A SUMMER TRAINING PROJECT REPORT ON CSPGCL

CSEB,KORBA(EAST)

ACKNOWLEDGEMENT
I take this opportunity to express my profound gratitude and deep regards to my Professors Smt. Vandana Bareth and Shri H.K. Baghel for their exemplary guidance, monitoring and constant encouragement throughout the course of this thesis. The blessing, help and guidance given by them time to time shall carry me a long way in the journey of life on which I am about to embark.

I also take this opportunity to express a deep sense of gratitude to Shri J.S. Mandavee, S.E., CSPGCL(Korba East), for his cordial support, valuable information and guidance, which helped me in completing this task through various stages.

I am obliged to all the members of PGTI, for the valuable information provided by them in their respective fields. I am grateful for their cooperation during the period of my assignment.

Lastly, I thank almighty, my parents, brother, sisters and friends for their constant encouragement without which this assignment would not be possible.

IRSHITA KHIRVAT

CONTENTS
1. 2. 3.

Introductionpg.3 Power Plants in Korba.pg.4 Coal Handling Plantpg.7 Conveyer belt Crushers Magnetic Separators

INTRODUCTION
A thermal power station is a power plant in which the prime mover is steam driven. Water is heated, turns into steam and spins a steam turbine which drives an electrical generator. After it passes through the turbine, the steam is condensed in a condenser and recycled to where it was heated.Certain thermal power plants also are designed to produce heat energy for industrial purposes of district heating, or desalination of water, in addition to generating electrical power.A Thermal Power Plant converts the heat energy of coal into electrical energy. Coal is burnt in a boiler which converts water into steam.Thermal Power Plants contribute maximum to the generation of Power for any country . Thermal Power Plants constitute 75.43% of the total installed captive and non-captive power generation in India . In thermal generating stations coal, oil, natural gas etc. are employed as primary sources of energy. 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 Nuclear = 4,120MW RES = 13242.41MW Annual power production 680 billion KWH Chattisgarh State Electricity Board (CSEB) is divided into five companies. CSPGCL Chattisgarh State Power Generation Company Limited. CSPTCL - Chattisgarh State Power Transmission Company Limited. CSPHCL - Chattisgarh State Power Holding Company Limited. CSPDCL - Chattisgarh State Power Distribution Company Limited. CSPTCL - Chattisgarh State Power Trading Company Limited.
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Thermal = 95151.74MW Hydro = 36877.76MW

POWER PLANTS IN KORBA

CSPGCL generates power through various Thermal and Hydroelectric Power Plants. Thermal Power Plants in Chhattisgarh : 1.Korba Thermal Power Station (4*50 MW,2*120 MW) ,Korba East. Generating Votage - 10.5 KV , 13.8 KV respectively(each). 2. Dr. Shyama Prasad Mukherjee Thermal Power station (2*250 MW). Generating Votage 10.5 KV(each). 3. Hasdeo Thermal Power Station (4*210MW) ,Korba West. Generating Votage -15.75 KV(each). 4. 6MW Co-generation Plant, Kawardha. 5. 2*500 MW Thermal Power Station, Marhwa. Generating Votage 21 KV(each). 6. 1*500 MW Thermal Power Station,Korba West extension. Generating Votage 21 KV. Hydel Power Plants in Chhattisgarh : 1. Hasdeo Bango Hydroelectric Plant (3*40 MW). 2. Gangrel Hydroelectric Plant (4*2.5 MW). 3. Sikasar Hydroelectric Plant (2*3.5 MW). 4. Mini Hydroelectric Plant (2*0.85 MW).

Typical coal thermal power station

Typical diagram of a coal-fired thermal power station : 1. Cooling tower 2. Cooling water pump 3. transmission line (3-phase) 4. Step-up transformer (3-phase) 5. Electrical generator (3-phase) 6. Low pressure steam turbine 7. Condensate pump 8. Surface condenser 9. Intermediate pressure turbine steam 10. Steam Control valve 11. High pressure steam turbine 12. Deaerator 13. Feedwater heater 14. Coal conveyor 15. Coal hopper 16. Coal pulverizer 17. Boiler steam drum 18. Bottom ash hopper 19. Superheater 20. Forced draught (draft) fan 21. Reheater 22. Combustion air intake 23. Economiser 24. Air preheater 25. Precipitator 26. Induced draught (draft) fan 27. Flue gas stack

CHP COAL HANDLING PLANT

The function of coal handling plant is automatic feeding of coal to the boiler furnace. At the receiving location stock yard or sent to coal bunkers To make sure to generate electricity when you want to, you have to make sure the coal is in the right place at the right time. Typically 15 days stock is maintained at site. The stock yard stocks these and helps in times of lean supply from the mines or when transportation is not available. MAIN EQUIPMENTS

WAGON TIPPLERS CONVEYORS PRIMARY CRUSHERS SECONDARY CRUSHERS COAL STOCK YARD STACKER CUM RECLAIMER MACHINES

Coal Conveyor It's a mechanical machine consisting of a continuous moving belt that transports materials from one place to another place. Coal conveyors are used to move coal around efficiently.
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Coal arriving by train can be stocked for later use or taken straight to the coal bunkers.

CHP control room with remote control system helps to ensure that the conveyors take the coal to the right bunkers. Crusher A crusher is a machine designed to reduce large rocks into smaller rocks, gravel, or rock dust.

Magnetic Separators

Korba East gets its coal from Manikpur region.The coal is sub-bituminus type.This coal gets collected in the 10 by 10 inched underground hoppers. Primary crushers are used to reduce coal size.From hoppers it goes to the conveyer belts.The conveyer belts take the coal to the secondary crushers. Before coming to crushers we have magnetic separators for removing the unwanted particles in the coal. Secondary crushers obstruct the large sized coal from getting inside the mill.There may be a no. of crushers according to the need and then again we have magnetic separators after it passes on to the mill through conveyer belts.

Ring Granulator

Pulverising plant Coal is pulverised i.e. ground to dust like size and carried to the furnace in a stream of hot air. Pulverising is a means of exposing a large surface area to the action of oxygen and consequently helping combustion. Pulverising mills are further classified as: Contact mill Ball mill Impact mill Ball Mill A ball mill, a type of grinder, is a cylindrical device used in grinding large coal particles. Ball mills rotate around a horizontal axis, partially filled with the material to be ground plus the grinding medium. An internal cascading effect reduces the material to a fine powder.

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FANS
A fan continuously moves mass of air, gas or vapour at the desired velocity by the action of its rotor.For achieving this objective there is a slight increase in the gas pressure across the fan rotor. However, the main aim of a fan is to move a gas without an appreciable increase in pressure PRIMARY AIR FANS (PA FAN) The purpose of primary fans is to provide air that is used to transport the pulverized coal from the mills and also to warm up the coal to remove any moisture content that might present in the coal. The primary air flowing out of PA fan is divided into 2 portions, one portion enters the regenerative air preheater and comes out as hot air,while the 2nd portion is cold air and both sent to the mill.Depending upon the temp.requirement of the coal at mill outlet the flow of primary air is controlled by dampers.

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FORCED DRAFT FANS (FD FAN) The main function of forced draught fan is to provide air for combustion in addition to the air supplied by the primary air fan.The air from the FD fans known as secondary air, is supplied to the furnace through regenerative air pre-heater, wind box and finally through secondary air damper controls.Two FD fans are provided for each Boiler. It supplies secondary air to furnace for complete combustion of fuel for more than stochiometric ratio 4%. It also supplies inlet air to scanner air fan for scanners cooling and oil guns cooling.

INDUCED DRAFT FAN The Induced Draught Fans are provided to evacuate the flue gas and to maintain vacuum inside the furnace to ensure effective combustion. The ID fan is driven by a constant speed induction motor. The speed variation of ID fan is effected using hydraulic coupling. The oil used in the hydraulic coupling is cooled by water which is circulated by a separate pump.

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WATER TREATMENT PLANT

Impurities present in water can be : Floating type materials. Colloidal particles. Dissolved gases. Dissolved solids. Suspended particles. Water here is taken from an inlet canal. A revolving screen removes all the floating type materials present in the water.The water is the passed on for purification. The purification process makes use of lime, alum and bleaching powder.O2 is removed from water as it is an oxidising agent.Permanent hardness of water is removed by adding lime.Lime increases pH value of water. Alum is used to accumulate dust particles and suspend them at the bottom.

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Bleaching powder is used to sterilize water.The water is then sent to a revolving bridge. De-Mineralisation plant uses Cation beds (HCl,H2 SO4), anion beds (NaOH) and mixed beds. De-gaser is used to remove the additional gases present.

Rankine cycle
The Rankine cycle is a mathematical model that is used to predict the performance of steam engines. The Rankine cycle is an idealised thermodynamic cycle of a heat engine that converts heat into mechanical work. The heat is supplied externally to a closed loop, which usually uses water as the working fluid.

Carnot cycle
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The Carnot cycle when acting as a heat engine consists of the following steps: Reversible isothermal expansion of the gas at the "hot" temperature, T1 (isothermal heat addition or absorption Isentropic (reversible adiabatic) expansion of the gas (isentropic work output). The entropy remains unchanged. Reversible isothermal compression of the gas at the "cold" temperature, T2. (isothermal heat rejection) Isentropic compression of the gas (isentropic work input).

BOILER HOUSE
A boiler or steam generator is a closed vessel in which water under pressure, is converted into steam.

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It is one of the major components of a thermal power plant Always designed to absorb maximum amount of heat released in the process of combustion. There are two types of boilers- fire tube ,water tube. Here walls are made of water tubes.Diesel ignition is used. To produce steam each 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.

Each boiler is as high as 60 mts and weighs about 40,00,000 kg (4000 T).
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Inside the boiler there is enough steel tubing to stretch the 500 kilometres and they are joined together by about 20,000 joints. Pressure inside the tubes could be about hundred times that of cars wheel pressure. SCHEME OF STEAM GENERATION IN BOILER Process of steam generation in boilers (Water pre-heating to the saturation temperature is done in an economizer, the formation of steam takes place in evaporating heating surfaces and steam superheating is carried out in a superheater).In these process water in the economizer and steam in the superheater come only once in contact with the heating surfaces.

The economizer offers hydraulic resistance to the motion of water,which must be overcome by provision of high head in the feed pump.

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The pressure developed by the feed pump must exceed the pressure at the entry to the zone of steam generation by the magnitude of the hydraulic resistance of the economizer. The motion of steam in the super-heater is due to pressure gradient between the zone of steam generation and the steam turbine.

Boiler light-up
Spark plug provides the initial ignition. Light Diesel oil is then fed to the burner and it catches fire This is followed by heavy furnace oil (HFO) Once a stable flame is established the coal/air mix is blown through the burner where it lights spontaneously The oil are then shut off. Burner position, coal flow and air flow are controlled to achieve desired output of temperature, pressure and flow and hence the electricity. Boiler fittings and accessories : Safety valve: It is used to relieve pressure and prevent possible explosion of a boiler. Water level indicators: They show the operator the level of fluid in the boiler, also known as a sight glass, water gauge or water column is provided. Bottom blowdown valves: They provide a means for removing solid particulates that condense and lie on the bottom of a boiler. As the name implies, this valve is usually located directly on the bottom of the boiler, and is occasionally opened to use the pressure in the boiler to push these particulates out.

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Continuous blowdown valve: This allows a small quantity of water to escape continuously. Its purpose is to prevent the water in the boiler becoming saturated with dissolved salts. Saturation would lead to foaming and cause water droplets to be carried over with the steam - a condition known as priming. Blowdown is also often used to monitor the chemistry of the boiler water. Flash Tank: High pressure blowdown enters this vessel where the steam can 'flash' safely and be used in a low-pressure system or be vented to atmosphere while the ambient pressure blowdown flows to drain. Automatic Blowdown/Continuous Heat Recovery System: This system allows the boiler to blowdown only when makeup water is flowing to the boiler, thereby transferring the maximum amount of heat possible from the blowdown to the makeup water. No flash tank is generally needed as the blowdown discharged is close to the temperature of the makeup water. Hand holes: They are steel plates installed in openings in "header" to allow for inspections & installation of tubes and inspection of internal surfaces. Steam drum internals, A series of screen, scrubber & cans (cyclone separators). Low- water cutoff: It is a mechanical means (usually a float switch) that is used to turn off the burner or shut off fuel to the boiler to prevent it from running once the water goes below a certain point. If a boiler is "dry-fired" (burned without water in it) it can cause rupture or catastrophic failure. Surface blowdown line: It provides a means for removing foam or other lightweight non-condensible substances that tend to float on top of the water inside the boiler. Circulating pump: It is designed to circulate water back to the boiler after it has expelled some of its heat.

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Feedwater check valve or clack valve: A non-return stop valve in the feedwater line. This may be fitted to the side of the boiler, just below the water level, or to the top of the boiler. Top feed: In this design for feedwater injection, the water is fed to the top of the boiler. This can reduce boiler fatigue caused by thermal stress. By spraying the feedwater over a series of trays the water is quickly heated and this can reduce limescale. Desuperheater tubes or bundles: A series of tubes or bundles of tubes in the water drum or the steam drum designed to cool superheated steam. Thus is to supply auxiliary equipment that does not need, or may be damaged by, dry steam. Chemical injection line: A connection to add chemicals for controlling feedwater pH. 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.

Economizer
Flue gases leaving the superheater and reheater still contain useful energy Water from the high pressure feed heaters is heated in the economiser from 250C to 290C before it continues to the steam drum Having given up its last heat in the boiler, the flue gases move on to the air heater.

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AIR PRE HEATER IT PREHEATS THE PRIMARY & SECONDARY AIR FROM THE WASTE EXHAUST FLUE GAS LEAVING AFTER THE ECONOMISER TO IMPROVE THE BOILER EFFICIENCY.

Drum
After leaving the economizer, the feedwater reaches the drum, which is a cylindrical vessel at the top of the boiler From here the water flows by natural circulation through downpipes into the boiler Saturated steam collects here ready to go to the superheater Drum does the important function of separating steam from a mixture of steam and water.
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Superheater and Reheater Superheater :

Superheater is a component of a steam-generating unit in which steam, after it has left the boiler drum, is heated above its saturation temperature. The amount of superheat added to the steam is influenced by the location, arrangement, and amount of super heater surface installed, as well as the rating of the boiler. The super heater may consist of one or more stages of tube banks arranged to effectively transfer heat from the products of combustion. Super heaters are classified as convection , radiant or combination of these.

Reheater :
Some of the heat of superheated steam is used to rotate the turbine where it loses some of its energy. Reheater is also steam boiler component in which heat is added to this intermediate-pressure steam, which has given up some of its energy in expansion through the high-pressure turbine. The steam after reheating is used to rotate the second steam turbine where the heat is converted to mechanical energy. This mechanical energy is used to run the alternator, which is coupled to turbine , there by generating electrical energy.

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. Condenser is located beneath the LPT. The used up steam from LPT is directly sent to condenser for condensing the steam to water. Cooling water received from CWPH is passed thro the cooling tubes to condense the steam. A Vacuum
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around 665 mmHg is maintained inside the condenser. The condensed water(condensate) is collected in the hotwell .The condensate is pumped to De-aerator thro Low Pressure heaters (LPH) by CEP.Loss in the system was make up at condenser.

Condensate Extraction Pump

The condensate water is drawn from the condenser by the extraction pump and sent to the low pressure feed heaters.

WHY CONDENSER IS REQUIRED The steam after doing work in LPT is converted into water in Condenser and sent back to the Boiler. By recycling, the requirement of DM water & cost is reduced. Higher the condenser vacuum, higher the work done in the Turbine.
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Dissolved air and non condensable gases in the water is removed in the condenser.

Feed water heater

Advantages of heating water before feeding back to the boiler:Feed water heating improves overall plant efficiency. The dissolved oxygen and carbon dioxide which would otherwise cause boiler corrosion are removed in feed water heater Thermal stresses due to cold water entering the boiler drum are avoided. Quantity of steam produced by the boiler is increased. Some other impurities carried by the steam and condensate, due to corrosion of boiler and condenser are precipitated outside the boiler.

Deaerator
From the low pressure feed heaters the water passes through the deaerator before going to the high pressure (HP) feed heaters.

Air preheater
After flue gases leave economiser, some further heat can be extracted from them and used to heat incoming heat. Cooling of flue gases by 20 degree centigrade increases the plant efficiency by 1%. Air preheaters may be of three types Plate type Tubular type Regenerative type

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Cooling towers
A condenser needs huge quantity of water to condense the steam .Typically a 2000MW plant needs about 1500MGallon of water. Most plants use a closed cooling system where warm water coming from condenser is cooled and reused.Small plants use spray ponds and medium and large plants use cooling towers.Cooling tower is a steel or concrete hyperbolic structure having a reservoir at the base for storage of cooled water Height of the cooling tower may be 150 m or so and diameter at the base is 150 m.

Draft system
The circulation of air is caused by a difference in pressure, known as Draft. Draft is a differential pressure b/w atmosphere and inside the boiler. It is necessary to cause the flow of gases through boiler setting It may be Natural draft Mechanical draft

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OPERATION & MAINTENANCE The furnace pressure in the boilers is maintained by the use of both forced draught fans and induced draught fans. The circulation of water is natural, i.e. from the drum through the down comers and then through the upraises to the water walls . As the water flows down through the down comers and fills the water walls, due to the firing in the furnace it gets converted into steam and rises due to lesser density.

Electro-Static Precipitator (ESP)

Each boiler has 4 passes with 7 fields each containing high voltage electrodes These attract the dust or ash from the flue gases At regular intervals the electrodes are rapped with motor-driven hammers and the PFA falls into hoppers below This is one of the ways to clean up the flue gases or smoke sent up the chimney Secondly this ash is used by construction industry for use in building materials (bricks !!, Cement Fillers).
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Chimney
It consists of flues each of which serve typically two or three boilers (two units). Flue gases have ash and several gases which are passed through the precipitator(dust collector) and go to atmosphere through chimney.

TURBINE
Steam turbine
A steam turbine converts heat energy of steam into mechanical energy and drives the generator. It uses the principle that steam when issuing from a small opening attains a high velocity. This velocity attained during expansion depends on the initial and final heat content of the steam. This difference b/w initial and final heat content repesents the heat energy converted into kinetic energy.

High Pressure Turbine

High pressure steam at 560C and 160 ksc pressure passes through the high pressure turbine.
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The exhaust steam from this section is returned to the boiler for reheating before being used in the next section of the turbine set. The blades in the high pressure turbine are the smallest of all the turbine blades, this is because the incoming steam has very high energy and occupies a low volume. The blades are fixed to a shaft and as the steam hits the blades it causes the shaft to rotate.

Intermediate Pressure Turbine

On leaving the boiler Reheater, steam enters the intermediate pressure turbine at 560C and 40 ksc pressure (1 ksc = 14.22 psi ) From here the steam goes straight to the next section of the turbine set The steam has expanded and has less energy when it enters this section, so here the turbine blades are bigger than those in the high pressure turbine The blades are fixed to a shaft and as the steam hits the blades it causes the shaft to rotate.

Low Pressure Turbine

From the intermediate pressure turbines, the steam continues its expansion in the three low pressure turbines. The steam entering the turbines is at 300C and 6 ksc pressure To get the most work out of the steam, exhaust pressure is kept very low, just 50 mille-bar above a complete vacuum The tip speed of the largest blades with the shaft spinning at 3,000 revolutions per minute is 2,000 kmph.

COOLING WATER SYSTEM

OBJECTIVE OF COOLING WATER:
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a) To condense the steam from LP Turbine b) To cool the plant auxiliary equipments. c) To flush the ash hoppers

ASH HANDLING PLANT

The percentage of ash in coal varies from 5% in good quality coal to about 40% in poor quality coal.

The stations use some conveyor arrangement to carry ash to dump sites directly or for carrying and loading it to trucks and wagons which transport it to the site of disposal.

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GENERATOR TRANSFORMER
A transformer is a static electrical device that transfers energy by inductive coupling between its winding circuits. A varying current in the primary winding creates a varying magnetic flux in the transformer's core and thus a varying magnetic flux through the secondary winding. This varying magnetic flux induces a varying electromotive force (emf) or voltage in the secondary winding. Transformers range in size from thumbnail-sized used in microphones to units weighing hundreds of tons interconnecting the power grid. A wide range of transformer designs are used in electronic and electric power applications. Transformers are essential for the transmission, distribution, and utilization of electrical energy. The ideal transformer induces secondary voltage ES =VS as a proportion of the primary voltage VP = EP and respective winding turns as given by the equation

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From the generator the electricity then goes to a transformer where the voltage is increased to 2,20,000 volts before sending it via cables for distribution. Primary voltage 13.8 KV , 10.5 KV. Frequency 50 Hz. Each 1 MW generates about 8 million units and gives about Rs 2 crores revenue every year. This generates enough electricity to power around 5,000 avg. homes.

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CURRENT TRANSFORMER Current transformers are used for reducing or stepping down A.C. current from higher value to lover for measurement protection or control.

VOLTAGE TRANSFORMER Voltage transformers are used for protection and measurement. Accordingly they are either measuring type or protective type voltage transformers. They may be either single or three phases. The primary of voltage transformer is connected directly to power circuit between phase and ground depending upon rated voltage and application.

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Power Transformer

Switch yard (220KV / 33 KV)

It is a part of an electrical generation, transmission, and distribution system. Switch yard transform voltage from high to low, or the reverse, or perform any of several other important functions. Between the generating station and consumer, electric power may flow through several switch yard at different voltage levels.Switch yard may be owned and operated by an electrical utility, or may be owned by a large industrial or commercial customer.

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A switch yard may include transformers to change voltage levels between high transmission voltages and lower distribution voltages, or at the interconnection of two different transmission voltages. 220 KV is generated here.

Relay:
A relay is an electrically operated switch. Relays are used where it is necessary to control a circuit by a low-power signal or where several circuits must be controlled by one signal.

Alternator :
An alternator is an electromechanical device that converts mechanical energy to electrical energy in the form of alternating current.Most alternators use a rotating magnetic field with a stationary armature but occasionally, a rotating armature is used with a stationary magnetic field; or a linear alternator is used. In principle, any AC electrical generator can be called an alternator, but usually the term refers to small rotating machines driven by automotive and other internal combustion engines.
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An alternator that uses a permanent magnet for its magnetic field is called amagneto. Alternators in power stations driven by steam turbines are called turboalternators.

Finally
The cleaned flue gas is discharged up the 275 metre high chimney which has been lined with steel plates/brick lining.

The generated power stepped upto 220 kilo volts is transmitted and handed over to distributors at lower voltages

Finally it is supplied to households at 230 volts and to industries at little higher voltages..

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HYDROGEN GAS COOLING SYSTEM ADVANTAGES OVER AIR

The density is lowest of all gases and is of that of air. Lesser windage and friction loss due to less density Requires less fan power Increase in efficiency The heat transfer capacity of hydrogen is about twice that of air Increase in pressure increase in out put For every 1.0 ksc pressure increase 0.5% increase output But more pressure will increase the density of gas in turn will increase the windage loss.

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Selection Of site :
Availability of cheap land. Availability of water. Availability of fuel. Possibility of future expansion of the plant. Away from the urban areas due to pollution. The initial cost of plant. Magnitude and nature of load to be handled.

Some CSEB firsts

History Chhattisgarh State Electricity Board was formed in accordance with the Section 5 of the Electricity Supply Act 1948 as per the Notification published in the gazette of the Government of Chhattisgarh dated 15 November 2000. Chhattisgarh State Electricity Board (CSEB) became functional w.e.f. 01.12.2000. Chhattisgarh State Electricity Board has been reorganized into five companies in accordance with the provisions contained in the Section 131-134 of Electricity Act 2003 by the Govt. of Chhattisgarh. Thus Chhattisgarh State Power Generation Company Limited became functional w.e.f. 01.01.2009. Generation capacity The installed capacity of CSEGCL as on 31.07.2010 is 1924.7 MW comprising 1786 MW from Coal based Thermal and 138.70 Hydro electric power stations. and some 6 MW is coming from co-generation sources.

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