash

Make up
Water

Boiler
feed
pump

STEAM
Deaerator
COAL

ASH

CE
P

Condenser

WATER
FLUE GASES

Cooling
Tower

Exciter

COMPONENTS
Main parts of the plant are :
1.
2.
3.
4.
5.
6.
7.

Coal handling Plant

DM Plant
Boiler
Super heater
Air preheater and Economizer
Deaerator
Turbine

8. Condenser
9. Cooling towers

COAL
HANDLING
PLANT

Ground Hopper

ED
ND
E
S P ET
SU GN
MA

V2 V3

1
C-

VS1

DRC
VS2
SM

V1

SECOND. CRUSHER HOUSE

C-

S
OS
CR RE ET
I
W A GN
M

I/C

5
CRSC

3
C-

PRIMARY CRUSHER HOUSE

BUNKER

COAL HANDLING PLANT

MAIN EQUIPMENTS IN CHP

DOUBLE ROLL CRUSHER

IMPACT CRUSHER
VIBRATING SCREEN
CONVEYOR
MAGNETIC SEPERATOR
VIBRO FEEDERS

DOUBLE ROLL CHRUSHER

IMPACT CRUSHER CHP

VIBRATING SCREEN CHP2

PROTECTION DEVICES ZERO

SPEED S/W, PULL CORD &
BELT SWAY S/W

PROTECTION DEVICES ZERO

SPEED S/W, PULL CORD &
BELT SWAY S/W
ZSS:- Zero speed s/w is used to detect
jamming/ slow speeding of motor, shaft
& thereby stopping the motor
automatically.
PULL CORD:- Pull cord switch also
known as Rope Operated Emergency
switch is used as a safety switch to
stop the conveyor belt in case of an

BSS:- Belt Sway Switch is a protective switch

for detecting the meandering (sway or
deviation) of belt conveyors, and sends out an
alarm signal and an emergency stop signal.
Suited to be used for belt breakage prevention
when running out of centre & overfeed
prevention due to the belt sway.
Emergency switch: it is present in the field.
One can operate it while some maintenance is
going on.

DM PLANT
The main aim of the DM Plant is to demineralize the raw water coming from a
water source (in this case Kharu river
nearby) from any mineral presence by
chemical dosing which may be harmful to
the pipeline and boilers.
Cooling tower also comes under DM Plant.

Cooling Tower
The warm water is taken from the
condenser tubes to about a quarter
of the way up the cooling tower.
This breaks the water up into a
very fine spray, increasing the
surface area of the water droplets
making it easier to cool.
The cooling tower is designed as
a natural draught chimney,
drawing cold air from outside
through the falling water.
Cool water is collected in pond at
the bottom of the cooling tower.
From here it is pumped back to
the condensers .

Boiler
To produce steam boiler converts
energy, in the form of coal, into steam
The boiler is lined with steel tubing in
which pure boiler feed water is turned
to steam by the heat created from the
burning of coal
This plant contains two types of boilers
namely:
I.

AFBC(Atmospheric Fluidized Bed

Combustion)
II. WHRB(Waste Heat Recovery Boiler)

Boiler details :
AFBC #1 =125TPH, 490c,65kg/cm
AFBC #2 =75 TPH, 490c,65kg/cm
WHRB #1=37TPH, 490c,65kg/cm
WHRB #2=37TPH, 490c,65kg/cm
WHRB#3=11.5TPH, 490c,65kg/cm
WHRB#4=11.5TPH, 490c,65kg/cm

TPH=TONNES PER
HOUR

BOILERS:
Atmospheric Fluidized Bed
Combustion(AFBC):-

Waste Heat Recovery

Boiler(WHRB):-

In this type of boiler water flows

inside the tubes and hot gases
flow outside the tubes. These
tubes are interconnected to
common water channels and to
steam outlet.
The AFBC boilers have
the WHRB boilers

In this type the products of

combustion pass through the
tubes which are surrounded by
water.
many advantages over

High evaporation capacity due to availability

of large heating surface.
Better heat transfer to the mass of water.
Better efficiency of plant owing to rapid and
uniform circulation of water in tubes.
Better overall control.

BOILER
Draught (ID) Fan
AUXILLARY
:
Forced Draught
(FD) Fan Induced
This fan forces the
atmospheric air through
the boiler furnace and
pushes out the hot gases
from the furnace through
superheater, reheater,
economizer and air heater
to stacks.

Here a fan called ID fan

is provided at the outlet
of boiler, that is, just
before the chimney.

This fan sucks hot

gases from the furnace
through the
superheaters,
economizer, reheater and
Primary air (PA) fan:discharges gas into the
Primary air fans (PA) are high pressure
chimney.
fans used to supply the air for the
transportation of coal directly to the
furnace .

ECONOMISER
Flue gases coming out of the boiler carries
lot of heat.
ECONOMISER extracts a part of heat
from the flue gases and uses for heating the
feed water.
Thus improves efficiency of plant.
Temp. inside ECONOMISER is about 315
deg c.

SUPER HEATER
Super heater is used to remove the moisture content

from the steam.

Super heater raises the temperature of steam above 540 degree C.
Advantages of super heater
1. Increases efficiency
2. Reduces corrosion of turbine blades.

AIR PREHEATER
It is used to preheat the air before entering
into furnace.
It is a heat exchanger in which some
further
heat is extracted from the flue gases and
use to heat the coming air for combustion.

Electrostat
ic
precipitato
r

BOILER CIRCUIT WITH ELECTROSTATIC

PRECIPITATOR

It is designed to trap and

remove dust particles from
the exhaust gas stream of
an industrial process.
. Precipitators typically
collect 99.9% or more of
the dust from the gas
stream.

The Precipitation Process

Involves
4 Main Functions:Corona Generation
Particle Charging
Particle Collection
Removal Of
Particles

Functions OF
Transformer(415/6
rapper
ESP
0kv)

collecti
ng

INLET = 80
g/m
Flue gas
+++++
++
----------DUST
LEVEL/STA
CK LEVEL
emitting

heavier
ash
particle
s

INSULATOR

CORON
A

Penta house
+
+
+
+
+
+
+

+
+
+
+
+
+
+

+
+
+
+
+
+
+

+
+
+
+
+
+
+

CHIMNE
Y

OUTLET = 50
mg/m
Towar
d ID
fan
lighter ash
particles
AS
H
SIL
TO ASH SILO O

TURBINE
GENERATOR
Main Components of Typical
TG SET consists of:

1. Permanent Magnet
Generator
(PMG)
2. Automatic Voltage
Regulator
(AVR)
3. BRUSHLESS EXCITER
4. GEAR BOX
5. ALTERNATER
6. TURBINE

TURBINE GENERATOR SET

3
SUPPL
Y TO
LOAD

P
M
G

EXCITE
R

ALTENATOR

GEAR
BOX

STEAM

TURBI
NE
INLET TEMP = 484
5C
INLET PRS = 6265KG/cm
SPEED= 7000 RPM

AVR

couplin
g

STATOR=MAGN
ETIC
FIELD
ROTOR=
EMF
BRUSHL

PMG

RECTIFIE
R

3
AC
AV
R

+
-

DC
SUPPLY

ESS
EXCITER

stato
r=
PM

3
supply
STEA
to
load M

ALTERNATO
R
Field
ROTOR=
exciter
FIELD
switch
STATOR
=EMF
DC
SUPPLY
WORKING

TURBIN
E

OF TUBINE
GENERATOR

11KV BUS
CC

VOLTAGE
CONTROL
INCREA
SE

FREQUENCY
CONTROL
INCREA
SE

DECRE
ASE

DECRE
ASE

DVM
11.2K
11KV
11.2K
V
V
DFM

GE
N

49.8
50
HZ
50
HZ

GRI
D

SKE
relay

TG

PHASE
SWITC
H
OVERLOAD RELAY

STOP
NC

HOLDI
NG
NO

START
NO

CONTACTOR
COIL
(K1)
NEUTR
AL

DIRECT ONLINE

M
R

A1

B1

C1

A2

B2

C2

WORKING OF STAR DELTA

STARTER

ELECTRICAL SLD FOR 60 MW

TG
3

15 MW
18.75MVA
11KV

CB
1600A

25 MVA
11/132 KV
TRAFOS

11 KV BUS

BC4

SAT#6
11/6.6KV
387.8A

CB
1600A

SMS

37 MW
TG 46.25MV
2
A
11KV

132 KV GRID

BC3

CB
1600A

FERRO

CB
3150A

BC2
CB
1600A

KILNS

TG 7.5 MW
1 10MVA
11KV
CB
1250A

BC1
SAT#2
11/6.6KV
387.8A

SAT#1
11/6.6KV
387.8A

6.6KV BUS
SAT# 5
6.6/433KV
218.7A

6.6 KV MOTORS

SAT# 5
6.6/433KV
218.7A

SAT# 4
6.6/433KV
218.7A

415 V PCC

AFBC#1
LOADS

AFBC#2
LOADS

WHRBS
LOADS

SAT# 3
6.6/433KV
218.7A

GENERATOR

11KV/132 KV

132KV/ 11KV

DISTRIBUTION

UTILIZATION
11 KV

INDUSTRIES
6/30/16

11
KV

RAIPUR

TRANSFORMER

BHILAI DURG

11KV/415V

11

TRANSFORMER

HOUSE

MALLS /
SHOPS

K
V

BILASPUR

OIL FLOW
OVERHEA
D TANK

OIL TANK

OIL
PUM
P

OIL
COOLER

LUBE OIL
FILTER

TURBIN
E

GEAR
BOX

GEN

Circulating Water Pumps

The circulating water pumps are
used to circulate the water from the
cooling tower to the condenser and
back again

Boiler Feed Pump

The boiler feed pump pumps water
into the boiler, overcoming the boiler
pressure of 160 bar to achieve it
The pump is driven by a steam
turbine or an electric motor
It runs at 7,000 revolutions per
minute

Low Pressure Feed Heaters

Feed water from the condensate
extraction pumps passes through low
pressure feed heaters. Steam is used
to heat the feed water
After the last feed heater, the feed
water is at around 160C.

High Pressure Feed Heaters

With a similar purpose to the low
pressure feed heaters, the high
pressure feed heaters are the last
stage of feed water heating before
the feed water enters the boiler
system at the economizer
Feed water leaving these heaters is at
250C

Condenser
With its useful energy spent in the
turbines the steam then passes to
condensers
Here it is condensed back into water
and pumped back to the boiler
This happens via a series of low
pressure and high pressure feed
heaters
Condensate Extraction Pump
The condensate water is drawn from
the condenser by the extraction
pump and sent to the low pressure
feed heaters

Deaerator

A deaerator is a device
that is widely used for the
removal of air and other
dissolved gases from the
feed water to steamgenerating boiler.

132 KV SWITCHYARD

47

Electrical switchyards are usually part of a

substation where electricity is transformed
from one voltage to another for the
transmission, distribution.

48

MAIN COMPONENTS
OF SWITCHYARD

1.TRANSFORMER
2.CURRENT TRANSFORMER
3.POTENTIAL
TRANSFORMER
4.CIRCUIT BREAKER
5.ISOLATOR
6.INSULATOR
7.LIGHTNING ARRESTOR
8.BUS BAR
49

TRANSFORME
Transformer is theR
most
convenient device for
transfer of power from
one voltage to another
voltage at the same
frequency. It works on
the principle of
electromagnetic
induction.

Transformers are of two types:

STEP-UP TRANSFORMER
Step-up the voltage at secondary side called step
up transformer.
STEP-DOWN TRANSFORMER
Step-down the voltage at secondary side are
called step-down transformer.

50

CURRENT
TRANSFORMER
CT is a type of instrument
transformer that is used in
power system for
measurement, detection,
protection of the system.
It is a device used to measure
large current by scaling large
primary current to a smaller ,
easy to measure, secondary
current.

51

POTENTIAL
TRANSFORMER
These are used to step-down
voltage for measurement .

52

CIRCUIT
BREAKER

A circuit breaker is an
automatically-operated
electrical switch
designed to protect an
electrical circuit from
damage caused by
overload or short circuit.
Its basic function is to
detect a fault condition
and, by interrupting
continuity, to
immediately discontinue
electrical flow.
It can make or break a
circuit eithermanuallyor

53

ISOLATOR
It is a disconnection switch
and to be operated on no
load.
Anisolator switchis used
to make sure that an
electrical circuit can be
completely de-energized for
service or maintenance

54

USES OF
ISOLATOR

It provide
electrical
isolation of
the
equipment,
bus bar, and
circuit from
the live parts
for

55

INSULATOR

An insulator, also called a

dielectric, is a material
that resists the flow of
electric
current.
In insulating materials
allianceelectronsare
tightly-bonded to their
atoms.
Insulator provides
necessary insulation
between line

56

LIGHTNING ARRESTER
A lightning arrester is a device used on
electrical power systems to protect the
insulation on the system from the damaging
effect of lightning

USES OF LIGHTNING ARRESTER

It protect the equipment from

lightning stroke.
Lightning arrester is used to provide
path to unwanted excessive currents.

57

BUSBAR
Conductors

to which a
number of circuits are
connected called busBars. In power plants,
shut down results
disconnection of supply
to a large are. Hence to
avoid shut down the
major plants should
have elaborate bus bar
arrangement with
duplicate buses.
58

USES OF BUSBAR
Bus bar are used to
carry high current.

59

ADVANTAGES OF THERMAL
POWER PLANT
Fuel used is cheaper
Smaller space is required compared to hydro
power plant
Economical in initial cost compared to hydro
plants and running costs are less compared to
gas plants or diesel plants
Thermal plants can be placed near load centers
unlike hydro and nuclear plants. Hence
transmission of power losses can be minimized
Thermal plants are able to respond to the load
demand more effectively and supports the
performance of the electrical grid

SITE SELECTION
Transportation network:Easy and enough access to
transportation network is required in both power plant
construction and operation periods.
Geology and soil type:The power plant should be built in
an area with soil and rock layers that could stand the weight
and vibrations of the power plant.
Topography:It is proved that high elevation has a negative
effect on production efficiency of gas turbines. In addition,
changing of a sloping area into a flat site for the construction
of the power plant needs extra budget. Therefore, the
parameters of elevation and slope should be considered.

 Water resources:For the construction and

operating of power plant different volumes of

water are required. This could be supplied from
either rivers or underground water resources.
Therefore having enough water supplies in
defined vicinity can be a factor in the selection
of the site.
Population centers:For the same reasons as
above, the site should have an enough distance
from population centers.
Area size:Before any other consideration,
the minimum area size required for the
construction of power plant should be defined.

Thanks to
Mr. G.S. BHATIA(HOD POWER)
Mr. M. SUBBA RAO(G.M.
ELECTRICAL)
Mr. B.D.MISHRA(Sr.DGM. C&I )
Mr. H.M.GUTPA(Sr.DGM. MECH )
Mr. N.V. SREENIVAS(Sr. DGM.
OPERATION)

AND
Special Thanks to:
Mr. B.L.VERMA(MANAGER)
Mr. D.CHAKRABARTY(DY.
MANAGER)
Mr. U.K.CHOBEY(DY. MANAGER)
Mr. C.K.SONI (Sr. Engineer)
Mr. S SINGH (Sr. Engineer)
Mr. AMRINDER SANDHU(Engineer)
And all staffs & workers of power
plant.

THANK YOU ALL

What ever you do,

do it with feeling.

DOUBLE ROLL CRUSHER

Material to be crushed:-Coal
Capacity :- 80TPH
Feed Size < 150mm
Product size < 50mm (90%)
RPM:- 173.73
Make:-SAYAJI/ELECON

TECHNICAL DETAIL OF I/CR

CAPACITY :-75TPH
SIZE:-1000Dia X 1000W
MATERIAL :-Coal, Char
FEED SIZE:-< 40mm
PRODUCT SIZE:-< 6mm (65%)
RPM:- 762

WORKING PRINCIPLES:
FARADAYS LAW OF
ELECTROMAGNETIC INDUCTION.
WHEN EVER CONDUCTOR IS ROTATED IN
MAGNETIC FILED, EMF IS INDUCED WHICH ARE
INDUCED EMF .
1) CONDUCTORS OF ELECTRICITY
2) MAGNETIC FIELD
3) CHANGE IN MAGNETIC FIELD

CORONA GENERATION

DUE TO THE IONISATION OF GAS MOLECULES, + VE

IONS, -VE IONS AND FREE ELECTRONS ARE
GENERATED.

ESP - PARTICLE CHARGING

THE -VE CHARGES OF IONS AND FREE ELECTRONS TRAVEL TOWARDS

+VE ELECTRODE AND THE +VE CHARGES OF IONS TRAVEL TOWARDS
-VE ELECTRODES.

WHEN -VE IONS TRAVEL TOWARDS +VE ELECTRODES, THE -VE

CHARGES GET ATTACHED TO THE DUST PARTICLES AND THUS THE
DUST PARTICLES ARE ELECTRICALLY CHARGED,